# US 10,870,987 B1 · Isocyanate-based foam construction boards

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- Number: US 10,870,987 B1
- Document ID: US10870987B1
- Status: Granted
- Kind: B1
- Application number: 16/209,038
- Filed: 2018-12-04
- Granted: 2020-12-22
- Earliest claimed: 2017-12-04
- Assignees: Firestone Building Products Company, LLC
- Applicants: Firestone Building Products Company, LLC
- Inventors: John B. Letts; Chunhua Yao; Michael J. Hubbard
- Web page: https://patentgrep.com/patent/US10870987B1

## CPC

- E04C 2/205: {of foamed plastics, or of plastics and foamed plastics, optionally reinforced}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/20: foamed in situ
- B32B 5/24: one layer being a fibrous or filamentary layer
- B32B 27/40: comprising polyurethanes
- C08J 9/141: {Hydrocarbons}
- C08J 9/142: {Compounds containing oxygen but no halogen atom}
- C08J 9/144: {containing carbon, halogen and hydrogen only}
- C08J 9/145: {only chlorine as halogen atoms}
- C08J 9/149: {Mixtures of blowing agents covered by more than one of the groups C08J9/141 - C08J9/143}
- B32B 2250/03: 3 layers
- B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
- B32B 2266/0278: Polyurethane
- B32B 2266/08: Closed cell foam
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2307/50: having particular mechanical properties
- B32B 2307/72: Density
- B32B 2307/734: Dimensional stability
- B32B 2419/06: Roofs, roof membranes
- C08J 2203/12: Organic compounds only containing carbon, hydrogen and oxygen atoms, e.g. ketone or alcohol
- C08J 2203/14: Saturated hydrocarbons, e.g. butane; Unspecified hydrocarbons
- C08J 2203/142: Halogenated saturated hydrocarbons, e.g. H3C-CF3
- C08J 2203/182: of physical blowing agents, e.g. acetone and butane
- C08J 2203/202: of physical blowing agents
- C08J 2205/052: Closed cells, i.e. more than 50% of the pores are closed
- C08J 2375/04: Polyurethanes
- C08J 2375/06: from polyesters
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)

## Abstract

A construction board comprising (i) a foam body having a generally planar shape with first and second planar surfaces, where said foam body is a closed-cell foam body including pentane and a blowing agent additive that has a Hansen Solubility Parameter that is greater than 17 MPa−0.5 contained within the foam body; and (ii) first and second facers attached to said first and second planar surfaces, respectively.

## Claims

### Claim 1

A construction board comprising:
(i) a foam body having a generally planar shape with first and second planar surfaces, where said foam body is a closed-cell foam body including an acyclic pentane and a blowing agent additive contained within the foam body, where the blowing agent additive has a Hansen Solubility Parameter of from 17.0 to 35.0 MPa-0.5, where the blowing agent additive has a boiling point, at one atmosphere, of less than 150° C., where said blowing agent additive is selected from the group consisting of ketones, aldehydes, ethers, esters, halogenated hydrocarbons, and aromatics, where the acyclic pentane and the blowing agent additive form a physical blowing agent mixture, where the physical blowing agent mixture includes from about 7 to about 35 mole % of the blowing agent additive based on the total moles of physical blowing agent mixture, where the closed-cell body is a polyurethane or polyisocyanurate foam body prepared by reacting an isocyanate-containing compound with an aromatic polyester polyol, and where the isocyanate-containing compound and the aromatic polyester polyol are reacted at a molar ratio to provide an iso index of at least 220; and
(ii) first and second facers attached to said first and second planar surfaces, respectively.

### Claim 2 (depends on 1)

The construction board of claim 1, where the foam body has a density of 1.0 to 2.5 lbs/ft3.

### Claim 3 (depends on 1)

The construction board of claim 1, where the foam body has an index of at least 225 and a density of 1.2 to 2.2 lbs/ft3.

### Claim 4 (depends on 1)

The construction board of claim 1, where the blowing agent additive has a Hansen Solubility Parameter of from 17.5 to 28.0 MPa−0.5.

### Claim 5 (depends on 1)

The construction board of claim 1, where the blowing agent additive has a Hansen Solubility Parameter that is greater than 19.0 MPa−0.5.

### Claim 6 (depends on 1)

The construction board of claim 1, where the blowing agent additive has a boiling point, at one atmosphere, of greater than 5° C.

### Claim 7 (depends on 1)

The construction board of claim 1, where blowing agent additive and the acyclic pentane are provided in amounts to provide a molar ratio of the blowing agent additive to the acyclic pentane of from about 1:20 to about 1:1.

### Claim 8 (depends on 1)

The construction board of claim 1, where blowing agent additive and the acyclic pentane are provided in amounts to provide a molar ratio of the blowing agent additive to the acyclic pentane of from about 1:4 to about 2:1.

### Claim 9 (depends on 1)

The construction board of claim 1, where the acyclic pentane and the blowing agent additive form a physical blowing agent mixture, and where the physical blowing agent mixture includes from about 10 to about 30 mole % of the blowing agent additive based on the total moles of physical blowing agent mixture.

### Claim 10 (depends on 1)

The construction board of claim 1, where the blowing agent additive is an aldehyde or a ketone.

### Claim 11 (depends on 1)

The construction board of claim 1, where the blowing agent additive is an ester.

### Claim 12 (depends on 1)

The construction board of claim 1, where the blowing agent additive is an ether.

### Claim 13 (depends on 1)

The construction board of claim 1, where the blowing agent additive is a halogenated hydrocarbon.

### Claim 14 (depends on 1)

The construction board of claim 1, where the blowing agent additive is an aromatic compound.