Coated reinforced composite facer and insulation assembly including the same

An insulation assembly comprising:

• a) an insulation substrate having a first insulation surface and a second insulation surface;
• and
• b) a coated reinforced composite facer, wherein the coated reinforced composite facer comprises:
• i) a carrier substrate having a first carrier surface and a second carrier surface;
• ii) a scrim;
• iii) a thermoplastic coating positioned between the scrim and the first carrier surface, wherein the thermoplastic coating adheres the scrim to the first carrier surface and comprises at least one of a polyolefin, a polyester, a polyamide, a polyimide, a polycarbonate, a polyurethane, or a fluoropolymer;
• and
• iv) a mineral coating adhered to the second carrier surface,
• wherein the scrim is attached to the first insulation surface or the second insulation surface.

A method of making a coated reinforced composite facer, the method comprising:

• a) directing a carrier substrate having a first carrier surface and a second carrier surface, a scrim, and a molten thermoplastic coating comprising at least one of a polyolefin, a polyester, a polyamide, a polyimide, a polycarbonate, a polyurethane, or a fluoropolymer into a laminating device such that the molten thermoplastic coating is positioned between the scrim and the first carrier surface;
• b) laminating together the scrim, the molten thermoplastic, and the carrier substrate;
• and
• c) applying a mineral coating onto the second carrier surface, thereby forming the coated reinforced composite facer.