Barrier coating composition for use in manufacturing insulation products with reduced halogenated blowing agents

A coated polymeric insulation product comprising:

• a polymer foam product having a first major surface, an opposing second major surface, and a plurality of minor surfaces extending therebetween, the foam product being formed from a foamable polymer composition comprising:
• a) a polymer matrix composition;
• and
• b) a blowing agent composition comprising 3 wt. % or less of a fluorinated alkene and at least 1.5 wt. % CO2, based on a total weight of the foamable composition;
• and
• a barrier coating present on each surface of the foam product in a total amount between 3 g/m2 and 225 g/m2, the barrier coating being formed from a barrier coating composition comprising a semi-crystalline polymer and at least one rheology modifier, the barrier coating composition having a surface tension no greater than 20 mN/m above a surface energy of the polymer foam and a viscosity between 50 cP and 5000 cP at 70% solids or less,
• wherein the coated insulation product has a 180-day R/in value of at least 4.8 and a compressive strength between 10 and 110 psi, measured in accordance with ASTM C578.

A sheathing system comprising:

• at least one structural portion, having a first surface and an opposing second surface;
• and
• at least one coated insulation product adhered to one of the first or second surfaces of the structural portion, the coated insulation product comprising:
• a foam product having a first major surface, an opposing second major surface, and four minor surfaces extending therebetween, the foam product being formed from a foamable composition comprising:
• a) a matrix composition;
• and
• b) a blowing agent composition comprising less than 3.5 wt. % of a fluorinated alkene, based on a total weight of the foamable composition;
• and
• a barrier coating present on at least one surface of the foam product in a total amount between 3 g/m2 and 225 g/m2, the barrier coating being formed from a barrier coating composition comprising:
• 40 wt. % to 99.9 wt. % of a barrier polymer, based on a total solids content of the barrier coating composition, the barrier polymer having a minimum degree of crystallinity of 10%;
• and
• 0.1 wt. % to 60 wt. % of at least one additive, based on a total solids content of the barrier coating composition, wherein the barrier coating composition has a surface tension no greater than 60 mN/m, and wherein the coated insulation product has a 180-day R/in value of at least 4.8.

A method of manufacturing a coated insulation product with reduced fluorinated blowing agent content, comprising:

• mixing a matrix polymer with 2.5 wt. % to 6.5 wt. % of a blowing agent composition to form a foamable polymer composition, the blowing agent composition comprising less than 3.5 wt. % of a fluorinated alkene, based on a total weight of the foamable composition;
• foaming the foamable polymer composition to produce a foam product having a first major surface, an opposing second major surface, and four minor surfaces extending therebetween;
• and
• applying a barrier coating to at least one surface of the foam product in a total amount between 3 g/m2 and 225 g/m2, the barrier coating being formed from a barrier coating composition comprising:
• 40 wt. % to 99.9 wt. % of a barrier polymer, based on a total solids content of the barrier coating composition, the barrier polymer having a minimum degree of crystallinity of 10%;
• and
• 0.01 wt. % to 60 wt. % of at least one additive, based on a total solids content of the barrier coating composition, wherein the barrier coating composition has a surface tension no greater than 40 mN/m, and wherein the coated insulation product has a 180-day R/in value of at least 4.8.