A Foam-Based, Structural Construction Panel

A method of preparing a foam-based, structural construction panel comprising:

• mixing a polyol with additives to form a resin mixture;
• blending the resin mixture with a suitable compound comprising isocyanate reactive groups to produce a polyurethane (PUR) or polyisocyanurate (PIR) closed cell, rigid insulation foam;
• dispensing the PUR or PIR closed cell, rigid insulation foam onto a porous structural board, said porous structural board in a mold, said mold comprising at least one plate and said mold arranged to contain the PUR or PIR closed cell, rigid insulation foam between the porous structural board and an opposite surface of the foam-based structural construction panel and sidewalls to contain the foam on four sides;
• subjecting the PUR or PIR closed cell, rigid insulation foam on the porous structural board in the mold to suitable temperature for a suitable period of time such that said PUR or PIR closed cell, rigid insulation foam enters into pores of the porous structural board and thereby bonds chemically and mechanically at and below the surface of the porous structural board, thereby forming a foam-based, structural construction panel.

A method of preparing a foam-based, structural construction panel comprising:

• mixing a polyol with additives to form a resin mixture;
• blending the resin mixture with a suitable compound comprising isocyanate reactive groups to produce a polyurethane (PUR) or polyisocyanurate (PIR) closed cell, rigid insulation foam;
• dispensing the PUR or PIR closed cell, rigid insulation foam onto a porous structural board, said porous structural board in a mold, said mold comprising at least one plate and said mold arranged to contain the PUR or PIR closed cell, rigid insulation foam between the porous structural board and an opposite surface of the foam-based, structural construction panel and sidewalls to contain the foam on two sides;
• subjecting the PUR or PIR closed cell, rigid insulation foam on the porous structural board in the mold to suitable temperature for a suitable period of time such that said PUR or PIR closed cell, rigid insulation foam enters into pores of the porous structural board and thereby bonds chemically and mechanically at and below the surface of the porous structural board, thereby forming a foam-based, structural construction panel.