Scrim/foil laminate
AssigneeBay Mills Limited
InventorTerence J. O'Connor
Life of this patent
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Abstract
A laminate providing a high strength, low flammability improved moisture vapor barrier for use in producing improved construction panels, to the construction panels which comprise a polyurethane foam interior having a top and a bottom laminate skin bonded thereto, and to the process for producing the construction panels. The laminate is composed of an outer metal skin, e.g., aluminum foil, a scrim and an adhesive tie-coat attaching the scrim to the outer skin. The adhesive tie-coat is carefully selected so that it will react during manufacture of the polyurethane foam to produce the panel and tightly bond the foam to the foil. The tie-coat is preferably a high molecular weight, linear epoxy resin adhesive having free hydroxyl groups which react with the isocyanate, or isocyanurate, used in producing the polyurethane foam.
Claims19
A laminate providing a high strength, low flammability, moisture vapor barrier, especially adapted for use in polyurethane foam construction panels comprising
- a metal foil;
- an adhesive tie-coat coating one surface of said foil, said tie-coat comprising an organic adhesive compound having a high hydroxyl functionality, low organic acid functionality, low flammability, and which is thermoplastic at temperatures above about 200.degree. F.;
- and
- a scrim attached to said foil by the tie-coat, said scrim being made of yarns which are non-flammable and dimensionally stable.
A process for producing a laminated construction panel comprising a polyurethane foam interior of a desired thickness having on at least one surface thereof a laminate comprising a metal foil, a scrim and a tie-coat and providing a high strength, low flammability, moisture vapor barrier, comprising
- coating a surface of said metal foil with said tie-coat;
- attaching said scrim to the tie-coated surface while said tie-coat is thermoplastic;
- producing on said tie-coated surface a polyurethane foam of said desired thickness, said polyurethane foam being prepared from polyurethane foam producing hydroxyl containing materials and an isocyanate material comprising an isocyanate or isocyanurate;
- said tie-coat comprising an organic adhesive compound having a hydroxyl functionality sufficient to provide hydroxyl groups in an amount effective to react with said polyurethane foam components during manufacture of the foam and bond the foam to the foil, a low organic acid functionality, low flammability and which is thermoplastic at temperatures above about 200.degree. F.
Dependencies are inferred from the claim text.