Foam insulation board faced with polymer-fibrous sheet composite
AssigneeThe Celotex Corporation
InventorsDavid G. Gluck, Wayne E. Laughlin
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Abstract
A thermally insulating structural laminate comprising a core of rigid plastic foam having two major surfaces, at least one of the major surfaces of the foam being attached to a facer comprising a fribrous sheet having at least one layer of an air- and moisture-impervious polymer disposed on the inner surface thereof and interposed between the fibrous sheet and the foam, the oxygen transmission of the polymer being a value of less than about 1 cc/100 in.sup.2 -24 hrs-atm sufficient to make the facer substantially impervious to the passage of air and water vapor, resulting in the long-term preservation of insulation value.
Claims44
A thermally insulating structural laminate comprising a core of rigid plastic foam having two major surfaces, at least one of the major surfaces of the foam being attached to a facer comprising a fibrous sheet having at least one polymeric layer comprising a vinylidene chloride copolymer disposed on the inner surface thereof and interposed between the fibrous sheet and the foam, the oxygen transmission of the facer being a value of less than about 1 cc/100 in.sup.2 -24 hrs-atm sufficient to make the facer substantially impervious to the passage of air and water vapor, and the foam being formed in contact with the polymeric layer.
A process for continuously producing a thermally insulating structural laminate comprising a rigid plastic foam core having two major surfaces and a facing material on at least one of the major surfaces, the method comprising:
- (a) conveying a lower facing material along a production line;
- (b) applying a foam-forming mixture to the lower facing material;
- (c) optionally supplying an upper facing material over the applied foam-forming mixture, at least one facing material comprising a fibrous sheet having at least one polymeric layer comprising a vinylidene chloride copolymer disposed on one surface thereof, the oxygen transmission of the facing material being a value of less than about 1 cc/100 in.sup.2 -24 hrs-atm sufficient to make the facing material substantially impervious to the passage of air and water vapor, and the fibrous sheet being positioned so that the polymeric layer is brought into contact with the foam-forming mixture;
- and
- (d) foaming and thermally curing the foam-forming mixture.
Dependencies are inferred from the claim text.