Structural laminates made with novel facing sheets
AssigneeAtlas Roofing Corporation
InventorRobert H. Blanpied
Life of this patent
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Abstract
A structural laminate comprises at least one planar facing sheet comprised largely of glass fibers but not having micro-glass as a filler. The facing sheet is self adhered to a rigid thermosetting plastic foam core. The non-glass filler material is chosen from a group consisting of clay, mica, talc, limestone (calcium carbonate), gypsum (calcium sulfate), aluminum trihydrate (ATH), antimony oxide, cellulose fibers, and plastic polymer fibers. The non-glass filler material improves containment of liquid plastic thermosetting polymer, and offers economic and safety advantages.
Claims7
A thermosetting plastic foam laminate comprising:
- (1) at least one planar facing sheet comprising:
- (A) from 60% to 90% by weight glass fibers exclusive of glass micro-fibers, and
- (B) from 10% to 40% by weight non-glass filler material, and
- (C) from 1% to 30% by weight non-asphaltic binder material which bonds the fibers together and bonds the filler materials to the fibers;
- (2) a rigid foam integrally attached upon formation of the foam to the surface of a facing sheet, the rigid foam formed from a thermosetting catalyzed plastic reaction product capable of being foamed.
A method of making a thermosetting plastic foam laminate, said method comprising:
- binding a non-glass filler material to a mat of glass fibers which does not contain glass micro-fibers to form a planar facing sheet, whereby said planar facing sheet comprises from 60% to 90% by weight glass fibers and from 10% to 40% by weight non-glass filler material;
- attaching a rigid foam formed from a thermosetting catalyzed plastic reaction product capable of being foamed to said planar facing sheet upon formation of the foam.
The method of 4, wherein said non-glass filler material is chosen from a group consisting of clay, mica, talc, limestone (calcium carbonate), gypsum (calcium sulfate), aluminum trihydrate (ATH), antimony oxide, cellulose fibers, and plastic polymer fibers.
Dependencies are inferred from the claim text.