Method for continuous manufacture of foam boards with isocyanate-impregnated facers
AssigneeThe Celotex Corporation
InventorsWayne E. Laughlin, Kenneth P. Klapper
Life of this patent
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Abstract
A method for the manufacture of paper faced foam which comprises (a) applying a foam-forming mixture to at least one advancing cellulosic sheet or composite thereof with an air- and/or moisture-impermeable material, the cellulosic sheet (i) being impregnated with cured polyisocyanate, (ii) being sufficiently flexible for unwinding from a roll for conveyance along a production line and (iii) having a moisture content which does not exceed about 10 percent and is evenly distributed throughout the cellulosic sheet, and (b) foaming and curing the faced foam-forming mixture.
Claims29
A method for continuously producing an insulation board 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 facing material along a production line for attachment to one major surface of the core,
- (b) applying a foam-forming mixture to the facing material,
- (c) optionally conveying a second facing material along the line for attachment to the other major surface of the core, at least one facing material comprising a cellulosic sheet or a composite of a cellulosic sheet with an air- and/or moisture-impermeable material, the air- and/or moisture-impermeable material being interposed between the cellulosic sheet and the foam-forming mixture or being positioned on the outside surface of the cellulosic sheet, wherein the cellulosic sheet has been impregnated with about 5 to 20% by weight of polyisocyanate, and the polyisocyanate has been cured, and the cellulosic sheet is (i) sufficiently flexible so that it can be supplied from a roll for conveyance along the production line, and (ii) has a moisture content not exceeding about 10 percent, the moisture being substantially evenly distributed throughout the cellulosic sheet, and
- (d) foaming and curing the faced foam-forming mixture.
Dependencies are inferred from the claim text.