# US 5,352,510 A · Method for continuous manufacture of foam boards with isocyanate-impregnated facers

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- Number: US 5,352,510 A
- Document ID: US5352510A
- Status: Granted
- Kind: A
- Application number: 08/126,864
- Filed: 1993-09-27
- Granted: 1994-10-04
- Earliest claimed: 1993-09-27
- Assignees: The Celotex Corporation
- Inventors: Wayne E. Laughlin; Kenneth P. Klapper
- Web page: https://patentgrep.com/patent/US5352510A

## CPC

- B32B 29/007: {next to a foam layer}
- B29C 44/326: {Joining the preformed parts, e.g. to make flat or profiled sandwich laminates}
- B32B 5/20: foamed in situ
- C08G 18/0895: {Manufacture of polymers by continuous processes (C08G18/0838 takes precedence)}
- C08J 9/12: by a physical blowing agent
- B32B 2266/0278: Polyurethane
- B32B 2317/122: Kraft paper
- B32B 2317/125: impregnated with thermosetting resin
- C08G 2170/60: Compositions for foaming; Foamed or intumescent adhesives
- Y10T 428/249953: Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T 428/31591: Next to cellulosic
- Y10T 442/651: Plural fabric layers
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## 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.

## Claims

### Claim 1

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.

### Claim 2 (depends on 1)

The method of claim 1 wherein the moisture content of the cellulosic sheet is no greater than about 6 weight percent.

### Claim 3 (depends on 1)

The method of claim 1 wherein the cellulosic sheet is less than 0.03 in thick.

### Claim 4 (depends on 1)

The method of claim 1 wherein the foam-forming mixture comprises a mixture for forming a rigid polymer foam selected from the group consisting of polyurethane, polyisocyanurate, phenolic, rubber, polyvinyl chloride, urea-aldehyde, melamine-aldehyde, polystyrene, polypropylene, polyethylene, cellulose acetate, epoxy, acrylonitrile-butadiene-styrene copolymer and silicone foams.

### Claim 5 (depends on 1)

The method of claim 1 wherein the air- and/or moisture-impermeable material is a barrier polymer.

### Claim 6 (depends on 1)

The method of claim 1 wherein the foam-forming mixture comprises a mixture for forming a rigid polymer foam selected from the group consisting of polyurethane and polyisocyanurate foams.

### Claim 7 (depends on 6)

The method of claim 6 wherein the density of the foam core is between 1.5 and 2.5 pounds per cubic foot.

### Claim 8 (depends on 6)

The method of claim 6 wherein the foam-forming mixture comprises a polyisocyanate, a polyol, a surfactant, a catalyst, and a blowing agent selected from the group consisting of water, air, nitrogen, carbon dioxide, readily volatile organic substances, compounds which decompose to liberate gases and combinations thereof.

### Claim 9 (depends on 1)

The method of claim 1 for continuously producing an insulation board having cellulosic sheets on both major surfaces of the foam core comprising:
(a) conveying at least one lower cellulosic sheet along the production line,
(b) depositing the foam-forming mixture on the lower cellulosic sheet,
(c) placing at least one advancing upper cellulosic sheet on the deposited foam-forming mixture to form an advancing sandwich of upper and lower cellulosic sheets and intermediate foam-forming mixture, and
(d) foaming and curing the foam-forming mixture in contact with, the cellulosic sheets to form a rigid plastic foam core covered on both major surfaces with the cellulosic sheets.

### Claim 10 (depends on 9)

The method of claim 9 wherein:
(a) the advancing sandwich of upper and lower cellulosic sheets and intermediate foam-forming mixture is passed through the nip of two rotating rolls to meter the amount of the foam-forming mixture, and
(b) the sandwich is thereafter passed from the nip of the two rotating rolls into a heated expansion zone, whereby the foam-forming mixture expands and cures in contact with the cellulosic sheets to form the rigid plastic foam core covered with the cellulosic sheets.

### Claim 11 (depends on 10)

The method of claim 10 wherein the moisture content of each cellulosic sheet is no greater than about 6 weight percent.

### Claim 12 (depends on 10)

The method of claim 10 wherein each cellulosic sheet is less than 0.03 in thick.

### Claim 13 (depends on 10)

The method of claim 10 wherein the foam-forming mixture comprises a mixture for forming a rigid polymer foam selected from the group consisting of polyurethane and polyisocyanurate foams.

### Claim 14 (depends on 10)

The method of claim 10 wherein the foam-forming mixture comprises a mixture for forming a rigid polyisocyanurate foam.

### Claim 15 (depends on 10)

The method of claim 10 wherein the heated expansion zone contains a pair of substantially horizontal, vertically spaced continuous conveyors to limit the maximum distance the outer surfaces of the cellulosic sheets can move apart, whereby the foam-forming mixture expands to the extent permitted by the conveyors and the resultant foam cures in contact with the cellulosic sheets to form the rigid plastic foam core covered with the cellulosic sheets.

### Claim 16 (depends on 15)

The method of claim 15 wherein the moisture content of each cellulosic sheet is no greater than about 6 weight percent and each cellulosic sheet is less than 0.03 in thick.

### Claim 17 (depends on 15)

The method of claim 15 wherein the foam-forming mixture comprises a mixture for forming a rigid polymer foam selected from the group consisting of polyurethane and polyisocyanurate foams.

### Claim 18 (depends on 1)

The insulation board produced by the method of claim 1.

### Claim 19 (depends on 10)

The insulation board produced by the method of claim 10.

### Claim 20 (depends on 15)

The insulation board produced by the method of claim 15.

### Claim 21 (depends on 1)

The method of claim 1 wherein the air- and/or moisture-impermeable material is positioned on the outside surface of the cellulosic sheet and is selected from the group consisting of a barrier polymer and a metallic foil sheet.

### Claim 22 (depends on 21)

The method of claim 21 wherein the air- and/or moisture-impermeable material comprises an aluminum foil sheet.

### Claim 23 (depends on 22)

The method of claim 22 wherein the second facing material is conveyed along the line and attached to the core, and each facing material comprises a composite of the polyisocyanate-impregnated cellulosic sheet with an aluminum foil sheet positioned on the outside surface of the cellulosic sheet.

### Claim 24 (depends on 23)

The method of claim 23 wherein the foam-forming material comprises a mixture for forming a rigid polymer foam selected from the group consisting of polyurethane and polyisocyanurate foams.

### Claim 25 (depends on 24)

The method of claim 24 wherein the foam-forming material comprises a mixture for forming a rigid polyisocyanurate foam.

### Claim 26 (depends on 21)

The insulation board produced by the method of claim 21.

### Claim 27 (depends on 23)

The insulation board produced by the method of claim 23.

### Claim 28 (depends on 24)

The insulation board produced by the method of claim 24.

### Claim 29 (depends on 25)

The insulation board produced by the method of claim 25.