U.S. patent application number 10/489014 was filed with the patent office on 2005-02-24 for composite foam products and method.
Invention is credited to Burgess, James H., Glorioso, Sammie J. (Joey).
Application Number | 20050042436 10/489014 |
Document ID | / |
Family ID | 23239241 |
Filed Date | 2005-02-24 |
United States Patent
Application |
20050042436 |
Kind Code |
A1 |
Glorioso, Sammie J. (Joey) ;
et al. |
February 24, 2005 |
Composite foam products and method
Abstract
Composite foam products and methods utilize a foam core to which
upper and lower consolidated fiberglass sheets are adhered. The
foam may be manufactured alternatively by directly foaming onto the
fiberglass sheets or by foaming between facer sheets and using an
adhesive to secure the fiberglass sheets thereto. A sufficient
adhesion between the fiberglass sheets and the foam core is
required to produce a strong lightweight sheet material suitable
for use as a structural building component in lieu of wood or the
like. The composite product has excellent strength and lightweight
characteristics.
Inventors: |
Glorioso, Sammie J. (Joey);
(Ridgeland, MS) ; Burgess, James H.; (Greenville,
SC) |
Correspondence
Address: |
VOLPE AND KOENIG, P.C.
UNITED PLAZA, SUITE 1600
30 SOUTH 17TH STREET
PHILADELPHIA
PA
19103
US
|
Family ID: |
23239241 |
Appl. No.: |
10/489014 |
Filed: |
March 8, 2004 |
PCT Filed: |
September 11, 2002 |
PCT NO: |
PCT/US02/28838 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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60318699 |
Sep 12, 2001 |
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Current U.S.
Class: |
428/304.4 ;
428/311.11; 428/311.51 |
Current CPC
Class: |
B32B 2262/0276 20130101;
B32B 2038/047 20130101; B32B 2266/0278 20130101; B32B 5/18
20130101; B32B 2038/0084 20130101; Y10T 156/1788 20150115; B32B
2262/0253 20130101; B32B 37/12 20130101; Y10T 428/249953 20150401;
B32B 2262/101 20130101; E04C 2/296 20130101; B29C 44/326 20130101;
Y10T 428/249964 20150401; B32B 2262/14 20130101; B32B 5/26
20130101; B32B 2305/08 20130101; B32B 5/245 20130101; Y10T
428/249962 20150401; B32B 7/12 20130101; B32B 2607/00 20130101 |
Class at
Publication: |
428/304.4 ;
428/311.11; 428/311.51 |
International
Class: |
B32B 003/26; B32B
005/24; D21H 011/00; D21H 013/00 |
Claims
What is claimed is:
1. A laminated foam product comprising a PUR/PIR foam core having a
density of at least four pounds per cubic foot and upper and lower
consolidated fiberglass sheets, wherein said consolidated
fiberglass sheet adheres to said foam core such that said product
has a tensile strength in the lamination direction of at least 30
psi.
2. The invention according to claim 1 wherein said foam core is
foamed between facer sheets and the upper and lower fiberglass
layers are adhesively secured to said facer sheets.
3. The invention according to claim 1 wherein the foam core is
foamed directly onto and between the fiberglass layers.
4. The laminated foam product according to claim 1, wherein the
consolidated fiberglass sheets are comprised of textile fiberglass
commingled with a material selected from the group consisting of a
polypropylene and polyester fiber.
5. The laminated foam product according to claim 1, wherein the
consolidated fiberglass sheets are comprised of continuous filament
fiberglass commingled with a material selected from the group
consisting of a polypropylene and polyester fiber.
6. The laminated foam product according to claim 1, wherein at
least one of the consolidated fiberglass sheets has a weight of at
least 10 ounces per square yard.
7. The laminated foam product according to claim 1, wherein at
least one of the consolidated fiberglass sheets has thickness of
less than 3 mm.
8. The laminated foam product according to claim 1, wherein at
least one of the consolidated fiberglass sheets has thickness
between about 0.5 mm and about 1.0 mm.
9. The laminated foam product according to claim 1, wherein the
laminate foam product has a thickness range of about 0.5 inches to
about 2.0 inches.
10. The laminated foam product according to claim 1, wherein the
laminate foam product has a thickness range of about 0.75 inches to
about 1.0 inches, and the consolidated fiberglass sheets have a
weight range of about 22 ounces per square yard to 44 ounces per
square yard.
11. A laminated foam product comprising: (a) a first layer
comprising a consolidated fiberglass sheet; (b) a second layer
bonded to the first layer, wherein the second layer comprises a
facer sheet; (c) a third layer bonded to the second layer, wherein
the third layer comprises a rigid PUR/PIR foam having a density of
at least four pounds per cubic foot; (d) a fourth layer bonded to
the third layer, wherein the fourth layer comprises a facer sheet;
and (e) a fifth layer bonded to the fourth layer, wherein the fifth
layer comprises a consolidated fiberglass sheet.
12. The laminated foam product according to claim 11, wherein at
least one said facer sheet comprises paper.
13. The laminated foam product according to claim 12, wherein the
paper facer sheet further comprises a fiberglass.
14. The laminated foam product according to claim 11, wherein at
least one said facer sheet comprises polypropylene.
15. The laminated foam product according to claim 11, wherein said
second layer facer sheet contains perforations such that said first
layer consolidated fiberglass sheet is at least in part directly
adhered to said foam.
16. The laminated foam product according to claim 11 wherein said
consolidated fiberglass sheets have a weight of at least 10 ounces
per square yard.
17. The laminated foam product according to claim 11, wherein said
consolidated fiberglass sheets have a thickness of less than 3
mm.
18. The laminated foam product according to claim 11, wherein the
laminate foam product has a thickness range of about 0.5 inches to
about 2.0 inches.
19. The laminated foam product according to claim 18, wherein the
laminate foam product has a thickness range of about 0.75 inches to
about 1.0 inches, said consolidated fiberglass sheets have a weight
range of about 22 ounces per square yard to 44 ounces per square
yard, and said facer sheets are attached to the consolidated
fiberglass sheet by means of moisture curing thermoset
adhesive.
20. A method for manufacturing panels comprising extruding PUR/PIR
foam ingredients to forming a PUR/PIR foam, and selectively
applying upper and lower sheets of consolidated fiberglass
material, such that said consolidated fiberglass sheets are adhered
to said foam with a tensile strength in the lamination direction of
at least 30 psi.
21. The method according to claim 20, wherein the extruded
ingredients are foamed directly onto at least one of the fiberglass
sheets, and wherein said foam is cured between said upper and lower
sheets of consolidated fiberglass material.
22. The method according to claim 20, wherein said consolidated
fiberglass material sheets has thickness between about 0.5 mm and
about 1.0 mm, wherein said fiberglass material is comprised of
continuous filament fiberglass commingled with a material selected
from the group consisting of a polypropylene and polyester fiber,
and said consolidated fiberglass sheets are applied to an amount of
foam which results in a laminate foam product having a thickness
between about 0.5 inches and about 2.0 inches.
23. The method according to claim 20, wherein said consolidated
fiberglass material sheets are cleaned by a corona treatment before
being selectively applied to said foam.
24. The method according to claim 20, wherein the PUR/PIR foam
ingredients are foamed between facer sheets and the upper and lower
fiberglass sheets are adhesively secured to said facer sheets.
25. The method for manufacturing panels according to claim 24,
further comprising perforating said facer sheets such that the
fiberglass sheets are in part directly adhered to the foam when
they are applied.
26. The method for manufacturing panels according to claim 24,
wherein said facer sheets are attached to the consolidated
fiberglass sheets by means of moisture curing thermoset adhesive.
Description
[0001] The present invention relates to composite PUR/PIR foam core
products and methods and, in particular, the manufacturer of such
foam core products having fiberglass exterior layers utilizing
formulations that produce lightweight, strong sheets and methods of
directly foaming or using adhesives for adhering a consolidated
fiberglass web to the foam core.
BACKGROUND
[0002] Polyurethane and polyisocyanurate (PUR/PIR) foams are well
known in the art. The density of these products is typically 2.0
pounds per cubic foot. Such foam is often used for insulation.
PUR/PIR foam is relatively lightweight, but is generally not used
by itself as a structural building material. It is desirable to
provide PUR/PIR foam products that are lightweight and strong
enough to use in place of plywood, composition board or the
like.
SUMMARY OF THE INVENTION
[0003] The invention provides composite PUR/PIR foam core products
and methods for producing same. Specifically, a composite foam
product having top and bottom layers of a fiberglass fiber web
which are adhered to a foam core to provide strong lightweight
sheets is disclosed. The core foam preferably has a density of at
least four pounds per cubic foot (64 kg/m.sup.3) and tensile
strength in the lamination direction of at least 30 psi (2.1 bar)
stress at break.
[0004] The composite foam may be made by either foaming directly
onto consolidated fiberglass webbing or using an adhesive to apply
top and bottom sheets of such consolidated webbing to premade foam.
Where direct foaming is performed, it is preferable to use an
extruder to mix the PUR/PIR foaming materials which are directly
deposited onto a bottom sheet of the consolidated fiberglass web
and apply a top sheet of the web via use of a conventional oven
laminator. Upon exit from the laminator, the product is cut into
sheets.
[0005] For the adhesion method, preferably the PUR/PIR foam is
formed into sheets having upper and lower facing material using a
conventional laminator such as disclosed in U.S. Pat. No.
4,795,763. To increase adhesion, a perforator is employed to make
holes into the foam sheet through the facer. The foam is preferably
then cut into standardized sheets and equivalent size sheets of
consolidated fiberglass webs are glued to the facing sheets on the
top and bottom of the foam core. The latter method produces less
waste of the consolidated fiberglass web which is generally
significantly more expensive than the foam and facer material.
[0006] The consolidated fiberglass sheet is preferably fiberglass
as a web intermingled with polypropylene or polyester fibers such
as fiberglass sold under the trademark TWINTEX.RTM.. The fiberglass
web is pre-treated using heat and pressure to consolidate the
fibers into a relatively rigid sheet. Preferably the consolidated
web weighs between 22 to 44 ounces per square yard (750-1490
g/m.sup.2) and has a thickness between 0.5 and 1.0 millimeters. For
better adhesion, a corona treatment may also be applied to the web
through which the web is subject to an electric field of about 50
dynes, such as when polypropylene/fiberglass material is used.
During the corona treatment, oxygen molecules within the discharge
area break into their atomic form and are free to bond to the ends
of the molecules in the material being treated, resulting in a
chemically-activated surface.
[0007] The foam composite product produced by the invention may be
commercially utilized to form panels. Such panels may be used in
place of heavier wood pallets and/or plywood. Such panels produced
are lighter and stronger than currently available panels, and have
commercial applications including, but not limited to chicken
cases, desks and tables, marine panels, entry doors, garage doors,
shipping rack floors and bleachers.
[0008] Other objects or advantages of the invention will be
apparent to one of ordinary skill in the art from the following
detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic illustration of a laminator system
which can be used to manufacture a composite foam product in
accordance with the present invention.
[0010] FIG. 2 is a schematic illustration of a preferred foam
mixing system.
[0011] FIG. 3 is a table listing various physical properties of
different embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] The composite foam of the present invention generally
comprises upper and lower layers of a consolidated fiberglass web
which are adhered to PUR/PIR foam core. Relatively thin sheets of
consolidated fiberglass material are used, preferably less than
{fraction (1/8)} inches (3.2 mm) in thickness and having a weight
of at least 10 ounces per square yard (340 g/m.sup.2), preferably
at least 20 ounces per square yard (680 g/cm.sup.2). By providing a
foam core which is sufficiently adhered to the fiberglass material
layers, a rigid lightweight, strong sheet is produced. Preferably
the foam core has a relatively high density of approximately four
(4) pounds per cubic foot (64 kg/m.sup.3) or more. The composite
foam is preferably manufactured to have a thickness of {fraction
(3/4)} inch to one inch (19 to 25 mm).
[0013] Preferably a TWINTEX.RTM. polypropylene/fiberglass web is
pre-treated with heat and pressure to form a consolidated
relatively rigid sheet. The consolidated fiberglass web maybe as
textile fiber glass commingled with either a polypropylene (PP) or
polyester (PET) fiber. Alternatively, the consolidated fiberglass
web may be continuous filament fiberglass commingled with either a
polypropylene (PP) or polyester (PET) fiber. Such consolidated
sheets are commercially available in various thicknesses such as 44
ounce per square foot material which is approximately 1 mm thick,
and 22 ounce per square yard material which is approximately 0.5 mm
thick. However, it is possible to use much thicker fiberglass webs.
Depending on the application it is possible to either produce the
thicker fiberglass web in a single sheet, or make combine several
thinner sheets. Both of these methods of preparing thicker sheets
sheet is well known in the art. Due to the relative cost of the
fiberglass material in comparison to the foam material, it is
preferred to minimize the use of the fiberglass material which is
more expensive. A sufficient thickness of fiberglass material is
required dependent upon the required strength of the resultant
material.
[0014] With reference to FIG. 1, there is shown a foam lamination
system 10. A foam mixing system 100 is provided which mixes the
foam ingredients which are introduced to the laminator system 10.
The laminator is provided with a roll 30 of lower facing material
31 and a roll of 30' of upper facing material 31'. The laminator is
also provided with metering rolls 32, 33, and an enclosed
heating/cooling system wherein the foam is cured which includes
heating section 34a and cooling section 34b. Hot and cold air,
respectively, may be circulated through the respective heating 34a
and cooling 34b sections by respective vents 35a, 35b. The
laminator also includes pull rolls 36, 37. A cutter 40a for cutting
off side excess material and a cutter 40b for severing the foam
produced into desired lengths, thereby producing panels of a
desired size. Although only one side cutter is shown, cutters are
provided on both sides of the laminator. The pull rolls 36 and 37
may have respective flexible outer sheaths 38, 39 or can be
configured with spikes to make perforations in the foam. Outer
sheaths 38, 39 are preferably provided with spikes when a separate
adhesion process is used to apply the consolidated fiberglass
sheeting material where direct foaming onto the fiberglass sheeting
material is performed, no perforations are made. In lieu of spikes
on the pull rolls, a separate perforator may be provided where
needed.
[0015] One method for making the composite foam products is to
supply the upper and lower layers of consolidated fiberglass web
material from rolls 30, 30' as sheets 31 and 31'. The PUR/PIR foam
core material is deposited from mixing equipment 100 onto the
bottom layer 31 of the consolidated fiberglass web directly and the
upper and lower layers of fiberglass web material bond to the
PUR/PIR foam as it passes through the heating and cooling sections
34a, 34b of the laminator 10. The laminated product is cut to size
via cutters 40a, 40b. However, inherent in this process is the side
waste material produced by the side cutter 40a. If during the
manufacturing process some defect is uncovered in the foam, the
entire panels may need to be discarded which results in scrapping
not only the foam core, but the adhered relatively expensive
fiberglass layers.
[0016] To reduce the potential for excessive scrap of relatively
expensive fiberglass web material, an alternate method is provided
to make the composite product. In lieu of foaming the PUR/PIR foam
directly onto the fiberglass web material, the core foam is foamed
onto inexpensive facing sheets such as paper sheets which may
contain a small amount of fiberglass fibers. Top and bottom face
sheets are applied as sheets 31, 31' of FIG. 1 and a perforator is
provided such as by using spikes on sheaths 38 and 39 to form small
holes in the foam. Foam sheets 46 of a desired size having front
and back facers are then further processed by applying
correspondingly sized sheets of the consolidated fiberglass web
material using an adhesive. Preferably a polyurethane moisture cure
thermoset adhesive such as ISO-SET 3030D, available from Ashland
Specialty Chemical Company, a division of Ashland, Inc.
[0017] Preferably the perforations through the facer are between
1/8 and {fraction (1/16)} of an inch in diameter and between
{fraction (1/2)} and {fraction (3/4)} of an inch deep. By
increasing the number of perforations and the amount of adhesive
applied, significant increases in adhesion of the fiberglass web
layers is achieved as reflected in the examples below.
[0018] With reference to FIG. 2, there is shown a preferred foam
mixing system in the form of an extruder system 102 comprising a
twelve-barrel extruder 104 and a reservoir system 106 for
introducing the various components into the extruder barrels C1-C12
during the foam making process. In addition to reservoirs 151, 153,
154, 155 and 156 for the introduction of fluid material, the
extruder includes feed ports 150 and 152 where granular material
and solids may be conveniently added and mixed in the screw of the
extruder as explained in detail in U.S. Patent RE 37,095.
Conventionally, the reservoirs 151, 153, 154, 155 and 156 are
maintained on site with the extruder in the foam manufacturing
area.
[0019] In manufacturing foam using the extrusion system of FIG. 2,
filler material such as glass fibers and/or microspheres may be
provided to the extruder system 102 at barrels C1 and C4 from
hoppers 150 and 152. A mixture of isocyanate and optionally
surfactant is preferably fed to the extruder 104 at barrel C2 from
reservoir 151. An additional mixture of isocyanate and optionally
surfactant may also be added to the extruder 104 at barrel C6 from
reservoir 153. A foaming agent (blowing agent) such as isopentane,
n-pentane, cyclopentane, other hydrocarbons,
hydrochlorofluorocarbons (HCFC), hydrofluorocarbons (HFC) or any
combination thereof is provided to the extruder 104 at barrel C8
from reservoir 154. Polyol, a foaming agent, such as pentane, HCFC,
or HFC, and surfactant are preferably fed to the extruder 104 at
barrel C9 from reservoir 155. If water is utilized as the
foaming/blowing agent precursor, it may be mixed with the polyol in
reservoir 155, thereby producing CO.sub.2 when it mixes with the
isocyanate. Alternatively, water and liquid CO.sub.2 may be
utilized. Finally, a catalyst or catalyst mixture, such as an amine
and potassium octoate is provided to the extruder head 120 from
reservoir 156. The extruded mixture of PUR/PIR foam ingredients
exits the extruder head 120 and is deposited in the laminator 10
where it foams, firms and cures during the lamination process as
discussed above in conjunction with FIG. 1.
[0020] A preferred formulation for the PUR/PIR foam include the
following ingredients identified as parts per weight:
1 TABLE 1 Polyester or Polyether Polyol 408 Surfactant 8.2 Blowing
Agent 6-45 Glass or Polymeric Microspheres 0-180 Catalyst 14.2
Isocyanate 400-650
EXAMPLES
[0021] Foam was made using the extruder and laminator using both
the direct foaming method and the adhesion foaming method onto
consolidated TWINTEX.RTM. polypropylene material having a thickness
of approximately 1 millimeter and weight of approximately 44 ounces
per square yard. The foam was made by introducing isocyanate at
barrels C2 and C6 of approximately 600 parts per weight of the foam
materials. An HCFC blowing agent 141b, available from Elf Atochem,
was introduced in extruder barrel C8 in the amount of about 20
parts per weight of the foam ingredients. A polyester polyol in the
amount of about 408 parts per weight, a silicon based surfactant,
available from Goldschmidt, in the amount of about 8.2 parts per
weight, and additional blowing agent, HCFC 22 available from
DuPont, in the amount of about 15 parts per weight were added to
the other foam ingredients in barrel C9 of the extruder 104.
Catalysts in the form of potassium octoate in the amount of about
12.2 parts per weight and amine, preferably DABCO.RTM. TMR-30
available from Air Products and Chemicals, in the amount of about 2
parts per weight were added in the extruder head from which the
mixed foam ingredients were extruded to produce the foam core
material.
[0022] In a first example, identified as Example 1, the foam was
extruded between facing sheets of polypropylene coated glass having
a weight of approximately 8 ounces per square yard and formed into
sheets of a pre-determined size. Thereafter ISO-SET 3030D
polyurethane moisture cure thermoset adhesive was applied to both
sides of the sheet to adhere upper and bottom layers of the
consolidated TWINTEX.RTM. polypropylene web.
[0023] In a second example, identified as Example 2, the same
process was followed, but the facer sheets which were used were a
20 gauge black paper having small amounts of fiberglass available
from GAF having a weight of approximately 5 ounces per square
yard.
[0024] A third example of composite product was made, identified as
Example 3, referred to as "direct" wherein the foam materials were
extruded directly between sheets of the consolidated TWINTEX.RTM.
polypropylene web to produce the consolidated product through the
laminator without any further adhesion processing. The tensile
strength tests showed that the direct sample exhibited excellent
adhesion strength.
[0025] The direct foam composite product proved to be an excellent
replacement for wood, but lighter in weight. Table 2 reflects
compressive strength of two samples 3a, 3b of the composite foam
made using the direct foam application method. The consolidated
sheets having a finished thickness of {fraction (3/4)} inches and a
core density of approximately 4.5 pounds per cubic foot.
2 TABLE 2 Sample 3a 3b Load at Max. Load (lbf) 724 761 Stress at
Max. Load (psi) 196 206 Load @ 10% Strain (lbf) 356 336 Stress @
10% Strain (psi) 96.5 90.9
[0026] A fourth example of the laminated product, identified as
Example 4, was made using the same foam formulation and facer as
used in sample 2, i.e. the black paper, but the number of
perforations in the faced foam was increased and the amount of
adhesive was increased in applying the TWINTEX.RTM. polypropylene
web. This dramatically improved the adhesion.
[0027] Additional samples were made utilizing only HCFC 141b as the
blowing agent in the amount of 30 parts per weight instead of
combination of HCFC 141b and HCFC 22 referenced above. In example
5, the foam was directly deposited onto the TWINTEX.RTM.
polypropylene web on a cleaned web having corona treatment. In
example 6, the foam was deposited on corona treated consolidated
TWINTEX.RTM. polypropylene without any cleaning.
[0028] While various parameters may vary, excellent lightweight,
strong structural sheet material has been produced through the
adhesion of relatively thin sheets of fiberglass with relatively
dense PUR/PIR foam core having a sufficient adhesion between the
core and the fiberglass.
* * * * *