U.S. patent application number 11/786921 was filed with the patent office on 2007-08-23 for method for manufacturing composite foam products.
This patent application is currently assigned to IP Rights, LLC. Invention is credited to James H. Burgess, Sammie J. (Joey) Glorioso.
Application Number | 20070193677 11/786921 |
Document ID | / |
Family ID | 23239241 |
Filed Date | 2007-08-23 |
United States Patent
Application |
20070193677 |
Kind Code |
A1 |
Glorioso; Sammie J. (Joey) ;
et al. |
August 23, 2007 |
Method for manufacturing composite foam products
Abstract
A method for manufacturing a laminated foam product in which
first and second consolidated fiberglass sheets are adhered to a
foam core. The consolidated fiberglass sheets are made of
fiberglass commingled with a polymer fiber and pre-treated with
heat and pressure. PUR/PIR foam ingredients are applied between the
first and second consolidated fiberglass sheets to form a PUR/PIR
foam. The foam may be manufactured 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
|
Assignee: |
IP Rights, LLC
Birmingham
AL
|
Family ID: |
23239241 |
Appl. No.: |
11/786921 |
Filed: |
April 11, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10489014 |
Mar 8, 2004 |
|
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PCT/US02/28838 |
Sep 11, 2002 |
|
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11786921 |
Apr 11, 2007 |
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60318699 |
Sep 12, 2001 |
|
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Current U.S.
Class: |
156/244.11 ;
156/244.12; 156/244.15; 156/272.6; 156/281 |
Current CPC
Class: |
B29C 44/326 20130101;
B32B 5/245 20130101; B32B 2607/00 20130101; B32B 37/12 20130101;
B32B 7/12 20130101; Y10T 156/1788 20150115; B32B 2262/0276
20130101; B32B 2266/0278 20130101; Y10T 428/249962 20150401; Y10T
428/249953 20150401; B32B 2262/0253 20130101; B32B 2305/08
20130101; B32B 2262/101 20130101; B32B 5/26 20130101; Y10T
428/249964 20150401; B32B 2262/14 20130101; B32B 2038/047 20130101;
B32B 5/18 20130101; B32B 2038/0084 20130101; E04C 2/296
20130101 |
Class at
Publication: |
156/244.11 ;
156/244.12; 156/244.15; 156/281; 156/272.6 |
International
Class: |
B29C 47/00 20060101
B29C047/00; B32B 37/00 20060101 B32B037/00; B32B 37/24 20060101
B32B037/24; B32B 38/16 20060101 B32B038/16 |
Claims
1. A method for manufacturing a laminated foam product comprising:
providing first and second consolidated fiberglass sheets, wherein
a material made of fiberglass commingled polymer fiber is
pre-treated with heat and pressure to form the consolidated
fiberglass sheets; and applying PUR/PIR foam ingredients between
the first and second consolidated fiberglass sheets to form the
foam product having a PUR/PIR foam core disposed between the first
and second consolidated fiberglass sheets.
2. The method of claim 1, wherein the step of pre-treating the
fiberglass material forms a single layer consolidated fiberglass
sheet.
3. The method of claim 1, wherein the first and second consolidated
fiberglass sheets are rigid.
4. The method of claim 1, further comprising curing the PUR/PIR
foam ingredients between the first and second consolidated
fiberglass sheets.
5. The method of claim 4, wherein a heating/cooling system is used
to cure the PUR/PIR foam ingredients.
6. The method of claim 1, further comprising bonding the PUR/PIR
foam core directly to the first and second consolidated fiberglass
sheets.
7. The method of claim 1, further comprising extruding the PUR/PIR
foam ingredients between the first and second consolidated
fiberglass sheets.
8. The method of claim 1, wherein the PUR/PIR foam core has a
density of at least four pounds per cubic foot.
9. The method of claim 1, wherein the polymer fiber is selected
from the group consisting of a polypropylene and polyester
fiber.
10. The method of claim 9, wherein the fiberglass is selected from
the group consisting of textile fiberglass and continuous filament
fiberglass.
11. The method of claim 1, wherein the fiberglass is selected from
the group consisting of textile fiberglass and continuous filament
fiberglass.
12. The method of claim 1, wherein the first and second
consolidated fiberglass sheets are porous.
13. The method of claim 1, wherein the first and second
consolidated fiberglass sheets are partially permeable to permit
air filtration.
14. The method of claim 1, wherein the first and second
consolidated fiberglass sheets are adhered to the foam with a
tensile strength in the lamination direction of at least 30
psi.
15. The method of claim 1, wherein the consolidated fiberglass
sheets have a thickness between about 0.5 mm and about 1.0 mm.
16. The method of claim 1, wherein the first and second
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.
17. The method according to claim 1, further comprising cleaning
the first and second consolidated fiberglass sheets with a corona
treatment before applying the PUR/PIR foam ingredients.
18. The method of claim 1, wherein the PUR/PIR foam ingredients are
applied between facer sheets and the first and second consolidated
fiberglass sheets are adhesively secured to the facer sheets.
19. The method of claim 18, further comprising perforating the
facer sheets such that the consolidated fiberglass sheets are in
part directly adhered to the foam core.
20. The method of claim 18, wherein the facer sheets are attached
to the consolidated fiberglass sheets by means of moisture curing
thermoset adhesive.
21. The method of claim 18, wherein the facer sheets are comprised
of at least one of the group consisting of paper, fiberglass, and
polypropylene.
22. The method for manufacturing panels according to claim 1,
wherein the first and second consolidated fiberglass sheets
comprise the outer layers of the laminated foam product.
23. A method for manufacturing a laminated foam product comprising:
providing first and second partially permeable consolidated
fiberglass sheets, wherein a material made of fiberglass commingled
polymer fiber is pre-treated with heat and pressure to form the
consolidated fiberglass sheets; and applying PUR/PIR foam
ingredients directly between the first and second consolidated
fiberglass sheets; and curing the PUR/PIR foam ingredients between
the first and second consolidated fiberglass sheets to form a
PUR/PIR foam core such that the PUR/PIR foam core directly adheres
to the first and second consolidated fiberglass sheets.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 10/489,014, filed Mar. 8, 2004, which is a section 371
National Phase of International Application Serial No.
PCT/US02/28838, filed Sep. 11, 2002, which claims the benefit of
U.S. Provisional Patent Application Ser. No. 60/318,099, filed Sep.
12, 2001, which are incorporated by reference as if fully set forth
herein.
FIELD OF INVENTION
[0002] 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
[0003] 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
[0004] 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.
[0005] 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.
[0006] 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.
[0007] 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.
[0008] 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.
[0009] 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
[0010] 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.
[0011] FIG. 2 is a schematic illustration of a preferred foam
mixing system.
[0012] FIG. 3 is a table listing various physical properties of
different embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] 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 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 3/4 inch to one inch
(19 to 25 mm).
[0014] 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.
[0015] 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.
[0016] 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.
[0017] 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.
[0018] Preferably the perforations through the facer are between
1/8 and 1/16 of an inch in diameter and between 1/2 and 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.
[0019] 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.
[0020] 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.
[0021] A preferred formulation for the PUR/PIR foam include the
following ingredients identified as parts per weight:
TABLE-US-00001 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
[0022] 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.
[0023] 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.
[0024] 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.
[0025] 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.
[0026] 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 3/4 inches and a core density
of approximately 4.5 pounds per cubic foot. TABLE-US-00002 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
[0027] 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.
[0028] 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.
[0029] 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.
* * * * *