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.

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.