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.

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.