Faced foam insulation board and froth-foaming method for making same

Abstract

A method for continuously producing an insulation board comprising a rigid plastic foam core having two major surfaces and a facing material on one or both of the major surfaces, the method including conveying a facing material along a production line, depositing a partially expanded froth foam of a plastic mixture, which contains at least one frothing agent, on the facing material, and further expanding and curing the froth foam in contact wiht the facing material to form the insulation board. The board is particularly useful as roof insulation.

We claim: 
     
       1. A method for continuously producing an insulation board comprising a rigid plastic foam core having two major surfaces and a .[.facing material.]. .Iadd.glass fiber mat .Iaddend.on at least one of the major surfaces, the method comprising: (a) conveying a .[.facing material.]. .Iadd.glass fiber mat having a thickness of from 15 to 55 mils and comprising randomly oriented relatively short glass fibers .Iaddend.along a production line,   (b) depositing a partially expanded froth foam, which contains at least one frothing agent, on the .[.facing material.]. .Iadd.glass fiber mat.Iaddend., the partially expanded froth foam comprising a mixture for forming a rigid polymer foam selected from the group consisting of polyurethane, polyisocyanurate, phenolic polymer, polyester and epoxide foams, and the frothing agent being easily vaporizable at atmospheric pressure, and   (c) further expanding and curing the froth foam in contact with the .[.facing material.]. .Iadd.glass fiber mat .Iaddend.to form the insulation board.Iadd.;   wherein the glass fiber mat has sufficient porosity to permit sufficient penetration of the mat by the frothed foam to provide integral attachment of the cured foam to the mat.Iaddend..   
     
     
       2. The method of claim 1 for continuously producing an insulation board having .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.on both major surfaces of a foam core comprising: (a) conveying at least one lower .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.along a production line,   (b) depositing the partially expanded froth foam on the lower .[.fibrous layer.]. .Iadd.glass fiber mat.Iaddend.,   (c) placing at least one advancing upper .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.on the deposited, partially expanded froth foam to form an advancing sandwich of upper and lower .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.and intermediate froth foam, and   (d) further expanding and curing the froth foam in contact with the .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.to form a rigid plastic foam core covered on both major surfaces with and penetrating interstices of the .[.fibrous layers.]. .Iadd.glass fiber mats.Iaddend..   
     
     
       3. The method of claim 1 for continuously producing an insulation board having .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.on both major surfaces of a foam core comprising: (a) conveying at least one lower .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.along a production line,   (b) depositing the partially expanded froth foam on the lower .[.fibrous layer.]. .Iadd.glass fiber mat.Iaddend.,   (c) placing at least one advancing upper .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.on the deposited, partially expanded froth foam to form an advancing sandwich of upper and lower .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.and intermediate froth foam,   (d) passing the sandwich through the nip of two rotating rolls to meter the amount of froth foam and help it to penetrate the interstices of the .[.fibrous layers.]. .Iadd.glass fiber mats.Iaddend., and   (e) thereafter passing the sandwich from the nip of the two rotating rolls into a heated expansion zone, whereby the froth foam further expands and cures in contact with the .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.to form a rigid plastic foam core covered on both major surfaces with and penetrating interstices of the .[.fibrous layers.]. .Iadd.glass fiber mats.Iaddend..   
     
     
       4. The method of claim 3 wherein: (a) a lower facing sheet is supplied below the lower .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.and both lower facing sheet and .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.are conveyed along the production line,   (b) the partially expanded froth foam is deposited on the lower .[.fibrous layer.]. .Iadd.glass fiber mat.Iaddend.,   (c) an advancing upper facing sheet is supplied above the advancing upper .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.and both upper facing sheet and .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.are placed on the deposited, partially expanded froth foam to form an advancing sandwich of upper and lower facing sheets and intermediate .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.and froth foam,   (d) the sandwich is passed through the nip of two rotating rolls to meter the amount of froth foam and help it to penetrate the interstices of the .[.fibrous layers.]. .Iadd.glass fiber mats.Iaddend., and   (e) thereafter the sandwich is passed from the nip of the two rotating rolls into a heated expansion zone, whereby the froth foam further expands and cures in contact with the .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.and facing sheets to form a rigid plastic foam core covered on both major surfaces with and penetrating interstices of the .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.and having adherent facing sheets exterior to the .[.fibrous layers.]. .Iadd.glass fiber mats.Iaddend..   
     
     
       5. The method of claim 3 wherein the partially expanded froth foam comprises a mixture for forming a rigid polymer foam selected from the group consisting of polyurethane and polyisocyanurate foams. 
     
     
       6. The method of claim 5 wherein the partially expanded froth foam is formed from at least two liquid components including a polyisocyanate-containing component and a polyol-containing component, the steps of forming the froth foam comprising: (a) providing the liquid components, a low boiling blowing agent being premixed with either the polyisocyanate-containing component or the polyol-containing component,   (b) passing the liquid components through separate conduits which discharge into a mixing head,   (c) charging one of the liquid components in its conduit with a volatile liquid frothing agent, the boiling point of the frothing agent being lower than that of the blowing agent,   (d) mixing the liquid components after their discharge into the mixing head,   (e) discharging the resulting mixture from the mixing head into a depositing means, and   (f) depositing the mixture from the depositing means onto the lower .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.in the form of a partially expanded froth foam.   
     
     
       7. The method of claim 6 wherein: (a) each of the upper and lower .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.comprises a mat of chopped, short glass fibers held together by a binder, and   (b) the mixture from the mixing head is deposited by a nozzle capable of laying down a wide band of froth foam on the lower .[.fibrous layer.]. .Iadd.glass fiber mat.Iaddend..   
     
     
       8. The method of claim 1 for continuously producing an insulation board having .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.on both major surfaces of a foam core comprising: (a) conveying at least one lower .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.along a production line,   (b) depositing the partially expanded froth foam on the lower .[.fibrous layer.]. .Iadd.glass fiber mat.Iaddend.,   (c) placing at least one advancing upper .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.on the deposited, partially expanded froth foam to form an advancing sandwich of upper and lower .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.and intermediate froth foam, and   (d) passing the sandwich between a pair of substantially horizontal, vertically spaced continuous conveyors to limit the maximum distance the outer surfaces of the .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.can move apart, the conveyors being located in a heated expansion zone, whereby the froth foam further expands to the extent permitted by the conveyors and cures in contact with the .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.to form a rigid plastic foam core covered on both major surfaces with and penetrating interstices of the .[.fibrous layers.]. .Iadd.glass fiber mats.Iaddend..   
     
     
       9. The method of claim 8 wherein: (a) a lower facing sheet is supplied below the lower .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.and both lower facing sheet and .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.are conveyed along the production line,   (b) the partially expanded froth foam is deposited on the lower .[.fibrous layer.]. .Iadd.glass fiber mat.Iaddend.,   (c) an advancing upper facing sheet is supplied above the advancing upper .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.and both upper facing sheet and .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.are placed on the deposited, partially expanded froth foam to form an advancing sandwich of upper and lower facing sheets and intermediate .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.and froth foam, and   (d) the sandwich is passed between a pair of substantially horizontal, vertically spaced continuous conveyors to limit the maximum distance the outer surfaces of the facing sheets can move apart, the conveyors being located in a heated expansion zone, whereby the froth foam further expands to the extent permitted by the conveyors and cures in contact with the .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.and facing sheets to form a rigid plastic foam core covered on both major surfaces with and penetrating interstices of the .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.having adherent facing sheets exterior to the .[.fibrous layers.]. .Iadd.glass fiber mats.Iaddend..   
     
     
       10. The method of claim 8 wherein the partially expanded froth foam comprises a mixture for forming a rigid polymer foam selected from the group consisting of polyurethane and polyisocyanurate foams. 
     
     
       11. The method of claim 10 wherein the partially expanded froth foam is formed from at least two liquid components including a polyisocyanate-containing component and a polyol-containing component, the steps of forming the froth foam comprising: (a) providing the liquid components, a low boiling blowing agent being premixed with either the polyisocyanate-containing component or the polyol-containing component,   (b) passing the liquid components through separate conduits which discharge into a mixing head,   (c) charging one of the liquid components in its conduit with a volatile liquid frothing agent, the boiling point of the frothing agent being lower than that of the blowing agent,   (d) mixing the liquid components after their discharge into the mixing head,   (e) discharging the resulting mixture from the mixing head into a depositing means and   (f) depositing the mixture from the depositing means onto the lower .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.in the form of a partially expanded froth foam.   
     
     
       12. The method of claim 11 wherein: (a) each of the upper and lower .[.fibrous layers.]. .Iadd.glass fiber mats .Iaddend.comprises a mat of chopped, short glass fibers held together by a binder, and   (b) the depositing means comprises a nozzle capable of laying down a wide band of froth foam on the lower .[.fibrous layer.]. .Iadd.glass fiber mat.Iaddend..   
     
     
       13. The method of claim 1 wherein the deposited, partially expanded froth foam contains a blowing agent .[.which boils.]. .Iadd.having a boiling point .Iaddend.higher than .Iadd.that of .Iaddend.the frothing agent. 
     
     
       14. The method of claim 13 wherein the frothing agent is dichlorodifluoromethane and the blowing agent is trichloromonofluoromethane. 
     
     
       15. The method of claim 2 wherein the deposited, partially expanded froth foam contains a blowing agent .[.which boils.]. .Iadd.having a boiling point .Iaddend.higher than .Iadd.that of .Iaddend.the frothing agent. 
     
     
       16. The method of claim 15 wherein the frothing agent is dichlorodifluoromethane and the blowing agent is trichloromonofluoromethane. 
     
     
       17. The method of claim 3 wherein the deposited, partially expanded froth foam contains a blowing agent .[.which boils.]. .Iadd.having a boiling point .Iaddend.higher than .Iadd.that of .Iaddend.the frothing agent. 
     
     
       18. The method of claim 17 wherein the frothing agent is dichlorodifluoromethane and the blowing agent is trichloromonofluoromethane. 
     
     
       19. The method of claim 4 wherein the deposited, partially expanded froth foam contains a blowing agent .[.which boils.]. .Iadd.having a boiling point .Iaddend.higher than .Iadd.that of .Iaddend.the frothing agent. 
     
     
       20. The method of claim 19 wherein the frothing agent is dichlorodifluoromethane and the blowing agent is trichloromonofluoromethane. 
     
     
       21. The method of claim 5 wherein the deposited, partially expanded froth foam contains a blowing agent .[.which boils.]. .Iadd.having a boiling point .Iaddend.higher than .Iadd.that of .Iaddend.the frothing agent. 
     
     
       22. The method of claim 21 wherein the frothing agent is dichlorodifluormethane and the blowing agent is trichloromonofluoromethane. 
     
     
       23. The method of claim 8 wherein the deposited, partially expanded froth foam contains a blowing agent .[.which boils.]. .Iadd.having a boiling point .Iaddend.higher than .Iadd.that of .Iaddend.the frothing agent. 
     
     
       24. The method of claim 23 wherein the frothing agent is dichlorodifluoromethane and the blowing agent is trichloromonofluoromethane. 
     
     
       25. The method of claim 9 wherein the deposited, partially expanded froth foam contains a blowing agent .[.which boils.]. .Iadd.having a boiling point .Iaddend.higher than .Iadd.that of .Iaddend.the frothing agent. 
     
     
       26. The method of claim 25 wherein the frothing agent is dichlorodifluoromethane and the blowing agent is trichloromonofluoromethane. 
     
     
       27. The method of claim 10 wherein the deposited, partially expanded froth foam contains a blowing agent .[.which boils.]. .Iadd.having a boiling point .Iaddend.higher than .Iadd.that of .Iaddend.the frothing agent. 
     
     
       28. The method of claim 27 wherein the frothing agent is dichlorodifluoromethane and the blowing agent is trichloromonofluoromethane. 
     
     
       29. .[.The.]. .Iadd.An .Iaddend.insulation board .Iadd.produced by the process .Iaddend.of claim 27 .[.wherein the deposited, partially expanded froth foam contains a blowing agent which boils higher than the frothing agent.].. .[.30. The insulation board of claim 29 wherein the frothing agent is dichlorodifluoromethane and the blowing agent is 
     
     
        trichloromonofluoromethane..].31. .[.The.]. .Iadd.An .Iaddend.insulation board .Iadd.produced by the process .Iaddend.of claim 28 .[.wherein the deposited, partially expanded froth foam contains a blowing agent which 
     
     
        boils higher than the frothing agent.].. .[.32.  The insulation board of claim 31 wherein the frothing agent is dichlorodifluoromethane and the blowing agent is trichloromonofluoromethane..]..[.33. The insulation board of claim 29 wherein the deposited partially expanded froth foam contains a blowing agent which boils higher than the frothing agent..]..[.34. The insulation board of claim 33 wherein the frothing agent is dichlorodifluoromethane and the blowing agent is trichloromonofluoromethane..]..[.35. The insulation board of claim 30 wherein the deposited, partially expanded froth foam contains a blowing agent which boils higher than the frothing agent..]..[.36. The insulation board of claim 35 wherein the frothing agent is dichlorodifluoromethane and the blowing agent is trichloromonofluoromethane..]..[.37. The insulation board of claim 36 wherein the deposited, partially expanded froth foam contains a blowing agent which boils higher than the frothing agent..]..[.38. The insulation board of claim 37 wherein the frothing agent is dichlorodifluoromethane and the blowing agent is 
     
     
        trichloromonofluoromethane..]..[.39.  The insulation board of claim 37 wherein the deposited, partially expanded froth foam contains a blowing agent which boils higher than the frothing agent..]..[.40. The insulation board of claim 39 wherein the frothing agent is dichlorodifluoromethane 
     
     
        and the blowing agent is trichloromonofluoromethane..].41. An insulation board comprising a core of rigid plastic foam having two major, substantially parallel surfaces and a .[.facing material.]. .Iadd.glass fiber mat .Iaddend.on at least one of the major surfaces of the core, the foam core being formed in accordance with the method of claim 1 by further expanding a partially expanded froth foam in contact with the .[.facing material.]. .Iadd.glass fiber mat.Iaddend., and the cells of the resulting foam core containing the volatile frothing agent employed in the method. 
     
     
          . The insulation board of claim 41 comprising a core of rigid plastic foam having two major, substantially parallel surfaces and at least one .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.on each of the major surfaces, portions of the foam core at the two major surfaces penetrating interstices in and interlocking with the .[.fibrous layers.]. .Iadd.glass 
     
     
        fiber mats.Iaddend.. 43. The insulation board of claim 42 wherein the .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.comprises a mat of chopped, short glass fibers held together by a binder on each of the major 
     
     
        surfaces. 44. The insulation board of claim 42 wherein the core is a member selected from the group consisting of polyurethane and 
     
     
        polyisocyanurate foams. 45. The insulation board of claim 44 wherein the cells of the core contain a mixture of a more volatile frothing agent and a less volatile blowing agent, and the .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.comprises a mat of chopped, short glass fibers held 
     
     
        together by a binder on each of the major surfaces. 46. The insulation board of claim 45 wherein the frothing agent is dichlorodifluoromethane 
     
     
        and the blowing agent is trichloromonofluoromethane. 47. The insulation board of claim 45 wherein the core of a polyisocyanurate foam comprising the reaction product of (a) an organic polyisocyanate mixture of the formula: ##STR6## wherein n is an integer from 0 to 8 inclusive, and the mixture has: (1) a functionality of 2.1 to 3.8, (2) an equivalent weight between 120 and 180, and   (3) a viscosity at 25° C. between 100 and 4,000 centipoises, and     (b) a minor amount of polyol component selected from the group consisting of (1) an aromatic polyester polyol prepared by the transesterification, with a glycol of molecular weight from about 60 to 400, of a by-product fraction from the manufacture of dimethyl terephthalate, the major portion of said fraction comprising about 15 to 70 weight percent of dimethyl terephthalate, and about 85 to 30 weight percent of a mixture of monomethyl terephthalate, by-ring esters and polymeric materials,   (2) an aromatic polyester polyol prepared by the transesterification, with a glycol of molecular weight from about 60 to about 400, of a residue remaining after dimethyl terephthalate and methyl p-toluate have been removed from a dimethyl terephthalate esterified oxidate reaction product, the major portion of said residue comprising a mixture of methyl and benzyl esters of benzene and biphenyl di- and tricarboxylic acids,   (3) mixtures of the aromatic polyester polyols, and   (4) mixtures of the aromatic polyester polyols with an alkylene oxide adduct of an aromatic amine of the formula ##STR7## wherein Z is a divalent aromatic radical, x, x', y, and y' each independently have an average value from about 1 to about 5, and each R is independently selected from the group consisting of hydrogen, alkyl or     
     
     
        aryl, provided that the adduct is capped with ethylene oxide units. 48. The insulation board of claim 47 wherein: (a) the aromatic polyester polyol (1) is transesterified with diethylene glycol and is charactertized by a viscosity in cps at 25° C. of about 700 to 2500, a free diethylene glycol content of from about 10 to 30 percent by weight of said mixture, a hydroxyl number within a range of from about 350 to 468, and an acid number of about 0.2 to 10,   (b) the aromatic polyester polyol (2) is transesterified with diethylene glycol and is characterized by a viscosity in cps at 25° C. of about 1,600 to about 2,800, a free diethylene glycol content of from about 20 to about 30 percent by weight of said mixture, a hydroxyl number within a range of from about 400 to about 490, and an acid number of about 0.2 to about 8, and   (c) the alkylene oxide adduct of an aromatic amine is an ethylene oxide adduct of toluene diamine isomers of the formula ##STR8## wherein the average number of oxyethylene units per polyoxyethylene chain   
     
     
        is from 2 to 3. 49. The insulation board of claim 48 wherein the frothing agent is dichlorodifluoromethane and the blowing agent is trichloromonofluoromethane, and a trimerization catalyst comprising a mixture of 2,4,6-tris(dimethylaminomethyl)phenol and potassium-2-ethylhexoate is employed in the production of the 
     
     
        polyisocyanurate foam. 50. The insulation board of claim .[.16.]. .Iadd.41 .Iaddend.comprising a core of rigid plastic foam having two major, substantially parallel surfaces, at least one .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.on each of the major surfaces, portions of the foam core at the two major surfaces penetrating interstices in and interlocking with the .[.fibrous layers.]. .Iadd.glass fiber mats.Iaddend., and a facing sheet exterior to the .[.fibrous layer.]. .Iadd.glass fiber mat .Iaddend.on each of the major surfaces and adherent 
     
     
        to the foam core. 51. The insulation board of claim 50 wherein the core is a member selected from the group consisting of polyurethane and polyisocyanurate foams. .[.52. The insulation board of claim 51 wherein the cells of the core contain a mixture of a more volatile frothing agent and a less volatile blowing agent, and the core has on each of the major surfaces a fibrous layer selected from the group consisting of a mat of chopped, short glass fibers held together by a binder and a mat of long, generally straight glass fibers held together by a binder, the long glass fibers of the mat being arranged in layers and the direction of the glass fibers in each layer being at an angle to the direction of the glass fibers in each next adjacent layer..]..[.53. The insulation board of claim 52 wherein the frothing agent is dichlorodifluoromethane and the blowing agent is trichloromonofluoromethane..]..[.54. The insulation board of claim 53 wherein the facing sheet on each of the major surfaces comprises aluminum foil..].