Atlas Roofing Corporation

Richard L Donald

Robert H Blanpied

Robert J Butkus

Andy I McLaughlin

Philip W Bush

James L Williams

James H Williams

William M Gay

In a method of producing a polyurethane modified polyisocyanurate foam, at least one alkali metal organo-salt catalyst is utilized in an aqueous solution free of aliphatic glycols. The catalyst preferably contains more chemical equivalents of at least one carboxylic acid than chemical equivalents of at least one alkali metal hydroxide dissolved in water. The use of extra or undissolved carboxylic acid, preferably 2-ethyl-hexoic acid, advantageously creates flame resistant amides, as well as creating carbon dioxide as a blowing agent. The use of extra or undissolved carboxylic acid can also reduce the water content of catalysts of the present invention which might have a water content in excess of the desired.

Method of producing rigid foams and products produced therefrom

In a method of producing a thermosetting foam, a first of two foam forming blends ('A-Blend') is prepared using a multi-functional isocyanate such as polymeric polymethylene polyphenylisocyanate ('PMDI'). A second of two foam forming blends ('B-Blend') is prepared by mixing together a polyol; water; a tertiary amine catalyst having at least two hydrogen bonding sites for one molecule; and, an alkali metal organo-salt catalyst. The tertiary amine catalyst is of a type wherein both the hydrogen segment and the hydroxyl segment of water are attracted by both of the hydrogen bonding cites on the catalyst molecule essentially simultaneously. A first blowing agent is included with one of the two foam forming blends. When the first and second foam forming blends are mixed together, the tertiary amine catalyst quickly initiates a reaction predominately of the polymeric polymethylene polyphenylisocyanate with water (as opposed to a reaction with the polyol). The quick reaction of the PMDI with water causes, prior to a gel point of the foam, both (1) the production of a second blowing agent for forming cells in the blends and for causing expansion in the liquid blends; and (2) sufficient exothermic heat to initiate boiling of the first blowing agent. Relatively large amounts of alkali metal organo-salt catalyst induce rapid vaporizing of the first blowing agent due to a high level of exothermic heat, whereby expansion of the mixed blends is substantially completed prior to the effective conversion of the mixed liquid blends to a solid. According to the method, a degree of completion of expansion of the foam at any point in time exceeds a degree of completion of chemical reactions of the foam. In another mode of the invention, a frothing agent is also employed.

In a method of producing a thermosetting foam, a first of two foam forming blends ('A Blend') is prepared using polymeric polymethylene polyphenylisocyanate ('PMDI'). A second of two foam forming blends ('B Blend') is prepared by mixing together a polyol; water; a tertiary amine catalyst having at least one ethyl (--CH.sub.2 --CH.sub.2 --) linkage between two heteroatoms, the heteroatoms being chosen from the group consisting of Nitrogen and Oxygen; and, an alkali metal organo-salt catalyst. A first blowing agent is included with one of the two foam forming blends. When the first and second foam forming blends are mixed together, the tertiary amine catalyst quickly initiates a reaction predominately of the polymeric polymethylene polyphenylisocyanate with water (as opposed to a reaction with the polyol). The quick reaction of the PMDI with water causes, prior to a gel point of the foam, both (1) the production of a second blowing agent for forming cells in the blends and for causing expansion in the liquid blends; and (2) sufficient exothermic heat to initiate boiling of the first blowing agent. Relatively large amounts of alkali metal organo-salt catalyst induce rapid vaporizing of the first blowing agent due to a high level of exothermic heat, whereby expansion of the mixed blends is substantially completed prior to the effective conversion of the mixed liquid blends to a solid. According to the method, a degree of completion of expansion of the foam at any point in time exceeds a degree of completion of chemical reactions of the foam. In another mode of the invention, a frothing agent is also employed.

Method for producing rigid foams and products produced therefrom

A method of producing a non-porous mat includes coating a predominantly glass fiber porous web substrate. The coating comprises an aqueous mixture of a mineral pigment; a first binder material comprised of a polymer latex adhesive material; and, a second binder material comprised of an inorganic adhesive material. On a dry weight basis, the first binder material comprises no more than 5.0% by weight, and the second binder material at least 0.5% by weight, of the total weight of the coating. The second binder preferably comprises an inorganic compound such as calcium oxide, calcium silicate, calcium sulfate, magnesium oxychloride, magnesium oxysulfate, or aluminum hydroxide. In one mode, the second binder is included in the mineral pigment, as in the cases wherein the mineral pigment includes aluminum trihydrate, calcium carbonate, calcium sulfate, magnesium oxide, and some clays and sands. A method of using the coated mat to produce a thermosetting plastic foam laminate panel is also disclosed.

Method and composition for coating mat and articles produced therewith

A coating composition and method of producing a non-porous mat includes coating a predominantly glass fiber porous web substrate. The coating comprises an aqueous mixture of a mineral pigment; a first binder material comprised of a polymer latex adhesive material; and, a second binder material comprised of asphalt emulsion material. The total dry weight basis of both binders does not exceed 24% of the total coating.

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Meridian, MS, United States of America

Richard L Donald