Abstract: A method for the manufacture of paper faced foam which comprises (a) applying a foam-forming mixture to at least one advancing cellulosic sheet or composite thereof with an air- and/or moisture-impermeable material, the cellulosic sheet (i) being impregnated with cured polyisocyanate, (ii) being sufficiently flexible for unwinding from a roll for conveyance along a production line and (iii) having a moisture content which does not exceed about 10 percent and is evenly distributed throughout the cellulosic sheet, and (b) foaming and curing the faced foam-forming mixture.

Abstract: Thermoformable polyisocyanurate foams are prepared by reacting together under foam-forming conditions an organic polyisocyanate and an isocyanate-reactive compound, especially an aromatic polyester polyol, the equivalent ratio of isocyanate groups to isocyanate reactive groups being at least about 1.2:1. The foams and faced composites thereof can be thermoformed for a wide range of uses, such as in the interior of motor vehicles, aircraft, ships and other transport means, and of both residential and commercial buildings.

Abstract: A closed cell, rigid polyisocyanurate foam which comprises the reaction product of a polyisocyanate and a polyol in the presence of (a) a hydrogen-containing blowing agent or a mixture of a hydrogen-containing blowing agent and at least one co-blowing agent, and (b) a siloxane oxyalkylene copolymer (i) having a molecular weight below about 7500 and an oxyalkylene portion containing greater than 60 weight percent of oxyethylene units and (ii) being prepared by the reaction of an organohydrogensiloxane with a polyoxyalkylene in an essentially solventless system or in the presence of a high boiling point polar polyol.

Abstract: Rigid, closed cell polyisocyanurate foams are prepared by reacting together a polyisocyanate and a polyester polyol or a mixture of a polyester polyol and at least one other isocyanate-reactive compound in the presence of (a) a hydrogen-containing blowing agent or a mixture of a hydrogen-containing blowing agent and at least one co-blowing agent and (b) a catalyst mixture comprising (i) a carboxylate salt of an alkali metal or an alkaline earth metal or mixtures thereof, (ii) a tertiary amine, and (iii) a quaternary ammonium carboxylate salt, wherein the equivalent ratio of carboxylate metal salt: tertiary amine is a value less than about 3:1, and the quaternary ammonium carboxylate salt is present in an amount which enhances the char structure of polyisocyanurate foams made with the catalyst mixture and subjected to flammability char tests.

Abstract: A closed cell, rigid, polymer foam comprising the reaction product of a polyisocyanate and an isocyanatereactive compound in the presence of (a) a foaming agent, (b) at least about 2 percent by weight of carbon black, based on the weight of the polymer in the foam, and (c) a capped polyoxyalkylene compound which helps bring about a uniform dispersion of the carbon black throughout the foam so that the aged k-factor of the foam is below the aged k-factor of the corresponding unfilled foam.

Abstract: An isocyanate-terminated quasi-prepolymer is prepared by reacting an organic polyisocyanate and a polyester polyol which comprises the reaction product of a polycarboxylic acid component and ethylene glycol or a mixture of ethylene glycol and at least one other glycol. The use of the quasi-prepolymer in the preparation of rigid cellular polymers, especially polyisocyanurate foams, enhances the thermal insulating properties of the foams, and helps to reduce their cost and blowing agent usage.

Abstract: A closed cell, rigid, polymer foam comprising the reaction product of a polyisocyanate and an isocyanate-reactive compound in the presence of (a) a foaming agent, (b) at least about 2 percent by weight of carbon black, based on the weight of the polymer in the foam, and (c) a capped polyoxyalkylene compound which helps bring about a uniform dispersion of the carbon black throughout the foam so that the aged k-factor of the foam is below the aged k-factor of the corresponding unfilled foam.

Abstract: A closed cell, rigid, polymer foam comprising the reaction product of a polyisocyanate and an isocyanate-reactive compound in the presence of (a) a foaming agent, (b) at least about 2 percent by weight of carbon black, based on the weight of the polymer in the foam, and (c) a capped polyoxyalkylene compound which helps bring about a uniform dispersion of the carbon black throughout the foam so that the aged k-factor of the foam is below the aged k-factor of the corresponding unfilled foam.

Abstract: A process for the manufacture of a rigid, closed-cell polyisocyanurate foam from a foam forming mixture comprising an organic polyisocyanate, a polyol, a blowing agent, and a catalyst, utilizing a polyester polyol as the sole polyol, and chlorodifluoromethane or a mixture of chlorodifluoromethane and at least one co-blowing agent as the blowing agent.

Abstract: Rigid cellular polymers are made by reacting an organic polyisocyanate with a polyol component comprising a polyester polyol having a free glycol content of less than about 7 percent by weight of the polyester polyol in the presence of a blowing agent. The use of the polyester polyol enhances the thermal insulating properties of the foams.

Abstract: A method for texturing the surface of an acoustical fiberboard by utilizing a wheel blast machine. The fiberboard is conveyed through a housing wherein at least one first centrifugal blasting wheel throws abrasive particles at a portion of the fiberboard surface to abrade it. A blower provided in the housing removes spent abrasive particles thrown by the first wheel(s), and then at least one second centrifugal blasting wheel in the housing throws abrasive particles at the remaining untreated surface to complete the abrasion, whereby removal of the spent particles by the blower prevents masking of the surface and allows the formation of a pleasing and uniform pattern over the entire fiberboard surface.

Abstract: A rigid, self-supporting, acoustical mineral fiberboard comprising a mixture of about 50 to 70 weight percent of mineral fibers, 15 to 35 weight percent of perlite, 1 to 10 weight percent of cellulosic fibers, and 4 to 15 weight percent of a binder with the proviso that the board forming solids do not include any clay filler. A pattern is formed on the fiberboard after the fiberboard has been dried.

Abstract: This invention provides a process which automatically and in a continuous and uninterrupted manner makes a roofing shingle by applying granules to the top surface of an asphalt impregnated glass mat, laminating a narrow strip of bituminous coated glass mat to the bottom side of a coated glass mat, said narrow strip being cut from said impregnated glass mat and being inverted before said laminating step and cutting the laminated product to produce a laminate having cut-out areas between the remaining tabs. The final shingle is made from a single glass mat which is processed into a two level shingle, each level being made of a portion of the original glass mat with each level having exposed granules.

Abstract: A continuous process for the production of gypsum board of variable yet predictable density, wherein a fibrous form of stucco produced from gypsum crystals or fibers is combined with standard calcined gypsum and formed into the board. The density of the resultant board varies inversely with the content of fibrous stucco. The process yields lightweight board suitable as standard wallboards and inorganic insulating boards.

Abstract: This invention relates to a process for preparing cellular polymers having urethane groups, isocyanurate groups, or both. The cellular polymers are prepared by reacting an organic polyisocyanate with a polyol in the presence of a blowing agent, a catalyst, and a perfluorinated hydrocarbon or a mixture of perfluorinated hydrocarbons. The use of the perfluorinated additives enhances the thermal insulating properties of the forms.

Abstract: A continuous process for the production of gypsum board of variable yet predictable density, wherein a fibrous from of stucco produced from gypsum crystals or fibers is combined with standard calcined gypsum and formed into the board. The density of the resultant board varies inversely with the content of fibrous stucco. The process yields lightweight boards suitable as standard wallboards and inorganic insulating boards.

Abstract: A binder/release system for the preparation of molded articles, especially lignocellulosic composites, which utilizes in combination with isocyanate-based binders a fatty material as an internal and/or external release agent, the fatty material being at least one polymerized fatty acid and/or at least one polycarboxyl compound containing a polymeric fatty radical(s).

Abstract: A method of producing an acoustical mineral fiberboard comprising(a) forming an aqueous slurry of mineral fiber-containing solids suitable for forming an acoustical board, the solids content of the slurry being sufficiently high to bring about predominant formation of nodules of mineral fiber throughout the slurry upon mixing of the slurry;(b) mixing the slurry to form the nodules of mineral fibers;(c) dewatering the slurry to form a wet felt;(d) drying the wet felt; and(e) texturing one surface of the dried felt without mechanically punching holes in the surface.

Abstract: A synthetic board is prepared by a process of contacting lignocellulosic material with a binder and subsequently forming the treated material into a board by the application of heat and pressure, wherein (a) the binder comprises an organic polyisocyanate and a reactive hydrogen-containing component, especially an aromatic polyester polyol, and (b) the lignocellulosic material is additionally contracted with a surfactant.

Abstract: A storage stable polyester polyol mixture is prepared by digesting polyalkylene terephthalate, particularly polyethylene terephthalate, with a digesting medium comprising a polycarboxylic acid component-containing polyol, wherein the polycarboxylic acid component has ring units with two ##STR1## groups on adjacent or alternate ring positions, the ring unit content of the polycarboxylic acid component being sufficient for improved storage stability of the digestion product. The polyester polyol mixture is useful in the preparation of cellular foam materials, particularly polyisocyanurate and polyurethane foams.