Abstract: A rigid closed cell polyisocyanate-based foams is created by reacting at least one organic polyisocyanate with compounds having at least two active hydrogen atoms in the presence of an n-pentane blowing agent. When the foam is formed into a laminated board with facers, the foam formulation includes a sufficient amount of a common blend of cleaning solvent chemicals to cause a noticeable improvement in facer adhesion. The chemicals used to improve facer adhesion are a standard blend of industrial cleaning solvents called “Di-Basic Esters” or DBE. The actual chemical compounds in one mode of this mixture are the methyl esters of about 59% glutaric acid, about 20% succinic acid, and about 21% adipic acid. The minimum rate of addition of the Di-Basic Esters” [DBE] thought to be effective may be less than about 0.5 parts per hundred parts of polyol (pphpp). The currently preferred embodiments use add-on rates within the range of about 0.5 to about 5.

Abstract: The non-woven web of the present invention is comprised of recycled cellulose fiber and untreated Clarifier Sludge, and optionally, recycled glass fiber. Unlike uses of reclaimed Clarifier Sludge whereby the material has been treated in some fashion to improve its quality, the non-woven web of the present invention utilizes untreated Clarifier Sludge. The Clarifier Sludge of the present invention is dry enough to handle, and in one example varies between about 30% and about 45% solids. The Clarifier Sludge can be added to web-forming equipment (e.g., papermaking equipment) either in a waste paper disintegrator or into a recycling apparatus (e.g., broke pulper) whose output is metered into a refiner tank of the web-forming equipment. In an embodiment utilizing a broke pulper for introduction of the Clarifier Sludge, the broke pulper is filled with clarifier sludge and water to a consistency of about 3.5% solids.

Abstract: A shape molding operation is performed to form a three dimensional building panel. The operation involves providing a mold having a cavity, the cavity having dimensions essentially identical to a finished three dimensional building panel suitable for installation. The shape molding operation involves pre-heating at least one of two major internal surfaces of the mold; introducing polystyrene foam beads into the cavity; heating the polystyrene foam beads; and causing the heated polystyrene foam beads to flatten and spread against the pre-heated major internal surface of the mold, thereby forming a sealed water-repellant skin at least on a face of the three dimensional building panel. In view of the corresponding size of the mold cavity, no cutting action is required on the expanded polystyrene (EPS) foam formed therein, so that a least a building-contacting face of the resultant boards acquires the sealed water-repellant skin that is otherwise lost when forming boards from buns of the prior art.

Abstract: A panel unit for roof drainage comprises plural panel sections with adjoining ones of the plural panel sections connected to be foldably collapsed on one another into a storage (e.g., transport) unit. In one embodiment, the panel sections are connected together for folding, e.g., by a hinge. Roofing saddles and roofing crickets of the present invention are formed using one or more sets of panel units. Sets of panel units are fabricated to have essentially the same footprint on the roof, although a lastly installed one of the sets of panel units is modified on site. A method of installing a roofing saddle comprised of the panel units is also provided.

Abstract: A panel unit for roof drainage comprises plural panel sections with adjoining ones of the plural panel sections connected to be foldably collapsed on one another into a storage (e.g., transport) unit. In one embodiment, the panel sections are connected together for folding, e.g., by a hinge. Roofing saddles and roofing crickets of the present invention are formed using one or more sets of panel units. Sets of panel units are fabricated to have essentially the same footprint on the roof, although a lastly installed one of the sets of panel units is modified on site. A method of installing a roofing saddle comprised of the panel units is also provided.

Abstract: A thermally insulative building construction panel (10) comprises a first or bottom sheet (20) of insulation material; a second or top sheet (24) of a rigid nail-anchoring material; and, a plurality of spacer members (22) sandwiched in fixed positions between the first sheet and the second sheet for defining air channels (25) between the sheets and the spacer members. The spacer members (22) are over three inches wide and are at least one-half inch thick. The spacer members (22) are comprised of a plastic foam insulation material selected from the group consisting of polyurethane modified polyisocyanurate foam, phenolic-formaldehyde foam, and polystyrene foam.

Abstract: A process of foaming asphalt comprises mixing sodium hydrogen carbonate with asphalt melted to a liquid state. The mixing yields carbon dioxide and water. The carbon dioxide gas foams the molten asphalt, and the foaming is enhanced by the boiling of the water. The rate of addition of the sodium hydrogen carbonate, and the temperature of the asphalt, are controlled in accordance with the desired specific gravity of the resultant foamed asphalt. The sodium hydrogen carbonate is added at a rate in a range of from about 2.0% by weight to about 6.0% by weight. The asphalt is melted at a temperature in a range from about 212.degree. F. to about 500.degree. F. The foamed asphalt is used, inter alia, by depositing the foamed asphalt on a substrate.

Abstract: 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.

Abstract: 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).

Abstract: 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).

Abstract: 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).

Abstract: Blowing agents and blowing agent mixtures for preparing a cellular thermosetting plastic foam comprise either (1) a non-chlorinated, partially hydrogenated fluorocarbon with the general formula H.sub.x F.sub.y C.sub.z ; (2) a non-chlorinated, partially hydrogenated fluorocarbon ether with the general formula H.sub.x F.sub.y C.sub.z --O--C.sub.m F.sub.n H.sub.p ; (3) a non-chlorinated, non-hydrogenated, fully fluoronated fluorocarbon; (4) an azeotropic mixture having a boiling point below 50 degrees Celsius; or (5) any mixture of the foregoing. The azeotropic mixtures are produced from organic compounds having surface active properties that enable the blended azeotropic mixture to become miscible with polymer resins. Among the preferred compounds for use in azeotropic mixtures are n-pentane, acetone, methyl alcohol, methyl formate, ethyl formate, ethyl alcohol, 2-methyl butane, nitromethane, cyclopentane, 2,3,-dimethyl butane, 2,2,-dimethyl butane, and dimethyl sulfide.

Abstract: 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.

Abstract: 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.

Abstract: A structural laminate comprises at least one planar facing sheet comprised largely of glass fibers but not having micro-glass as a filler. The facing sheet is self adhered to a rigid thermosetting plastic foam core. The non-glass filler material is chosen from a group consisting of clay, mica, talc, limestone (calcium carbonate), gypsum (calcium sulfate), aluminum trihydrate (ATH), antimony oxide, cellulose fibers, and plastic polymer fibers. The non-glass filler material improves containment of liquid plastic thermosetting polymer, and offers economic and safety advantages.