Abstract: Hollow thermoexpandable particles or microspheres are provided that contain hydrocarbon blowing agents and have a shell polymer that can be softened at the onset of the expansion temperature and solidified at a higher temperature (thermoset) in an expanded state. Preferably, the microspheres have a shell of thermally expandable and thermally crosslinkable polymer and a hollow interior that contains a hydrocarbon liquid that boils at a temperature below the heat activated crosslinking temperature of the polymer shell. The crosslinking of the shell polymer during or after expansion, which is heat activated at an elevated temperature, can solidify the shell polymer and, then, maintain the expanded volume of the microspheres. The thermoexpandable thermoset polymer particles are useful in insulation, packaging, for making foam materials such as polyurethane or polyisocyanurate rigid foams.

Abstract: A synthetic polymer foam is produced which incorporates fine particles of expandable graphite which surprisingly impart excellent fire resistant properties to the foam, particularly to foam made with a non-halogenated hydrocarbon as the primary blowing agent. For best results, the foam is produced through mixing the constituent materials, including the expandable graphite using a screw extruder. The foam can also be produced by creating a graphite/polyol or graphite/isocyanate dispersion in an extruder then mixing the remaining components in a conventional batch mixing or high pressure spraying process. Alternatively, conventional mixing can be used for the entire process, but use of a screw extruder in whole or in part is preferred.

Abstract: An apparatus and a continuous process produce composite structural insulated panels (SIPs). Lower boards are placed on a conveying system through a foam application zone and then upper boards are applied. The foam material adheres to the upper and lower boards to form a structural insulated panel after passing through a curing apparatus.

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.

Abstract: A polyurethane and/or polyisocyanurate foam is made using expandable microspheres which encapsulate a primary blowing agent. By expanding during the foam making process, the microspheres function as a blowing agent. The foam preferably has at least 10% by weight expandable micro spheres which encapsulate a non-halogenated hydrocarbon chemical or a non-halogenated hydrocarbon chemical blend and less than 2% by weight of any non-encapsulated blowing agents.