Abstract: A method for continuously manufacturing an insulation board by facing a foam-forming composition with one or two facing sheets to form a singly or doubly faced composite, at least one sheet comprising either a tough polymeric layer or a laminate of a tough polymeric layer with at least one other facing material, the tough polymeric layer of at least one sheet facing to the outside of the composite, and foaming and curing the faced foam-forming mixture to produce an insulation board having an exceptional hardness and puncture resistance.

Abstract: Closed cell, rigid polymer foams are prepared by (a) continuously conveying a carrier along a production line, (b) supplying on the carrier a foam-forming mixture comprising a polyisocyanate, a catalyst, a hydrogen-containing blowing agent or a mixture of the hydrogen-containing blowing agent and at least one co-blowing agent, and an isocyanate-reactive component comprising (i) a high acid polyester polyol having an acid number greater than 1, or (ii) a mixture of the high acid polyester polyol and at least one other isocyanate-reactive compound, (c) passing the carrier and mixture between two constricting members forming therebetween a metering gap, and (d) allowing the mixture after passing through the gap to freely expand to form a plastic foam, wherein the acid number and amount of the high acid polyester polyol in the mixture are sufficiently high to result in a superior resistance to cold temperature shrinkage.

Abstract: A plastic foam-forming mixture, e.g. a polyurethane or polyisocyanurate foam mix, deposited on a carrier, is metered through two spaced opposed members forming therebetween a metering gap. At least one of the members is malleable through changes in temperature so that the profile of the metering gap can be variously defined. Foam boards having a highly uniform thickness are thereby continuously and expeditiously producible.

Abstract: Closed cell, rigid polymer foams are prepared by (a) continuously conveying a carrier along a production line, (b) supplying on the carrier a foam-forming mixture comprising a polyisocyanate, a catalyst, a hydrogen-containing blowing agent or a mixture of the hydrogen-containing blowing agent and at least one co-blowing agent, and an isocyanate-reactive component comprising (i) a high acid polyester polyol having an acid number greater than 1, or (ii) a mixture of the high acid polyester polyol and at least one other isocyanate-reactive compound, (c) passing the carrier and mixture between two constricting members forming therebetween a metering gap, and (d) allowing the mixture after passing through the gap to freely expand to form a plastic foam, wherein the acid number and amount of the high acid polyester polyol in the mixture are sufficiently high to result in a superior resistance to cold temperature shrinkage.