Abstract: According to one embodiment, a halogen free roof system is described. The roof system includes a structural deck that is positioned above joists or other support members. Polyisocyanurate foam insulation is positioned atop the structural deck. The polyisocyanurate foam insulation has an isocyanate index greater than 200 and includes a polyisocyanurate core having a halogen free fire retardant. A water proof membrane is positioned atop the polyisocyanurate foam insulation. The polyisocyanurate core is able to form a sufficiently stable char when exposed to flame conditions such that the polyisocyanurate core is able to pass the ASTM E-84 test.

Abstract: According to one embodiment, a polyisocyanurate foam board is described. The foam board includes a polyisocyanurate core that is produced from: an isocyanate, a polyol, and a phosphorous containing non-halogenated fire retardant. The foam board also includes a facer material that is applied to at least one surface of the polyisocyanurate core. The polyisocyanurate core has an isocyanate index greater than about 200 and is able to forms a sufficiently stable char when exposed to flame conditions to enable the polyisocyanurate core to pass the ASTM E-84 test. The foam board has an initial R-value of at least 6.40 and exhibits an ASTM E1354-11b test performance that is equivalent with or better than a similar foam board having a halogenated fire retardant, such as tris(2-chloroisopropyl)phosphate (TCPP).

Abstract: According to one embodiment, a halogen free wall system is described. The wall system includes wall studs that are coupled together to form a frame and polyisocyanurate insulation boards that are positioned on an exterior side of the frame to form an exterior wall. The polyisocyanurate foam boards include a polyisocyanurate core having a halogen free fire retardant. Wall boards are attached to an interior side of the frame to form an interior wall. The wall boards are free of a halogenated fire retardant. The wall studs, polyisocyanurate foam boards, and wall board define a plurality of wall cavities within which an insulation material is positioned. The insulation material is free of a halogenated fire retardant.

Abstract: Provided by the present invention is a rigid polyurethane/polyisocyanurate foam board product. The board product is comprised of a castor oil based rigid polyurethane/polyisocyanurate foam. Preferably, the board product is based on a polyol mixture of a highly functional castor oil and a polyester and/or polyether polyol.

Abstract: A bond is created during gypsum board cure between a gypsum matrix and a tacky coating applied onto a glass fiber. The tacky coating is comprised of a polymer composed of methacrylic acid and dimethyldiallyammonium chloride. The polymer is dissolved in an acidic aqueous solution and is roller coated onto the glass fibers. The chopped glass fibers may also be placed in such an acidic solution, which is made alkaline by the addition of alkali, thereby precipitating the polymer out of solution as a tacky composition that produces a tacky coating on the glass fibers. The glass fibers with the tacky bond coating are incorporated in an alkaline gypsum slurry to form a gypsum board having a first and second facer sheet. The tacky coating on the glass fibers bonded to the gypsum matrix result in compliant load transfer between the gypsum matrix and the glass fibers, yielding improved flexure strength and nail pullout resistance.

Abstract: A bond is created between a gypsum matrix formed from an aqueous acidic gypsum slurry comprising a monomer mixture. The monomer mixture is composed of a monomer having acidic functionality and a monomer having hydroxyl or amine functionality. A silane-based sizing composition is coated onto glass fibers causing a cross-linking network of silane and monomer mixture to form during curing of the gypsum board. Hydrophilic water extraction at the gypsum matrix-sizing interface reduces void formation and promotes bonding with the crosslinked monomer mixture and growth of smaller gypsum crystals within larger crystals in microstructurally identifiable regions adjacent to the glass fiber. A bond is created between a gypsum matrix formed from an aqueous acidic gypsum slurry comprising a monomer mixture. The monomer mixture is composed of a monomer having acidic functionality and a monomer having hydroxyl or amine functionality.

Abstract: A gypsum board includes a set gypsum core and front and rear paper facers adhered thereto. At least the front paper facer has substantially isotropic tensile strength, thereby providing the gypsum board with enhanced nail pull resistance. A process for manufacturing such gypsum board is further provided.

Abstract: Fibrous, nonwoven mats are disclosed that are bound with a formaldehyde-free, heat resistant resin in direct contact with the fibers. The heat resistant resin is capable of withstanding coating with a hot, molten material like asphalt or a mixture containing asphalt having a temperature of at least about 300 degrees F. and up to 450 degrees F. or higher. The preferred heat resistant resins are epoxies and urethanes, or mixtures thereof. The methods of making these mats with wet processes are also disclosed.

Abstract: A bond is created between gypsum crystals and between gypsum crystals and glass fiber reinforcement in a gypsum board during cure by incorporation of titanium or zirconium based coupling compositions incorporated in the gypsum slurry. The commercially available titanium or zirconium based coupling has a generic formula of the type [RO—}-nTi-[—OXR?Y]4-n or [RO—}-nZr-[—OXR?Y]4-n. These coupling compositions chemically bond to glass fibers by replacing the —OH groups present on the glass fibers in aqueous solutions with Ti—O or Zr—O bonds. The X functionality of the coupling composition is selected to be a phosphato or pyrophosphato group to form bond with calcium ions of the gypsum crystal. The bond created by the titanium or zirconium based coupling composition results in load transfer between gypsum crystals in the gypsum matrix and between the glass fibers and gypsum matrix, resulting in improved flexure strength and nail pullout resistance.

Abstract: A bond is created during gypsum board cure between a gypsum matrix and a tacky coating applied onto a glass fiber. The tacky coating is comprised of a polymer composed of methacrylic acid and dimethyldiallyammonium chloride. The polymer is dissolved in an acidic aqueous solution and is roller coated onto the glass fibers. The chopped glass fibers may also be placed in such an acidic solution, which is made alkaline by the addition of alkali, thereby precipitating the polymer out of solution as a tacky composition that produces a tacky coating on the glass fibers. The glass fibers with the tacky bond coating are incorporated in an alkaline gypsum slurry to form a gypsum board having a first and second facer sheet. The tacky coating on the glass fibers bonded to the gypsum matrix result in compliant load transfer between the gypsum matrix and the glass fibers, yielding improved flexure strength and nail pullout resistance.

Abstract: A bond is created between a gypsum matrix and titanium or zirconium based coupling coating applied onto a glass fiber during gypsum board cure. The commercially available titanium or zirconium based coupling has a generic formula of the type [RO-}-nTi—[—OXR?Y]4-n or [RO-}-nZr—[—OXR?Y]4-n. These coupling compositions chemically bond to glass fibers by replacing the —OH groups present on the glass fibers in aqueous solutions with Ti—O or Zr—O bonds. In order to bond with calcium ions in hydrated gypsum crystals, the X functionality is selected to be a phosphate or pyrophosphato group. The bond between the glass fiber and the titanium or zirconium based coupling composition is due to the formation of a monolayer, while the bond between the hydrated gypsum crystal and the coupling composition is intermittent due the acicular structure of gypsum crystals.

Abstract: A bond is created between a gypsum matrix formed from an aqueous acidic gypsum slurry comprising a monomer mixture. The monomer mixture is composed of a monomer having acidic functionality and a monomer having hydroxyl or amine functionality. A silane-based sizing composition is coated onto glass fibers causing a cross-linking network of silane and monomer mixture to form during curing of the gypsum board. Hydrophilic water extraction at the gypsum matrix-sizing interface reduces void formation and promotes bonding with the crosslinked monomer mixture and growth of smaller gypsum crystals within larger crystals in microstructurally identifiable regions adjacent to the glass fiber. A bond is created between a gypsum matrix formed from an aqueous acidic gypsum slurry comprising a monomer mixture. The monomer mixture is composed of a monomer having acidic functionality and a monomer having hydroxyl or amine functionality.

Abstract: Provided is a fiberglass binder composition which comprises a polycarboxy polymer modified with a fatty acid, and a polyol. The binder also preferably includes a catalyst which is an alkali metal salt of a phosphorus-containing organic acid. The resultant binder provides minimal processing difficulties and a fiberglass product which exhibits minimal water absorption.

Abstract: Provided is a fiberglass binder composition which comprises a polycarboxy polymer modified with a fatty acid, and a polyol. The binder also preferably includes a catalyst which is an alkali metal salt of a phosphorus-containing organic acid. The resultant binder provides minimal processing difficulties and a fiberglass product which exhibits minimal water absorption.

Abstract: Provided is a fiberglass binder composition which comprises a polycarboxy polymer modified with a fatty acid, and a polyol. The binder also preferably includes a catalyst which is an alkali metal salt of a phosphorus-containing organic acid. The resultant binder provides minimal processing difficulties and a fiberglass product which exhibits minimal water absorption.

Abstract: Provided is a fiberglass binder composition which comprises a polycarboxy polymer, polyol and an imidazoline. The binder also preferably includes a catalyst which is an alkali metal salt of a phosphorus-containing organic acid. The resultant binder provides minimal processing difficulties and a product which exhibits minimal water absorption.

Abstract: Provided is a fiberglass binder composition which comprises a polycarboxy polymer, polyol and an imidazoline. The binder also preferably includes a catalyst which is an alkali metal salt of a phosphorus-containing organic acid. The resultant binder provides minimal processing difficulties and a product which exhibits minimal water absorption.