Abstract: A construction product described herein includes a fiber core that includes a plurality of entangled glass fibers. The fiber core also includes a binder that bonds the plurality of entangled glass fibers together and an Aerogel material that is homogenously or uniformly disposed within the fiber core. In some instances, the fiber core includes between 40 and 80 weight percent of the Aerogel material. The construction product has an R-value of at least 6.5 per inch, a flame spread index of no greater than 5, and a smoke development index of no greater than 20 as measured according to the ASTM E-84 tunnel test.

Abstract: A polyisocyanurate foam insulation product is produced from an isocyanate component, a polyol-containing component, and a blowing agent. The polyol-containing component comprises one or more polyols, a fire retardant, and one or more surfactants, and the polyisocyanurate foam insulation product has an R-value per inch of at least 5.7 when measured at 40° F. In some formulations, the polylol-containing component may include a fire retardant, a metallo-organic compound, or combinations thereof. The cell size of the foam may be less than 120 microns. The polyol-containing component may include a mixture of polyols having different functionalities.

Abstract: A polyisocyanurate foam insulation product includes polyisocyanurate foam produced from reacting an isocyanate and a polyol blend having a functionality of at least 2.2. The isocyanate and the polyol blend are reacted so that the polyisocyanurate foam has an isocyanate index equivalent with or greater than 300. The polyisocyanurate foam includes a fire retardant and includes between 0.02 and 0.45 weight percent of a zinc salt compound. The foam insulation board exhibits a flame spread of no greater than 25 and a smoke index of no greater than 50 when exposed to flame conditions in accordance with an 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 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 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 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: 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 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: 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 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: A acoustic and fire retardant foam coating composition for a fibrous mat which comprises (i) one or more fillers such as ceramic microspheres having a particle size of D90%?300 ?m, a density of less than 3 g/cm3 and hardness of at least 5 on the Moh's scale and (ii) one or more binders with each organic binder having a peak heat release rate of ?1000 kW/m2 as measured by ASTM E1354, flux 30 kW/m2. A coated fiberglass mat comprising the coating composition has a FIGRA value of ?120 W/s according to EN 13823, and a flame index of ?25 and a smoke index of ?50 according to ASTM E84 and a NRC (noise reduction coefficient) of ?0.2 according to ASTM C423, mounting type A.

Abstract: A fire retardant coating composition for a fibrous mat comprises one or more fillers and one or more binders with each organic binder having a peak heat release rate of ?1000 kW/m2 as measured by ASTM E1354, flux 30 kW/m2. A coated fiberglass mat comprising the coating composition has a FIGRA value of ?120 W/s according to EN 13823, 0.4 MJ and a flame index of ?25 and a smoke index of ?50 according to ASTM E84.

Abstract: Provided is a novel foam composition for preparing polyisocyanurate foam. The composition comprises an isocyanate reactive compound, poyisocyanate, blowing agent and talc filler component. The talc filler is loaded from 0.5 to 20 wt % based on the isocyanate reaction compound, preferably a polyol, and the average particle size of the filler is in the range of from 7? to 20?. The foam material prepared contains a high loading of filler, yet still exhibits excellent foam properties.

Abstract: Provided is a novel polyisocyanurate foam composition. The composition comprises an isocyanate reactive compound, polyisocyanate and an aqueous polymer emulsion. The unique foam can be synthesized without a blowing agent. and provides a foam material that is economical but still exhibits excellent foam properties.

Abstract: Provided is a novel foam composition for preparing polyisocyanurate foam. The composition comprises an isocyanate reactive compound, polyisocyanate, blowing agent and mica filler component. The mica filler is loaded from 0.5 to 20 wt % based on the isocyanate reaction compound, preferably a polyol, and the average particle size of the filler is greater than 7? but less than 11?. The foam material prepared contains a high loading of filler, yet still exhibits excellent foam properties.

Abstract: Coating compositions for fibrous nonwoven and woven coated mats comprising a platey filler, mica, talc, clay, etc., of particular critical mean particle sizes and aspect ratios, one or more pigments of particular particle sizes and a resin binder producing a good surface and low permeabilities achieved with low coating weights are disclosed. Also, disclosed are fibrous mats coated on at least one surface with the coating compositions and laminates having a coated fibrous mat bonded to at least one surface of the substrate of the laminate. The platey mica in the coating has a mean particle size of about 38+/?8 or less microns and an aspect ratio of about 36+/?7 or less.

Abstract: Provided is a novel foam composition for preparing polyisocyanurate foam. The composition comprises an isocyanate reactive compound, polyisocyanate, blowing agent and calcium carbonate filler component. The filler is loaded from 0.5 to 20 wt % based on the isocyanate reactive compound, preferably a polyol, and the average particle size of the filler ranges from 14? to 40?. The foam material prepared contains a high loading of filler, yet still exhibits excellent foam properties.

Abstract: A novel coated nonwoven fibrous mat having properties particularly suited for a facer on gypsum wallboard, laminates made therefrom and the method of making the mat is disclosed. The mat preferably contains a major portion of glass fibers and a minor portion of a resinous binder. The coating is permeable and reduces fiber dust, and yields a smooth surface. The coating comprises mineral pigment and an organic binder.

Abstract: A novel nonwoven fiberglass mat having properties particularly suited for a facer on gypsum wallboard, laminates made therefrom and the method of making the mat is disclosed. The mat has a controlled permeability, with the permeability of the mat being controlled by perforation of the mat.