Abstract: A continuous process for preparing insulation panels having thick (0.2 mm to 1 mm) metal facing panels and a fiber-reinforced polymer foam core is disclosed. In the process, a bottom metal facing panel is continuously supplied. A mat of reinforcing fibers and a foamable resin composition are applied to the bottom facing panel. A flexible barrier layer is applied atop the foamable resin composition, and the assembly is passed through nip rolls to compress the assembly and force the resin composition into the fiber mat. An adhesive layer and top metallic facing layer are then applied on top of the flexible barrier layer, and the resulting assembly is gauged and cured by passing it through a double band laminator.

Abstract: A continuous process for preparing insulation panels having thick (0.2 mm to 1 mm) metal facing panels and a fiber-reinforced polymer foam core is disclosed. In the process, a bottom metal facing panel is continuously supplied. A mat of reinforcing fibers and a foamable resin composition are applied to the bottom facing panel. A flexible barrier layer is applied atop the foamable resin composition, and the assembly is passed through nip rolls to compress the assembly and force the resin composition into the fiber mat. An adhesive layer and top metallic facing layer are then applied on top of the flexible barrier layer, and the resulting assembly is gauged and cured by passing it through a double band laminator.

Abstract: A continuous process for preparing insulation panels having thick (0.2 mm to 1 mm) metal facing panels and a fiber-reinforced polymer foam core is disclosed. In the process, a bottom metal facing panel (2) is continuously supplied. A mat (10) of reinforcing fibers and a foamable resin composition (19) are applied to the bottom facing panel. A flexible barrier layer (5) is applied atop the foamable resin composition, and the assembly is passed through nip rolls (12,13) to compress the assembly and force the resin composition into the fiber mat. An adhesive layer (4) and top metallic facing layer (1) are then applied on top of the flexible barrier layer, and the resulting assembly is gauged and cured by passing it through a double band laminator (11).

Abstract: A panel with fire barrier comprises: a metal facing; an insulating foam layer; and at least one fire barrier layer between the metal facing and the foam layer, the fire barrier layer(s) comprising at least one of porous silica; hollow glass microspheres; glass fibres; an inorganic ceramifying composition; a dispersion in a polyurethane polymer matrix or polyurethane/polyisocyanurate polymer matrix or polyurethane/polyurea polymer matrix of expandable graphite. A panel arrangement with fire barrier material in the joint regions between panels, methods of forming the panel and panel arrangement, fire barrier compositions, and reactants for forming the fire barrier compositions are also described.

Abstract: An insulation panel includes a first non-steel based facing that is a combustible material, a glass-fleece based material, or a low melting temperature thin metal foil; an insulating foam layer; and a fire barrier layer adjacent to the first non-steel based facing and between the first non-steel based facing and the insulating foam layer. The fire barrier layer includes a dispersion of expandable graphite in a polyisocyanate polymer matrix and the amount of expandable graphite per unit area is at least 50 g/m2.

Abstract: A panel includes a first metal facing, an insulating foam layer, and a fire barrier layer between the first metal facing and the foam layer. The fire barrier layer includes a dispersion of expandable graphite in a polyisocyanurate polymer matrix. The polymer matrix is formed by reaction at an isocyanate index of more than 250 of an isocyanate-containing reactant and a polyol reactant including a long chain polyol of equivalent weight of more than 300. The amount of expandable graphite per unit area in the fire barrier layer is at least 200 g/m2.

Abstract: A continuous process for preparing insulation panels having thick (0.2 mm to 1 mm) metal facing panels and a fiber-reinforced polymer foam core is disclosed. In the process, a bottom metal facing panel (2) is continuously supplied. A mat (10) of reinforcing fibers and a foamable resin composition (19) are applied to the bottom facing panel. A flexible barrier layer (5) is applied atop the foamable resin composition, and the assembly is passed through nip rolls (12,13) to compress the assembly and force the resin composition into the fiber mat. An adhesive layer (4) and top metallic facing layer (1) are then applied on top of the flexible barrier layer, and the resulting assembly is gauged and cured by passing it through a double band laminator (11).

Abstract: The present invention relates to polyurethane rigid foams formulations. More particularly, the present invention relates to polyurethane rigid foams formulations, prepared from aromatic polyester polyols, which show improved compressive strength. The formulations include an isocyanate reacting mixture, at least one polymeric diphenylmethane diisocyanate, having a functionality of at least 2.7, and at least one blowing agent; such that the stoichiometric index of the polyisocyanate to the isocyanate reacting mixture is 1.0-1.8.

Abstract: A panel with fire barrier comprises: a metal facing; an insulating foam layer; and at least one fire barrier layer between the metal facing and the foam layer, the fire barrier layer(s) comprising at least one of porous silica; hollow glass microspheres; glass fibres; an inorganic ceramifying composition; a dispersion in a polyurethane polymer matrix or polyurethane/polyisocyanurate polymer matrix or polyurethane/polyurea polymer matrix of expandable graphite. A panel arrangement with fire barrier material in the joint regions between panels, methods of forming the panel and panel arrangement, fire barrier compositions, and reactants for forming the fire barrier compositions are also described.

Abstract: A layered insulation panel including a rigid polyisocyanurate foam layer and, adhered to at least one surface thereof, a facing material. The two materials are adhered by a two-component polyisocyanurate adhesive, and both the polyisocyanurate adhesive and the polyisocyanurate foam layer undergo polymerization concurrently and in place. The result is that the tensile bond strength between the polyisocyanurate foam layer and the facing surface is improved, due to interaction between the polymerization occurring at the surface of the foam layer and the polymerization of the polyisocyanurate adhesive.