Abstract: A thermosetting plastic foam solid formed from the reaction product of: (a) either polyisocyanate or isocyanate; (b) a polyol; (c) a catalyst which is capable of promoting the thermosetting reaction between the polyisocyanate or isocyanate and the polyol; and (d) a blowing agent comprised at least partially from a high purity cyclopentane product, wherein the high purity cyclopentane product is about 95% or greater pure cyclopentane, and, optionally, (e) water and/or (f) liquid flame retardant.

Abstract: A thermosetting plastic foam solid formed from the reaction product of: (a) either polyisocyanate or isocyanate; (b) a polyol; (c) a catalyst which is capable of promoting the thermosetting reaction between the polyisocyanate or isocyanate and the polyol; and (d) a blowing agent comprised at least partially from a high purity cyclopentane product, wherein the high purity cyclopentane product is about 95% or greater pure cyclopentane, and, optionally, (e) water and/or (f) liquid flame retardant.

Abstract: A thermosetting plastic foam solid is obtained using a blowing agent comprised at least partially from depolymerization of dicyclopentadiene into essentially pure cyclopentane. This unique hydrocarbon is miscible in polyester polyols, where others, such as extracted cyclopentane, are not. In a blend of 15 parts of liquid flame retardant per hundred parts polyester polyol, the mixture is both stable and has a suitably low viscosity.

Abstract: In a method of producing a polyurethane modified polyisocyanurate foam, at least one alkali metal organo-salt catalyst is utilized in an aqueous solution free of aliphatic glycols. The catalyst preferably contains more chemical equivalents of at least one carboxylic acid than chemical equivalents of at least one alkali metal hydroxide dissolved in water. The use of extra or undissolved carboxylic acid, preferably 2-ethyl-hexoic acid, advantageously creates flame resistant amides, as well as creating carbon dioxide as a blowing agent. The use of extra or undissolved carboxylic acid can also reduce the water content of catalysts of the present invention which might have a water content in excess of the desired.

Abstract: In a method of producing a thermosetting foam, a first of two foam forming blends ("A-Blend") is prepared using a multi-functional isocyanate such as polymeric polymethylene polyphenylisocyanate ("PMDI"). A second of two foam forming blends ("B-Blend") is prepared by mixing together a polyol; water; a tertiary amine catalyst having at least two hydrogen bonding sites for one molecule; and, an alkali metal organo-salt catalyst. The tertiary amine catalyst is of a type wherein both the hydrogen segment and the hydroxyl segment of water are attracted by both of the hydrogen bonding cites on the catalyst molecule essentially simultaneously. A first blowing agent is included with one of the two foam forming blends. When the first and second foam forming blends are mixed together, the tertiary amine catalyst quickly initiates a reaction predominately of the polymeric polymethylene polyphenylisocyanate with water (as opposed to a reaction with the polyol).

Abstract: In a method of producing a thermosetting foam, a first of two foam forming blends ("A-Blend") is prepared using a multi-functional isocyanate such as polymeric polymethylene polyphenylisocyanate ("PMDI"). A second of two foam forming blends ("B-Blend") is prepared by mixing together a polyol; water; a tertiary amine catalyst having at least two hydrogen bonding sites for one molecule; and, an alkali metal organo-salt catalyst. The tertiary amine catalyst is of a type wherein both the hydrogen segment and the hydroxyl segment of water are attracted by both of the hydrogen bonding cites on the catalyst molecule essentially simultaneously. A first blowing agent is included with one of the two foam forming blends. When the first and second foam forming blends are mixed together, the tertiary amine catalyst quickly initiates a reaction predominately of the polymeric polymethylene polyphenylisocyanate with water (as opposed to a reaction with the polyol).

Abstract: In a method of producing a thermosetting foam, a first of two foam forming blends ("A Blend") is prepared using polymeric polymethylene polyphenylisocyanate ("PMDI"). A second of two foam forming blends ("B Blend") is prepared by mixing together a polyol; water; a tertiary amine catalyst having at least one ethyl (--CH.sub.2 --CH.sub.2 --) linkage between two heteroatoms, the heteroatoms being chosen from the group consisting of Nitrogen and Oxygen; and, an alkali metal organo-salt catalyst. A first blowing agent is included with one of the two foam forming blends. When the first and second foam forming blends are mixed together, the tertiary amine catalyst quickly initiates a reaction predominately of the polymeric polymethylene polyphenylisocyanate with water (as opposed to a reaction with the polyol).

Abstract: Blowing agents and blowing agent mixtures for preparing a cellular thermosetting plastic foam comprise either (1) a non-chlorinated, partially hydrogenated fluorocarbon with the general formula H.sub.x F.sub.y C.sub.z ; (2) a non-chlorinated, partially hydrogenated fluorocarbon ether with the general formula H.sub.x F.sub.y C.sub.z --O--C.sub.m F.sub.n H.sub.p ; (3) a non-chlorinated, non-hydrogenated, fully fluoronated fluorocarbon; (4) an azeotropic mixture having a boiling point below 50 degrees Celsius; or (5) any mixture of the foregoing. The azeotropic mixtures are produced from organic compounds having surface active properties that enable the blended azeotropic mixture to become miscible with polymer resins. Among the preferred compounds for use in azeotropic mixtures are n-pentane, acetone, methyl alcohol, methyl formate, ethyl formate, ethyl alcohol, 2-methyl butane, nitromethane, cyclopentane, 2,3,-dimethyl butane, 2,2,-dimethyl butane, and dimethyl sulfide.

Abstract: A method of producing a non-porous mat includes coating a predominantly glass fiber porous web substrate. The coating comprises an aqueous mixture of a mineral pigment; a first binder material comprised of a polymer latex adhesive material; and, a second binder material comprised of an inorganic adhesive material. On a dry weight basis, the first binder material comprises no more than 5.0% by weight, and the second binder material at least 0.5% by weight, of the total weight of the coating. The second binder preferably comprises an inorganic compound such as calcium oxide, calcium silicate, calcium sulfate, magnesium oxychloride, magnesium oxysulfate, or aluminum hydroxide. In one mode, the second binder is included in the mineral pigment, as in the cases wherein the mineral pigment includes aluminum trihydrate, calcium carbonate, calcium sulfate, magnesium oxide, and some clays and sands. A method of using the coated mat to produce a thermosetting plastic foam laminate panel is also disclosed.

Abstract: A coating composition and method of producing a non-porous mat includes coating a predominantly glass fiber porous web substrate. The coating comprises an aqueous mixture of a mineral pigment; a first binder material comprised of a polymer latex adhesive material; and, a second binder material comprised of asphalt emulsion material. The total dry weight basis of both binders does not exceed 24% of the total coating.

Abstract: A structural laminate comprises at least one planar facing sheet comprised largely of glass fibers but not having micro-glass as a filler. The facing sheet is self adhered to a rigid thermosetting plastic foam core. The non-glass filler material is chosen from a group consisting of clay, mica, talc, limestone (calcium carbonate), gypsum (calcium sulfate), aluminum trihydrate (ATH), antimony oxide, cellulose fibers, and plastic polymer fibers. The non-glass filler material improves containment of liquid plastic thermosetting polymer, and offers economic and safety advantages.

Abstract: Copolyester polyol resins comprising the reaction product of an aromatic component selected from phthalic derivatives, polyethylene terephthalate, or dimethyl terephthalate, an aliphatic component selected from certain dibasic compounds, at least one primary hydroxyl glycol, and at least small amounts of a secondary hydroxyl glycol, the mole ratios of the components being:(a) glycols to aromatic plus aliphatic component of from about 1.3 to 2:1;(b) aromatic component to aliphatic component of from about 0.6 to 4.0:1;(c) a secondary to primary hydroxyl glycol of from 0.05 to 0.4:1; and(d) ethylene glycol content to aromatic component of from about 0.01 to 0.5:1.0.The invention also comprises polyol blends utilizing from 30 percent up to 90 percent of such resins and resultant polyurethane modified polyisocyanurate foams made by reacting such polyol blends with polymeric polymethylene polyphenylisocyanate.

Abstract: A composite panel for use in the construction industry includes a core of foamed plastic material and a skin on at least one of its faces comprised of a two-ply material consisting of aluminum foil bonded to a mat of randomly oriented glass fibers into which the foam core has been expanded.The core material comprises the rection product of isocyanurate and polyester/polyether polyol with the isocyanurate in sufficient excess to form trimmer rings and to react with the polyol to form urethane linkages.Panels formed of the core material and the two-ply skins have excellent thermal insulation and fire retardant properties and the skins have excellent mechanical strength.

Abstract: Copolyester polyol resins comprising the reaction product of an aromatic component, an aliphatic component selected from certain dibasic compounds, at least one primary hydroxyl glycol, and at least one secondary hydroxyl glycol, the mole ratios of the components being:(i) glycols to aromatic plus aliphatic component of about 1.3 to 2:1,(ii) aliphatic component to aromatic component of about 0.3 to 1.7:1, and(iii) primary glycol to secondary glycol of about 0.6 to 2.5:1.The invention also comprises foamable blends utilizing such resins and resultant polyisocyanurate foams.

Abstract: Apparatus for fastening building construction insulating panels to a supporting wall structure comprising a slotted channel member and an anchoring clip. The channel has flanges by which it is secured to a supporting wall structure and a slotted mounting surface spaced from the supporting wall a preselected distance to provide improved insulation. The anchoring clip has opposed flanges on one end for engaging the edges of adjacent insulating wall panels and an anchor on the opposite end for engaging the slot in the channel and thereby holding the insulated panel to the supporting wall with the preselected spacing.