Abstract: A method for manufacturing a laminated foam product in which first and second consolidated fiberglass sheets are adhered to a foam core. The consolidated fiberglass sheets are made of fiberglass commingled with a polymer fiber and pre-treated with heat and pressure. PUR/PIR foam ingredients are applied between the first and second consolidated fiberglass sheets to form a PUR/PIR foam. The foam may be manufactured by directly foaming onto the fiberglass sheets or by foaming between facer sheets and using an adhesive to secure the fiberglass sheets thereto. A sufficient adhesion between the fiberglass sheets and the foam core is required to produce a strong lightweight sheet material suitable for use as a structural building component in lieu of wood or the like. The composite product has excellent strength and lightweight characteristics.

Abstract: Composite foam products and methods utilize a foam core to which upper and lower consolidated fiberglass sheets are adhered. The foam may be manufactured alternatively by directly foaming onto the fiberglass sheets or by foaming between facer sheets and using an adhesive to secure the fiberglass sheets thereto. A sufficient adhesion between the fiberglass sheets and the foam core is required to produce a strong lightweight sheet material suitable for use as a structural building component in lieu of wood or the like. The composite product has excellent strength and lightweight characteristics.