CA2241695A1 - Insulating compositions - Google Patents

Insulating compositions Download PDF

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Publication number
CA2241695A1
CA2241695A1 CA 2241695 CA2241695A CA2241695A1 CA 2241695 A1 CA2241695 A1 CA 2241695A1 CA 2241695 CA2241695 CA 2241695 CA 2241695 A CA2241695 A CA 2241695A CA 2241695 A1 CA2241695 A1 CA 2241695A1
Authority
CA
Canada
Prior art keywords
insulating
layer
binder
expanded polystyrene
layered
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA 2241695
Other languages
French (fr)
Inventor
Brian Boudreau
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SPECIALTY COATINGS Ltd
Original Assignee
SPECIALTY COATINGS LTD.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by SPECIALTY COATINGS LTD. filed Critical SPECIALTY COATINGS LTD.
Priority to CA 2241695 priority Critical patent/CA2241695A1/en
Publication of CA2241695A1 publication Critical patent/CA2241695A1/en
Abandoned legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/22After-treatment of expandable particles; Forming foamed products
    • C08J9/228Forming foamed products
    • C08J9/236Forming foamed products using binding agents
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00Layered products comprising a layer of natural or synthetic rubber
    • B32B25/02Layered products comprising a layer of natural or synthetic rubber with fibres or particles being present as additives in the layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/65Low-molecular-weight compounds having active hydrogen with high-molecular-weight compounds having active hydrogen
    • C08G18/66Compounds of groups C08G18/42, C08G18/48, or C08G18/52
    • C08G18/6633Compounds of group C08G18/42
    • C08G18/6637Compounds of group C08G18/42 with compounds of group C08G18/32 or polyamines of C08G18/38
    • C08G18/664Compounds of group C08G18/42 with compounds of group C08G18/32 or polyamines of C08G18/38 with compounds of group C08G18/3203
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L75/00Compositions of polyureas or polyurethanes; Compositions of derivatives of such polymers
    • C08L75/04Polyurethanes
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2325/00Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Derivatives of such polymers
    • C08J2325/02Homopolymers or copolymers of hydrocarbons
    • C08J2325/04Homopolymers or copolymers of styrene
    • C08J2325/06Polystyrene
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2475/00Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L25/00Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
    • C08L25/02Homopolymers or copolymers of hydrocarbons
    • C08L25/04Homopolymers or copolymers of styrene
    • C08L25/06Polystyrene

Landscapes

  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Building Environments (AREA)
  • Paints Or Removers (AREA)

Abstract

An insulating composition and method is disclosed. The insulating composition comprises an admixture of heat expanded polystyrene (EPS) beads in a liquid, solvent-free binder, comprising an aromatic isocyanate cured with a polyol resin. The ratio of EPS to binder is about 50:1 by volume. The composition is applied to a surface coat of the binder and finished with a top coat of the binder. A reinforcing fabric layer is optimal.

Description

INSULATING COMPOSITIONS
FIELD OF THE INVENTION
The present invention relates to an insulating composition.
BACKGROUND OF THE INVENTION
Insulating compositions which contain expanded polystyrene (EPS) particles bound means of a polymeric binder matrix are well known. As well, it is well known to use polyurethane foam as a spray-on insulating coating. Both of these prior art techniques have disadvantages which limit their applications.
Insulating compositions which use EPS beads and polymeric binders are typically about 80% EPS by volume and utilize aqueous based binding agents because of the susceptibility of EPS to many solvents such as aromatic hydrocarbons, ketones, aldehydes or polyester resins. Suitable binding agents disclosed in the prior art include synthetic resin latex or acrylic resins: see U.S. Patent No. 4,379,857 issued to Hansen et al.
However, such resins are expensive and must be used in ratios of up to 60% by volume of the insulating composition. In contrast, the EPS is very inexpensive and is the primary insulating component in the composition. The resin is non-insulating, therefore, minimizing the binder agent may increase insulating effectiveness as well as reducing expense.
Spray-on polyurethane foam using carbon dioxide as the foaming gas is well known. However, the carbon dioxide leaks out over time and is replaced by oxygen and nitrogen, which are poorer insulators than carbon dioxide. It is also susceptible to consumption by rodents.
The use of EPS foam admixed with a latex resin binder as a roofing material is described in U.S. Patent No. 4,413,026 to Sherno. As disclosed therein, such a composition may be advantageous in comparison to asphalt based roof coating compositions which require a good deal of maintenance and are poor insulators. However, the insulating composition disclosed in this patent still has the disadvantages stated above.
Therefore, there is a need in the art for an insulating composition which maximizes insulation value and cost-effectiveness by minimizing the quantity of the binding agent while avoiding the drawbacks of the prior art. It would be further advantageous if such an insulating composition to moisture proof, rigid and light-weight while providing a structurally strong and permanent base for various applications and roofing applications in particular.
SUMMARY OF INVENTION
In one aspect of the invention and in general terms, the invention comprises an insulating composition comprising a plurality of expanded polyurethane foam particles bond on a solvent-free binder.
In another aspect of the invention, the invention comprises a layered implementing system comprising:
(a) a primer coat layer applied to the substrate to enhance adhesion of an insulating layer to the substrate;
(b) an insulating layer applied over the primer coat layer comprising a plurality of expanded polystyrene particles dispersed in a solvent free polyurethane rubber binder; and (c) a surface finish layer comprising a fabric mesh and at least one sealing coat of the solvent free polyurethane rubber.
DETAILED DESCRIPTION OF THE INVENTION
The insulating composition of the present invention comprises an admixture of heat expanded plastic granules or beads in a liquid, solvent free binder. The heat expanded granules are preferably expanded polystyrene (EPS) granules or beads which are preferably dispersed in the liquid binder. Alternatively, heat expanded materials such as vermiculite or perlite may be used if treated to eliminate or reduce their moisture absorption characteristics.
The EPS beads used are preferably about 5mm in diameter although the actual size of the beads is not critical to this invention. EPS beads or ground EPS particles are well known in the art and are readily commercially available.
The liquid binder is solvent free and is preferably a two component polyurethane rubber comprised of an aromatic isocyanate, preferably diphenylmethane diisocyanate, cured with a suitable polyol resin. The polyol resin comprises polyether polyol and chain extenders consisting of low molecular weight diols, below about 200 grams per mole. The chain extenders preferably comprise about 15% of the polyol resin but may vary from about 5% to about 25%. The polyol resins employed in the present invention are blended in accordance with well-known paint manufacturing processes.
Preferably, the polyol resin is mixed with the isocyanate in a 2:1 to 1:1 ratio by volume.
The polyol resin may optionally contain additives such as pigments, surfactants, catalysts and/or fire retardants. Titanium dioxide may be used as a white pigment. There are many known catalysts which accelerate the curing process such as dibutyl tin.
A fire retardant additive such as a phosphate ester is also optional.
The insulating composition is then prepared by combining the EPS beads with the polyurethane binder at a ratio of approximately 5:3 (resin to EPS) by weight. This is equivalent to a ratio of approximately 1:50 (resin to EPS) by volume. The composition may then be applied to the substrate and allowed to cure. Before the composition is finally cured, it may be levelled, sloped or contoured with relative ease.
In the preferred method of applying the insulating composition, the solvent free polyurethane binder is used as a primer coat layer on the substrate to ensure good adhesion of the insulating composition to the substrate. In the preferred method, one coat of the binder is applied to about a 5 mil thickness.
If the substrate surface temperature could potentially exceed the melting temperature of polystyrene, it may be necessary to provide a heat shielding layer to prevent melting of the EPS component in the insulating composition. It has been found that a layer of ceramic microspheres bound with a polymeric binder is sufficient for most applications.
Z-lightTM spheres from 3M are suitable for this application. Although any latex or polyurethane binder may be used for the ceramic microspheres, it is preferable to use the solvent free polyurethane of the preferred embodiment herein.
In the preferred embodiment, a reinforcing fabric surface finish layer is applied over the insulating EPS layer once the EPS layer has cured. The fabric should preferably exhibit good tensile strength and a tight weave. Preferably, spunbonded polyester, fibreglass mesh, polyester or high density polyester mesh fabric are used. The fabric layer is applied over the EPS layer and at least one coat of the solvent free polyurethane is applied to seal the fabric surface. Preferably, an additional coat or two to provide a top coat of about 30 mil thickness are applied to reinforce the surface. Optionally, prior to the surface finish, a layer of expanded polystyrene board or other suitable roofing board may be applied over the EPS
layer to provide additional insulation and some additional structural strength.
The solvent free polyurethane cured with an aromatic isocyanate such as diphenylmethane diisocyanate is not stable when exposed to ultraviolet light and will discolor or potentially degrade if exposed to UV light. Therefore, if the insulating composition is used in outdoor applications such as a roofing material, then it is preferable to provide an additional top coat which is UV light resistant such as acrylic latex or a two component solvent free polyurethane employing an aliphatic isocyanate in place of the aromatic isocyanate of the preferred embodiment.
As will be apparent to those skilled in the art, various modifications, adaptations and variations of the foregoing specific disclosure can be made without departing from the teachings of the present invention.

Claims (19)

1. An insulating composition comprising in combination:
(a) a plurality of expanded polystyrene foam particles; and (b) a solvent free binder.
2. The insulating composition of claim 1 wherein the binder is comprised of a two-component polyurethane rubber.
3. The insulating composition of claim 2 wherein the polyurethane rubber is comprised of an aromatic isocyanate cured with a suitable polyol resin.
4. The insulating composition of claim 3 wherein the aromatic isocyanate is diphenylmethane diisocyanate.
5. The insulating composition of claim 3 wherein the polyol resin is comprised of polyester polyol and chain extenders comprising low molecular weight diols.
6. The insulating composition of claim 4 wherein the polyol resin further comprises one or more additives chosen from the following group: pigments, surfactants, catalysts and/or fire retardants.
7. The insulating composition of claim 1 wherein the binder is combined with the expanded polystyrene particles at a ratio of about 5:3 by weight.
8. The insulating composition of claim 1 wherein the binder is combined with an expanded polystyrene particles at a ratio of about 1:50 by volume.
9. A layered insulating system applied to a substrate comprising:
(a) a primer coat layer applied to the substrate to enhance adhesion of an insulating layer to the substrate;
(b) an insulating layer applied over the primer coat layer comprising a plurality of expanded polystyrene particles dispersed in a solvent free polyurethane rubber binder; and (c) a surface finish layer comprising a fabric mesh and at least one sealing coat of the solvent free polyurethane rubber.
10. The layered insulating system of claim 9 further comprising a heat shield layer disposed between the primer coat layer and the insulating layer wherein the heat shield layer comprises a plurality of ceramic microspheres dispersed within a suitable binding agent.
11. The layered insulating system of claim 9 further comprising a board layer disposed between the insulating layer and the surface finish layer.
12. The layered insulating system of claim 11 wherein the board layer is comprised of expanded polystyrene board.
13. The layered insulating system of claim 11 further comprising a heat shield layer disposed between the primer coat layer and the insulating layer wherein the heat shield layer comprises a plurality of ceramic microspheres dispersed within a suitable binding agent.
14. The layered insulating system of claim 9 wherein the polyurethane rubber is comprised of an aromatic isocyanate cured with a suitable polyol resin.
15. The layered insulating system of claim 14 wherein the aromatic isocyanate is diphenylmethane diisocyanate.
16. The layered insulating system of claim 15 wherein the polyol resin is comprised of polyester polyol and chain extenders comprising low molecular weight diols.
17. The layered insulating system of claim 16 wherein the polyol resin further comprises one or more additives chosen from the following group: pigments, surfactants, catalysts and/or fibre retardants.
18. The layered insulating system of claim 9 wherein the binder is combined with the expanded polystyrene particles at a ratio of about 5:3 by weight.
19. The layered insulating system of claim 9 wherein the binder is combined with the expanded polystyrene particles at a ratio of about 1:50 by volume.
CA 2241695 1998-06-24 1998-06-24 Insulating compositions Abandoned CA2241695A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA 2241695 CA2241695A1 (en) 1998-06-24 1998-06-24 Insulating compositions

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA 2241695 CA2241695A1 (en) 1998-06-24 1998-06-24 Insulating compositions

Publications (1)

Publication Number Publication Date
CA2241695A1 true CA2241695A1 (en) 1999-12-24

Family

ID=29409535

Family Applications (1)

Application Number Title Priority Date Filing Date
CA 2241695 Abandoned CA2241695A1 (en) 1998-06-24 1998-06-24 Insulating compositions

Country Status (1)

Country Link
CA (1) CA2241695A1 (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1712585A2 (en) 2005-04-15 2006-10-18 Whirlpool Corporation Method for the production of expanded polymeric materials
WO2013123919A1 (en) * 2012-02-20 2013-08-29 Tomas Bata University In Zlin Method of the production of expanded polystyrene based compact parts with integrated functional and/or decorative elements
BE1021837B1 (en) * 2014-04-30 2016-01-21 Es-Projects, Besloten Vennootschap Met Beperkte Aansprakelijkheid COMPOSITION OF AN INSULATION MATERIAL, METHOD FOR MANUFACTURING INSULATION MATERIAL AND USE OF SUCH INSULATION MATERIAL

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1712585A2 (en) 2005-04-15 2006-10-18 Whirlpool Corporation Method for the production of expanded polymeric materials
EP1712585A3 (en) * 2005-04-15 2010-04-28 Whirlpool Corporation Method for the production of expanded polymeric materials
US7893123B2 (en) 2005-04-15 2011-02-22 Whirlpool Corporation Method for the production of expanded polymeric materials and expanded polymeric material obtained by the method
WO2013123919A1 (en) * 2012-02-20 2013-08-29 Tomas Bata University In Zlin Method of the production of expanded polystyrene based compact parts with integrated functional and/or decorative elements
BE1021837B1 (en) * 2014-04-30 2016-01-21 Es-Projects, Besloten Vennootschap Met Beperkte Aansprakelijkheid COMPOSITION OF AN INSULATION MATERIAL, METHOD FOR MANUFACTURING INSULATION MATERIAL AND USE OF SUCH INSULATION MATERIAL

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