US3874980A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Composite foam panel with fibrous facing sheets
Assignee: Owens Corning Fiberglas Technology Inc
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Filing: 1972-06-09
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Granted: 1975-04-01
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Expires: 1992-06-09
Abstract
Abstract A composite panel is provided which comprises an organic foam core with layers of inorganic fibers on opposite major surfaces of the core. The fibrous layers are affixed to the core in a manner such that they are functionally integral therewith, thereby providing dimensional stability for the core. In a preferred embodiment, the panel is embodied in roof insulation which consists of a core of organic foam with a mat of inorganic fibers located on an upper surface of the foam core and a layer of inorganic fibers located on a lower surface of the core. The lower surface of the insulation is affixed to an underlying roof structure by a layer of adhesive and specifically asphalt. Alternate layers of asphalt and fibrous mats are applied over the upper mat of the inorganic fibers to complete the roof insulation system.
Inventors
- 👤 David O Richards
- 👤 Isaac P Jones
- 👤 Homer W Duffee
- 👤 Charles E Nutter
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 23:45
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/22; B32B5/24; B32B5/245; E; E04; E04D; E04D3/00; E04D3/35; E04D3/351; E04D3/352; B29; B29C; B29C44/00; B29C44/20; B29C44/32; B29C44/329; B32B5/18; B29K; B29K2075/00; B29K2105/00; B29K2105/06; B29K2105/08; B32B2262/00; B32B2262/10; B32B2262/101; B32B2266/00; B32B2266/02; B32B2266/0214; B32B2266/0278; B32B2605/00; B32B2605/18; B32B2607/00; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T428/249967; Y10T428/249969; Y10T428/249981; Y10T428/249986; Y10T428/249994; Y10T428/249999; Y10T428/26; Y10T428/266
Claims Analysis
Total Claims: 15
Claim 1
Independent Claim
204 words
A COMPOSITE PANEL COMPRISING A CORE OF A CELLULAR, EXPANDED MATERIAL HAVING TWO MAJOR SUBSTANTIALLY PARALLEL SURFACES AND A PERIPHERAL EDGE OF PREDETERMINED SHAPE, A FIRST LAYER OF INORGANIC FIBERS ON ONE OF THE MAJOR SURFACES OF THE CORE WITH THE LAYER BEING DISPOSED SUBSTANTIALLY UNIFORMLY OVER THE ENTIRE SAID ONE MAJOR SURFACE, WITH PORTIONS OF THE CELLULAR MATERIAL AT SAID ONE MAJOR SURFACE PENETRATING INTERSTICES IN THE FIBROUS LAYER TO CAUSE THE FIBROUS LAYER TO BE FUNCTIONALLY INTEGRAL WITH THE CORE, THE INORGANIC FIBERS IN SAID FIRST LAYER BEING RANDOMLY DISPOSED IN A THIN MAT IN A PLANE GENERALLY PARALLEL TO SAID ONE MAJOR SURFACE OF SAID CORE, AND A SECOND LAYER OF INORGANIC FIBERS ON THE OTHER MAJOR SURFACE OF THE CORE WITH THE SECOND FIBROUS LAYER BEING SUBSTANTIALLY UNIFORMLY DISPOSED OVER THE ENNTIRE SAID OTHER MAJOR SURFACE OF THE CORE, WITH PORTIONS OF THE CELLULAR MATERIAL AT SAID OTHER MAJOR SURFACE PENETRATING INTERSTICES IN SAID SECOND FIBROUS LAYER TO CAUSE THE SECOND LAYER TO BE FUNCTIONALLY INTEGRAL WITH THE CORE, SAID FIRST AND SECOND FIBROUS LAYERS THEREBY SUBSTANTIALLY INCREASING THE DIMENSIONAL STABILTIY OF THE CORE, SAID SECOND LAYER BEING A PREFORMED, RIGID BOARD OF GLASS FIBERS HELD TOGETHER BY A BINDER.
Claim 2
Dependent Claim
204 words
A COMPOSITE PANEL COMPRISING A CORE OF A CELLULAR, EXPANDED MATERIAL HAVING TWO MAJOR SUBSTANTIALLY PARALLEL SURFACES AND A PERIPHERAL EDGE OF PREDETERMINED SHAPE, A FIRST LAYER OF INORGANIC FIBERS ON ONE OF THE MAJOR SURFACES OF THE CORE WITH THE LAYER BEING DISPOSED SUBSTANTIALLY UNIFORMLY OVER THE ENTIRE SAID ONE MAJOR SURFACE, WITH PORTIONS OF THE CELLULAR MATERIAL AT SAID ONE MAJOR SURFACE PENETRATING INTERSTICES IN THE FIBROUS LAYER TO CAUSE THE FIBROUS LAYER TO BE FUNCTIONALLY INTEGRAL WITH THE CORE, THE INORGANIC FIBERS IN SAID FIRST LAYER BEING RANDOMLY DISPOSED IN A THIN MAT IN A PLANE GENERALLY PARALLEL TO SAID ONE MAJOR SURFACE OF SAID CORE, AND A SECOND LAYER OF INORGANIC FIBERS ON THE OTHER MAJOR SURFACE OF THE CORE WITH THE SECOND FIBROUS LAYER BEING SUBSTANTIALLY UNIFORMLY DISPOSED OVER THE ENNTIRE SAID OTHER MAJOR SURFACE OF THE CORE, WITH PORTIONS OF THE CELLULAR MATERIAL AT SAID OTHER MAJOR SURFACE PENETRATING INTERSTICES IN SAID SECOND FIBROUS LAYER TO CAUSE THE SECOND LAYER TO BE FUNCTIONALLY INTEGRAL WITH THE CORE, SAID FIRST AND SECOND FIBROUS LAYERS THEREBY SUBSTANTIALLY INCREASING THE DIMENSIONAL STABILTIY OF THE CORE, SAID SECOND LAYER BEING A PREFORMED, RIGID BOARD OF GLASS FIBERS HELD TOGETHER BY A BINDER.
Claim 3
Dependent Claim
23 words
A composite panel according to claim 1 characterized by said fibers in said first layer being of glass and in dispersed filamentary form.
Claim 4
Dependent Claim
192 words
A composite panel comprising a slab of organic foam having two major, substantially planar, substantially parallel surfaces and a peripheral edge of rectangular shape, said slab having a thickness from about 1/2 inch to about 4 inches, a thin mat of substantially randomly disposed glass fibers on one of said major surfaces of said slab with the mat being disposed substantially uniformly over the entire said one major surface, said glass fibers being in dispersed, filamentary form, and a layer of glass fibers on the other major surface of said slab with the layer disposed substantially uniformly over the entire said other surface of said slab, said layer comprising a second mat of randomly disposed glass fibers in dispersed, filamentary form, portions of the foam at said one major surface penetrating interstices in the thin mat to cause said thin mat to be functionally integral with said slab, and portions of the foam at said other major surface penetrating interstices in said second mat to cause said second mat to be functionally integral with said slab, said mats of glass fibers thereby substantially increasing the dimensional stability of said organic foam slab.
Claim 5
Dependent Claim
192 words
A composite panel comprising a slab of organic foam having two major, substantially planar, substantially parallel surfaces and a peripheral edge of rectangular shape, said slab having a thickness from about 1/2 inch to about 4 inches, a thin mat of substantially randomly disposed glass fibers on one of said major surfaces of said slab with the mat being disposed substantially uniformly over the entire said one major surface, said glass fibers being in dispersed, filamentary form, and a layer of glass fibers on the other major surface of said slab with the layer disposed substantially uniformly over the entire said other surface of said slab, said layer comprising a second mat of randomly disposed glass fibers in dispersed, filamentary form, portions of the foam at said one major surface penetrating interstices in the thin mat to cause said thin mat to be functionally integral with said slab, and portions of the foam at said other major surface penetrating interstices in said second mat to cause said second mat to be functionally integral with said slab, said mats of glass fibers thereby substantially increasing the dimensional stability of said organic foam slab.
Claim 6
Dependent Claim
143 words
Roof insulation for use on top of a generally flat, structural roof of a building, said insulation comprising a core of a cellular expanded polymeric material having two major, substantially planar and parallel surfaces, with a peripheral edge of predetermined shape, a mat of randomly disposed and dispersed inorganic fibers on the upper major surface of said core, said mat being disposed substantially uniformly over the entire upper major surface, the fibers being held together by a binder and the mat being affixed to the upper major surface in a manner to be functionally integral therewith, a layer of inorganic fibers on the lower major surface of the core with said layer being affixed to the lower surface in a manner to be functionally integral therewith, said layer of fibers being a mat of randomly disposed glass fibers held together by a binder.
Claim 7
Dependent Claim
143 words
Roof insulation for use on top of a generally flat, structural roof of a building, said insulation comprising a core of a cellular expanded polymeric material having two major, substantially planar and parallel surfaces, with a peripheral edge of predetermined shape, a mat of randomly disposed and dispersed inorganic fibers on the upper major surface of said core, said mat being disposed substantially uniformly over the entire upper major surface, the fibers being held together by a binder and the mat being affixed to the upper major surface in a manner to be functionally integral therewith, a layer of inorganic fibers on the lower major surface of the core with said layer being affixed to the lower surface in a manner to be functionally integral therewith, said layer of fibers being a mat of randomly disposed glass fibers held together by a binder.
Claim 8
Dependent Claim
18 words
Roof insulation according to claim 4 characterized by said mat being of glass fibers dispersed in filamentary form.
Claim 9
Dependent Claim
25 words
Roof insulation according to claim 4 characterized by said core being a urethane foam having a thickness from about 1/2 inch to about 4 inches.
Claim 10
Dependent Claim
19 words
Roof insulation according to claim 6 characterized by said urethane foam having a density from 1.4 to 2.6 pcf.
Claim 11
Dependent Claim
131 words
Roof insulation for use on top of a generally flat, structural roof of a building, said insulation comprising a slab of urethane foam having two major, substantially planar, substantially parallel surfaces and a peripheral edge of rectangular shape, said slab having a thickness from about 1/2 inch to about 4 inches, a mat of fibers held together by a binder on the upper major surface of said slab, with the mat disposed substantially over the entire major surface, said fibers being held together by a binder, and a rigid preformed board of glass fibers affixed to the lower major surface of said slab, said board having an apparent density from about 6 to about 12 pcf and said board having a thickness from about 1/2 inch to about 2 1/2 inches.
Claim 12
Dependent Claim
131 words
Roof insulation for use on top of a generally flat, structural roof of a building, said insulation comprising a slab of urethane foam having two major, substantially planar, substantially parallel surfaces and a peripheral edge of rectangular shape, said slab having a thickness from about 1/2 inch to about 4 inches, a mat of fibers held together by a binder on the upper major surface of said slab, with the mat disposed substantially over the entire major surface, said fibers being held together by a binder, and a rigid preformed board of glass fibers affixed to the lower major surface of said slab, said board having an apparent density from about 6 to about 12 pcf and said board having a thickness from about 1/2 inch to about 2 1/2 inches.
Claim 13
Dependent Claim
29 words
Roof insulation according to claim 8 characterized by said board having a modified phenolic resin binder present in an amount from about 6 to about 12 percent, by weight.
Claim 14
Dependent Claim
17 words
Roof insulation according to claim 8 characterized by said insulation having a ''''C'''' value of about 0.050.
Claim 15
Dependent Claim
18 words
Roof insulation according to claim 8 characterized by said mat being of glass fibers dispersed in filamentary form.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-03-31 | 1978-09-30 | 1979-04-01 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-03-31 | 1982-09-30 | 1983-04-01 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-03-31 | 1986-09-30 | 1987-04-01 | $7700.00 | Window Closed / Lapsed |