US3978264A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Coating for porous surfaces
Assignee: International Permalite Inc
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Filing: 1975-06-20
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Granted: 1976-08-31
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Expires: 1995-06-20
Abstract
Abstract When a porous substrate such as perlite insulation board is surfaced with a foamed polymer layer formed in place from liquid components, the liquid components will often partially penetrate the surface, resulting in loss of materials and uneven foaming. A barrier coating which can prevent penetration is provided by applying to the porous substrate an aqueous mix of a thermosetting resin which cures through methylol groups, such as urea formaldehyde, with a component containing a hydroxyl group, such as starch, cereal flour, or the like. When the barrier coating is dried, a water insoluble cross-linked surface is formed which is impenetrable to foam constituents. A greater foam thickness is obtained for a given amount of foamable material and a more uniform thickness also results.
Inventors
- 👤 Harlan E. Tarbell
- 👤 Donald W. Mogg
- 👤 David L. Ruff
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 10:04
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/18; C; C08; C08J; C08J9/00; B32B37/00; B32B37/14; B32B37/24; B32B38/00; B32B2038/0052; B32B2038/0084; B32B2305/00; B32B2305/02; B32B2305/022; B32B2305/026; B32B2307/00; B32B2307/30; B32B2307/304; B32B2307/70; B32B2307/724; B32B2307/7242; B32B2607/00; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T428/249981; Y10T428/249987; Y10T428/249991; Y10T428/249992; Y10T428/31504; Y10T428/31547; Y10T428/31942
Claims Analysis
Total Claims: 11
Claim 1
Independent Claim
87 words
In a composite product having a polymer foam layer applied to the surface of a porous substrate, the improvement comprising a barrier coating between said surface of said porous substrate and said foam layer wherein said coating comprises a cured, cross-linked formulation of a hydroxyl group containing material selected from the group consisting of starch, cereal grain flour, and mixtures thereof, and a thermosetting resin selected from the group consisting of urea formaldehydes, phenol formaldehydes, melamine formaldehydes, and mixtures and interpolymers thereof which cures through methylol groups.
Claim 2
Dependent Claim
87 words
In a composite product having a polymer foam layer applied to the surface of a porous substrate, the improvement comprising a barrier coating between said surface of said porous substrate and said foam layer wherein said coating comprises a cured, cross-linked formulation of a hydroxyl group containing material selected from the group consisting of starch, cereal grain flour, and mixtures thereof, and a thermosetting resin selected from the group consisting of urea formaldehydes, phenol formaldehydes, melamine formaldehydes, and mixtures and interpolymers thereof which cures through methylol groups.
Claim 3
Dependent Claim
24 words
The improvement of claim 1 wherein said formulation further comprises on a solids basis about 0.2 to about 5.0 weight percent of a biocide.
Claim 4
Dependent Claim
22 words
The improvement of claim 2 wherein said biocide is selected from the group consisting of halophenols, salts of halophenols, and halogenated aromatics.
Claim 5
Dependent Claim
11 words
The improvement of claim 2 wherein said biocide is sodium pentachlorophenate.
Claim 6
Dependent Claim
33 words
The improvement of claim 1 wherein said formulation comprises about 0.3 to about 30 parts of said hydroxyl group containing material for each part of said thermosetting resin, on a solids weight basis.
Claim 7
Dependent Claim
33 words
The improvement of claim 1 wherein said formulation comprises about four to about fifteen parts of said hydroxyl group containing material for each part of said thermosetting resin, on a solids weight basis.
Claim 8
Dependent Claim
12 words
The improvement of claim 1 wherein said foam is a polyurethane foam.
Claim 9
Dependent Claim
12 words
The improvement of claim 1 wherein said foam is a polyisocyanurate foam.
Claim 10
Dependent Claim
52 words
The improvement of claim 1 wherein said composite product is a rigid substantially flat board product comprising a rigid porous substrate board, said barrier coating applied to the surface of said board, a rigid foam layer applied to the surface of said barrier coating and a top skin on the foam layer.
Claim 11
Dependent Claim
34 words
The improvement of claim 9 wherein said substrate board contains at least 50% by weight of expanded perlite and the rigid foam is selected from the group consisting of polyurethane foam and polyisocyanurate foam.
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) | 1979-08-31 | 1980-03-01 | 1980-08-31 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1983-08-31 | 1984-03-01 | 1984-08-31 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1987-08-31 | 1988-03-01 | 1988-08-31 | $7700.00 | Window Closed / Lapsed |