US-12617180-B2 - Coated reinforced composite facer and insulation assembly including the same

US12617180B2US 12617180 B2US12617180 B2US 12617180B2US-12617180-B2

Abstract

A coated reinforced composite facer. an insulation assembly, and a method of making a coated reinforced composite facer are provided. The coated reinforced composite facer includes a carrier substrate, a scrim, a thermoplastic coating, and a mineral coating. The thermoplastic coating adheres the scrim to one surface of the carrier substrate and the mineral coating is adhered to an opposite surface of the carrier substrate. An insulation assembly including a coated reinforced composite facer has a pull-through strength that allows the insulation assembly to be installed using fewer fasteners, while also rendering the insulation assembly relatively impermeable.

Inventors

Shane POLEN
Jianhui Wu
Mitchell STEINDLER
Kevin Click
Tyler Musick
Eric Ramey

Assignees

OWENS CORNING INTELLECTUAL CAPITAL, LLC

Dates

Publication Date: 20260505
Application Date: 20220803

Claims (20)

1 . A coated reinforced composite facer comprising: a) a carrier substrate having a first carrier surface and a second carrier surface; b) a scrim; c) a thermoplastic coating positioned between the scrim and the first carrier surface, wherein the thermoplastic coating adheres the scrim to the first carrier surface and comprises at least one of a polyolefin, a polyester, a polyamide, a polyimide, a polycarbonate, a polyurethane, or a fluoropolymer; and d) a mineral coating adhered to the second carrier surface.
2 . The coated reinforced composite facer according to claim 1 , wherein a total basis weight of the coated reinforced composite facer is from 185 g/m 2 to 810 g/m 2 .
3 . The coated reinforced composite facer according to claim 1 , wherein the carrier substrate comprises at least one of a glass mat, a coated glass mat, an impregnated glass mat, a paper, or a metal foil, and wherein the carrier substrate has a basis weight of 25 g/m 2 to 150 g/m 2 .
4 . The coated reinforced composite facer according to claim 1 , wherein the scrim comprises at least one of a fiberglass or a polymer, wherein the scrim is a laid scrim or a woven scrim, and wherein the scrim has a basis weight of 50 g/m 2 to 200 g/m 2 .
5 . The coated reinforced composite facer according to claim 1 , wherein the thermoplastic coating has a basis weight of 10 g/m 2 to 60 g/m 2 .
6 . The coated reinforced composite facer according to claim 5 , wherein the thermoplastic coating further comprises an additive comprising at least one of a fire retardant, a dye, a pigment, a UV stabilizer, an anti-static agent, or a filler.
7 . The coated reinforced composite facer according to claim 1 , wherein the mineral coating comprises an inorganic filler material and a binder, and wherein the mineral coating has a basis weight of 100 g/m 2 to 400 g/m 2 .
8 . The coated reinforced composite facer according to claim 1 , wherein the coated reinforced composite facer has an average Gurley porosity of at least 2,000 seconds.
9 . The coated reinforced composite facer according to claim 1 , wherein a pull-through strength of the coated reinforced composite facer is from 350 lbf to 600 lbf when the scrim of the coated reinforced composite facer is interfaced with a polyisocyanurate foam substrate.
10 . An insulation assembly comprising: a) an insulation substrate having a first insulation surface and a second insulation surface; and b) a coated reinforced composite facer, wherein the coated reinforced composite facer comprises: i) a carrier substrate having a first carrier surface and a second carrier surface; ii) a scrim; iii) a thermoplastic coating positioned between the scrim and the first carrier surface, wherein the thermoplastic coating adheres the scrim to the first carrier surface and comprises at least one of a polyolefin, a polyester, a polyamide, a polyimide, a polycarbonate, a polyurethane, or a fluoropolymer; and iv) a mineral coating adhered to the second carrier surface, wherein the scrim is attached to the first insulation surface or the second insulation surface.
11 . The insulation assembly according to claim 10 , wherein the insulation substrate comprises at least one of a polyisocyanurate foam, a polyurethane foam, a polystyrene foam, or a mineral wool, and wherein the insulation substrate has a thickness of 0.5 cm to 12.7 cm.
12 . The insulation assembly according to claim 10 , wherein a total basis weight of the coated reinforced composite facer is from 185 g/m 2 to 810 g/m 2 .
13 . The insulation assembly according to claim 10 , wherein the carrier substrate comprises at least one of a glass mat, a coated glass mat, an impregnated glass mat, a paper, or a metal foil, and wherein the carrier substrate has a basis weight of 25 g/m 2 to 150 g/m 2 .
14 . The insulation assembly according to claim 10 , wherein the scrim comprises at least one of a fiberglass or a polymer, wherein the scrim is a laid scrim or a woven scrim, and wherein the scrim has a basis weight of 50 g/m 2 to 200 g/m 2 .
15 . The insulation assembly according to claim 10 , wherein the thermoplastic coating has a basis weight of 10 g/m 2 to 60 g/m 2 .
16 . The insulation assembly according to claim 15 , wherein the thermoplastic coating further comprises an additive comprising at least one of a fire retardant, a dye, a pigment, a UV stabilizer, an anti-static agent, or a filler.
17 . The insulation assembly according to claim 10 , wherein the mineral coating comprises an inorganic filler material and a binder, and wherein the mineral coating has a basis weight of 100 g/m 2 to 400 g/m 2 .
18 . The insulation assembly according to claim 10 , wherein the coated reinforced composite facer has an average Gurley porosity of at least 2,000 seconds.
19 . The insulation assembly according to claim 10 , wherein a pull-through strength of the insulation assembly is from 350 lbf to 600 lbf.
20 . A method of making a coated reinforced composite facer, the method comprising: a) directing a carrier substrate having a first carrier surface and a second carrier surface, a scrim, and a molten thermoplastic coating comprising at least one of a polyolefin, a polyester, a polyamide, a polyimide, a polycarbonate, a polyurethane, or a fluoropolymer into a laminating device such that the molten thermoplastic coating is positioned between the scrim and the first carrier surface; b) laminating together the scrim, the molten thermoplastic, and the carrier substrate; and c) applying a mineral coating onto the second carrier surface, thereby forming the coated reinforced composite facer.

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application is the U.S. national stage entry of PCT/US2022/039251, filed on Aug. 3, 2022, which claims priority to and all benefit of U.S. Provisional Patent Application No. 63/230,298, filed on Aug. 6, 2021, the entire disclosures of which are fully incorporated herein by reference. FIELD The general inventive concepts relate to facer materials and, more particularly, to a coated reinforced composite facer that includes a carrier substrate, a scrim, a thermoplastic coating, and a mineral coating. The coated reinforced composite facer is useful as a facer for insulation substrates, particularly insulation substrates that are used in roofing systems. BACKGROUND A commercial roof tends to have a low slope or be entirely flat and is much larger than a typical residential roof. Roofing systems for commercial roofs typically include many insulation panels having a core formed of polyisocyanurate or other insulative materials that are secured to the roof deck. Protective cover boards are placed on top of the insulation panels. The cover boards may also have a core formed of polyisocyanurate or other insulative materials. The cores of the insulation panels and cover boards are generally sandwiched between facer materials. A conventional facer material for insulation panels and cover boards, particularly an upper surface thereof, is a coated glass facer, which is formed by applying a mineral-based coating onto a nonwoven glass mat. The cover boards are secured to the underlying insulation panels and the roof deck using a number of fasteners, such as sixteen (16) fasteners per coverboard. In addition to containing the core materials, the facer materials serve a variety of functions. For example, facer materials can add structural integrity and dimensional stability to the insulation panels and coverboards. Also, facer materials can provide improved performance with respect to wind uplift as well as indentation resistance. Wind uplift can cause fastener pull-through and failure of the roofing system. In typical roofing systems, improved wind uplift performance is accomplished by using additional fasteners to secure the cover boards and insulation panels to the roof deck. However, using more fasteners increases the amount of labor and materials required to install the roofing system, which also increases the total amount of time and cost associated with installing the roofing system. Accordingly, there is a need in the art for facer materials for insulation panels and coverboards that provide acceptable performance in a roofing system while requiring fewer fasteners. SUMMARY The general inventive concepts relate to a coated reinforced composite facer, an insulation assembly that includes a coated reinforced composite facer, and a method of making a coated reinforced composite facer. To illustrate various aspects of the general inventive concepts, several exemplary embodiments of coated reinforced composite facers, insulation assemblies, and methods of making the coated reinforced composite facer are disclosed. In accordance with one aspect of the present disclosure, a coated reinforced composite facer is provided. The coated reinforced composite facer includes a carrier substrate having a first carrier surface and a second carrier surface, a scrim, a thermoplastic coating, and a mineral coating. The thermoplastic coating is positioned between the scrim and the first carrier surface and adheres the scrim to the first carrier surface. The mineral coating is adhered to the second carrier surface. In accordance with one aspect of the present disclosure, an insulation assembly is provided. The insulation assembly includes an insulation substrate and a coated reinforced composite facer. The insulation substrate has a first insulation surface and a second insulation surface. The coated reinforced composite facer includes a carrier substrate having a first carrier surface and a second carrier surface, a scrim, a thermoplastic coating, and a mineral coating. The thermoplastic coating is positioned between the scrim and the first carrier surface and adheres the scrim to the first carrier surface. The mineral coating is adhered to the second carrier surface. The scrim of the coated reinforced composite facer is attached to at least one of the first insulation surface or the second insulation surface. In accordance with one aspect of the present disclosure, a method of making a coated reinforced composite facer is provided. The method includes the steps of: a) directing a carrier substrate having a first carrier surface and a second carrier surface, a scrim, and a molten thermoplastic coating into a laminating device such that the molten thermoplastic coating is positioned between the scrim and the first carrier surface; b) laminating together the scrim, the molten thermoplastic coating, and the carrier substrate; and c) applying a mineral coating onto the second carrier surface to for