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The thermal barrier is flowed or sprayed onto the foamed polymeric material, optionally, with an adhesive interlayer or "tie-coat" therebetween, to form a fire resistant laminate which laminate meets the "15-minute finish rating" or "hourly rated" requirement of building codes as determined by a testing procedure currently designated.

Claims About Spray Foam Insulation

What is claimed about spray foam insulation is:

1. A fire-protective thermal barrier comprising a cured thermosetting synthetic resinous material having dispersed therein an effective amount of a finely divided, crystalline, hydrated inorganic salt extender, sufficient to provide a predetermined level of fire resistance as specifically determined by ASTM E-119-76 or other fire resistance testing procedures, said hydrated extender being characterized by having at least 35% by weight water of crystallization, the major portion of which is released upon heating to a temperature in the range from about 200.degree. F. but below 600.degree. F.

2. The fire-protective thermal barrier of claim 1 wherein said hydrated extender is selected from the group consisting of hydrated salts of Group II A elements of the Periodic Table, and said thermosetting resinous material is selected from the group consisting of a polyester, polyrurethane, polyacrylate, epoxy and urea-formaldehyde resin.

3. The fire-protective thermal barrier of claim 1 wherein said thermal barrier includes catalysts promoters, viscosity modifiers and pigments.

4. The fire-protective thermal barrier of claim 1 including in addition to said hydrated extender, an inorganic particulate filler in an amount from about 1 part by wt to about 15 parts by weight per 100 part of thermal barrier.

5. The fire-protective thermal barrier of claim 2 wherein said hydrated salts are selected from the group consisting of magnesium sulfate heptahydrate, magnesium sulfite, and magnesium monohydroorthophosphate.

6. The fire-protective thermal barrier of claim 5 wherein said magnesium sulfate heptahydrate (MgSO.sub.4.7H.sub.2 O) is present in an amount from about 30 parts to about 80 parts by weight per 100 parts of mixed resin an hydrated extender.

7. The fire-protective thermal barrier of claim 1 further charactized, in that it is essentially impermeable to moisture, said thermal barrier in a thickness of 0.135 inch having a perm rating of 0.0295 as determined by testing procedure designated ASTM E 96-66, and impact resistance in excess of about 20 inch pounds as determined by the Gardner Drop Dart test.

8. A fire-protective insulating laminate comprising a foam plastic and bonded thereto a thermal barrier comprising a cured thermosetting synthetic resinous material having dispersed therein an effective amount of a finely divided, crystalline, hydrated inorganic salt extender, sufficient to provide a predetermined level of fire resistance as determined specifically by a testing procedure designated ASTM E-119-76, or other fire resistance testing procedures, said hydrated extender being characterized by having at least 35% by weight water of crystallization, the major portion of which is released upon heating to a temperature in the range from about 200.degree. F. but below 600.degree. F.

9. The fire-protective laminate of claim 8 wherein said hydrated extender is selected from the group consisting of hydrated salts of Group II A elements of the Periodic Table, and said thermosetting synthetic resinous material is selected from the group consisting of a polyester, polyurethane, polyacrylate, epoxy, and urea-formaldehyde resin.

10. The fire-protective laminate of claim 8 including in addition to said hydrated extender, an inorganic particulate filler in an amount from about 1 part by weight to about 15 parts by weight per 100 parts of thermal barrier.

11. The fire-protective laminate of claim 8 wherein said thermal barrier includes catalysts, promoters, viscosity modifiers and pigments.

12. The fire-protective laminate of claim 8 wherein said foam plastic is a synthetic material selected from the group consisting of a polyurethane foam, a polyisocyanurate foam, a urea-formaldehyde foam, and a polystyrene foam.

13. The fire-protective laminate of claim 9 wherein said hydrated salts are selected from the group consisting of magnesium sulfate heptahydrate, magnesium sulfite, and magnesium monohydroorthophosphate.

14. The fire-protective laminate of claim 13 wherein said magnesium sulfate heptahydrate (MgSO.sub.4.7H.sub.2 O) is present in an amount from about 30 parts to about 80 parts by weight per 100 parts of mixed resin and hydrated extender. 

15. The fire-protective laminate of claim 10 wherein said foam plastic and said thermal barrier are each selectively field-applied.

16. The fire-protective laminate of claim 8 wherein said foam plastic consists essentially of a synthetic resinous material selected from the group consisting of a polyurethane foam, a polyisocyanurate foam, a urea-formaldehyde foam, and a polystyrene foam.

17. The fire-protective laminate of claim 8 wherein said thermal barrier is self-adhered to said foam plastic.

18. A fire-protective insulating panel comprising an inner and outer skin and a laterally coextensive laminate bonded thereto, said laminate comprising a foam plastic and bonded to one side a thermal barrier comprising a cured thermosetting synthetic resinous material having dispersed therein an effective amount of a finely divided, crystalline, hydrated inorganic salt extender, sufficient to provide a predetermined level of fire resistance as specifically determined by testing procedure designated ASTM E-119-76, or other fire resistance testing procedures, said hydrated extender being characterized by having at least 35% by weight of crystallization, the major portion of which is released upon heating to a temperature in the range from about 200.degree. F. but below 600.degree. F.

19. The fire-protective insulating panel of claim 18 including in addition, an inner and outer skin and a laterally coextensive laminate bonded thereto, said laminate comprising a foam plastic and bonded to each side a first and second thermal barrier, said second thermal barrier being of similar composition to said first thermal barrier.

20. A spraying or flowing method for forming a fire-protective laminate comprising a foam plastic and, bonded thereto, a thermal barrier comprising a mixture of liquid thermosetting synthetic resin and said inorganic material dispersed therein, said method comprising:

(a) admixing into said liquid resin from about 30 parts to about 80 parts by weight of a hydrated inorganic salt extender consisting essentially of a hydrated salt of a Group II A element, said hydrated salt being present in the size range from about 10 U.S. Standard mesh to about 325 mesh,

(b) admixing into said liquid resin sufficient catalyst to provide cured resin in a predetermined period of time, and

(c) bonding said resin to a foam plastic to form said laminate, so as to provide said laminate with fire resistant properties sufficient to meet the requirements as determined by a testing procedure designated ASTM E-119-76 or other fire resistance testing procedures.

21. The method of claim 20 including continuously forming a building panel having a foam plastic core comprising applying a predetermined thickness of said resin, including catalyst, heating said thickness of resin to effect an incomplete cure, and foaming said foam plastic in place on said resin prior to said resin being fully cured, so as subsequently to effect bonding of said foam plastic to said cured resin.

22. The method of claim 20 comprising applying said thermal barrier to foam plastic board stock.

23. The method of claim 20 comprising spraying said thermal barrier in a fluent state on foam plastic which is applied to walls, ceilings, decks, roofs and the exterior surfaces of tanks, vessels and pipes. Spray foam can be used as an insulating and air sealing product for residential wall and ceiling cavities. The insulation is sprayed, via special equipment, into wall cavities and expands to fill all the nooks and crannies in a wall cavity. Excess foam is scraped off the studs to form a uniform wall cavity. Spray foam insulation makes it easy to completely fill wall cavities with insulation and to perform air sealing in the same step.

There are two types of spray foam: open-cell (isocyanurate) and closed cell (polyurethane). The closed cell foams typically have a higher R-value than open-cell foam.

Sprayed foam insulation is applied as a liquid which contains a polymer (such as polyurethane or modified urethane) and a foaming agent. The liquid is sprayed through a nozzle into wall, ceiling, and floor cavities where it expands to fill every nook and cranny. Because it expands into tight areas, sprayed foam is ideal for insulating steel framing and around outlets. By acting as a wind and air barrier, it often eliminates the need for separate air-tightness detailing which can increase energy efficiency and allow downsizing of the heating and cooling system equipment. Sprayed foam insulation does not shrink, sag, settle, or biodegrade.

Spray-Insulation Limited supplies Handi-Foam DIY Spray Foam Insulation kits for do-it-yourself Insulation projects. Handi-Foam is a 2 component, polyurethane expanding foam system, which is easy to use.

Converting a loft?

Handi-foam Spray-on Insulation is the ideal way to insulate your loft conversion without the need for costly insulation contractors. What's more, Handi-foam is an excellent foam sealant as spray foam is the only true seamless insulation on the market.

Traditional insulation board and batts all require accurate cutting and edge sealing to prevent unwanted draughts.

Handi-foam Spray-on Insulation expands to seal gaps and uneven surfaces and insulates at the same time! This is particularly important under the new building regulations (April 2006) that require air-leakage testing of buildings to reduce energy requirements.

What is Spray Foam Insulation?

Spray Foam, Spray Insulation, Expanding Foam and Foam sealant are common terms for insulation, which is sprayed into place unlike traditional sheets or rolls of insulation, which must be cut and fixed into place.

 

It is produced from two liquid components that, when combined and sprayed, produce an expanding foam froth. This expanding foam froth then hardens within 3-5 minutes to form a rigid foam with excellent insulating properties. Sprayed foam insulation is now available in do-it-yourself (DIY) kits.

Visit our Spray Foam Video Page for video clips of spray foam insulation in action!

Typical applications for Spray on Foam Insulation include:

DIY roof, loft and attic insulation. Insulating foam sprayed onto the underside of roof tiles not only insulates, but fixes the tiles in place and prevents slippage - perfect for roofs which are past their prime.

Spray on Foam Insulation for Barn conversions and renovation. The foam can be sprayed between beams and joists, which greatly reduces the time to do the job when compared to traditional insulating methods.

Insulating Narrowboats, canal boats & Barges - preventing condensation and improving your comfort.

Insulation of Dormer window and Bay window roofs - preventing heat loss and condensation in architectural features.

Cellar or basement insulation - The cured foam can be plastered or sanded and painted.

Spa bath and Jacuzzi Insulation to reduce heat loss and save energy.

Summerhouse Insulation - beat the heat in summer.

What are the Advantages of Spray Foam?

The properties of Handi-Foam Spray Foam Insulation make it versatile for many uses:

The sprayed foam sticks to most surfaces including metal, wood, bricks, concrete and tiles, making it easy and quick to apply.

The closed cell structure of two Component Polyurethane Foam makes it ideal for buoyancy or flotation applications

The kits produce an expanding polyurethane foam which expands at a ratio of 8:1 which makes it perfect  for void filling and sealing out cold drafts.

The Quick Cure nature of the Spray Foam means it can be sprayed onto walls and roofs (just like paint) and it won't drip or sag.

The Slow Rise version of foam can be injected into a cavity or moulds where the expanding foam and fills the void before curing.

Closed-cell polyurethane foam insulation has been proven in commercial and residential buildings for more than 30 years. In liquid spray form, it fills in cavities between wall studs, window and door frames, surface irregularities and gaps around plumbing, wiring and HVAC components. The foam surrounds the structure in a lightweight blanket of insulation that creates a controlled comfort zone inside the home and contributes to its overall structural integrity.

Here are some of the benefits of spray foam insulation made with RUBINATE® Products

waste energy. Unsealed spaces around windows and doors, for example, are among the most recognized culprits. But hidden air movement behind walls, under baseboards, around joists, plumbing and electrical connections can also cause energy bills to skyrocket. Air movement through the shell of a home disrupts its interior temperature, air pressure and humidity levels, causing heat to move out of the house in winter, and into the home in summer and, in turn, causing HVAC systems to work even harder to maintain comfort levels.

If these "invisible" gaps aren't found and sealed before the house is finished, it will waste energy the rest of its life. Spray foam insulation with RUBINATE® Products provides the solution

There is no better home insulating material that can seal your home from air and moisture intrusion, save on costly utility bills, strengthen your home, and protect your family’s health from dangerous mold than Spray Foam insulation.

Benefits of Spray Foam Insulation

Often times no expensive building wrap or additional vapor protection is required during construction when using SPF, saving money yet again.

High R-Value

Sprayed polyurethane foam has an aged R-value of approximately 6.0 per 1 inch thickness (depending on the particular formulation and application, higher values have been achieved), enabling it to provide more thermal resistance with less material than any other type of commercial insulation material. SPF systems are frequently used to insulate and protect a wide variety of residential, commercial, and industrial buildings.

Monthly energy and utility savings of 30% or greater can be achieved when compared to the alternative roofing and insulation systems. The cost of an SPF roof or insulation system can often be recovered in less than 5 years, simply through energy savings alone.

Prevents Air, Moisture and Gas Infiltration

Studies have shown that as much as 40% of a building’s total energy loss is due to air infiltration. Traditional fiberglass insulati