A continuous process for preparing insulation panels having thick (0.2 mm to 1 mm) metal facing panels and a fiber-reinforced polymer foam core is disclosed. In the process, a bottom metal facing panel is continuously supplied. A mat of reinforcing fibers and a foamable resin composition are applied to the bottom facing panel. A flexible barrier layer is applied atop the foamable resin composition, and the assembly is passed through nip rolls to compress the assembly and force the resin composition into the fiber mat. An adhesive layer and top metallic facing layer are then applied on top of the flexible barrier layer, and the resulting assembly is gauged and cured by passing it through a double band laminator.

A foam roofing underlayment is provided with a reinforcement membrane having an array of fastener elements for engaging fastener elements on a flexible roof membrane. The underlayment is formed by molding foam between the reinforcement membrane and a carrier membrane. The underlayment in secured to the roof using washers having fastener elements for engaging the fastener elements of the flexible roof membrane. An anti-peel flap with fastener elements is provided around the periphery of the washers. A slip sheet is used between the underlayment and the flexible roof membrane to permit accurate positioning of the flexible roof membrane prior to engagement of the fastener elements. The interstices between the fastener elements provide lateral moisture paths to vents in the flexible roof membrane.

PLA polymers that can be expanded into microporous articles having a node and fibril microstructure are provided. The fibrils contain PLA polymer chains oriented with the fibril axis. Additionally, the PLA polymers have an inherent viscosity greater than about 3.8 dL/g and a calculated molecular weight greater than about 150,000 g/mol. The PLA polymer article may be formed by bulk polymerization where the PLA bulk polymer is made into a preform that is subsequently expanded at temperatures above the glass transition temperature and below the melting point of the PLA polymer. In an alternate embodiment, a PLA polymer powder is lubricated, the lubricated polymer is subjected to pressure and compression to form a preform, and the preform is expanded to form a microporous article. Both the preform and the microporous article are formed at temperatures above the glass transition temperature and below the melting point of the PLA polymer.

PLA polymers that can be expanded into microporous articles having a node and fibril microstructure are provided. The fibrils contain PLA polymer chains oriented with the fibril axis. Additionally, the PLA polymers have an inherent viscosity greater than about 3.8 dL/g and a calculated molecular weight greater than about 150,000 g/mol. The PLA polymer article may be formed by bulk polymerization where the PLA bulk polymer is made into a preform that is subsequently expanded at temperatures above the glass transition temperature and below the melting point of the PLA polymer. In an alternate embodiment, a PLA polymer powder is lubricated, the lubricated polymer is subjected to pressure and compression to form a preform, and the preform is expanded to form a microporous article. Both the preform and the microporous article are formed at temperatures above the glass transition temperature and below the melting point of the PLA polymer.

A method for continuous foaming of a panel of the type including outer layers of web material between which an intermediate layer of insulating foam is interposed, includes the steps of supplying first and second web materials, which are precursors of the outer layers, according to respective mutually converging directions to a dispensing station of reactive mixture intended for generating the intermediate layer of insulating foam. The first and second web materials are oriented according to planes that tilt mutually and converge downwards so as to bound a V-shaped hopper zone. Between the web materials, a calibrated slit is defined in the bottom of the hopper zone for dragging the reactive mixture with squeezing and distribution to the end edges of the web materials. The hopper zone is at least partially filled with the reactive mixture for simultaneously wetting the two web materials advancing downwards. The two web materials are continually advanced along a very steep, vertical or very tilted portion of path, dragging the reactive mixture progressively downwards. A guiding and resting action is supplied along the vertical portion to the first and second web materials to advance the first and second web materials substantially mutually parallel at a controlled mutual distance. Downstream of the portion of vertical or very tilted path, the web materials are diverted along a successive curved portion of foaming path. Downstream of the curved portion, the first web material is guided along a first resting and guiding plane, that is horizontal or almost horizontal, and the second web material is guided along a second resting and guiding plane, tilted with respect to the first resting and guiding plane, such that the first and second web materials advance in a mutually divergent manner at a growing distance from one another along a transition portion of the foaming path along which a guided expansion of the reactive mixture develops. A resting action is provided to the web materials and, with the interposed expanding foam, by two parallel belt conveying devices, along a substantially horizontal final portion of the path to enable the foam reaction to be completed and the shape of the foam to be stabilised. An apparatus for implementing the aforesaid method is also provided.

A method for continuous foaming of a panel of the type including outer layers of web material between which an intermediate layer of insulating foam is interposed, includes the steps of supplying first and second web materials, which are precursors of the outer layers, according to respective mutually converging directions to a dispensing station of reactive mixture intended for generating the intermediate layer of insulating foam. The first and second web materials are oriented according to planes that tilt mutually and converge downwards so as to bound a V-shaped hopper zone. Between the web materials, a calibrated slit is defined in the bottom of the hopper zone for dragging the reactive mixture with squeezing and distribution to the end edges of the web materials. The hopper zone is at least partially filled with the reactive mixture for simultaneously wetting the two web materials advancing downwards. The two web materials are continually advanced along a very steep, vertical or very tilted portion of path, dragging the reactive mixture progressively downwards. A guiding and resting action is supplied along the vertical portion to the first and second web materials to advance the first and second web materials substantially mutually parallel at a controlled mutual distance. Downstream of the portion of vertical or very tilted path, the web materials are diverted along a successive curved portion of foaming path. Downstream of the curved portion, the first web material is guided along a first resting and guiding plane, that is horizontal or almost horizontal, and the second web material is guided along a second resting and guiding plane, tilted with respect to the first resting and guiding plane, such that the first and second web materials advance in a mutually divergent manner at a growing distance from one another along a transition portion of the foaming path along which a guided expansion of the reactive mixture develops. A resting action is provided to the web materials and, with the interposed expanding foam, by two parallel belt conveying devices, along a substantially horizontal final portion of the path to enable the foam reaction to be completed and the shape of the foam to be stabilised. An apparatus for implementing the aforesaid method is also provided.

Floor panel for forming a floor covering, where the floor panel includes a carrier on the basis of a thermoplastic material and a top layer provided on the carrier. The thermoplastic material is free from plasticizers or includes a plasticizer in an amount up to maximum 20 phr, where the thermoplastic material is foamed or expanded, and where the carrier is provided with a reinforcement layer.

A low-carbon insulative foam board includes an agricultural product mixed with petroleum-derived polymer foam. The foam board exhibits insulation, durability, and mechanical properties substantially similar to a foam board without the mixed agricultural product. In an embodiment, a polyisocyanurate board includes bubble walls carrying milled biomass, which displaces a portion of the polyisocyanurate.

A low-carbon insulative foam board includes an agricultural product mixed with petroleum-derived polymer foam. The foam board exhibits insulation, durability, and mechanical properties substantially similar to a foam board without the mixed agricultural product. In an embodiment, a polyisocyanurate board includes bubble walls carrying milled biomass, which displaces a portion of the polyisocyanurate.

A continuous forming apparatus for molding foam material into foam products that includes a first endless belt and a second endless belt that cooperates with the first endless belt to mold the foam material. The continuous forming apparatus may also include a first plurality of cleats and a second plurality of cleats opposed to the first plurality of cleats that support the first endless belt and the second endless belt respectively. The first plurality of cleats may include a three-dimensional abutment surface that provides transverse and lateral support to the first endless belt. Additionally, the continuous forming apparatus may include a first frame disposed to support the first plurality of cleats, a second frame disposed to support the second plurality of cleats, and a drive mechanism for imparting motion to the first endless belt, the second endless belt, the first plurality of cleats, and the second plurality of cleats.