A device for the application of foaming reaction mixtures to a substrate which makes it possible to apply that foaming reaction mixture uniformly, a process for the production of foaming reaction mixtures using this device, apparatus for producing composites which include the device of the present invention and composites produced using such apparatus are disclosed. Use of the device of the present invention to produce foams makes it possible to produce foams having improved surface quality at higher production rates than were previously possible. The device of the present invention is particularly useful for the production of sandwich composite elements.

A method of adhering a polyurethane foam layer is used to successively stick the polyurethane foam layer with at least one surface layer by way of polyurethane system components in polymerization foaming action. The method contains steps of: A. delivering a release layer toward a cladding position by using a first rolling set; B. cladding the polyurethane system components on the release layer at the cladding position; C. delivering the polyurethane system components to a surface layer by using a second rolling set, after the polyurethane system components foam and polymerize on the release layer; D. conveying the surface layer and the polyurethane system components to a press roller so that the polyurethane system components foam to produce the polyurethane foam layer which adheres with the surface layer; and E. delivering the polyurethane foam layer away from the press roller.

A method of adhering multiple polyurethane foam layers together sticks a first polyurethane foam layer with a second polyurethane foam layer by using polyurethane system components in polymerization foaming reaction. The method contains steps of: A. delivering the first polyurethane foam layer toward a cladding position; B. cladding or depositing the polyurethane system components on the first polyurethane foam layer at the cladding position so that the polyurethane system components start foaming polymerization on and adhere with the first polyurethane foam layer; C. delivering the polyurethane system components and the first polyurethane foam layer to a press roller so that the polyurethane system components foam to produce the second polyurethane foam layer, and the second polyurethane foam layer adheres with the first polyurethane foam layer; and D. conveying the second polyurethane foam layer and the first polyurethane foam layer away from the press roller.

According to one aspect, a roofing system comprises a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation. Each of the plurality of insulation boards has opposing planar surfaces and has a facer on at least one planar surface, and each of the plurality of insulation boards comprises polyisocyanurate foam having a first polyisocyanurate foam density. The roofing system further comprises a plurality of cover boards adapted for overlying the layer of insulation. Each of the plurality of cover boards has opposing planar surfaces and has a facer on at least one planar surface, and each of the plurality of cover boards comprises polyisocyanurate foam having a second polyisocyanurate foam density greater than the first polyisocyanurate foam density. The greater polyisocyanurate foam density provides for a compressive strength to resist deformation.

The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.

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.

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 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.

The invention relates to a method for producing sandwich construction elements for substantially load-bearing and self-supporting building parts. In one embodiment of the invention, a method is provided including a) producing at least one layer of a mechanically bonded fiber nonwoven which is impregnated with a binder based on at least one heat-curable resin system b) curing the heat-curable resin system in order to produce at least one hardened layer of the fiber nonwoven, and fixed thermally, c) bringing a heat-foamable or heat-foamed phenol resin into contact with that surface of at least one hardened layer of the fiber nonwoven which has been modified according to step b), d) possibly annealing the composite produced in a) to c), and e) curing the further binder based on at least one heat-curable resin system.