SYSTEM FOR MANUFACTURE OF FOAM SHEETS RIGIDIZED WITH POLYMER INFILTRATION

Abstract

An eco-wood formulation finds new uses as construction materials. A rigid polymer material sheet for use in building construction comprises a polymer mixture of ultrafine particles of polyvinylchloride (PVC) impact modifier, plant fiber, coupling agent, smoke suppressant, activated clay, lubricant, an activator, environmentally friendly flame retardant, heat stabilizers, odorless crosslinking agent, foaming agent, desmopressin agent. Alternatively, the rigid polymer material sheet is composed of: a polymer mixture of PVC, plasticizer, nitrile rubber, PCC, stearate, zinc oxide, retardant heat, heat stabilizers, crosslinking agent, vesicant; whereby said rigid polymer material sheet provides enhanced thermal resistance and sound attenuation properties for use in building construction, aviation and marine industries.

Claims

1) A rigid polymer material sheet for use in building construction, the rigid polymer material sheet composed of: a polymer mixture of ultrafine particles of polyvinylchloride (PVC) impact modifier, plant fiber, coupling agent, smoke suppressant, activated clay, lubricant, an activator, environmentally friendly flame retardant, heat stabilizers, odorless crosslinking agent, foaming agent, desmopressin agent; whereby said rigid polymer material sheet provides enhanced thermal resistance and sound attenuation properties for use in building construction, aviation and marine industries.

2) The rigid polymer material sheet as recited by claim 1, wherein said rigid polymer material sheet has the following weight percent ranges: PVC: 55-85, impact modifier: 4-15, plant fiber: 10-40, coupling agent: 0.5-5, smoke suppressant: 5-25, activated clay: 2-25, lubricant: 0.3-5, the activator: 2-10, environmentally friendly flame retardant: 5-15, heat stabilizers: 2-12, odorless crosslinking agent: 0.2-2.5, the foaming agent: 0.5-7, desmopressin agent: from 0.5-8.

3) The rigid polymer material sheet as recited as recited by claim 1, said sheet being suitable for use for at least one member of a group consisting of: a wall board, wall, floor and ceiling assembly systems, and sheathing board, due to its increased thermal insulation properties and bend properties.

4) The rigid polymer material sheet as recited as recited by claim 1, said sheet being suitable for use for at least one member of a group consisting of: lumber and framing structures and in wall, floor and ceiling assembly systems due to its increased thermal insulation properties and bend properties.

5) The rigid polymer material sheet as recited by claim 1, said sheet being suitable for use as a flooring material due to its increased thermal insulation properties.

6) The rigid polymer material sheet as recited by claim 1, said sheet being suitable for use as siding or embossed interior/exterior insulation sheets due to its increased thermal insulation properties.

7) The rigid polymer material sheet as recited by claim 1, said sheet being suitable for use as a building board due to its increased strength, bend capability and thermal insulation properties.

8) The rigid polymer material sheet as recited by claim 1, said sheet being suitable for use for at least one member of a group consisting of: door and window and door framing due to its increased strength, bend capability, paintability and thermal insulation properties.

9) The rigid polymer material sheet as recited by claim 1, wherein said sheet is used in aeronautic acoustic thermal insulation systems.

10) A rigid polymer material sheet for use in building construction, the rigid polymer material sheet composed of: a polymer mixture of polyvinylchloride (PVC), plasticizer, nitrile rubber, PCC, stearate, zinc oxide, retardant heat, heat stabilizers, crosslinking agent, vesicant; whereby said rigid polymer material sheet provides enhanced thermal resistance and sound attenuation properties for use in building construction, aviation and marine industries.

11) The rigid polymer material sheet as recited by claim 10, wherein said rigid polymer material sheet has the following weight percent ranges: PVC: 45-135, plasticizer: 2-15, nitrile rubber: 5-30; PCC 2-25, Stearate 0.5-3.5, Zinc Oxide: 2-10, Retardant Heat 5-15, Heat Stablizers 2-15, Crosslinking Agent 0.2-2.5, Vesicant 2.5-7.

12) The rigid polymer material sheet as recited as recited by claim 10, said sheet being suitable for use for at least one member of a group consisting of: a wall board, wall systems, and sheathing board, due to its increased thermal insulation properties and bend properties.

13) The rigid polymer material sheet as recited as recited by claim 10, said sheet being suitable for use for at least one member of a group consisting of: lumber and framing structures and in wall, floor and ceiling assembly systems due to its increased thermal insulation properties and bend properties.

14) The rigid polymer material sheet as recited by claim 10, said sheet being suitable for use as a flooring material due to its increased thermal insulation properties.

15) The rigid polymer material sheet as recited by claim 10, said sheet being suitable for use as siding and interior/exterior insulation sheets due to its increased thermal insulation properties.

16) The rigid polymer material sheet as recited by claim 10, said sheet being suitable for use as a building board due to its increased strength, bend capability and thermal insulation properties.

17) The rigid polymer material sheet as recited by claim 10, said sheet being suitable for use for at least one member of a group consisting of: door and window and door framing due to its increased strength, bend capability, paintability and thermal insulation properties.

18) The rigid polymer material sheet as recited by claim 10, wherein said sheet is used in aeronautic acoustic thermal insulation systems.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0047] The invention will be more fully understood and further advantages will become apparent when reference is had to the following detailed description of the preferred embodiments of the invention and the accompanying drawing, in which:

[0048] FIG. 1a illustrates the process steps in the manufacture of the rigid polymer material sheet;

[0049] FIG. 1b illustrates a graph showing the relationship between the Fikentscher K value and the molecular weight of PVC polymers;

[0050] FIG. 2 is a micrograph of the rigid polymer material sheet; and

[0051] FIG. 3 illustrates thermal resistance or R-value measurement procedure;

[0052] FIG. 4 illustrates hardness measurement of rigid polymer sheet;

[0053] FIG. 5 illustrates bend test measurement of the rigid polymer sheet;

[0054] FIG. 6a illustrates the thermal bridge;

[0055] FIG. 6b illustrates the energy lost through studs;

[0056] FIG. 7a illustrates the framing factor concept;

[0057] FIG. 7b illustrates the framing factor concept with an IR image;

[0058] FIG. 8 illustrates an embodiment of the invention wherein the rigid polymer material sheet is used in an aviation acoustic thermal insulation system; and

[0059] FIG. 9 illustrates a framed structure wherein a humidity expansion gap of has been eliminated.

DETAILED DESCRIPTION OF THE INVENTION

[0060] The invention involves using eco-wood formulations to make building construction materials. Eco-wood formulations are utilized to make furniture, interior decoration and other decorative plates. These interior furnishings and decorations were not known to have the capacity for structural support, structure bend, and thermal and acoustic properties as a building material in the construction industry. It has been found that eco-wood formulations are suitable for use as actual building construction materials. The material has been found to have increased strength, bend capability, improved thermal insulation properties and improved acoustic insulation over current building construction materials.

[0061] Preferably, the rigid polymer material sheet for use in building construction is composed of: a polymer mixture of ultrafine particles of polyvinylchloride (PVC) impact modifier, plant fiber, coupling agent, smoke suppressant, activated clay, lubricant, an activator, environmentally friendly flame retardant, heat stabilizers, odorless crosslinking agent, foaming agent, desmopressin agent. The rigid polymer material sheet has been found to provide enhanced thermal resistance and sound attenuation properties for use in building construction, aviation or other industries. The rigid polymer material sheet preferably has the following weight percent ranges: PVC: 55-85, impact modifier: 4-15, plant fiber: 10-40, coupling agent: 0.5-5, smoke suppressant: 5-25, activated clay: 2-25, lubricant: 0.3-5, the activator: 2-10, environmentally friendly flame retardant: 5-15, heat stabilizers: 2-12, odorless crosslinking agent: 0.2-2.5, the foaming agent: 0.5-7, desmopressin agent: from 0.5-8.

[0062] Optionally, a rigid polymer material sheet for use in building construction is provided composed of: a polymer mixture of polyvinylchloride (PVC), plasticizer, nitrile rubber, PCC, stearate, zinc oxide, retardant heat, heat stabilizers, crosslinking agent, vesicant; whereby said rigid polymer material sheet provides enhanced thermal resistance and sound attenuation properties for use in building construction, aviation or other industries, and decorative applications. Preferably, the rigid polymer material sheet has the following weight percent ranges: PVC: 45-135, plasticizer: 2-15, nitrile rubber: 5-30; PCC 2-25, Stearate 0.5-3.5, Zinc Oxide: 2-10, Retardant Heat 5-15, Heat Stablizers 2-15, Crosslinking Agent 0.2-2.5, Vesicant 2.5-7.

[0063] It has been found that the rigid polymer material sheet is suitable for use for at least one member of a group consisting of: a wallboard, wall systems, and sheathing board, due to its increased thermal insulation properties and bend properties. It has also been found that the rigid polymer material sheet is suitable for use for at least one member of a group consisting of: lumber and framing structures and in wall assembly systems due to its increased thermal insulation properties and bend properties. The rigid polymer material sheet has also been found to be suitable for use as a flooring material due to its increased thermal insulation properties, as well as siding. It has further been found that the sheet is suitable for forming building board due a finding that it poses increased strength, bend capability and thermal insulation properties. The rigid polymer material sheet has also been found suitable for use for at least one member of a group consisting of: door and window and door framing due to its increased strength, bend capability, paintability and thermal insulation properties. What is more, it has been found that the rigid polymer material sheet can be used in aeronautic acoustic thermal insulation systems.

[0064] The plant fiber is pretreated in preparing the material. The plant fiber is pretreated by baking to reduce the plant fiber moisture content to 2.5% or less and it is then fed into a high-speed mixer. Coupling agent, 1-3 parts by weight, is added and the mixture stirred for 5-20 minutes. Next, the mixture is kneaded and PVC, 60-70 parts by weight, is added along with the impact modifier (9 -11 parts by weight), smoke suppressant (10-20 parts by weight), from 5-15 parts by weight of clay (preferably attapulgite), lubricants (0.5-1.5) parts by weight, activator (4-6 parts by weight), environmentally friendly flame retardant (8-10 parts by weight), heat stabilizer (4-8 parts by weight), desmopressin agent (1-5 parts by weight). The mixture is kneaded at 6080N of pressure for about 10-15min with sweep 2 to 3 times. During the kneading process after heating, the mixer temperature rises to within a range of 140142 C., then odorless and/or tasteless cross-linking agent (0.5-1.5 parts by weight) is added along with 1-5 parts by weight of a blowing agent. The mixture is then kneaded 23min, the material, resulting rubber compound. Open mill soak is carried out, mix into the open mill thick run through twice, followed by thin through twice, cross stacker, with temperature controlled at 125130 C. The mixture is then fed into a machine the film, the temperature of the machine's control in 105110 C., prepared film. Next, the compound is fed into a vulcanizing mold foaming machine, curing temperature control 165170 C., foaming time is 3035min, foaming dealt with relief, that was a foam. Lastly, the material is compacted, with temperature below 20 C., the cooling plate applied 1520min after compaction to form the rigid polymeric sheet, trimmed, cut or molded for the building construct. After the addition of a heat stabilizer 1 to 2 parts by weight of a dispersant, 0.5 to 1.5 parts by weight of an antioxidant, 0.5 to 1.0 parts by weight of an ultraviolet absorber may be added, followed by kneading with the above-described processing of other substances.

[0065] Alternatively, the composition if prepared through the following steps: (1) kneading: 45-135 parts by weight of the PVC resin, 5-30 parts by weight of nitrile rubber (NBR), 2-15parts by weight of a plasticizer, 2-20 parts by weight of light calcium carbonate, the mixture was mixed 3.5 parts by weight of stearic acid, 2-10 parts by weight of zinc oxide, 5-15 parts by weight of a flame retardant, 2-15 parts by weight of a heat stabilizer into the mixer, and pressurized to 75 liters 7-8KG kneading 10-12min; 140-150 C. discharge, obtain compound; (2) Thermal refining: Step (1) mixing the resulting compound into 18-inch mill refining heat hit triangle bag; three times thinner package, and then put into 18-inch mill heat refining play triangle bag, then resort to the secondary thick packet, mixing machine temperature control 145-150 C.; (3) a film: the after step (2) soak and then put into the plastic material 18-inch mill, a refining machine temperature control 145-150 C., film thickness of 2-3mm the film, the film is cut into strips, cooling cooled to obtain a green sheet of plastic; (4) vulcanizing mold: will be closed-cell foam vulcanization, sulfur within the step (3) the resulting sheet into the embryo glue curing machine dies 1300 tons of pressure, curing time of 30 to 35 minutes, curing temperature 160 5 C., obtain foam to be stable foam form, cooled to obtain a decorative plate products.

[0066] The polyvinylchloride used in the present invention is in the form of 100 to 150 micrometer particles produced by suspension or emulsion polymerization. The K value of the polyvinylchloride homopolymer or copolymer with polyvinyl acetate has a K value greater than 65 representing a molecular weight of 60,000 as shown in the graph in FIG. 1b, showing a graph reproduced from PVC Plastics by W. V. Titow. A K value of 50 is a low molecular weight soft PVC while a K value of 80 is a high molecular weight strong PVC.

[0067] When a plasticizer is added to the fine power of polyvinylchloride based resin, it enters the resin molecule at the atomic level creating screens between polymer chains or hinge locations between polymer chains promoting polymer flexibility. Since the polyvinylchloride foams produced have a very thin polymer layer surrounding the air cell, it requires a great amount of flexibility to prevent crack propagation and fracture. Conventional phthalate plasticizers have been determined to be a biohazard according to U.S. Consumer Product Safety Commission at https://www.cpsc.gov/PageFiles/98260/dinp.pdf. For this reason, non-phthalate plasticizers, such as DINCH are preferred.

[0068] A foaming agent is kneaded to allow the formation of a plurality of micron-sized air cells to produce the low-density polyvinylchloride polymeric sheet. When the polymeric composition is heated in a mold, at a specific temperature the polymer softens. If the foaming agent releases a large volume of gaseous decomposition products at the same time when the polyvinylchloride resin softens, a closed cell microcellular structure is formed. While a number of foaming agents are available, their decomposition temperature does not match the softening point of polyvinylchloride resin which is in the range of 170 to 190 C. Specifically, azodicarbonamide foaming agent has a decomposition temperature of 215 to 219 C., but it may be bought down using a ZnO kicker. Using this combination micro fine cells are formed in the low density polyvinylchloride sheet.

[0069] Another requirement for the formation of the microcellular sheet during foaming step requires the ultrafine particles of polyvinylchloride particle and wood cellulous or ultra-fine cellulous particles to touch each other, since the quantity of polyvinylchloride in the sheet is quite small. This is accomplished by mixing the polyvinyl ultrafine particles along with additives with and anionic aqueous solution of isopropyl alcohol forming a slurry. During drying of the slurry, the surface tension brings the polyvinylchloride particles close to each other, forming a film.

[0070] The air cells formed have to be stabilized so that they remain until the polyvinylchloride polymer sets. The stabilizers are typically organic or inorganic compounds such as barium/zinc, calcium/zinc or organ tin stabilizers

[0071] The present invention uses two distinctly different low-density polyvinylchloride sheets. The first embodiment uses fine particles of polyvinylchloride homopolymer in combination with wood cellulose or wood fibers and/or a higher amount of DINCH non-phthalate plasticizer. A typical example of the polymer slurry used in the mold is shown below.

TABLE-US-00001 Suspension PVC K value 70 (S-PVC) 100.0 parts [55-85% wt. percent] PVC 65 Impact modifier 5 Mesh wood fiber plant 10 Coupling agent 0.5 Smoke suppressant 5 Clay 3 Lubricant 0.5 Zinc oxide 2 Green flame retardant 5 Heat stabilizer 2 tasteless crosslinking agent 0.5

[0072] The subject invention's samples were found to have superior per inch R Value insulation properties to Fiberglass. Measured thermal properties and the R values of the different thickness specimens are shown as a comparative basis as compared to other commonly available construction materials.

Subject Invention vs. Common Building Material With Identical Thickness R-Value Comparison

[0073]

TABLE-US-00002 Subject Invention Material: Common Foaming Board Building/Sheathing Building Material .145 gm/cc .165 gm/cc Board Thickness R-Value R-Value R-Value Gypsum Wall 0.45 2.06 1.93 Board Plywood 0.62 2.05 1.93 Plywood 0.94 3.03 2.95 Plywood 1 1.25 4.00 3.91 Fiber board 1.32 2.02 1.96 sheathing Fiber board 1 2.64 4.02 3.92 sheathing Medium Density 0.53 2.03 1.97 Particle Board Fiberglass 3.00 3.03 2.93 sheathing Fiberglass 1 4.00 4.00 3.91 sheathing Fiberglass 1 6.00 6.05 5.87 sheathing

TABLE-US-00003 Subject Invention Common Foaming Board Building .145 .165 Material: Insulating Materials Material gm/cc gm/cc (Per 1 inch Thickness) Thickness R-Value R-Value R-Value Fiberglass Batt 1 3.14 4.02 3.93 Fiberglass Blown (Attic) 1 2.20 4.02 3.93 Fiberglass Blown (Wall) 1 3.20 4.02 3.93 Rock Wool Batt 1 3.14 4.02 3.93 Rock Wool Blown (Attic) 1 3.10 4.02 3.93 Rock Wool Blown (Wall) 1 3.03 4.02 3.93 Cellulous Blown (Attic) 1 3.13 4.02 3.93 Cellulous Blown (Wall) 1 3.70 4.02 3.93 Vermiculite 1 2.13 4.02 3.93 Autoclaved Aerated Concrete 1 3.90 4.02 3.93 Urea Terpolymer Foam 1 4.48 4.02 3.93 Rigid Fiberglass (>4 lb/ft3) 1 4.00 4.02 3.93 Expanded Polystyrene 1 4.00 4.02 3.93 (Beadboard) Extruded Polystyrene 1 5.00 4.02 3.93 Polyurethane (foamed-in-place) 1 6.00 4.02 3.93 Foil Faced Polyisocyanurate 1 6.00 4.02 3.93

[0074] This invention relates to a molding process for producing rigid polymer polyvinyl chloride-based sheet material, or composite, sheet. Slurry of polymer powder with additives and fillers and fire retardant material is fed to an oversized mold whose height is approximately twice that of the sheet thickness desired while width and the length of the mold are close to that of the desired dimensions of the sheet. The liquid portion of the slurry is optionally drained and dried first and the mold is heated to a temperature below 190 F. when the mold is pressurized by a die set. This application of pressure and temperature forms the sheet with a density ranging from about 5% to 98%, and preferably from about 10% to about 40%, of a solid polyvinyl chloride sheet with closed air cells finely distributed within the sheet. The presence of closed air cells enhances the thermal resistance of the sheet product as well as provide sound absorption characteristics. The die may have milled decorations, which are replicated in the final product.

[0075] The rigid polymer sheet rated product has a low density, and water does not penetrate the product. The polymer slurry mixture used comprises PVC (Polyvinyl chloride) and polyvinyl acetate polymers along with wood chip and flame retardant additives, depending on the application of the final product. External casing sheets may be used to cover the rigid polymer sheet during the heating and pressure application step to bond the encasing sheets thereto. The rigid polymer composite sheet is inherently fire retardant due to the usage of PVC in the polymer infiltration composition to release chlorine and expel oxygen near a flame, thereby extinguishing the flame.

[0076] The objective of the invention is to utilize eco-wood formulations in building construction materials making a durable rigid polymer sheet, which may be painted and is useful as a building material. The process used herein is very reproducible and produces sheets with exceptional properties. It does not crack when bent 90 degrees or more and is extremely shock absorbing even though it is rigid. Accordingly, the rigid polymer sheet is well suited for wall boards, lumber and wall assembly systems.

[0077] The rigid polymer filled foam composite is the newest construction material developed as detailed herein. The rigid polymer composite sheet is anti-flaming, fireproof, moisture proof, anti-corrosion, termite proof, formaldehyde free. It exhibits a low amount of smoke, and is highly resistant to flame penetration. The surface of the sheet can be treated by spray coating, and can be adhered to many kinds of materials. In combination, these features have made the rigid polymer filled foam composite an excellent eco-green construction material.

[0078] The rigid polymer sheet can be used as a replacement for wooden board, thus reducing deforestation, and protecting the environment. At the same time, it is waterproof, moisture proof, soundproof, vibration absorbing, resistant to acid and alkali, resistant to climate ageing, anti-flaming and fireproof. In these aspects, the rigid polymer filled foam material sheet is superior to all other building materials.

[0079] Different kinds of materials are added into the rigid polymer filled foam material sheet for different purposes: [0080] 1. For wood frame construction, wall, floor, and ceiling assemblies, interior/exterior home decoration, large amount of plant fibers (such as wood chips, husk of rice, etc.) are added, to increase the hardness and nail holding ability; [0081] 2. For application in cars, yachts and ships, aircrafts, and bullet trains, and application as embossing materials, thermal preservation materials, nitrile butadiene rubber (NBR) is added to greatly improve its performance of shaping, toughness, and impact resistance, and make it much easier for hot pressing, embossing, bending and carving; [0082] 3. A smoke suppressant, calcium stearate powder, and flame retardant are added to increase its performance of fireproof and impact resistance, to reduce the density of smoke, and to make it more ecofriendly. [0083] 4. This rigid polymer sheet is clearly the newest formaldehyde free, eco-green, flame resistant and fireproof building material.

[0084] Features and Usages of rigid polymer filled foam material sheet

[0085] 1. Due to its lightweight, large range of density and flexibility, hard body, and easy installation, it can be used in building material industry as a suitable eco green replacement for wood and engineered wood materials such as but not limited to Framing Lumber, Plywood, Particle board, Oriented strand board (OSB) Type A,B,C, Medium density fiberboard (MDF), High Density fiberboard (HDF), Glued laminated timber (glulam), Laminated veneer lumber (LVL), hardwood, Cross-Laminated Timber (CLT), Structural Composite Lumber (SCL), Laminated strand lumber (LSL), Parallel strand lumber (PSL) 610, Timber, Finger-jointed lumber, High and Medium Density Overlay plywood (HDO and MDO). In such applications as but not limited to subflooring, flooring, wall and roof sheathing, ceiling and deck sheathing, lumber, timber, rafters, exterior wall studs, purlins, headers, garage door headers, door jams, doors, crown moldings, batten moldings, rim boards, studs, columns, concrete forming, siding, mezzanine decks, and furniture; in addition in transportation industries such as for aircrafts as Aviation thermal acoustic insulation systems, as the roofs, bodies, and core layers of ships, cars, trucks, and trains. Many kinds of materials can be easily adhered to its surface.

[0086] 2. Due to its good performance of fire resistance and self-extinguishing, it can be used as fireproof doors, fire doors fill core, I Joists (webs and flanges), roof trusses, ridge beams, floor beams, lumber, sheathing board, sauna timber, flooring and furniture for home usages, and in commercial buildings, hotels, and other public areas. It can also be used in framing structures and as the main body of archaizing buildings and temples.

[0087] 3. Due to its good performance of water-proof and moisture-proof, it can be made into kitchen cabinets, bathroom fixtures, countertops, and bathroom decoration materials. It is also a good choice for outdoor projects, waterfront facilities, road and bridge projects, and templates for construction projects.

[0088] 4. Due to its good anti-corrosion and termite-proof performance, it is a good choice for industrial anti-corrosion projects, industrial containers, industrial tanks, highway panels and archaizing building repairing projects. It is also a good choice as flooring or subflooring, siding, wall assembly systems, and roof for home usages due to its high R-value and waterproof characteristics.

[0089] 5. As its surface can precede spray treatment, and due to its very low thermal transfer and good thermal preservation, it can be used in walk-in/free standing coolers, cold storage insulation board, refrigerated box truck bodies, refrigerated semi-tractor trailers, freezers, and as the internal and external walls for hotels, and other buildings.

[0090] 6. Due to its excellent insulating and flexibility properties, it can be used as thermal insulation lumber, thermal insulation sheets, aviation insulation systems, thermal insulation board, structural insulated panels, brick or stone insulation panels, exterior insulation blocks, as the bodies of electrical appliances, bodies of outdoor transformers, and circuit insulation boards, etc.

[0091] 7. The rigid polymer filled foam material sheet is created by hot pressing first followed by cold pressing, and it is easily carved; thus is well suited for use in melamine board, melamine flooring board, melamine cabinet board, polyboard laminate, cabinets, wall and ceiling decoration board, embossed wall and ceiling decoration board, ceiling tiles, ceiling medallions, cloth veneer acoustic soft pack panel, cloth veneer soundproof hard pack acoustic panel advertising boards, office furniture, entertainment centers, embossed leather panel for video wall backdrop screen, and hospital furniture.

[0092] FIG. 1a illustrates generally at 100 the process steps involved in the creation of the rigid polymer filled foam material sheet. The polyurethane or rubber foam has a plurality of pores, which will be filled with a polymer during the process, as hereinafter described, thereby creating a rigid polymer filled foam material sheet. In the first step, the foam is cut to shape according to the desired product size. In the second step, a mixture of polymers including one or more of ABS (Acrylonitrile Butadiene Styrene), PMMA (Poly methyl methacrylate) and PVC (Polyvinyl chloride) polymers is mixed with a solvent to create a slurry. Additional ingredients may include wood chips/wood fiber/finely-ground cellulose is wood cellulose, fire retardant materials such as calcium silicate. The foam is completely covered with the slurry and in one embodiment is allowed to dry. In the next step, the polymer covered foam is placed in a die of a heating and pressing machine. Any solvent, if present, is evaporated quickly. ABS melts at about 105 C., PMMA melts at about 165 C., and PVC melts at about 160 C. When the mold is heated to temperatures below 170 C., all the polymeric ingredients are softened. Thus, during the heating process, the polymer slurry composition densifies to a formsheet structure. When the densification is complete after a selected process time, the rigid polymer material sheet may be removed from the mold.

[0093] PVC has a large amount of chlorine and when the rigid polymer filled foam material sheet is exposed to flame, the degradation of PVC releases a large amount of chlorine that extinguishes the flame and thereby provides fire retardant properties to the rigid polymer filled foam material sheet.

[0094] FIG. 1b is a graph showing the relationship between the Fikentscher K value and the molecular weight of PVC polymers. Preferably, the polyvinylchloride used in the present invention is in the form of 100 to 150 micrometer particles produced by suspension or emulsion polymerization. The K value of the polyvinylchloride homopolymer or copolymer with polyvinyl acetate has a K value greater than 65 representing a molecular weight of 60,000 as shown in the graph below reproduced from PVC Plastics by W. V. Titow. A K value of 50 is a low molecular weight soft PVC while a K value of 80 is a high molecular weight strong PVC.

[0095] FIG. 2 illustrates generally at 200 a micrograph of the rigid polymer material sheet. The millimeter marker is shown in the figure. Individual air cells of the polymer sheet are clearly seen. This sample is sample A, which had a dimension of 25 cm length. 13 cm width and 1.2 cm in thickness with a volume of 390 cc and weighed 77 grams. Thus the density of this sample A is 0.197 gm/cc.

[0096] FIG. 3 illustrates generally at 300 the method used for measuring the thermal conductivity of the sheet. The subject sheet can be made into different hardness for different Industries, and different Industrial end uses and applications. The formula can be adjusted to fit virtually any Industrial application or end use. Heat flow meter testing in accordance with ASTM C518 was conducted on 0.145 gm/cc and 0.165 gm/cc density specimens with varying thicknesses resulting in R values (see below). Chambers 301 and 302 are maintained at different temperatures and heat flow is measured.

ASTM Data Results

[0097]

TABLE-US-00004 ASTM C518-10 .145 gm/cc .165 gm/cc R Value (thick) 2.00 1.96 (thick) 3.04 2.94 (1thick) 4.01 3.90 (1thick) 6.05 5.86

[0098] The subject invention's samples were found to have superior per inch R Value insulation properties to Fiberglass. Yet also exhibits vastly different material properties and attributes. *Testing Results ASTM C518-10 (above)

[0099] The measured thermal properties and the R values of the different thickness specimens are shown as a comparative basis as compared to other commonly available construction materials.

Subject Invention Vs. Common Building Material with Identical Thickness R-Value Comparison

[0100]

TABLE-US-00005 Subject Invention Material: Common Foaming Board Building/Sheathing Building Material .145 gm/cc .165 gm/cc Board Thickness R-Value R-Value R-Value Gypsum Wall 0.45 2.00 1.96 Board Plywood 0.62 2.00 1.96 Plywood 0.94 3.04 2.94 Plywood 1 1.25 4.01 3.90 Fiber board 1.32 2.00 1.96 sheathing Fiber board 1 2.64 4.01 3.90 sheathing Medium Density 0.53 2.00 1.96 Particle Board Fiberglass 3.00 3.04 2.94 sheathing Fiberglass 1 4.00 4.01 3.90 sheathing Fiberglass 1 6.00 6.05 5.86 sheathing

TABLE-US-00006 Subject Invention Common Foaming Board Building .145 .165 Material: Insulating Materials Material gm/cc gm/cc (Per 1 inch Thickness) Thickness R-Value R-Value R-Value Fiberglass Batt 1 3.14 4.01 3.90 Fiberglass Blown (Attic) 1 2.20 4.01 3.90 Fiberglass Blown (Wall) 1 3.20 4.01 3.90 Rock Wool Batt 1 3.14 4.01 3.90 Rock Wool Blown (Attic) 1 3.10 4.01 3.90 Rock Wool Blown (Wall) 1 3.03 4.01 3.90 Cellulous Blown (Attic) 1 3.13 4.01 3.90 Cellulous Blown (Wall) 1 3.70 4.01 3.90 Vermiculite 1 2.13 4.01 3.90 Autoclaved Aerated Concrete 1 3.90 4.01 3.90 Urea Terpolymer Foam 1 4.48 4.01 3.90 Rigid Fiberglass (>4 lb/ft3) 1 4.00 4.01 3.90 Expanded Polystyrene 1 4.00 4.01 3.90 (Beadboard) Extruded Polystyrene 1 5.00 4.01 3.90 Polyurethane (foamed-in-place) 1 6.00 4.01 3.90 Foil Faced Polyisocyanurate 1 6.00 4.01 3.90

TABLE-US-00007 Subject Invention Common Foaming Board Building .145 .165 Material gm/cc gm/cc Material: Siding Thickness R-Value R-Value R-Value Hardboard 0.34 2.00 1.96 Plywood 0.62 2.00 1.96 Plywood 0.93 3.04 2.94 Wood Bevel Lapped 0.80 3.04 2.94 Aluminum/Steel/Vinyl (not 0.61 3.04 2.94 insulated) Aluminum/Steel/Vinyl ( 1.80 3.04 2.94 insulation)

TABLE-US-00008 Subject Invention Common Foaming Board Material: Interior Building Material .145 gm/cc .165 gm/cc Finish Materials Thickness R-Value R-Value R-Value Gypsum Board 0.45 2.00 1.96 (Drywall) Paneling 0.31 1.00 1.00 Paneling 2.00 1.96 Paneling 3.04 2.94 Paneling 1 4.01 3.90

TABLE-US-00009 Subject Inveinton Common Foaming Board Material: Building Material .145 gm/cc .165 gm/cc Flooring Materials Thickness R-Value R-Value R-Value Plywood 0.94 3.04 2.94 Plywood 1 1.25 4.01 3.90 Particle Board 1 1.31 4.01 3.90 (underlayment) Hardwood Flooring 0.68 3.04 2.94 Hardwood Flooring 1 0.91 4.01 3.90 Tile, Linoleum 0.05 2.00 1.96 OSB Insulated 2 7.00 8.02 7.80 Subfloor Panel System

TABLE-US-00010 Subject Invention Common Foaming Board Building Material .145 gm/cc .165 gm/cc Material: Doors Thickness R-Value R-Value R-Value Wood Hollow Core 1 2.17 7.05 6.84 Flush Wood Solid core Flush 1 3.03 7.05 6.84 Wood Solid core Flush 2 3.70 9.02 8.80 Insulated metal door 2 15.00 8.02 7.80 (2 w/urethane)

[0101] In all cases, the sheet of the present invention provides better R values as compared to any of the commercially available construction material. The sheet of the present invention is also Fire Proof, Water Proof (water absorption 0.81%), Termite Proof, Sound Proof, Acid Proof, and is the next state of the art Eco Green Building Material comprised of 100% Formaldehyde Free components.

[0102] Sound/Acoustic properties are set forth below:

[0103] Acoustical Performance Test Report: Density 0.145 gm/cc and 0.165 gm/cc

[0104] Tube Diameter: 57 mm

[0105] Impedance tube tests were performed on Density 0.145 gm/cc and 0.165 gm/cc samples. Three test specimens were provided for each. Test methods were conducted in accordance with ASTM E1050-12, Standard Test Method for Impedance and Absorption of Acoustical Materials Using a Tube, Two Microphones and A Digital Frequency Analysis System. Instrumentation used is set forth below.

Instrumentation:

[0106]

TABLE-US-00011 ATI Date of Instrument Manufacturer Model Description Number Calibration Analyzer Agilent 35670A Environmental Noise Analyzer Y002929 June 2013* Microphone One G.R.A.S Type 40 AR , pressure type, condenser 063359 September 2014 microphone Microphone One Preamp G.R.A.S Type 26 AK , preamplifier Y003251 September 2014 Microphone Two G.R.A.S Type 40 AR , pressure type, condenser Y003245 September 2014 microphone Microphone Two Preamp G.R.A.S Type 26 AK , preamplifier Y003248 September 2014 Microphone Calibrator Larson Davis CAL 200 PistonphoneCalibrator 065327 September 2014 Driver JBL 2426H Compression Driver 005719 N/A Equalizer Rane RPE 228 Digital equalizer 005081 N/A Weather Station Davis 615C Weather station Y003257 July 2014 57 mm Impedance Tube Architectural N/A 57 mm Impedance tube with 005712 N/A Testing, Inc. microphone holder, stand, and acrylic sample holder with plunger *Note: The calibration frequency for this equipment is every two years per the manufacturer's recommendation.

Signal Processing Parameters:

[0107]

TABLE-US-00012 Frequency Resolution 1600 Lines Frequency Span 3200 Hertz Averaging Type RMS Number of Averages 25 Windowing Function Hanning Window Overlap 66.70%

N/A-Non Applicable

[0108] Each specimen was installed flush with the open end of the specimen holder. Any gaps that existed between the specimen and holder were sealed with petroleum jelly. The holder was installed onto the open end of the impedance tube. Random noise was generated in the tube, and 50 measurements were conducted and averaged. The air temperature, relative humidity and atmospheric pressure conditions were monitored and recorded during the test measurements. The results for the specimens were averaged. The r/pc, x/pc, gpc, bpc and the normal incidence sound absorption coefficients were calculated. Density 0.145 gm/cc:

TABLE-US-00013 Specimen Description Thickness (cm) Weight (g) A Foam board 1.875 7.529 B Foam board 1.920 7.560 C Foam board 1.915 7.560
Density 0.165 gm/cc:

TABLE-US-00014 Specimen Description Thickness (cm) Weight (g) A Foam board 2.017 24.012 B Foam board 2.019 24.591 C Foam board 2.019 24.560

TABLE-US-00015 ASTM E1050 .145 gm/cc .165 gm/cc Acoustic 0.03-0.17 (250-2000 hz) 0.03-0.05 (250-2000 hz) Absorption No Absorption No Absorption
Density 0.145 gm/cc:

TABLE-US-00016 Summary of Test Results Data 1/3 Octave Normal Incidence Sound Absorption Coefficients File at the Octave Band Frequencies No. 63 125 250 500 1000 2000 4000 E7935.01 N/A N/A 0.03 0.03 0.05 0.17 N/A N/A indicates the frequency is not applicable to the respective tube diameter.
Density 0.165 gm/cc

TABLE-US-00017 Summary of Test Results Data 1/3 Octave Normal Incidence Sound Absorption Coefficients File at the Octave Band Frequencies No. 63 125 250 500 1000 2000 4000 E7255.01A N/A N/A 0.03 0.03 0.02 0.05 N/A N/A indicates the frequency is not applicable to the respective tube diameter.
Physical properties of the samples were determined, as set forth below 0.145 gm/cc density:

TABLE-US-00018 ASTM D 635 PASS - Failure to sustain burn Rate of Burn corresponds to a CC1/HB classification.

TABLE-US-00019 ASTM C 367 281 LBF Average Hardness

TABLE-US-00020 ASTM C 367 0.05 Average Mass Loss Friability

TABLE-US-00021 ASTM C 367 Average Sag 0.033 Sag Test Ave Recovery 0.037 conditioning for 17 hours at 32 C. and 90% relative humidity 6 hour wet recovery period at 23 C. and 50% relative humidity

TABLE-US-00022 ASTM C367 Machine Cross Transverse Direction Direction Strength Average Average Width 3.082 3.085 Depth 0.0754 0.0751 Max Load (lbf) 33.8 32.4 Max Deflection (in) 3.502 3.598 (Maximum range of Testing machine capability) Modulus of 347 335 Rupture (psi)

[0109] The subject foaming boards can be manufactured into standard building board size, and any standard lumber size specification. For example, the molds and machinery to form the foaming boards are typically available in standard size of 1220 mm2440 mm (48 inch96 inch). Therefore the variance is the thickness of the mold, which in turn produces different thicknesses of slab. Once the finished slab has been removed from the mold, the board can be cut into building board sizes or lumber sizes according to needs and applications.

[0110] FIG. 4 illustrates at 400 the harness measurement of the rigid polymer sheet having 0.145 gm/cc density according to ASTM C 36. The figure shows the test set up and the indentation. Hardness test was conducted on five 4 in. by 4 in. specimens. A compressive load was applied to each specimen utilizing an Instron Universal Testing Machine (ICN: 005741) through a 2 in. diameter ball at a rate of 0.10 in/min until a sample penetration of 0.250 in was achieved.

[0111] Hardness Results

TABLE-US-00023 .145 gm/cc density Thickness (in.) Hardness (lbf) Average 0.7542 281

[0112] ASTM C 367Transverse Strength tests were conducted. Five, 3 in. by 14 in. by 0.750 in. specimen having a density of 0.145 gm/cc were cut from the submitted panels in a machine direction, and another five were cut in the cross direction. Test specimen dimensions were measured using a 12 inch (by 0.001 inch) digital caliper (ICN: 004722). Specimens were individually mounted in an Instron Model 3369 Universal Testing Machine (ICN: 005740) using a three-point flexural loading setup. Test specimens were supported at a span of 12 in. The diameter of the loading nose and the support rods were 1.25 in. The specimens were loaded at a rate of 0.50 in/min until either peak load was achieved or a deflection of 3.5 in. was reached. As illustrated by FIG. 5, the specimens exhibited excellent flexibility exceeding 110. Midspan deflection was continuously recorded during the loading process using the crosshead movement of the test machine.

[0113] Transverse Strength Results

TABLE-US-00024 Maximum Modulus of Width Maximum Deflection Rupture MD results (in) Depth (in) Load (lbf) (in) (psi) Average 3.082 0.754 33.8 3.502 347

TABLE-US-00025 Maximum Modulus of Maximum Deflection Rupture CD results Width (in) Depth (in) Load (lbf) (in) (psi) Average 3.085 0.751 32.4 3.598 335

[0114] ASTM C 367Friability tests were conducted. Twelve, 1 in. by 1 in. by 0.750 in. specimens were weighed using a Mettler Toledo analytical balance (ICN: 003449) and placed within the oak friability tumbler along with twenty-four, oak cubes. The tumbler was closed to prevent the test materials from being ejected and the tumbler was rotated around its axis at a rate of 60 rpm for 10 minutes. The sample set was then removed from the tumbler and weighed for mass loss. They were then reinserted into the tumbler without the previous debris being removed, and the mechanism operated for 10 additional minutes. At the conclusion of the second 10 minutes, the samples were removed and reweighed, resulting in a final mass loss.

[0115] Friability Test Results

TABLE-US-00026 10 Minute Mass Loss Next 10 min Mass Loss Initial weight Weight (g) (%) weight (g) (%) Average 2.1824 2.1813 0.05% 2.1801 0.11

[0116] FIG. 5 illustrates at 500 the bending of the rigid polymer sheet. The sample is reversibly bent to 110 without cracks. It represents the only building board used for drywall, or wall assembly sheathing that can flex to an angle exceeding 120 degrees and then return to its original shape without any breaking, cracking or exterior flawing in its appearance or rigidity.

[0117] Other test samples marked Sample B had a dimension of 25 cm length. 15 cm width and 2 cm in thickness with a volume of 750 cc and weighed 275 grams. Thus the density of this sample B is 0.367 gm/cc. A third sample, Sample C had a dimension of 24.5 cm length. 12 cm width and 0.5 cm in thickness with a volume of 147 cc and weighed 275 grams. Thus the density of this sample C is 0.558 gm/cc. Clearly the rigid polymer sheet fabrication process such as the amount of slurry added during molding of the sheet, the temperature of the mold and the pressure applied determines the density. In addition, the presence of decorative structure on the sheet increases both the hardness and the density of the sheet formed.

[0118] Wall Assembly SystemsFoaming Board Composite Wall Assembly Systems and Foaming Board Related Products of the subject invention eliminates or greatly reduces Thermal Bridging and Framing Factor to the wall assembly and achieves a 114.33% increase in R-Value (using California Energy Commission of 25% framing factor) throughout the entire wall assembly system and building envelope creating a thermal break and uniform increase in thermal resistance.

[0119] A thermal bridge, also called a cold bridge, is an unwanted path for heat flow that bypasses the main insulation of a building envelope. A thermal bridge is a fundamental of heat transfer where a penetration of the insulation layer by a highly conductive or non-insulating material takes place in the separation between the interior (or conditioned space) and exterior environments of a building assembly (also known as the building enclosure, building envelope, or thermal envelope).Placing a good conductor in parallel with good insulation is often referred to as thermal bridging because it provides a path for heat flow that bypasses the main insulation.

[0120] Energy loss inside the building envelope occurs by two forces conduction and convection. Conduction is the transfer of heat through a solid material, which is what insulation is designed to prevent, and is responsible for 60 percent of heat or cooling loss in the average home. Convection is the transfer of air through gaps in the walls and roof of the home. Outside air leaking into the home or air infiltration, is responsible for 40 percent of heat or cooling loss in the average home.

[0121] Wood-framed homes rely on dimensional lumber, referred to as studs, at regular intervals to provide structural support. Lumber is a very poor insulator and forms a thermal bridge from the outside of the home to the inside of the home where heat can pass through by conduction. Door Framing, steel studs, and wood or metal window frames are also common thermal bridges.

[0122] Insulation around a thermal bridge is of little help in preventing heat loss or gain due to thermal bridging; the bridging has to be eliminated, rebuilt with a reduced cross-section or with materials that have better insulating properties, or with a section of material with low thermal conductivity installed between metal components to retard the passage of heat through a wall or window assembly, called a thermal break.

[0123] FIGS. 6a and 6b illustrate the thermal bridge and energy lost through studs. FIGS. 7a and 7b illustrate the framing factor concept.

[0124] Foaming Board Composite Wall Assembly Systems and Foaming Board related products comprising the subject inventive material create a thermal break in the thermal bridging occurring in wall assemblies of the building envelope resulting in a 114.33% increase in R-Value wall assembly system and building envelope. (See Wall Assembly R-Value Below).

Calculating Assembly Wall R-Value* (Standard 24 Wall Assembly)

[0125] *This example is just for wood frame construction. Steel studs are a more complex calculation Formula: Assembly R-Value=1/(Assembly U-Value)=1/(U-studs x%+U-cavity x%)

TABLE-US-00027 Common Building Material Subject invention R-Value R-Value Assembly R-Value R-Value Assembly component Studs Cavity R-Value Studs Cavity R-Value Wall-Outside Air 0.17 0.17 0.17 0.17 Film (Winter) Siding-Wood 0.80 0.80 3.96 3.96 Bevel (1/2 .45 gm/cc + 1/2 .165 gm/cc) Plywood 0.63 0.63 3.93 3.93 (1 Sheathing (1/2) thick .165 gm/cc) 3 1/2 Fiberglass 13.00 13.00 Batt 3 1/2 Stud 4.38 13.65 (3.5 3.90 .165 gm/cc) 1/2 Drywall 0.45 0.45 3.96 3.96 (1 thick .165 gm/cc) Inside Air Film 0.68 0.68 0.68 0.68 Percent for 25% 75% 25% 75% 16 O.C. + Additional Studs.sup. Total Wall 7.11 15.73 26.35 25.70 Component R-Value Wall Component 0.1406 0.0636 0.0379 0.0389 U-Value Total Wall 12.07 25.87 Assembly R-Value (California Dept. Energy 25% framing factor)

TABLE-US-00028 Standard Subject Percent increase in Wall Invention Wall Assembly R- R-Value R-Value Value California Energy 12.07 25.87 25.87 12.07 = Commission 13.80 (25% Framing Factor) (13.80/12.07) 100 = 114.33%
*Foaming board wall assembly systems using the subject inventive material result in an increase in total wall assembly R-value from 12.07 to 25.87 which is an increase of 114.33%.

[0126] The foaming board composite wall assembly systems and foaming board related products of the subject invention eliminate or reduce to a measurable insignificant fraction thermal bridging and framing factor in the building envelope by applying its composite materials with superior industry leading R-Values to achieve a uniform thermal resistance throughout the entire wall assembly system.

[0127] The term framing factor is widely used to express a percent of the total wall area occupied by framing members. The extent to which a wall, roof, or floor's framing reduces the R-value of its insulation is called its framing factor. It is simply a percentage reduction in R-value when thermal bridging occurs and a heal flow is created by conduction through the wood or steel frame of a building envelope. The more framing members in a wall structure, the higher the framing factor. Steel stud assemblies often have framing factors of 50% and above, while wood framing is usually closer to 25%. For example, a wall with R-20 insulation and a framing factor of 25% would have an overall insulation value of R-15.

[0128] According to a 2002 Report framing factors up to 27% can be found in residential walls in California in 2001. In 2003 a study by ASHRAE found an average of 25% framing factor for U.S. Homes. The result of these studies demonstrated significant sensitivity in some configurations of residential walls to the framing factor and insulation imperfections.

[0129] In keeping with the Energy modal Engineering report for the California Energy Commission, ALL wall assemblies in this report have framing factors of approximately 27% (1). It is well known that a presence of framing members (like wood or steel profiles) reduces the R-Value of a wall system. The measure of this effect is known as the framing factor coefficient F of a wall, which is calculated using the following simple expression that contains clear-wall R-Value, Rcw, and the center-of-cavity R-Value, R n: f=[1Rcw/Rn]*100.

[0130] The subject invention density 0.145 gm/cc is the only building board that can flex to an angle exceeding 130 degrees and then return to its original shape without any breaking, cracking or exterior flawing in its appearance or rigidity. (0.145 gm/cc density) Some concrete flexible cement board is available on the market. However, flexible cement board can only flex approximately 20 degrees and is not a thermal insulator. Foaming Board of the subject invention is the leading insulator with a multitude of applications and flexibility that is unmatched in the building material industry.

[0131] Eagle America Framing SystemCommon Wood and Engineered lumber are specifically prone to humidity induced water absorption resulting in Buckling, Crowning, and Cupping of panels and flooring when no space for humidity expansion is allotted for. Light-frame construction using platform framing and standardized dimensional lumber has become the dominant construction method in North America. Such light-frame structures usually gain strength from rigid panels (plywood and other plywood-like composites such as oriented strand board (OSB). However, due to humidity swelling properties of common and engineered wood, a installation gap allowance for wood swelling must be inserted between panels when installing subfloors, floors, walls, ceilings, and roofs in the framed structure.

[0132] The present invention was humidity conditioned under ASTM C 367 humidity test for 17 hours at 32 C. and 90% relative humidity, and then a 6 hour wet recovery period at 23 C. and 50% relative humidity at 145.28 kg/m3 density. Resulting in deflection of 0.033 of an inch at 90% humidity, and recovery of 0.037 of an inch when reduced to 50% relative humidity.

[0133] The present invention's minimal water absorption is in direct opposition to common and engineered wood building material attributes, and eliminates the need for the installation gap allowance for wood swelling between panels when installing subfloors, floors, walls, ceilings, and roofs in a framed structure, and eliminates subsequent building defects associated with humidity swelling.

[0134] The elimination of the gap creates an entirely new method of framing construction, and is known as The Eagle America Framing System.

[0135] The Eagle America Framing System of present invention differentiates itself from common building materials, and standard platform framing construction by elimination of the gap allowance for wood swelling. When assembled in accordance with present invention, said panels can be butted flush against each other increasing the overall structural stability. In addition, the system effectively seals the structure from moisture, air penetration and natural air drafts, eliminates pest pathways, increases the overall strength of the framed structure, and eliminates or reduces to a measurably insignificant fraction energy loss from thermal bridging due to (i) the elimination of the gap, and (ii) the increased thermal insulation properties of present invention in sheet or lumber form verses common wood and wood related building materials.

Example #1

A rigid Polymer Material Sheet for use Building Materials was Prepared as Follows:

[0136]

TABLE-US-00029 Component Type/size Parts by weight PVC BL-2 65 Impact modifier NBR3305 5 Mesh wood fiber plant 20 10 Coupling agent Titanate 0.5 Smoke suppressant 5 Clay 900 mesh 3 Lubricant PE wax 0.5 Zinc oxide Activator 2 Green flame retardant Ammonium polyphosphate 5 Heat stabilizer Calcium and zinc 2 tasteless crosslinking agent BIPB 0.5 Foaming agent AC-3000 1 Deammoniation agent HJ-1-- 0.5
1) Plant fiber pretreated baking to reduce plant fiber moisture content to 2.5% and fed into a high-speed mixer. 2) Coupling agent addedmixture stirred for 10 minutes. 3) Knead mixtureadd PVC, impact modifier, smoke suppressant, clay (attapulgite), lubricants, activator, flame retardant, heat stabilizer, desmopressin agent. 4) mixture is kneaded at 65N of pressure for 10 min. with sweep 2 times; temperature within a range of 140-142 C.; 5) cross-linking and blowing agents added. Mixture kneaded 3 min; 6) open mill soak, mill thick run, thin through at 125 C. Mixture fed into a vulcanizing mold foaming machine, curing temperature control 170 C., foaming time is 45min; 7) material is compacted and cooled. Formed into sheets for building materialsR-values measured:

TABLE-US-00030 Subject Invention Foaming Board .145 gm/cc .165 gm/cc Thickness R-Value R-Value Material: building material Plywood 3.02 2.91 Plywood 1 3.99 3.88 Particle Board (underlayment) 1 3.98 3.92 Hardwood Flooring 3.06 2.95 Hardwood Flooring 1 3.99 3.92 Tile, Linoleum 2.01 1.94 OSB Insulated Subfloor Panel 2 8.03 7.82 System Material: Doors Wood Hollow Core 1 7.01 6.86 Flush Wood Solid core Flush 1 7.02 6.87 Wood Solid core Flush 2 9.04 8.81 Insulated metal door 2 8.03 7.83 (2 w/urethane)

Example #2

A Rigid Polymer Material Sheet for Use Building Materials was Prepared as Follows:

[0137]

TABLE-US-00031 Component Type/size Parts by weight PVC BL-3 55 Plasticizers Chlorinated paraffins 6 Nitrate Rubber NBR3305 12 Pyridinium 900 eye 4 Chlorochromate (PCC) Stearate SA1840 1 Zinc Oxide BA01-05I 3 Flame Retardants CA117 10 Crosslinking Agents DCP 1 Vesicant ADC complex foaming agent 3 Heat stabilizers STM981A 5
(1) kneading: PVC, rubber (NBR), plasticizer, 5 light calcium carbonate, stearate, zinc oxide, flame retardant, heat stabilizer; pressurized to 75 liters 7-8KG kneading 10; 140-145 C. discharge, obtain compound; (2) Thermal refining: Step (1) mixing the resulting compound into 20-inch mill refining heat hit triangle bag; three times thinner package, and then put into 20-inch mill heat refining play triangle bag, then resort to the secondary thick packet, mixing machine temperature control 145-150 C.; (3) a film: the after step (2) soak and then put into the plastic material 20-inch mill, a refining machine temperature control 145-150 C., film thickness of 2-3 mm the film, the film is cut into strips, cooling cooled to obtain a green sheet of plastic; (4) vulcanizing mold: will be closed-cell foam vulcanization, sulfur within the step (3) the resulting sheet into the embryo glue curing machine dies 1300 tons of pressure, curing time of 35 minutes, curing temperature 1605 C., obtain foam to be stable foam form, cooled to obtain a building material. Formed into sheets for building materialsR-values measured:

TABLE-US-00032 Subject Invention Foaming Board .145 gm/cc .165 gm/cc Thickness R-Value R-Value Material: building material Plywood 3.00 2.92 Plywood 1 4.01 3.89 Particle Board (underlayment) 1 3.99 3.91 Hardwood Flooring 3.07 2.96 Hardwood Flooring 1 3.99 3.90 Tile, Linoleum 2.00 1.93 OSB Insulated Subfloor Panel 2 8.02 7.8 System Material: Doors Wood Hollow Core 1 7.00 6.87 Flush Wood Solid core Flush 1 7.03 6.87 Wood Solid core Flush 2 9.05 8.83 Insulated metal door 2 8.04 7.82 (2 w/urethane)

[0138] Having thus described the invention in rather full detail, it will be understood that such detail need not be strictly adhered to, but that additional changes and modifications may suggest themselves to one skilled in the art, all falling within the scope of the invention as defined by the subjoined claims.