Dual-reinforced construction board
A dual-reinforced construction board is disclosed comprising a core having an upper surface and an opposing lower surface, a first reinforced fibrous facer adhered to the upper surface of the core and a second fibrous facer adhered to the lower surface of the core. Each of the first and second fibrous facer comprise a non-woven mat coated on a first surface with a coating composition. The first fibrous facer and optionally the second fibrous facer further include a reinforcement layer adhered to at least a portion of the first surface of the non-woven mat. The dual-reinforced construction board has a fastener pull-through strength of at least 400 lbf.
1. A dual-reinforced insulation board comprising:
a core having an upper surface and an opposing lower surface, defining a thickness therebetween of from 1.0 to 5.0 inches;
a first reinforced fibrous facer adhered to the upper surface of the core, said first reinforced fibrous facer comprising:
a non-woven mat comprising a plurality of fibers bound by a binder composition, the non-woven mat being impregnated by a first coating composition that is free of filler and coated on a first surface with a second coating composition; and
a reinforcement layer adhered to at least a portion of the first surface of the non-woven mat; and
a second fibrous facer adhered to the lower surface of the core, said second fibrous facer comprising:
a non-woven mat coated on a first surface with a coating composition; and
optionally, a reinforcement layer adhered to at least a portion of the first surface of the non-woven mat;
wherein the dual-reinforced insulation board has a fastener pull-through strength of at least 400 lbf.
2. The dual-reinforced insulation board of claim 1 , wherein the non-woven mats of at least one of the first reinforced fibrous facer and second fibrous facer comprise glass fibers.
3. The dual-reinforced insulation board of claim 1 , wherein the second coating composition of the first reinforced fibrous facer and the coating composition of the second fibrous facer comprise a polymeric binder component and a filler component.
4. The dual-reinforced insulation board of claim 1 , wherein the reinforcement layer on the first fibrous non-woven facer or the second fibrous non-woven facer comprises a scrim, a secondary coating, a secondary non-woven mat, a reinforcement tape, or a layer of insulation glass.
5. The dual-reinforced insulation board of claim 4 , wherein the scrim comprises glass fibers, synthetic fibers, or a combination thereof.
6. The dual-reinforced insulation board of claim 1 , wherein the core of the dual-reinforced insulation board comprises a polymer foam having a density of less than 3.0 lbs./ft 3 .
7. The dual-reinforced insulation board of claim 1 , wherein at least one of the first reinforced fibrous facer and second fibrous facer has a tensile strength of at least 250 lbf.
8. A dual-reinforced coverboard comprising:
a core having an upper surface and an opposing lower surface, defining a thickness therebetween of from 0.2 to 3.0 inches and having a density of greater than 3.0 lbs./ft 3 ;
a first reinforced fibrous facer adhered to the upper surface of the core, said first reinforced fibrous facer comprising:
a non-woven mat comprising a plurality of fibers bound by a binder composition, the non-woven mat being impregnated by a first coating composition that is free of filler and coated on a first surface with a second coating composition; and
a reinforcement layer adhered to at least a portion of the first surface of the non-woven mat; and
a second fibrous facer adhered to the lower surface of the core, said second reinforced fibrous facer comprising:
a non-woven mat coated on a first surface with a coating composition; and
optionally, a reinforcement layer adhered to at least a portion of the first surface of the non-woven mat;
wherein the dual-reinforced coverboard has a fastener pull-through strength of at least 150 lbf.
9. The dual-reinforced coverboard of claim 8 , wherein the non-woven mats of at least one of the first reinforced fibrous facer and second fibrous facer comprises glass fibers.
10. The dual-reinforced coverboard of claim 8 , wherein at least one of the second coating composition of the first reinforced fibrous facer and the coating composition of the second fibrous facer comprises a polymeric binder component and a filler component.
11. The dual reinforced coverboard of claim 8 , wherein the reinforcement layer of at least one of the first fibrous non-woven facer and the second fibrous non-woven facer comprises a scrim, a second non-woven mat, a reinforcement tape, or a layer of insulation glass.
12. The dual-reinforced coverboard of claim 11 , wherein the scrim comprises glass fibers, synthetic fibers, or a combination thereof.
13. The dual-reinforced coverboard of claim 8 , wherein at least one of the first reinforced fibrous facer and second fibrous facer has a tensile strength of at least 250 lbf.
14. A dual-reinforced coverboard comprising:
a core having an upper surface and an opposing lower surface, defining a thickness therebetween of from 0.2 to 3.0 inches;
a first fibrous facer adhered to the upper surface of the core, said first reinforced fibrous facer comprising:
a non-woven mat comprising a plurality of nonwoven glass fibers bound by a thermoset binder composition, wherein the non-woven mat is impregnated with a first coating composition and further includes a second coating composition applied on a first surface of the non-woven mat, and
wherein the dual-reinforced coverboard has a fastener pull-through strength of at least 150 lbf,
wherein the first coating composition is free of filler;
wherein the second coating composition comprises from about 2% to about 20% of a polymeric binder and from 65 wt. % to 98 wt. % filler, based on the total weight of the second coating composition.
15. A dual-reinforced insulation board comprising:
a core having an upper surface and an opposing lower surface, defining a thickness therebetween of from 1.0 to 5.0 inches;
a fibrous facer adhered to the upper surface of the core, said fibrous facer comprising:
a coated non-woven mat comprising a plurality of nonwoven glass fibers bound by a thermoset binder composition, wherein the non-woven mat is impregnated with a first coating composition and further includes a second coating composition applied on a first surface of the non-woven mat, and
wherein the dual-reinforced insulation board has a fastener pull-through strength of at least 400 lbf,
wherein the first coating composition is free of filler,
wherein the second coating composition comprises from about 2% to about 20% of a polymeric binder and from 65 wt. % to 98 wt. % filler, based on the total weight of the second coating composition.
16. The dual-reinforced coverboard of claim 15 , wherein the first coating composition is applied to the non-woven mat in an amount from 15 g/m 2 to 50 g/m 2 .
17. The dual-reinforced coverboard of claim 15 , wherein the second coating composition is applied to the non-woven mat in an amount from 10 g/m 2 to 200 g/m 2 .
18. The dual-reinforced coverboard of claim 15 , wherein the coated non-woven mat has an LOI in the range of from 20% to 45%.
19. The dual-reinforced coverboard of claim 15 , wherein the coated non-woven mat has a basis weight of from 200 g/m 2 to 525 g/m 2 .