HK1242359A1 - System for manufacture of foam sheets rigidized with polymer infiltration - Google Patents

Abstract

A rigid polymer porous material sheet is produced by feeding a slurry of polymer mixture comprising ultrafine polyvinylchloride particle, non-phthalate plasticizer, foaming agent and thermal stabilizer, polymer chips, fillers and fire retardant chemicals into a heated mold and pressing the mixture with high applied pressure. The temperature of the mold is below 190 C to soften the polymer mixture and decompose the foaming agent forming the closed cell polyvinylchloride foam with 10 to 40% density with closed air cells. The thermal resistance of the rigid polymer porous sheet and sound attenuation properties are significantly improved. The rigid polymer porous sheet can be bent at sharp angles without crack formation facilitating its use as wall boards. The sheets produced may be embossed or molded to produce decoration boards, advertising boards, cabinet doors and furniture with decorative features. They can also be used in aeronautical applications as acoustic thermal insulation systems.

Description

System for producing a foamed sheet that is cured by infiltration with a polymer

The present application claims the benefit OF provisional application No. 62/174,462 entitled "SYSTEM FOR manual OF form OF menu SYSTEMs having multiple dimensions WITH multiple information" filed on day 11 OF 2015, which in turn claims the benefit OF provisional application No. 62172059 entitled "SYSTEM FOR manual OF menu SYSTEMs having multiple dimensions WITH multiple information" filed on day 6 OF 2015, which in turn claims the benefit OF provisional application No. 62/177,656 entitled "SYSTEM FOR manual OF menu SYSTEMs having multiple dimensions WITH multiple information" filed on day 20 OF 3 OF 2015, the disclosures OF these provisional applications being incorporated herein by reference in their entirety.

1. Field of the invention

The present invention relates to the manufacture of rigid foam industrial sheeting (rigid foam industrial sheet) having applications not limited to building materials such as wallboard (wall board), tile, lumber (lumber), various wood products and wood related products and the like; and more particularly to a system for forming an undecorated or decorative low density high strength high modulus rigid sheet by a high temperature high pressure molding process that forms a polyvinyl chloride polymer foam incorporating a polymer additive.

2. Description of the prior art

Decorative panels currently available on the market include, for example, wood panels (woodenboard), particle board, oriented strand board ("OSB board"), plywood, density board, fiber composite board, PVC foam board, and fire retardant board (fire of board). Wood, OSB, particle, density and fiber composite boards exhibit very low fire retardant and fire resistance properties. They are not waterproof or moisture resistant and therefore enjoy somewhat limited applications. The fire protection plate is typically a sandwich panel (sandwich board) having 3 layers. Metal sheets (aluminum sheets, stainless steel sheets, colored iron sheets, titanium zinc sheets, titanium sheets, copper sheets, etc.) comprise a metal surface and a bottom layer, and a halogen-free, flame-retardant inorganic composition comprising an intermediate layer. This hot pressed composite panel exhibits good fire retardant and fire resistant properties, but it is heavy, expensive and not waterproof.

Many prior art patents and publications relate to forming sheet materials from polymeric foams. In particular, these polymer foams are not infiltrated with a polymer to produce an unadorned or decorative rigid sheet for structural or decorative building materials and other applications.

U.S. patent No. 4,284,681 to tidmalh et al discloses a composite sheet material. The composite material comprises a layer of highly plasticized polyvinyl chloride comprising 15 to 45% by weight polyvinyl chloride and 55 to 85% by weight of a plasticizer, a fibrous backing material and an intermediate layer of polymeric material between the polyvinyl chloride layer and the backing material. Various adhesives may be used to adhere the composite to substrates such as walls, ceilings, and floors. If the interlayer is not completely impermeable to the plasticizer in the highly plasticized layer, the adhesive should preferably resist plasticizer migration. This composite is a coating on a structural object, but is not itself a structural material.

U.S. patent No. 4,510,201 to Takeuchi et al discloses a polyvinyl chloride resin molded sheet product. A polyvinyl chloride resin composition containing a honeycomb filler such as Silus Balloon and pearlite and a molded product is prepared by subjecting the composition to heating under increased pressure. The molded product may be combined with a core layer such as a nonwoven fabric and victoria fine cloth (victoria lawn), a foamed layer such as PVC paste resin foam, and a surface layer such as a non-foamed synthetic resin, and molded into a laminated sheet product. These sheet products are made lighter and superior in sound and heat insulation effects, bending strength, dry touch (dry touch), water resistance, dimensional stability, cold resistance, and the like. The sheet product can be used as floor covering and other applications. This is a multi-layer PVC molded sheet and is not a low density single layer PVC foam.

U.S. patent No. 5,300,533 to Dahl et al discloses a method for producing a crosslinked foam. This method produces a foamed, crosslinked vinyl chloride-containing polymer in which a blowing agent is added to a copolymer produced by copolymerizing a monomer composition comprising vinyl chloride and a glycidyl-containing monomer. Foaming of the copolymer occurs by decomposition products of the blowing agent or decomposition products from the reaction of the chemically reactive azodicarbonamide blowing agent with the epoxy groups of the copolymer. The glycidyl group-containing monomer is glycidyl acrylate or glycidyl methacrylate or glycidyl butylacrylate. It is possible to crosslink the foamed vinyl chloride polymer by adding epoxy groups introduced via the copolymer. Crosslinking takes place with the aid of decomposition products from the blowing agent. This requires the formation of the copolymer of vinyl chloride and glycidyl methacrylate to be produced by suspension polymerization, microsuspension polymerization, emulsion polymerization or bulk polymerization.

U.S. patent No. 5,695,870 to Kelch et al discloses a laminated foam insulation board with enhanced strength. The laminated insulating foam panel comprises a panel (panel) comprising a plastic foam thickness of about 1/4 inches to about 1 inch; and a first thermoplastic face film and a second thermoplastic face film each adhered to a major, opposing surface of the panel, the face films being biaxially oriented, the face films each having a thickness of from about 0.35 mil to about 10.0 mil. The resulting sheet has an ultimate elongation of less than 200% in both the machine direction and the cross direction, and a tensile strength at yield (yield tensile) of at least 7000 pounds per square inch in both the machine direction and the cross direction, and a 1% secant modulus of at least 200,000 pounds per square inch in both the machine direction and the cross direction. The laminated foam insulation is a panel of extruded polystyrene plastic foam material rather than polyvinyl chloride foam.

U.S. patent No. 6,254,956 to Kjellqvist et al discloses a floor covering, a wall covering, or a ceiling covering. Such floor, wall or ceiling coverings comprise one or more substantially random interpolymers prepared by polymerizing one or more alpha-olefin monomers with one or more vinylidene aromatic monomers and/or one or more hindered aliphatic or cycloaliphatic vinylidene monomers, and optionally with other polymerizable ethylenically unsaturated monomers (ethylenically unsaturated monomers). The floor covering, wall covering or ceiling covering has a good balance of properties, such as sufficient flexibility and conformability (conformability) for uneven or contoured surfaces, sufficient scratch resistance, sufficient indentation resistance, indentation recovery and/or sufficient abrasion resistance for effective application to a floor, wall or ceiling. The floor covering, wall covering or ceiling covering is prepared by polymerizing one or more polymers. The floor covering, wall covering or ceiling covering is not a polyvinyl chloride foam product prepared by hot pressing the slurry composition.

U.S. patent No. 8,097,658 to Rosthauser discloses a process for producing medium density decorative molded foam with good fire resistance properties with reduced mold time, fire resistant compositions and foams produced by the process. This fire resistant, medium density molded polyurethane foam is said to be removed from the mold in significantly less time than previously possible. These reduced demold times (de-mold time) are achieved by including a solid flame retardant composition in the polyurethane foam from which the composition is formed. The solid flame retardant composition comprises melamine coated ammonium polyphosphate and zinc borate. This process uses polyurethane foam that forms a reactive mixture and is not indicated as a low density polyvinyl chloride foamed structural material.

U.S. patent application No. 20060264523 discloses polyvinyl chloride foam. The polyvinyl chloride foam exhibits improved mechanical strength and non-flammability. Microcellular polyvinyl chloride foam (microcellular polyvinyl chloride foam) having a closed cell structure has a high foaming efficiency even with a small amount of foaming agent. Polyvinyl chloride foam comprises a vinyl chloride resin layered silicate nanocomposite wherein the layered silicate is dispersed onto a vinyl chloride resin comprising a blowing agent. Foaming of the composition is achieved by the mechanical action of carbon dioxide injection and the specific gravity of the foam formed is very high, greater than 1 gram/cc.

U.S. patent application No. 20130310471 discloses the use of di (isononyl) cyclohexanecarboxylate (DINCH) in expandable PVC formulations. The present invention relates to foamable compositions comprising at least one polymer selected from the group consisting of: polyvinyl chloride, polyvinylidene chloride, polyvinyl butyrate, polyalkyl (meth) acrylates and copolymers thereof. The plasticizer used is 1, 2-cyclohexane dicarboxylic acid diisononyl ester (DINCH) and phthalic acid diisononyl ester (DINP) is a plasticizer which is chemically hazardous, as in the american society for consumer product safety (u.s.consumer product safety Commission) athttps://www.cpsc.gov/PageFiles/98260/dinp.pdfIs indicated at. Foam-forming products of azodicarbonamide. The foam stabilizer is ZnO, which acts as a catalyst for the decomposition of azodicarbonamide (kicker). The polymer composition forms a low viscosity plastisol and must be applied to a support during over vulcanization (over curing). Thus, the' 471 application does not produce freestanding, low density PVC sheets.

China patent application No. CN103265776A of Hou Yu Hung Yi-Drain discloses ecological wood (eco-wood) and a preparation method thereof. Ecological wood provides a waterproof, moisture-proof material that does not contain formaldehyde, toluene, and other harmful substances. Ecological wood is flame retardant, has a low amount of smoke, and has ductility, toughness, good impact resistance, and acid corrosion resistance. The preparation method of the long-life ecological wood comprises the following components in parts by weight: chlorine-vinegar copolymer resin (chlorine vinegar copolymer resin): 60 to 70, impact modifier (nitrile rubber): 9-11, plant fiber: 20 to 30, coupling agent (titanate): 1 to 3, smoke suppressant: 10-20, activated clay: 5-15, lubricant (polyethylene wax): from 0.5 to 1.5, activator (ZnO): 4-6, green flame retardant (ammonium phosphate): 8-10, thermal stabilizers (Ca and Zn compounds): 4-8, odorless crosslinker agent (odorless crosslinking agent): 0.5 to 1.5, blowing agent (AC-3000, which is azodicarbonamide): 1 to 5, desmopressin agent: 1 to 5. The preparation method comprises the modes of plant fiber pretreatment, kneading mixer, open mill soaker, film machine film, closed-chamber foam die and cooling stabilization. The composition of the ecological wood includes plant fibers and depends on the toughness of polyvinyl chloride resin including polyvinyl acetate and others without using plasticizers such as phthalate esters. The amount of copolymer addition is not specified, and thus the flexibility of the ecological wood is unclear.

In thathttps://vtechworks.lib.vt.edu/bitstream/handle/10919/42108/ McGrane2.pdf？sequence＝1&isAllowed＝yThe pages therein disclose Vacuum Assisted Resin Transfer Molding (Vacuum Assisted Resin Transfer Molding) of foam sandwich composites. The method involves dry carbon preform (dry carbon preform) andresin transfer molding of polymethacrylimide foam core to produce composite sandwich structure. The present disclosure does not produce hot-pressed polymer sheets to produce rigid, non-decorative or decorative structural sheets.

The publication "efficiency of additives on flexible PVC foam formation" discusses in journal Materials Processing Technology 2007.04.123 the Effect of Ca/Zn stearate and organotin heat stabilizers and zeolite, CaCO3, cellulose and loofah flour fillers (luffa flours fillers) and their concentrations (2.5%, 5%, 10% and 20% by weight) on the production of flexible PVC foams by chemical blowing agents. Azodicarbonamide was studied. The stabilizer reduces the decomposition temperature of azodicarbonamide from 200 ℃ to a PVC processing temperature of 160 ℃ to 190 ℃.

https://en.wikipedia.org/wiki/1,2-Cyclohexane_dicarboxylic_acid_ diisononyl_esterDiisononyl 1, 2-cyclohexanedicarboxylates are plasticizers used in the manufacture of flexible plastic articles in sensitive applications such as toys, medical devices and food packaging. From a chemical point of view, it belongs to the group of aliphatic esters. In 2002, BASF began to sell 1, 2-cyclohexane dicarboxylic acid diisononyl ester under the trade name Hexamoll DINCH as an alternative to phthalate plasticizers. [3]

http://www.sustainableproduction.org/downloads/PhthalateAlternatives-January2011.pdf

Table 2 optional plasticizer DOS: dioctyl sebacate, TXIB: 2,2, 4-trimethyl-1, 3-pentanediol diisobutyrate, TEHPA: tris (2-ethylhexyl) phosphate, DEHPA: di (2-ethylhexyl) phosphate, Eastman 168: bis (2-ethylhexyl) -1, 4-phthalate, TETM: tri-2-ethylhexyl trimellitate, ESBO: epoxidized soybean oil, DOTP: dioctyl terephthalate. DINCH: cyclohexane-1, 2-dicarboxylic acid diisononyl ester.

Based on the foregoing, there is a need in the art for an easy to use process for making building materials in the form of an undecorated or decorative rigid structural sheet that exhibits flame resistance, enhanced insulating properties, and non-mold properties.

Summary of The Invention

The present invention provides rigid polyvinyl chloride based foam sheets that are particularly well suited for, but not limited to, building construction (building construction). The sheet has a density in the range of from 0.12 to 0.66 grams/cc that is about 10 to 40 percent of solid flexible PVC (which typically exhibits a density of 1.1 to 1.35 grams/cc). The sheet formed according to the present invention has a very large number of closed microchambers (closed microcells) ranging in size from 10 to 70 microns. The chamber has chamber walls of a polyvinyl chloride-based polymer. These sheets also have uniformly distributed closed cells of very small size of air pockets (air pockets), which enhance thermal insulation properties and provide sound attenuation characteristics. The density of the resulting sheet depends on the composition of the PVC resin, the mold fill, and the pressure and temperature applied during sheet formation. Methods for making the rigid polymeric porous material sheet are also provided.

The production method of the polyvinyl chloride-based sheet uses ultrafine particles of virgin polyvinyl chloride synthesized by suspension polymerization, micro suspension polymerization, emulsion polymerization, or bulk polymerization. The PVC particles in stage I are about 4 nanometers, agglomerated in stage II into particles of 1 micron to 2 microns, and many particles agglomerated in stage III into particles typically in the range of 100 microns to 150 microns in size. These ultra-fine homopolymers of polyvinyl chloride and copolymers of polyvinyl chloride and polyvinyl acetate are free-flowing and they become the raw materials for preparing the slurry used to form the sheet according to the invention. The K-value of the PVC polymer used has a value greater than 65, which represents a molecular weight greater than 60,000. The amount of polyvinyl acetate present in the copolymer has a strong effect on increasing the flexibility of the resulting final product, as polyvinyl acetate reduces the stiffness, strength and modulus of the final sheet product and is maintained in the range of 2% to 30% of the copolymer.

In order for the final PVC sheet formed to have suitable flexibility, the plasticizer needs to be incorporated during the sheet forming process. Plasticizers are chemicals that dissolve into the PVC composition chain and facilitate flexing at the molecular level through a screening or hinge mechanism (change mechanism). Many plasticizers are known, for example derivatives of phthalic acid such as diisodecyl phthalate, derivatives of phosphoric acid such as tricresyl phosphate, derivatives of adipic acid such as dioctyl adipate and diisodecyl adipate, derivatives of azelaic acid such as dioctyl azelate, derivatives of benzoic acid such as diethylene glycol dibenzoate, epoxy plasticizers, derivatives of citric acid such as tributyl citrate, derivatives of sebacic acid such as dioctyl sebacate, derivatives of trimellitic acid such as trioctyl trimellitate; sulfonic acid derivatives, fatty acid esters, glycerol derivatives, chlorinated paraffins, chlorinated biphenyls, pyromellitic acid derivatives and polyester plasticizers. Due to the recently discovered biohazard of phthalates, the present invention uses phthalate-free plasticizers, such as 1, 2-cyclohexane dicarboxylic acid diisononyl ester (DINCH). Other phthalate-free plasticizers are DOS: dioctyl sebacate, TXIB: 2,2, 4-trimethyl-1, 3-pentanediol diisobutyrate, TEHPA: tris (2-ethylhexyl) phosphate, DEHPA: di (2-ethylhexyl) phosphate, Eastman 168: bis (2-ethylhexyl) -1, 4-phthalate, TETM: tri-2-ethylhexyl trimellitate, ESBO: epoxidized soybean oil, DOTP: dioctyl terephthalate. Subsequent reduction of the plasticizer incorporation will result in increased rigidity of the sheet.

The formation of foamed products requires a foaming agent that creates fine pores with respect to sheets based on molded PVC. The blowing agent decomposes at the decomposition temperature to produce a large amount of gaseous reaction products. Many blowing agents for the production of foamed PVC are known and include, for example, azodicarbonamide, dinitrosopentamethylenetetramine (dinitrosopentamethylenetetramine), p-toluenesulfonyl hydrazide, and 4,4' -oxybis (benzenesulfonyl hydrazide). The preferred blowing agent is azodicarbonamide because it has a decomposition temperature of about 215 ℃ to 219 ℃. This decomposition temperature is slightly higher than the softening temperature of the PVC composition, which is generally in the range of 170 ℃ to 190 ℃. A catalyst compound such as ZnO may be used to bring the decomposition temperature of the azodicarbonamide to the softening temperature range of the PVC resin used.

The PVC particles in the range of 100 to 150 microns incorporate all additives, including plasticizers and blowing agents, and are wetted by water or isopropyl alcohol forming a slurry aided by anionic surfactants. This slurry is loaded into a mold and heated while the slurry is under pressure between two plates. The drying of the slurry promotes intimate contact of the PVC composition particles with each other due to surface tension, and at the softening point of the PVC composition, the PVC composition particles are linked together and at the same time the blowing agent decomposes and releases a large amount of gas, producing a low density PVC foam. The distribution of porosity in the molded PVC sheet is controlled by the particle size of the blowing agent and its distribution in the slurry.

The air chamber formed must be stabilized so that it remains until the polyvinyl chloride polymer is cured. Stabilizers (stables) are generally organic or inorganic compounds, for example barium/zinc stabilizers, calcium/zinc stabilizers or organotin stabilizers.

The present invention produces two types of PVC sheets. The first type still uses a homopolymer of PVC that is densified with sufficient 1, 2-cyclohexane dicarboxylic acid diisononyl ester (DINCH) plasticizer to produce a flexible product, and does not have any phthalate biohazard. The second type of PVC uses a copolymer of PVC with 2% to 30% polyvinyl chloride. Due to the enhanced flexibility of PVC compositions comprising polyvinyl acetate, a smaller amount of 1, 2-cyclohexane dicarboxylic acid diisononyl ester (DINCH) plasticizer is required.

Applications of the present invention are also contemplated for use in aerospace, including noise cancellation aerospace insulation systems. These systems include insulating materials while also uniquely providing enhanced acoustic properties to minimize cabin sounds from outside the aircraft. The subject material is ideal for use as an aircraft thermal/acoustic insulation material due to its physical properties. Both thermal and acoustic insulation are required on passenger aircraft. Historically, both functions have been provided by the same material system, which has been primarily fiberglass batting encapsulated in a plastic pillow cover covering. The cover plastic has been primarily PET (e.g., polyethylene terephthalate, commonly sold by DuPont under the trade name Mylar) and smaller amounts of polyvinyl fluoride (PVF) (commonly sold by DuPont under the trade name Tedlar), and polyimide films (commonly sold by DuPont under the trade name Kapton) have been used. Use of the material of the present invention provides the ability to replace at least some, if not all, of the materials currently used with respect to the innermost sheet, thereby increasing thermal properties while also improving acoustics in the aircraft cabin. More importantly, the use of the subject materials results in cost savings and a slight reduction in weight, which, without being bound by theory, in turn reduces fuel costs.

Typically, the thermal environment outside the aircraft generates a fuselage skin temperature (fuselage skin temperature) from about-60F when flying at flight altitude to +160F when parked in direct sunlight in a desert. The amount of insulation required for an air conditioning/heating system to economically produce a comfortable cabin temperature varies with aircraft type and location. However, apart from several places, such as the roof area on the rear passenger cabin and the lower half fuselage area below the passenger floor, acoustic requirements prevail. Thus, except where, the amount of insulation present exceeds the amount required for thermal demand.

With respect to acoustics, outside noise is generated by aerodynamics and the engine. Insulation is used to attenuate outside noise to allow a reasonable level of comfort and verbal communication within the passenger and cockpit compartments. The required acoustic attenuation varies from aircraft to aircraft, but is usually substantial, and insulating materials with very high acoustic efficiency are used to minimize the amount (weight, volume) required. The use of fiberglass batting of very small fiber diameter is a highly effective acoustic attenuator.

Currently, insulation using fiberglass batting will resist fire penetration in lower strength thermal environments. The load compartment needs to have a lining that is a fire barrier. In some cargo compartments, thermal insulation used as fuselage lining provides a fire barrier. For these areas, a bunsen lamp test is required which includes the glass fiber batting passing easily. The FAA has published information in news stories and the FFA program proposes the following requirements: the insulation is resistant to burn through (burnthrough) in a strong thermal environment such as the environment of a fuel-fed fire. All insulation systems will have to be redesigned to meet this requirement.

Thus, the novel materials of the present invention provide improved acoustical, thermal, and fire barrier functions while providing cost savings. As noted above, the practice of the material of the present invention provides the ability to replace at least some, if not all, of the fiberglass materials currently used with respect to the innermost sheet that is proximate the interior of the cabin. This increases the thermal properties while also improving the acoustics within the aircraft cabin and improving the fire resistance. This improved acoustics produces an acoustically protective spray (acoustic coating) with noise deflection properties. Any new insulation system cannot significantly exceed the weight of existing systems, which averages about 0.1 lb/sq ft. The glass batting varied from 0.34 lb/cubic foot to about 1.5 lb/cubic foot, with a lighter weight predominated. The batting thickness was about 5 inches in the top area, 3 inches along the sides, and 1 inch below the passenger floor. The covering material varies from 0.5 oz/square code to about 1.5 oz/square code, with 0.5 oz/square code and 0.9 oz/square code predominating. Resulting in cost savings and a slight reduction in weight, which, without being bound by theory, in turn reduces fuel costs.

The material of the invention not only exhibits optimal thermal, acoustic and fire-resistant properties, but also does not additionally absorb large amounts of water, does not cause or promote corrosion of the aluminium fuselage structure of the aircraft, nor is it electrically conductive or interferes with the inspection of the fuselage structure for corrosion, cracks, etc. In fact, using this material as a sheet provides easier viewing of the fuselage than the plastic bagged fiberglass (fiberglass) and other materials currently in use, while all of the materials provide cleaner, safer installations and environmentally benign properties.

The production of rigid polymeric porous materials or composites, sheets begins with a mold filled with a slurry of polyvinyl chloride-based polymeric material with plasticizers, blowing agents, and other filler ingredients mixed with an aqueous solution with an anionic surfactant or isopropanol. The slurry is compacted, the liquid portion is drained and dried, bringing the polyvinyl chloride fine particles into close contact with each other, forming a film. The contents of the mold are compressed under high applied pressure and heating temperature sufficient to soften or melt the polyvinyl chloride composition while at the same time allowing the blowing agent to decompose, releasing a large amount of gaseous decomposition products within the mold. This draining step may be unnecessary because the heating step automatically volatilizes the liquid portion of the slurry. The pressed sheet has a typical density in the range from 15% to 35% and contains fine-sized air pockets or air cells. The mold size may be any size, shape or curvature; but is typically as large as 1220mm x 2440mm and a die depth of 60 mm. Depending on the amount of slurry poured into the mold, the thickness of the resulting sheet varies. For example, 10 kilograms of slurry can produce a sheet with a thickness of 40mm (1.57 inches). If a 120mm (4.72 inch) die is used to produce an 80mm (3.15 inch) board, twice the amount (20 kg) of virgin stock is added to the die. Then, while under an applied pressure, the mold is heated. Changing the mold dimensions will change the final dimensions of the resulting sheet. In this process, there is no limitation on the size of the sheet produced, since the size of the sheet depends only on the size of the mold. The mould and top plate (top plate) may have an embossed structure which is replicated in the finished sheet product from which the decorative building material sheet is produced.

The polymer blend of the slurry for the rigid polymeric porous sheet material has one or more of PVC (polyvinyl chloride) polymer and polyvinyl acetate polymer, and in some cases is a composite sheet, and further contains wood chips and fire resistant chemicals. These polymers melt below 190 ℃.

In one embodiment, the polymeric porous sheet slurry comprises polymeric particles and additives such as fillers and fire resistant chemicals. The mold with the slurry is optionally drained of the liquid component, and the mold is heated to less than 190 ℃ while under an applied pressure. The application of pressure and heat consolidates the slurry solids content, producing a sheet that is porous with pores having small sizes, and the overall density of the sheet product is about 10% to 40% of the solid polyvinyl chloride sheet, depending on the pressure and heat applied. The presence of the closed cell air pocket enhances the heat resistance properties of the sheet material and exhibits a high R-value which is much greater than that obtainable for typical gypsum based building sheets, plywood, wood, OSB, fiberboard, particle board and similar materials. The sheet or timber produced by the process of the invention produces wall panels, wall fitting systems and other building products that provide improved warmth to an enclosure, which significantly improves the thermal efficiency of a home building (home building) or commercial building by eliminating or greatly reducing the phenomenon known as thermal bridging, which occurs in part through the phenomenon known as the framing factor (front factor). The mold may have a decorative feature that is replicated on the surface of the sheet of rigid polymeric porous material. Impermeable decorative sheets such as bakelite sheet (Formica sheet), aluminum foil, and stainless steel sheet may be used to cover the rigid polymeric porous material sheet during the molding step.

In a second embodiment, the polymer syrup mixture may be injected into a mold in a manner similar to resin transfer molding and heated to a processing temperature.

In a preferred embodiment, the rigid polymeric porous material sheet of the present invention comprises:

1) oversized dies having the length and width of a normal sheet, but typically having a height twice the thickness of the intended sheet;

2) the mould is injected with a slurry polymer mixture and discharges the liquid component of the slurry and is heated at a temperature that melts the polymer in the polymer mixture;

3) while the mold is pressurized, it is heated to a temperature below 190 ℃, which compacts the polymer mixture in the mold to a density in the range from 10% to 40%, and the closed chamber of the air pocket is present within the formed sheet;

4) the mold having a decorative marker transferred to a sheet of molded rigid polymeric porous material;

thus, the compaction of the polymer mixture forming the sheet with the enclosed air cells imparts heat resistance and sound attenuation properties to the sheet, allowing the sheet to be used in building construction as well as decorative applications.

Brief Description of Drawings

The present invention will be more fully understood and further advantages will become apparent when reference is made to the following detailed description of the preferred embodiments of the invention and the accompanying drawings, in which:

FIG. 1 illustrates process steps in making a sheet of rigid polymeric porous material;

FIG. 2 is a photomicrograph of a sheet of rigid polymeric porous material; and

FIG. 3 illustrates a heat resistance or R value measurement procedure;

FIG. 4 illustrates hardness measurements of a rigid polymeric porous sheet;

FIG. 5 illustrates a bend test measurement of a rigid polymeric porous sheet;

FIG. 6a illustrates a thermal bridge;

FIG. 6b illustrates the energy lost through the stud;

FIG. 7a illustrates a box factor concept;

FIG. 7b illustrates the box factor concept with IR images;

FIG. 8 illustrates an embodiment of the present invention in which a sheet of rigid polymeric cellular material is used in an airborne acoustic thermal insulation system; and

fig. 9 illustrates a framework structure in which the humidity expansion gap (humidity expansion gap) of 1/8 "has been eliminated.

Detailed Description

The polyvinyl chloride used in the present invention is in the form of particles of 100 to 150 microns produced by suspension polymerization or emulsion polymerization. The K-value of polyvinyl chloride homopolymer or copolymer with polyvinyl acetate has a K-value of greater than 65, which represents a molecular weight of 60,000, as shown in the graph reproduced below in PVC Plastics of 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.

FIG. 3.1 Fikenschel K value (DIN 53726-

And the molecular weight of the PVC polymer

When the plasticizer is added to a fine powder of polyvinyl chloride-based resin, the plasticizer enters the resin molecules at an atomic level, which creates a mesh between polymer chains or creates hinge positions between polymer chains, promoting polymer flexibility. Since the resulting polyvinyl chloride foam has a very thin polymer layer surrounding the air chamber, it requires a great deal of flexibility to prevent crack propagation and fracture. According to the American Commission on safety of Consumer goodshttps://www.cpsc.gov/PageFiles/ 98260/dinp.pdf，Conventional phthalate plasticizers have been identified as biohazards. Thus, the present invention uses only non-phthalate plasticizers, such as DINCH.

Blowing agents are needed to allow the formation of multiple micron sized air cells to produce a low density polyvinyl chloride polymer sheet. When the polymer composition is heated in the mold, the polymer softens at a specific temperature. If the blowing agent releases a large amount of gaseous decomposition products while the polyvinyl chloride resin is softened, a closed-cell microcellular structure is formed. Although many blowing agents are available, their decomposition temperatures do not match the softening point of the polyvinyl chloride resin, which is in the range of 170 ℃ to 190 ℃. Specifically, the azodicarbonamide foaming agent has a decomposition temperature of 215 ℃ to 219 ℃, but the decomposition temperature can be lowered using a ZnO catalyst. Using this combination, micro-cells are formed in the low density polyvinyl chloride sheet.

Another requirement for forming a microporous sheet during the foaming step is that the ultra-fine particles of polyvinyl chloride particles are required to be in contact with each other, since the amount of polyvinyl chloride in the sheet is rather small. This is accomplished by mixing the polyvinyl chloride ultra-fine particles together with additives with an anionic aqueous solution of isopropyl alcohol to form a slurry. During drying of the slurry, surface tension forces the polyvinyl chloride particles to approach each other, forming a film.

The air chamber formed must be stabilized so that it remains until the polyvinyl chloride polymer is cured. The stabilizers are usually organic or inorganic compounds, for example barium/zinc stabilizers, calcium/zinc stabilizers or organotin stabilizers.

The present invention uses two distinct low density polyvinyl chloride sheets. The first embodiment uses fine particles of polyvinyl chloride homopolymer combined with higher amounts of DINCH non-phthalate plasticizers. Typical examples of polymer slurries used in the mold are shown below.

The second example shown below uses polyvinyl chloride copolymer and uses a smaller amount of DINCH plasticizer.

The present invention relates to a moulding process for the production of sheet materials or composite materials, sheets based on rigid polymeric cellular polyvinyl chloride. The slurry of polymer powder with additives and fillers and refractory material is fed to an oversized die having a height of about twice the desired sheet thickness and a width and length close to the width and length of the desired sheet size. The liquid portion of the slurry is optionally first drained and dried, and the mold is heated to a temperature below 190 ° f as it is pressurized through a die set. The application of this pressure and temperature forms a sheet having a density in the range of from about 5% to 98%, and preferably from about 10% to about 40%, of the solid polyvinyl chloride sheet, with the enclosed air cells finely distributed within the sheet. The presence of the enclosed air chambers enhances the heat resistance of the sheet product as well as providing sound absorbing properties. The die may have a knurled finish (knurled finish) that is reproduced in the final product.

The rigid polymeric porous sheet grade product has a low density and is water impermeable. The polymer syrup mixture used comprises PVC (polyvinyl chloride) and polyvinyl acetate polymers along with wood chips and flame retardant additives, depending on the end product application. An outer sleeve sheet (outer casting sheet) may be used to cover the rigid polymeric porous sheet during the heat and pressure application steps to bond the encased sheet thereto. The rigid polymeric porous composite sheet is inherently fire resistant due to the use of PVC in the polymer infiltration composition to release chlorine and repel oxygen in the vicinity of the flame, thereby extinguishing the flame.

It is an object of the present invention to produce durable, rigid, polymeric porous sheets that can be painted and used as building materials. The process used herein is very reproducible and produces sheets with extraordinary properties. When bent 90 degrees or more, the sheet does not break and is extremely shock absorbing even if it is hard. Thus, the rigid polymeric porous sheet is well suited for wallboard, lumber, and wall assembly systems.

Rigid polymer filled foam composites are the latest building materials developed as detailed herein. The rigid polymeric porous composite sheet material is flame retardant, fire resistant, moisture resistant, corrosion resistant, termite resistant, formaldehyde free. It exhibits low smoke and is highly resistant to flame penetration. The surface of the sheet may be treated by spraying and may adhere to many kinds of materials. In combination, these characteristics have made rigid polymer filled foam composites excellent eco-green building materials.

The rigid polymeric porous sheet material may be used as a substitute for wood based boards, thereby reducing deforestation and protecting the environment. At the same time, it is waterproof, moisture-proof, sound-insulating, shock-absorbing, acid and alkali resistant, weathering resistant, flame retardant and fire-resistant. Among these aspects, rigid polymer-filled foam sheets are superior to all other building materials.

For different purposes, different kinds of materials are added to the rigid polymer-filled foam sheet:

1. for wood frame construction (wood frame construction), wall, floor and ceiling assemblies, home decoration and furniture applications, large amounts of plant fibers (e.g., wood chips, rice hulls, etc.) are added to increase stiffness and nail holding power (NAILL ABILITY);

2. for applications in automobiles, yachts and ships, aircraft and high-speed trains, and as embossing materials, insulation materials, nitrile rubber (NBR) is added to greatly improve its properties of forming, toughness and impact resistance, and to make it easier to hot-press, emboss, bend and engrave;

3. a smoke suppressant, calcium stearate powder and a flame retardant are added to increase their fire and impact resistance properties, to reduce smoke density and to make them more environmentally friendly.

4. This rigid polymeric porous sheet is clearly the latest formaldehyde-free, eco-green, fire retardant and fire retardant building material.

Characterization and use of rigid polymer-filled foam sheets

1. Due to the light weight, large density and flexibility range of the rigid polymer filled foam sheet material, the rigid body and ease of installation, it can be used as a suitable eco-green substitute for wood materials and engineered wood materials in the building materials industry, such as, but not limited to, framed wood, plywood, particle board, oriented strand board type a (OSB), oriented strand board type B, oriented strand board type C, Medium Density Fiberboard (MDF), High Density Fiberboard (HDF), laminated wood (plywood laminate), Laminated Veneer Lumber (LVL), hardwood, cross-laminated wood (CLT), structural composite wood (SCL), laminated wood shavings (LSL), parallel wood shavings (PSL)610, wood (Timber), finger joint wood, high density veneered plywood, and medium density veneered plywood (HDO and MDO). In such applications, for example, but not limited to, subfloors, flooring, wall and roof panels, ceiling and deck cladding, lumber, rafters, studs, purlins, headers, garage door headers, door stoppers (door jam), doors, roof molding (crown molding), batten molding (batten molding), border board (rim board), studs, columns, concrete forming, siding (siding), sandwich decks and furniture; furthermore, in the transportation industry, for example, as aeronautical thermoacoustic insulation systems for aircraft, as roof, body and core layers for ships, cars, trucks and trains. Many kinds of materials can easily adhere to their surfaces.

2. Due to its good fire and self-extinguishing properties, the rigid polymer filled foam sheet can be used as a fire door, fire door filler core, I-Joist (I Joist) (web and flange), roof truss, ridge beam, floor beam, wood, sheeting (sheathboarding), steam bathroom wood (sauna timeber), flooring and furniture for home use, as well as in commercial buildings, hotels and other public areas. It can also be used in framing structures and as a main body of archaized buildings and temples.

3. Due to its good water and moisture resistance, the rigid polymer-filled foam sheet can be made into kitchen cabinets, bathroom fixtures, counter tops (counter tops) and bathroom trim. Rigid polymer-filled foam sheets are also a good choice for outdoor engineering, beach facilities, road and bridge engineering and for panels for construction engineering.

4. Due to its good corrosion and termite resistance properties, rigid polymer filled foam sheets are a good choice for industrial corrosion protection projects, industrial containers, industrial storage tanks, highway panels (highway panels) and antique building repair projects. Due to its high R-value and water-repellent properties, rigid polymer-filled foam sheets are also a good choice as flooring or sub-flooring for domestic use, siding, wall assembly systems and roofing.

5. Since the surface of the rigid polymer filled foam sheet can be prior to spray treatment, and due to its very low heat transfer and good thermal insulation, it can be used in walk-in/free-standing coolers, cold storage insulation panels, refrigerated van truck bodies, refrigerated semi-trailer tractor trailers, freezer boxes, and as interior and exterior walls for hotels and other buildings.

6. Due to its excellent insulating and flexible properties, the rigid polymer-filled foam sheet can be used as thermal insulation lumber (thermal insulation member), a thermal insulation sheet, a thermal insulation board, a structural insulation panel, a brick or stone insulation panel, an external insulation block, as a main body of electric appliances, a main body of an outdoor transformer, and a circuit insulation board, etc.

7. The rigid polymer-filled foam sheet is produced by first hot pressing followed by cold pressing, and it is easily engraved; and are therefore well suited for use in melamine boards, melamine floors, melamine cabinet boards, multi-board laminates (polyboard laminates), cabinets, wall and ceiling trim, embossed wall and ceiling trim, ceiling tiles, ceiling domes, fabric sound absorbing sheet panels (cloth corrugated), fabric sound insulating hard pack sound absorbing sheets (cloth corrugated sound absorbing sheets), advertising boards, office furniture, entertainment centers, embossed leather boards for television wall backlighting screens, and hospital furniture.

Fig. 1 illustrates, generally at 100, the process steps involved in the production of a rigid polymer-filled foam sheet. The polyurethane or rubber foam has a plurality of cells that will be filled with polymer during the process, as described below, resulting in a rigid polymer-filled foam sheet. In a first step, the foam is cut into a shape according to the desired product size. In a second step, a mixture of polymers comprising one or more of ABS (acrylonitrile butadiene styrene) polymer, PMMA (polymethyl methacrylate) polymer and PVC (polyvinyl chloride) polymer is mixed with a solvent to produce a slurry. Additional ingredients may include wood chips, refractory 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 the die of a heating and pressing machine. Any solvent, if present, is rapidly evaporated. ABS melts at about 105 ℃, PMMA melts at about 165 ℃, and PVC melts at about 160 ℃. When the mold is heated to a temperature below 170 ℃, all of the polymer components are softened. Thus, during heating, the polymer syrup composition densifies into a porous sheet structure. When densification is complete after a selected processing time, the sheet of rigid polymeric porous material may be removed from the mold.

PVC has a high amount of chlorine, and when the rigid polymer-filled foam sheet is exposed to a flame, the degradation of PVC releases a high amount of chlorine that extinguishes the flame and thereby provides the rigid polymer-filled foam sheet with fire resistant properties.

Figure 2 illustrates a photomicrograph of a sheet of rigid polymeric porous material, generally at 200. Millimeter marks are shown in this figure. The separate air chamber of the porous polymer sheet is clearly seen. This sample was sample a, which had dimensions of 25cm length, 13cm width and 1.2cm thickness, and a volume of 390cc and weighed 77 grams. Thus, the density of this sample A was 0.197 gm/cc.

FIG. 3 illustrates a method for measuring thermal conductivity of a sheet material generally at 300. The subject sheet material can be made to different hardnesses for different industries, and different industrial end uses and applications. The formulation can be tailored to suit almost any industrial application or end use. Heat flow meter testing according to ASTM C518 was performed on.145 gm/cc and.165 gm/cc density samples of varying thickness, yielding R values (see below). Cell 301 and cell 302 were maintained at different temperatures and heat flows were measured.

Results of ASTM data

The samples of the present invention were found to have R-value per inch insulation properties superior to glass fibers. In addition, it also exhibits vastly different material properties and attributes.^*Test results ASTM C518-10 (supra)

The measured thermal properties and R-values of the different thickness samples are shown as a basis for comparison compared to other commonly available building materials.

R value comparison of the present invention with respect to common building materials having the same thickness

In all cases, the sheets of the present invention provide better R values than any of the commercially available building materials. The sheets of the invention are also fire-resistant, water-resistant (water absorption 0.81%), termite-resistant, sound-insulating, acid-resistant and are ecological green building materials of the next generation of state of the art containing 100% formaldehyde-free components.

The sound/acoustic properties are stated below:

acoustic performance test report: densities of.145 gm/cc and.165 gm/cc

Tube diameter: 57mm

Impedance tube testing was performed on density.145 gm/cc and.165 gm/cc samples. Three test specimens were provided for each test. The test method was performed according to ASTM E1050-12 using standard test methods for impedance and absorption of acoustic materials for pipes, two microphones and digital frequency analysis systems. The instrumentation used is set out below.

The instrument comprises the following steps:

note: the calibration frequency of the instrument is according to the manufacturer's recommendations every two years

Signal processing parameters

Frequency resolution	1600 lines
		Span of frequencies	3200 Hz
Type of averaging	RMS
		Mean number of	25
Window function	Hanning window
		Overlap	66.70％

N/A-not applicable

Each sample was mounted flush with the open end of the sample holder. Any gap that exists between the sample and the holder is sealed with petroleum jelly. The retainer is mounted to the open end of the impedance tube. Random noise was generated in the tube and 50 measurements were taken and averaged. Air temperature conditions, relative humidity conditions, and barometric pressure conditions were monitored and recorded during the test measurements. The results of the samples are averaged. R/pc, x/pc, gpc, bpc and normal incidence sound absorption coefficients were calculated.

Density 145 gm/cc:

sample(s)	Description of the invention	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 165 gm/cc:

sample(s)	Description of the invention	Thickness (cm)	Weight (g)
				A	Foam board	2.013	24.012
B	Foam board	2.019	24.591
				C	Foam board	2.019	24.560

Density 145 gm/cc:

N/A indicates that the frequency is not applicable for the corresponding tube diameter

Density 165gm/cc

N/A indicates that the frequency is not applicable for the corresponding tube diameter

The physical properties of the samples were determined as set forth below for the 145gm/cc density:

the subject foaming board can be manufactured in standard building board sizes, as well as any standard wood size specification. For example, molds and machines that form blister boards are generally available in standard sizes of 1220mm by 2440mm (48 inches by 96 inches). The variable is therefore the thickness of the die, which in turn produces slabs (slab) of different thickness. After the finished slab has been removed from the die, the board may be cut to building board size or timber size, as desired and applied.

FIG. 4 illustrates at 400 hardness measurements of a rigid polymeric porous sheet having a density of.145 gm/cc according to ASTM C36. The figure shows the test setup and indentation. Hardness testing was performed on five 4 inch by 4 inch samples. An Instron Universal testing machine (ICN: 005741) was used to apply a compressive load to each sample at a rate of 0.10in/min through a 2 inch diameter ball until a sample penetration of 0.250 inch was produced.

Hardness results

145 g/cc Density	Thickness (inch)	Hardness (lbf)
			Mean value of	0.7542	281

ASTM C367-transverse strength testing was performed. Five 3 inch by 14 inch by 0.750 inch samples having a density of.145 grams/cc were cut in the machine direction from the submitted panel, and five more in the cross direction. The test specimen dimensions were measured using a 12 inch (x 0.001 inch) digital caliper (ICN: 004722). The samples were mounted in an Instron model 3369 Universal testing machine (ICN: 005740) using a three-point bending load setup. The test specimens were supported at 12 inch spans. The diameter of the loading nose and support rod is 1.25 inches. The sample was loaded at a rate of 0.50in/min until peak load was achieved or a deflection of 3.5 inches was reached. As illustrated by fig. 5, the sample exhibited excellent flexibility exceeding 110 °. During the loading process, the mid-span deflection is continuously recorded using the crosshead motion of the test machine.

Transverse strength results

ASTM C367-performs brittleness tests. Twelve 1 inch by 0.750 inch samples were weighed using a Mettler Toledo analytical balance (ICN: 003449) and placed in an oak crisper drum (oak free drum) along with twenty-four 3/4 "oak cubes. The drum was closed to prevent ejection of the test material and the drum was rotated about its axis at a rate of 60rpm for 10 minutes. The sample set was then removed from the drum and weighed for mass loss. They are then reinserted into the drum, the previous pieces are not removed, and the mechanism is operated for an additional 10 minutes. At the end of the second 10 minutes, the sample was removed and re-weighed, resulting in a final mass loss.

Results of brittleness test

Fig. 5 illustrates at 500 the bending of a rigid polymeric porous sheet. The sample was bent upside down (reversible) to 110 ° without cracks. It represents the only building panel for drywall or wall assembly sheeting that can be flexed to an angle in excess of 120 degrees and then returned to its original shape without any cracking, breaking or external cracking of its appearance or rigidity.

The other test sample, labeled sample B, had dimensions of 25cm length, 15cm width, and 2cm thickness, and a volume of 750cc and weighed 275 grams. Thus, the density of this sample B was 0.367 gm/cc. A third sample, sample C, had dimensions of 24.5cm length, 12cm width, and 0.5cm thickness, and a volume of 147cc and weighed 275 grams. Thus, the density of this sample C was 0.558 gm/cc. Clearly, the rigid polymeric porous sheet manufacturing 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. Furthermore, the presence of the decorative structure on the sheet increases both the stiffness and the density of the formed sheet.

Wall assembly systemThe foam board composite wall assembly system and foam board related products of the present invention eliminate or greatly reduce the "heat bridge" and "framing factor" of the wall assembly and achieve an 114.33% R value increase (using the 25% framing factor of the California Energy Commission (California Energy Commission)) throughout the wall assembly system and building envelope, resulting in a thermal break zone (thermal break) and a uniform increase in heat resistance.

The hot bridge, also called cold bridge, is the path of unwanted heat flow that bypasses the main insulation of the enclosure. Thermal bridges are the basis for heat transfer, in which the penetration of an insulating layer by a highly conductive or non-insulating material takes place at the separation between the internal environment (or conditioned space) and the external environment of a building assembly (also known as a building envelope, building envelope or thermal envelope). Placing a good conductor parallel to a good insulation is often referred to as a "thermal bridge" because it provides a path for heat flow that bypasses the primary insulation.

Energy losses within the building envelope occur through two types of force conduction (force con-duction) and convection. Conduction is the transfer of heat through solid materials that insulation is designed to prevent and accounts for 60% of the heat or cooling loss in an ordinary household (average home). Convection is the transfer of air through gaps in the walls and roofs of the home. Leakage of outside air into the home or infiltration of air is a cause of 40% of heat or cooling loss in ordinary homes.

Wood framed households rely on space timbers called studs at regular intervals to provide structural support. Wood is a very poor insulator and forms a thermal bridge from outside to inside the home through which heat can be conducted. Door frames, steel studs and wooden or metal window frames are also common thermal bridges.

Insulation around the thermal bridge is of little help in preventing heat loss or gain due to the thermal bridge; the bridging must be eliminated, modified with a reduced cross section or with a material with better insulating properties, or with a length of material with low thermal conductivity installed between the metal parts, to block the passage of heat through the wall or window assembly, known as a thermal discontinuity.

Fig. 6a and 6b illustrate thermal bridging and energy loss through the stud. Fig. 7a and 7b illustrate the box factor concept.

The foam board composite wall assembly system and foam board related products comprising the material of the present invention create thermal discontinuities in the thermal bridges that occur in the wall assembly of a building envelope, resulting in 114.33% increase in the R-value of the wall assembly system and the building envelope. (see wall mount R values below).

Calculating wall assembly R value^*(Standard 2X4 wall Assembly)

^*This example is only for wood frame construction. Steel studs are a more complex calculation

Formula (II): set R value 1/(set U-value) 1/(U-stud x% + U-cavity x%)

(California department of energy 25% frame factor)

^*The foamed panel wall assembly system using the material of the present invention resulted in an increase in the total wall assembly R-value from 12.07 to 25.87, which is an increase of 114.33%.

The present blistered panel composite wall assembly system and blistered panel related products eliminate or reduce thermal bridges and framing factors in a building envelope to measurable, insignificant fractions by applying their composite materials with superior industry-leading R-values to achieve uniform heat resistance throughout the entire wall assembly system.

The term "framing factor" is used broadly to refer to the percentage of the total wall area occupied by the frame members. The extent to which the frame of a wall, roof or floor reduces its insulating R-value is referred to as its "framing factor". It is simply the percentage reduction in R-value when a thermal bridge occurs and heat flow is generated by conduction through the wooden or steel frames of the enclosure. The more frame members in a wall structure, the higher the framing factor. Steel stud assemblies typically have framing factors of 50% and above, while wooden frames are typically closer to 25%. For example, a wall with R-20 insulation and a framing factor of 25% would have a total insulation value of R-15.

According to the 2002 report, framing factors of up to 27% of the residential walls in california in 2001 can be found. In 2003, ASHRAE studies found an average of 25% framing factors for U.S. households. The results of these studies demonstrate significant sensitivity to framing factor and insulation defects in certain configurations of residential walls.

Consistent with the Energy modal engineering report of the california Energy commission (Energy modular engineering report), all wall components in this report have a framing factor of about 27% (1). It is well known that the presence of frame members, such as wood profiles or steel profiles, reduces the R-value of a wall system. The measure of this effect is called the boxed factor coefficient "F" for the wall, which is calculated using the following simple expression containing the clear wall R-Value (clear-wall R-Value) Rcw and the cavity center R-Value (center-of-cavity R-Value) Rn: f ═[1-Rcw/Rn]^*100。

The density of the present invention 145gm/cc is the only building panel that can be flexed to an angle in excess of 130 degrees and then returned to its original shape without any cracking, breaking or external cracking of its appearance or rigidity. (.145gm/cc density) certain concrete flexible cement panels are available on the market. However, flexible cement boards can only flex about 20 degrees and are not thermal insulators. The foam board of the present invention is a leading insulator with a variety of applications and incomparable flexibility in the building materials industry.

Eagle-type American Framing System (Eagle America Framing System)) Common wood and engineered wood are particularly prone to moisture-induced water uptake, which results in wrinkling (Buckling), Crowning (curling) and Cupping (Cupping) of panels and floors when no moisture-expanded space is allocated. Light-frame construction (light-frame construction) using "platform frame" and standardized space timber has become the main construction method in north america. Such light frame structures are typically derived from hard facing sheets of plywood and other plywood-like composites such as Oriented Strand Board (OSB). However, due to the moisture swelling properties of common and engineered woods, when installing subfloors, floors, walls, ceilings, and roofs in a frame structure, "1/8 for wood swelling" installation clearance margin "must be inserted between the panels.

The invention was conditioned at 32 ℃ and 90% relative humidity for 17 hours according to ASTM C367 humidity test at a density of 145.28kg/m3 and then a 6 hour "wet" recovery period at 23 ℃ and 50% relative humidity. Resulting in a deflection of 0.033 per inch at 90% humidity and a recovery of 0.037 per inch when reduced to 50% relative humidity.

The minimum water absorption of the present invention is directly opposite to common and engineered wood building material properties (directoposition) and eliminates the "1/8" installation gap allowance between panels for wood swelling when installing subfloors, floors, walls, ceilings and roofs in a frame structure and eliminates the ensuing building disadvantages associated with moisture expansion.

The elimination of the "1/8" gap creates a completely new approach to the frame structure and is known as the "eagle-style U.S. framing system".

The eagle-style U.S. framing system of the present invention distinguishes itself from common building materials and standard "platform" frame structures by eliminating the 1/8 "clearance margin for wood swelling. When assembled in accordance with the present invention, the panels may butt flush against each other, which increases overall structural stability. Furthermore, due to (i) the elimination of 1/8 "gaps, and (ii) the increased thermal insulation properties of the present invention in sheet or wood form relative to common wood building materials and wood related building materials, the system effectively seals the structure from moisture, air infiltration, and natural ventilation, eliminates pest pathways, increases the overall strength of the frame structure, and eliminates or reduces energy loss from the thermal bridge to a measurably insignificant fraction.

Having thus described the invention with 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.

Claims (30)

1. A rigid polyvinyl chloride-based polymeric porous material sheet comprising:

a) a polymer mixture slurry of a composition of ultra-fine particles based on polyvinyl chloride, a non-phthalate plasticizer, a foaming agent having a decomposition temperature very close to the softening point of the ultra-fine particles of polyvinyl chloride, a thermal stabilizer, and the slurry is fed to a die having a height of about twice the desired thickness of the resulting sheet;

b) the mold is non-decorative or has a decorative structure;

c) the mold is heated and subjected to high pressure to allow compaction of the polymer mixture slurry into a rigid polyvinyl chloride-based polymeric porous sheet having about 0.16 to 0.66 g/cc or 10 to 40% solid PVC;

d) removing the rigid polymeric porous sheet from the mold;

thus, the compaction of the polymer mixture slurry produces a rigid polymeric porous sheet with enclosed air chambers that provides enhanced heat resistance and sound attenuation properties for use in building construction, aerospace or other industries, and decorative applications.

2. The rigid polyvinyl chloride-based polymeric porous material sheet according to claim 1, wherein the polyvinyl chloride-based ultrafine particle composition comprises polyvinyl acetate in an amount ranging from 2% to 30%.

3. The rigid polyvinyl chloride-based polymer porous material sheet according to claim 1, wherein the non-phthalate plasticizer is 1, 2-cyclohexane dicarboxylic acid diisononyl ester (DINCH).

4. The rigid polyvinyl chloride-based polymeric porous material sheet according to claim 1, wherein the foaming agent is azodicarbonamide.

5. The rigid polyvinyl chloride-based polymeric porous material sheet according to claim 1, wherein the slurry has propanol wetting the ultrafine particles.

6. The rigid polyvinyl chloride-based polymeric porous material sheet according to claim 1, wherein the slurry has an anionic surfactant in an aqueous medium that wets the ultrafine particles.

7. The rigid polyvinyl chloride-based polymeric porous material sheet according to claim 1, wherein the polymeric mixture further comprises wood chips and fire resistant chemicals.

8. The rigid polyvinyl chloride-based polymeric porous material sheet according to claim 3, wherein the fire resistant chemical is calcium silicate.

9. The rigid polyvinyl chloride-based polymer cellular material sheet according to claim 1, which is suitable for use as a wallboard, sheathing, interior finishing panel, subfloor, floor, wall and roof panel, ceiling and deck covering, lumber, rafters, exterior wall studs, purlins, header beams, ridge beams, floor beams, garage door header beams, i-beams (webs and flanges), roof trusses, door obstructions, doors, roof trim lines, batten trim lines, deckle boards, studs, columns, concrete forms, siding, steam bathroom lumber, furniture, office furniture, entertainment centers, sandwich decks, melamine panels, melamine flooring, melamine cabinet panels, multi-panel laminates, cabinets, furniture, tiles, ceiling domes, fabric veneer soft package sound absorbers, due to the increased thermal insulation properties and bending properties of the sheet Fabric veneer sound insulating hardpack sound absorbing panels, wall and ceiling trim panels, embossed wall and ceiling trim panels, bathroom fixtures, counter tops, fire door filler cores, embossed leather panels for television wall backlighting screens, marine and marine applications, automotive and train applications, industrial containers, industrial storage tanks, refrigerated van truck bodies, refrigerated tractor trailers, aerospace thermoacoustic insulation systems, framing structures, and for wall assembly systems.

10. The rigid polyvinyl chloride-based polymer cellular material sheet according to claim 1, which is suitable for use as flooring, thermal insulation lumber, thermal insulation sheet, thermal insulation board, tile or stone insulation panel, exterior insulation block, structural insulation panel, walk-in/free-standing cooler, cold storage insulation board, and siding due to the increased thermal insulation properties of the sheet.

11. The rigid polyvinyl chloride-based polymeric cellular material sheet of claim 1, which is suitable for use as a building panel or lumber due to the increased strength, bending ability and thermal insulation properties of the sheet.

12. The rigid polyvinyl chloride-based polymeric cellular material sheet of claim 1, suitable for use as doors, highway panels, and frames for windows and doors due to the increased strength, bendability, paintability, and thermal insulation properties of the sheet.

13. A method for forming a rigid polyvinyl chloride based polymeric porous material sheet comprising the steps of:

a) selecting a mold having the same length and width as the desired sheet, but having a height of twice the desired thickness of the rigid polymeric porous sheet;

b) feeding a polymer syrup mixture to the mold, the polymer syrup mixture comprising ultrafine particles of polyvinyl chloride wetted by a solution that causes the ultrafine particles of polyvinyl chloride to contact by surface tension, a plasticizer, a foaming agent, and a heat stabilizer;

c) heating the mold at less than 190 ℃ under pressure whereby the polymer slurry mixture is compacted to form a rigid polymeric porous sheet having a density in the range of from about 85% to about 98%; and

d) removing the rigid polymeric porous sheet from the mold;

the presence of the closed air cells in the rigid polymeric porous sheet thereby provides enhanced thermal insulation properties and sound attenuation properties.

14. A method of forming a rigid polymeric porous material sheet according to claim 9, wherein said polymer slurry is dried after being fed to said mold and prior to the application of heat and pressure.

15. A wall assembly system comprising the sheet of rigid polymeric cellular material of claim 1.

16. A wall assembly system comprising the rigid polymeric porous wood formed by the method of claim 9.

17. A wall assembly system comprising the sheet of rigid polymeric porous material of claim 1, wherein said sheet has a thickness ranging between 1/2 "-11/2" and an R-value ranging between 1.96 and 6.05.

18. A framing system in which all of the sheathing, ceiling, roof and floor sheets are flush butted against one another, eliminating the need for 1/8 "expansion gap allowance for moisture swelling.

19. A wall assembly system comprising the sheet of rigid polymeric cellular material of claim 1, wherein the sheet is used in an airborne acoustic thermal insulation system.

20. A wall system comprising a sheet of rigid polymeric cellular material, the wall system comprising:

a) a polymer mixture slurry of polymer platelets and additives fed to a die having a height of about twice the desired thickness of the resulting sheet;

b) the mold is non-decorative or has a decorative structure;

c) the mold is heated and subjected to high pressure to allow the polymer mixture slurry to compact into a rigid polymeric porous sheet having about 10% to 40% solid PVC;

d) removing the rigid polymeric porous sheet from the mold;

whereby said compaction of said polymer mixture produces a rigid polymeric porous sheet with enclosed air chambers that provides enhanced heat resistance and sound attenuation properties for forming said wall system and having applications for building construction, aeronautics, and decorative applications.

21. The wall system of claim 20, wherein the sheet material has a high deflection range.

22. The wall system of claim 20, wherein the sheet is capable of flexing at an angle in excess of 130 degrees without any cracking, breaking or external cracking in its appearance or rigidity.

23. The wall system of claim 20, wherein the sheet has a thickness ranging between 1/2 "-11/2" and an R-value ranging between 1.96 and 6.05 ".

24. The wall system of claim 20, wherein the sheet has an acoustic absorption in a range from 0.03-0.17(250Hz-2000 Hz).

25. The wall system of claim 20, wherein the sheet is fire resistant.

26. The wall system of claim 20, wherein the sheet is alkali resistant.

27. The wall system of claim 20, wherein the sheet is pest resistant.

28. The wall system of claim 20, wherein the sheet has a water absorption of less than 1%.

29. The wall system of claim 20, wherein the sheet exhibits a density variation of 5% to 98% of a solid polyvinyl chloride sheet.

30. The wall system of claim 20, wherein the sheet material is a suitable eco-green substitute for wood building materials, engineered wood building materials, and wood-related products including framed wood, plywood, particle board, oriented strand board a (OSB), oriented strand board B, oriented strand board C, Medium Density Fiberboard (MDF), High Density Fiberboard (HDF), plywood laminated wood (plywood laminate), veneer laminated wood (LVL), hardwood, cross laminated wood (CLT), structural composite wood (SCL), laminated wood shavings (LSL), parallel wood shavings (PSL), lumber, finger joint lumber, high and medium density veneers (HDO and MDO).