Claims
- 1. An improved method for forming a composite wall comprising a thermal insulation board disposed between concrete layers, the method comprising:setting into place spaced-apart rigid forms to define a thickness for the composite wall and circumscribe a cavity; setting into place a thermal insulation foam panel, the panel having opposed, spaced-apart and generally parallel primary surfaces, the foam board being placed within the cavity and between the forms so as to define two subcavities, each subcavity being defined by a form and a proximate primary surface of the thermal insulation foam panel; and filling the subcavities with concrete and thereafter curing the concrete which fills the cavities to form the concrete layers of the composite wall; wherein the improvement comprises adhering, a thermoplastic facer film to each of the primary surfaces of the foam panel to form a foam board, each thermoplastic facer having a thickness of from 0.35 mils (10 micrometers) to 10 mils (250 micrometers), an ultimate elongation of less than 200% in both machine and transverse directions, a yield strength of at least 7,000 pounds per square inch (48,400 kPa) in both machine and transverse directions, and a 1 percent secant modulus of at least 200,000 pounds per square inch (1,380 megapascals), adhesion between the facer films and the foam panel being sufficient to provide a peel strength of at least 100 grams per inch (39.4 gm/cm).
- 2. The method of claim 1, wherein peel strength between the facer films and the panel is at least 250 grams per inch (98.5 gm/cm).
- 3. The method of claim 1, wherein the panel is an extruded polystyrene foam panel.
- 4. The method of claim 1, wherein the facer films are polypropylene films.
- 5. The method of claim 1, wherein the facer film thickness is from 0.5 mils (13 micrometers) to 2 mils (50 micrometers).
- 6. The method of claim 1, wherein the facer film yield strength is at least 10,000 pounds per square inch (69,000 kPa) in both machine and transverse directions.
- 7. The method of claim 1, wherein the facer films are adhered to the foam panel by means of an adhesive layer.
- 8. The method of claim 1, wherein the facer film thickness is from 0.5 mils (13 micrometers) to 2 mils (50 micrometers), peel strength between the facer films and the panel is at least 250 grams per inch (98.5 gm/cm), the facer film yield strength is at least 10,000 pounds per square inch (69,000 kPa) in both machine and transverse directions, and the facer films are adhered to the foam panel by means of adhesive layers.
- 9. A composite wall comprising:a thermal insulation foam board disposed between concrete layers, the thermal insulation foam board comprising a panel of a plastic foam material, the foam panel having opposite primary surfaces, a first thermoplastic facer film adhered to one of the opposite primary surfaces of the foam panel and a second thermoplastic facer film adhered to the other of the opposite primary surfaces of the foam panel, wherein the first thermoplastic facer film and the second thermoplastic facer film each have a thickness of 0.35 mils (10 micrometers) to 10 mils (25 micrometers), an ultimate elongation of less than 200% in both machine and transverse directions, a yield tensile strength of at least 7,000 pounds per square inch (48,400 kPa) in both machine and transverse directions, and a 1 percent secant modulus of at least 200,000 pounds per square inch (1,380 megapascals), and wherein the adhesion between the facer films and the panel provides a peel strength of at least 100 grams per inch (39.4 gm/cm).
- 10. The composite wall of claim 9 in which the peel strength between the facer films and the panel is at least 250 grams per inch (98.5 gm/cm).
- 11. The composite wall of claim 9, wherein the panel is of extruded polystyrene foam.
- 12. The composite wall of claim 9, wherein the facer films are polypropylene films.
- 13. The composite wall of claim 9, wherein the facer film is from about 0.5 mils (13 micrometers) to about 3 mils (75 micrometers) thick.
- 14. The composite wall of claim 9, wherein the panel is of extruded polystyrene foam.
- 15. The composite wall of claim 9, wherein the facer film has a yield strength of at least 10,000 pounds per square inch (69,000 kPa) in both machine and transverse directions.
- 16. The composite wall of claim 9, wherein the facer films are adhered to the panel by means of adhesive layers.
- 17. The composite wall of claim 9, wherein the facer film is from 0.5 mils (13 micrometers) to 3 mils (75 micrometers) thick, the peel strength between the facer films and the panel is at least 250 grams per inch (98.5 gm/cm), the facer films have a yield strength of at least 10,000 per square inch (69,000 kPa) in both machine and transverse directions, and the facer films are adhered to the panel by means of adhesive layers.
Parent Case Info
This application claim benefit to Provisional Application No. 60/132,081 Apr. 30, 1999.
US Referenced Citations (7)
Foreign Referenced Citations (2)
Number |
Date |
Country |
2018875 |
Oct 1979 |
GB |
WO 9718360 |
May 1997 |
WO |
Non-Patent Literature Citations (2)
Entry |
Plastic Foams, Part II; Frisch et al, pp. 544-585, Marcel Dekker, Inc., 1973. |
Plastic Materials, Brydson, 5th edition, pp. 426-429, Butterworths, 1989. |
Provisional Applications (1)
|
Number |
Date |
Country |
|
60/132081 |
Apr 1999 |
US |