US 12,168,338 B2
Extruded polystyrene boardstock and roof structure containing the extruded polystyrene boardstock
Joseph Rofrano, Wilmington, DE (US); Valentina Woodcraft, Midland, MI (US); Brian Deshano, Midland, MI (US); and Mark Barger, Midland, MI (US)
Assigned to DDP SPECIALTY ELECTRONIC MATERIALS US, LLC, Wilmington, DE (US); and DUPONT SAFETY & CONSTRUCTION, INC., Wilmington, DE (US)
Filed by DDP SPECIALTY ELECTRONIC MATERIALS US, LLC, Wilmington, DE (US); and DUPONT SAFETY & CONSTRUCTION, INC., Wilmington, DE (US)
Filed on Jun. 16, 2022, as Appl. No. 17/842,213.
Claims priority of provisional application 63/352,687, filed on Jun. 16, 2022.
Claims priority of provisional application 63/214,303, filed on Jun. 24, 2021.
Prior Publication US 2023/0405979 A1, Dec. 21, 2023
Int. Cl. B32B 27/06 (2006.01); B32B 5/18 (2006.01); B32B 7/12 (2006.01); B32B 27/08 (2006.01); B32B 27/20 (2006.01); B32B 27/30 (2006.01); B32B 27/32 (2006.01)
CPC B32B 27/065 (2013.01) [B32B 5/18 (2013.01); B32B 27/08 (2013.01); B32B 27/20 (2013.01); B32B 27/306 (2013.01); B32B 27/32 (2013.01); B32B 7/12 (2013.01); B32B 2250/40 (2013.01); B32B 2262/106 (2013.01); B32B 2266/0228 (2013.01); B32B 2307/41 (2013.01); B32B 2307/416 (2013.01); B32B 2307/5825 (2013.01); B32B 2307/7244 (2013.01); B32B 2307/7246 (2013.01); B32B 2419/06 (2013.01)] 14 Claims
OG exemplary drawing
 
1. A polymer foam insulation board comprising a foamed polymer layer that includes one or more organic polymers, the organic polymers comprising at least 70% by weight of one or more alkenyl-aromatic polymers, the foamed polymer layer having opposing first and second major surfaces and a thickness orthogonal to the opposing major surfaces; a first facer sealingly bonded to the first major surface to form a first outer surface and a second facer sealingly bonded to the second major surface to form a second outer surface, wherein:
the foamed polymer layer has a foam density of at most 56 kg/m3 (3.5 pounds per cubic foot), a thickness of at least 0.6 cm (0.25 inches), an RSI-value of at least 0.95 K·m2/W per 25.4 mm of thickness (R-value of 5.11° F.·ft2·h/BTU/inch of thickness), and contains at least 0.25 weight percent, based on the weight of the foamed polymer layer, of an infrared radiation attenuating additive;
wherein the infrared radiation attenuating additive is one or more of graphite; carbon black; soot; a carbonized fiber, flake, or powder; carbon nanotubes, fullerenes, graphene, graphene oxide, or graphite nanoplatelets,
wherein each of said first and second facers is constituted by layers comprising films assembled into a multilayer structure, each of said first and second facers having a thickness of 19.05 to 63.5 μm,
the layers comprising, in order from the foamed polymer layer to an outermost surface of the polymer foam insulation board, an interior moisture barrier layer facing the foamed polymer layer, a tie-layer comprising polyolefin, an oxygen barrier polymer layer, a tie-layer comprising polyolefin, and an exterior moisture barrier layer, wherein the interior moisture barrier layer comprises ethylene-vinyl acetate polymer and the exterior moisture barrier layer comprises polyethylene;
wherein each interior moisture barrier layer has a thickness of 2.54 to 12.7 μm,
wherein each exterior moisture barrier layer has a thickness of 2.54 to 12.7 μm and further comprises a reflective filler, wherein the reflective filler, by itself, reflects at least 80% of incident visible light,
wherein each of the first and second facer has an opacity of at least 65%, an oxygen transfer rate of at most 0.65 cc/m2-day, an oxygen permeation rate of at most 0.9 cc-mil/m2-day, and an Elmendorf tear strength of at least 120 g/25.4 μm in at least one direction;
and
wherein each of the first outer surface and the second outer surface exhibits a surface solar reflectance of at least 35% as measured according to ASTM C1549.