Shingle tear strength with fiber mixture of different fibers

• US 20040166751A1
• Filed: 02/26/2004
• Published: 08/26/2004
• Est. Priority Date: 01/18/2000
• Status: Active Grant

• Current Assignee: Building Materials Corporation Of America
• Original Assignee: Building Materials Investment Corporation (Standard Industries, Inc.)
• Inventors: Roberts, Betty C., Srinivasan, Krishna, Peng, Qinyun, Bittle, Bill, McAteer, Mark
• Granted Patent: US 6,851,240 B2
• Time in Patent Office: Days
• US Class Current: 442/59
• CPC Class Codes: B32B 17/067 of fibres or filaments
• CPC Class Codes: C03C 25/26 Macromolecular compounds or prepolymers
• CPC Class Codes: C08L 2666/72 Fillers; Inorganic pigments; Reinforcing additives
• CPC Class Codes: C08L 95/00 Compositions of bituminous materials, e.g. asphalt, tar, pitch
• CPC Class Codes: D04H 1/4218 Glass fibres
• CPC Class Codes: D04H 1/587 characterised by the bonding agents used
• CPC Class Codes: D04H 1/64 the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• CPC Class Codes: D06N 3/128 with silicon polymers
• CPC Class Codes: D06N 5/00 Roofing materials comprising a fibrous web coated with bitumen or another polymer, e.g. pitch compositions of bituminous materials C08L95/00, roof covering E04D5/00, roofing underlays E04D12/002
• CPC Class Codes: D21H 13/40 vitreous, e.g. mineral wool, glass fibres
• CPC Class Codes: D21H 17/49 with compounds containing hydrogen bound to nitrogen
• CPC Class Codes: D21H 17/59 obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon
• CPC Class Codes: E04D 5/02 of materials impregnated with sealing substances, e.g. roofing felt
• CPC Class Codes: Y10T 428/1362 Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
• CPC Class Codes: Y10T 428/141 Bituminous
• CPC Class Codes: Y10T 428/1414 Ceramic, glass, glasslike, vitreous
• CPC Class Codes: Y10T 428/15 Sheet, web, or layer weakened to permit separation through thickness
• CPC Class Codes: Y10T 428/166 Glass, ceramic, or metal sections [e.g., floor or wall tile, etc.]
• CPC Class Codes: Y10T 428/237 Noninterengaged fibered material encased [e.g., mat, batt, etc.]
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/24364 : with transparent or protective coating
• CPC Class Codes: Y10T 428/24372 : Particulate matter
• CPC Class Codes: Y10T 428/2438 : Coated
• CPC Class Codes: Y10T 428/24388 : Silicon containing coating
• CPC Class Codes: Y10T 428/24405 : Polymer or resin [e.g., natural or synthetic rubber, etc.]
• CPC Class Codes: Y10T 428/24421 : Silicon containing
• CPC Class Codes: Y10T 428/249924 : Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/24994 : Fiber embedded in or on the surface of a polymeric matrix
• CPC Class Codes: Y10T 428/249946 : Glass fiber
• CPC Class Codes: Y10T 428/31873 : Urea or modified urea-aldehyde
• CPC Class Codes: Y10T 428/31942 : Of aldehyde or ketone condensation product
• CPC Class Codes: Y10T 442/20 : Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
• CPC Class Codes: Y10T 442/2098 : At least two coatings or impregnations of different chemical composition
• CPC Class Codes: Y10T 442/2803 : Polymeric coating or impregnation from a silane or siloxane not specified as lubricant or water repellent
• CPC Class Codes: Y10T 442/2828 : Coating or impregnation contains aldehyde or ketone condensation product
• CPC Class Codes: Y10T 442/2836 : Phenol-aldehyde condensate
• CPC Class Codes: Y10T 442/2861 : Coated or impregnated synthetic organic fiber fabric
• CPC Class Codes: Y10T 442/291 : Coated or impregnated polyolefin fiber fabric
• CPC Class Codes: Y10T 442/2918 : Polypropylene fiber fabric
• CPC Class Codes: Y10T 442/2959 : Coating or impregnation contains aldehyde or ketone condensation product
• CPC Class Codes: Y10T 442/2975 : Coated or impregnated ceramic fiber fabric
• CPC Class Codes: Y10T 442/2992 : Coated or impregnated glass fiber fabric
• CPC Class Codes: Y10T 442/3976 : Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]
• CPC Class Codes: Y10T 442/60 : Nonwoven fabric [i.e., nonwoven strand or fiber material]

Abstract

A coated fiber mat of improved tear strength upon dividing pieces of the coated mat and the coating is provided. The coated mat is a cured, non-woven mat including a mixture of fibers having different fiber lengths. The fibers contain a polysiloxane compound and are fixedly distributed in a binder.

Claims

1. A cured, non-woven mat comprising a mixture of fibers having different fiber lengths, said fibers containing a polysiloxane compound, and fixedly distributed in a binder.

2. The cured, non-woven mat of claim 1 wherein from about 0 to about 100 weight % of said fibers have a fiber length of from about 0.5 to about 60 mm, and from about 0 to about 100 weight % of said fibers have a fiber length of from about 10 to about 150 mm.

3. The cured, non-woven mat of claim 2 wherein from about 20 to about 80 weight % of said fibers have a fiber length of from about 10 to about 45 mm, and from about 20 to about 80 weight % of said fibers have a fiber length of from about 30 to about 80 mm.

4. The cured, non-woven mat of claim 1 wherein said fibers comprise fibers of glass, wood, polyethylene, polypropylene, polyester, Nylon®

, Orlon®

or mixtures thereof.

5. The cured, non-woven mat of claim 4 wherein said fibers are glass fibers having an average diameter of from about 1 to about 100 μ

m.

6. The cured, non-woven mat of claim 1 wherein said fibers are present in an amount of from about 50 to about 95 weight %, said polysiloxane is present in an amount of from about 0.001 to about 20 weight % and said binder is present in an amount of from about 5 to about 50 weight %.

7. The cured, non-woven mat of claim 6 wherein said fibers are present in an amount of from about 65 to about 90 weight %, said polysiloxane is present in an amount of from about 0.01 to about 10 weight % and said binder is present in an amount of from about 10 to about 35 weight %.

8. The cured, non-woven mat of claim 1 wherein said binder is formaldehyde type binder containing between about 0.1 and about 20 weight % of a crosslinked styrene/(meth)acrylic polymer binder modifier.

9. The cured, non-woven mat of claim 8 wherein said formaldehyde type binder comprises formaldehyde and a compound selected from the group consisting of urea, phenol, resorcinol, melamine and mixtures thereof.

10. The cured, non-woven mat of claim 9 wherein said compound is urea.

11. The cured, non-woven mat of claim 8 where the styrene/(meth)acrylic polymer is crosslinked with a polyfunctional nitrogen-containing crosslinking agent.

12. The cured, non-woven mat of claim 1 wherein said polysiloxane is a polyalkylsiloxane.

13. The cured, non-woven mat of claim 12 wherein said polyalkylsiloxane is polydimethylsiloxane.

14. The cured, non-woven mat of claim 1 wherein said mat is a roofing material and is coated on at least one surface with asphalt.

15. The cured, non-woven mat of claim 1 wherein said mat is a glass mat employed in a roofing shingle.

16. An asphalt coated roofing material comprising a cured non-woven mat that comprises a mixture of fibers having different fiber lengths, said fibers containing a polysiloxane compound, and fixedly distributed in a binder.

17. The asphalt coated roofing material of claim 16 wherein from about 0 to about 100 weight % of said fibers have a fiber length of from about 0.5 to about 60 mm, and from about 0 to about 100 weight % of said fibers have a fiber length of from about 10 to about 150 mm.

18. The asphalt coated roofing material of claim 16 wherein said fibers comprise fibers of glass, wood, polyethylene, polypropylene, polyester, Nylon®

, Orlon®

or mixtures thereof.

19. The asphalt coated roofing material of claim 18 wherein said fibers are glass fibers having an average diameter of from about 1 to about 100 μ

m.

20. The asphalt coated roofing material of claim 16 wherein said fibers are present in an amount of from about 50 to about 95 weight %, said polysiloxane is present in an amount of from about 0.001 to about 20 weight % and said binder is present in an amount of from about 5 to about 50 weight %.

21. The asphalt coated roofing material of claim 16 wherein said binder is formaldehyde type binder containing between about 0.1 and about 20 weight % of a crosslinked styrene/(meth)acrylic polymer binder modifier.

22. The asphalt coated roofing material of claim 21 wherein said formaldehyde type binder comprises formaldehyde and a compound selected from the group consisting of urea, phenol, resorcinol, melamine and mixtures thereof.

23. The asphalt coated roofing material of claim 22 wherein said compound is urea.

24. The asphalt coated roofing material of claim 21 where the styrene/(meth)acrylic polymer is crosslinked with a polyfunctional nitrogen-containing crosslinking agent.

25. The asphalt coated roofing material of claim 16 wherein said polysiloxane is a polyalkylsiloxane.

26. The asphalt coated roofing material of claim 25 wherein said polyalkylsiloxane is polydimethylsiloxane.

27. The asphalt coating roofing material of claim 16 wherein said fibers are glass fibers.

28. The asphalt coated roofing material of claim 16 wherein said material is a shingle.

29. The asphalt coated roofing material of claim 16 wherein said material is a sheet or roll.