Shingle tear strength with fiber mixture of different fibers

• US 6,851,240 B2
• Filed: 02/26/2004
• Issued: 02/08/2005
• Est. Priority Date: 01/18/2000
• Status: Expired due to Term

• Current Assignee: Building Materials Corporation Of America
• Original Assignee: Building Materials Investment Corporation (Standard Industries, Inc.)
• Inventors: McAteer, Mark, Roberts, Betty C., Srinivasan, Krishna, Peng, Qinyun, Bittle, Bill
• Primary Examiner(s): SINGH-PANDEY, ARTI R
• Application Number:
  US10/787,362
• Publication Number:
  US 20040166751A1
• Time in Patent Office: 348 Days
• Field of Search: 442/157, 442/160, 442/170, 442/171, 442/176, 442/178, 442/180, 442/301, 525/14, 525/145, 525/18, 525/34, 525/37, 428/36.1, 428/40.3, 428/40.4, 428/43, 428/49, 428/74, 428/141, 428/142, 428/143, 428/144, 428/145, 428/149, 428/292.1, 428/297.4, 428/299.4, 428/484, 428/505, 428/524, 428/147
• US Class Current: 52/514
• 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. 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.

2. The asphalt coated roofing 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 about 100 weight % of said fibers of said fibers have a preferable fiber length of from about 0.5 to about 60 mm.

3. The asphalt coated roofing material of claim 1 wherein said fibers comprise fibers of glass, wood, polyethylene, polypropylene, polyester, nylon and Orlon acrylic fibers or mixtures thereof.

4. The asphalt coated roofing material of claim 3 wherein said fibers are glass fibers having an average diameter of from about 1 to about 100 μ

m.

5. The asphalt coated roofing material 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 %.

6. The asphalt coated roofing material 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.

7. The asphalt coated roofing material of claim 6 wherein said formaldehyde type binder comprises formaldehyde and a compound selected from the group consisting of urea phenol, resorcinol, melamine and mixtures thereof.

8. The asphalt coated roofing material of claim 7 wherein said compound is urea.

9. The asphalt coated roofing material of claim 6 where the styrene/(meth)acrylic polymer is crosslinked with a polyfunctional nitrogen-containing crosslinking agent.

10. The asphalt coated roofing material of claim 1 wherein said polysiloxane is polyalkylsiloxane.

11. The asphalt coated roofing material of claim 10 wherein said polyalkylsiloxane is polydimethylsiloxane.

12. The asphalt coating roofing material of claim 1 wherein said fibers are glass fibers.

13. The asphalt coated roofing material of claim 1 wherein said material is a shingle.

14. The asphalt coated roofing material of claim 1 wherein said material is a sheet or roll.