Wet formed mat having improved hot wet tensile strengths

Inactive Publication Date: 2007-02-22
OWENS CORNING INTELLECTUAL CAPITAL LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0020] It is an advantage of the present invention that chopped strand mats formed according to any embodiment of the present invention as disclosed herein may be formed with fibers treated with a size composition that does or does not include a coupling agent. As a result, virtually any glass fiber may be utilized in forming the chopped strand glass mats of the present invention.
[0021] It is another advantage of the present invention that the two-part binder composition of the present invention may utilized in a chopped strand mat forming process without having to change process parameters or modify the equipment on existing wet-laid mat processing lines.
[0022] It is yet another advantage of the present invention that the application or inclusion of at least one coupling agent to the chopped strand mat during a wet-laid ma

Problems solved by technology

However, some of the conventional binders utilized to form the roofing mats, such as urea-formaldehyde resins, tend to d

Method used

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  • Wet formed mat having improved hot wet tensile strengths
  • Wet formed mat having improved hot wet tensile strengths
  • Wet formed mat having improved hot wet tensile strengths

Examples

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Effect test

example 1

Hot Tensile Strength Retention of Chopped Strand Glass Mats Formed With Two-Part Inventive Binder Compositions

[0063] Binder compositions set forth in Tables 2-6 were prepared in buckets as described generally below. In particular, Control Binder Composition A (Table 2) was prepared by mixing the urea-formaldehyde resin (Bordon FG 472 from Bordon Chemical Co.), the latex binder (DL 490NA from Dow Reichhold), and water.

[0064] Binder pre-mixes for inventive Binder Compositions B-E (Tables 3-6) were prepared by mixing the urea-formaldehyde resin (Bordon FG 472), latex binder (DL 490NA from Dow Reichhold), and water. Acetic acid and water were mixed to form an acidic solution. Aminosilanes A-1100 and Y-9669 (GE Silicones) were added to the acidic solutions as designated in Tables 3-6 and moderately agitated to permit hydrolyzation. The hydrolyzed aminosilane(s) were then added to the binder pre-mixes with agitation to form Binder Compositions B-E. Once formed, Binder Compositions B-E w...

example 2

Hot Tensile Strengths of Chopped Strand Glass Mats and Shinglets Formed With Two-Part Inventive Binder Compositions

[0074] E-type chopped strand glass fibers sized with a conventional sizing composition containing one or more film forming agents, at least one lubricant, and a coupling agent were formed into chopped strand glass mats on a sheetformer using Binder Compositions A, B, and D set forth in Tables 2, 3, and 5 respectively. The chopped strand glass fibers had a length of 1¼ inches and a percent moisture of 13.22%. A chopped strand mat using Binder Composition A (Control) was replicated to confirm the reproducibility of the forming process and the data for the average of the two tests were used as data in Tables 9 and 10 for Binder Composition A. 2 inch wide test specimens of the chopped strand mats containing Binder Compositions A, B, and D were then evaluated for wet tensile strength on an Instron tensile testing apparatus. Each of the chopped strand mat samples were soaked...

example 3

Hot Tensile Strengths of Chopped Strand Glass Mats and Shinglets Formed With Two-Part Inventive Binder Compositions

[0078] E-type chopped strand glass fibers sized with a conventional sizing composition containing one or more film forming agents, at least one lubricant, and at least one coupling agent were formed into chopped strand glass mats on a sheetforner using Binder Compositions A, B, and D set forth in Tables 2, 3, and 5 respectively. The chopped strand glass fibers had a length of 1 ¼ inches and a percent moisture of 13.69%. A chopped strand mat using Binder Composition A (Control) was replicated to confirm the reproducibility of the forming process and the data for the average of the two tests were used as data in Tables 11 and 12 for Binder Composition A. Wet tensile strength of the chopped strand mats were determined according to the procedure set forth in Example 2 above. The test results are set forth in Table 11. Shinglet samples were then formed and tested for tear s...

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Abstract

Wet-laid chopped strand glass mats for use in roofing applications that have improved hot wet tensile strengths are provided. The chopped strand mats are formed by the application or inclusion of at least one coupling agent to the chopped strand mat during a wet-laid mat forming process. The coupling agent may be added to the chopped strand mat as part of a two-part binder composition that includes a binder and at least one coupling agent. Alternatively, the coupling agent may be added directly to the chopped strand mat independent of the binder. As a further alternative, the coupling agent(s) may be added to the white water in the wet-laid mat forming process and incorporated into the formed glass mat via the glass fibers. The binder may be a modified urea-formaldehyde binder, a non-modified urea-formaldehyde binder, and/or a formaldehyde-free binder. The coupling agent(s) may be silane coupling agents and/or reactive siloxanes.

Description

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION [0001] The present invention relates generally to chopped strand mats utilized in roofing applications, and more particularly, to chopped strand glass mats that have improved hot wet tensile strengths. BACKGROUND OF THE INVENTION [0002] Glass fibers are commonly used as reinforcements in the building composite industry because they do not shrink or stretch in response to changing atmospheric conditions. Roofing materials such as roofing shingles, roll roofing, and commercial roofing, are typically constructed of a glass fiber mat, an asphalt coating on the fibrous mat, and a surface layer of granules embedded in the asphalt coating. [0003] To form a chopped strand mat suitable for use in a roofing material, glass fibers are first formed by attenuating streams of a molten glass material from a bushing or orifice. The molten glass may be attenuated by a winder which collects gathered filaments into a package or by rollers w...

Claims

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Application Information

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IPC IPC(8): D21H27/00
CPCC03C25/16D21H13/40E04D5/02D21H17/49D21H17/47C03C25/40E04D5/00
Inventor LEE, JERRY H.C.CHEN, LIANGMIRTH, DAVEO'BRIEN-BERNINI, FRANK C.
Owner OWENS CORNING INTELLECTUAL CAPITAL LLC
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