Substrate, method of making the substrate, and bituminous roofing product

Abstract

A substrate includes a non-woven material including glass fibers and at least one natural fiber; wherein the substrate includes a tear strength of at least 350 gf as measured by TAPPI T1006 standard and a tensile strength of at least 30 lbf per 3 inch as measured by TAPPI T1009 standard.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 774,542, entitled “A SUBSTRATE, METHOD OF MAKING THE SUBSTRATE, AND BITUMINOUS ROOFING PRODUCT,” filed Mar. 19, 2025, by Erin Lynn CAMPONESCHI BROTHERSON et al., which is assigned to the current assignee hereof and is incorporated herein by reference in its entirety.FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to a substrate and in particular, a substrate for construction products.BACKGROUND

[0003] Building materials for construction, such as roofing shingles, gypsum wall boards, cement boards, and tiles, are typically constructed with a substrate such as a fiber mat. Chopped strand mat, suitable for use in construction materials, generally includes glass fibers because they are of high strength and tend not to shrink during use. The glass fibers are typically formed by attenuating streams of molten glass material from a bushing. The fibers are drawn from the bushing and the fibers are then chopped directly into a container. The chopped fibers are then dispersed in a water slurry which contains surfactants, viscosity modifiers, dispersants and other chemical agents. The fibers and slurry are agitated to disperse the fibers prior to depositing the mixture onto a moving screen where most of the water is removed. Although this generally describes a wet-laid process, a dry-laid process may be used. A polymeric binder is then applied. After application of the polymeric binder, the resulting mat is heated to remove the remaining water and cure the binder.

[0004] Important properties for a fiber mat include caliper, tensile strength, and tear strength. These properties are useful in determining the efficacy of the manufacture of fiber mat products and final properties of the fiber mat. The use of fiber mat is widespread and, in many cases, it might be desirable to provide a material that is sustainable. Sustainability is advantageous to reduce waste. However, modification of the fiber mats should maintain tensile strength as well as tear strength.

[0005] Accordingly, a need continues to exist in the art for improved fiber mats.SUMMARY

[0006] In an embodiment, a substrate includes a non-woven material including glass fibers and at least one natural fiber; wherein the substrate includes a tear strength of at least 350 gf as measured by TAPPI T1006 standard and a tensile strength of at least 30 lbf per 3 inch as measured by TAPPI T1009 standard.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Embodiments are illustrated by way of example and are not limited in the accompanying figures.

[0008] FIG. 1 is a graphical depiction of tensile strength for a mat containing a homogenously blended hemp fiber / glass fiber blend with varying % hemp fiber content.

[0009] FIG. 2 includes a graphical depiction of tear strength for a mat containing a homogenously blended hemp fiber / glass fiber blend with varying % hemp fiber content.

[0010] FIG. 3 includes a graphical depiction of tensile strength for a mat containing a homogenously blended flax fiber / glass fiber blend with varying % flax fiber content.

[0011] FIG. 4 includes a graphical depiction of tear strength for a mat containing a homogenously blended flax fiber / glass fiber blend with varying % flax fiber content.

[0012] FIG. 5 includes a graphical depiction of tensile strength for mats containing varying natural fibers.

[0013] FIG. 6 includes a graphical depiction of tear strength for mats containing varying natural fibers.

[0014] FIG. 7 includes a graphical depiction of tensile strength for mats containing varying natural fibers.

[0015] FIG. 8 includes a graphical depiction of tear strength for mats containing varying natural fibers.

[0016] FIG. 9 includes a graphical depiction of tear strength for shinglets containing varying natural fibers having different lengths.

[0017] FIG. 10 includes a graphical depiction of tear strength for shinglets containing varying amounts of natural fiber blends.

[0018] FIG. 11 includes a graphical depiction of tensile strength for mats containing varying amounts of natural fiber blends.

[0019] FIG. 12 includes a graphical depiction of tear strength for mats containing varying amounts of natural fiber blends.

[0020] Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the invention.DETAILED DESCRIPTION

[0021] The following description in combination with the figures is provided to assist in understanding the teachings disclosed herein. The following discussion will focus on specific implementations and embodiments of the teachings. This focus is provided to assist in describing the teachings and should not be interpreted as a limitation on the scope or applicability of the teachings. However, other teachings can certainly be used in this application.

[0022] Before addressing details of the embodiments described below, some terms are defined or clarified. Unless indicated otherwise, all measurements are at room temperature, i.e., about 25° C. For instance, values for viscosity are at about 25° C., unless indicated otherwise.

[0023] As used herein, the terms “comprises”, “comprising”, “includes”, “including”, “has”, “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive- or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0024] Also, the use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.

[0025] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent not described herein, many details regarding specific materials and processing acts are conventional and may be found in reference books and other sources within the structural arts and corresponding manufacturing arts.

[0026] In an embodiment, the present invention provides a substrate. The substrate is a non-woven material. The non-woven material includes glass fibers and at least one natural fiber. Advantageously, the substrate has a tear strength of at least 350 gf as measured by TAPPI T1006 standard and a tensile strength of at least 30 pounds-force (lbf) per 3 inch as measured by TAPPI T1009 standard. In particular, the tear strength may be within a range of at least 350 gf and not greater than 1200 gf, such as within a range of at least 350 gf and not greater than 575 gf, such as within a range of at least 350 gf and not greater than 550 gf, such as within a range of at least 350 gf and not greater than 525 gf, or even within a range of at least 375 gf and not greater than 500 gf. Advantageously, the substrate provides desirable tensile strength and tear strength particularly when used in a bituminous roofing product, compared to an equivalent bituminous roofing product made with an equivalent weight substrate containing a homogenous glass fiber mat structure throughout the entirety of the mat. In an embodiment, the substrate is more sustainable than a homogenous glass fiber mat structure. Further, a lighter weight and / or a thinner caliper mat may also be formed that is more sustainable than a homogenous glass fiber mat structure. A “bituminous roofing product” as used herein includes the substrate and at least one coating of asphalt.

[0027] The non-woven material is an “assembly of fibers” as discussed herein and refers to an assembly of fibers that are integrally intertwined through at least a portion of a thickness of the substrate. In an embodiment, the glass fibers and the at least one natural fiber are integrally intertwined. Typically, the glass fibers and the at least one natural fiber are also homogenously mixed throughout the thickness of the non-woven material. In particular, the non-woven material may be a mat, including an arrangement of randomly oriented filaments. In a particular embodiment, the glass fibers and the at least one natural fiber are chopped strand. The term “filament” is intended to mean an elongated structure or fiber of any suitable length. A “chopped strand” typically describes randomly oriented chopped filaments or fibers, wherein the chopped filaments or fibers are randomly oriented individually or in a group.

[0028] In an embodiment, any natural fiber is envisioned. The natural fiber includes, for example, an animal-based fiber, a plant-based fiber, or combination thereof. In an embodiment, the at least one natural fiber includes a cellulose-containing material, a lignin-containing material, or combination thereof. In a more particular embodiment, the at least one natural fiber is a cellulose-containing material. In an embodiment, the at least one natural fiber includes a material selected from the group consisting of hemp, flax, jute, sisal, bagasse, bamboo, kenaf, ramie, abaca, coir, palm, pineapple, curaua, fique, wheat, rice husk, rice straw, or a combination thereof. In a more particular embodiment, the at least one natural fiber includes a material selected from the group consisting of hemp, flax, jute, or a combination thereof. In a more particular embodiment, the at least one natural fiber is flax. In another embodiment, the at least one natural fiber is hemp. In yet another embodiment, the at least one natural fiber is jute.

[0029] Any reasonable amount of the at least one natural fiber is envisioned in the substrate. In an embodiment, the natural fiber is an amount of at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 15 wt %, such as at least 20 wt %, such as at least 25 wt %, such as at least 30 wt %, such as at least 35 wt %, such as at least 40 wt %, such as at least 45 wt %, such as at least 50 wt %, such as at least 55 wt %, such as at least 60 wt %, such as at least 65 wt %, such as at least 70 wt %, such as at least 75 wt %, such as at least 80 wt %, or even at least 85 wt %, based on a total weight of the substrate. In an embodiment, the substrate includes the natural fiber in an amount of not greater than 90 wt %, such as not greater than 85 wt %, such as not greater than 80 wt %, such as not greater than 75 wt %, such as not greater than 70 wt %, such as not greater than 65 wt %, such as not greater than 60 wt %, such as not greater than 55 wt %, such as not greater than 50 wt %, such as not greater than 45 wt %, such as not greater than 40 wt %, such as not greater than 35 wt %, such as not greater than 30 wt %, such as not greater than 25 wt %, such as not greater than 20 wt %, such as not greater than 15 wt %, or even not greater than 10 wt % for a total weight of the substrate. The natural fiber in combination with the glass fibers provides a desirable substrate compared to a substrate with a homogeneous glass fiber mat structure.

[0030] In an embodiment, the substrate can include at least one natural fiber and in particular, at least two different types of natural fiber. For instance, the substrate includes a first type of natural fiber and a second type of natural fiber. Any first type of natural fiber and any second type of natural fiber is envisioned. For instance, the substrate includes at least two different types of natural fibers selected from the group consisting of hemp, flax, jute, sisal, bagasse, bamboo, kenaf, ramie, abaca, coir, palm, pineapple, curaua, fique, wheat, rice husk, and rice straw. In a particular embodiment, the substrate includes at least two different types of natural fibers selected from the group consisting of material selected from the group consisting of hemp, flax, and jute. In an embodiment, the substrate includes a greater content of the glass fiber as compared to the content of the natural fiber. In an alternative embodiment, the substrate includes a greater content of the natural fiber as compared to the content of the glass fiber.

[0031] In an embodiment, any amount of the first type of natural fiber, the second type of natural fiber, and glass fibers is envisioned. In an example, the first type of natural fiber is hemp and the second type of natural fiber is flax; however, any first type of natural fiber and second type of natural fiber is envisioned. In an embodiment, the substrate includes a content (wt %) of glass fibers (Cgf) and a content (wt %) of a first natural fiber (Cnf1), and wherein the substrate comprises a first content ratio [Cgf / Cnf1] of least 0.1, such as at least 0.15, such as at least 0.2, such as at least 0.25, such as at least 0.3, such as at least 0.35, such as at least 0.4, such as at least 0.45, such as at least 0.5, such as at least 0.55, such as at least 0.6, such as at least 0.65, such as at least 0.7, such as at least 0.75, such as at least 0.8, such as at least 0.85, such as at least 0.9, such as at least 0.95, such as at least 1, such as at least 1.05, such as at least 1.1, such as at least 1.15, such as at least 1.2, such as at least 1.25, such as at least 1.3, such as at least 1.35, such as at least 1.4, such as at least 1.45, such as at least 1.5, such as at least 1.55, such as at least 1.6, such as at least 1.65, such as at least 1.7, such as at least 1.75, such as at least 1.8, such as at least 1.85, such as at least 1.9, such as at least 1.95, such as at least 2, such as at least 2.25, such as at least 2.5, such as at least 2.75, such as at least 3, such as at least 3.25, such as at least 3.5, such as at least 3.75, such as at least 4, such as at least 4.5, such as at least 5, such as at least 5.5, such as at least 6, such as at least 6.5, such as at least 7, such as at least 7.5, such as at least 8, such as at least 8.5, such as at least 9, such as at least 9.5, or even at least 10. In particular, the substrate includes a content (wt %) of glass fibers (Cgf) and a content (wt %) of a first natural fiber (Cnf1), and wherein the substrate comprises a first content ratio [Cgf / Cnf1] of not greater than 100, such as not greater than 90, such as not greater than 80, such as not greater than 70, such as not greater than 60, such as not greater than 50, such as not greater than 40, such as not greater than 30, such as not greater than 20, such as not greater than 19, such as not greater than 18, such as not greater than 17, such as not greater than 16, such as not greater than 15, such as not greater than 14, such as not greater than 13, such as not greater than 12, such as not greater than 11, such as not greater than 10, such as not greater than 9, such as not greater than 8.5, such as not greater than 8, such as not greater than 7.5, such as not greater than 7, such as not greater than 6.5, such as not greater than 6, such as not greater than 5.5, such as not greater than 5, such as not greater than 4.5, such as not greater than 4, such as not greater than 3.5, such as not greater than 3, such as not greater than 2.5, such as not greater than 2, such as not greater than 1.5, such as not greater than 1, such as not greater than 0.9, such as not greater than 0.8, such as not greater than 0.7, such as not greater than 0.6, such as not greater than 0.5, such as not greater than 0.4, or even not greater than 0.3.

[0032] For instance, the substrate includes a content (wt %) of glass fibers (Cgf) and a content (wt %) of the second natural fiber (Cnf2), and wherein the substrate includes a second content ratio [Cgf / Cnf2] of least 0.01, such as at least 0.02, such as at least 0.05, such as at least 0.08, such as at least 0.1, such as at least 0.15, such as at least 0.2, such as at least 0.25, such as at least 0.3, such as at least 0.35, such as at least 0.4, such as at least 0.45, such as at least 0.5, such as at least 0.55, such as at least 0.6, such as at least 0.65, such as at least 0.7, such as at least 0.75, such as at least 0.8, such as at least 0.85, such as at least 0.9, such as at least 0.95, such as at least 1, such as at least 1.05, such as at least 1.1, such as at least 1.15, such as at least 1.2, such as at least 1.25, such as at least 1.3, such as at least 1.35, such as at least 1.4, such as at least 1.45, such as at least 1.5, such as at least 1.55, such as at least 1.6, such as at least 1.65, such as at least 1.7, such as at least 1.75, such as at least 1.8, such as at least 1.85, such as at least 1.9, such as at least 1.95, such as at least 2, such as at least 2.25, such as at least 2.5, such as at least 2.75, such as at least 3, such as at least 3.25, such as at least 3.5, such as at least 3.75, such as at least 4, such as at least 4.5, such as at least 5, such as at least 5.5, such as at least 6, such as at least 6.5, such as at least 7, such as at least 7.5, such as at least 8, such as at least 8.5, such as at least 9, such as at least 9.5, or even at least 10. In particular, the second content ratio [Cgf / Cnf2] is not greater than 100, such as not greater than 90, such as not greater than 80, such as not greater than 70, such as not greater than 60, such as not greater than 50, such as not greater than 40, such as not greater than 30, such as not greater than 20, such as not greater than 19, such as not greater than 18, such as not greater than 17, such as not greater than 16, such as not greater than 15, such as not greater than 14, such as not greater than 13, such as not greater than 12, such as not greater than 11, such as not greater than 10, such as not greater than 9, such as not greater than 8.5, such as not greater than 8, such as not greater than 7.5, such as not greater than 7, such as not greater than 6.5, such as not greater than 6, such as not greater than 5.5, such as not greater than 5, such as not greater than 4.5, such as not greater than 4, such as not greater than 3.5, such as not greater than 3, such as not greater than 2.5, such as not greater than 2, such as not greater than 1.5, such as not greater than 1, such as not greater than 0.9, such as not greater than 0.8, such as not greater than 0.7, such as not greater than 0.6, such as not greater than 0.5, such as not greater than 0.4, such as not greater than 0.3, such as not greater than 0.2, such as not greater than 0.1, or even not greater than 0.08.

[0033] Any ratio of the first type of natural fiber and the second type of natural fiber may be envisioned as well. For instance, the substrate includes a content (wt %) of the first type of natural fiber (Cnf1) and a content (wt %) of the second natural fiber (Cnf2), and wherein the substrate comprises a first natural fiber content ratio [Cnf1 / Cnf2] of at least 1, such as at least 1.05, such as at least 1.1, such as at least 1.15, such as at least 1.2, such as at least 1.25, such as at least 1.3, such as at least 1.35, such as at least 1.4, such as at least 1.45, such as at least 1.5, such as at least 1.55, such as at least 1.6, such as at least 1.65, such as at least 1.7, such as at least 1.75, such as at least 1.8, such as at least 1.85, such as at least 1.9, such as at least 1.95, such as at least 2, such as at least 2.25, such as at least 2.5, such as at least 2.75, such as at least 3, such as at least 3.25, such as at least 3.5, such as at least 3.75, such as at least 4, such as at least 4.5, such as at least 5, such as at least 5.5, such as at least 6, such as at least 6.5, such as at least 7, such as at least 7.5, such as at least 8, such as at least 8.5, such as at least 9, such as at least 9.5, or even at least 10. Further, the first natural fiber content ratio [Cnf1 / Cnf2] is not greater than 100, such as not greater than 90, such as not greater than 80, such as not greater than 70, such as not greater than 60, such as not greater than 50, such as not greater than 40, such as not greater than 30, such as not greater than 20, such as not greater than 19, such as not greater than 18, such as not greater than 17, such as not greater than 16, such as not greater than 15, such as not greater than 14, such as not greater than 13, such as not greater than 12, such as not greater than 11, such as not greater than 10, such as not greater than 9, such as not greater than 8, such as not greater than 7, such as not greater than 6, such as not greater than 5, such as not greater than 4, such as not greater than 3, such as not greater than 2, such as not greater than 1, such as not greater than 0.8, such as not greater than 0.5, such as not greater than 0.2, or even not greater than 0.1.

[0034] In a particular embodiment, the natural fibers can be any length such as continuous strand, chopped, or combination thereof. In a more particular embodiment, the natural fibers are chopped into a suitable length to provide a substantially random orientation of fibers. Any reasonable length of fibers is envisioned. Generally, the at least one natural fiber includes a plurality of a first type of natural fibers, and wherein the plurality of the first type of natural fibers comprises an average length (Lnf1) of at least 1 mm, such as at least 5 mm, such as at least 10 mm, such as at least 20 mm, such as at least 40 mm, such as at least 60 mm, such as at least 80 mm, such as at least 100 mm, such as at least 200 mm, such as at least 500 mm, such as at 800 mm, or even at least 1000 mm. In an embodiment, the plurality of the first type of natural fibers includes an average length (Lnf1) of not greater than 5000 mm, such as not greater than 4000 mm, such as not greater than 3000 mm, such as not greater than 2000 mm, such as not greater than 1000 mm, such as not greater than 900 mm, such as not greater than 800 mm, such as not greater than 700 mm, such as not greater than 600 mm, such as not greater than 500 mm, or even not greater than 400 mm. In an embodiment, any reasonable diameter of the plurality of the first type of natural fibers is envisioned. For instance, the at least one natural fiber includes a plurality of a first type of natural fibers, and wherein the plurality of the first type of natural fibers comprises an average diameter (Df1) of at least 1 μm, such as at least 3 μm, such as at least 5 μm, such as at least 7 μm, or even at least 10 μm. In a particular embodiment, the plurality of the first type of natural fibers includes an average diameter (Dnf1) of not greater than 250 μm, such as not greater than 225 μm, such as not greater than 200 μm, such as not greater than 175 μm, such as not greater than 150 μm, such as not greater than 125 μm, such as not greater than 100 μm, or even not greater than 75 μm. Although generally described as a diameter, one skilled in the art would understand that the diameter includes a major axis of the plurality of first type of natural fibers if a cross-section is circular or non-circular. In an embodiment, any reasonable denier of the first type of natural fibers is envisioned. For instance, the first type of natural fibers has a denier of about 1 to about 10, such as about 1 to about 7, such as about 2 to 7, such as about 2 to about 5, or even about 3 to about 5.

[0035] Generally, the at least one natural fiber includes a plurality of the second type of natural fibers, and wherein the at least one natural fiber includes a plurality of a first type of natural fibers and a plurality of a second type of natural fibers, and wherein the plurality of the second type of natural fibers comprises an average length (Lnf2) of at least 1 mm, such as at least 5 mm, such as at least 10 mm, such as at least 20 mm, such as at least 40 mm, such as at least 60 mm, such as at least 80 mm, such as at least 100 mm, such as at least 200 mm, such as at least 500 mm, such as at 800 mm, or even at least 1000 mm. In an embodiment, the plurality of the second type of natural fibers includes an average length (Lnf2) of not greater than 5000 mm, such as not greater than 4000 mm, such as not greater than 3000 mm, such as not greater than 2000 mm, such as not greater than 1000 mm, such as not greater than 900 mm, such as not greater than 800 mm, such as not greater than 700 mm, such as not greater than 600 mm, such as not greater than 500 mm, or even not greater than 400 mm. In an embodiment, any reasonable diameter of the plurality of the second type of natural fibers is envisioned. For instance, the at least one natural fiber includes a plurality of a first type of natural fibers and a plurality of a second type of natural fibers, and wherein the plurality of a second type of natural fibers includes an average diameter (Dnf2) of at least 1 μm, such as at least 3 μm, such as at least 5 μm, such as at least 7 μm, or even at least 10 μm. In a particular embodiment, the plurality of the second type of natural fibers includes an average diameter (Dnf2) of not greater than 250 μm, such as not greater than 225 μm, such as not greater than 200 μm, such as not greater than 175 μm, such as not greater than 150 μm, such as not greater than 125 μm, such as not greater than 100 μm, or even not greater than 75 μm. Although generally described as a diameter, one skilled in the art would understand that the diameter includes a major axis of the plurality of second type of natural fibers if a cross-section is circular or non-circular. In an embodiment, any reasonable denier of the second type of natural fibers is envisioned. For instance, the second type of natural fibers has a denier of about 1 to about 10, such as about 1 to about 7, such as about 2 to 7, such as about 2 to about 5, or even about 3 to about 5.

[0036] In an embodiment, the substrate further includes glass fibers. Any glass fiber is envisioned. In an example, the glass fibers include an A-type glass fiber, a C-type glass fiber, an E-type glass fiber, an S-type glass fiber, an E-CR-type glass fiber, a wool glass fiber, or a combination thereof. In an embodiment, the glass fiber includes E-type glass fiber. Any reasonable amount of glass fibers is envisioned. In an embodiment, the substrate includes the glass fiber in an amount of at least 10 wt %, such as at least 12 wt %, such as at least 14 wt %, such as at least 16 wt %, such as at least 18 wt %, such as at least 20 wt %, such as at least 25 wt %, such as at least 30 wt %, such as at least 35 wt %, such as at least 40 wt %, such as at least 45 wt %, such as at least 50 wt %, such as at least 55 wt %, such as at least 60 wt %, such as at least 65 wt %, such as at least 70 wt %, such as at least 75 wt %, such as at least 80 wt %, or even at least 85 wt % for a total weight of the substrate. In an embodiment, the substrate includes the glass fiber in an amount of not greater than 90 wt %, such as not greater than 88 wt %, such as not greater than 86 wt %, such as not greater than 84 wt %, such as not greater than 82 wt %, such as not greater than 80 wt %, such as not greater than 75 wt %, such as not greater than 70 wt %, such as not greater than 65 wt %, such as not greater than 60 wt %, such as not greater than 55 wt %, such as not greater than 50 wt %, such as not greater than 45 wt %, such as not greater than 40 wt %, such as not greater than 35 wt %, such as not greater than 30 wt %, such as not greater than 25 wt %, such as not greater than 20 wt %, such as not greater than 15 wt %, or even not greater than 12 wt % for a total weight of the substrate.

[0037] In a particular embodiment, the glass fibers can be any length such as continuous strand, chopped, or combination thereof. In a more particular embodiment, the glass fibers are chopped into a suitable length to provide a substantially random orientation of fibers. Any reasonable length of fibers is envisioned. Generally, the glass fibers have an average length (Lgf) of at least 1 mm, such as at least 5 mm, such as at least 10 mm, such as at least 20 mm, such as at least 40 mm, such as at least 60 mm, such as at least 80 mm. such as at least 100 mm, such as at least 200 mm, such as at least 500 mm, such as at 800 mm, or even at least 1000 mm. In an example, the glass fibers have an average length (Lgf) of not greater than 5000 mm, such as not greater than 4000 mm, such as not greater than 3000 mm, such as not greater than 2000 mm, such as not greater than 1000 mm, such as not greater than 900 mm, such as not greater than 800 mm, such as not greater than 700 mm, such as not greater than 600 mm, such as not greater than 500 mm, or even not greater than 400 mm. In an embodiment, any reasonable diameter of the glass fibers is envisioned. For instance, an average diameter (Dgf) of at least 1 μm, such as at least 3 μm, such as at least 5 μm, such as at least 7 μm, or even at least 10 μm are used. In a particular embodiment, the glass fibers the glass fibers have an average diameter (Dgf) of not greater than 400 μm, such as not greater than 375 μm, such as not greater than 350 μm, such as not greater than 325 μm, such as not greater than 300 μm, such as not greater than 275 μm, such as not greater than 250 μm, such as not greater than 225 μm, such as not greater than 200 μm, such as not greater than 175 μm, such as not greater than 150 μm, such as not greater than 125 μm, such as not greater than 100 μm, such as not greater than 75 μm, or even not greater than 50 μm. Although generally described as a diameter, one skilled in the art would understand that the diameter includes a major axis of the glass fiber if a cross-section is circular or non-circular. In an embodiment, any reasonable denier of the glass fiber is envisioned. For instance, the glass fiber has a denier of about 1 to about 10, such as about 1 to about 7, such as about 2 to 7, such as about 2 to about 5, or even about 3 to about 5.

[0038] In a particular embodiment, any glass fiber and at least one natural fiber is envisioned in any amount. For instance, the at least one natural fiber includes a first type of natural fiber and a second type of natural fiber, where the first and the second types are different. “Different types” may include different in composition, average length, average diameter, or combination thereof. For instance, the first type of natural fiber may be hemp and the second type of natural fiber may be flax. Any amount of fibers may be envisioned for the substrate and include, for instance, a) 20-80 wt % glass fiber; b) 2-50 wt % hemp; and c) 2-50 wt % flax, wherein the total content of a), b), and c) is not greater than 100 wt %. In an embodiment, the content of flax is less than the content of hemp. With respect to the glass fibers and the at least one natural fiber, any content ratio is envisioned depending on the properties desired for the final substrate. For instance, the substrate includes: a) a first content ratio [Cgf / Cnf1] within a range of at least 0.1 and not greater than 100, wherein Cgf represents a content (wt %) of glass fibers (Cgf) and Cnf1 represents a content (wt %) of the first type of natural fibers (Cnf1); b) a second content ratio [Cgf / Cnf2] within a range of least 0.01 and not greater than 100, wherein Cnf2 represents a content (wt %) of the second type of natural fibers (Cnf1); and c) a first natural fiber content ratio [Cnf1 / Cnf2] within a range of at least 1 and not greater than 100.

[0039] In an embodiment, the substrate having the glass fibers and at least one natural fiber has desirable properties. The glass fiber amount and type can be configured to custom tailor the substrate and its properties. Further, the at least one natural fiber amount and type can be configured to custom tailor the substrate and its properties. In particular, the glass fibers and at least one natural fiber can provide desirable properties to the final substrate as well as any final product, such as a bituminous roofing product. For instance, the substrate has a tensile strength within a range of at least 50 lbf and not greater than 200 lbf, such as within a range of at least 50 lbf and not greater than 150 lbf, such as within a range of at least 50 lbf and not greater than 125 lbf, such as within a range of at least 50 lbf and not greater than 110 lbf, such as within a range of at least 50 lbf and not greater than 100 lbf, or even within a range of at least 60 lbf and not greater than 100 lbf. As discussed, the substrate further has a desirable tear strength. Although not being bound by theory, by forming a substrate with the glass fibers and at least one natural fibers, the properties of tear strength and tensile strength can be selectively tailored and achieve both desirable tear strength and tensile strength, particularly when the substrate is used in a bituminous roofing product.

[0040] The substrate may also include a binder used to fixedly bond the fibers. The binder is a composition that includes any suitable organic resin. The organic resin can include one or more suitable monomers, oligomers, polymers, copolymers, a suitable blend, or combination thereof. In a particular embodiment, the organic resin is any reasonable resin envisioned for substrate applications. In an embodiment, the organic resin includes one or several of a urea-formaldehyde composition, a latex composition, an acrylic composition, a styrene-butadiene rubber (SBR) composition, a vinyl acetate ethylene composition, a blend or combination thereof. In a particular embodiment, the organic resin includes a urea-formaldehyde composition, a latex composition, or combination thereof. In an embodiment, the latex is present at an amount of up to about 5% by weight, such as up to about 7% by weight, or even up to about 100% by weight, based on the total weight % of the binder composition. In an embodiment, the organic resin may be a photocurable polymer. Further, any form of the binder may be envisioned such as a liquid, a powder, or any combination thereof.

[0041] The composition of the binder may also contain a variety of other known additives such as an adhesion promoter to enhance the adhesion of the binder to the substrate to increase the bonding strength between the assembly of fibers, a silica colloid to enhance fire resistance, antifoamers, biocides, pigments, the like, or combinations thereof. In an embodiment, the binder can include less than about 25% by weight of additives, based on the total weight of the binder composition. In another embodiment, the binder is substantially free of additives. “Substantially free” as used herein refers to less than about 1% by weight of additives, less than about 0.5% by weight of additives, or even less than about 0.1% by weight of additives, based on the total weight of the binder composition. Any amount of total binder on the substrate is envisioned but it will usually be found convenient and satisfactory to make up the total binder in the range from about 5% by weight to about 50% by weight, such as about 10% by weight to about 40% by weight, such as about 10% by weight to about 30% by weight of the cured substrate. In an embodiment, the binder is substantially uniformly distributed throughout the substrate. “Substantially uniformly distributed” as used herein refers to a varying binder concentration of not greater than 5%, such as not greater than 4%, such as not greater than 3%, such as not greater than 2%, or even not greater than 1% from the top surface to the bottom surface of the substrate.

[0042] Any method of providing the substrate of the present invention is envisioned and depends upon the final properties desired for the mat. An exemplary method of forming a substrate in accordance with the present invention begins with an assembly of fibers, such as chopped bundles of fibers of suitable length. An exemplary method of making the substrate includes providing the glass fibers and the at least one natural fibers. The glass fibers for the minority portion and the at least one set of natural fibers may be provided by any reasonable means or sequence. Any method of providing the glass fibers and the at least one natural fibers is envisioned, with the proviso that the fibers are substantially randomly laid out such that they are uniformly, non-uniform throughout the substrate. In an embodiment, the assembly of fibers may include any number of layers such as a first layer of the glass fibers and a second layer of the at least one natural fibers.

[0043] Typically, the glass fibers and at least one natural fibers are added to a dispersant medium to form an aqueous slurry, known in the art as “white water”. The white water typically contains fibers, dispersant(s), viscosity modifier(s), foam control and biocide additives. The fibrous slurry is then agitated to form a workable, uniform dispersion of fibers having a suitable consistency. The dispersant may contain polyacrylamide, hydroxyethyl cellulose, and other additives such as surfactants, lubricants, defoamers, the like, or combinations thereof.

[0044] Fibers and white water dispersion are then passed onto a mat-forming machine containing a mat forming screen. The dispersion is usually diluted with water to a lower fiber concentration prior to being dispersed on a screen. The fibers are collected at the screen in the form of a wet fiber mat, and the excess water is removed by gravity or, more preferably, by vacuum in a conventional manner, such as by vacuum boxes. Although this generally describes a wet-laid process, a dry-laid process may also be envisioned. For instance, with a dry-laid process, fibers may be spun from a bushing directly onto a moving web. The binder is subsequently applied.

[0045] Any method of providing the binder is envisioned. The binder is traditionally applied to the gravity- or vacuum-assisted de-watered white fiber mat. Applying the binder includes at least one application of the binder on the assembly of fibers. Application of the binder may be accomplished by any conventional means, such as by soaking the mat in an excess of binder solution, or by coating the mat surface by means of a binder applicator such as a sprayer, roll, or curtain. Other methods include, for example, applying as a film, a slot die, or any reasonable extrusion method. The components of the binder may be applied separately or mixed together by any method envisioned. For instance, if applied separately, the components of the binder may be added by the same or a different method. In an embodiment, any other sequence of adding the components of the binder is envisioned. The total concentration of components in the binder in an aqueous solution can vary widely in accordance with the practice of the present invention.

[0046] Following application of the binder, the non-woven fiber mat is de-watered by any reasonable means, such as under vacuum, to remove excess binder solution. In an embodiment, the fiber mat is dried prior to cure. Any method of drying the fiber mat is envisioned. In a particular embodiment, the drying is at a temperature wherein the fiber mat does not reach the cure temperature of the binder and is dependent upon the binder composition chosen. For instance, drying is with forced heated air, such as a convection oven, a gas fired oven, an infrared heater, a heated drum, a belt laminator, photoinitiation, ultraviolet (UV) initiation, or combination thereof. In an exemplary embodiment, at least about 95%, such as at least about 90%, or even at least about 80% of water weight of the aqueous binder is removed during the drying process. In an embodiment, the binder is partially cured during the drying step, with a cure of not greater than 50%, as measured by a ratio of dry tensile strength to tensile strength of a wet fiber mat subjected to 10 minutes exposure to 80° C. hot water.

[0047] Although primarily described as a single binder and a single application of binder, any number of binder compositions, applications of binder, or combination thereof is envisioned. If there is more than one application of the binder, any subsequent applications of binder may be, for example, the binder or a second binder. Any sequence of providing and curing the binder and any second binder is envisioned.

[0048] In an embodiment, the cure of the binder is facilitated with heat provided by any reasonable means. Any heat source is envisioned and includes, for example, oven, infrared heating, heating with a metal plate in contact with the fiber mat, and the like. Any reasonable time and temperatures is envisioned and is dependent upon the binder composition and the desired process speed. In an embodiment, heat treatment is sufficient to effect curing. In an embodiment, catalytic curing may also be used. In an embodiment, dimensional constraint may be applied to the fiber mat during cure. Although cure is primarily described as via a heat treatment, any other method is reasonable, such as, for example, ultraviolet cure.

[0049] Although an exemplary method is described, any sequence of providing any fiber and any binder is envisioned, depending on the composition of the substrate and the final properties desired for the substrate. For instance, although described as providing the binder on the assembly of fibers, the binder may be provided on the fibers in any sequence and method envisioned.

[0050] Typically, the substrate can have any caliper desired. In an example, the caliper at 1.8 pounds (lbs) per 100 square feet is at least about 15 mil, such as about 15 mil to about 200 mil, such as about 20 mil to about 75 mil, such as about 20 mil to about 40 mil, such as about 25 mil to about 35 mil. In an example, the caliper of the substrate is not greater than about 200 mil, such as not greater than about 100 mil, such as not greater than 50 mil.

[0051] In an exemplary embodiment, any one or more suitable components are envisioned for the substrate depending upon the final product and properties desired. For instance, the substrate may be coated with a polymer film coating. Any reasonable polymer film coating is envisioned. Typically, the polymer film coating chosen is dependent upon the final properties desired for the construction product. In an embodiment, the polymer film coating includes a latex, an ethylene methyl acrylate, ethylene vinyl acetate, polyethylene terephthalate, polyamide, hot melt adhesive, fluoropolymer, polyolefin, or combination thereof. The method of applying the polymer film coating is dependent upon the material. Any method is envisioned such as coating, extruding, spraying, or laminating. For instance, a polymer film coating may be extruded directly onto the substrate without any intervening layers. In another embodiment, a polymer film coating may be laminated, with or without an adhesive, onto the substrate.

[0052] In an example, the polymer film coating can be provided on the substrate and can be positioned on any portion of the substrate desired. In an embodiment, the polymer film coating can partially or substantially coat at least one surface of the substrate. In an embodiment, the polymer film coating can partially coat at least two surfaces of the substrate. In a particular embodiment, the polymer film coating can substantially coat the substrate and can penetrate the substrate. The polymer film coating can also include more than one layer on the substrate, each of which can be allowed to set, harden, dry, or otherwise cure before any additional layers of polymer film coating are applied. The polymer film coating can include any suitable thickness such as at least about 5 microns, or range of thicknesses, such as between about 5 microns and about 300 microns.

[0053] In an embodiment, the substrate can include at least one additional component such as a nonwoven laid scrim, a knitted fabric, or combination thereof. In another embodiment, the substrate can include more than one component, such as one or more scrims, either woven or nonwoven, suitably coupled to one or more mats, either woven or nonwoven. For example, a woven scrim including glass fibers can be coupled to the substrate. The term “scrim” is intended to mean a woven or non-woven fabric that includes at least two filaments oriented in two different directions, including but not limited to a mesh. The term “laid scrim” is intended to mean a scrim in which at least one filament overlies at least one other filament to create the scrim. In an embodiment, the substrate does not include any additional component. A “knitted fabric” typically includes fabrics produced by interloping chains of filaments, roving, or yarn.

[0054] The substrate as described has advantageous and unexpected properties. The substrate of the present invention has desirable properties such as tensile strength and tear strength. In a more particular embodiment, the substrate of the present invention achieves both desirable tensile strength and tear strength, particularly when used in a bituminous roofing product.

[0055] The substrate as described above can be provided in any suitable manner to provide for a construction product. Any construction product is envisioned where tensile strength, tear strength, air and liquid permeability, flexural strength, conformability, surface roughness, flatness, etcetera are desired. An exemplary construction product includes, for example, a bituminous roofing product, a gypsum wall board, a cement board, a PVC flooring, a rug backing, a tile backing, an insulation facer, a foam facer, a ceiling tile, etcetera, and the like. In an embodiment, the substrate can also be used as, composite gypsum building panels, gypsum fiber building panels, cement board, fibrous cement boards, gypsum fiber siding, fibrous cement siding, cement siding, gypsum cove or cornice, fibrous gypsum cove and cornice, cement cove and cornice, fibrous cove and cornice, magnesium oxide building boards, magnesium oxide cove and cornice, magnesium oxide siding, magnesium oxide shingles, asphalt impregnated shingles, asphalt coated shingles, asphalt impregnated building wraps, organic polymer coated, inorganic coated building wraps, organic / inorganic blended coated building wraps, composite siding, tapes incorporating continuous or non-continuous or blended continuous and non-continuous (mats, scrims, tissues, fabrics) materials, corner bead, carpet, reinforced plywood, reinforced layered polymer composites, and reinforced molded or extruded organic or inorganic or blended organic and inorganic materials (including reinforced geometrical substrates, reinforced rigid or flexible plastic tubing, and reinforced cylinders).

[0056] In an embodiment, the construction product is a bituminous roofing product. The substrate can be provided in the cementitious product to provide structural integrity to the resulting bituminous roofing product. The substrate may be situated in any suitable configuration within the bituminous roofing product. In a typical embodiment, the substrate is coated with at least one layer of asphalt. For example, the substrate can be produced as described above and then coated with at least one layer of asphalt. In an embodiment, the substrate is coated with at least one layer of asphalt on both the top surface and the bottom surface. Alternatively, the substrate can be produced simultaneously or concurrently while it is being coupled to a bituminous roofing product. In an embodiment, at least a portion of the substrate can be embedded to any suitable depth from a surface or edge of the bituminous roofing product. In an embodiment, the asphalt substantially impregnates a plurality of interstices between the assembly of fibers. For instance, the substrate has desirable air permeability to allow impregnation of the asphalt into the substrate. In an embodiment, the substrate has an air permeability of at least 750 CFM / ft2. In a particular embodiment, the bituminous roofing product is a roofing shingle. For instance, the roofing shingle further includes granules overlying the substrate. Any reasonable granule for roofing applications are envisioned. In an embodiment, the bituminous roofing product has a weight of at least about 160 pounds / 100 square feet, such as about 175 pounds / 100 square feet to about 250 pounds / 100 square feet, such as about 200 pounds / 100 square feet to about 250 pounds / 100 square feet.

[0057] Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the embodiments as listed below.

[0058] Embodiment 1. A substrate includes a non-woven material including glass fibers and at least one natural fiber; wherein the substrate includes a tear strength as measured by TAPPI T1006 standard of at least 350 gf and a tensile strength of at least 30 lbf as measured by TAPPI T1009 standard.

[0059] Embodiment 2. The substrate of embodiment, wherein the substrate includes the natural fiber in an amount of at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 15 wt %, such as at least 20 wt %, such as at least 25 wt %, such as at least 30 wt %, such as at least 35 wt %, such as at least 40 wt %, such as at least 45 wt %, such as at least 50 wt %, such as at least 55 wt %, such as at least 60 wt %, such as at least 65 wt %, such as at least 70 wt %, such as at least 75 wt %, such as at least 80 wt %, or even at least 85 wt %, based on a total weight of the substrate.

[0060] Embodiment 3. The substrate of any one of the preceding embodiments, wherein the substrate includes the natural fiber in an amount of not greater than 90 wt %, such as not greater than 85 wt %, such as not greater than 80 wt %, such as not greater than 75 wt %, such as not greater than 70 wt %, such as not greater than 65 wt %, such as not greater than 60 wt %, such as not greater than 55 wt %, such as not greater than 50 wt %, such as not greater than 45 wt %, such as not greater than 40 wt %, such as not greater than 35 wt %, such as not greater than 30 wt %, such as not greater than 25 wt %, such as not greater than 20 wt %, such as not greater than 15 wt %, or even not greater than 10 wt % for a total weight of the substrate.

[0061] Embodiment 4. The substrate of any one of the preceding embodiments, wherein the substrate includes the glass fiber in an amount of at least 10 wt %, such as at least 12 wt %, such as at least 14 wt %, such as at least 16 wt %, such as at least 18 wt %, such as at least 20 wt %, such as at least 25 wt %, such as at least 30 wt %, such as at least 35 wt %, such as at least 40 wt %, such as at least 45 wt %, such as at least 50 wt %, such as at least 55 wt %, such as at least 60 wt %, such as at least 65 wt %, such as at least 70 wt %, such as at least 75 wt %, such as at least 80 wt %, or even at least 85 wt % for a total weight of the substrate.

[0062] Embodiment 5. The substrate of any one of the preceding embodiments, wherein the substrate includes the glass fiber in an amount of not greater than 90 wt %, such as not greater than 88 wt %, such as not greater than 86 wt %, such as not greater than 84 wt %, such as not greater than 82 wt %, such as not greater than 80 wt %, such as not greater than 75 wt %, such as not greater than 70 wt %, such as not greater than 65 wt %, such as not greater than 60 wt %, such as not greater than 55 wt %, such as not greater than 50 wt %, such as not greater than 45 wt %, such as not greater than 40 wt %, such as not greater than 35 wt %, such as not greater than 30 wt %, such as not greater than 25 wt %, such as not greater than 20 wt %, such as not greater than 15 wt %, or even not greater than 12 wt % for a total weight of the substrate.

[0063] Embodiment 6. The substrate of any one of the preceding embodiments, wherein the tear strength is within a range of at least 350 gf and not greater than 1200 gf, such as within a range of at least 350 gf and not greater than 575 gf, such as within a range of at least 350 gf and not greater than 550 gf, such as within a range of at least 350 gf and not greater than 525 gf, or even within a range of at least 375 gf and not greater than 500 gf.

[0064] Embodiment 7. The substrate of any one of the preceding embodiments, wherein the tensile strength is within a range of at least 50 lbf and not greater than 200 lbf, such as within a range of at least 50 lbf and not greater than 150 lbf, such as within a range of at least 50 lbf and not greater than 125 lbf, such as within a range of at least 50 lbf and not greater than 110 lbf, such as within a range of at least 50 lbf and not greater than 100 lbf, or even within a range of at least 60 lbf and not greater than 100 lbf.

[0065] Embodiment 8. The substrate of any one of the preceding embodiments, wherein the substrate includes a greater content of the glass fiber as compared the content of the natural fiber.

[0066] Embodiment 9. The substrate of any one of the preceding embodiments, wherein the substrate includes a greater content of the natural fiber as compared to the content of the glass fiber.

[0067] Embodiment 10. The substrate of any one of the preceding embodiments, wherein the at least one natural fiber includes a cellulose-containing material, a lignin-containing material, or combination thereof.

[0068] Embodiment 11. The substrate of any one of the preceding embodiments, wherein the at least one natural fiber includes a material selected from the group consisting of hemp, flax, jute, sisal, bagasse, bamboo, kenaf, ramie, abaca, coir, palm, pineapple, curaua, fique, wheat, rice husk, rice straw or a combination thereof.

[0069] Embodiment 12. The substrate of any one of the preceding embodiments, wherein the at least one natural fiber includes a material selected from the group consisting of hemp, flax, jute, or a combination thereof.

[0070] Embodiment 13. The substrate of any one of the preceding embodiments, wherein the at least one natural fiber includes flax.

[0071] Embodiment 14. The substrate of any one of the preceding embodiments, wherein the at least one natural fiber includes hemp.

[0072] Embodiment 15. The substrate of any one of the preceding embodiments, wherein the at least one natural fiber includes jute.

[0073] Embodiment 16. The substrate of any one of the preceding embodiments, wherein the substrate includes a content (wt %) of glass fibers (Cgf) and a content (wt %) of a first natural fiber (Cnf1), and wherein the substrate comprises a first content ratio [Cgf / Cnf1] of least 0.1, such as at least 0.15, such as at least 0.2, such as at least 0.25, such as at least 0.3, such as at least 0.35, such as at least 0.4, such as at least 0.45, such as at least 0.5, such as at least 0.55, such as at least 0.6, such as at least 0.65, such as at least 0.7, such as at least 0.75, such as at least 0.8, such as at least 0.85, such as at least 0.9, such as at least 0.95, such as at least 1, such as at least 1.05, such as at least 1.1, such as at least 1.15, such as at least 1.2, such as at least 1.25, such as at least 1.3, such as at least 1.35, such as at least 1.4, such as at least 1.45, such as at least 1.5, such as at least 1.55, such as at least 1.6, such as at least 1.65, such as at least 1.7, such as at least 1.75, such as at least 1.8, such as at least 1.85, such as at least 1.9, such as at least 1.95, such as at least 2, such as at least 2.25, such as at least 2.5, such as at least 2.75, such as at least 3, such as at least 3.25, such as at least 3.5, such as at least 3.75, such as at least 4, such as at least 4.5, such as at least 5, such as at least 5.5, such as at least 6, such as at least 6.5, such as at least 7, such as at least 7.5, such as at least 8, such as at least 8.5, such as at least 9, such as at least 9.5, or even at least 10.

[0074] Embodiment 17. The substrate of any one of the preceding embodiments, wherein the substrate includes a content (wt %) of glass fibers (Cgf) and a content (wt %) of a first natural fiber (Cnf1), and wherein the substrate comprises a first content ratio [Cgf / Cnf1] of not greater than 100, such as not greater than 90, such as not greater than 80, such as not greater than 70, such as not greater than 60, such as not greater than 50, such as not greater than 40, such as not greater than 30, such as not greater than 20, such as not greater than 19, such as not greater than 18, such as not greater than 17, such as not greater than 16, such as not greater than 15, such as not greater than 14, such as not greater than 13, such as not greater than 12, such as not greater than 11, such as not greater than 10, such as not greater than 9, such as not greater than 8.5, such as not greater than 8, such as not greater than 7.5, such as not greater than 7, such as not greater than 6.5, such as not greater than 6, such as not greater than 5.5, such as not greater than 5, such as not greater than 4.5, such as not greater than 4, such as not greater than 3.5, such as not greater than 3, such as not greater than 2.5, such as not greater than 2, such as not greater than 1.5, such as not greater than 1, such as not greater than 0.9, such as not greater than 0.8, such as not greater than 0.7, such as not greater than 0.6, such as not greater than 0.5, such as not greater than 0.4, or even not greater than 0.3.

[0075] Embodiment 18. The substrate of any one of the preceding embodiments, wherein the substrate includes a first type of natural fiber and a second type of natural fiber, and wherein the substrate includes a content (wt %) of glass fibers (Cgf) and a content (wt %) of the second natural fiber (Cnf2), and wherein the substrate includes a second content ratio [Cgf / Cnf2] of least 0.01, such as at least 0.02, such as at least 0.05, such as at least 0.08, such as at least 0.1, such as at least 0.15, such as at least 0.2, such as at least 0.25, such as at least 0.3, such as at least 0.35, such as at least 0.4, such as at least 0.45, such as at least 0.5, such as at least 0.55, such as at least 0.6, such as at least 0.65, such as at least 0.7, such as at least 0.75, such as at least 0.8, such as at least 0.85, such as at least 0.9, such as at least 0.95, such as at least 1, such as at least 1.05, such as at least 1.1, such as at least 1.15, such as at least 1.2, such as at least 1.25, such as at least 1.3, such as at least 1.35, such as at least 1.4, such as at least 1.45, such as at least 1.5, such as at least 1.55, such as at least 1.6, such as at least 1.65, such as at least 1.7, such as at least 1.75, such as at least 1.8, such as at least 1.85, such as at least 1.9, such as at least 1.95, such as at least 2, such as at least 2.25, such as at least 2.5, such as at least 2.75, such as at least 3, such as at least 3.25, such as at least 3.5, such as at least 3.75, such as at least 4, such as at least 4.5, such as at least 5, such as at least 5.5, such as at least 6, such as at least 6.5, such as at least 7, such as at least 7.5, such as at least 8, such as at least 8.5, such as at least 9, such as at least 9.5, or even at least 10.

[0076] Embodiment 19. The substrate of embodiment, wherein the second content ratio [Cgf / Cnf2] is not greater than 100, such as not greater than 90, such as not greater than 80, such as not greater than 70, such as not greater than 60, such as not greater than 50, such as not greater than 40, such as not greater than 30, such as not greater than 20, such as not greater than 19, such as not greater than 18, such as not greater than 17, such as not greater than 16, such as not greater than 15, such as not greater than 14, such as not greater than 13, such as not greater than 12, such as not greater than 11, such as not greater than 10, such as not greater than 9, such as not greater than 8.5, such as not greater than 8, such as not greater than 7.5, such as not greater than 7, such as not greater than 6.5, such as not greater than 6, such as not greater than 5.5, such as not greater than 5, such as not greater than 4.5, such as not greater than 4, such as not greater than 3.5, such as not greater than 3, such as not greater than 2.5, such as not greater than 2, such as not greater than 1.5, such as not greater than 1, such as not greater than 0.9, such as not greater than 0.8, such as not greater than 0.7, such as not greater than 0.6, such as not greater than 0.5, such as not greater than 0.4, such as not greater than 0.3, such as not greater than 0.2, such as not greater than 0.1, or even not greater than 0.08.

[0077] Embodiment 20. The substrate of embodiment, wherein the substrate includes a content (wt %) of the first type of natural fiber (Cnf1) and a content (wt %) of the second natural fiber (Cnf2), and wherein the substrate comprises a first natural fiber content ratio [Cnf1 / Cnf2] of at least 1, such as at least 1.05, such as at least 1.1, such as at least 1.15, such as at least 1.2, such as at least 1.25, such as at least 1.3, such as at least 1.35, such as at least 1.4, such as at least 1.45, such as at least 1.5, such as at least 1.55, such as at least 1.6, such as at least 1.65, such as at least 1.7, such as at least 1.75, such as at least 1.8, such as at least 1.85, such as at least 1.9, such as at least 1.95, such as at least 2, such as at least 2.25, such as at least 2.5, such as at least 2.75, such as at least 3, such as at least 3.25, such as at least 3.5, such as at least 3.75, such as at least 4, such as at least 4.5, such as at least 5, such as at least 5.5, such as at least 6, such as at least 6.5, such as at least 7, such as at least 7.5, such as at least 8, such as at least 8.5, such as at least 9, such as at least 9.5, or even at least 10.

[0078] Embodiment 21. The substrate of embodiment, wherein the first natural fiber content ratio [Cnf1 / Cnf2] is not greater than 100, such as not greater than 90, such as not greater than 80, such as not greater than 70, such as not greater than 60, such as not greater than 50, such as not greater than 40, such as not greater than 30, such as not greater than 20, such as not greater than 19, such as not greater than 18, such as not greater than 17, such as not greater than 16, such as not greater than 15, such as not greater than 14, such as not greater than 13, such as not greater than 12, such as not greater than 11, such as not greater than 10, such as not greater than 9, such as not greater than 8 5, such as not greater than 7, such as not greater than 6, such as not greater than 5, such as not greater than 4, such as not greater than 3, such as not greater than 2, such as not greater than 1, such as not greater than 0.8, such as not greater than 0.5, such as not greater than 0.2, or even not greater than 0.1.

[0079] Embodiment 22. The substrate of any one of the preceding embodiments, wherein the substrate includes at least two different types of natural fibers selected from the group consisting of hemp, flax, jute, sisal, bagasse, bamboo, kenaf, ramie, abaca, coir, palm, pineapple, curaua, fique, wheat, rice husk, and rice straw.

[0080] Embodiment 23. The substrate of any one of the preceding embodiments, wherein the substrate includes at least two different types of natural fibers selected from the group consisting of material selected from the group consisting of hemp, flax, and jute.

[0081] Embodiment 24. The substrate of any one of the preceding embodiments, wherein the glass fibers include an average length (Lgf) of at least 1 mm, such as at least 5 mm, such as at least 10 mm, such as at least 20 mm, such as at least 40 mm, such as at least 60 mm, such as at least 80 mm. such as at least 100 mm, such as at least 200 mm, such as at least 500 mm, such as at 800 mm, or even at least 1000 mm.

[0082] Embodiment 25. The substrate of embodiment, wherein the glass fibers include an average length (Lgf) of not greater than 5000 mm, such as not greater than 4000 mm, such as not greater than 3000 mm, such as not greater than 2000 mm, such as not greater than 1000 mm, such as not greater than 900 mm, such as not greater than 800 mm, such as not greater than 700 mm, such as not greater than 600 mm, such as not greater than 500 mm, or even not greater than 400 mm.

[0083] Embodiment 26. The substrate of any one of the preceding embodiments, wherein the glass fibers include an average diameter (Dgf) of at least 1 μm, such as at least 3 μm, such as at least 5 μm, such as at least 7 μm, or even at least 10 μm.

[0084] Embodiment 27. The substrate of embodiment, wherein the glass fibers include an average diameter (Dgf) of not greater than 400 μm, such as not greater than 375 μm, such as not greater than 350 μm, such as not greater than 325 μm, such as not greater than 300 μm, such as not greater than 275 μm, such as not greater than 250 μm, such as not greater than 225 μm, such as not greater than 200 μm, such as not greater than 175 μm, such as not greater than 150 μm, such as not greater than 125 μm, such as not greater than 100 μm, such as not greater than 75 μm, or even not greater than 50 μm.

[0085] Embodiment 28. The substrate of any one of the preceding embodiments, wherein the at least one natural fiber includes a plurality of a first type of natural fibers, and wherein the plurality of the first type of natural fibers comprises an average length (Lnf1) of at least 1 mm, such as at least 5 mm, such as at least 10 mm, such as at least 20 mm, such as at least 40 mm, such as at least 60 mm, such as at least 80 mm, such as at least 100 mm, such as at least 200 mm, such as at least 500 mm, such as at 800 mm, or even at least 1000 mm.

[0086] Embodiment 29. The substrate of embodiment, wherein the plurality of the first type of natural fibers includes an average length (Lnf1) of not greater than 5000 mm, such as not greater than 4000 mm, such as not greater than 3000 mm, such as not greater than 2000 mm, such as not greater than 1000 mm, such as not greater than 900 mm, such as not greater than 800 mm, such as not greater than 700 mm, such as not greater than 600 mm, such as not greater than 500 mm, or even not greater than 400 mm.

[0087] Embodiment 30. The substrate of any one of the preceding embodiments, wherein the at least one natural fiber includes a plurality of a first type of natural fibers, and wherein the plurality of the first type of natural fibers comprises an average diameter (Df1) of at least 1 μm, such as at least 3 μm, such as at least 5 μm, such as at least 7 μm, or even at least 10 μm.

[0088] Embodiment 31. The substrate of embodiment, wherein the plurality of the first type of natural fibers includes an average diameter (Dnf1) of not greater than 250 μm, such as not greater than 225 μm, such as not greater than 200 μm, such as not greater than 175 μm, such as not greater than 150 μm, such as not greater than 125 μm, such as not greater than 100 μm, or even not greater than 75 μm.

[0089] Embodiment 32. The substrate of any one of the preceding embodiments, wherein the at least one natural fiber includes a plurality of a first type of natural fibers and a plurality of a second type of natural fibers, and wherein the plurality of the second type of natural fibers comprises an average length (Lnf2) of at least 1 mm, such as at least 5 mm, such as at least 10 mm, such as at least 20 mm, such as at least 40 mm, such as at least 60 mm, such as at least 80 mm, such as at least 100 mm, such as at least 200 mm, such as at least 500 mm, such as at 800 mm, or even at least 1000 mm.

[0090] Embodiment 33. The substrate of embodiment, wherein the plurality of the second type of natural fibers includes an average length (Lnf2) of not greater than 5000 mm, such as not greater than 4000 mm, such as not greater than 3000 mm, such as not greater than 2000 mm, such as not greater than 1000 mm, such as not greater than 900 mm, such as not greater than 800 mm, such as not greater than 700 mm, such as not greater than 600 mm, such as not greater than 500 mm, or even not greater than 400 mm.

[0091] Embodiment 34. The substrate of any one of the preceding embodiments, wherein the at least one natural fiber includes a plurality of a first type of natural fibers and a plurality of a second type of natural fibers, and wherein the plurality of a second type of natural fibers includes an average diameter (Dnf2) of at least 1 μm, such as at least 3 μm, such as at least 5 μm, such as at least 7 μm, or even at least 10 μm.

[0092] Embodiment 35. The substrate of embodiment, wherein the plurality of the second type of natural fibers includes an average diameter (Dnf2) of not greater than 250 μm, such as not greater than 225 μm, such as not greater than 200 μm, such as not greater than 175 μm, such as not greater than 150 μm, such as not greater than 125 μm, such as not greater than 100 μm, or even not greater than 75 μm.

[0093] Embodiment 36. The substrate of any one of the preceding embodiments, wherein a substrate includes a non-woven material including glass fibers a plurality of a first type of natural fibers, and a plurality of a second type of natural fibers different than the first type of natural fibers.

[0094] Embodiment 37. The substrate of embodiment, wherein the glass fibers include an A-type glass fiber, a C-type glass fiber, an E-type glass fiber, an S-type glass fiber, an E-CR-type glass fiber, a wool glass fiber, or a combination thereof.

[0095] Embodiment 38. The substrate of embodiment, wherein the first type of natural fibers includes hemp.

[0096] Embodiment 39. The substrate of embodiment, wherein the second type of natural fibers includes flax.

[0097] Embodiment 40. The substrate of embodiment, wherein the substrate includes: a) 20-80 wt % glass fiber; b) 2-50 wt % hemp; and c) 2-50 wt % flax, wherein the total content of a), b), and c) is not greater than 100 wt %.

[0098] Embodiment 41. The substrate of embodiment, wherein the content of flax is less than the content of hemp.

[0099] Embodiment 42. The substrate of embodiment, wherein the substrate includes: a) a first content ratio [Cgf / Cnf1] within a range of at least 0.1 and not greater than 100, wherein Cgf represents a content (wt %) of glass fibers (Cgf) and Cnf1 represents a content (wt %) of the first type of natural fibers (Cnf1); b) a second content ratio [Cgf / Cnf2] within a range of least 0.01 and not greater than 100, wherein Cnf2 represents a content (wt %) of the second type of natural fibers (Cnf1); and c) a first natural fiber content ratio [Cnf1 / Cnf2] within a range of at least 1 and not greater than 100.

[0100] Embodiment 43. The substrate of embodiment, wherein the substrate includes a tear strength within a range of 350 gf and not greater than 550 gf as measured by TAPPI T1006 standard and wherein the tensile strength is within a range of at least 30 lbf per 3 inch and not greater than 100 lbf as measured by TAPPI T1009 standard.

[0101] Embodiment 44. The substrate of any one of the preceding embodiments, wherein the substrate further includes a binder.

[0102] Embodiment 45. A building product including the substrate of any one of the preceding embodiments.

[0103] Embodiment 46. The building product of embodiment, further including a bitumen-containing layer overlying the substrate.

[0104] Embodiment 47. The building product of embodiment, further including a plurality of granules overlying the substrate.

[0105] The following examples are provided to better disclose and teach processes and compositions of the present invention. They are for illustrative purposes only, and it must be acknowledged that minor variations and changes can be made without materially affecting the spirit and scope of the invention as recited in the claims that follow.EXAMPLESExample 1

[0106] Hand sheets are constructed in the lab to a fiber weight of 0.78-1.98 lbs / 100 ft2 and then 0.12-0.77 lbs / 100 ft2 of binder is added to create a 10-35% LOI hand sheet with a total weight of 1.2-2.2 lbs / 100 ft2. In the exemplary hand sheets, blends of glass fibers and natural fibers were constructed and measured for different mechanical properties. Combinations of blends can be seen in Table 1. All composite mats had an average length of 6 mm or 30 mm natural fibers and average diameter of 50-125 μm. for hemp fibers, 20-100 μm for flax fibers, and 70-80 μm for jute fibers. The glass fibers had an average length of 32 mm and an average diameter of 16 microns. Further, the dispersion was improved via mixing in the glass and at least one natural fiber in a white water solution of at least one of: a dispersant, viscosity modifier, defoamer, a biocide, a pH modifier, other process aids, or combination thereof.TABLE 1Fiber CelluloseHemicelluloseLigninWaxesFiber(wt. %)(wt. %)(wt. %)(wt. %)Flax7118.6-20.62.21.5Jute61-7114-2012-130.5Kenaf7220.39—Hemp6815100.8Banana56-6320-257-93

[0107] The blends of hemp fibers and glass fibers (75 wt % / 25 wt %, respectively) provided an advantageous mat having desirable tensile strength as measured by TAPPI T1009 standard and tear strength as measured by TAPPI T1006 standard. For instance, the hemp / glass fiber blend met the tensile strength requirements and exceeded the tear strength requirements. Target tensile strength was in a range of 60 lbf to 80 lbf and target tear strength was greater than 375 gf. A graphical depiction of the results can be seen in FIGS. 1 and 2.

[0108] The blends of flax fibers and glass fibers (25 wt % / 75 wt %, respectively) provided an advantageous mat having desirable tensile strength and tear strength, measured by TAPPI T1009 standard and TAPPI T1006 standard, respectively. For instance, the flax / glass fiber blend met the tensile strength requirements and exceeded the tear strength requirements. Target tensile strength was in a range of 60 lbf to 80 lbf and target tear strength was greater than 375 gf. 50 wt % flax fibers / 50 wt % glass fibers could be optimized to meet tensile strength requirements; however, exceeded tear strength requirements. A graphical depiction of the results can be seen in FIGS. 3 and 4.Example 2

[0109] Handsheets were made in accordance with Example 1 with a control sample of 100 wt % glass fibers and varying amounts of natural fibers, with 10 wt. % of the glass fibers of the total weight of the fibers in the mat being replaced with natural fibers (i.e., 90 wt. % of fibers in the mat were glass fibers and 10 wt. % of the fibers in the mat were natural fibers). The glass fibers had a length of 30 mm with the natural fibers having a length of 6 mm. The natural fibers were: 10 wt. % hemp fibers, 10 wt. % flax fibers, 10 wt. % jute, a 5 wt. % hemp / 5 wt. % jute fibers mix, and a 5 wt. % jute / 5 wt. % flax fibers mix. A graphical depiction of the results of tensile strength and tear strength, measured as described in Example 1, can be seen in FIGS. 5 and 6. Mixed hemp and jute fibers and mixed jute and flax fibers had a greater tensile and tear strength compared to hemp, flax, or jute, individually at equivalent loading.Example 3

[0110] Handsheets were made in accordance with Example 1 with a control sample of 100 wt % glass fibers and varying amounts of natural fibers, with 10 wt. % of the glass fibers of the total weight of the fibers in the mat being replaced with natural fibers (i.e., 90 wt. % of fibers in the mat were glass fibers and 10 wt. % of the fibers in the mat were natural fibers). The glass fibers had a length of 30 mm with the natural fibers having a length of 6 mm. The natural fibers were: 10 wt. % hemp fibers, 10 wt. % flax fibers, 10 wt. % jute fibers, a 5 wt. % hemp / 5 wt. % flax fibers mix, a 5 wt. % hemp / 5 wt. % jute fibers mix, and a 5 wt. % jute / 5 wt. % flax fibers mix. A graphical depiction of the results of tensile strength and tear strength, measured as described in Example 1, can be seen in FIGS. 7 and 8. At higher natural fiber loading compared to Example 2, there were no significant trends in tensile and tear. Mixed fibers had no increase in tensile and tear compared to hemp, flax, or jute alone at equivalent loading.Example 4

[0111] Shinglets were made with mats with a control sample of 100 wt % glass fibers versus mats with 5 wt. % of the glass fibers of the total weight of the fibers in the mat being replaced with flax or hemp (i.e., 95 wt. % of fibers in the mat were glass fibers and 5 wt. % of the fibers in the mat were natural fibers). The glass fibers had a length of 30 mm with the natural fibers having a length of 6 mm or 30 mm. Flax fibers had a 6 mm length and the hemp fiber had a 6 mm or a 30 mm length.

[0112] Shinglets were made with the mats via the following process: at about 400 degrees fillcoat (66% filler, 34% asphalt) was applied to a ~2.5×11 inch strip by pouring into a drawdown square, which was moved down the mat at a constant speed via a drawdown table. This was done once for each side of mat with fillcoat drawn down separately onto the back and front side. Four tear samples of 2.25×2.5 are cut out from each strip for testing.

[0113] A graphical depiction of the results of tear strength, measured as described in Example 1, can be seen in FIG. 9. Replacing 5 wt. % of glass fibers with hemp or flax fibers in the mat maintained or increased shinglet tear strength. When comparing 30 mm to 6 mm of the same hemp fibers at equivalent loadings, the increased fiber length increased the average tear strength by at least greater than 10%.Example 5

[0114] Shinglets were made as described in Example 4 with mats replacing the glass fibers with a natural fiber blend of 50 wt. % hemp / 50 wt. % flax fibers blend. The natural fibers had a length of 6 mm. Varying amounts of the natural fiber blends (0 wt. %, 10 wt. % (i.e. 10 wt. % natural fiber blend and 90 wt. % glass fibers), 20 wt. % (i.e. 20 wt. % natural fiber blend and 80 wt. % glass fibers), and 50 wt. % (i.e. 50 wt. % natural fiber blend and 50 wt. % glass fibers) based on the total weight of the fibers in the mat) were loaded into a mat, the glass fibers being 30 mm in length. A graphical depiction of the results of tear strength, measured as described in Example 1, can be seen in FIG. 10. Replacing 5 wt. % of glass fibers with a blend of hemp and flax fibers in the mat maintained or increased shinglet tear strength. Shinglets exhibited similar trends to handsheets with 10 wt. % natural fiber loading having the highest tear; tear also decreased with increased natural fiber loading.Example 6

[0115] Handsheets were made in accordance with Example 1 with a control sample of 100 wt. % glass fibers and varying amounts of loading of the natural fibers in the mat. The natural fibers were a 50 wt. % hemp / 50 wt. % flax fibers mix. The glass fibers had a length of 30 mm with the natural fibers having a length of 6 mm. The glass fibers were replaced with the natural fiber mix, with natural fibers loaded at 5 wt. % (i.e. 5 wt. % natural fiber mix and 95 wt. % glass fibers), 10 wt. % (i.e. 10 wt. % natural fiber mix and 90 wt. % glass fibers), 20 wt. % (i.e. 20 wt. % natural fiber mix and 80 wt. % glass fibers), and 50 wt. % (i.e. 50 wt. % natural fiber mix and 50 wt. % glass fibers), based on the total weight of the fibers in the mat. A graphical depiction of the results of tensile strength and tear strength, measured as described in Example 1, can be seen in FIGS. 11 and 12. A 5 wt. % natural fiber loading achieved higher average tensile and tear strength over the control. As the loading of natural fibers increased, the overall tensile and tear strength decreased.

[0116] Certain features, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, reference to values stated in ranges includes each and every value within that range.

[0117] Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

[0118] The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.

Claims

1. A substrate comprising:a non-woven material comprising glass fibers and at least one natural fiber;wherein the substrate comprises a tear strength of at least 350 gf as measured by TAPPI T1006 standard and a tensile strength of at least 30 lbf, per 3 inch as measured by TAPPI T1009 standard.

2. The substrate of claim 1, comprising the natural fiber in an amount of at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 15 wt %, such as at least 20 wt %, such as at least 25 wt %, such as at least 30 wt %, such as at least 35 wt %, such as at least 40 wt %, such as at least 45 wt %, such as at least 50 wt %, such as at least 55 wt %, such as at least 60 wt %, such as at least 65 wt %, such as at least 70 wt %, such as at least 75 wt %, such as at least 80 wt %, or even at least 85 wt %; andnot greater than 90 wt %, such as not greater than 85 wt %, such as not greater than 80 wt %, such as not greater than 75 wt %, such as not greater than 70 wt %, such as not greater than 65 wt %, such as not greater than 60 wt %, such as not greater than 55 wt %, such as not greater than 50 wt %, such as not greater than 45 wt %, such as not greater than 40 wt %, such as not greater than 35 wt %, such as not greater than 30 wt %, such as not greater than 25 wt %, such as not greater than 20 wt %, such as not greater than 15 wt %, or even not greater than 10 wt % based on a total weight of the substrate.

3. The substrate of claim 1, comprising the glass fibers in an amount of at least 10 wt %, such as at least 12 wt %, such as at least 14 wt %, such as at least 16 wt %, such as at least 18 wt %, such as at least 20 wt %, such as at least 25 wt %, such as at least 30 wt %, such as at least 35 wt %, such as at least 40 wt %, such as at least 45 wt %, such as at least 50 wt %, such as at least 55 wt %, such as at least 60 wt %, such as at least 65 wt %, such as at least 70 wt %, such as at least 75 wt %, such as at least 80 wt %, or even at least 85 wt %; andnot greater than 90 wt %, such as not greater than 88 wt %, such as not greater than 86 wt %, such as not greater than 84 wt %, such as not greater than 82 wt %, such as not greater than 80 wt %, such as not greater than 75 wt %, such as not greater than 70 wt %, such as not greater than 65 wt %, such as not greater than 60 wt %, such as not greater than 55 wt %, such as not greater than 50 wt %, such as not greater than 45 wt %, such as not greater than 40 wt %, such as not greater than 35 wt %, such as not greater than 30 wt %, such as not greater than 25 wt %, such as not greater than 20 wt %, such as not greater than 15 wt %, or even not greater than 12 wt % based on a total weight of the substrate.

4. The substrate of claim 1, wherein the tear strength is within a range of at least 350 gf and not greater than 1200 gf, such as within a range of at least 350 gf and not greater than 575 gf, such as within a range of at least 350 gf and not greater than 550 gf, such as within a range of at least 350 gf and not greater than 525 gf, or even within a range of at least 375 gf and not greater than 500 gf.

5. The substrate of claim 1, wherein the tensile strength is within a range of at least 50 lbf and not greater than 200 lbf, such as within a range of at least 50 lbf and not greater than 150 lbf, such as within a range of at least 50 lbf and not greater than 125 lbf, such as within a range of at least 50 lbf and not greater than 110 lbf, such as within a range of at least 50 lbf and not greater than 100 lbf, or even within a range of at least 60 lbf and not greater than 100 lbf.

6. The substrate of claim 1, wherein the at least one natural fiber comprises a cellulose-containing material.

7. The substrate of claim 1, wherein the at least one natural fiber comprises a material selected from the group consisting of hemp, flax, jute, sisal, bagasse, bamboo, kenaf, ramie, abaca, coir, palm, pineapple, curaua, fique, wheat, rice husk, rice straw or a combination thereof.

8. The substrate of claim 1, comprising a content (wt %) of glass fibers (Cgf) and a content (wt %) of a first natural fiber (Cnf1), and wherein the substrate comprises a first content ratio [Cgf / Cnf1] of least 0.1, such as at least 0.15, such as at least 0.2, such as at least 0.25, such as at least 0.3, such as at least 0.35, such as at least 0.4, such as at least 0.45, such as at least 0.5, such as at least 0.55, such as at least 0.6, such as at least 0.65, such as at least 0.7, such as at least 0.75, such as at least 0.8, such as at least 0.85, such as at least 0.9, such as at least 0.95, such as at least 1, such as at least 1.05, such as at least 1.1, such as at least 1.15, such as at least 1.2, such as at least 1.25, such as at least 1.3, such as at least 1.35, such as at least 1.4, such as at least 1.45, such as at least 1.5, such as at least 1.55, such as at least 1.6, such as at least 1.65, such as at least 1.7, such as at least 1.75, such as at least 1.8, such as at least 1.85, such as at least 1.9, such as at least 1.95, such as at least 2, such as at least 2.25, such as at least 2.5, such as at least 2.75, such as at least 3, such as at least 3.25, such as at least 3.5, such as at least 3.75, such as at least 4, such as at least 4.5, such as at least 5, such as at least 5.5, such as at least 6, such as at least 6.5, such as at least 7, such as at least 7.5, such as at least 8, such as at least 8.5, such as at least 9, such as at least 9.5, or even at least 10; andnot greater than 100, such as not greater than 90, such as not greater than 80, such as not greater than 70, such as not greater than 60, such as not greater than 50, such as not greater than 40, such as not greater than 30, such as not greater than 20, such as not greater than 19, such as not greater than 18, such as not greater than 17, such as not greater than 16, such as not greater than 15, such as not greater than 14, such as not greater than 13, such as not greater than 12, such as not greater than 11, such as not greater than 10, such as not greater than 9, such as not greater than 8.5, such as not greater than 8, such as not greater than 7.5, such as not greater than 7, such as not greater than 6.5, such as not greater than 6, such as not greater than 5.5, such as not greater than 5, such as not greater than 4.5, such as not greater than 4, such as not greater than 3.5, such as not greater than 3, such as not greater than 2.5, such as not greater than 2, such as not greater than 1.5, such as not greater than 1, such as not greater than 0.9, such as not greater than 0.8, such as not greater than 0.7, such as not greater than 0.6, such as not greater than 0.5, such as not greater than 0.4, or even not greater than 0.3.

9. The substrate of claim 1, comprising a first type of natural fiber and a second type of natural fiber, and wherein the substrate comprises a content (wt %) of glass fibers (Cgf) and a content (wt %) of the second natural fiber (Cnf2), and wherein the substrate comprises a second content ratio [Cgf / Cnf2] of least 0.01, such as at least 0.02, such as at least 0.05, such as at least 0.08, such as at least 0.1, such as at least 0.15, such as at least 0.2, such as at least 0.25, such as at least 0.3, such as at least 0.35, such as at least 0.4, such as at least 0.45, such as at least 0.5, such as at least 0.55, such as at least 0.6, such as at least 0.65, such as at least 0.7, such as at least 0.75, such as at least 0.8, such as at least 0.85, such as at least 0.9, such as at least 0.95, such as at least 1, such as at least 1.05, such as at least 1.1, such as at least 1.15, such as at least 1.2, such as at least 1.25, such as at least 1.3, such as at least 1.35, such as at least 1.4, such as at least 1.45, such as at least 1.5, such as at least 1.55, such as at least 1.6, such as at least 1.65, such as at least 1.7, such as at least 1.75, such as at least 1.8, such as at least 1.85, such as at least 1.9, such as at least 1.95, such as at least 2, such as at least 2.25, such as at least 2.5, such as at least 2.75, such as at least 3, such as at least 3.25, such as at least 3.5, such as at least 3.75, such as at least 4, such as at least 4.5, such as at least 5, such as at least 5.5, such as at least 6, such as at least 6.5, such as at least 7, such as at least 7.5, such as at least 8, such as at least 8.5, such as at least 9, such as at least 9.5, or even at least 10; andnot greater than 100, such as not greater than 90, such as not greater than 80, such as not greater than 70, such as not greater than 60, such as not greater than 50, such as not greater than 40, such as not greater than 30, such as not greater than 20, such as not greater than 19, such as not greater than 18, such as not greater than 17, such as not greater than 16, such as not greater than 15, such as not greater than 14, such as not greater than 13, such as not greater than 12, such as not greater than 11, such as not greater than 10, such as not greater than 9, such as not greater than 8.5, such as not greater than 8, such as not greater than 7.5, such as not greater than 7, such as not greater than 6.5, such as not greater than 6, such as not greater than 5.5, such as not greater than 5, such as not greater than 4.5, such as not greater than 4, such as not greater than 3.5, such as not greater than 3, such as not greater than 2.5, such as not greater than 2, such as not greater than 1.5, such as not greater than 1, such as not greater than 0.9, such as not greater than 0.8, such as not greater than 0.7, such as not greater than 0.6, such as not greater than 0.5, such as not greater than 0.4, such as not greater than 0.3, such as not greater than 0.2, such as not greater than 0.1, or even not greater than 0.08.

10. The substrate of claim 9, comprising a content (wt %) of the first type of natural fiber (Cnf1) and a content (wt %) of the second natural fiber (Cnf2), and wherein the substrate comprises a first natural fiber content ratio [Cnf1 / Cnf2] of at least 1, such as at least 1.05, such as at least 1.1, such as at least 1.15, such as at least 1.2, such as at least 1.25, such as at least 1.3, such as at least 1.35, such as at least 1.4, such as at least 1.45, such as at least 1.5, such as at least 1.55, such as at least 1.6, such as at least 1.65, such as at least 1.7, such as at least 1.75, such as at least 1.8, such as at least 1.85, such as at least 1.9, such as at least 1.95, such as at least 2, such as at least 2.25, such as at least 2.5, such as at least 2.75, such as at least 3, such as at least 3.25, such as at least 3.5, such as at least 3.75, such as at least 4, such as at least 4.5, such as at least 5, such as at least 5.5, such as at least 6, such as at least 6.5, such as at least 7, such as at least 7.5, such as at least 8, such as at least 8.5, such as at least 9, such as at least 9.5, or even at least 10; andnot greater than 100, such as not greater than 90, such as not greater than 80, such as not greater than 70, such as not greater than 60, such as not greater than 50, such as not greater than 40, such as not greater than 30, such as not greater than 20, such as not greater than 19, such as not greater than 18, such as not greater than 17, such as not greater than 16, such as not greater than 15, such as not greater than 14, such as not greater than 13, such as not greater than 12, such as not greater than 11, such as not greater than 10, such as not greater than 9, such as not greater than 8 5, such as not greater than 7, such as not greater than 6, such as not greater than 5, such as not greater than 4, such as not greater than 3, such as not greater than 2, such as not greater than 1, such as not greater than 0.8, such as not greater than 0.5, such as not greater than 0.2, or even not greater than 0.1.

11. The substrate of claim 1, wherein the glass fibers comprise an average length (Lgf) of at least 1 mm, such as at least 5 mm, such as at least 10 mm, such as at least 20 mm, such as at least 40 mm, such as at least 60 mm, such as at least 80 mm. such as at least 100 mm, such as at least 200 mm, such as at least 500 mm, such as at 800 mm, or even at least 1000 mm; andnot greater than 5000 mm, such as not greater than 4000 mm, such as not greater than 3000 mm, such as not greater than 2000 mm, such as not greater than 1000 mm, such as not greater than 900 mm, such as not greater than 800 mm, such as not greater than 700 mm, such as not greater than 600 mm, such as not greater than 500 mm, or even not greater than 400 mm.

12. The substrate of claim 1, wherein the glass fibers comprise an average diameter (Dgf) of at least 1 μm, such as at least 3 μm, such as at least 5 μm, such as at least 7 μm, or even at least 10 μm; andnot greater than 400 μm, such as not greater than 375 μm, such as not greater than 350 μm, such as not greater than 325 μm, such as not greater than 300 μm, such as not greater than 275 μm, such as not greater than 250 μm, such as not greater than 225 μm, such as not greater than 200 μm, such as not greater than 175 μm, such as not greater than 150 μm, such as not greater than 125 μm, such as not greater than 100 μm, such as not greater than 75 μm, or even not greater than 50 μm.

13. The substrate of claim 1, wherein the at least one natural fiber comprises a plurality of a first type of natural fibers, and wherein the plurality of the first type of natural fibers comprises an average length (Lnf1) of at least 1 mm, such as at least 5 mm, such as at least 10 mm, such as at least 20 mm, such as at least 40 mm, such as at least 60 mm, such as at least 80 mm, such as at least 100 mm, such as at least 200 mm, such as at least 500 mm, such as at 800 mm, or even at least 1000 mm; andnot greater than 5000 mm, such as not greater than 4000 mm, such as not greater than 3000 mm, such as not greater than 2000 mm, such as not greater than 1000 mm, such as not greater than 900 mm, such as not greater than 800 mm, such as not greater than 700 mm, such as not greater than 600 mm, such as not greater than 500 mm, or even not greater than 400 mm.

14. The substrate of claim 1, wherein the at least one natural fiber comprises a plurality of a first type of natural fibers, and wherein the plurality of the first type of natural fibers comprises an average diameter (Df1) of at least 1 μm, such as at least 3 μm, such as at least 5 μm, such as at least 7 μm, or even at least 10 μm; andnot greater than 250 μm, such as not greater than 225 μm, such as not greater than 200 μm, such as not greater than 175 μm, such as not greater than 150 μm, or even not as not greater than 125 μm.

15. The substrate of claim 1, wherein the at least one natural fiber comprises a plurality of a first type of natural fibers and a plurality of a second type of natural fibers, and wherein the plurality of the second type of natural fibers comprises an average length (Lnf2) of at least 1 mm, such as at least 5 mm, such as at least 10 mm, such as at least 20 mm, such as at least 40 mm, such as at least 60 mm, such as at least 80 mm, such as at least 100 mm, such as at least 200 mm, such as at least 500 mm, such as at 800 mm, or even at least 1000 mm; andnot greater than 5000 mm, such as not greater than 4000 mm, such as not greater than 3000 mm, such as not greater than 2000 mm, such as not greater than 1000 mm, such as not greater than 900 mm, such as not greater than 800 mm, such as not greater than 700 mm, such as not greater than 600 mm, such as not greater than 500 mm, or even not greater than 400 mm.

16. The substrate of claim 1, wherein the at least one natural fiber comprises a plurality of a first type of natural fibers and a plurality of a second type of natural fibers, and wherein the plurality of a second type of natural fibers comprises an average diameter (Dnf2) of at least 1 μm, such as at least 3 μm, such as at least 5 μm, such as at least 7 μm, or even at least 10 μm; andnot greater than 250 μm, such as not greater than 225 μm, such as not greater than 200 μm, such as not greater than 175 μm, such as not greater than 150 μm, or even not greater than 125 μm.

17. The substrate of claim 1, comprising the non-woven material comprising the glass fibers, a plurality of a first type of natural fibers, and a plurality of a second type of natural fibers different than the first type of natural fibers.

18. The substrate of claim 1, wherein the substrate comprises:a) 20-80 wt % glass fibers;b) 2-50 wt % hemp; andc) 2-50 wt % flax, wherein the total content of a), b), and c) is not greater than 100 wt %.

19. A building product comprising a substrate, the substrate comprising:a non-woven material comprising glass fibers and at least one natural fiber;wherein the substrate comprises a tear strength of at least 350 gf as measured by TAPPI T1006 standard and a tensile strength of at least 30 lbf, per 3 inch as measured by TAPPI T1009 standard.

20. The building product of claim 19, further comprising a bitumen-containing layer overlying the substrate, a plurality of granules overlying the substrate, or any combination thereof.

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