CA1045910A - Fibrous mat especially suitable for roofing products and a method of making the mat - Google Patents
Fibrous mat especially suitable for roofing products and a method of making the matInfo
- Publication number
- CA1045910A CA1045910A CA184,383A CA184383A CA1045910A CA 1045910 A CA1045910 A CA 1045910A CA 184383 A CA184383 A CA 184383A CA 1045910 A CA1045910 A CA 1045910A
- Authority
- CA
- Canada
- Prior art keywords
- approximately
- mat
- web
- fiber bundles
- fibers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
- D21H13/36—Inorganic fibres or flakes
- D21H13/38—Inorganic fibres or flakes siliceous
- D21H13/40—Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D5/00—Roof covering by making use of flexible material, e.g. supplied in roll form
- E04D5/02—Roof covering by making use of flexible material, e.g. supplied in roll form of materials impregnated with sealing substances, e.g. roofing felt
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2095/00—Use of bituminous materials as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
- B29K2309/08—Glass
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Textile Engineering (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Inorganic Chemistry (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Paper (AREA)
- Roof Covering Using Slabs Or Stiff Sheets (AREA)
Abstract
Abstract of the Disclosure An economical and uniform fibrous glass mat displaying improved tear strength and a wet formin?
process of making such a mat is disclosed herein. The mat, which is especially suitable as a carrier material in the manufacture of asphalt shingles or other such roofing products, includes a web of base fibers comprising individual monofilament glass fibers and reinforcement fibers in the form of glass fiber bundles interspersed throughout the web in a randomly oriented pattern. The mat also includes a binder substance to assist in holding the base fibers and reinforcement fiber bundles together.
process of making such a mat is disclosed herein. The mat, which is especially suitable as a carrier material in the manufacture of asphalt shingles or other such roofing products, includes a web of base fibers comprising individual monofilament glass fibers and reinforcement fibers in the form of glass fiber bundles interspersed throughout the web in a randomly oriented pattern. The mat also includes a binder substance to assist in holding the base fibers and reinforcement fiber bundles together.
Description
~)4~
A FIBROVS Ml\T ESPECIALLY SUITABLE FOR RQO~ING PRODUC'rS
AND A METHOD OF MI~KIN(; THE MAT
Back round of the Invention g Field of the Invention ~, The present invention relates generallY to fibrous glass mats and more particularlv to an improved fibrous glass mat especially suitable for use in roofiny shingles and a method of making such a mat.
Description of the Prior Art .
In the past, most asphalt roofing shingles were constructed of organic rag felt impregnated and coated with asphalt or other such bituminous substance, the rag felt, in most cases, being made on a cylinder paper machine.
More recentl~, the demand for and production of this type of shingle has increased substantially. For example, in 1961, the industry produced and sold approximately ;
40 million squares of asphalt shingle for customer use. ~-A square covers lO0 square feet of roof area and, in 1961, `
cost the contractor approximately seven dollars. In 1971, approximately 57 million squares of asphalt shingles were produced and sold at a cost of about nine dollars a s~uare.
The estimated industry production and sale of asphalt `
shingles in 1981 is approximately 74 million squares. It should be apparent rom these figures that the asphalt roofing market is highly significant and growing at a rapid rate.
In responding to the afores-tated increase in demand and production of asphalt roofing material, industry has found that the addition of new cylinder paper machines for producing rag felt is very expensive. Further, in ~ ;~
depleting the supply of materials needed in making rag felt, the latter has itself become more expensive. For :
. ; : .
~4S~O
1 these r~asons, industry has taken a look at other type~
of shin~le ~ats and particularly mats made of fiber glass.
In developing a new type of glass mat especially suitable for roofing shingles, there are three basic objectives which should be achieved. Firstly t the glass mat should be inexpensive so that competitively priced shingles can be produced. Secondly, the glass mat should be uniform so as to avoid production discontinuity and waste which otherwise increases the manufacturing cost of the mat and therefore the shingle. Thirdly, the mat should display sufficient tearing resistance for maintaining integrity and resistance against blow-offs of the applied shingles under severe wind conditions.
Heretofore, the prior art has not satisfactorily met all three of the foregoing objectives. For example, one suggestion has been to provide a steam-blown glass fiber mat. While this type of mat is relatively inexpensive to manufacture, it has been found to display unsatisfactory tear resistance, thereby resulting in a shingle highly
A FIBROVS Ml\T ESPECIALLY SUITABLE FOR RQO~ING PRODUC'rS
AND A METHOD OF MI~KIN(; THE MAT
Back round of the Invention g Field of the Invention ~, The present invention relates generallY to fibrous glass mats and more particularlv to an improved fibrous glass mat especially suitable for use in roofiny shingles and a method of making such a mat.
Description of the Prior Art .
In the past, most asphalt roofing shingles were constructed of organic rag felt impregnated and coated with asphalt or other such bituminous substance, the rag felt, in most cases, being made on a cylinder paper machine.
More recentl~, the demand for and production of this type of shingle has increased substantially. For example, in 1961, the industry produced and sold approximately ;
40 million squares of asphalt shingle for customer use. ~-A square covers lO0 square feet of roof area and, in 1961, `
cost the contractor approximately seven dollars. In 1971, approximately 57 million squares of asphalt shingles were produced and sold at a cost of about nine dollars a s~uare.
The estimated industry production and sale of asphalt `
shingles in 1981 is approximately 74 million squares. It should be apparent rom these figures that the asphalt roofing market is highly significant and growing at a rapid rate.
In responding to the afores-tated increase in demand and production of asphalt roofing material, industry has found that the addition of new cylinder paper machines for producing rag felt is very expensive. Further, in ~ ;~
depleting the supply of materials needed in making rag felt, the latter has itself become more expensive. For :
. ; : .
~4S~O
1 these r~asons, industry has taken a look at other type~
of shin~le ~ats and particularly mats made of fiber glass.
In developing a new type of glass mat especially suitable for roofing shingles, there are three basic objectives which should be achieved. Firstly t the glass mat should be inexpensive so that competitively priced shingles can be produced. Secondly, the glass mat should be uniform so as to avoid production discontinuity and waste which otherwise increases the manufacturing cost of the mat and therefore the shingle. Thirdly, the mat should display sufficient tearing resistance for maintaining integrity and resistance against blow-offs of the applied shingles under severe wind conditions.
Heretofore, the prior art has not satisfactorily met all three of the foregoing objectives. For example, one suggestion has been to provide a steam-blown glass fiber mat. While this type of mat is relatively inexpensive to manufacture, it has been found to display unsatisfactory tear resistance, thereby resulting in a shingle highly
2~ susceptible to blow-off. On the other hand, a dry forming process swirl reinforced mat utilizing a web of base fibers and swirled continuous glass filaments as reinforcement fibers has also been suggestecl by the prior art. While the latter type of mat has been found to display better tear resistance than the steam-blown mat, the dry process utilized in forming such a mat is expensive and slow. Due to rela- -tively low production output and relatively high labor re-quirements utilized with this process, the ultimate product is relatively expensive. In addition, it has been found ~0 that this type of mat is not reliably uniform in production, resulting in production discontinulty and waste and therefore i9~
1 u~necessar~ co~t and delay. For the most part, t~e prior art h~5 been unable to produce such a ma-t other than by -the dry process. This drastically limits the ability to adequately disperse the reinforcement fibers throughout the base fiher web, resulting in a limitation on the tear strength of the ultimately produced mat.
Even in view of the foregoing deficiencies, industry has continued to look towards glass mat for the production of asphalt shingles. For example, in 1961, the use of glass mat for this purpose was substantially non-existent. In 1971, approximately 250,000 squares of asphalt shingles with glass mat were produced and sold.
The projection for 1981 is that approximately 11 million squares of asphalt shingle using glass mat will be produced and sold in that year. Because of this increased demand for roofing shingles and mat generally and glass mat in particular, competition in this field has become keener.
In addition, the capability to produce a more economical and uniform mat with satisfactory tear resistance has become increasingly more important.
As will be seen hereinafter, the present invention has overcome many o the problems left unsolved in the prior art by providing a fibrous glass mat which is more economicallv and uniforml~ produced and which displays improved teax resistance. In this manner, a more economical and higher -quality shingle can be produced.
Ob ects and Summar of the Invention :1 Y - ~ ~
In accordance with the foregoing, an object of the present invention is to provide an economical `~
method of making a uniform fibrous glass mat displaying improved tear resistance.
1 u~necessar~ co~t and delay. For the most part, t~e prior art h~5 been unable to produce such a ma-t other than by -the dry process. This drastically limits the ability to adequately disperse the reinforcement fibers throughout the base fiher web, resulting in a limitation on the tear strength of the ultimately produced mat.
Even in view of the foregoing deficiencies, industry has continued to look towards glass mat for the production of asphalt shingles. For example, in 1961, the use of glass mat for this purpose was substantially non-existent. In 1971, approximately 250,000 squares of asphalt shingles with glass mat were produced and sold.
The projection for 1981 is that approximately 11 million squares of asphalt shingle using glass mat will be produced and sold in that year. Because of this increased demand for roofing shingles and mat generally and glass mat in particular, competition in this field has become keener.
In addition, the capability to produce a more economical and uniform mat with satisfactory tear resistance has become increasingly more important.
As will be seen hereinafter, the present invention has overcome many o the problems left unsolved in the prior art by providing a fibrous glass mat which is more economicallv and uniforml~ produced and which displays improved teax resistance. In this manner, a more economical and higher -quality shingle can be produced.
Ob ects and Summar of the Invention :1 Y - ~ ~
In accordance with the foregoing, an object of the present invention is to provide an economical `~
method of making a uniform fibrous glass mat displaying improved tear resistance.
-3- ;
1 ~nother ob~ect of the present invention is to provide such a mat displayinc3 uniformity and improved tear resistance.
Yet, another object of the present invention i5 to provide a roofinc3 product utilizing the aforestated mat such that the roofing product is economical and dis-plays improved blow-off resistance.
As will be seen in more detail hereinafter, these objects, as well as other objects and features, are attained and manv of the deficiencies of the prior art are eliminated by the present invention which sets forth a wet forming process of making a fibrous glass mat especially suitable for use in shingles. The mat comprises a web of monofila-ment glass fibers and elongated glass fiber bundles having ends and binder substance to assist in holding the mono-filament fibers and fiber bundles together. By making such a mat by the particular process of the present inven-tion, the mat can be made in a more economical and uniform manner. Further, the glass fibers and fiber bundles are dispersed in a randomly oriented fashion throughout the web and a majority of the ends of the fiber bundles are within the confines of the web. This, in turn, increases the tearing resistance of the mat and therefore the blow-off resistance of a shingle made with the mat.
Brief Descri tion of the Drawings ;
P
Figure 1 is an enlarged perspective view of a fibrous glass mat designed in accordance with the present invention.
Figure 2 is a schematic illustration o-f a method of making the mat in accordance with the present ;
invention.
; .
~a~s~o 1 Figure 3 is a graphic lllustration displaying tear resistance o an asphalt shingle made with a ylass mat of the present invention.
Detailed Description Turning to the drawings, a fibrous glass ma~
constructed in accordance with the present invention is illustrated in Figure 1 and generally designated by the reference num~ral 10. The mat is comprised of a web 12 of monofilament glass fibers (base fibers) and elongated ;~
glass fiber bundles 14 (reinforcement bundles) having ends, the glass fibers and fiber bundles being dispersed through-out the web in a randomly oriented pattern. In addition, a suitable binder substance is provided to assist in holding the base fibers and reinforcement bundles together.
The glass fiber bundles, a majority of which have their opposite ends terminating well within the confines of the ~ -~
web, provide highly satisfactory tear resistance to the ` ~`
mat, especially where the latter is used as part of an asphalt shingle. ~ ~
As will be described in more detail hereinafter, ' fibrous glass mat 10 is made by forming a slurry, preferablv a water slurry, including the base fibers and reinforcement bundles such that the solids content o the slurry is very low, preferably approximately 0.2~. Under intense agitation, the base fibers and reinforcement bundles are substantially completely dispersed throughout the slurry. After this dispersing operationl the fiber containing slurry is applied to a moving screen where, by means of vacuum, a majority of -the water is removed resulting in the aforedescribed web of base fibers and reinforcement bundles. After formation of the web, a binder substance is applied thereto so as to -~
:':
' ' ~' -5- ~
~sg~o 1 assist in bonding the Fiber5 and Eiber bundles togeth~r.
Thereafter, the bonded web is passecl through a dryer for evaporating any water remaining in the web and for curing the binder.
It should be noted that by providing a fibrous slurry, and preferably a slurry of low fiber content, a highly uniform mat can be produced, especially in com-parison to the less uniform mat formed by the dry forming process. This, of course, minimiæes production dis-continuity and product wastage and therefore minimizes manuacturing cost. In addition, by providing this slurry, the reinforcement bundles, that is, the glass iber bundles can be readil~ dispersed throughout the web in the manner described above, thereby resulting in a mat with improved tear resistance. Further, by pro-viding a wet forming process of the type described herein, the rapidity of production can be substantially increased over that of the dry forming process, in some cases ten fold, and the re~uirement of producing base fibers simul-2~ taneously with the production of the mat can be eliminated.
Both of these latter features maximize efficiency and minimize cost in mat production.
Having briefly described the fibrous glass mat 10 and process for making the same in accordance with the present invention, attention is now directed to a more detailed analysis of the components making up the mat.
In this regard, attention is directed to the base fibers ~ ;
which, as set forth above, are~monofilament glass fibers.
i .
These monofilament fibers are pre-chopped to desired lengths from continuous strands, preferably in an independent operation apart from and unrelated to the forming operation , :.
.
-6- ~
~C)459~
1 of mat 10. Thi~ independent operation has been found to be less costly than the simultaneous production of base fiber and mat typically carried out in the dry forming process of a glass mat. ~s will be seen hereinafter, the strands break up into individual monofilament fibers when placed in the slurry.
While there is no absolute limitation on dis-crete length of the monofilament fibers, a preferred broad range is between approximately 12 mm and 60 mm.
With respect to monofilament fibers below 12 mm, it has been found that the chopping machinery used to date has been unable to satisactorily chop the continuous filaments ~;
to such shorter lengths. On the other hand, monofilament fibers above approximately 60 mm tend to cause fiber entanglement in the slurry and poor dispersion. It has been found that the best operating range is between approxi-mately 22 mm and 35 mm. ;~-Like the length of the monofilament glass fibers ~ ;
or base fibers, there is no ahs~Qlute limitation on the diameter of these fibers. However, due to practical and ~;
economical considerations, they are preferably between approximately 12~ and 19~ in diameter. This range includes ;~
the K, M and P filaments, all o which are readily available and economical to use. In addition, the density of the ~ ~
ultimately produced mat is related to the diameter of the ~;
base ibers and therefore can be regulated by the proper selection of base fiber diameter.
The preferred amount of base fiber used in mat 10 is dependent upon the amount o fiber content provided by the reinforcement fiber bundles. Hence, this will be discussed hereinafter with respect to the detailed discussion of the latter.
~s9~
1 Attention is now directed to the elongated cJlass fiber bundles or reinforcement bundles. Each of -these bundles is macle from a plurality of monofilament ylass fibers which are preferably in the diameter range of approximately 12 ~ to l9~L( for the same reasons dis-cussed above. The exact number of monofilaments provided in each bundle will depend upon the desired strength and thickness of the latter. A good working range has been found to be between approximatel~ 20 and 300 monofilaments 0 per bundle. Since it is important to keep these bundles intact throughout the mat forming process, they are coated with a water or other such liquid insoluble binder of known kind. This keeps the bundles bonded together even when exposed to the forming slurry.
There is no absolute limitation on the length of the glass fiber bundles. However, when the fiber bundles ..
are below approximately 15 mm in length, their function as a reinforcement is, in many cases, unreliable, especially where the ultimately produced mat is to be used as part of a roofing shingle. On the other hand, when the bundles ~ ;
are above approximately 100 mm in length, they tend to tangle up in the slurry. ~s a good operating range, the fiber bundles are preferably between approximately 65 mm and 75 mm in length.
As stated above, the amount of monofilament base fibers in mat 10 will depend upon the fiber content of the reinforcement bundles. In this regard, of the total fiber content (by dry weight) attributed to the base fibers and fiber bundles, there can be as little as 5%
fiber content attributed to the bundles or as much as 90%.
Below 5%, the fiber bundles do not contribute any significant ~gi~
1 reinforcem~nt to the mat and ab~ve 90% the Eibers tend to provide an ov~rl~ dense and non-uniform mat.
Where the contemplated use or mat 10 i5 the carrier material for an asphalk shingle, the pre~erred range of fiber content atkributed to ~he fiber bundles i~ between approximately 5% and 30% (by dry weiyht). With this range, there is adequate xeinorcement for improved tear resistance in the ultimately produced ma-t but the mat is not so dense to be unsuitable or shingle use. Within ~-this latter range, a highly satisfactory mat or use in shingles has been found to include approximately 15% fiber content attributed to the reinforcement bundles.
As stated above, the foregoing percentages of fiber content are those attributed to the fiber bundles in relation ~o the total of base Eibers and iber bundles.
Hence, the amount of base fiber in any given mat can be ;
readily calculated from the amount of fiber comprising the reinforcement bundles. These percentages will, of course, decrease when the binder is taken into consider-ation. In this regard, mat 10 includes a binder to cooperate in holding the monofilament base fibers and fiber bundles together. The amount of binder provided ~`
will depend upon the use of the ultimately formed mat. ~;
As a general range, the mat may include binder as low as j~ 3% of the total dry weight of the mat or as high as 45%.
' For use in shingles, however, best results are attained by using binding substance in an amount equal to approxi-mately 15~ of the total dry weight of the mat. An amount substantially less than this figure does not adequately hold the fibers together while an amount substantially greater than this figure does not appear to he necessary.
Any suitable blnder known by those skilled ~n the art can be used, such as, ~or example, urea-~ormaldehyde.
With fibrous glass mat 10 constructed ln the foregoing manner, attention is now d~rected to fI6. 2 which illustrates a method of making the mat in accordance with the present invention. Specifically, the aforedescribed mono-filament base fibers whlch are compressed together in bundles and reinforcement Fiber bundles, having been provided and chopped to the preferred lengths, are dispersed into an opening mixing tank 20 which includes a water slurry. A
suitable dispersan~ such as, for example, a cationic surfac-tant, for example one designated by the trademark AEROSOL, is also introduced into the slurry. At this point, the bundles of monofilament base fibers start to separate into individual monofilaments in the slurry. Both types of fiber are carefully metered into the tank in constant relation to ;
the slurry so as to maintain an exact, preferably very low~
fiber concentration. In fact, a preferred ~iber concentration is approximately 0.2%. The metering operation also measures and limits the relative amounts by weight of base fibers to reinforcement fiber bundles to be provided in the slurry, such as, for example, 85X base ~ibers to 15% fiber bundles.
From opening tank 20, the fibrous slurry is passed through two larger tanks, a pre-mixing tank 22 and a main mixing tank 24, where it is intensely agitated so as to cause the bundles of monofilament base fiber to completely break up and to achieve complete dispersion of the fibers generally. As the dispersed fibrous slurry - ~ ;~
passes downstream from main tank 24, the fiber concentra- -tion is further reduced at point 26 by introduction of additional water. At this point the fiber concentration -10- ; . .
~i , ,, , :
5~
1 is preferably approximately l/20th of the ori~inal sluxry concentration.
From polnt 26, the slurry passe~ to a conven-tionally known head box or h~droformer 28. In the hydroformer, -the fi~rous slurry passes over a moving wire screen arranc3ement 30 where most of the water is removed by vacuum, as indicated at 32, thus forming a web of base fibers and reinforcement bundles. The water removed b~ vacuum enters either of two recycle tanks 34 where it can be recirculated to opening tank 20 and point 26.
After the web is formed on moving screen 30, ~;
it is moved downstream where a binder i9 applied thereto by means of a conventional applicator device 36 which, as illustrated, may provide recirculation of excess binder.
Downstream from applicator device 36, the bonded fibrous mat is transferred to a moving conveyor 38 which passes ~;~
the mat through a drying oven for evaporation of water contained in the mat and curing of the binder.
As set forth above, the reinforcement fiber bundles are pre~chopped and introduced to the slurry in the opening tank 20. It is to be understood that the ;~
fiber bundles could also be introduced into the premixing tank 22, main mixing tank 24 or directly into the ;;
hydroformer 28. However, it has been found that intro-duction into the opening tank provides best dispersion of the fibers.
The foregoing method of making mat lO is both rapid and economical, especially compared to the dry forming process of making the aforedescribed swirl rein~
forced mat. In addition, by using a slurry of low fiber ,,~
~o~s~
1 concentration in producing mat 10, mat uniEormity can be readily and consistentl~ a-ttained. F~lrther, the slurry of low fiber concentration allows -the fiber bundles to disperse throughout the web of monofilament base ibers in a randomly oriented pattern such that a subs-tantial number of the bundles have their ends terminating well within the con-fine~ oE the web. This substantially increases the tear resistance of the ultimately produced mat, as will be shown with respect to Figure 3.
~fter mat 10 has been made, it can be used for ~`
many different purposes. IIowever, a major use for the mat is its incorporation into bituminous roofing products gen-erally and asphalt roofiny shingles in particular. In this case, the mat is preferably 0.035 inches thick and preferablv displays a weight of approximately 2.05 lbs./100 sq. t. As stated above, the weight is best regulated by regulating the diameter of the afore-described monofilament base fibers.
Hence, it has been found that base fibers displaying a diameter between approxi-mately 14 ~ and 16 ~ are satisfactory to achieve this weight. ~
The specific methods of making asphalt shingles ~ `
or other roofing products with glass mat are well known to those skilled in the art. ~lence, a specific dis-cussion of these methods will not be given herein. It shall suffice to state that in all cases the mat is coated with asphalt or other bituminous substance. The amount and tvpe of asphalt or other such bituminous substances used will depend on the particular roofing product made.
Attention is now directed to Figure 3 which graphically illustrates the tear resistance of asphalt :~L134~
1 shingles usln~ glass mat of the present invention, however, with varying amounts of reinforcement fiber bundles. More specifically, over forty asphalt shinyle samples were pre- ;
pared from mats. The mats of these shingles had approxi-mately the same weight (2.00 - 2.40 lbs./100 sq. ft.), approximately the same length monofilament base fiber (30 mm) and reinforcement fiber bundle (70 mm) and used the same amount and type of binder. The mats for the shingles were made in the manner described above. However, the amount of fiber content attributed to the reinforcement bundles and the amount of fiber content attributed to the monofilament `~
base iber have been varied to display their affect or tear resistance. Specifically, samples were made with 0%, 5%, 10%, 15%, 20% and 25% dry weight fiber content attributed to the reinforcement fiber bundles of the total of base fiber and reinforcement fiber. Hence, the samples respectivelv in-cluded 100%, 95%j 90%, 85%, 80% and 75% fiber content attributed to the base fiber. All of these samples were tested for tear resistance (in grams/lb. mat on an Elmendorf type apparatus in accordance with ASTM No. 1224 Standards.
The results have been graphically displayed in Figure 3 where a Cartesian coordinate is shown. The abscissa represents the percent of fiber attributed to the reinforcement bundles and the ordinate represents the tearing resistance attained for the given samples in grams/
lb. mat. It should be noted that for each percentage of reinforcement fiber, a number of test samples were pro-vided, compiled and averaged out for purposes of the graph. Upon inspecting the graph, it can be seen that the average tear strength of those shingles without reinforcement fiber bundles is approximately 320 grams/lb. mat. At 10% fiber S9~0 1 bundle content, tear resistance im~roves. This improve~
ment continues as more bundles are provided. Hence, at 25% fiber bundle content, the tear strength is approxi-mately 690 grams/lb. mat. ~t between 10~ and 25~, the shingle displays tear resistance as good and ln many cases better than that found with the previously described swirl mat and, in addition, has the other advantages described above.
It is to be understood that the foregoing graphlc display of tear resistance is for illustrative purposes only.
It is set forth only to show how tear resistance is related to the glass mat of the present invention and particularly the reinforcement fiber bundles used with the glass mat.
.
: `
~' .
~;
' ' ; ~
1 ~nother ob~ect of the present invention is to provide such a mat displayinc3 uniformity and improved tear resistance.
Yet, another object of the present invention i5 to provide a roofinc3 product utilizing the aforestated mat such that the roofing product is economical and dis-plays improved blow-off resistance.
As will be seen in more detail hereinafter, these objects, as well as other objects and features, are attained and manv of the deficiencies of the prior art are eliminated by the present invention which sets forth a wet forming process of making a fibrous glass mat especially suitable for use in shingles. The mat comprises a web of monofila-ment glass fibers and elongated glass fiber bundles having ends and binder substance to assist in holding the mono-filament fibers and fiber bundles together. By making such a mat by the particular process of the present inven-tion, the mat can be made in a more economical and uniform manner. Further, the glass fibers and fiber bundles are dispersed in a randomly oriented fashion throughout the web and a majority of the ends of the fiber bundles are within the confines of the web. This, in turn, increases the tearing resistance of the mat and therefore the blow-off resistance of a shingle made with the mat.
Brief Descri tion of the Drawings ;
P
Figure 1 is an enlarged perspective view of a fibrous glass mat designed in accordance with the present invention.
Figure 2 is a schematic illustration o-f a method of making the mat in accordance with the present ;
invention.
; .
~a~s~o 1 Figure 3 is a graphic lllustration displaying tear resistance o an asphalt shingle made with a ylass mat of the present invention.
Detailed Description Turning to the drawings, a fibrous glass ma~
constructed in accordance with the present invention is illustrated in Figure 1 and generally designated by the reference num~ral 10. The mat is comprised of a web 12 of monofilament glass fibers (base fibers) and elongated ;~
glass fiber bundles 14 (reinforcement bundles) having ends, the glass fibers and fiber bundles being dispersed through-out the web in a randomly oriented pattern. In addition, a suitable binder substance is provided to assist in holding the base fibers and reinforcement bundles together.
The glass fiber bundles, a majority of which have their opposite ends terminating well within the confines of the ~ -~
web, provide highly satisfactory tear resistance to the ` ~`
mat, especially where the latter is used as part of an asphalt shingle. ~ ~
As will be described in more detail hereinafter, ' fibrous glass mat 10 is made by forming a slurry, preferablv a water slurry, including the base fibers and reinforcement bundles such that the solids content o the slurry is very low, preferably approximately 0.2~. Under intense agitation, the base fibers and reinforcement bundles are substantially completely dispersed throughout the slurry. After this dispersing operationl the fiber containing slurry is applied to a moving screen where, by means of vacuum, a majority of -the water is removed resulting in the aforedescribed web of base fibers and reinforcement bundles. After formation of the web, a binder substance is applied thereto so as to -~
:':
' ' ~' -5- ~
~sg~o 1 assist in bonding the Fiber5 and Eiber bundles togeth~r.
Thereafter, the bonded web is passecl through a dryer for evaporating any water remaining in the web and for curing the binder.
It should be noted that by providing a fibrous slurry, and preferably a slurry of low fiber content, a highly uniform mat can be produced, especially in com-parison to the less uniform mat formed by the dry forming process. This, of course, minimiæes production dis-continuity and product wastage and therefore minimizes manuacturing cost. In addition, by providing this slurry, the reinforcement bundles, that is, the glass iber bundles can be readil~ dispersed throughout the web in the manner described above, thereby resulting in a mat with improved tear resistance. Further, by pro-viding a wet forming process of the type described herein, the rapidity of production can be substantially increased over that of the dry forming process, in some cases ten fold, and the re~uirement of producing base fibers simul-2~ taneously with the production of the mat can be eliminated.
Both of these latter features maximize efficiency and minimize cost in mat production.
Having briefly described the fibrous glass mat 10 and process for making the same in accordance with the present invention, attention is now directed to a more detailed analysis of the components making up the mat.
In this regard, attention is directed to the base fibers ~ ;
which, as set forth above, are~monofilament glass fibers.
i .
These monofilament fibers are pre-chopped to desired lengths from continuous strands, preferably in an independent operation apart from and unrelated to the forming operation , :.
.
-6- ~
~C)459~
1 of mat 10. Thi~ independent operation has been found to be less costly than the simultaneous production of base fiber and mat typically carried out in the dry forming process of a glass mat. ~s will be seen hereinafter, the strands break up into individual monofilament fibers when placed in the slurry.
While there is no absolute limitation on dis-crete length of the monofilament fibers, a preferred broad range is between approximately 12 mm and 60 mm.
With respect to monofilament fibers below 12 mm, it has been found that the chopping machinery used to date has been unable to satisactorily chop the continuous filaments ~;
to such shorter lengths. On the other hand, monofilament fibers above approximately 60 mm tend to cause fiber entanglement in the slurry and poor dispersion. It has been found that the best operating range is between approxi-mately 22 mm and 35 mm. ;~-Like the length of the monofilament glass fibers ~ ;
or base fibers, there is no ahs~Qlute limitation on the diameter of these fibers. However, due to practical and ~;
economical considerations, they are preferably between approximately 12~ and 19~ in diameter. This range includes ;~
the K, M and P filaments, all o which are readily available and economical to use. In addition, the density of the ~ ~
ultimately produced mat is related to the diameter of the ~;
base ibers and therefore can be regulated by the proper selection of base fiber diameter.
The preferred amount of base fiber used in mat 10 is dependent upon the amount o fiber content provided by the reinforcement fiber bundles. Hence, this will be discussed hereinafter with respect to the detailed discussion of the latter.
~s9~
1 Attention is now directed to the elongated cJlass fiber bundles or reinforcement bundles. Each of -these bundles is macle from a plurality of monofilament ylass fibers which are preferably in the diameter range of approximately 12 ~ to l9~L( for the same reasons dis-cussed above. The exact number of monofilaments provided in each bundle will depend upon the desired strength and thickness of the latter. A good working range has been found to be between approximatel~ 20 and 300 monofilaments 0 per bundle. Since it is important to keep these bundles intact throughout the mat forming process, they are coated with a water or other such liquid insoluble binder of known kind. This keeps the bundles bonded together even when exposed to the forming slurry.
There is no absolute limitation on the length of the glass fiber bundles. However, when the fiber bundles ..
are below approximately 15 mm in length, their function as a reinforcement is, in many cases, unreliable, especially where the ultimately produced mat is to be used as part of a roofing shingle. On the other hand, when the bundles ~ ;
are above approximately 100 mm in length, they tend to tangle up in the slurry. ~s a good operating range, the fiber bundles are preferably between approximately 65 mm and 75 mm in length.
As stated above, the amount of monofilament base fibers in mat 10 will depend upon the fiber content of the reinforcement bundles. In this regard, of the total fiber content (by dry weight) attributed to the base fibers and fiber bundles, there can be as little as 5%
fiber content attributed to the bundles or as much as 90%.
Below 5%, the fiber bundles do not contribute any significant ~gi~
1 reinforcem~nt to the mat and ab~ve 90% the Eibers tend to provide an ov~rl~ dense and non-uniform mat.
Where the contemplated use or mat 10 i5 the carrier material for an asphalk shingle, the pre~erred range of fiber content atkributed to ~he fiber bundles i~ between approximately 5% and 30% (by dry weiyht). With this range, there is adequate xeinorcement for improved tear resistance in the ultimately produced ma-t but the mat is not so dense to be unsuitable or shingle use. Within ~-this latter range, a highly satisfactory mat or use in shingles has been found to include approximately 15% fiber content attributed to the reinforcement bundles.
As stated above, the foregoing percentages of fiber content are those attributed to the fiber bundles in relation ~o the total of base Eibers and iber bundles.
Hence, the amount of base fiber in any given mat can be ;
readily calculated from the amount of fiber comprising the reinforcement bundles. These percentages will, of course, decrease when the binder is taken into consider-ation. In this regard, mat 10 includes a binder to cooperate in holding the monofilament base fibers and fiber bundles together. The amount of binder provided ~`
will depend upon the use of the ultimately formed mat. ~;
As a general range, the mat may include binder as low as j~ 3% of the total dry weight of the mat or as high as 45%.
' For use in shingles, however, best results are attained by using binding substance in an amount equal to approxi-mately 15~ of the total dry weight of the mat. An amount substantially less than this figure does not adequately hold the fibers together while an amount substantially greater than this figure does not appear to he necessary.
Any suitable blnder known by those skilled ~n the art can be used, such as, ~or example, urea-~ormaldehyde.
With fibrous glass mat 10 constructed ln the foregoing manner, attention is now d~rected to fI6. 2 which illustrates a method of making the mat in accordance with the present invention. Specifically, the aforedescribed mono-filament base fibers whlch are compressed together in bundles and reinforcement Fiber bundles, having been provided and chopped to the preferred lengths, are dispersed into an opening mixing tank 20 which includes a water slurry. A
suitable dispersan~ such as, for example, a cationic surfac-tant, for example one designated by the trademark AEROSOL, is also introduced into the slurry. At this point, the bundles of monofilament base fibers start to separate into individual monofilaments in the slurry. Both types of fiber are carefully metered into the tank in constant relation to ;
the slurry so as to maintain an exact, preferably very low~
fiber concentration. In fact, a preferred ~iber concentration is approximately 0.2%. The metering operation also measures and limits the relative amounts by weight of base fibers to reinforcement fiber bundles to be provided in the slurry, such as, for example, 85X base ~ibers to 15% fiber bundles.
From opening tank 20, the fibrous slurry is passed through two larger tanks, a pre-mixing tank 22 and a main mixing tank 24, where it is intensely agitated so as to cause the bundles of monofilament base fiber to completely break up and to achieve complete dispersion of the fibers generally. As the dispersed fibrous slurry - ~ ;~
passes downstream from main tank 24, the fiber concentra- -tion is further reduced at point 26 by introduction of additional water. At this point the fiber concentration -10- ; . .
~i , ,, , :
5~
1 is preferably approximately l/20th of the ori~inal sluxry concentration.
From polnt 26, the slurry passe~ to a conven-tionally known head box or h~droformer 28. In the hydroformer, -the fi~rous slurry passes over a moving wire screen arranc3ement 30 where most of the water is removed by vacuum, as indicated at 32, thus forming a web of base fibers and reinforcement bundles. The water removed b~ vacuum enters either of two recycle tanks 34 where it can be recirculated to opening tank 20 and point 26.
After the web is formed on moving screen 30, ~;
it is moved downstream where a binder i9 applied thereto by means of a conventional applicator device 36 which, as illustrated, may provide recirculation of excess binder.
Downstream from applicator device 36, the bonded fibrous mat is transferred to a moving conveyor 38 which passes ~;~
the mat through a drying oven for evaporation of water contained in the mat and curing of the binder.
As set forth above, the reinforcement fiber bundles are pre~chopped and introduced to the slurry in the opening tank 20. It is to be understood that the ;~
fiber bundles could also be introduced into the premixing tank 22, main mixing tank 24 or directly into the ;;
hydroformer 28. However, it has been found that intro-duction into the opening tank provides best dispersion of the fibers.
The foregoing method of making mat lO is both rapid and economical, especially compared to the dry forming process of making the aforedescribed swirl rein~
forced mat. In addition, by using a slurry of low fiber ,,~
~o~s~
1 concentration in producing mat 10, mat uniEormity can be readily and consistentl~ a-ttained. F~lrther, the slurry of low fiber concentration allows -the fiber bundles to disperse throughout the web of monofilament base ibers in a randomly oriented pattern such that a subs-tantial number of the bundles have their ends terminating well within the con-fine~ oE the web. This substantially increases the tear resistance of the ultimately produced mat, as will be shown with respect to Figure 3.
~fter mat 10 has been made, it can be used for ~`
many different purposes. IIowever, a major use for the mat is its incorporation into bituminous roofing products gen-erally and asphalt roofiny shingles in particular. In this case, the mat is preferably 0.035 inches thick and preferablv displays a weight of approximately 2.05 lbs./100 sq. t. As stated above, the weight is best regulated by regulating the diameter of the afore-described monofilament base fibers.
Hence, it has been found that base fibers displaying a diameter between approxi-mately 14 ~ and 16 ~ are satisfactory to achieve this weight. ~
The specific methods of making asphalt shingles ~ `
or other roofing products with glass mat are well known to those skilled in the art. ~lence, a specific dis-cussion of these methods will not be given herein. It shall suffice to state that in all cases the mat is coated with asphalt or other bituminous substance. The amount and tvpe of asphalt or other such bituminous substances used will depend on the particular roofing product made.
Attention is now directed to Figure 3 which graphically illustrates the tear resistance of asphalt :~L134~
1 shingles usln~ glass mat of the present invention, however, with varying amounts of reinforcement fiber bundles. More specifically, over forty asphalt shinyle samples were pre- ;
pared from mats. The mats of these shingles had approxi-mately the same weight (2.00 - 2.40 lbs./100 sq. ft.), approximately the same length monofilament base fiber (30 mm) and reinforcement fiber bundle (70 mm) and used the same amount and type of binder. The mats for the shingles were made in the manner described above. However, the amount of fiber content attributed to the reinforcement bundles and the amount of fiber content attributed to the monofilament `~
base iber have been varied to display their affect or tear resistance. Specifically, samples were made with 0%, 5%, 10%, 15%, 20% and 25% dry weight fiber content attributed to the reinforcement fiber bundles of the total of base fiber and reinforcement fiber. Hence, the samples respectivelv in-cluded 100%, 95%j 90%, 85%, 80% and 75% fiber content attributed to the base fiber. All of these samples were tested for tear resistance (in grams/lb. mat on an Elmendorf type apparatus in accordance with ASTM No. 1224 Standards.
The results have been graphically displayed in Figure 3 where a Cartesian coordinate is shown. The abscissa represents the percent of fiber attributed to the reinforcement bundles and the ordinate represents the tearing resistance attained for the given samples in grams/
lb. mat. It should be noted that for each percentage of reinforcement fiber, a number of test samples were pro-vided, compiled and averaged out for purposes of the graph. Upon inspecting the graph, it can be seen that the average tear strength of those shingles without reinforcement fiber bundles is approximately 320 grams/lb. mat. At 10% fiber S9~0 1 bundle content, tear resistance im~roves. This improve~
ment continues as more bundles are provided. Hence, at 25% fiber bundle content, the tear strength is approxi-mately 690 grams/lb. mat. ~t between 10~ and 25~, the shingle displays tear resistance as good and ln many cases better than that found with the previously described swirl mat and, in addition, has the other advantages described above.
It is to be understood that the foregoing graphlc display of tear resistance is for illustrative purposes only.
It is set forth only to show how tear resistance is related to the glass mat of the present invention and particularly the reinforcement fiber bundles used with the glass mat.
.
: `
~' .
~;
' ' ; ~
Claims (45)
1. A fibrous glass mat consisting essentially of (a) a fibrous web consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length and between approximately 12 microns and 19 microns in diameter, said fibers comprising between approximately 70% and 95% of the total fibrous material in said web, and (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said web;
(b) said glass fibers and fiber bundles cooperating with one another in a random Fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed through said web and, (ii) a majority of the ends of said bundles are within the confines of said web; and (c) a binder substance to cooperate in holding said web of monofilament fibers and fiber bundles together to form said glass mat.
(b) said glass fibers and fiber bundles cooperating with one another in a random Fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed through said web and, (ii) a majority of the ends of said bundles are within the confines of said web; and (c) a binder substance to cooperate in holding said web of monofilament fibers and fiber bundles together to form said glass mat.
2. A fibrous glass mat according to Claim 1 wherein said mat has a thickness of approximately 0.035 inches.
3. A fibrous glass mat according to Claim 1 wherein said mat has a weight of between approximately 2.00 and 2.40 lbs/100 square feet.
4. A fibrous glass mat according to Claim 1 wherein said glass fiber bundles are comprised of mono-filament fibers between approximately 12 microns and 19 microns in diameter.
5. A fibrous glass mat according to Claim 1 including approximately 15% binder substance by dry weight of said mat.
6. A fibrous glass mat according to Claim 1 wherein each of said glass fiber bundles is comprised of between approximately 20 and 300 monofilaments.
7. A fibrous glass mat consisting essentially of:
(a) a fibrous mat consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length, said fibers comprising between approximately 70% and 95% of the total fibrous material in said web, and (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said web;
(b) said glass fibers and fiber bundles cooperating with one another in a random fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed throughout said web and, (ii) a majority of the ends of said bundles are within the confines of said web;
(c) a binder substance to cooperate in holding said web of monofilament fibers and fiber bundles together to form said glass mat; and (d) said mat being approximately 0.035 inch thick.
(a) a fibrous mat consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length, said fibers comprising between approximately 70% and 95% of the total fibrous material in said web, and (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said web;
(b) said glass fibers and fiber bundles cooperating with one another in a random fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed throughout said web and, (ii) a majority of the ends of said bundles are within the confines of said web;
(c) a binder substance to cooperate in holding said web of monofilament fibers and fiber bundles together to form said glass mat; and (d) said mat being approximately 0.035 inch thick.
8. A fibrous mat according to Claim 7 wherein said mat has a weight of between approximately 2.00 and 2.40 lbs/100 square feet.
9. A fibrous mat according to Claim 7 wherein said glass fiber bundles are comprised of monofilament fibers between approximately 12 microns and 15 microns in diameter.
10. A fibrous mat according to Claim 7 including approximately 15% binder by dry weight of said mat.
11. A fibrous glass mat consisting essentially of:
(a) a fibrous web consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length, said fibers comprising between approximately 70% and 95% of the total fibrous material in said web, and (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said web;
(b) said glass fibers and fiber bundles cooperating with one another in a random fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed throughout said web and, (ii) a majority of the ends of said bundles are within the confines of said web;
(c) a binder substance to cooperate in holding said web of monofilament fibers and fiber bundles together to form said glass mats; and (d) said mat having a weight of between approximately 2.00 and 2.40 lbs/100 square feet.
(a) a fibrous web consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length, said fibers comprising between approximately 70% and 95% of the total fibrous material in said web, and (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said web;
(b) said glass fibers and fiber bundles cooperating with one another in a random fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed throughout said web and, (ii) a majority of the ends of said bundles are within the confines of said web;
(c) a binder substance to cooperate in holding said web of monofilament fibers and fiber bundles together to form said glass mats; and (d) said mat having a weight of between approximately 2.00 and 2.40 lbs/100 square feet.
12. A fibrous mat according to Claim 11 wherein said glass fiber bundles are comprised of monofilament fibers between approximately 12 microns and 19 microns in diameter.
13. A fibrous mat according to Claim 11 including approximately 15% binder by dry weight of said mat.
14. A fibrous glass mat consisting essentially of:
(a) a fibrous web consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length and between approximately 12 microns and 19 microns in diameter, said fibers comprising between approximately 70% and 95% of the total fibrous material in said web, and (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments between approximately 12 microns and 19 microns in diameter held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said web;
(b) said glass fibers and fiber bundles cooperating with one another in a random fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed throughout said web and, (ii) a majority of the ends of said bundles are within the confines of said web;
(c) a binder substance to cooperate in holding said web of monofilament fibers and fiber bundles together to form said glass mat; and (d) said mat being approximately 0.035 inch thick and having a weight of between approximately 2.00 and 2.40 lbs/100 square feet.
(a) a fibrous web consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length and between approximately 12 microns and 19 microns in diameter, said fibers comprising between approximately 70% and 95% of the total fibrous material in said web, and (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments between approximately 12 microns and 19 microns in diameter held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said web;
(b) said glass fibers and fiber bundles cooperating with one another in a random fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed throughout said web and, (ii) a majority of the ends of said bundles are within the confines of said web;
(c) a binder substance to cooperate in holding said web of monofilament fibers and fiber bundles together to form said glass mat; and (d) said mat being approximately 0.035 inch thick and having a weight of between approximately 2.00 and 2.40 lbs/100 square feet.
15. A roofing product comprising:
(a) a fibrous mat consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length and between approximately 12 microns and 19 microns in diameter, said fibers comprising between approximately 70% and 95% of the total fibrous material in said mat, (ii) a binder substance holding said mono-filament fibers and fiber bundles together, (iii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said web;
(b) said glass fibers and fiber bundles cooperating with one another in a random fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed throughout said web, and (ii) a majority of the ends of said bundles are within the confines of said web, and (c) a bituminous substance coated on both sides of said mat.
(a) a fibrous mat consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length and between approximately 12 microns and 19 microns in diameter, said fibers comprising between approximately 70% and 95% of the total fibrous material in said mat, (ii) a binder substance holding said mono-filament fibers and fiber bundles together, (iii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said web;
(b) said glass fibers and fiber bundles cooperating with one another in a random fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed throughout said web, and (ii) a majority of the ends of said bundles are within the confines of said web, and (c) a bituminous substance coated on both sides of said mat.
16. A roofing product according to Claim 15 wherein said mat has a thickness of approximately 0.035 inches.
17. A roofing product according to Claim 15 wherein said mat has a weight of between approximately 2.00 and 2.40 lbs/100 square feet.
18. A roofing product according to Claim 15 wherein said glass fiber bundles are comprised of monofilament fibers between approximately 12 microns and 19 microns in diameter.
19. A roofing product according to Claim 15 wherein said mat includes approximately 15% binder substance by dry weight of said mat.
20. A roofing product according to Claim 15 wherein each of said glass fiber bundles is comprised of between approximately 20 and 300 monofilaments.
21. A roofing product according to Claim 15 wherein said product is a roofing shingle.
22. A roofing product comprising:
(a) a fibrous mat having a thickness of approximately 0.035 inch and consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length, said fibers comprising between approximately 70% and 95% of the total fibrous material in said mat.
(ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundles by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said mat.
(iii) a binder substance holding said monofilament fibers and fiber bundles together;
(b) said glass fibers and fiber bundles cooperating with one another in a random fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed throughout said web and, (ii) a majority of the ends of said bundles are within the confines of said web; and (c) a bituminous substance coated on both sides of said mat.
(a) a fibrous mat having a thickness of approximately 0.035 inch and consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length, said fibers comprising between approximately 70% and 95% of the total fibrous material in said mat.
(ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundles by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said mat.
(iii) a binder substance holding said monofilament fibers and fiber bundles together;
(b) said glass fibers and fiber bundles cooperating with one another in a random fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed throughout said web and, (ii) a majority of the ends of said bundles are within the confines of said web; and (c) a bituminous substance coated on both sides of said mat.
23. A roofing product according to Claim 22 wherein said mat has a weight of between approximately 2.00 and 2.40 lbs/100 square feet.
24. A roofing product according to Claim 22 wherein said glass fiber bundles are comprised of monofilament fibers between approximately 12 microns and 19 microns in diameter.
25. A roofing product according to Claim 22 wherein solid mat includes approximately 15% binder by dry weight of said mat.
26. A roofing product according to Claim 22 wherein said product is a roofing shingle.
27. A roofing product comprising:
(a) a fibrous mat having a weight between approximately 2.00 and 2.40 lbs/100 square feet and consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length, said fibers comprising between approximately 70% and 95% of the total fibrous material in said mat, (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 5% and 30% of the total fibrous material in said mat, and (iii) a binder substance holding said monofilaments and fiber bundles together;
(b) said glass fibers and fiber bundles cooperating with one another in a random fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed throughout said web and, (ii) a majority of the ends of said bundles are within the confines of said web;
(c) a bituminous substance coated on both sides of said mat.
(a) a fibrous mat having a weight between approximately 2.00 and 2.40 lbs/100 square feet and consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length, said fibers comprising between approximately 70% and 95% of the total fibrous material in said mat, (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 5% and 30% of the total fibrous material in said mat, and (iii) a binder substance holding said monofilaments and fiber bundles together;
(b) said glass fibers and fiber bundles cooperating with one another in a random fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed throughout said web and, (ii) a majority of the ends of said bundles are within the confines of said web;
(c) a bituminous substance coated on both sides of said mat.
28. A roofing product according to Claim 27 wherein said glass fiber bundles are comprised of monofilament fibers between approximately 12 microns and 19 microns in diameter.
29. A roofing product according to Claim 27 wherein said mat includes approximately 15% binder by dry weight of said mat.
30. A roofing product according to Claim 27 wherein said roofing product is a roofing shingle.
31. A roofing shingle comprising:
(a) a fibrous mat having a thickness of approximately 0.035 inch and a weight of between approximately 2.00 and 2.40 lbs/100 square feet and consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length and between approximately 12 microns and 19 microns in diameter, said fibers comprising between approximately 70% and 95% of the total fibrous material in said mat, (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments between approximately 12 microns and 19 microns in diameter held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said mat, and (iii) approximately 15% binder substance by weight of said mat for holding said monofilament fibers and fiber bundles together;
(b) said glass fibers and fiber bundles cooperating with one another in a random fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed throughout said web, and (ii) a majority of the ends of said bundles are within the confines of said web; and (c) a bituminous substance coated on both sides of said mat.
(a) a fibrous mat having a thickness of approximately 0.035 inch and a weight of between approximately 2.00 and 2.40 lbs/100 square feet and consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length and between approximately 12 microns and 19 microns in diameter, said fibers comprising between approximately 70% and 95% of the total fibrous material in said mat, (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments between approximately 12 microns and 19 microns in diameter held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said mat, and (iii) approximately 15% binder substance by weight of said mat for holding said monofilament fibers and fiber bundles together;
(b) said glass fibers and fiber bundles cooperating with one another in a random fashion to form a web such that (i) said monofilament fibers and fiber bundles are substantially randomly oriented and uniformly dispersed throughout said web, and (ii) a majority of the ends of said bundles are within the confines of said web; and (c) a bituminous substance coated on both sides of said mat.
32. A method of making a fibrous glass mat, comprising:
(a) forming a water slurry including fibrous material consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 12 microns and 19 microns in diameter, said fibers comprising between approximately 70%
and 95% of the total fibrous material in said mat, and (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said mat;
(b) mixing said slurry so as to disperse said fibers and fiber bundles therein;
(c) forming from said slurry a web with said mono-filament fibers and fiber bundles being dispersed throughout said web in a randomly oriented fashion and with a majority of the ends of said bundles being located within the confines of said web;
(d) applying a binder substance to said web; and (e) heating said web after application of said binder substance.
(a) forming a water slurry including fibrous material consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 12 microns and 19 microns in diameter, said fibers comprising between approximately 70%
and 95% of the total fibrous material in said mat, and (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said mat;
(b) mixing said slurry so as to disperse said fibers and fiber bundles therein;
(c) forming from said slurry a web with said mono-filament fibers and fiber bundles being dispersed throughout said web in a randomly oriented fashion and with a majority of the ends of said bundles being located within the confines of said web;
(d) applying a binder substance to said web; and (e) heating said web after application of said binder substance.
33. A method according to Claim 32 wherein said mat is formed to a thickness of approximately 0.035 inches.
34. A method according to Claim 32 wherein said mat is formed to have a weight of between approximately 2.00 and 2.40 lbs/100 square feet.
35. A method according to Claim 32 wherein said slurry is formed with said glass fiber bundles comprised of monofilament fibers between approximately 12 microns and 19 microns in diameter.
36. A method according to Claim 32 wherein approxi-mately 15% binder by dry weight of said mat is applied to said web.
37. A method according to Claim 32 wherein each of said glass fiber bundles is comprised of between approximately 20 and 300 monofilaments.
38. A method of making a fibrous glass mat, com-prising:
(a) forming a water slurry including fibrous material consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length, said fibers comprising between approximately 70% and 95% of the total fibrous material in said mat, and (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said mat;
(b) mixing said slurry so as to disperse said fibers and fiber bundles therein;
(c) forming from said slurry a web with said mono-filament fibers and fiber bundles being dispersed throughout said web in a randomly oriented fashion and with a majority of the ends of said bundles being located within the confines of said web;
(d) applying a binder substance to said web, said web with said binder being approximately 0.035 inches thick; and (e) heating said web after application of said binder substance.
(a) forming a water slurry including fibrous material consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length, said fibers comprising between approximately 70% and 95% of the total fibrous material in said mat, and (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said mat;
(b) mixing said slurry so as to disperse said fibers and fiber bundles therein;
(c) forming from said slurry a web with said mono-filament fibers and fiber bundles being dispersed throughout said web in a randomly oriented fashion and with a majority of the ends of said bundles being located within the confines of said web;
(d) applying a binder substance to said web, said web with said binder being approximately 0.035 inches thick; and (e) heating said web after application of said binder substance.
39. A method according to Claim 38 wherein said mat is formed to have a weight of between approximately 2.00 and 2.40 lbs/100 square feet.
40. A method according to Claim 38 wherein said slurry is formed with said glass fiber bundles comprised of monofilament fibers between approximately 12 microns and 19 microns in diameter.
41. A method according to Claim 38 wherein approx-imately 15% binder by dry weight of said mat is applied to said web.
42. A method of making a fibrous glass mat, com-prising:
(a) forming a water slurry including fibrous material consisting essentially of (i) A plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length, said fibers comprising between approximately 70% and 95% of the total fibrous material in said mat, and (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said mat;
(b) mixing said slurry so as to disperse said fibers and fiber bundles therein;
(c) forming from said slurry a web with said mono-filament fibers and fiber bundles being dispersed throughout said web in a randomly oriented fashion and with a majority of the ends of said bundles being located within the confines of said web;
(d) applying a binder substance to said web, said web with said binder having a weight of between approximately 2.00 and 2.40 lbs/100 square feet; and (e) heating said web after application of said binder substance.
(a) forming a water slurry including fibrous material consisting essentially of (i) A plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length, said fibers comprising between approximately 70% and 95% of the total fibrous material in said mat, and (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said mat;
(b) mixing said slurry so as to disperse said fibers and fiber bundles therein;
(c) forming from said slurry a web with said mono-filament fibers and fiber bundles being dispersed throughout said web in a randomly oriented fashion and with a majority of the ends of said bundles being located within the confines of said web;
(d) applying a binder substance to said web, said web with said binder having a weight of between approximately 2.00 and 2.40 lbs/100 square feet; and (e) heating said web after application of said binder substance.
43. A method according to Claim 42 wherein said slurry is formed with said glass fiber bundles comprised of monofilament fibers between approximately 12 microns and 19 microns in diameter.
44. A method according to Claim 42 wherein approx-imately 15% binder by dry weight of said mat is applied to said web.
45. A method of making a fibrous glass mat, com-prising:
(a) forming a water slurry including fibrous material consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length and between approximately 12 microns and 19 microns in diameter, said fibers comprising between approximately 70% and 95% of the total fibrous material in said mat, and (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments between approximately 12 microns and 19 microns in diameter held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said mat;
(b) mixing said slurry so as to disperse said fibers and fiber bundles therein;
(c) forming from said slurry a web with said mono-filament fibers and fiber bundles being dispersed throughout said web in a randomly oriented fashion and with a majority of the ends of said web;
(d) applying approximately 15% binder substance by weight of said mat to said web, said web including said binder substance being approximately 0.035 inch thick and having a weight of between approximately 2.00 and 2.40 lbs/100 square feet; and (e) heating said web after application of said binder substance.
(a) forming a water slurry including fibrous material consisting essentially of (i) a plurality of individual monofilament glass fibers between approximately 22 mm and 35 mm in length and between approximately 12 microns and 19 microns in diameter, said fibers comprising between approximately 70% and 95% of the total fibrous material in said mat, and (ii) a plurality of glass fiber bundles having ends, each of said bundles consisting essentially of a plurality of monofilaments between approximately 12 microns and 19 microns in diameter held together in said bundle by a water insoluble binder substance, said glass fiber bundles being between approximately 65 mm and 75 mm in length, and comprising between approximately 5% and 30% of the total fibrous material in said mat;
(b) mixing said slurry so as to disperse said fibers and fiber bundles therein;
(c) forming from said slurry a web with said mono-filament fibers and fiber bundles being dispersed throughout said web in a randomly oriented fashion and with a majority of the ends of said web;
(d) applying approximately 15% binder substance by weight of said mat to said web, said web including said binder substance being approximately 0.035 inch thick and having a weight of between approximately 2.00 and 2.40 lbs/100 square feet; and (e) heating said web after application of said binder substance.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US30157872A | 1972-10-27 | 1972-10-27 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1045910A true CA1045910A (en) | 1979-01-09 |
Family
ID=23163991
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA184,383A Expired CA1045910A (en) | 1972-10-27 | 1973-10-26 | Fibrous mat especially suitable for roofing products and a method of making the mat |
Country Status (4)
| Country | Link |
|---|---|
| AT (1) | AT335696B (en) |
| BE (1) | BE806512A (en) |
| CA (1) | CA1045910A (en) |
| GB (1) | GB1429949A (en) |
-
1973
- 1973-10-22 GB GB4909673A patent/GB1429949A/en not_active Expired
- 1973-10-25 AT AT908873A patent/AT335696B/en not_active IP Right Cessation
- 1973-10-25 BE BE137062A patent/BE806512A/en not_active IP Right Cessation
- 1973-10-26 CA CA184,383A patent/CA1045910A/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| BE806512A (en) | 1974-04-25 |
| AT335696B (en) | 1977-03-25 |
| GB1429949A (en) | 1976-03-31 |
| ATA908873A (en) | 1976-07-15 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US4112174A (en) | Fibrous mat especially suitable for roofing products | |
| US4129674A (en) | Fibrous mat especially suitable for roofing products and a method of making the mat | |
| US4258098A (en) | Glass fiber mat with improved binder | |
| US4284470A (en) | High-strength roofing products using novel glass fiber mats | |
| US4310478A (en) | Reinforcing fibers and method of producing same corona treatment of thermoplastic fibers | |
| US4233353A (en) | High-strength built-up roofing using improved glass fiber mats | |
| US4242404A (en) | High-strength glass fiber mat particularly useful for roofing products | |
| DE2142683A1 (en) | UNWOVEN FIBER LAMINATE | |
| EP1674633A2 (en) | Wood fiber insulating panel or mat | |
| CA2000619A1 (en) | Building sheets of cement material reinforced with plastics mesh and glass fibres | |
| US2057167A (en) | Manufacture of impregnated sheet products | |
| EP0340691B1 (en) | Method and device for fabricating a fibremat | |
| CA1045910A (en) | Fibrous mat especially suitable for roofing products and a method of making the mat | |
| US4200487A (en) | Economical method of making high-strength glass fiber mats particularly useful for roofing products | |
| DE1635590A1 (en) | Process for the production of fibrous sheet materials | |
| FI62158B (en) | FOERFARINGSSAETT FOER FRAMSTAELLNING AV EN FIBERKOMPOSITION | |
| DE2301481A1 (en) | CARPET PAD | |
| US2405978A (en) | Manufacture of artificial fibrous sheet material | |
| DE1444166A1 (en) | Process for impregnating nonwovens | |
| HRP931057A2 (en) | Process and apparatus for dynamic-flow production of ductile, highly tear-resistant fiber mats | |
| US4256524A (en) | Process for solvent bonding blended nonwoven fabrics and fabric produced therefrom | |
| JPH0958200A (en) | Canvass of nonwoven fabric | |
| EP0019465B1 (en) | High strength glass fiber mat particularly useful for roofing products, built-up roofing membranes and systems and method of making such products | |
| US3326740A (en) | Multi-directional strectchable nonwoven fabric | |
| EP0025115B1 (en) | High-strength roofing products using novel glass fiber mats; multiply systems and glass fiber mats per se |