MXPA00002173A - Structural mat matrix - Google Patents

Abstract

A structural mat matrix comprises (a) a substrate which consists essentially of from 80%to 99%by weight fiberglass fibers and from 20%to 1%by weight wood pulp and (b) a binder which consists essentially of from 80%to 95%by weight urea formaldehyde and from 20%to 5%by weight acrylic copolymer. The binder bonds the substrate fiberglass fibers and wood pulp together and comprises from 5%to 15%by weight of said matrix, preferably 10%by weight of the matrix.

Description

MATRIX OF STRUCTURAL MAT DESCRIPTION BACKGROUND OF THE INVENTION This invention relates to a structural ester matrix such as a roof tile mat matrix.

For many years, structural articles such as roof tiles have been composed of glass fiber substrates coated with a binder which joins the fibers of the glass fiber substrate together. Such substrates are non-woven glass fiber mats which are desirable because they are lighter in weight than the previously used mats. Fiberglass mats have also been preferred as roof tile substrates due to their fire-resistant nature, their resistance to moisture damage, their excellent dimensional stability, their resistance to winding with temperature changes, to its resistance to decay and decay, and its ability to accept more heavily filled asphalt coatings.

Thus far, efforts to optimize fiberglass roof tile substrates have focused on attempts to improve their tear resistance and tensile strength without unduly increasing the weight of the tile. Heavier tiles and other structural items are usually more expensive due to more raw material and more transportation costs. Operating within such weight and cost constraints, fabric manufacturers have found that to improve tear resistance, they have to sacrifice tensile strength and vice versa.

U.S. Patent No. 4,112,174 discloses a suitable mat in the manufacture of roofing products which includes monofilament glass fibers, glass fiber bundles and a relatively small amount of binder, for example, the binder which it is 15% by dry weight of the mat. The mat weighs between approximately 2.00 and 2.40 pounds per 100 square feet. U.S. Patent No. 4,242,404 describes a fiberglass mat useful for roofing products that includes single filament glass fibers and expanded glass fiber elements and a binder applied in an amount of about 3% to 45%. % po weight of the finished mat. The basis weight of the finished mat is described as being at least 1 pound per 100 square feet and preferably about 2.0 to 3.0 pounds per square foot.

U.S. Patent No. 4,472,243 discloses sheet-type roofing material for use in roof construction and roof tile manufacture. The cut glass fibers are dispersed in a solution of cellulosic fibers and the binder is added. According to the patent, the material comprises 10-60% by weight of glass fibers of varying lengths, 15-80% by weight of cellulose fibers and 5-25% of binder. The patent states that the proportions and sizes of the glass cellulosic fibers described herein "provide the desired balance of structural properties" in the material to make it "suitable as a substrate for the roofing material" to "meet the desired standards for strength. mechanics and resistance to fire " The patent further notes that the glass fiber content of the felt of the invention is important for controlling its porosity and skeletal structure. ... On the high end of the glass fiber content the felt substrate tends to be porous with a high order of skeletal structure. Such felt will uncontrollably absorb excessive amounts of asphaltic saturant at a very high rate during the processing of the roof tile and this has a deleterious effect on the spread of the flame test due to the cover plates filled with severe asphalt.

Surprisingly, the Applicant has found that by producing a mat having a relatively high glass fiber content and a relatively low cellulosic component and binder contents, the mat matrix has the same physical properties (such as resistance to stress). ) of heavier and more expensive mats, with an essentially increased tear resistance.

SYNTHESIS OF THE INVENTION The present invention is a strutural ester matrix comprising (a) a substrate which consists essentially of from 80% to 99% by weight of glass fibers of from 20% to 1% by weight of wood pulp and (b) u binder which joins together fiberglass fibers and wood pulp. The binder consists essentially of from 80% to 95% by weight of urea formaldehyde resin and from 20% to 5% by weight of acrylic copolymer. The binder comprises from 5% to 15% by weight of the matrix, preferably 10%.

In a preferred embodiment, (a) the substrate consists essentially of 95% by weight of glass fiber and 5% by weight of wood pulp and (b) the binder consists essentially of 90% by weight of urea formaldehyde resin and 10% by weight of acrylic copolymer.

DETAILED DESCRIPTION The structural articles of the present invention are useful, inter alia, as roof tile mats, construction roof mats, facade mats, base game sheets. The articles produced according to the invention are lighter in weight but possess the same physical properties of tear resistance, tensile strength, wet tensile strength, porosity breaking strength as the prior art counterparts. In addition, the structural mat matrices of the applicant's invention achieve those results with lower raw material costs.

The structural mat matrices of the present invention comprise (a) a substrate which consists essentially of from 80% to 99% by weight of fiberglass fibers and from 20% to 1% by weight of wood pulp and ( b) a binder which consists essentially of from 80% to 95% by weight of urea formaldehyde resin and from 20% to 5% by weight of acrylic copolymer. The fiberglass fibers which can be used in the substrate of the invention include fibers of 14 to 18 microns in diameter, from 1 inch to 1 inch in length, cut and wet which can be obtained from Owens Corning Fiberglas, from Schuller and PPG Industries, Inc. Wood pulp can be cellulose fibers, cellulose pulp, kraft pulp, hard wood pulp and soft wood pulp which can be obtained from, for example, International Paper Company, Rayonier, James Rive and Weyerhaeuser and other pulp manufacturers.

The formaldehyde urea resin in the binder may be a latex of about 60% solids, such as Casin Resin C511 or Casco Resin FG-413F which can be obtained from Borden Chemical, Inc. The acrylic copolymer can be an acrylic copolymer of vinyl around 49% solids such as Franklin International Covinax 830 or Rohm and Haas Rhople GL-618. In a preferred embodiment, the binder comprises 10% by weight of the matrix.

The structural mat matrices made in accordance with this invention can be of any shape and can be used in a variety of products including roof tiles, building roof, facades, etc. Preferably, such matrices are flat.

Additionally, the structural matrices can be coated with a water repellent material. Two such water repellent materials are Aurapel 33R or Aurapel 391 available from Auralux Corporation of Norwich, CT. Additional structural matrices made according to the invention can be coated with a material against fungi, such as Micro-Chek IIP, an antibacterial material such as Micro-Chek ll-S-160, a surface friction agent such com Byk-375, and / or a coloring dye such as T-1133A.

The materials used in the manufacture of the dies and the methods of their preparation are described respectively in the following trade literature: International Pape ALBACEL product literature for bleached South Pine pulp available from International Pulp Sales, 2 Manhattanville Road, Purchase, New York, and International Pape Product Literature SUPERCELL AO-2, 0047-3 / 97 for Fully bleached wood pulp kraft available from International Pulp Sales, 1290 Avenue de las Americas, New York, New York; the Owens Corning 786 WUCS product bulletin (1995) from Owens Corning World Headquarters, Fiberglas Tower, Toledo, Ohio; wet cut wire bulletin of PPG 8239 2.3.1, PPG fiberglass products reviewed 2/95, from one PPG Place, Pittsburgh, Pennsylvania; Resin Borden C511 Helmet DATA SHEETS TDS XA-C511 06/97 and DATA SHEETS Resin FG-413F TDS XA 413F 11/96, North American Resins Worldwide Packaging and Industrial Products (Borden Division, Inc.) 520 112 Avenue , Northeast, Bellevue, WA; Franklin International Covinax 830 3/20/95 data sheet, Franklin International, 20N2 Bruck Street, Colu bus, Ohio; product literature Rohm and Haas Rhoplex GL-618 20N2, September 1994, Rohm and Haa Company, Charlotte, North Carolina. The descriptions of each of the aforementioned trade publications are hereby incorporated by reference.

EXAMPLE I The Applicant developed a strutural ester matrix with physical performance characteristics of heavy duty mats achieved at lower base weights by increasing the glass fiber content of the ester relative to the normal binder content and including a relatively smaller amount of wood pulp in the substrate matrix. The matrix was produced as follows: Preparation in Matrix Laboratory A 12 inch by 12 inch Williams sheet mold fitted with a Lightnin mixer mounted on an upper eyebrow was filled with approximately 5 gallons of softened water. Stirring was started and 10 milliliters of Nalco 2388 viscosity modifier and 5 milliliters of fluid dispersant were added. 5.94 grams of Owens-Corning 786 1-inch "M" chopped glass fiber (16 microns) was added and mixing continued for 12 minutes. 0.31 grams of International Paper A02 Supercell wood pulp was dispersed for 15 seconds in a Waring blender containing 30 milliliters of water. The pulp solution was added to the leaf mold, the water drained and the fabric formed on the wire at the bottom of the leaf mold. After opening the sheet mold, a more open mesh wire was placed over the upper part of the tissue which was transferred and passed over a vacuum slot to remove excess water.

The tissue was transferred to a third wire and embedded in a rectangular tray containing a 90:10 by weight (solid) mixture of urea-formaldehyde resin from Casco C-511X and acrylic latex from Franklin International Covina 830 to a 14% total solids. The supported tissue was passed over a vacuum slot to remove the excess saturant and placed in a circulating air oven set at 400 degrees F for 2 minutes for drying and curing.

Laboratory Preparation of a Tile Coupon The filled asphalt coating composition was prepared by heating 350 grams of Trumbull oxidized asphalt in a one-sample sample can equipped with a high-speed mixer and an electrically heated blanket. When the asphalt temperature reached 400 degrees F, 650 grams of JTM ash of Alsil-04TR was added very slowly with stirring until a uniform mixture was obtained.

The pre-cut release paper (7 and one half inches by 11 inches) was placed in a Pacific-Scientific pull-down apparatus. A piece of matrix was mounted on the release paper using the transparent tape pulling the skimmer meter down to 45 mils (0.045 inches). The hot coating compound (400 degrees F) was poured in front of the blade, the electric impeller was ignited and the blade was pulled through the length of the matrix sample. The excess coating was removed from the blade and the tray. The sample was removed from the apparatus and the asphalt was traced from side to side on a fresh piece of release paper. The meter and skimmer was set to 90 mils and the reverse side was coated with asphalt compound in the same manner as indicated above.

After cooling to room temperature, the coupon, placed in sandwich form between the sheets of the release paper, was placed in a Carver press, having the plates preheated to 250 degrees F, and pressed under pressure of 1000 pounds per inch. square for 30 seconds, resulting in a final coupon thickness of about 65 thousandths of an inch.

EXAMPLES II to VII The laboratory handsheet matrix samples were prepared by the same procedure described above by Example I as using the substrat compositions listed in Table I, the binder compositions listed in Table III and the matrix compositions listed in FIG. Table V, with the quantities of each raw material calculated to obtain the matrix base weights listed for each example in Table V.

Example II of the present invention is a modification of Example I, with the part of the wood pulp and the substrate 'increased to 10%. Example III is a modification of Example I, in which the binder is 100% formaldehyde urea resin. Example IV is a modification of Example I, having 15% content of acrylic copolymer resin and the binder. Example V is a modification of Example I without wood pulp in the substrate. Examples VI and VII are matrix samples of conventional composition having base weights of about 1.4 and 1.8 pounds / square respectively, to serve as controls.

The unique coupons were prepared in a manner identical to that described above for Example I.

EXAMPLES VIII and IX The matrix rolls used in these examples were prepared using conventional paper making equipment commonly used in the roofing mats industry. The binder was added to the line with a conventional wet tissue impregnation equipment. The drying and curing of the matrix rolls was achieved with gas-fired furnaces.

Example VIII is the preferred matrix of the present invention. Example IX is a normal matrix of a higher bas weight and a higher binder content used in the production of tiles and was included to serve as a control.

The tiles were used using the conventional roof tile production equipment and contained raw materials and granules.

PHYSICAL PROPERTIES The properties of the matrix samples and the tile coupons of Examples I to VII are shown in Table VII. Those of the production matrices and tiles of Examples VIII and IX are listed in Table VIII. Normal test procedures as published by the Technical Association of the Pulp and Paper Industry (Tappi) and by the American Society for Testing and Materials (ASTM) with modifications adopted for the roofing industry used as described below.

PROCEDURE A The basis weight of the structural ester matrix was measured according to the TAPPI method T 1011 ora-92 using a 10-inch by 10-inch test specimen cut from a sheet of hands. The value is reported in pounds per square inch (100 square feet) as is customary in the roofing industry.

PROCEDURE B The ignition loss of the structural ester matrix was tested by the TAPPI method T 1013 om-92; the results are reported as a percentage of the weight of the initial matrix.

PROCESS The tensile strength of the structural mat matrix was measured according to the ASTM D-828 test. The width of jaw and the width of samples were both of 3 inches; the initial separation of the jaws was 3 inches; The jaw separation rate was 12 inches per minute, the test results are reported in pounds per 3 inches of sample width.

PROCEDURE D Tear resistance of the structural mat matrix was measured according to the TAPPI method T 1006 sp-92, using the Elmendorf tear tester described in the method TAPPI T 414. A single stratum sample was tested. The results are reported in grams.

PROCEDURE E The tensile strength of a tile coupon was tested according to ASTM D-828. The width of the jaw and the width of the samples were both 2 inches; the initial separation between the jaws was 3 inches; the jaw separation rate was 2 inches for 2 minutes. Test results are reported in pounds per 2 inches of sample width.

PROCESS Tear strength of a tile coupon was measured according to ASTM D-3462 using an Elmendorf ripped tester. The results were reported in grams.

TABLE I Substrate Formula for Laboratory Hand Sheets (percent by weight) TABLE II Production Substrate Formula (percent by weight) TABLE III Binder Formula for Laboratory Hand Sheets (percent by weight) TABLE IV Production Binder Formula (percent by weight) TABLE V Base Weight and Composition of Matrix for Laboratory Hand Sheet TABLE VI Base Weight and Composition of Production Matrix TABLE VII Physical Properties of Laboratory Matrix Samples and Laboratory Tile Coupons TABLE VIII Physical Properties of the Texas Production and Production Matrix Surprisingly, the applicant has discovered that by reducing the binder content and increasing the amount of overall fiber and including a smaller amount of wood pulp, the desired weight of the mat can be achieved while the breaking strength of the mat is dramatically improved. matrix and the tile produced from the matrix. Although it is not desired to be bound by any particular theory, the Applicant believes that the pulp cellulose component of the matrix in the invention bridges the glass fibers in order to increase the tensile strength, thereby allowing a decrease in the binding of binder and increasing the content of glass fibers to provide the surprising results indicated in Tables VII and VIII mentioned above.

It should be understood that the above-mentioned examples are illustrative and that the various components those described above can be used while using the adjacent principles of the present invention. For example, other sources of wood pulp as well as mixtures of urea formaldehyde and / or acrylic latex can be used in the formulation of the matrices. Other types of latex can be used in combination with formaldehyde urea to improve the properties of the matrices as long as the glass fiber comprises the main proportion of the matrix. The dies can be used for roofing materials, such as roof tiles, roof construction, rolled roof and other products such as facades etc.

Claims (6)

R E I V I N D I C A C I O N S
1. A structural mat matrix which includes: a) a substrate which consists essentially of from 80% to 99% by weight of fiberglass fibers and from 20% to 1% by weight of wood pulp; Y b) a binder which consists essentially of from 80% to 95% by weight of formaldehyde urea resin and d from 20% to 5% by weight of acrylic copolymer; wherein said binder binds the fibr fibers of substrate glass and wood pulp together and where said binder comprises from 5% to 15% by weight of matrix dich.
2. 2. A structural mat matrix as claimed in clause 1 characterized in that the binder comprises 10% by weight of said matrix.
3. 3. A structural mat matrix as claimed in clause 2 characterized in that it comprises: a) a substrate which consists essentially of 95% by weight of fiberglass fibers and 5% by weight of wood pulp; Y b) a binder which consists essentially of 90% by weight of formaldehyde urea resin and 10% by weight of acrylic copolymer.
4. 4. Such a structural mat matrix is claimed in clause 3 characterized in that said acrylic copolymer is a vinyl acrylic copolymer.
5. 5. A method for making a structural ester matrix which comprises: a) forming a wet mat which essentially consists of from 80% to 99% by weight of fiberglass fibers and from about 20% to 1% by weight of wood pulp; b) applying a binder which essentially consists of from 80% to 95% by weight of formaldehyde urea resin and from 20% to 5% by weight of acrylic copolymer; Y c) drying and curing said mat and binder at elevated temperatures.
6. 6. A product for roof which includes: a) a structural mat matrix which comprises: i) a substrate which essentially consists of from 80% to 99% by weight of fiberglass fibers and from 20% to 1% by weight of wood pulp; Y ii) a binder which essentially consists of from 80% to 95% by weight of formaldehyde urea resin and from 20% to 5% by weight of acrylic copolymer; wherein said binder bonds the fiberglass fibers of the substrate and the wood pulp together and where said binder comprises from 5% to 15% by weight of matrix dich; Y b) a filled asphalt which impregnates and / or coats the mat matrix. ? U M E N A structural mat matrix comprising a) a substrate which consists essentially of from 80% to 99% by weight of fiberglass fibers and from 20% to 1% by weight of wood pulp and b) a binder which It consists essentially of from 80% to 95% by weight of ure formaldehyde and from 20% to 5% by weight of acrylic copolymer. The binder bonds the fiberglass fibers of the substrate and the wood pulp together and comprises from 5% to 15% by weight of said matrix, preferably 10% by weight of the matrix.