EP0025115B1 - Matériaux de couverture à haute ténacité à base de nouveaux feutres en fibres de verre; produits à plusieurs couches et feutres en fibres de verre en soi - Google Patents

Matériaux de couverture à haute ténacité à base de nouveaux feutres en fibres de verre; produits à plusieurs couches et feutres en fibres de verre en soi Download PDF

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Publication number
EP0025115B1
EP0025115B1 EP80104567A EP80104567A EP0025115B1 EP 0025115 B1 EP0025115 B1 EP 0025115B1 EP 80104567 A EP80104567 A EP 80104567A EP 80104567 A EP80104567 A EP 80104567A EP 0025115 B1 EP0025115 B1 EP 0025115B1
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European Patent Office
Prior art keywords
mat
fibers
glass fiber
roofing
glass
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Expired
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EP80104567A
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German (de)
English (en)
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EP0025115A2 (fr
EP0025115A3 (en
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Alfredo A. Bondoc
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GAF Corp
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GAF Corp
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Priority claimed from US06/070,991 external-priority patent/US4269886A/en
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Priority to AT80104567T priority Critical patent/ATE4653T1/de
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Publication of EP0025115A3 publication Critical patent/EP0025115A3/en
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N5/00—Roofing materials comprising a fibrous web coated with bitumen or another polymer, e.g. pitch

Definitions

  • This invention relates to high-strength roofing products using novel glass fiber mats, and more particularly, to ashalt shingles and built up roofing products having exceptional tensile strengths.
  • Thin sheets or mats of glass fibers are finding Increasing application in the building materials industry, as for example, as felts in roofing products. These glass fiber mats are replacing base sheets made traditionally of cellulosic and/or asbestos fibers. Glass fiber mats usually are made commercially by a wet-laid process, which is carried out on modified paper-making machine, as described, for example, in the book by 0. A. Battista, Synthetic Fibers in Papermaking (Wiley 1964: N. Y.) A number of U.S.
  • patents also provides a rather complete description of the wet-laid process and glass mats produced thereby, including 2,477,555, 2,731,066, 2,906,660, 3,012,929, 3,021,255, 3,050,427, 3,103,461, 3,108,891, 3,228,825, 3,634,054, 3,749,638, 3,760,458, 3,766,003, 3,838,995, 3,853,683, 3,905,067, 4,052,257, 4,112,174,4,129,674 and 4,135,029.
  • FR-A-2 204 582 and US-A-4 112 174 disclose a uniform fibrous mat consisting of a 2- fiber component system.
  • the known mats are composed of both individual monofilament glass fibers of given fiber length and, in addition, a plurality of glass fiber bundles of elongated dimension whose filaments are held together in said bundles by a water insoluble system. According to the state of the art, the . increased mat strength is achieved by the presence of these elongated bundles.
  • EP-A-0 002 002 and EP-A-0 006 963 disclose the formation of a uniform fibrous mat in a wet-laid process.
  • the glass fiber mat is made from a dispersion of glass fibers in an aqueous dispersant medium which includes as dispersant components an amine oxide or guar gum only as a dispersant.
  • a specific object of this invention is to provide a high tensile strength built up roofing membrane and system which includes a novel glass fiber mat which has at least 70% by weight of the fibers therein in the form of uniformly enmeshed individual filament fibers.
  • Another object of the invention is to provide such roofing products in which less than 20% of the area of the mat are voids which extend through the thickness of the mat, the rest being fibrous material.
  • a further object of the invention is to provide roofing products including glass fiber mats wherein at least 8096, 30% and 10% of the voids have an equivalent diameter whose size is correspondingly less than 50 micrometers, 10 micrometers and 5 micrometers, respectively.
  • Still another object herein is to provide such roofing products including a novel glass fiber mat with fibers having a length of 6.3 mm to 76.2 mm and a diameter of 3 to 20 micrometers, the mat including 70% to 90% glass fibers and 10% to 30% binder to hold the fibers together, and wherein the mat has a thickness of 0.1 mm. to 3 mm. and a basis weight of 20 glm2 to 200 g/m2.
  • Yet another object herein is to provide roofing products having glass fiber mats whose structure exhibits excellent tensile strength in both the machine and cross machine directions.
  • a novel glass fiber mat comprising glass fibers, voids extending through the thickness of said mat and a binder to hold said fibers together, said fibers having a length of 6.3 to 76.2 mm and a diameter of 3-20 micrometers said mat having a thickness of 0.1 to 3.0 mm and a basis weight of 20-200 g/m 2 , which is characterised in that at least 70% by weight of said fibers are substantially of the same length and uniformly enmeshed individual filament fibers; less than 20% of the area of said mat are voids which extend through the thickness of the mat the rest being fibers, and at least 80%, 30% and 10% of said voids have an equivalent diameter which is less than 50, 10 and 5 micrometers respectively, the mat being formed by the wet laid process using a dispersion of said fibers in an aqueous dispersant medium including as dispersant components a derivatized guar gum including substituent groups attached to the guar gum and
  • FIG. 1 shows a photograph of the glass mat used as a felt in the roofing products of the invention.
  • the mat generally referred to by reference numeral 10, includes a plurality of substantially uniformly enmeshed individual filament fibers 11 which comprise at least 70%, preferably 80% and optimally 90% or greater, by weight of the fibrous component of the mat. Less than 20% of the area of the mat are voids 12 which extend through the thickness of the mat, the rest being fibrous material. At least 80%, 30% and 10% of the voids have an equivalent diameter whose size is correspondingly less than 50 micrometers, 10 micrometers and 5 micrometers respectively.
  • the fibers suitably have a length of 6.3 mm to 76.2 mm and a diameter of 3 to 20 micrometers.
  • the mat has a thickness of 0.1 to 3 mm., preferably 0.3 to 2 mm. and a basis weight, including a binder material to hold the fibers together, of 20 to 200 g./m 2 .
  • the fibrous material usually comprises 70% to 90% by weight of the mat, and the binder 10% to 30%. Any suitable binder substance may be used, which is usually a resinous material.
  • the wet-laid process of forming the mat comprises first forming an aqueous suspension or dispersion of a plurality of chopped bundles of glass fibers, each of which contains from 20 to 300 fibers per bundle, by intense agitation of the bundles in a dispersant medium in a mixing tank.
  • the process is intended to filamentize or separate the fibers in the bundle within the aqueous dispersant medium.
  • the dispersant composition then is fed through a moving screen on which the filaments enmesh themselves while water is being removed.
  • the dispersant medium includes a derivatized guar gum (hereinafter defined) in combination with a second dispersant component, suitably such as a tertiary amine oxide (also defined later).
  • a second dispersant component suitably such as a tertiary amine oxide (also defined later).
  • the glass fiber dispersion is made by first thoroughly mixing the derivatized guar gum in tap water to form a viscous mixture. Then the tertiary amine oxide constituent is added with stirring, and the chopped bundles of glass fibers are admixed to form the desired fiber dispersion composition.
  • the dispersion is pumped to a head box of a mat-forming machine where the desired glass mat is formed as a wet mat on the belt of the machine.
  • a suitable binder then is applied to the formed mat, which is then dried, set and/or cured.
  • the derivatized guar gum component of the dispersion composition includes substituent groups attached to guar gum itself.
  • Derivatized guars suitable for use herein are identified as such in the commercial products which are available from Stein, Hall and Co., Inc.
  • Typical derivatized guars include Jaguar CMHP, which is a carboxymethylhydroxypropylated guar gum; C-13, which is a quaternary ammonium guar gum; and Jaguar HP-11, which is hydroxypropylated guar gum.
  • the amine oxide surfactant component of the dispersion composition is a tertiary amine oxide having the formula: where R j , R 2 and R 3 suitably are hydrocarbon groups containing between 1-30 carbon atoms.
  • the hydrocarbon groups can be aliphatic or aromatic, and, if aliphatic, can be linear, branched or cyclic, and can be the same or different in each radical.
  • the aliphatic hydrocarbon radical also can contain ethylenic unsaturation.
  • aliphatic groups are selected from among alkyl groups, such as lower alkyl or hydroxyalkyl groups having from 1-4 carbon atoms, and other substituted alkyl groups thereof, or long chain alkyl groups, having from 12-30 carbon atoms, such as stearyl, laurel, oleyl, tridecyl, tetradecyl, hexadecyl, dodecyl, octadecyl, nonadecyl, or substituted groups thereof, derived from natural or synthetic sources.
  • the sum of the R j , R 2 and R 3 groups is 14-40 carbon atoms, and, most preferably, 18-24 carbon atoms.
  • Typical commercial amine oxides prepared for use herein include Aromox DMHT, which is dimethyl hydrogenated tallow amine oxide; Aromox DM16, which is dimethylhexadecyl- amine oxide; Aromox T/12, which is bis(2-hydroxyethyl) tallow amine oxide, available from Armak Co.; and Ammonyx SO, which is dimethylstearylamine oxide, available from Onyx Chemical Co.
  • a particularly useful amine oxide is Aromox DMHT, which has the formula: where R HT is R T hydrogenated to saturation, and R T Is 3% tetradecyl, 27% hexadecyl, 16% octadecyl, 48% octadecenyl and 6% octa- decadienyl.
  • glass fibers which form dispersions in the composition of the mat employed in the invention may be used herein, including, for example, glass fiber types E or C. Such fibers may be sized or unsized, and usable as dry or wet chopped form.
  • the glass mats produced in the process are uniform mats which have high tensile and tear strengths.
  • fibers of relatively lower diameters are used, while higher tear strengths are enhanced by using longer length and smaller diameter fibers.
  • the basis weight of the finished mat (with binder) for built up roofing products should be at least 49 g/sq.m. and, optimally, 98 to 148 g/sq.m.
  • these mats have a tensile strength in the machine direction (MD) of at least 300 N/50 mm. width, and in the cross-machine direction (CMD) of at least 100 N/50 mm. width, at a basis weight of 98 g/sq.m.
  • MD machine direction
  • CMD cross-machine direction
  • the mats have a tensile strength values of 500 to 700 MD and 150 to 250 CMD.
  • the mats have a tensile strength of 800 MD and 300 CMD.
  • These glass mats are used as felts in the manufacture of improved roofing products, in this invention, including roofing shingles, built up roofing membranes, and multi-ply systems, which are characterized by very high tensile and tear strengths.
  • the roofing products of the present invention may be made by conventional techniques.
  • a built up roofing membrane may be manufactured by coating the glass mat with hot bituminous material, which, optionally, may be admixed with a fine mineral filler, such as talc, mica or sand, thereby to impregnate the mat with the bituminous (asphaltic) material. Thereafter the membrane is cooled and wound into rolls.
  • a fine mineral filler such as talc, mica or sand
  • bituminous material For the manufacture of a roofing shingle product, generally the bituminous material is coated on both sides of the glass mat, and a layer of the material remains on the surfaces of the mat. Finally, roofing granules are applied to the bituminous material and adhered to the surfaces.
  • the membrane includes the glass mat 10 as a felt material which is impregnated with bituminous material 13.
  • FIG. 3 shows a typical built up roofing system of the invention.
  • the embodiment illustrated is a 3-ply system, generally indicated by reference numeral 30.
  • the system is secured to a roof deck 14 covered by appropriate insulation 15 (optional), by means of a bituminous adhesive coating 16 or mechanical fasteners.
  • the successive membranes are adhered to each other with bituminous coatings 16.
  • the top membrane is also covered with a bituminous coating layer 17 which may include therein aggregate surfacing material 18.
  • the top membrane optionally, may be covered with suitable surface coatings, such as fibered aluminum roof coatings, cold applied solvent cutback, asphalt mastic and/or roofing granules.
  • the mat-forming machine was a 0.5 m inclined wire Hydroformer which was adjusted to a processing condition to give a preferred fiber orientation in the machine direction (MD) over the cross machine direction (CMD).
  • the dispersion composition consisted of Aromox DMHT, 20 ppm, CMHP, 0.2%, E-type glass fibers, 25 mm length, 16 micrometers diameter, sized, and wet chopped.
  • the dispersion consistency was 0.5% the diluted formation consistency was lowered to 0.03 after dilution with additional dispersion composition removed during mat formation at the headbox.
  • the formed glass mat then is impregnated with ureaformaldehyde resin, and cured.
  • the glass mat, with about 25% by weight binder had an excellent tensile strength, N/50 mm width, MD/CMD of 506/412, at a basis weight of 114 glm 2 and a thickness of 0.8 mm.
  • Example 1 The mat of Example 1 was impregnated with bituminous material having a softening point of about 104-110°C and a penetration test value (ASTM D5-65) at 25°C of about 16-18 millidecimeters. The impregnation was about 432%, based on the weight of the glass mat. The surfaces of the impregnated mat then were dusted with talc to prevent sticking upon rolling up the membrane. The tensile strengths MD/CMD, at 25°C., of the membrane were 686/525 N/50 mm. width, respectively. In use, this roofing membrane exhibits excellent high-strength and wear properties.
  • Example 2 The membranes of Example 2 were unrolled and asphaltic adhesive material, (ASTM D312-71, Type III) was applied at a level usage of about 8.8 g/cm 2 between successive membrane layers.
  • the tensile strength of this system was 56.3 kp/cm (CMD) at -18°C and 36 kp/cm (CMD) at +25°C.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Glass Compositions (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
  • Cell Separators (AREA)
  • Paper (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)

Claims (31)

1. Natte de fibres de verre comprenant des fibres de verre, des vides s'étendant sur toute l'épaisseur de ladite natte et un liant maintenant les fibres assemblées, lesdites fibres ayant une longueur de 6,3 à 76,2 mm et un diamètre de 3 à 20 micromètres, la natte ayant une épaisseur de 0,1 à 3,0 mm et un poids par unité de surface de 20 à 200 g/m2, caractérisé en ce que
a) au moins 70% en poids desdites fibres sont des fibres filamenteuses individuelles ayant sensiblement la même longueur et étant uniformément emmêlées,
b) moins de 20% de l'aire de ladite natte sont formés de vides qui s'étendent sur toute l'épaisseur de la natte, le reste étant formé de fibres, et
c) au moins 80%, 30% et 10% des vides ont un diamètre équivalent de moins de 50, 10 et 5 micromètres, respectivement, .

la natte étant formée par le procédé par voie humide en utilisant une dispersion desdites fibres dans un milieu dispersant aqueux comprenant comme composants dispersants
A) un dérivé de gomme guar portant des groupes substituants liés à la gomme guar et
B) un surfactant qui est un oxyde d'amine de formule:
Figure imgb0007
dans laquelle R,, R2 et R3 représentent avantageusement des groupes hydrocarbonés contenant 1 à 30 atomes de carbone.
2. Natte de verre suivant la revendication 1, dans laquelle lesdites fibres filamenteuses individuelles constituent au moins 80% en poids des fibres en question.
3. Natte de verre suivant la revendication 1 et/ou la revendication 2, dans laquelle les fibres filamenteuses individuelles constituent au moins 90% en poids des fibres en question.
4. Natte de fibres de verre suivant l'une quelconque des revendications 1-3, dans laquelle la longueur des fibres va de 12,7 à 38,1 mm.
5. Natte de fibres de verre suivant l'une quelconque des revendications 1 à 4, dans laquelle le diamètre desdites fibres est de 8 à 19 micromètres.
6. Natte de fibres de verre suivant l'une quelconque des revendications 1 à 5, dont l'épaisseur est de 0,3 à 2 mm.
7. Natte de fibres de verre suivant l'une quelconque des revendications 1 à 6, dont le poids surfacique est de 40 à 110 g/m2.
8. Natte de fibres de verre suivant l'une quelconque des revendications 1-7, dans laquelle les fibres constituent 70 à 90% et le liant 10 à 40% en poids de la natte.
9. Natte de fibres de verre suivant l'une quelconque des revendications 1 à 8, dans laquelle la résistance à la traction est d'au moins 300/100 N/50 mm de largeur SM/STM, respectivement, pour un poids surfacique de 100 g/m2.
10. Natte de fibres de verre suivant l'une quelconque des revendications 1 à 9, dans laquelle au moins 15% des vides ont un diamètre équivalent inférieur à 5 micromètres.
11. Natte de fibres de verre suivant l'une quelconque des revendications 1 à 10, ayant une longueur de fibres de 25,4 mm, un diamètre de fibres de 16 micromètres, une épaisseur de natte de 1 mm, un poids surfacique de 110 g/m2, des teneurs en fibres et en liant d'environ 80% et 20%, respectivement, une résistance à la traction de 500/280 N/50 mm de largeur SM/STM, respectivement, caractérisée en outre en ce que 85% en poids desdites fibres consistent en fibres filamenteuses individuelles quasiuniformément emmêlées, 18,4% de la surface de ladite natte sont desvides, le reste étant composé de fibres, 82,9, 37,0 et 17,9% desdits vides ayant un diamètre équivalent qui est, respectivement, inférieur à 50, 10 et 5 micromètres.
12. Matériau de couverture de grande résistance mécanique, comprenant:
(A) une natte de fibres de verre suivant l'une quelconque des revendications 1-11 et
(B) une matière bitumineuse imprégnant la natte.
13. Matériau de couverture suivant la revendication 12, dans lequel le diamètre desdites fibres est de 12 à 19 micromètres.
14. Matériau de couverture suivant la revendication 12 et/ou la revendication 13, dans lequel le poids surfacique de la natte de verre est de 40 à 150 g/m2.
15. Matériau de couverture suivant l'une quelconque des revendications 12 à 14, dans lequel les fibres constituent 70 à 90% et le liant 10 à 30% en poids de ladite natte.
16. Matériau de couverture suivant l'une quelconque des revendications 12 à 15, dans lequel la résistance à la traction de la natte de verre est d'au moins 300 et la largeur d'au moins 100 N/50 mm, SM et STM, respectivement.
17. Matériau de couverture suivant l'une quelconque des revendications 12 à 16, qui est un bardeau de toiture.
18. Matériau de couverture suivant l'une quelconque des revendications 12 à 17, dans lequel la matière bitumineuse est également présente comme revêtement sur les deux faces de la natte.
19. Matériau de couverture suivant l'une quelconque des revendications 12-18, dans lequel les fibres de verre dans (A) ont une longueur de fibres de 25,4 mm, un diamètre de fibres de 16 micromètres, avec une épaisseur de la natte de verre de 1 mm, un poids surfacique de 110 g/m2, des teneurs en fibres et en liant de 80% et 20%, respectivement, des résistances à la traction de 500 et 400 N/50 mm de largeur, SM et STM, respectivement, caractérisé en outre par le fait que a) 85% en poids desdites fibres sont des fibres filamenteuses individuelles quasi uniformément emmêlées, dans b) 18,4% de l'aire de ladite natte sont formés de vides, le reste étant formé de fibres, dans c) 82,9%, 37,0% et 17,9% desdits vides ont un diamètre équivalent qui est inférieur à 50, 10 et 5 micromètres, respectivement.
20. Matériau de couverture suivant l'une quelconque des revendications 12 à 19, qui est une membrane sous la forme enroulée.
21. Matériau de couverture multicouche suivant la revendication 20, ayant une résistance à la traction de 500 à 700 SM et de 150 à 250 STM.
22. Matériau suivant la revendication 20, dans lequel la résistance à la traction est de 800 SM et de 300 STM.
23. Matériau suivant la revendication 20, dans lequel la résistance à la traction SM est à peu près égale à la résistance à la traction STM.
24. Matériau suivant la revendication 20, dans lequel la résistance à la traction SM est d'au moins 100, 300 ou 500 N/50 mm.
25. Système de couverture multicouche, comprenant:
a) des couches multiples dudit produit de couverture multicouche à haute résistance mécanique tel que défini dans l'une quelconque des revendications 12 à 24, et
b) des revêtements adhésifs bitumineux entre lesdites membranes.
26. Système suivant la revendication 25, comprenant trois couches desdits matériaux de couverture.
27. Système suivant la revendication 25 et/ou la revendication 26, dans lequel la couche inférieure est fixée à une dalle de toiture par un revêtement bitumineux adhésif additionnel.
28. Système suivant l'une quelconque des revendications 25-27, dans lequel la couche inférieure est fixée à une dalle de toiture à l'aide d'un élément mécanique de fixation.
29. Système suivant l'une quelconque des revendications 25-28, caractérisé en outre en ce qu'il comprend sur la couche supérieure une surcouche de revêtement bitumineux.
30. Système suivant la revendication 29, dans lequel la surcouche de revêtement bitumineux porte une matière de surface formée d'agrégats.
31. Système de couverture à trois couches suivant l'une quelconque des revendications 26-30, ayant une résistance à la traction STM à -18°C de 56,3 kp/cm et une résistance à la traction STM à +25°C de 36 kp/cm, pour un poids surfacique de la natte de verre de 114 g/m 2.
EP80104567A 1979-08-30 1980-08-01 Matériaux de couverture à haute ténacité à base de nouveaux feutres en fibres de verre; produits à plusieurs couches et feutres en fibres de verre en soi Expired EP0025115B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT80104567T ATE4653T1 (de) 1979-08-30 1980-08-01 Dachbahnen mit hoher reissfestigkeit unter verwendung von neuen glasfaservliesen; mehrschichtprodukte und glasfaservliese an sich.

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US70991 1979-08-30
US06/070,991 US4269886A (en) 1978-07-11 1979-08-30 Novel glass fiber mat
US79192 1979-09-26
US06/079,192 US4284470A (en) 1978-07-11 1979-09-26 High-strength roofing products using novel glass fiber mats

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EP0025115A2 EP0025115A2 (fr) 1981-03-18
EP0025115A3 EP0025115A3 (en) 1981-05-27
EP0025115B1 true EP0025115B1 (fr) 1983-09-14

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EP (1) EP0025115B1 (fr)
AT (1) ATE4653T1 (fr)
CA (1) CA1147541A (fr)
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Publication number Priority date Publication date Assignee Title
GB9012517D0 (en) * 1990-06-05 1990-07-25 Emberson Richard H A floor and a method for making a floor
US5965638A (en) * 1997-09-08 1999-10-12 Elk Corporation Of Dallas Structural mat matrix
US20060096205A1 (en) * 2004-11-09 2006-05-11 Griffin Christopher J Roofing cover board, roofing panel composite, and method
PL3048212T3 (pl) * 2015-01-23 2021-09-13 Triflex GmbH & Co. KG Układ powłokowy z włókniną
US20210032866A1 (en) * 2019-07-29 2021-02-04 Owens Corning Intellectual Capital, Llc Roofing shingle

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Publication number Priority date Publication date Assignee Title
US2077720A (en) * 1935-05-28 1937-04-20 Johns Manville Felted product and method of making the same
GB865465A (en) * 1957-03-15 1961-04-19 Celanese Corp Making moulded articles
DD108927A5 (fr) * 1972-10-27 1974-10-12
US4112174A (en) * 1976-01-19 1978-09-05 Johns-Manville Corporation Fibrous mat especially suitable for roofing products
US4179331A (en) * 1977-11-15 1979-12-18 Gaf Corporation Glass fiber dispersions for making uniform glass fiber mats by the wet-laid process
US4183782A (en) * 1978-07-11 1980-01-15 Gaf Corporation Method of producing glass mats using novel glass fiber dispersion composition

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ATE4653T1 (de) 1983-09-15
DE3064822D1 (en) 1983-10-20
EP0025115A2 (fr) 1981-03-18
EP0025115A3 (en) 1981-05-27
CA1147541A (fr) 1983-06-07

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