US20140205789A1 - Coated fabrics including expandable graphite - Google Patents

Coated fabrics including expandable graphite Download PDF

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Publication number
US20140205789A1
US20140205789A1 US13/798,413 US201313798413A US2014205789A1 US 20140205789 A1 US20140205789 A1 US 20140205789A1 US 201313798413 A US201313798413 A US 201313798413A US 2014205789 A1 US2014205789 A1 US 2014205789A1
Authority
US
United States
Prior art keywords
expandable graphite
coating
fabric
binder
sheet
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.)
Abandoned
Application number
US13/798,413
Other languages
English (en)
Inventor
Wensheng Zhou
Joseph Carr
Michael J. Hubbard
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Firestone Building Products Co LLC
Original Assignee
Firestone Building Products Co LLC
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Firestone Building Products Co LLC filed Critical Firestone Building Products Co LLC
Priority to US13/798,413 priority Critical patent/US20140205789A1/en
Assigned to Firestone Building Products Co., LLC reassignment Firestone Building Products Co., LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HUBBARD, MICHAEL J., CARR, JOSEPH, ZHOU, WENSHENG
Priority to AU2014209366A priority patent/AU2014209366B2/en
Priority to MX2015008581A priority patent/MX2015008581A/es
Priority to CN201811217622.4A priority patent/CN109537816A/zh
Priority to PCT/US2014/012732 priority patent/WO2014116815A1/fr
Priority to BR112015017536A priority patent/BR112015017536A2/pt
Priority to BR112015017538A priority patent/BR112015017538A2/pt
Priority to RU2015135599A priority patent/RU2660868C2/ru
Priority to AU2014209430A priority patent/AU2014209430B2/en
Priority to EP14704957.1A priority patent/EP2948603B1/fr
Priority to RU2015135508A priority patent/RU2655317C2/ru
Priority to JP2015555268A priority patent/JP6117942B2/ja
Priority to CA2893993A priority patent/CA2893993C/fr
Priority to CN201480005419.4A priority patent/CN104937165A/zh
Priority to CA2897650A priority patent/CA2897650C/fr
Priority to US14/162,273 priority patent/US9523203B2/en
Priority to EP14704954.8A priority patent/EP2948586B1/fr
Priority to JP2015555263A priority patent/JP2016511332A/ja
Priority to MX2015008816A priority patent/MX2015008816A/es
Priority to PCT/US2014/012683 priority patent/WO2014116791A1/fr
Priority to CN201480005911.1A priority patent/CN105026660A/zh
Publication of US20140205789A1 publication Critical patent/US20140205789A1/en
Priority to US15/292,925 priority patent/US10273693B2/en
Priority to US15/354,009 priority patent/US20170067257A1/en
Priority to JP2017057837A priority patent/JP6564413B2/ja
Priority to AU2017216527A priority patent/AU2017216527B2/en
Priority to JP2017237589A priority patent/JP6608115B2/ja
Priority to US16/375,945 priority patent/US10941573B2/en
Priority to US16/665,765 priority patent/US11168479B2/en
Priority to US17/193,221 priority patent/US12006691B2/en
Priority to US17/505,030 priority patent/US20220034092A1/en
Abandoned legal-status Critical Current

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    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D06M11/74—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof with carbon or graphite; with carbides; with graphitic acids or their salts
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
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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
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
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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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
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    • E04C2/16—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of fibres, chips, vegetable stems, or the like
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    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2861—Coated or impregnated synthetic organic fiber fabric
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2926—Coated or impregnated inorganic fiber fabric
    • Y10T442/2992—Coated or impregnated glass fiber fabric

Definitions

  • Embodiments of the present invention are directed toward coated fabrics wherein the coating includes expandable graphite.
  • the coated fabrics are particularly useful as construction materials.
  • Coated fabrics are commonly used in the construction industry. These fabrics, which may also be referred to as webbed sheets, coated mats, or coated facers, generally include a fabric, a binder, and a filler.
  • the binder generally serves to adhere the filler particles to the fabric surface.
  • Coated fabrics have been used as underlayment under roofing or siding, or as facers for various construction materials such as foamed insulation boards.
  • U.S. Pat. No. 5,112,678 teaches webbed mats coated with an aqueous mixture of mineral pigment, a polymer latex adhesive, and an inorganic binder.
  • the coating yields a liquid impermeable mat that is useful as an underlayment or as a facer in a foam board laminating process.
  • U.S. Pat. No. 5,614,256 teaches a coating composition for producing water-tight, vapor-permeable, and flame-retardant articles formed by applying the coating composition to a woven, knitted, or non-woven support material.
  • the coating composition includes an aqueous dispersion of a vinyl chloride copolymer, a flame-proofing agent, a crosslinker, and a thickener.
  • the coated textile support materials are useful in building protection such as underlayments for roof tiles or exterior walls.
  • Embodiments of the present invention provide a coated fabric comprising a fabric substrate and a coating on said substrate, the coating comprising a binder and expandable graphite dispersed throughout the binder.
  • FIG. 1 is a perspective view of a woven fabric according to one or more embodiments of the present invention.
  • FIG. 2 is a perspective view of a non-woven fabric according to one or more embodiments of the present invention.
  • FIG. 3 is an exploded perspective view of a membrane including a fabric reinforcement according to one or more embodiments of the present invention.
  • FIG. 4 is a cross-section perspective view of an insulation board having a fabric facer according to one or more embodiments of the present invention.
  • FIG. 5 is a cross-sectional view of a membrane carrying a fleece backing according to one or more embodiments of the present invention.
  • FIG. 6 is a perspective view of an underlayment fabric according to one or more embodiments of the present invention.
  • Embodiments of the present invention are based, at least in part, on the discovery of a coated fabric wherein the coating includes expandable graphite. Accordingly, coated fabrics of this invention exhibit fire resistivity and/or resistance to flame spread. As a result, the coated fabrics are advantageously useful in preparing construction materials that are characterized by improved flame resistance and/or resistance to flame spread.
  • coated fabrics include a coating that includes a polymeric binder, expandable graphite, and optionally additional binders and/or fillers.
  • the coating compositions may include other conventional ingredients typically added to fabric coating compositions.
  • the coating is formed by applying a coating composition to a fabric substrate.
  • the coating composition may be an aqueous or solvent-borne composition wherein the constituents of the coating (e.g., binders, fillers, and expandable graphite) are dissolved or dispersed within the compositions.
  • the fabric that is coated according to one or more embodiments of the present invention may include a woven, knitted, or non-woven fabric.
  • An exemplary woven fabric is shown in FIG. 1
  • an exemplary non-woven fabric is shown in FIG. 2 .
  • the coating 12 that is deposited on fiber or filament 14 forms a layer or partial layer with the fiber or filament.
  • the coating forms a layer or partial layer with the entire surface of the fabric.
  • the fabric is a fiberglass mat such as a non-woven fiberglass mat.
  • the fiber may include one or more substrate coatings in addition to the coatings applied according to the present invention.
  • the fabric is a polymeric fabric such as a non-woven polyester and/or polypropylene fabric.
  • the fabric is a non-woven fiberglass mat characterized by a weight of from about 0.05 to about 0.15 kg/m 2 , or in other embodiments from about 0.08 to about 0.12 kg/m 2 .
  • the fabric is a non-woven polyester mat characterized by a weight of from about 0.11 to about 0.24 kg/m 2 , or in other embodiments from about 0.15 to about 0.20 kg/m 2 .
  • the fabric is a polymeric fleece such as a polyester or polyolefin fleece.
  • the fabric is a cellulosic fabric.
  • the cellulosic fabric is kraft paper.
  • the kraft paper may be reinforced with fiberglass.
  • the non-woven fiberglass mat may be wet-formed using known techniques such as a Fourdrinier machine.
  • Exemplary fabrics that may be used in the practice of this invention are disclosed in U.S. Pat. Nos. 7,429,544, 7,338,702, 7,300,892, 7,833,638, 7,473,440, 7,321,010, 4,284,4,470, 4,539,254, 4,871,605, 5,112,678, and 5,614,256, which are incorporated herein by reference and U.S. Publication Nos 2008/0160301, 2009/0163097, and 2006/0275561, which are incorporated herein by reference.
  • polymer latex binders useful in the practice of one or more embodiments of this invention include, but are not limited to, styrene-butadiene-rubber (SBR), styrene-butadiene-styrene (SBS), ethylene-vinyl-chloride (EVCl), poly-vinylidene-chloride (PVdC), modified poly-vinyl-chloride (PVC), poly-vinyl-alcohol (PVOH), ethylene-vinyl-actate (EVA), and poly-vinyl-acetate (PVA).
  • the binder may include an asphalt. In other embodiments, the binder is devoid of asphalt.
  • the binder may include acrylic or epoxy binders or resins, which are known in the art.
  • acrylic binders or resins include latex polymers that derive from the polymerization of acrylates, acrylic acids, methacrylates, methacrylic acids, acrylonitrile, and/or acrylamide monomer.
  • the binder may include a polyurethane.
  • inorganic binders that may be used with the latex binders include, but are not limited to, calcium oxide, calcium silicate, calcium sulfate, magnesium oxychloride, magnesium oxysulfate, and other complexes of some Group IIA elements (alkaline earth metals), as well as aluminum hydroxide.
  • a complex inorganic binder such as portland cement, which is a mixture of various calcium-aluminum silicates, may be used.
  • the oxychloride or oxysulfate of aluminum hydroxide and/or calcium silicate may also be used.
  • quicklime which does not hydrate in a coating mix, but cures by slowly converting to limestone by adding carbon dioxide from the air, may be used.
  • Expandable graphite may also be referred to as expandable flake graphite, intumescent flake graphite, or expandable flake; and, for the purposes herein, these terms may be used interchangeably.
  • expandable graphite includes intercalated graphite in which an intercallant material is included between the graphite layers of graphite crystal or particle.
  • intercallant materials include halogens, alkali metals, sulfates, nitrates, various organic acids, aluminum chlorides, ferric chlorides, other metal halides, arsenic sulfides, and thallium sulfides.
  • the expandable graphite includes non-halogenated intercallant materials.
  • the expandable graphite includes sulfate intercallants, also referred to as graphite bisulfate. As is known in the art, bisulfate intercalation is achieved by treating highly crystalline natural flake graphite with a mixture of sulfuric acid and other oxidizing agents which act to catalyze the sulfate intercalation.
  • expandable graphite examples include HPMS Expandable Graphite (HP Materials Solutions, Inc., Woodland Hills, Calif.) and Expandable Graphite Grades 1721 (Asbury Carbons, Asbury, N.J.).
  • HPMS Expandable Graphite HP Materials Solutions, Inc., Woodland Hills, Calif.
  • Expandable Graphite Grades 1721 Align Carbons, Asbury, N.J.
  • Other commercial grades contemplated as useful in the present invention include 1722, 3393, 3577, 3626, and 1722HT (Asbury Carbons, Asbury, N.J.).
  • the expandable graphite may be characterized as having a mean or average size in the range from about 30 ⁇ m to about 1.5 mm, in other embodiments from about 50 ⁇ m to about 1.0 mm, and in other embodiments from about 180 to about 850 ⁇ m. In certain embodiments, the expandable graphite may be characterized as having a mean or average size of at least 30 ⁇ m, in other embodiments at least 44 ⁇ m, in other embodiments at least 180 ⁇ m, and in other embodiments at least 300 ⁇ m.
  • expandable graphite may be characterized as having a mean or average size of at most 1.5 mm, in other embodiments at most 1.0 mm, in other embodiments at most 850 ⁇ m, in other embodiments at most 600 ⁇ m, in yet other embodiments at most 500 ⁇ m, and in still other embodiments at most 400 ⁇ m.
  • Useful expandable graphite includes Graphite Grade #1721 (Asbury Carbons), which has a nominal size of greater than 300 ⁇ m.
  • the expandable graphite may be characterized as having a nominal particle size of 20 ⁇ 50 (US sieve). US sieve 20 has an opening equivalent to 0.841 mm and US sieve 50 has an opening equivalent to 0.297 mm. Therefore, a nominal particle size of 20x50 indicates the graphite particles are at least 0.297 mm and at most 0.841 mm.
  • the expandable graphite may be characterized as having a carbon content in the range from about 70% to about 99%. In certain embodiments, the expandable graphite may be characterized as having a carbon content of at least 80%, in other embodiments at least 85%, in other embodiments at least 90%, in yet other embodiments at least 95%, in other embodiments at least 98%, and in still other embodiments at least 99% carbon.
  • the expandable graphite may be characterized as having a sulfur content in the range from about 0% to about 8%, in other embodiments from about 2.6% to about 5.0%, and in other embodiments from about 3.0% to about 3.5%. In certain embodiments, the expandable graphite may be characterized as having a sulfur content of at least 0%, in other embodiments at least 2.6%, in other embodiments at least 2.9%, in other embodiments at least 3.2%, and in other embodiments 3.5%. In certain embodiments, the expandable graphite may be characterized as having a sulfur content of at most 8%, in other embodiments at most 5%, in other embodiments at most 3.5%.
  • the expandable graphite may be characterized as having an expansion ratio (cc/g) in the range from about 10:1 to about 500:1, in other embodiments at least 20:1 to about 450:1, in other embodiments at least 30:1 to about 400:1, in other embodiments from about 50:1 to about 350:1.
  • cc/g expansion ratio
  • the expandable graphite may be characterized as having an expansion ratio (cc/g) of at least 10:1, in other embodiments at least 20:1, in other embodiments at least 30:1, in other embodiments at least 40:1, in other embodiments at least 50:1, in other embodiments at least 60:1, in other embodiments at least 90:1, in other embodiments at least 160:1, in other embodiments at least 210:1, in other embodiments at least 220:1, in other embodiments at least 230:1, in other embodiments at least 270:1, in other embodiments at least 290:1, and in yet other embodiments at least 300:1.
  • the expandable graphite may be characterized as having an expansion ratio (cc/g) of at most 350:1, and in yet other embodiments at most 300:1.
  • the expandable graphite as it exists with the asphaltic component of the asphaltic sheet of the present invention, is partially expanded.
  • the expandable graphite is not expanded, however, to a deleterious degree, which includes that amount or more of expansion that will deleteriously the ability to form the sheet product and the ability of the graphite to serve as flame retardant at desirable levels, which include those levels that allow proper formation of the sheet.
  • the expandable graphite is expanded to at most 100%, in other embodiments at most 50%, in other embodiments at most 40%, in other embodiments at most 30%, in other embodiments at most 20%, and in other embodiments at most 10% beyond its original unexpanded size.
  • the expandable graphite may be characterized as having a pH in the range from about 1 to about 10; in other embodiments from about 1 to about 6; and in yet other embodiments from about 5 to about 10. In certain embodiments, the expandable graphite may be characterized as having a pH in the range from about 4 to about 7. In one or more embodiments, the expandable graphite may be characterized as having a pH of at least 1, in other embodiments at least 4, and in other embodiments at least 5. In certain embodiments, the expandable graphite may be characterized as having a pH of at most 10, in other embodiments at most 7, in other embodiments at most 6.5, in other embodiments at most 6, and in other embodiments at most 5.
  • the expandable graphite may be characterized by an onset temperature ranging from about 100° C. to about 280° C.; in other embodiments from about 160° C. to about 225° C.; and in other embodiments from about 180° C. to about 200° C.
  • the expandable graphite may be characterized by an onset temperature of at least 100° C., in other embodiments at least 130° C., in other embodiments at least 160° C., in other embodiments at least 170° C., in other embodiments at least 180° C., in other embodiments at least 190° C., and in other embodiments at least 200° C.
  • the expandable graphite may be characterized by an onset temperature of at most 250° C., in other embodiments at most 225° C., and in other embodiments at most 200° C.
  • Onset temperature may also be interchangeably referred to as expansion temperature; it may also be referred to as the temperature at which expansion of the graphite starts.
  • useful fillers include, but are not limited to, ground limestone (calcium carbonate), clay, sand, mica, talc, gypsum (calcium sulfate), aluminum trihydrate (ATH), antimony oxide, or a combination of any two or more of these substances.
  • the filler is characterized by a particle size such that at least 95% of the filler passes a 325 mesh wire screen.
  • the coating compositions may include other constituents such as flow and leveling agents, defoaming agents, stabilizers, preservatives, thickeners, dispersants, waxes, processing agents, surfactants, pH buffers or adjusters, and the like.
  • the coating composition employed to coat the fabrics according to the present invention include at least 10% by wt., in other embodiments at least 20% by wt., and in other embodiments at least 30% by wt. solids based on the total weight of the coating composition.
  • the coating compositions include at most 80% by wt., in other embodiments at most 70% by wt., and in other embodiments at most 60% by wt., solids based on the entire weight of the coating composition.
  • the coating compositions include from about 10 to about 80, in other embodiments from about 20 to about 70, and in other embodiments from about 30 to about 60% by wt. solids based on the entire weight of the coating composition.
  • the coating compositions include at least 5% by wt., in other embodiments at least 10% by wt., and in other embodiments at least 15% by wt. polymeric binder (solids) based on the total weight of the coating composition. In these or other embodiments, the coating compositions include at most 75% by wt., in other embodiments at most 65% by wt., and in other embodiments at most 55% by wt., polymeric binder (solids) based on the entire weight of the coating composition. In one or more embodiments, the coating compositions include from about 5 to about 75, in other embodiments from about 10 to about 65, and in other embodiments from about 15 to about 55% by wt. polymeric binder based on the entire weight of the coating composition.
  • the coating compositions include at least 1% by weight, in other embodiments at least 2% by wt., in other embodiments at least 5% by wt., and in other embodiments at least 7% by wt. expandable graphite based on the total weight of the solids component of the coating composition.
  • the coating compositions include at most 50% by wt., in other embodiments at most 40% by wt., and in other embodiments at most 30% by wt., expandable graphite based on the total weight of the solids component of the coating composition.
  • the coating compositions include from about 2 to about 50, in other embodiments from about 5 to about 40, and in other embodiments from about 7 to about 30% by wt. expandable graphite based on the total weight of the solids component of the coating composition.
  • the coating compositions include at least 1% by wt., in other embodiments at least 3% by wt., and in other embodiments at least 5% by wt. inorganic binder based on the total weight of the solids component of the coating composition. In these or other embodiments, the coating compositions include at most 20% by wt., in other embodiments at most 15% by wt., and in other embodiments at most 10% by wt., inorganic binder based on the total weight of the solids component of the coating composition. In one or more embodiments, the coating compositions include from about 0 to about 20, in other embodiments from about 1 to about 15, and in other embodiments from about 3 to about 10% by wt. inorganic binder based on the total weight of the solids component of the coating composition. In particular embodiments, the coating composition is devoid of inorganic binder.
  • the coating compositions include at least 1% by wt., in other embodiments at least 3% by wt., and in other embodiments at least 5% by wt. filler based on the total weight of the solids component of the coating composition.
  • the coating compositions include at most 90% by wt., in other embodiments at most 70% by wt., in other embodiments at most 50% by wt., and in other embodiments at most 30% by wt., filler based on the total weight of the solids component of the coating composition.
  • the coating compositions include from about 0 to about 70, in other embodiments from about 3 to about 50, and in other embodiments from about 5 to about 30% by wt. filler based on the total weight of the solids component of the coating composition.
  • the coating composition is devoid of fillers other than expandable graphite.
  • a raw glass mat (e.g., the “substrate”) enters a coating station at a level lower than a top of an applicator roll.
  • the direction of travel of the glass mat is parallel to a “machine direction” (M.D.) of a facer produced by the machine, while a dimension perpendicular to the machine direction is understood to be the “cross machine direction” (C.M.D.) of a resultant facer similarly oriented.
  • the applicator roll is driven to rotate about its axis (either clockwise or counterclockwise).
  • a coating pan is filled with a coating mix up to a level that is sufficient for the applicator roll to pull an adequate amount of coating to the top of the applicator roll.
  • the speed of rotation of applicator roll is used to get adequate amounts of coating mix up into the glass mat as the glass mat is conveyed. In its path of conveyance, the glass mat extends around applicator roll in a wrap-arc.
  • a scraper blade is placed so that the excess coating scraped off returns into the coating pan. After the excess is scraped off, the coated mat proceeds into a dryer section where the coated glass mat facer is dried and wrapped into rolls.
  • the coated fabrics of the present invention can be used as reinforcements in various membranes.
  • the coated fabric can be used as reinforcement in roofing membranes such as asphaltic membranes, thermoplastic membranes (e.g. PVC and TPO membranes), and rubber membranes (EPDM membranes).
  • roofing membranes such as asphaltic membranes, thermoplastic membranes (e.g. PVC and TPO membranes), and rubber membranes (EPDM membranes).
  • An exemplary membrane is shown in FIG. 3 .
  • the membrane 20 which is shown in exploded view, includes polymeric layers (e.g., polyolefin or EPDM) 22 and 24 . Sandwiched therebetween is reinforcement 26 that carries coating 28 according to one or more embodiments of the present invention.
  • the coated fabrics of the present invention can be used as facers for various construction boards including, but not limited to, polyisocyanurate and polyurethane insulation boards, cover boards, and gypsum boards.
  • An exemplary insulation board is shown in FIG. 4 .
  • the board 30 includes foam body 31 having first and second planar surfaces 32 and 34 , respectively. At least one planar surface (e.g., planar surface 34 ) is mated with and/or adhered to facer 36 , which includes a coating pursuant to one or more embodiments of this invention.
  • the coated fabrics of the present invention may be used as backing or surface treatments for various construction materials.
  • the fabrics may be used as fleece backing for roofing membranes.
  • An exemplary membrane carrying a fleece backing is shown in FIG. 5 .
  • membrane 42 includes polymeric layer 44 and fleece backing 46 , which is adhered or otherwise secured thereto.
  • the backing e.g. fleece backing coated pursuant to this invention
  • the backing may be secured by mating the backing to the TPO membrane while the membranes is in its molten or semi-molten state.
  • the backing is secured using other modes of attachment such as chemical or adhesive attachment.
  • this membrane can be applied to roof surface 41 by employing adhesive 43 .
  • the membrane carrying the backing e.g. fabric coated pursuant to this invention
  • the membrane carrying the backing can be secured to the roof using mechanical attachment mechanisms, which are readily known in the art.
  • Fleece or other fabric 46 carries a coating pursuant to one or more embodiments of the present invention.
  • the coated fabrics of the present invention can be used as underlayments in various construction situations such as roofing underlayment and floor underlayment.
  • roofing underlayment may be used in conjunction with shingles or metal roof systems.
  • floor underlayment may be used in conjunction with tile flooring.
  • An exemplary underlayment is shown in FIG. 6 .
  • roofing system 50 includes roof deck 54 having deposited thereon underlayment 56 .
  • Covering underlayment 56 is an exterior shingle 58 , although the skilled person will understand that a metal roof exterior may also be applied.
  • Underlayment 56 includes a coating according to embodiments of the present invention.
  • the coated fabrics of the present invention may be used as barrier fabrics in various construction situations.
  • the coated fabrics can be used as fire barriers, vapor barriers, and moisture barriers in walls.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Wood Science & Technology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Paints Or Removers (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
  • Laminated Bodies (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
US13/798,413 2013-01-23 2013-03-13 Coated fabrics including expandable graphite Abandoned US20140205789A1 (en)

Priority Applications (30)

Application Number Priority Date Filing Date Title
US13/798,413 US20140205789A1 (en) 2013-01-23 2013-03-13 Coated fabrics including expandable graphite
CA2893993A CA2893993C (fr) 2013-01-23 2014-01-23 Tissus enduits comprenant du graphite expanse
CA2897650A CA2897650C (fr) 2013-01-23 2014-01-23 Systeme de toit resistant au feu et membrane composite
JP2015555263A JP2016511332A (ja) 2013-01-23 2014-01-23 膨張可能なグラファイトを含むコーティングされた布
US14/162,273 US9523203B2 (en) 2013-01-23 2014-01-23 Fire-resistant roof system and membrane composite
PCT/US2014/012732 WO2014116815A1 (fr) 2013-01-23 2014-01-23 Système de toit résistant au feu et membrane composite
BR112015017536A BR112015017536A2 (pt) 2013-01-23 2014-01-23 sistema de telhado resistente a fogo e composto de membrana
BR112015017538A BR112015017538A2 (pt) 2013-01-23 2014-01-23 tecidos revestidos incluindo grafite expansível
RU2015135599A RU2660868C2 (ru) 2013-01-23 2014-01-23 Полотна с покрытием, включающим вспененный графит
AU2014209430A AU2014209430B2 (en) 2013-01-23 2014-01-23 Coated fabrics including expandable graphite
EP14704957.1A EP2948603B1 (fr) 2013-01-23 2014-01-23 Système de toit résistant au feu et membrane composite
RU2015135508A RU2655317C2 (ru) 2013-01-23 2014-01-23 Огнестойкая кровельная система и мембранный композит
JP2015555268A JP6117942B2 (ja) 2013-01-23 2014-01-23 耐火屋根システム及び膜複合材料
MX2015008581A MX2015008581A (es) 2013-01-23 2014-01-23 Telas revestidas que incluyen grafito expandible.
CN201480005419.4A CN104937165A (zh) 2013-01-23 2014-01-23 包含可膨胀石墨的涂层织物
AU2014209366A AU2014209366B2 (en) 2013-01-23 2014-01-23 Fire-resistant roof system and membrane composite
CN201811217622.4A CN109537816A (zh) 2013-01-23 2014-01-23 耐火屋顶系统和膜复合材料
EP14704954.8A EP2948586B1 (fr) 2013-01-23 2014-01-23 Membrane de toiture comprenant du graphite expansible
CN201480005911.1A CN105026660A (zh) 2013-01-23 2014-01-23 耐火屋顶系统和膜复合材料
MX2015008816A MX2015008816A (es) 2013-01-23 2014-01-23 Sistema de techo resistente al fuego y material compuesto de membrana.
PCT/US2014/012683 WO2014116791A1 (fr) 2013-01-23 2014-01-23 Tissus enduits comprenant du graphite expansé
US15/292,925 US10273693B2 (en) 2013-01-23 2016-10-13 Coated fabrics including expandable graphite
US15/354,009 US20170067257A1 (en) 2013-01-23 2016-11-17 Fire-resistant roof system and membrane composite
JP2017057837A JP6564413B2 (ja) 2013-01-23 2017-03-23 耐火屋根システム及び膜複合材料
AU2017216527A AU2017216527B2 (en) 2013-01-23 2017-08-17 Fire-resistant roof system and membrane composite
JP2017237589A JP6608115B2 (ja) 2013-01-23 2017-12-12 ルーフィング膜複合体
US16/375,945 US10941573B2 (en) 2013-01-23 2019-04-05 Coated fabrics including expandable graphite
US16/665,765 US11168479B2 (en) 2013-01-23 2019-10-28 Fire-resistant roof system and membrane composite
US17/193,221 US12006691B2 (en) 2013-01-23 2021-03-05 Coated fabrics including expandable graphite
US17/505,030 US20220034092A1 (en) 2013-01-23 2021-10-19 Fire-resistant roof system and membrane composite

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US201361755666P 2013-01-23 2013-01-23
US13/798,413 US20140205789A1 (en) 2013-01-23 2013-03-13 Coated fabrics including expandable graphite

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US14/162,273 Continuation-In-Part US9523203B2 (en) 2013-01-23 2014-01-23 Fire-resistant roof system and membrane composite
US15/292,925 Continuation US10273693B2 (en) 2013-01-23 2016-10-13 Coated fabrics including expandable graphite

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US15/292,925 Active US10273693B2 (en) 2013-01-23 2016-10-13 Coated fabrics including expandable graphite
US16/375,945 Active 2033-05-21 US10941573B2 (en) 2013-01-23 2019-04-05 Coated fabrics including expandable graphite
US17/193,221 Active 2034-08-21 US12006691B2 (en) 2013-01-23 2021-03-05 Coated fabrics including expandable graphite

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US17/193,221 Active 2034-08-21 US12006691B2 (en) 2013-01-23 2021-03-05 Coated fabrics including expandable graphite

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US (4) US20140205789A1 (fr)
EP (1) EP2948586B1 (fr)
JP (2) JP2016511332A (fr)
CN (1) CN104937165A (fr)
AU (1) AU2014209430B2 (fr)
BR (1) BR112015017538A2 (fr)
CA (1) CA2893993C (fr)
MX (1) MX2015008581A (fr)
RU (1) RU2660868C2 (fr)
WO (1) WO2014116791A1 (fr)

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US10941573B2 (en) 2021-03-09
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US20190226213A1 (en) 2019-07-25
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US20210189731A1 (en) 2021-06-24
US12006691B2 (en) 2024-06-11
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RU2015135599A (ru) 2017-03-02
AU2014209430A1 (en) 2015-06-18
EP2948586B1 (fr) 2019-07-10
US10273693B2 (en) 2019-04-30
US20170030081A1 (en) 2017-02-02
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JP2018066260A (ja) 2018-04-26
BR112015017538A2 (pt) 2020-02-04

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