Johns Manville

Other

Manville Corporation

Christopher Paul Sandoval

Jawed Asrar

Mingfu Zhang

Klaus Friedrich Gleich

Michael John Block

Asheber Yohannes

Derek Cooper Bristol

Craig Donald DePorter

Mauro Vittorio Battaglioli

Mary Margaret Georgene Bauer

Philip Francis Miele

Don August Forte

Albert Patrick Faulkinbury

Stanislav Kukatin

Ruben Gregory Garcia

Frank A McCampbell

Majid H Hindi

Bradley Ray Lockwood

Edwing Chaparro-Chavez

Steven Douglas Dawson

Donald R Steinle

Christopher McBride

Steven R Martinez

David Chee-Fai Law

Matthew Walp

Nicholas Gene Fitzpatrick

According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.

System for producing a fully impregnated thermoplastic prepreg

According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40&#xb0; C. and 100&#xb0; C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.

Fiber-containing polymethyl methacrylate (PMMA) prepregs are described that include a first and second plurality of fibers. The second plurality of fibers is made from a different material than the first plurality of fibers. The PMMA prepregs also contain a polymerized resin that includes polymethyl methacrylate that has been formed from a reactive resin composition that includes methyl methacrylate. Methods of making fiber-containing PMMA prepregs are also described.

A thermoplastic prepreg includes a web or mesh of fibers in which the web or mesh of fibers includes chopped fibers. The thermoplastic prepreg also includes a thermoplastic material that fully impregnates the web or mesh of fibers so that the thermoplastic prepreg has a void content of less than 5%. The thermoplastic material is polymers that are formed by in-situ polymerization of monomers or oligomers in which greater than 90% of the monomers or oligomers react to form the thermoplastic material. The thermoplastic prepreg includes between 5 and 95 weight percent of the thermoplastic material and the chopped fibers that form the web or mesh of fibers are un-bonded.

Provided herewith is a fiberglass binder comprising an aqueous solution of a polycarboxy polymer, a polyol and at least 30 weight percent of a filler material, preferably clay. The clay filler material is generally present in the aqueous solution as a suspension of particles having an average size of 3 &mgr;m or less. The clay filler extended fiberglass binder of the present invention is more cost effective without significantly altering the appearance or function of the binder.

Filler extended fiberglass binder

A single ply membrane roofing system includes a roofing insulation board which, preferably, is at least 45% by dry weight expanded perlite. One major surface of the insulation board is coated with a latex coating comprising, by dry weight, between 48.3% and 96% clay; between 3.1% and 33.3% latex; and between 0% and 34% sodium silicate. A single ply roofing membrane is adhered to the coated major surface of the insulation board with a roofing contact adhesive.

Coated roofing insulation and roofing systems including such insulations

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Littleton, CO, United States of America

Christopher Paul Sandoval