Atlas Roofing Corporation

Exxon Chemical Patents, Inc.

Exxonmobil Chemical Patents Inc.

Robert H Blanpied

James Darryl Thornsberry

Philip W Bush

Richard L Donald

James Richardson Lattner

Steven E Silverberg

Leonel E Sanchez

Tronze-I Dennis Wu

C Harry McMullen

Freddie Lee Murphy

Robert J Butkus

Andy I McLaughlin

Jimmy Rogers Dubose

James L Williams

James H Williams

William M Gay

Joseph M Konieczka

Robert Nolan Moore

Gregory Islas

Ricky Burkeen

A coated glass mat comprises a glass mat substrate having non-woven glass fibers and a coating which essentially uniformly penetrates the glass mat substrate to desired fractional thickness of the coated glass mat. The coating imparts a tensile strength to the coated glass mat which on average is at least 1.33 times greater than the tensile strength of the glass mat substrate without the coating. In example embodiments, penetration of the coating into the glass mat substrate preferably extends to a depth of from twenty five percent of a thickness of the coated glass mat to seventy five percent of the thickness of the coated glass mat. Moreover, a non-coated thickness of the coated glass mat is sufficiently thick for bonding purposes with, e.g., a gypsum slurry or other core materials such as thermoplastic or thermosetting plastics. The coating has a porosity in a range of from 1.3 CFM to 5.0 CFM, e.g., the coating comprises a coating blend which provides the coated glass mat with a porosity sufficient to allow water vapor to escape from a gypsum slurry when heated. The coating is preferably a coating blend comprised of water, latex binder, inorganic pigment, and inorganic binder.

Method and composition for coating mat and articles produced therewith

A nonwoven web has a weight sufficient for construction industry use and comprises at least forty percent (40%) recycled waste paper. At least one surface of the web bears a biocide, e.g., has a biocide applied thereto. Preferably the weight of the web is greater than fifteen pounds per thousand square feet (15-lbs/MSF). Preferably the biocide is zinc pyrithione. The web preferably bears at least 50-grams of biocide per thousand square feet per side of said web. One example use of the web is as builders felt, with other uses including as a facer for a laminate board and for asphalt-impregnated webs. The biocide-bearing nonwoven web is specifically directed to use in building construction. One example use of the web is as builders felt, with other uses including as a facer for a laminate board and for asphalt-impregnated webs. Because building construction products must be tough, but priced as low as possible, this web is made largely from recycled waste paper (as opposed to virgin cellulose fiber, as a cost-reducing measure), and optionally clarifier sludge.

Building construction felt paper with biocide/anti-microbial treatment

A rigid closed cell polyisocyanate-based foams is created by reacting at least one organic polyisocyanate with compounds having at least two active hydrogen atoms in the presence of an n-pentane blowing agent. When the foam is formed into a laminated board with facers, the foam formulation includes a sufficient amount of a common blend of cleaning solvent chemicals to cause a noticeable improvement in facer adhesion. The chemicals used to improve facer adhesion are a standard blend of industrial cleaning solvents called 'Di-Basic Esters' or DBE. The actual chemical compounds in one mode of this mixture are the methyl esters of about 59% glutaric acid, about 20% succinic acid, and about 21% adipic acid. The minimum rate of addition of the Di-Basic Esters'[DBE] thought to be effective may be less than about 0.5 parts per hundred parts of polyol (pphpp). The currently preferred embodiments use add-on rates within the range of about 0.5 to about 5.0 pphpp, with the currently most preferred range being from about 1.0 to about 3.0 pphpp. The blend of cleaning chemicals employed by the present invention surprisingly enhance the adhesion between the foam and the facer.

Thermosetting plastic foams and methods of production thereof using adhesion additives

The non-woven web of the present invention is comprised of recycled cellulose fiber and untreated Clarifier Sludge, and optionally, recycled glass fiber. Unlike uses of reclaimed Clarifier Sludge whereby the material has been treated in some fashion to improve its quality, the non-woven web of the present invention utilizes untreated Clarifier Sludge. The Clarifier Sludge of the present invention is dry enough to handle, and in one example varies between about 30% and about 45% solids. The Clarifier Sludge can be added to web-forming equipment (e.g., papermaking equipment) either in a waste paper disintegrator or into a recycling apparatus (e.g., broke pulper) whose output is metered into a refiner tank of the web-forming equipment. In an embodiment utilizing a broke pulper for introduction of the Clarifier Sludge, the broke pulper is filled with clarifier sludge and water to a consistency of about 3.5% solids.

Non-woven web made with untreated clarifier sludge

A thermosetting plastic foam solid formed from the reaction product of: (a) either polyisocyanate or isocyanate-based foam; (b) a polyol-based foam; (c) a catalyst which is capable of promoting the thermosetting reaction between the polyisocyanate or isocyanate-based foam and the polyol-based foam; and (d) a blowing agent which comprises a high purity cyclopentane product, wherein the high purity cyclopentane product is about 95% or greater pure cyclopentane, and, optionally, (e) water and/or (f) liquid flame retardant.

Method of producing rigid foams and products produced therefrom

Thermosetting plastic foam

Butt portion of a roofing shingle

A thermosetting plastic foam solid formed from the reaction product of: (a) either polyisocyanate or isocyanate; (b) a polyol; (c) a catalyst which is capable of promoting the thermosetting reaction between the polyisocyanate or isocyanate and the polyol; and (d) a blowing agent comprised at least partially from a high purity cyclopentane product, wherein the high purity cyclopentane product is about 95% or greater pure cyclopentane, and, optionally, (e) water and/or (f) liquid flame retardant.

A thermosetting plastic foam solid is obtained using a blowing agent comprised at least partially from depolymerization of dicyclopentadiene into essentially pure cyclopentane. This unique hydrocarbon is miscible in polyester polyols, where others, such as extracted cyclopentane, are not. In a blend of 15 parts of liquid flame retardant per hundred parts polyester polyol, the mixture is both stable and has a suitably low viscosity.

In a method of producing a polyurethane modified polyisocyanurate foam, at least one alkali metal organo-salt catalyst is utilized in an aqueous solution free of aliphatic glycols. The catalyst preferably contains more chemical equivalents of at least one carboxylic acid than chemical equivalents of at least one alkali metal hydroxide dissolved in water. The use of extra or undissolved carboxylic acid, preferably 2-ethyl-hexoic acid, advantageously creates flame resistant amides, as well as creating carbon dioxide as a blowing agent. The use of extra or undissolved carboxylic acid can also reduce the water content of catalysts of the present invention which might have a water content in excess of the desired.

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Meridian, MS, United States of America

Robert H Blanpied