Gaf Corporation

Building Materials Investment Corporation

Gaf Materials Corporation

V Robert Canfield

Alfredo A Bondoc

B Randall Ziegler

Robson F Storey

Betty C Roberts

William J Woodring

Mira C Kubiak

Philip A Jackey

A composite sheet material, useful as a component of roofing shingles, and a process of making same, which includes a glass fiber web bound with a thermosetting resin which includes a fatty acid amide having the structural formula RCOONH, where R is a C-Calkyl.

Composite sheet material and process of making

A composite sheet material, useful as a component of roofing shingles, and a process of making same, which includes a glass fiber web bound with a thermosetting resin which includes a fatty acid amide having the structural formula RCOONH, where R is a C&#x2013;Calkyl.

Process of making composite sheet material

Lighter weight, high strength, built-up roofing (BUR) membranes, systems and process for obtaining same are provided herein. These BUR membranes are made by using an improved ply sheet having uniform ventability and attachment in the overall assembly and superior resistance to wind uplift. The improved structure involves a ply sheet carrying 1/8 inch diameter or larger perforations along its longitudinal border in an area comprising between 1/5 and about 1/2 the width of the ply sheet. The ply sheets here employed for the BUR assembly or membrane have a thickness essentially not in excess of the layer of bonding agent applied over each ply in the assembly.

High-strength built-up roofing using improved ply sheets

What is described herein is a method of improving the wet tensile strength of sized glass fiber mats characterized by forming the mat from a plurality of glass fibers and a binder composition therefor which consists essentially of a urea-formaldehyde resin and about 0.01 to 5% by weight of a surfactant which is both highly water soluble and which wets the surfaces of sized glass fibers. The preferred surfactant is an anionic surfactant such as a sodium dodecylbenzene sulfonate. The glass mats thus made retained up to 79% of their tensile strength upon being subjected to severe wet conditions.

Method of improving the wet tensile strength of glass fiber mats

What is provided herein is a glass fiber mat having a novel structure and high-strength properties which is particularly useful for roofing products, including built up roofing membranes and systems. The glass mat of the invention is comprised of two fibrous components, namely, individual filament glass fibers and extended glass fiber elements, which are formed in situ in a wet-laid process from original bundles of glass fibers. The individual filaments appear by conventional filamentation of the bundles. The extended fiber elements, however, are formed by longitudinal extension of a given bundle whose fibers are connected longitudinally. Thereby the effective length of a fiber element is very much greater than the length of the fibers therein. The fiber elements are further characterized by a non-uniform diameter, as contrasted to the fibers themselves, being thicker in the mid-section of the element where connection of fibers is maximized, and tapered towards its ends, where fiber connection is at a minimum. The extended fiber elements preferably predominate by weight of the fibrous content of the mat over the individual filaments. The desired ratio of the two components is achieved by using bundles whose fibers have a long length, and by very gentle agitation of the dispersion slurry for a short period of time.

High-strength glass fiber mat particularly useful for roofing products

High-strength built-up roofing (BUR) membranes and systems are provided herein. These BUR products are made using improved glass fiber mat structures having unusual tear resistance in place of organic felts. The glass fiber mats are constructed from two fibrous components, namely, individual filaments, which provide the uniform denseness required for impregnation of saturant asphalt in the interstices of the mat, and extended fiber elements formed by longitudinal extension and connection of fibers from bundles of glass fibers in a wet-laid process, which furnish tear resistance and tensile strength to the BUR membranes and systems. The BUR membranes and systems of this invention have exceedingly high strengths compared with commercially available products of similar construction, and, advantageously, they can be manufactured by a very economical process.

High-strength built-up roofing using improved glass fiber mats

The glass mat made herein is comprised of two fibrous components, namely, individual filament glass fibers and extended glass fiber elements. These components are formed herein in situ in a wet-laid process from original bundles of glass fibers. The individual filaments appear by conventional filamentation of the bundles. The extended fiber elements, however, are formed by longitudinal extension of a given bundle whose fibers are connected longitudinally. Thereby the effective length of a fiber element is very much greater than the length of the fibers therein. The fiber elements are further characterized by a non-uniform diameter, as contrasted to the fibers themselves, being thicker in the midsection of the element where connection of fibers is maximized, and tapered towards its ends, where fiber connection is at a minimum. The extended fiber elements preferably predominate by weight of the fibrous content of the mat over the individual filaments. The desired ratio of the two components is achieved in the method of the invention by using bundles whose fibers have a long length, and by very gentle agitation of the dispersion slurry for a short period of time.

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Martinsville, NJ, United States of America

V Robert Canfield