U.S. patent application number 10/182723 was filed with the patent office on 2003-07-03 for glass fibre mat and use thereof for built-up roofing.
Invention is credited to Droux, Michel.
Application Number | 20030124932 10/182723 |
Document ID | / |
Family ID | 8846813 |
Filed Date | 2003-07-03 |
United States Patent
Application |
20030124932 |
Kind Code |
A1 |
Droux, Michel |
July 3, 2003 |
Glass fibre mat and use thereof for built-up roofing
Abstract
The invention relates to a fibre-based mat that can be used for
making up bituminous membranes, comprising glass fibres, organic
fibres and a binder, characterized in that the organic fibres have
a shrinkage at 130.degree. C. of less than or equal to 5%. The
invention also relates to a bituminous membrane comprising a
substrate coated, covered or impregnated with a bituminous matrix,
in which the substrate is a mat as above. The mat and the membrane
can be used for the production of roofing and/or damp-proofing.
Inventors: |
Droux, Michel; (La Ravoire,
FR) |
Correspondence
Address: |
OBLON, SPIVAK, MCCLELLAND, MAIER & NEUSTADT, P.C.
1940 DUKE STREET
ALEXANDRIA
VA
22314
US
|
Family ID: |
8846813 |
Appl. No.: |
10/182723 |
Filed: |
November 20, 2002 |
PCT Filed: |
January 31, 2001 |
PCT NO: |
PCT/FR01/00297 |
Current U.S.
Class: |
442/164 ;
442/118; 442/180; 442/59 |
Current CPC
Class: |
Y10T 442/20 20150401;
Y10T 442/2484 20150401; D21H 13/40 20130101; E04D 5/02 20130101;
D06N 5/00 20130101; D21H 13/24 20130101; Y10T 442/2861 20150401;
Y10T 442/2992 20150401 |
Class at
Publication: |
442/164 ; 442/59;
442/180; 442/118 |
International
Class: |
B32B 027/12; B32B
003/00; B32B 005/02; B32B 009/00; B32B 027/04; B32B 017/04; B32B
017/02; B32B 027/02 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 9, 2000 |
FR |
0001611 |
Claims
1. Fibre-based mat that can be used for making up bituminous
membranes, comprising glass fibres, organic fibres and a binder,
characterized in that the organic fibres have a shrinkage at
130.degree. C. of less than or equal to 5%.
2. Mat according to claim 1, characterized in that the organic
fibres have a shrinkage at 130.degree. C. of less than or equal to
3%.
3. Mat according to claim 1 or 2, characterized in that the organic
fibres are based on a semicrystalline polymer.
4. Mat according to any one of the preceding claims, characterized
in that the fibres are polyester, especially polyethylene
terephthalate, fibres.
5. Mat according to any one of the preceding claims, characterized
in that the organic fibres contain a sizing composition allowing
the individual filaments to be dispersed in water.
6. Mat according to any one of the preceding claims, characterized
in that the proportion of organic fibres is about 5 to 30% by
weight with respect to the total weight of fibres.
7. Mat according to any one of the preceding claims, characterized
in that the binder content is about 15 to 30% by weight with
respect to the total weight of the mat.
8. Mat according to any one of the preceding claims, characterized
by a grammage of 30 to 150 g/m2.
9. Bituminous membrane comprising a substrate coated, covered or
impregnated with a bituminous matrix, characterized in that the
substrate is a mat according to any one of the preceding claims.
Description
[0001] The present invention relates to the field of fibre-based
sheet materials and more particularly to a glass mat that can be
used as a substrate for the production of products coated, covered
or impregnated with bitumen, especially for roofing and/or
damp-proofing applications.
[0002] In the field of roofing or damp-proofing, it is known to use
bituminous membranes that are applied to the surface to be roofed
or damp-proofed. These membranes generally consist of a substrate
in the form of a sheet coated or impregnated with a bituminous
matrix.
[0003] Sheet materials may be of various types and are usually
obtained from organic or mineral fibres, preferably in the form of
nonwovens.
[0004] Among materials that can be used, glass mats or veils are of
great interest as they guarantee the dimensional stability of the
bituminous membrane over time.
[0005] Glass mats can be obtained by any technique known per se, in
particular the so-called wet technique described especially in the
reference work "The Manufacturing Technology of Continuous Glass
Fibres" by K. L. Loewenstein, Publ. Elsevier, 2nd edition, 1983,
pp. 315-317. This technique, which is similar to papermaking
techniques, consists in preparing an aqueous suspension of chopped
glass fibres, in depositing this suspension as a film on a filter
belt to which suction is applied in order to-remove some of the
water from the film deposited, in applying a binder composition to
the wet film, in drying the mat and crosslinking the binder in an
oven, and then packaging the mat in the desired manner. The final
product is in the form of quite a thin sheet (with a thickness of
about 0.2. to 0.8 mm) and generally packaged in rolls.
[0006] The binder is often an aqueous composition based on a
urea-formaldehyde resin, this resin having a satisfactory
temperature withstand at the temperatures used subsequently for the
bitumen impregnation.
[0007] However, glass mats have the drawback of having a relatively
low tear strength, which detracts from the ease of use and
especially forces the user to take precautions when handling it for
making up the membrane or for laying it on a roof.
[0008] To remedy this drawback, there are complex substrates which
combine a mat based on organic fibres and having a high tear
strength with a glass mesh which gives the combination dimensional
stability. However, these complexes combining two intermediate
products are complicated to manufacture.
[0009] The object of the invention is to provide a glass-based
material with an improved tear strength, without its manufacture
being more complicated than that of a conventional mat.
[0010] EP-A-0 763 505 describes a glass fibre mat for the
manufacture of asphalt roof shingles, the strength of which is
improved thanks to a urea-formaldehyde binder modified by a
self-crosslinkable vinyl additive. In this mat, a minor proportion
of fibres may not consist of glass, and may especially be chosen
from organic fibres such as nylon, polyester, polyethylene and
polypropylene fibres. That document provides no specific
information about these organic fibres and contains no particular
example illustrating this possibility.
[0011] The present invention is based on the discovery that many
organic fibres are not suitable for the manufacture of a mat and
even have a very negative effect on the properties of the mat in
bituminous roofing applications, but this drawback may be overcome
by very carefully selecting the synthetic materials.
[0012] In this regard, the subject of the invention is a
fibre-based mat that can be used for making up bituminous
membranes, comprising glass fibres and organic fibres bound
together by a binder, characterized in that the fibres have a
shrinkage at 130.degree. C. of less than or equal to 5%.
[0013] It shall be noted that the wording <<glass mat>>
or <<glass veil>> encompasses according to the
invention materials well known from the person skilled in the art
of glass fibre-based products. These are thin sheet-like materials,
of an essentially isotropic structure, that is to say that there is
no preferred orientation of the fibres. Practically, a veil can be
characterized through the so-called 1 anisotropy ratio = tensile
strength of the veil in the machine direction tensile strength of
the veil in the cross direction ,
[0014] which is generally about 1, especially about 1 to 1.5,
sometimes up to 2. This essentially random orientation of the
fibres is generally achieved through providing the glass fibres in
the form of chopped strands for the production of the veil, for
instance using the above mentioned wet technique.
[0015] Choosing organic fibres according to the above criterion
results in the mat being of high quality, and in particular having
mechanical and thermal strength compatible with its being used
subsequently for impregnation with bitumen, whereas other fibres
result in the mat having insufficient thermal and/or mechanical
strength.
[0016] Firstly, the organic fibres used in the mat manufacture have
a high melting point in order to prevent them from degrading during
the thermal steps in the manufacture of the mat, especially oven
drying and crosslinking, and in the use of the mat, particularly
when in contact with the bituminous binder. In general, the
synthetic organic material is chosen to have a melting point above
about 220.degree. C.
[0017] According to the invention, the fibres are selected
according to their thermal shrinkage: this parameter corresponds to
the dimensional variation, in this case the shortening, of the
fibre after it has been exposed to a given temperature for a
defined time. To do this, the initial length Li of the fibre before
heating and then the final length Lf are measured, the shrinkage r
being equal to
[0018] r=(Li-Lf)/Li(expressed as a percentage).
[0019] The key shrinkages according to the invention are expressed
for a temperature of 130.degree..degree.C., produced in an
atmosphere of vapour, and for a time of 30 minutes.
[0020] According to the invention, the shrinkage is chosen to be
less than or equal to 5%, preferably less than or equal to 4% and
particularly less than or equal to 3%, for example about 2 to
3%.
[0021] Advantageously, this fibre quality may be obtained using
semicrystalline polymer materials, particularly those in which the
spinning process allows them to undergo drawing which increases the
degree of crystallinity. Other manufacturing conditions such as
presence of nucleation agents or the temperature factor may also
lead to the organisation of the base macromolecules so that the
polymer of initial amorphous structure starts to adopt a
crystalline structure and to turn semi-crystalline.
[0022] Fibres satisfying the requirements of the invention may be
found among polyester fibres, especially polyalkylene terephthalate
and particularly polyethylene terephthalate fibres.
[0023] Organic fibres suitable for wet processes for manufacturing
nonwovens are preferred, these fibres containing a sizing
composition allowing the individual filaments to be dispersed in
water.
[0024] The organic fibres may have variable dimensions, with a mean
diameter of about 7 to 25 .mu.m for a linear density of about 0.5
to 2 dtex. The fibres are advantageously chopped to a length of the
order of one millimetre to a few tens of millimetres, especially 6
to 30 mm.
[0025] The effect of the organic fibres is clearly perceptible
above 5% by weight with respect to the total weight of fibres. The
proportion of organic fibres is advantageously about 5 to 30%,
especially 20 to 30% and particularly about 25% by weight with
respect to the total weight of fibres.
[0026] The glass fibres used according to the invention are of a
type conventional for the production of mat, preferably in the form
of chopped yarns, having a length of the order of ten millimetres,
especially 6 to 30 mm and preferably about 10 to 20 mm, for example
12 to 18 mm. It should be understood that a certain proportion of
yarns (for example 5 to 10%) may be chopped to a length of up to
100 mm. Moreover, continuous yarn, especially glass yarn, may be
introduced into the mat as reinforcement in the machine
direction.
[0027] The binder used to form the mat is advantageously based on a
urea-formaldehyde resin, preferably one which is modified by vinyl
and/or acrylic additives in the manner known especially from U.S.
Pat. No. 4,681,802 and EP-A-0 763 505. The amount of binder
corresponds to generally a solids content of from 15 to 30% by
weight with respect to the mat.
[0028] The mat is manufactured with a grammage, usual for glass
mats, of about 30 to 150 g/m.sup.2, particularly 50 to 120
g/m.sup.2.
[0029] Given the difference in density between glass and organic
fibres, the amount of material in the mat according to the
invention for a given grammage is slightly greater than that
contained in a glass mat, which means that the thickness is
relatively greater and/or the porosity is less. For example, the
porosity is about 1500 to 1900 l/m.sup.2.s for a 50 g/m.sup.2
mat.
[0030] Since the mat according to the invention is particularly
suitable for damp-proofing and/or roofing applications, the subject
of the invention is also a bituminous membrane comprising a
substrate coated, covered or impregnated with a bituminous matrix,
characterized in that the substrate is a mat as described
above.
[0031] The bituminous matrix may be chosen from matrices known per
se: natural, modified or unmodified bitumen, or a synthetic binder
such as a "light-coloured binder" making it possible in particular
to give the membrane a decorative colour.
[0032] The following examples, given non-limitingly, illustrate the
invention.
EXAMPLE 1
[0033] An aqueous suspension of fibres is prepared, in which the
fibres comprise:
[0034] 75% by weight of chopped E-glass yarn, having a filament
diameter of 10 .mu.m and a linear density of 360 tex, the chopped
length being 12 mm;
[0035] 25% by weight of chopped polyester yarn available from
KURARAY under the reference EP 133, suitable for papermaking
processes and water-dispersible. This yarn is characterized by a
filament diameter of 12 .mu.m and a linear density of 1.4 dtex, the
chopped length being 15 mm. The yarn is a polyethylene
terephthalate yarn drawn to increase its crystallinity, having a
shrinkage of about 2% at 130.degree. C. after exposure for 30
minutes in a wet environment and a shrinkage of 3% at 170.degree.
C. after exposure for 15 minutes in a dry atmosphere.
[0036] The fibre suspension, which also contains the usual
additives, namely antifoam, dispersant, viscosity modifier, etc.,
is processed under standard conditions on a mat manufacturing
machine comprising (i) a hydroformer on which a partially dewatered
wet film is formed, (ii) a station for applying the binder by
spraying, coating [a curtain coater] or passing through a bath
containing an aqueous composition based on a urea-formaldehyde
resin plasticized by an acetate and an acrylic, which deposits on
the mat an amount of binder corresponding to a solids content of
19% by weight with respect to the weight of mat, and (iii) a drying
and crosslinking oven having several temperature zones from 135 to
215.degree. C. through which the mat runs with an average residence
time of about 30 seconds, preferably slightly less than 30
seconds.
[0037] The mat poses no problem in manufacture and is obtained with
a grammage of 50 g/m2, a thickness of 0.3 mm and a porosity of 1580
l/m.sup.2.s.
[0038] This mat is subjected to mechanical strength tests at room
temperature and at high temperature, the results of which are given
in Table 1 below.
[0039] Tensile Strength
[0040] Ten test pieces in the machine direction and 10 test pieces
in the cross direction were cut in widths of 50 mm and lengths of
250 mm from the mat specimen. Each test piece was fixed between the
jaws of a tensile testing machine and the system for driving the
movable clamp was actuated until the specimen broke: the values of
the tensile strength (in newtons) and of the elongation at break
(as a percentage of the nominal length) were then measured. Also
taken was a measurement of the tensile strength at 250.degree. C.
under a fixed load equal to 10% of the strength value measured
previously, and the time required for the test piece to break was
measured.
[0041] Tear Strength
[0042] Ten test pieces in the machine direction and 10 test pieces
in the cross direction were cut in widths of 50 mm and lengths of
100 mm from the mat specimen. A sharp cut was made on each test
piece starting from the edge of a short side and parallel to the
long sides halfway between the long sides, and 50 mm in length. The
distance between the jaws of a tensile testing machine was set to
be equal to 50 mm, the test piece was fixed in the jaws and the
tensile tester was actuated, setting the pull rate at 100 mm/min.
The maximum load (in N) when the test piece completely split into
two parts was recorded. The tear strength was expressed as the
average of the ten measurements.
[0043] The mat of Example 1 had very satisfactory mechanical
properties and dimensional stability. It was processed on a
continuous bituminous-membrane manufacturing line by impregnation
with hot bitumen at about 200.degree. C., having a good amenability
to impregnation, even giving the membrane a very attractive
appearance.
[0044] Comparative Example 1
[0045] A mat was manufactured in the manner indicated in Example 1,
but exclusively based on glass yarn. The mat had a grammage of 50
g/m.sup.2, a binder content corresponding to a 24% solids content
by weight with respect to the weight of mat, a thickness of 0.3 mm
and a porosity of 2000 l/m.sup.2.s. It was subjected to the same
mechanical tests as the mat of Example 1.
[0046] Comparative Example 2
[0047] Example 1 was repeated with an organic fibre that does not
meet the criteria of the invention. It was a polyester fibre sold
by Tergal Fibres under the reference "1.6 dtex T110 mi-mat coup"
[1.6 dtex T110 chopped half-mat], which is also water-dispersible,
characterized by a linear density of 1.6 dtex, a chop length of 12
mm, a shrinkage at 130.degree. C. in a steam atmosphere of 7%.
[0048] A 50 g/m.sup.2 mat, with a binder content of 24% by weight,
a thickness of 0.3 to 0.4 mm and a porosity of 1700 l/m.sup.2.s,
was manufactured.
[0049] The manufacturing posed problems at the end of the line,
since the formation of wrinkling, which may be ascribed to the
phenomenon of thermal shrinkage of the organic fibre, was observed
after the mat left the oven.
[0050] As the mechanical tests show, this mat has a low mechanical
strength, less than that of the conventional glass mat. In
particular, it may be seen that the anisotropy of the mat is
greatly increased. Furthermore, the mechanical strength at
250.degree. C. is non-existent.
[0051] This mat is not suitable for the production of bituminous
membranes.
1 TABLE 1 Ex. 1 Comp. Ex. 1 Comp. Ex. 2 TENSILE STRENGTH Machine
direction (N/5 cm) 214 165 150 Cross direction (N/5 cm) 133 93 70
Anisotropy 1.6 1.7 2.1 Elongation (%) 1.9 1.1 1.2 TEAR STRENGTH
Machine direction (N) 3.0 1.5 3.2 Cross direction (N) 3.5 1.7 3
STRENGTH at 250.degree. C. >4 min >4 min 0 WRINKLING on the
line No No Yes
[0052] The invention was described in detail for the case of the
wet manufacture of a mat having a particular grammage for
application in the production of bituminous membranes, but it
should be understood that the invention is not limited to this
embodiment and in particular it encompasses other (dry) mat
manufacturing techniques, other grades of mats, possibly reinforced
with continuous glass yarns, and other products that can be used
for roofing and/or damp-proofing.
* * * * *