IP Library Granted Patent US 7,172,678
Granted Patent B2
US 7,172,678 · App. 10/463,921 · Granted Feb 6, 2007

Process of making composite sheet material

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Quick Facts
Patent No.
US 7,172,678
App. No.
10/463,921
Granted
Feb 6, 2007
Kind
B2
Abstract

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 2 , where R is a C 8 –C 25 alkyl.

Claims (15)

1. A process of making a composite sheet, which comprises the steps of dispersing glass fibers in an aqueous dispersant;

screening said glass fibers so that said dispersed glass fibers form a glass fiber mat;

contacting said glass fiber mat with a resin binder, wherein a resin binder laden glass fiber mat is formed;

adding a fatty acid amide to said resin binder laden glass fiber mat, said fatty acid amide present in a concentration in the range of between 0.25% and about 5% based on the total weight of said resin binder; and

curing said composite sheet.

2. A process in accordance with claim 1 wherein said resin binder includes urea formaldehyde.

3. A process in accordance with claim 1 wherein said fatty acid amide has the structural formula RCOONH 2 , where R is a C 8 –C 25 alkyl.

4. A process in accordance with claim 1 wherein said composition sheet is cured at a temperature in the range of between about 270° C. and about 325° C., at atmospheric pressure, over a period of about 5 to about 15 seconds.

5. A process in accordance with claim 4 wherein said resin binder includes a polymeric modifier.

6. A process in accordance with claim 1 wherein said fatty acid amide is stearamide or tallowamide.

7. A process of making a composite sheet, which comprises the steps of:

dispersing glass fibers in an aqueous dispersant;

screening said glass fibers so that said dispersed glass fibers form a glass fiber mat;

contacting said glass fiber mat with a resin binder which includes a fatty acid amide to form a resin binder laden glass fiber mat, said fatty acid amide present in a concentration in the range of between 0.25% and about 5% based on the total weight of said resin binder; and

curing said resin binder laden glass fiber mat.

Assignments (2)
SECURITY INTEREST Recorded Sep 23, 2021
From: BMIC LLC; ELKCORP; ELK COMPOSITE BUILDING PRODUCTS, INC.; ELK PREMIUM BUILDING PRODUCTS, INC.; HBP ACQUISITION LLC; GAF ENERGY LLC; SIPLAST, INC.; SPECIALTY GRANULES INVESTMENTS LLC
To: DEUTSCHE BANK AG NEW YORK BRANCH
Reel/Frame 057572/0607 →
CHANGE OF NAME Recorded Aug 24, 2021
From: BUILDING MATERIALS INVESTMENT CORPORATION
To: BMIC LLC
Reel/Frame 057292/0184 →