Shingle and mat tensile strength with urea formaldehyde resin modifier
View Patent ↗A composite sheet, and a process of making the same, including cured modified urea formaldehyde reinforced by glass fibers. The modifier is an acrylonitrile-butadiene-styrene copolymer. A roofing shingle, formed by coating the composite sheet with filled asphalt, represents a major application of the composite sheet.
1. A composite sheet material comprising a cured urea formaldehyde mat reinforced by glass fibers wherein said urea formaldehyde is modified by an acrylonitrile-butadiene-styrene copolymer prior to curing.
2. A composite sheet in accordance with claim 1 wherein said acrylonitrile-butadiene-styrene copolymer is present in a concentration of between about 0.5% and about 20%, said percentages being by weight, based on total weight of the resin binder solids including the urea formaldehyde.
3. A composite sheet in accordance with claim 2 wherein said acrylonitrile-butadiene-styrene copolymer is present in a concentration of between about 0.75% and about 15%.
4. A composite sheet in accordance with claim 3 wherein said acrylonitrile-butadiene-styrene copolymer is present in a concentration of between about 1% and about 10%.
5. A roof covering product comprising said composite sheet of claim 1 coated with filled asphalt.
6. A roof covering product comprising said composite sheet of claim 2 coated with filled asphalt.
7. A roof covering product comprising said composite sheet of claim 3 coated with filled asphalt.
8. A roof covering product comprising said composite sheet of claim 4 coated with filled asphalt.
9. A process of making a composite sheet comprising the steps of:
dispersing glass fibers in an aqueous dispersant;
screening said glass fiber dispersion whereby said dispersed glass fibers form a mat;
contacting said mat with a urea formaldehyde resin modified with an acrylonitrile-butadiene-styrene copolymer; and
curing said modified urea formaldehyde resin.
10. A process in accordance with claim 9 wherein said acrylonitrile-butadiene-styrene copolymer is present in a concentration of between about 0.5% and about 20%, said percentages being by weight, based on the weight of the urea formaldehyde resin.
11. A process in accordance with claim 10 wherein said acrylonitrile-butadiene-styrene copolymer is present in a concentration of between about 0.75% and about 15%.
12. A process in accordance with claim 11 wherein said acrylonitrile-butadiene-styrene copolymer is present in a concentration of between about 1% and about 10%.
13. A process of making a roofing shingle comprising the steps of:
dispersing glass fibers in an aqueous dispersant;
screening said glass fiber dispersion whereby said dispersed glass fibers form a mat;
contacting said mat with a urea formaldehyde resin modified with an acrylonitrile-butadiene-styrene copolymer;
curing said modified urea formaldehyde resin, whereby a cured urea formaldehyde mat reinforced with glass fibers is formed; and
coating said cured mat with filled asphalt.
14. A process in accordance with claim 13 wherein said acrylonitrile-butadiene-styrene copolymer is present in a concentration in the range of between 5 about 0.5% and about 20%, said percentages being by weight, based on the weight of said urea formaldehyde resin.
15. A process in accordance with claim 14 wherein said acrylonitrile-butadiene-styrene copolymer is present in a concentration in the range of between about 0.75% and about 15%.
16. A process in accordance with claim 15 wherein said acrylonitrile-butadiene-styrene copolymer is present in a concentration in the range of between about 1% and about 10%.
17. A process in accordance with claim 13 wherein curing is done by heating.
18. A process in accordance with claim 17 wherein curing is effected at atmospheric pressure at a temperature range of 250° C. to 325° C.
19. A process in accordance with claim 18 wherein curing is effected at atmospheric pressure at a temperature range of 270° C. to 300° C. for a period of 2 to 15 seconds.