US4637951A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Fibrous mat facer with improved strike-through resistance
Assignee: Johns Manville
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Filing: 1984-12-24
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Granted: 1987-01-20
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Expires: 2004-12-24
Abstract
Abstract An economical and versatile fibrous glass mat displaying improved resistance to wetting or strike-through by various curable materials when said materials are placed on one surface of said mat while in liquid state is disclosed. This mat, which is especially suited as a carrier, substrate or facer for such curable substances, comprises a blend of fibers. This blend of fibers includes a majority of base fibers having a mean diameter in the range of ten (10) microns with a minor amount of microfibers. The binder formulation, which when cured holds the blend of fibers together to form a self-supporting mat, includes conventional binder resins with a minor amount of wet proofing resinous materials. Preferably, the resulting mat has a porosity of no greater than two-hundred and twenty-five (225) cubic feet per minute per square foot of mat in accordance with the Frazier Air Permeability Test. Also, claimed is a laminate comprising this novel mat and a vinyl plastisol coating or a coating of a foam insulation material such as a polyurethane or polyisocyanurate foam.
Inventors
- 👤 Frederick A. Gill
- 👤 Mario P. Tocci
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 16:58
CPC Classifications
D; D04; D04H; D04H5/00; D04H5/12; D04H1/00; D04H1/40; D04H1/58; D04H1/587; D04H1/64; D04H5/04; Y; Y10; Y10S; Y10S428/00; Y10S428/903; Y10T; Y10T428/00; Y10T428/24; Y10T428/24942; Y10T428/2495; Y10T428/24967; Y10T428/24975; Y10T428/249921; Y10T428/249953; Y10T428/249981; Y10T428/249982; Y10T428/249984; Y10T428/249985; Y10T428/249986; Y10T428/26; Y10T428/266; Y10T428/268; Y10T428/269; Y10T428/31504; Y10T428/3154; Y10T428/31544; Y10T442/00; Y10T442/60; Y10T442/608; Y10T442/614; Y10T442/619; Y10T442/69
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
141 words
A porous, non-woven fabric mat for use as a facer, substrate, or carrier for receiving a curable substance while in the fluid state, said mat comprising a blend of dispersed, substantially randomly oriented fibers and a binder for holding said blend of fibers together; said blend of fibers comprising microfibers intermixed with base fibers said microfibers comprising between two percent (2%) and about forty percent (40%) of the total weight of said blend, said base fibers having a mean diameter of between about eight (8) microns and about twenty-five (25) microns; said binder comprising a water miscible combination of a heat settable binder resin and an effective amount of a wet proofing polymer resin compatible with said heat settable binder resin, said wet proofing polymer being selected from a group consisting of a water based silicone elastomer and a fluorchemical emulsion.
Claim 2
Dependent Claim
141 words
A porous, non-woven fabric mat for use as a facer, substrate, or carrier for receiving a curable substance while in the fluid state, said mat comprising a blend of dispersed, substantially randomly oriented fibers and a binder for holding said blend of fibers together; said blend of fibers comprising microfibers intermixed with base fibers said microfibers comprising between two percent (2%) and about forty percent (40%) of the total weight of said blend, said base fibers having a mean diameter of between about eight (8) microns and about twenty-five (25) microns; said binder comprising a water miscible combination of a heat settable binder resin and an effective amount of a wet proofing polymer resin compatible with said heat settable binder resin, said wet proofing polymer being selected from a group consisting of a water based silicone elastomer and a fluorchemical emulsion.
Claim 3
Dependent Claim
166 words
A porous non-woven fabric mat for use as a facer, substrate or carrier for receiving a curable substance while in the fluid state, said mat comprising of a blend dispersed substantially randomly oriented fibers and a binder for holding said blend of fibers together; said blend of fibers comprising a minor amount of microfibers intermixed with said base fibers, said base fibers having a mean diameter of between eight (8) microns and about twenty-five (25) microns, said binder comprising a water miscible combination of a heat settable binder resin and an effective amount of a wet proofing polymer compatible with said heat settable resin, said wet proofing polymer selected from a group consisting of a water based silicone elastomer emulsion and a fluorchemical emulsion, said mat being permeable to air but having a Frazier Air Permeability of not more than about two hundred and twenty-five (225) cubic feet per minute, the mat having a thickness of between about ten (10) mils and about sixty (60) mil.
Claim 4
Dependent Claim
166 words
A porous non-woven fabric mat for use as a facer, substrate or carrier for receiving a curable substance while in the fluid state, said mat comprising of a blend dispersed substantially randomly oriented fibers and a binder for holding said blend of fibers together; said blend of fibers comprising a minor amount of microfibers intermixed with said base fibers, said base fibers having a mean diameter of between eight (8) microns and about twenty-five (25) microns, said binder comprising a water miscible combination of a heat settable binder resin and an effective amount of a wet proofing polymer compatible with said heat settable resin, said wet proofing polymer selected from a group consisting of a water based silicone elastomer emulsion and a fluorchemical emulsion, said mat being permeable to air but having a Frazier Air Permeability of not more than about two hundred and twenty-five (225) cubic feet per minute, the mat having a thickness of between about ten (10) mils and about sixty (60) mil.
Claim 5
Dependent Claim
33 words
A mat as set forth in claim 1 having a Frazier Air Permeability of between about forty (40) cubic feet per minute and about two hundred and twenty-five (225) cubic feet per minute.
Claim 6
Dependent Claim
32 words
A mat as set forth in either claim 1 or claim 2 having a total weight of between six (6) grams per square foot and about ten (10) grams per square foot.
Claim 7
Dependent Claim
136 words
A laminate comprising a coating of a curable substance adhered to at least one surface of a mat, said mat comprising a blend of dispersed, substantially randomly oriented fibers and a binder for holding said blend of fibers together; said blend of fibers comprising microfibers intermixed with base fibers said microfibers comprising between two percent (2%) and about forty percent (40%) of the total weight of said blend, said base fibers having a mean diameter of between about eight (8) microns and about twenty-five (25) microns; said binder comprising a water miscible combination of a heat settable binder resin and an effective amount of a wet proofing polymer resin compatible with said heat settable binder resin, said wet proofing polymer being selected from a group consisting of a water based silicone elastomer and a fluorochemical emulsion.
Claim 8
Dependent Claim
136 words
A laminate comprising a coating of a curable substance adhered to at least one surface of a mat, said mat comprising a blend of dispersed, substantially randomly oriented fibers and a binder for holding said blend of fibers together; said blend of fibers comprising microfibers intermixed with base fibers said microfibers comprising between two percent (2%) and about forty percent (40%) of the total weight of said blend, said base fibers having a mean diameter of between about eight (8) microns and about twenty-five (25) microns; said binder comprising a water miscible combination of a heat settable binder resin and an effective amount of a wet proofing polymer resin compatible with said heat settable binder resin, said wet proofing polymer being selected from a group consisting of a water based silicone elastomer and a fluorochemical emulsion.
Claim 9
Dependent Claim
16 words
A laminate as set forth in claim 5 wherein said curable substance comprises a vinyl plastisol.
Claim 10
Dependent Claim
29 words
A laminate as set forth in claim 5 wherein said curable coating is a foam insulation selected from a group consisting of a polyurethane, a polyisocyanurate, phenolic, and polystyrene.
Claim 11
Dependent Claim
48 words
A mat as set forth in any of claims 1 and 2 wherein said base fibers are glass monofilament fibers having an average length of between one-eighth (1/8) inch and one-half (1/2) inch and an average diameter of between about eight (8) microns and about eleven (11) microns.
Claim 12
Dependent Claim
44 words
A mat as set forth in either claim 1 or claim 2 wherein said microfibers are monafilament glass fibers having a mean length of between one-eighth (1/8) and one-quarter (1/4) inch and an average diameter of between about 0.025 microns and six (6) microns.
Claim 13
Dependent Claim
160 words
A laminate comprising a coating of a curable substance adhered to at least one surface of a mat, said mat comprising a blend of dispersed substantially randomly oriented fibers and a binder for holding said blend of fibers together; said blend of fibers comprising a minor amount of microfibers intermixed with base fibers, said base fibers having a mean diameter of between eight (8) microns and about twenty-five (25) microns, said binder comprising a water miscible combination of a heat settable binder resin and an effective amount of a wet proofing polymer compatible with said heat settable resin, said wet proofing polymer selected from a group consisting of a water based silicone elastomer emulsion and a fluorochemical emulsion, said mat being permeable to air but having a Frazier Air Permeability of no more than about two hundred and twenty-five (225) cubic feet per minute, the mat having a thickness of between about ten (10) mils and about sixty (60) mil.
Claim 14
Dependent Claim
160 words
A laminate comprising a coating of a curable substance adhered to at least one surface of a mat, said mat comprising a blend of dispersed substantially randomly oriented fibers and a binder for holding said blend of fibers together; said blend of fibers comprising a minor amount of microfibers intermixed with base fibers, said base fibers having a mean diameter of between eight (8) microns and about twenty-five (25) microns, said binder comprising a water miscible combination of a heat settable binder resin and an effective amount of a wet proofing polymer compatible with said heat settable resin, said wet proofing polymer selected from a group consisting of a water based silicone elastomer emulsion and a fluorochemical emulsion, said mat being permeable to air but having a Frazier Air Permeability of no more than about two hundred and twenty-five (225) cubic feet per minute, the mat having a thickness of between about ten (10) mils and about sixty (60) mil.
Claim 15
Dependent Claim
16 words
A laminate as set forth in claim 10 wherein said curable substance comprises a vinyl plastisol.
Claim 16
Dependent Claim
163 words
A laminate comprising a coating of a curable substance adhered to at least one surface of a mat, said mat comprising: a blend of dispersed substantially randomly oriented fibers and a binder for holding said blend of fibers together; said blend of fibers comprising a minor amount of microfibers intermixed with said base fibers, said base fibers having a mean diameter of between eight (8) microns and about twenty-five (25) microns, said binder comprising a water miscible combination of a heat settable binder resin and an effective amount of a wet proofing polymer compatible with said heat settable resin, said wet proofing polymer selected from a group consiting of a water based silicone elastomer emulsion and a fluorochemical emulsion, said mat being permeable to air but having a Frazier Air Permeability of between about forty (40) and about two hundred and twenty-five (225) cubic feet per minute, the mat having a thickness of between about ten (10) mils and about sixty (60) mils.
Claim 17
Dependent Claim
163 words
A laminate comprising a coating of a curable substance adhered to at least one surface of a mat, said mat comprising: a blend of dispersed substantially randomly oriented fibers and a binder for holding said blend of fibers together; said blend of fibers comprising a minor amount of microfibers intermixed with said base fibers, said base fibers having a mean diameter of between eight (8) microns and about twenty-five (25) microns, said binder comprising a water miscible combination of a heat settable binder resin and an effective amount of a wet proofing polymer compatible with said heat settable resin, said wet proofing polymer selected from a group consiting of a water based silicone elastomer emulsion and a fluorochemical emulsion, said mat being permeable to air but having a Frazier Air Permeability of between about forty (40) and about two hundred and twenty-five (225) cubic feet per minute, the mat having a thickness of between about ten (10) mils and about sixty (60) mils.
Claim 18
Dependent Claim
16 words
A laminate as set forth in claim 12 wherein said curable substance comprises a vinyl plastisol.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1990-01-19 | 1990-07-21 | 1991-01-20 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-01-19 | 1994-07-21 | 1995-01-20 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-01-19 | 1998-07-21 | 1999-01-20 | $7700.00 | Window Closed / Lapsed |