Fatty amide composition for wet use chopped strand glass fibers

Abstract

A size composition containing one or more film forming agents, at least one coupling agent, and a fatty amide lubricant synthesized from a (poly)ethylene amine and a C 5 -C 20 unsaturated fatty acid is provided. The fatty acid is preferably a conjugated fatty acid and the (poly)ethylene amine is preferably tetraethylenepentamine. The fatty amide lubricant may be modified by maleinized rubber or carboxylated rubber. The size is advantageously applied to glass fibers such as wet use chopped strand glass and used to form roofing composites, such as shingles. The fatty amide lubricant facilitates interfacial bonding between the glass and asphalt through a vulcanizing mechanism. The unsaturation of the fatty amide modifies the surface energy of the glass fibers to make the glass more compatible with the asphalt, enhances the compatibility between the glass and the asphalt, and improves glass/asphalt interactions through the reduced interfacial tensions.

1 . A sizing composition for glass fibers comprising: 
 at least one film forming polymer;    one or more silane coupling agents; and    a fatty amide lubricant synthesized from a (poly)ethylene amine and an unsaturated conjugated C 5 -C 20  fatty acid.    
     
     
         2 . The sizing composition of  claim 1 , wherein said (poly)ethylene amine is selected from the group consisting of tetraethylenepentamine, diethylenetriamine, tetraethylenetriamine, ethylene diamine, diethylene triamine, triethylene tetramine and pentaethylene hexamine.  
     
     
         3 . The sizing composition of  claim 2 , wherein said one or more silane coupling agents comprises an aminosilane coupling agent and a vinyl silane coupling agent.  
     
     
         4 . The sizing composition of  claim 2 , further comprising a member selected from the group consisting of a secondary lubricant, a pH adjuster, viscosity modifiers, biocides, glycols and glycol ethers.  
     
     
         5 . The sizing composition of  claim 1 , wherein said fatty amide lubricant is modified by incorporating an elastomeric material.  
     
     
         6 . The sizing composition of  claim 5 , wherein said elastomeric material is selected from the group consisting of a maleinized rubber and a carboxylated rubber.  
     
     
         7 . The sizing composition of  claim 1 , wherein said at least one film forming polymer is present in said sizing composition in an amount of from 30-80% by weight of total solids, said one or more silane coupling agents are present in said sizing composition in an amount of from 5-30% by weight of total solids, and said fatty amide lubricant is present in said sizing composition in an amount of from 5-30% by weight of total solids.  
     
     
         8 . A reinforced composite roofing material comprising a plurality of glass fibers sized with a sizing composition including: 
 at least one film forming polymer;    one or more silane coupling agents; and    a fatty amide lubricant which is the reaction product of a (poly)ethylene amine and an unsaturated C 5 -C 20  fatty acid.    
     
     
         9 . The composite roofing material as claimed in  claim 8 , wherein said fatty acid is a conjugated fatty acid.  
     
     
         10 . The composite roofing material as claimed in  claim 8 , wherein said one or more silane coupling agents comprises an aminosilane coupling agent and a vinyl silane coupling agent.  
     
     
         11 . The composite roofing material as claimed in  claim 8 , wherein said (poly)ethylene amine is selected from the group consisting of tetraethylenepentamine, diethylenetriamine, tetraethylenetriamine, ethylene diamine, diethylene triamine, triethylene tetramine and pentaethylene hexamine.  
     
     
         12 . The composite roofing material as claimed in  claim 8 , wherein said fatty amide lubricant is modified with an elastomeric material selected from the group consisting of a maleinized rubber and a carboxylated rubber.  
     
     
         13 . The sizing composition of  claim 8 , wherein said at least one film forming polymer is present in said sizing composition in an amount of from 30-80% by weight of total solids, said one or more silane coupling agents are present in said sizing composition in an amount of from 5-30% by weight of total solids, and said fatty amide lubricant is present in said sizing composition in an amount of from 5-30% by weight of total solids.  
     
     
         14 . The composite roofing material as claimed in  claim 8 , wherein said composite roofing material is in the form of an asphalt shingle.  
     
     
         15 . The composite roofing material as claimed in  claim 9 , wherein said fatty amide lubricant modifies the surface energy of said glass fibers and improves the compatibility of said glass fibers to asphalt present in said asphalt shingle.  
     
     
         16 . The composite roofing material as claimed in  claim 8 , further comprising at least one member selected from the group consisting of a secondary lubricant, a viscosity modifier, a pH adjusting agent, a biocide, glycol and glycol ether.  
     
     
         17 . A roofing shingle comprising: 
 a mat formed of a plurality of randomly oriented fibers sized with a sizing composition that includes at least one film forming polymer, one or more silane coupling agents, and a fatty amide lubricant, said fatty amide lubricant being the reaction product of a (poly)ethylene amine and an unsaturated C 5 -C 20  fatty acid; and    an asphalt coating on at least a portion of one outer surface of said mat.    
     
     
         18 . The roofing shingle of  claim 17 , wherein said fatty acid is a conjugated fatty acid.  
     
     
         19 . The roofing shingle of  claim 17 , wherein said (poly)ethylene amine is selected from the group consisting of tetraethylenepentamine, diethylenetriamine, tetraethylenetriamine, ethylene diamine, diethylene triamine, triethylene tetramine and pentaethylene hexamine.  
     
     
         20 . The roofing shingle of  claim 19 , wherein said one or more silane coupling agents comprises an aminosilane coupling agent and a vinyl silane coupling agent.  
     
     
         21 . The roofing shingle of  claim 17 , wherein said at least one film forming polymer is present in said sizing composition in an amount of from 30-80% by weight of total solids, said one or more silane coupling agents are present in said sizing composition in an amount of from 5-30% by weight of total solids, and said fatty amide lubricant is present in said sizing composition in an amount of from 5-30% by weight of total solids.  
     
     
         22 . The roofing shingle of  claim 17 , wherein said fibers are glass fibers and said fatty amide lubricant modifies the surface energy of said glass fibers and improves the compatibility of said glass fibers to said asphalt.  
     
     
         23 . The roofing shingle of  claim 17 , wherein said fatty amide lubricant is modified by incorporating an elastomeric material during the synthesis of the fatty amide lubricant.  
     
     
         24 . The roofing shingle of  claim 17 , wherein said fatty amide lubricant modifies the surface energy of said glass fibers and improves the compatibility of said glass fibers to said asphalt.  
     
     
         25 . The roofing shingle of  claim 17 , wherein unsaturated hydrophobic tails on the synthesized fatty amide react with the asphalt and crosslink the glass and the asphalt.  
     
     
         26 . The roofing shingle of  claim 17 , further comprising a sulfur catalyst to promote interfacial bonding between the glass and the asphalt.  
     
     
         27 . A method of forming a roofing shingle comprising the steps of: 
 forming a mat composed of randomly oriented glass fibers sized with a sizing composition including: 
 at least one film forming polymer;  
 one or more silane coupling agents; and  
 a fatty amide lubricant, said fatty amide lubricant being the reaction product of a (poly)ethylene amine and a C 5 -C 20  unsaturated fatty acid; and  
   applying a coating of asphalt on at least one surface of said mat.    
     
     
         28 . The method of  claim 27 , wherein said (poly)ethylene amine is selected from the group consisting of tetraethylenepentamine, diethylenetriamine, tetraethylenetriamine, ethylene diamine, diethylene triamine, triethylene tetramine and pentaethylene hexamine.  
     
     
         29 . The method of  claim 28 , wherein said one or more silane coupling agents comprises an aminosilane coupling agent and a vinyl silane coupling agent.  
     
     
         30 . The method of  claim 27 , wherein said fatty acid is a conjugated fatty acid.  
     
     
         31 . The method of  claim 27 , further comprising the step of: 
 cutting said mat into an appropriate shape and size of a roofing shingle.    
     
     
         32 . The method of  claim 27 , further comprising the step of: 
 coating said asphalt with protective granules.    
     
     
         33 . The method of  claim 27 , further comprising the step of reacting the unsaturated hydrophobic tails on the synthesized fatty amide with the asphalt to crosslink the glass and the asphalt.  
     
     
         34 . The method of  claim 33 , further comprising the step of providing a sulfur catalyst to promote interfacial bonding between the glass and the asphalt.