Abstract: A process for forming a reinforced product suitable for use as a roofing material is provided, comprising: (a) providing a composition comprising a matrix material; and (b) extruding the composition with an extruder to form a reinforced product, wherein a plurality of fibers is combined with the matrix material prior to or during the extrusion step. Also provided is a process for forming a reinforced product suitable for use as a roofing material, comprising: (a) forming a first layer comprising a first matrix material; (b) providing a plurality of fibers on the first layer; (c) forming a second layer comprising a second matrix material, above the plurality of fibers; and (d) combining the plurality of fibers with the first matrix material and/or the second matrix material, to form a reinforced product.

Abstract: Sizing compositions for fibers having a viscosity of greater than about 300 centipoise and a binder resin concentration of at least about 90 wt. percent based on the dry weight of sizing chemicals in the sizing are disclosed. Wet, sized glass fibers having such a sizing on their surface and having an LOI of at least about 1 wt. percent are used to make mats by conventional dry laid and preform processes without having to add any additional binder to bond the fibers together. Wet sized, chopped glass fiber products and wet sized fiber roving products having a moisture content of 0.5 to about 20 wt. percent or higher are disclosed. Methods of making wet sized fibers of the invention are disclosed. Methods of using these sized glass fibers to make nonwoven fibrous mats and preforms are also disclosed.

Abstract: Systems and methods are disclosed for making a moldable polymer mixture containing long reinforcing fibers that suffered no significant damage during plastication. The system and method produces a mixture in which the long fibers are longer and have encountered less damage than moldable mixtures made in previous plasticators. The plasticator system has a single screw, but with multiple zones for treating the materials differently. The long fibers, wet or dry, are fed into a downstream zone, distributed over a large port in a low density concentration, and heated and dispersed with low shear to separate the long fibers and surround them with polymer for protection before subjecting them to medium to high shear to finalize the dispersion of the long fibers.

Abstract: Systems and methods are disclosed for making a moldable polymer mixture and molded composite products containing reinforcing fibers that were shipped wet, having a moisture content above about 1.0 wt. % and then are dried just before being added to a mixer, plasticator or compounder. The systems and methods produce a compound that when molded produces a molded product having superior properties to conventionally made compounds. Another method uses a drum type dryer and IR heating to dry the fibers in the fiber manufacturer's plant.

Abstract: Methods and systems for making fiber reinforced moldable mixtures for making FRP products by mixing and/or compounding of at least one, normally hot, polymer and at least one wet fiber product. Intermediate FRP moldable mixtures and finished FRP products produced by the methods and systems are also disclosed. The polymers preferred are thermoplastic polymers, but mixtures that form thermoset polymers are can also be used. Wet fiber product(s) containing water, a solvent, or other liquid are used by the systems and methods disclosed. Packaged wet roving fiber strand products are also disclosed. The FRP products made with the invention have lower cost, more complete and uniform fiber dispersion and/or more uniform and improved appearance and/or physical properties than conventional FRP products made using conventional dry reinforcing fiber products.

Abstract: A bond is created between a gypsum matrix and titanium or zirconium based coupling coating applied onto a glass fiber during gypsum board cure. The commercially available titanium or zirconium based coupling has a generic formula of the type [RO-}-nTi—[—OXR?Y]4-n or [RO-}-nZr—[—OXR?Y]4-n. These coupling compositions chemically bond to glass fibers by replacing the —OH groups present on the glass fibers in aqueous solutions with Ti—O or Zr—O bonds. In order to bond with calcium ions in hydrated gypsum crystals, the X functionality is selected to be a phosphate or pyrophosphato group. The bond between the glass fiber and the titanium or zirconium based coupling composition is due to the formation of a monolayer, while the bond between the hydrated gypsum crystal and the coupling composition is intermittent due the acicular structure of gypsum crystals.

Abstract: A bond is created between gypsum crystals and between gypsum crystals and glass fiber reinforcement in a gypsum board during cure by incorporation of titanium or zirconium based coupling compositions incorporated in the gypsum slurry. The commercially available titanium or zirconium based coupling has a generic formula of the type [RO—}-nTi-[—OXR?Y]4-n or [RO—}-nZr-[—OXR?Y]4-n. These coupling compositions chemically bond to glass fibers by replacing the —OH groups present on the glass fibers in aqueous solutions with Ti—O or Zr—O bonds. The X functionality of the coupling composition is selected to be a phosphato or pyrophosphato group to form bond with calcium ions of the gypsum crystal. The bond created by the titanium or zirconium based coupling composition results in load transfer between gypsum crystals in the gypsum matrix and between the glass fibers and gypsum matrix, resulting in improved flexure strength and nail pullout resistance.

Abstract: The manufacture of a plastic material, particularly provided with fibers, is frequently carried out in an extruder (10). Various problems have arisen in this connection. For example, problems arise in working long or endless reinforcement fibers, for example rovings (27), into the plastic. On the one hand, the fibers are so badly broken up that they have only very small lengths. On the other hand, it has proved difficult to impregnate the fibers sufficiently. According to the invention, in order to feed in fibers, the plastic is moved in batches past a pre-plastifying worm (11). This is achieved by a secondary worm (18) located next to the pre-plastifying worm (11).