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1. WO1997016483 - SHEET FELT

Note: Text based on automatic Optical Character Recognition processes. Please use the PDF version for legal matters

WHAT IS CLAIMED IS:

1. A light weight felt composition suitable for siding and roofing underlayment and insulation board facing which comprises, on a dry basis,
(a) 60-80 wt.% cellulose fibers;
(b) 15-30 wt.% glass fibers having a diameter
hot in excess of 14 microns and a fiber
length of 3/8-3/4 inch;
(c) 4-10 wt.% binder and
(d) 0.5-10 wt.% of non-asphaltic water
repellant sizing agent having a flash
point higher than 150°F. and an
evaporation rate less than one which is
selected from the group of
anionic/rosinous sizes and C16 to C30
amphipathic sizes and mixtures thereof.

2. The felt of claim 1 wherein said binder is a latex.

3. The felt of claim 2 wherein said latex is

SBR.

4. The felt composition of claim 1 wherein the water repellant sizing agent is selected from the group of anionic and cationic sizes and mixtures thereof.

5. The felt composition of claim 1 wherein the sizing agent is an alum/rosin sizing agent.

6. The felt composition of claim 1 wherein the concentration of the sizing agent in the total
composition is between about 0.8 and about 2.5 wt.%.

7. The felt composition of claim 1 wherein component (b) has a fiber aspect ratio of between about 600 and about 1450 and a filament diameter of from about 5 to about 16.5.

8. The felt composition of claim 7 wherein (b) has a filament diameter of from about 8.8 to about 14.

9. The felt composition of claim 1 wherein component (a) is a paper waste containing fibers of at least 50% of 1.5-3.5 millimeter length.

10. The felt composition of claim 9 wherein the paper waste is a mixture of newsprint paper and corrugated Kraft paper having mixed fiber lengths of between about 0.5 and about 1.4 short fibers and between about 1.5 and about 3.5 long fibers.

11. The felt composition of claim 1 in rolled form and having a weight of between about 15 and about 23 lbs/480 square feet.

12. An insulating board having a foam core laminated to a felt sheet having the composition of one of claims 1-10.

13. The insulating board of claim 12 wherein said foamed core is a polymer of urethane, isocyanurate, vinyl chloride, urea-formaldehyde and melamine, styrene, a C2 to C3 alkylene, epoxy, acrylonitrile-butadiene-styrene or cellulose acetate and mixtures thereof.

14. The insulating board of claim 13 wherein said foamed core is polyurethane or polyisocyanurate.

15. The aqueous composition of claim 1 additionally containing an adjuvant selected from the group of a flocculant, a defoamer, a coloring agent and/or a defoamer.

16. The composition of claim 1 which
additionally contains about 2 lbs of flocculant/ton of (a) + (b) + (c) + (d) and about 70 lbs of alum/ton of (a) + (b) + (c) + (d).