Fiberglass reinforced composites

Abstract

A fiberglass reinforced composite is provided with improved physical properties. The fiberglass reinforced composite incorporates core-shell rubber nanoparticles within the resinous binder of the composite and/or within a sizing composition coated directly onto the individual glass fibers.

1 . A fiberglass reinforced polymer composite comprising a plurality of individual glass fibers fiberglass and a resinous binder, wherein core-shell rubber nanoparticles are incorporated within the resinous binder of the composite. 
     
     
         2 . The fiberglass reinforced polymer composite of  claim 1 , wherein said individual glass fiber form a fiberglass mat held together by the resinous binder. 
     
     
         3 . The fiberglass reinforced polymer composite of  claim 1 , wherein the resinous binder includes 0.1 to 20 wt. % rubber core-shell nanoparticles, based on the total amount of resin in the binder. 
     
     
         4 . The fiberglass reinforced composite of  claim 1 , wherein the average particle size of the rubber core-shell nanoparticles is 250 nm or less. 
     
     
         5 . The fiberglass reinforced composite of  claim 1 , wherein the resinous binder is formed from a urea formaldehyde resin, an acrylic resin or a mixture thereof. 
     
     
         6 . The fiberglass reinforced composite of  claim 1 , wherein the core of the rubber core-shell nanoparticles is made from a synthetic polymer rubber selected from the group consisting of styrene/butadiene, polybutadiene, silicone rubber (siloxanes), acrylic rubbers and mixtures thereof. 
     
     
         7 . The fiberglass reinforced composite of  claim 1 , wherein said composite is an asphalt roofing shingle. 
     
     
         8 . An improved roofing mat for use in making asphalt roofing shingles, the improved roofing mat comprising a fiberglass mat composed of multiple glass fibers and a resinous binder holding the individual glass fibers together, wherein the resinous binder includes rubber core-shell nanoparticles. 
     
     
         9 . The roofing mat of  claim 8 , wherein the resinous binder includes 0.1 to 20 wt. % rubber core-shell nanoparticles, based on the total amount of resin in the binder. 
     
     
         10 . The roofing mat of  claim 8 , wherein the resinous binder is formed from a urea formaldehyde resin, an acrylic resin or a mixture thereof. 
     
     
         11 . The roofing mat of  claim 8 , wherein the core of the rubber core-shell nanoparticles is made from a synthetic polymer rubber selected from the group consisting of styrene/butadiene, polybutadiene, silicone rubber (siloxanes), acrylic rubbers and mixtures thereof. 
     
     
         12 . An improved asphalt roofing shingle comprising a fiberglass roofing mat composed of multiple glass fibers and a resinous binder holding the individual glass fibers together, an asphalt coating covering the fiberglass roofing mat, the asphalt coating including an inorganic particulate filler therein, the asphalt coating further containing roofing granules embedded therein, wherein the resinous binder of the fiberglass roofing mat includes rubber core-shell nanoparticles. 
     
     
         13 . The asphalt roofing shingle of  claim 12 , wherein the resinous binder includes 0.1 to 20 wt. % rubber core-shell nanoparticles, based on the total amount of resin in the binder. 
     
     
         14 . The asphalt roofing shingle of  claim 12 , wherein the resinous binder is formed from a urea formaldehyde resin, an acrylic resin or a mixture thereof. 
     
     
         15 . The asphalt roofing shingle of  claim 12 , wherein the core of the rubber core-shell nanoparticles is made from a synthetic polymer rubber selected from the group consisting of styrene/butadiene, polybutadiene, silicone rubber (siloxanes), acrylic rubbers and mixtures thereof. 
     
     
         16 . The asphalt roofing shingle of  claim 12 , wherein the asphalt coating includes 30 to 80 wt. %, based on the entire weight of the filled asphalt of an inorganic particular filler selected from the group consisting of dolomite, silica, slate dust and high magnesium carbonate. 
     
     
         17 . A fiberglass reinforced polymer composite comprising a matrix polymer and glass fibers dispersed in the matrix polymer, wherein the surfaces of the glass fibers carry a coating of core-shell rubber nanoparticles. 
     
     
         18 . The fiberglass reinforced polymer composite of  claim 17 , wherein the surfaces of the glass fibers carry a coating comprising a mixture of core-shell rubber nanoparticles and a film-forming polymer. 
     
     
         19 . The fiberglass reinforced polymer composite of  claim 17 , wherein the glass fibers are made by combining multiple attenuated glass filaments together to form individual fibers, and further wherein the incipient size composition is applied to the individual glass filaments before they are combined. 
     
     
         20 . The fiberglass reinforced polymer composite of  claim 17 , wherein the surfaces of the glass fibers carry a second coating of a secondary incipient size composition applied to the fibers during fiber manufacture after the individual glass filaments are combined, the secondary incipient size composition comprising additional core-shell rubber nanoparticles and a film-forming polymer.