公开(公告)号：US12220879B2

公开(公告)日：2025-02-11

申请号：US17173370

申请日：2021-02-11

Applicant: JOHNS MANVILLE

Inventor： Mingfu Zhang ,  Jieyu Hu ,  Lance Wang ,  Jawed Asrar

IPC: B29C70/02 ,  B22D41/02 ,  B29C70/50 ,  B29K33/00 ,  B29K101/12 ,  B29K105/16

Abstract: A lightweight polymer-based composite product may include a polymer material body and a lightweight filler material that is embedded in the polymer. The polymer material body may be an in-situ polymerized polymer formed via casting of a reactive resin in a mold. The polymer may have a density of at least 1.0 g/cm3. The lightweight filler material may be concentrated on at least a portion of a first surface of the polymer material body. The lightweight filler material may have a density of between 0.1 and 1.0 g/cm3. The lightweight polymer-based composite product may have a density that is less than a comparable product that consists mainly of the polymer.

公开(公告)号：US12070933B2

公开(公告)日：2024-08-27

申请号：US17533333

申请日：2021-11-23

Applicant: JOHNS MANVILLE

Inventor： Mingfu Zhang ,  Jawed Asrar

IPC: B32B5/28 ,  B29C70/12 ,  B29C70/50 ,  B32B27/12

CPC classification number: B32B5/28 ,  B29C70/12 ,  B29C70/506 ,  B29C70/508 ,  B32B27/12 ,  B32B2260/021 ,  B32B2260/046 ,  B32B2262/101

Abstract: A chopped roving thermoplastic composite sheet includes a web or mesh of chopped rovings and a thermoplastic resin that fully saturates the web or mesh of chopped rovings. The web or mesh of chopped rovings is not mechanically bonded and does not include a binder that bonds or adheres the chopped rovings together other than thermoplastic resin. As such, the thermoplastic resin and the web or mesh of chopped rovings are able to flow and conform to a mold or cavity when the chopped roving thermoplastic composite sheet is pressed within the mold or cavity and when the chopped roving thermoplastic composite sheet is heated to above the melting temperature of the thermoplastic resin.

公开(公告)号：US11987728B2

公开(公告)日：2024-05-21

申请号：US17987165

申请日：2022-11-15

Applicant: JOHNS MANVILLE

Inventor： Kiarash Alavi ,  Uranchimeg Lester ,  Ameya Natu ,  James Cottier ,  Jawed Asrar ,  Philip Francis Miele

IPC: C09J103/02 ,  C09J4/00 ,  C09J4/06 ,  C09J5/06 ,  C09J131/06 ,  C09J133/06 ,  C09J199/00 ,  D04H1/4209 ,  D04H1/4218 ,  D04H1/587 ,  D04H1/64 ,  E04B1/78 ,  E04B1/80

CPC classification number: C09J103/02 ,  C09J4/00 ,  C09J4/06 ,  C09J5/06 ,  C09J131/06 ,  C09J133/06 ,  C09J199/00 ,  D04H1/4218 ,  D04H1/587 ,  D04H1/64 ,  E04B1/78 ,  E04B1/80 ,  C09J2400/26 ,  C09J2471/00 ,  D04H1/4209

Abstract: Fiber-containing composites are described that include woven or non-woven fibers, and a binder that holds the fibers together. The binder may include the reaction product of a starch and a polycarboxylic acid. The starch has a weight average molecular weight that ranges from 1×106 Daltons to 10×106 Daltons. The fiber-containing composite has an unaged tensile strength of greater than 4.0 and an aged tensile strength greater than 3.0. Also described are methods of making the fiber-containing composites. The methods may include applying a binder composition to fibers to form coated fibers, measuring a moisture content of the coated fibers, and curing the coated fibers in a curing oven to form the fiber-containing composite. The binder composition may include a starch having a weight average molecular weight that ranges from 1×106 Daltons to 10×106 Daltons, and a polycarboxylic acid.

公开(公告)号：US11952689B2

公开(公告)日：2024-04-09

申请号：US17012471

申请日：2020-09-04

Applicant: JOHNS MANVILLE

Inventor： Zhihua Guo ,  Uranchimeg Lester ,  Jawed Asrar ,  Kiarash Alavi ,  Mingfu Zhang

IPC: D04H1/64 ,  C08K7/14 ,  C08L3/02 ,  C08L61/20 ,  C08L61/24 ,  C08L61/32 ,  C09J101/28 ,  C09J103/02 ,  C09J105/00 ,  D04H1/4218 ,  D04H1/4242 ,  D04H1/587 ,  D04H13/00 ,  D21H13/40 ,  D21H17/20 ,  D21H23/48

CPC classification number: D04H13/008 ,  C08K7/14 ,  C08L3/02 ,  C08L61/20 ,  C08L61/24 ,  C08L61/32 ,  C09J101/28 ,  C09J101/286 ,  C09J103/02 ,  C09J105/00 ,  D04H1/4218 ,  D04H1/4242 ,  D04H1/587 ,  D04H1/64 ,  D21H13/40 ,  D21H17/20 ,  D21H23/48 ,  Y10T442/604 ,  C09J105/00 ,  C08K7/14 ,  C09J103/02 ,  C08K7/14 ,  C09J101/28 ,  C08K7/14 ,  C09J101/286 ,  C08K7/14 ,  C09J101/286 ,  C08K7/14 ,  C08L61/32 ,  C09J103/02 ,  C08K7/14 ,  C08L61/32 ,  C09J105/00 ,  C08K7/14 ,  C08L61/32 ,  C09J101/28 ,  C08K7/14 ,  C08L61/32

Abstract: Processes of making a non-woven glass fiber mat are described. The process may include forming an aqueous dispersion of fibers. The process may also include passing the dispersion through a mat forming screen to form a wet mat. The process may further include applying a carbohydrate binder composition to the wet mat to form a binder-containing wet mat. The binder compositions may include a carbohydrate, a nitrogen-containing compound, and a thickening agent. The binder compositions may have a Brookfield viscosity of 7 to 50 centipoise at 20° C. The thickening agents may include modified celluloses such as hydroxyethyl cellulose (HEC) and carboxymethyl cellulose (CMC), and polysaccharides such as xanthan gum, guar gum, and starches. The process may include curing the binder-containing wet mat to form the non-woven glass fiber mat.

公开(公告)号：US11951716B2

公开(公告)日：2024-04-09

申请号：US17220657

申请日：2021-04-01

Applicant: JOHNS MANVILLE

Inventor： Diego Pedrazzoli ,  Lichih R Peng ,  Lance Wang ,  Jawed Asrar

IPC: B32B27/08 ,  B32B27/30 ,  B32B27/32 ,  B32B37/15 ,  C08L23/00 ,  C08L27/06 ,  E04D5/10

CPC classification number: B32B27/08 ,  B32B27/304 ,  B32B27/32 ,  B32B37/153 ,  C08L23/00 ,  C08L27/06 ,  E04D5/10 ,  B32B2419/06

Abstract: A roofing membrane includes a thermoplastic polyolefin (TPO) layer and a polyvinyl chloride (PVC) layer. The TPO layer forms a bottom layer of the roofing membrane, and the PVC layer is positioned atop the TPO layer so that the PVC layer forms a top layer of the roofing membrane. The TPO layer and the PVC layer are configured to be chemically compatible so that the TPO layer and the PVC layer are chemically bonded and function as a single roofing membrane. Compatibilizing includes at least one of (i) adding a compatibilizing agent to at least one of the TPO material and the PVC material prior to extrusion and (ii) positioning at least one compatibilizing film, prior to bonding, between the TPO material and the PVC material.

公开(公告)号：US11850809B2

公开(公告)日：2023-12-26

申请号：US17524561

申请日：2021-11-11

Applicant: JOHNS MANVILLE

Inventor： Mingfu Zhang ,  Klaus Friedrich Gleich ,  Asheber Yohannes ,  Michael John Block ,  Jawed Asrar ,  Derek Cooper Bristol ,  Christopher P Sandoval ,  Matthew Walp ,  Edwing Chaparro-Chavez ,  Stanislav O Kukatin ,  Albert Patrick Faulkinbury ,  Christopher McBride ,  Bradley Ray Lockwood ,  Nicholas Gene Fitzpatrick

IPC: B29C70/50 ,  B05C5/02 ,  B05C9/12 ,  B05C9/14 ,  B05C11/02 ,  B29B15/12 ,  B32B5/28 ,  B05C9/10 ,  B05D1/40 ,  B05D3/02 ,  B29B11/12 ,  B29B11/16 ,  B29B13/02 ,  B29B13/06 ,  B29B15/14 ,  B29C70/06 ,  C08J3/24 ,  C08J5/24 ,  C08K7/14 ,  C08L77/02 ,  D06M15/51 ,  D06M15/61 ,  D06M15/71 ,  B29K33/00 ,  B29K105/08 ,  B29K105/00 ,  B29L7/00 ,  B29L9/00 ,  D06M15/705

CPC classification number: B29C70/50 ,  B05C5/0245 ,  B05C5/0254 ,  B05C9/10 ,  B05C9/12 ,  B05C9/14 ,  B05C11/021 ,  B05D1/40 ,  B05D3/0227 ,  B05D3/0272 ,  B29B11/12 ,  B29B11/16 ,  B29B13/02 ,  B29B13/06 ,  B29B15/12 ,  B29B15/122 ,  B29B15/14 ,  B29C70/06 ,  B29C70/504 ,  B32B5/28 ,  C08J3/242 ,  C08J3/247 ,  C08J5/24 ,  C08K7/14 ,  C08L77/02 ,  D06M15/51 ,  D06M15/61 ,  D06M15/71 ,  B29K2033/12 ,  B29K2105/089 ,  B29K2105/0872 ,  B29K2105/256 ,  B29L2007/002 ,  B29L2009/00 ,  D06M15/705 ,  Y10T442/2992

Abstract: According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.

公开(公告)号：US20230405877A1

公开(公告)日：2023-12-21

申请号：US18239418

申请日：2023-08-29

Applicant: JOHNS MANVILLE

Inventor： Mingfu Zhang ,  Jawed Asrar

IPC: B29B11/16 ,  B29B11/12

CPC classification number: B29B11/16 ,  B29B11/12 ,  B29K2101/12

Abstract: A thermoplastic composite sheet may be composed of a polymer material matrix and a lightweight material that is disposed throughout the polymer material matrix. The polymer material matrix may extend continuously throughout a length, width, and thickness of the thermoplastic composite sheet. The polymer material matrix may be a fully polymerized thermoplastic material. The lightweight material may be fully saturated by the thermoplastic material of the polymer material matrix. The thermoplastic composite sheet may include between 50 and 99 weight percent of the thermoplastic material and between 1 and 50 weight percent of the lightweight material. The thermoplastic composite sheet may be free of reinforcing fibers.

公开(公告)号：US11820044B2

公开(公告)日：2023-11-21

申请号：US17369025

申请日：2021-07-07

Applicant: JOHNS MANVILLE

Inventor： Mingfu Zhang ,  Jawed Asrar

IPC: C08J9/32 ,  B29B11/16 ,  B29B11/12 ,  B29K101/12 ,  B29K509/08

CPC classification number: B29B11/16 ,  B29B11/12 ,  B29K2101/12 ,  B29K2509/08 ,  B29K2995/0063

Abstract: A thermoplastic composite sheet may be composed of a polymer material matrix and a lightweight material that is disposed throughout the polymer material matrix. The polymer material matrix may extend continuously throughout a length, width, and thickness of the thermoplastic composite sheet. The polymer material matrix may be a fully polymerized thermoplastic material. The lightweight material may be fully saturated by the thermoplastic material of the polymer material matrix. The thermoplastic composite sheet may include between 50 and 99 weight percent of the thermoplastic material and between 1 and 50 weight percent of the lightweight material. The thermoplastic composite sheet may be free of reinforcing fibers.

公开(公告)号：US20230083883A1

公开(公告)日：2023-03-16

申请号：US17900965

申请日：2022-09-01

Applicant: JOHNS MANVILLE

Inventor： Lichih R. Peng ,  Jordan Kortmeyer ,  ChangQing Shen ,  Lance Wang ,  Jawed Asrar

IPC: C08L23/08

Abstract: Provided is a polymer blend composition comprising linear low density polyethylene, a polypropylene polymer, generally comprising a random polypropylene copolymer, and a compatibilizer. In one embodiment, there is provided a polymer blend composition comprising 15 to 35 wt % of a polypropylene polymer, 30-60 wt % of a linear low density polyethylene, and a compatibilizer polymer composition comprising 21-50 wt % of the polymer blend. The polymer blend is quite useful in a roofing membrane.

公开(公告)号：US20230027108A1

公开(公告)日：2023-01-26

申请号：US17901117

申请日：2022-09-01

Applicant: JOHNS MANVILLE

Inventor： Mingfu Zhang ,  Jawed Asrar

IPC: B29C70/50 ,  B05C9/12 ,  B05C9/14 ,  B05C11/02 ,  B05D1/40 ,  B05D3/02 ,  B29B11/12 ,  B29B11/16 ,  B29B13/02 ,  B29B13/06 ,  B29B15/12 ,  B29B15/14 ,  B29C70/06 ,  C08J5/04 ,  C08K7/04 ,  D06M15/71 ,  D06M15/705 ,  D06M15/61 ,  D06M15/51 ,  B05C9/10 ,  B29C48/285 ,  C08J5/24

Abstract: A thermoplastic prepreg includes a mat, web, or fabric of fibers and hollow glass microspheres that are positioned atop the mat, web, or fabric of fibers or dispersed therein. The thermoplastic prepreg also includes a thermoplastic polymer that is fully impregnated through the mat, web, or fabric of fibers and the hollow glass microspheres so that the thermoplastic prepreg has a void content of less than 3% by volume of the thermoplastic prepreg. The thermoplastic material is polymerized monomers and oligomers in which greater than 90% by weight of the monomers or oligomers react to form the thermoplastic material.