WO2001011129A1 - Composite structure incorporating a composite material - Google Patents
Composite structure incorporating a composite material Download PDFInfo
- Publication number
- WO2001011129A1 WO2001011129A1 PCT/US2000/021653 US0021653W WO0111129A1 WO 2001011129 A1 WO2001011129 A1 WO 2001011129A1 US 0021653 W US0021653 W US 0021653W WO 0111129 A1 WO0111129 A1 WO 0111129A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fibers
- matrix
- web portion
- composite material
- binder composition
- Prior art date
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 82
- 239000011230 binding agent Substances 0.000 claims abstract description 55
- 239000000203 mixture Substances 0.000 claims abstract description 41
- 239000000463 material Substances 0.000 claims abstract description 23
- 239000002657 fibrous material Substances 0.000 claims abstract description 7
- 239000000835 fiber Substances 0.000 claims description 38
- 239000000654 additive Substances 0.000 claims description 36
- 229920000126 latex Polymers 0.000 claims description 19
- -1 polyethylene Polymers 0.000 claims description 15
- 229920001577 copolymer Polymers 0.000 claims description 12
- MTAZNLWOLGHBHU-UHFFFAOYSA-N butadiene-styrene rubber Chemical compound C=CC=C.C=CC1=CC=CC=C1 MTAZNLWOLGHBHU-UHFFFAOYSA-N 0.000 claims description 11
- 239000003795 chemical substances by application Substances 0.000 claims description 10
- 238000010276 construction Methods 0.000 claims description 10
- 239000002174 Styrene-butadiene Substances 0.000 claims description 7
- 150000002148 esters Chemical class 0.000 claims description 7
- 239000011115 styrene butadiene Substances 0.000 claims description 7
- 229920003048 styrene butadiene rubber Polymers 0.000 claims description 7
- 240000008564 Boehmeria nivea Species 0.000 claims description 6
- 229920000297 Rayon Polymers 0.000 claims description 6
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 claims description 5
- 238000004806 packaging method and process Methods 0.000 claims description 5
- 229920000742 Cotton Polymers 0.000 claims description 4
- 230000000996 additive effect Effects 0.000 claims description 4
- 238000004513 sizing Methods 0.000 claims description 4
- 229920002994 synthetic fiber Polymers 0.000 claims description 4
- 239000012209 synthetic fiber Substances 0.000 claims description 4
- 244000198134 Agave sisalana Species 0.000 claims description 3
- 244000025254 Cannabis sativa Species 0.000 claims description 3
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 claims description 3
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 claims description 3
- 240000000491 Corchorus aestuans Species 0.000 claims description 3
- 235000011777 Corchorus aestuans Nutrition 0.000 claims description 3
- 235000010862 Corchorus capsularis Nutrition 0.000 claims description 3
- 241000202844 Eriophorum Species 0.000 claims description 3
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 3
- 239000005977 Ethylene Substances 0.000 claims description 3
- 244000166124 Eucalyptus globulus Species 0.000 claims description 3
- 240000006240 Linum usitatissimum Species 0.000 claims description 3
- 235000004431 Linum usitatissimum Nutrition 0.000 claims description 3
- 240000000907 Musa textilis Species 0.000 claims description 3
- 229920002367 Polyisobutene Polymers 0.000 claims description 3
- 229920001131 Pulp (paper) Polymers 0.000 claims description 3
- 229920002522 Wood fibre Polymers 0.000 claims description 3
- 235000009120 camo Nutrition 0.000 claims description 3
- 235000005607 chanvre indien Nutrition 0.000 claims description 3
- 229920001971 elastomer Polymers 0.000 claims description 3
- 239000011121 hardwood Substances 0.000 claims description 3
- 239000011487 hemp Substances 0.000 claims description 3
- 229920001084 poly(chloroprene) Polymers 0.000 claims description 3
- 229920001195 polyisoprene Polymers 0.000 claims description 3
- 229920002635 polyurethane Polymers 0.000 claims description 3
- 239000004814 polyurethane Substances 0.000 claims description 3
- 229920002689 polyvinyl acetate Polymers 0.000 claims description 3
- 239000011118 polyvinyl acetate Substances 0.000 claims description 3
- 239000002964 rayon Substances 0.000 claims description 3
- 239000004627 regenerated cellulose Substances 0.000 claims description 3
- 239000005060 rubber Substances 0.000 claims description 3
- 239000010902 straw Substances 0.000 claims description 3
- 229920001897 terpolymer Polymers 0.000 claims description 3
- 239000002699 waste material Substances 0.000 claims description 3
- 239000002025 wood fiber Substances 0.000 claims description 3
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 2
- 239000006057 Non-nutritive feed additive Substances 0.000 claims description 2
- 239000004698 Polyethylene Substances 0.000 claims description 2
- 239000004743 Polypropylene Substances 0.000 claims description 2
- 229920002334 Spandex Polymers 0.000 claims description 2
- 229920001617 Vinyon Polymers 0.000 claims description 2
- 150000001242 acetic acid derivatives Chemical class 0.000 claims description 2
- 239000003242 anti bacterial agent Substances 0.000 claims description 2
- 229940121375 antifungal agent Drugs 0.000 claims description 2
- 239000003429 antifungal agent Substances 0.000 claims description 2
- 239000003963 antioxidant agent Substances 0.000 claims description 2
- 239000004917 carbon fiber Substances 0.000 claims description 2
- 239000003054 catalyst Substances 0.000 claims description 2
- 239000007799 cork Substances 0.000 claims description 2
- 239000003431 cross linking reagent Substances 0.000 claims description 2
- 239000002270 dispersing agent Substances 0.000 claims description 2
- 239000000975 dye Substances 0.000 claims description 2
- 239000003995 emulsifying agent Substances 0.000 claims description 2
- 239000003365 glass fiber Substances 0.000 claims description 2
- 239000010985 leather Substances 0.000 claims description 2
- 239000000314 lubricant Substances 0.000 claims description 2
- 239000002557 mineral fiber Substances 0.000 claims description 2
- 229920001778 nylon Polymers 0.000 claims description 2
- 239000000049 pigment Substances 0.000 claims description 2
- 229920001748 polybutylene Polymers 0.000 claims description 2
- 239000004417 polycarbonate Substances 0.000 claims description 2
- 229920000515 polycarbonate Polymers 0.000 claims description 2
- 229920000728 polyester Polymers 0.000 claims description 2
- 229920000573 polyethylene Polymers 0.000 claims description 2
- 229920001155 polypropylene Polymers 0.000 claims description 2
- 239000004759 spandex Substances 0.000 claims description 2
- 239000003381 stabilizer Substances 0.000 claims description 2
- 239000004094 surface-active agent Substances 0.000 claims description 2
- 229920003051 synthetic elastomer Polymers 0.000 claims description 2
- 239000005061 synthetic rubber Substances 0.000 claims description 2
- 239000000080 wetting agent Substances 0.000 claims description 2
- 210000002268 wool Anatomy 0.000 claims description 2
- 239000011087 paperboard Substances 0.000 claims 4
- JHPBZFOKBAGZBL-UHFFFAOYSA-N (3-hydroxy-2,2,4-trimethylpentyl) 2-methylprop-2-enoate Chemical compound CC(C)C(O)C(C)(C)COC(=O)C(C)=C JHPBZFOKBAGZBL-UHFFFAOYSA-N 0.000 claims 2
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 claims 2
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 claims 2
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 claims 2
- 244000193174 agave Species 0.000 claims 2
- NTXGQCSETZTARF-UHFFFAOYSA-N buta-1,3-diene;prop-2-enenitrile Chemical compound C=CC=C.C=CC#N NTXGQCSETZTARF-UHFFFAOYSA-N 0.000 claims 2
- 229920000131 polyvinylidene Polymers 0.000 claims 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 claims 1
- 229920006397 acrylic thermoplastic Polymers 0.000 claims 1
- 229920003052 natural elastomer Polymers 0.000 claims 1
- 229920001194 natural rubber Polymers 0.000 claims 1
- 229920003229 poly(methyl methacrylate) Polymers 0.000 claims 1
- ISXSCDLOGDJUNJ-UHFFFAOYSA-N tert-butyl prop-2-enoate Chemical compound CC(C)(C)OC(=O)C=C ISXSCDLOGDJUNJ-UHFFFAOYSA-N 0.000 claims 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 abstract description 12
- 229920006173 natural rubber latex Polymers 0.000 abstract description 4
- 229920006174 synthetic rubber latex Polymers 0.000 abstract description 4
- 239000011159 matrix material Substances 0.000 description 38
- 238000000034 method Methods 0.000 description 17
- 239000000047 product Substances 0.000 description 15
- 239000002002 slurry Substances 0.000 description 14
- 239000004816 latex Substances 0.000 description 12
- 238000000151 deposition Methods 0.000 description 10
- 230000008021 deposition Effects 0.000 description 7
- 238000005470 impregnation Methods 0.000 description 7
- 238000004519 manufacturing process Methods 0.000 description 4
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- 241000233866 Fungi Species 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 239000002655 kraft paper Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000000123 paper Substances 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 1
- 240000004246 Agave americana Species 0.000 description 1
- 241000894006 Bacteria Species 0.000 description 1
- 229920003043 Cellulose fiber Polymers 0.000 description 1
- RRHGJUQNOFWUDK-UHFFFAOYSA-N Isoprene Chemical compound CC(=C)C=C RRHGJUQNOFWUDK-UHFFFAOYSA-N 0.000 description 1
- 239000006096 absorbing agent Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000003679 aging effect Effects 0.000 description 1
- XMQFTWRPUQYINF-UHFFFAOYSA-N bensulfuron-methyl Chemical compound COC(=O)C1=CC=CC=C1CS(=O)(=O)NC(=O)NC1=NC(OC)=CC(OC)=N1 XMQFTWRPUQYINF-UHFFFAOYSA-N 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000011437 continuous method Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 230000009931 harmful effect Effects 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 239000002648 laminated material Substances 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 230000021715 photosynthesis, light harvesting Effects 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 239000010817 post-consumer waste Substances 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 230000035882 stress Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 235000013311 vegetables Nutrition 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
- B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/28—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/02—Cellular or porous
- B32B2305/024—Honeycomb
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/07—Parts immersed or impregnated in a matrix
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2479/00—Furniture
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2553/00—Packaging equipment or accessories not otherwise provided for
Definitions
- the invention relates to a composite structure having a corrugated, fluted, pleated or the like matrix, especially a composite sandwich construction, to be used in the packaging, construction, transportation, recreational, furniture and aerospace industries.
- Still a further object of the invention is to provide composite structures having a matrix having a balance of stiffness and softness to provide good energy dissipation.
- Yet another object of the invention is to provide composite structures having a matrix which is water-resistant and does not deteriorate, crack, or become brittle and harden after being wetted.
- a further object of the invention is to provide composite structures having a matrix for use in those applications where resistance to mold, mildew and fungi are required.
- An additional object of the invention is to provide composite structures having a matrix which is easily secured in position between solid and flexible surfaces.
- An even further object of the invention is to provide composite structures having a matrix made from renewable, recyclable, and/or recycled components, utilizing post-consumer waste.
- An additional object of the invention is to provide composite structures having a matrix which may be combined with all known adhesive systems including, but not be limited to, water-based, synthetic or natural latex, as well as 100% solids hot melt systems.
- the invention relates to composite structures or products for use in the packaging, construction, transportation, recreational, furniture and aerospace industries which have improved durability and are lighter than conventional products.
- the invention provides composite structures or products for the manufacture of boxes, cartons, containers, or lids and for use in the construction, transportation, recreational, furniture, and aerospace industries.
- the matrix may be used as a sound absorber or reinforcing matrix in hollow core doors, or as a reinforcement of fiberglass boat hulls, shower stalls, and bathtubs.
- the products are made of a composite matrix material having a substantially continuous web portion impregnated with a binder composition.
- the web portion of the composite material is made of a particulate, matrix forming material, preferably a natural or synthetic fibrous material.
- the binder composition binds the particulate, matrix forming material in the web and imparts resiliency and water resistance to the composite material.
- the binder composition is a natural or synthetic rubber latex.
- the single face or double faced corrugated, fluted, pleated or the like matrix material has superior physical strength as related to ring crush, edge crush and puncture resistance as well as improved dimensional stability.
- the corrugated, fluted, pleated or the like impregnated fiber matrix may be resaturated.
- the invention provides products which exhibit superior dimensional stability, maintain a proper balance of rigidity and flexibility during their useful lives and are resistant to cracking and embrittlement, which contribute to durability.
- the composite material for the matrix may be made by methods based on paper making processes, including, but not limited to, wet web impregnation, dry web impregnation, latex beater deposition, and continuous latex wet-end deposition.
- the impregnated matrix materials may be produced in gauges ranging from 0.005 to .126" in single ply or laminated form.
- the impregnated matrix material may be produced in electrostatic dissipative (ESD) as well as conductive form.
- ESD electrostatic dissipative
- the impregnated matrix materials may be treated, for example, to resist mold and mildew.
- the composite matrix material is produced in the form of sheets or rolls, and the matrix material can be corrugated, fluted, pleated or the like from roll or sheet form.
- the composite matrix material can be fixedly secured, by mechanical and/or chemical methods, to a liner(s) or facer(s) to create composite structures or products of either single faced or double faced construction.
- the composite structures or products may be combined with other products, single faced or double faced, and may be combined with other lesser quality composites.
- the FIGURE is a cross-sectional view of at least one first layer of a composite material having a substantially continuous web portion and a plurality of alternating ridges and grooves, and at least one second layer, more specifically two second layers, attached to the first layer in accordance with the present invention.
- the FIGURE shows a double faced composite structure 10 having a matrix or medium layer 12 formed from a composite material and top and bottom liners, facers or layers 14 and 16, respectively.
- the composite structure or combination is made of a composite material having a substantially continuous web portion impregnated with a binder composition.
- the composite material is a matted, felted, non-woven sheet containing a web portion optionally with web portion additives, and a binder composition optionally with binder additives.
- the web portion and web portion additives preferably comprise from about 50% to about 90% by weight of the dry weight of the composite material, and more preferably comprise from about 65% to about 75% by weight of the dry weight of the composite material.
- the binder composition and binder additives preferably comprise from about 10% to about 50% by weight of the dry weight of the composite material, and more preferably comprise from about 25% to about 35% by weight of the dry weight of the composite material.
- the web portion of the composite mate ⁇ al includes at least one particulate, matrix- forming component
- suitable particulate, matnx- forming matenals include natural fibers including cellulosic fibers de ⁇ ved from a single source or a plurality of sources such as wood pulp, rags and cotton hnters, and other cotton and vegetable fibers such as flax, hemp, abaca, jute, straw, ramie, sisal, istle, china grass, cotton grass, agave, pita, esparto, eucalyptus, evergreen and coniferous wood fibers, deciduous and broad-leaf hardwood fibers, comminuted and macerated waste fibers, viscose fibers, regenerated cellulose or cuprammonium type
- the particulate mat ⁇ x-formmg component is a fibrous mate ⁇ al having a denier of about 0 2 microns to about 40 microns and a fiber length of about 0 1 millimeter to about
- the binder composition is a mate ⁇ al capable of binding the particulate matrix- forming component in the web and preferably includes at least one natural or synthetic rubber latex
- suitable synthetic rubber latices include resms such as styrene-butadiene, carboxylated styrene-butadiene, polyacryhc ester, polymethacryhc ester, copolymers of acrylic ester and methacryhc ester, acrylomt ⁇ le-acryhc ester copolymer, polyvinyl acetate, polyisobutylene, a copolymer of vinyl acetate and acrylic ester, polychloroprene, acrylomt ⁇ lebutadiene, carboxylated acrylomt ⁇ le butadiene, polyurethanes.
- the binder composition may include a single natural or synthetic rubber latex or a mixture of two or more such rubber latices An especially prefe ⁇ ed binder composition comp ⁇ ses styrene-butadiene
- the binder composition imparts water resistance to the composite matenal. while maintaining the other desirable properties of the web portion of the composite mate ⁇ al
- both the web portion and the binder composition optionally contain additives
- additives function as processing additives and/or end product additives to achieve certain desired results during the manufacture of the composite mate ⁇ al and/or to impart certain desired characteristics to the combination
- Additives are classified as "web portion” additives and "binder” additives based on which component, the web forming component or the binder composition, the additive is initially mixed with.
- the same types of additives can be both web portion additives and binder additives.
- the additives useful in the composite material are conventional additives, which are used for their known properties in preparing the composite material of the invention.
- suitable web portion additives include antifungal agents, antimildew agents, antibacterial agents, dyes, pigments, dispersants, wet strength aids, web processing aids, defoamers and sizing agents.
- suitable binder additives include: surfactants, antioxidants, lubricants, crosslinking agents, catalysts, anti-ozonates, emulsifiers, wetting agents, colloidal stabilizing agents, vulcanizing agents, sizing agents, and defoamers.
- the total amount of additives, both web portion and binder additives, in the composite material is preferably between about 0.5% and about 5.0% by weight based on the dry weight of the composite material.
- the composite material has a thickness of between about 0.005 inch and 0.126 inch, more typically between about 0.015 and
- Composite materials for use in this invention can be made by modified paper-making processes wherein an aqueous slurry of the matrix-forming component and optionally the web portion additives is formed and then the slurry or a web formed from the slurry is impregnated with the binder composition and optionally the binder additives.
- modified paper-making processes in particular can be used to make the composite material for the combination of this invention: wet web impregnation; dry web impregnation; latex beater deposition and continuous latex- wet-end deposition.
- fibrous is to be construed as including particulate matrix-forming materials which are not technically fibers.
- the basic processes discussed herein are modified paper making processes, which do involve primarily cellulosic fibers as the web or matrix-fonning component, the conventional term "fibrous" will be used.
- the fibrous matrix-forming component(s) and web portion additive are dispersed in water to prepare a slurry stock and the slurry stock passes through a refiner or beater which cuts the fibers and ruptures the surfaces of the fibers to improve their bondability
- the refined slurry stock is fed to a sheet former of conventional construction
- a fibrous web is formed by removal of water from the approximately 99% by weight water content of the refined slurry stock feed to a fibrous web having about 72% by weight water
- a press section which removes water from the web to reduce the water content to about 50% to 60% by weight
- the pressed web then passes to a saturator which introduces the binder composition and binder additives into the fibrous web
- Excess binder composition and bmder additives are removed from the fibrous web and then the binder impregnated fibrous web passes to dryers which dry the impregnated web to a moisture content less
- the dry web impregnation is similar to the wet web impregnation method, with the exception that the fibrous web proceeds directly to the dryers from the press section to produce a dry, non-impregnated fibrous web
- the fibrous web is subsequently impregnated with the binder composition and binder additives, m a separate production process, by passing the dry fibrous web through a bath of the binder composition and binder additives, removing excess binder composition and binder additives, and then drying the impregnated web to a moisture content less than about 3% by weight
- the bmder composition and bmder additives are mixed with the refined slurry stock in a latex deposition chest before the slurry stock is fed to the sheet former
- a deposition agent or combination of agents is added to the latex deposition chest as well, to break the binder latex composition and deposit binder panicles uniformly on the fibers
- the binder composition and binder additives are mixed with the refined fiber slurry stock in a batch
- the continuous latex wet-end deposition method differs from the latex beater deposition method in that the binder composition and binder additives are introduced into the slurry stock, before the sheet former, continuously rather than m a batchwise manner
- all binder composition and binder additives are added to the slurry stock before the slurry is formed into a web by the sheet foroier, for example, at the inlet to a fan pump or in the headbox of the sheet former
- the above methods are examples of methods for making the composite mate ⁇ al for the composite structure or combination of the invention, but should not be construed as the only suitable methods.
- the composite material made by the above methods is in the form of large, continuous sheets which can be cut and stacked or can be rolled around a supporting core.
- the composite material is corrugated, fluted, pleated or the like and combined with one or more facers or liners or incorporated into other structures using conventional techniques and equipment well known in the art.
- the facers or liners or other layers of the composite structures or products may be made of any conventional material including a substantially continuous web as described herein either impregnated or not impregnated with a binder composition.
- an elastomeric matrix material is specifically designed for use as reinforcement in composite sandwich constructions.
- the matrix material is fluted or corrugated or the like to produce a matrix with a high strength-to-weight ratio.
- the wet web saturation process for example, is used to produce a material which is fluted, for example, to the maximum potential with maximum resistance to crushing of the flutes.
- the matrix material offers dry and wet dimensional stability and is thermoplastic for molding or fluting or the like. It is water-resistant and contains excellent physical properties even when wet.
- the matrix may be treated to be resistant to the growth and harmful action of bacteria, fungi and mold.
- the products are preferably made from cellulose fibers which are formed into a web that is then saturated in a latex bath. The latex impregnates the fibers and coats each fiber within the web. In curing and drying, this web is chemically bonded to give a product which has high internal and overall strength, good dimensional stability and excellent aging properties.
- a typical composite structure is a matrix material web as described above in co ⁇ ugated form having a gauge of .018" combined with a kraft liner or sheet having a gauge of .009" to form a single faced product.
- Another typical composite structure is a matrix material web as described above in corrugated form having a gauge of .018" combined with a matrix material as described above in sheet form having a gauge of .018" to form a single face product.
Landscapes
- Laminated Bodies (AREA)
- Nonwoven Fabrics (AREA)
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU68965/00A AU6896500A (en) | 1999-08-10 | 2000-08-09 | Composite structure incorporating a composite material |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US37099999A | 1999-08-10 | 1999-08-10 | |
US09/370,999 | 1999-08-10 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2001011129A1 true WO2001011129A1 (en) | 2001-02-15 |
Family
ID=23462081
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2000/021653 WO2001011129A1 (en) | 1999-08-10 | 2000-08-09 | Composite structure incorporating a composite material |
Country Status (2)
Country | Link |
---|---|
AU (1) | AU6896500A (en) |
WO (1) | WO2001011129A1 (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1950253A1 (en) * | 2005-11-18 | 2008-07-30 | Bussan Nanotech Research Institute Inc. | Recycled composite material |
GB2490539A (en) * | 2011-05-06 | 2012-11-07 | Wool Packaging Company Ltd | Laminated packaging sheet comprising stiff and hygroscopic fibre layers |
CN103085362A (en) * | 2012-11-15 | 2013-05-08 | 苏州金尚豪纺织有限公司 | Wind-resistant comfortable denim fabric |
CN104558773A (en) * | 2014-12-30 | 2015-04-29 | 苏州康华净化系统工程有限公司 | Antibacterial polyethylene material used for air purifying equipment and preparation method thereof |
CN107142775A (en) * | 2017-05-22 | 2017-09-08 | 谷照林 | Straw bulking composite packaging boxboard manufacturing process |
CN108532123A (en) * | 2018-04-04 | 2018-09-14 | 杭州诺邦无纺股份有限公司 | A kind of spun lacing non-woven material and preparation method thereof containing natural dry petal |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5505264A (en) * | 1993-12-16 | 1996-04-09 | Georgia Bonded Fibers, Inc. | Leather-like hoof pad of composite material |
US5508083A (en) * | 1993-05-19 | 1996-04-16 | Chapman, Jr.; Francis L. | Machine direction fluted combined corrugated containerboard |
-
2000
- 2000-08-09 WO PCT/US2000/021653 patent/WO2001011129A1/en active Application Filing
- 2000-08-09 AU AU68965/00A patent/AU6896500A/en not_active Abandoned
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5508083A (en) * | 1993-05-19 | 1996-04-16 | Chapman, Jr.; Francis L. | Machine direction fluted combined corrugated containerboard |
US5505264A (en) * | 1993-12-16 | 1996-04-09 | Georgia Bonded Fibers, Inc. | Leather-like hoof pad of composite material |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1950253A1 (en) * | 2005-11-18 | 2008-07-30 | Bussan Nanotech Research Institute Inc. | Recycled composite material |
EP1950253A4 (en) * | 2005-11-18 | 2009-05-13 | Mitsui Bussan | Recycled composite material |
GB2490539A (en) * | 2011-05-06 | 2012-11-07 | Wool Packaging Company Ltd | Laminated packaging sheet comprising stiff and hygroscopic fibre layers |
CN103085362A (en) * | 2012-11-15 | 2013-05-08 | 苏州金尚豪纺织有限公司 | Wind-resistant comfortable denim fabric |
CN104558773A (en) * | 2014-12-30 | 2015-04-29 | 苏州康华净化系统工程有限公司 | Antibacterial polyethylene material used for air purifying equipment and preparation method thereof |
CN107142775A (en) * | 2017-05-22 | 2017-09-08 | 谷照林 | Straw bulking composite packaging boxboard manufacturing process |
CN108532123A (en) * | 2018-04-04 | 2018-09-14 | 杭州诺邦无纺股份有限公司 | A kind of spun lacing non-woven material and preparation method thereof containing natural dry petal |
Also Published As
Publication number | Publication date |
---|---|
AU6896500A (en) | 2001-03-05 |
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