EP0929715A1 - Procede d'obtention d'un mat de fibres de verre non tissees comprenant un ensemble de faisceaux de fibres - Google Patents

Procede d'obtention d'un mat de fibres de verre non tissees comprenant un ensemble de faisceaux de fibres

Info

Publication number
EP0929715A1
EP0929715A1 EP97940900A EP97940900A EP0929715A1 EP 0929715 A1 EP0929715 A1 EP 0929715A1 EP 97940900 A EP97940900 A EP 97940900A EP 97940900 A EP97940900 A EP 97940900A EP 0929715 A1 EP0929715 A1 EP 0929715A1
Authority
EP
European Patent Office
Prior art keywords
fibers
slurry
bundles
ppm
fiber mat
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP97940900A
Other languages
German (de)
English (en)
Other versions
EP0929715A4 (fr
Inventor
Gregory S. Helwig
Vallipuram Pathmanathan
Robert W. Heseltine
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Owens Corning Veil UK Ltd
Owens Corning
Original Assignee
Owens Corning
Owens Corning Fiberglas Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Owens Corning, Owens Corning Fiberglas Corp filed Critical Owens Corning
Publication of EP0929715A1 publication Critical patent/EP0929715A1/fr
Publication of EP0929715A4 publication Critical patent/EP0929715A4/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/36Inorganic fibres or flakes
    • D21H13/38Inorganic fibres or flakes siliceous
    • D21H13/40Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/06Paper forming aids
    • D21H21/12Defoamers
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/14Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
    • D21H21/22Agents rendering paper porous, absorbent or bulky
    • D21H21/24Surfactants

Definitions

  • the present invention relates to a process for producing a non-woven glass fiber mat. and more particularly, to a wet-laid process for forming a glass fiber mat comprised of small bundles of glass fibers.
  • a water slurry is provided into which the fibers are dispersed.
  • the water slurry may contain surfactants, viscosity modifiers, defoaming agents, or other chemical agents.
  • Chopped fibers are then introduced into the slurry and agitated such that the fibers become dispersed.
  • the slurry containing the fibers is then deposited onto a moving screen, and a substantial portion of the water is removed to form a web.
  • a binder is then applied, and the resulting mat is dried to remove the remaining water and to cure the binder.
  • the resulting non-woven mat consists of an assembly of dispersed, individual glass filaments as shown in Fig. 1.
  • a wet-laid process is preferred in applications where a very uniform distribution of fibers is desired.
  • Another method of forming glass fiber mats is a dry-laid process in which the resulting mats are comprised of bundles of fibers (i.e.. multiple fibers associated closely together in substantially parallel relationship).
  • fibers are chopped and air blown onto a conveyor, and a binder is then applied to form the mat.
  • a dry-laid process is desirable in instances where an open structure is desired in the resulting mat to allow the rapid penetration of viscous liquids or resins, or in applications where it is desirable to minimize the volume of the glass fibers.
  • the present invention meets that need by providing a method of forming a wet-laid glass fiber mat in which the components in the water slurry may be modified so as to cause the fibers to form discrete bundles of closely associated multiple fibers in a substantially parallel relationship.
  • the resulting mat may comprise small or large bundles of fibers, is of a uniform weight, and has a porous structure.
  • uniform weight it is meant that there is a uniform distribution of fiber weight within the mat.
  • the process is economical as it utilizes low-cost standard wet-chopped fibers.
  • a method of forming a wet-laid glass fiber mat includes the steps of adding chopped glass fibers to an aqueous slurry containing a surfactant and a viscosity modifier, agitating the fibers to cause them to disperse, removing water from the fibers to form a web. and applying a binder to the web to form a glass fiber mat.
  • the surfactant contained in the slurry is preferably a cationic surfactant which is present in an amount of from about 30 to about 200 ppm.
  • the surfactant 5 functions to lubricate the fibers and aid in dispersion of the fibers when they are initially placed in the slurry.
  • the viscosity modifier is preferably hydroxyethyl cellulose, which is present in an amount of about 2000 ppm. The viscosity modifier maintains a highly viscous aqueous slurry which helps facilitate agitation and allows control of water drainage when water is removed from the fibers.
  • the method of forming the mat also includes the step of adding a sufficient amount of a hydrophobic agent to the slurry to cause the chopped fibers to form bundles in the slurry.
  • a hydrophobic agent we mean a composition which is attracted to the surface of the fibers and which repels water.
  • the hydrophobic agent preferably comprises a polyalkoxane defoaming agent which is added to the slurry in an amount of from about
  • the method may further optionally include the step of adding a complexing agent for the surfactant to the slurry.
  • the complexing agent functions to tie up the surfactant, thus aiding in fiber bundle formation.
  • the complexing agent is a polycarboxylate salt, which is added in an amount of from about 20 to about 100 ppm.
  • the method also includes the step of drying the mat after application of the binder.
  • the resulting non-woven glass fiber mat comprises bundles of chopped fibers.
  • the chopped fibers used in the present invention are wet- chopped fibers having a length of from about 3 mm to about 50 mm, and more preferably, from about 25 mm to about 50 mm.
  • the size of the bundles in the resulting mat is preferably from about 50 to about 500 fibers and is controlled by the amount of the hydrophobic agent in the slurry.
  • small bundles comprise about 50 individual filaments, while larger bundles may be defined as those comprising from about 300 to about 500 individual filaments.
  • the non-woven glass fiber mat preferably has a basis weight of from about
  • the thickness of the mat is typically thinner than wet-laid mats comprised of dispersed fibers, but may vary depending on the bundle size. For example, smaller bundles produce thicker mats, while larger bundles produce thinner mats.
  • the method of the present invention provides an advantage over prior processes in that the components in the slurry which cause or aid in bundle formation may be easily modified to form mats comprising dispersed fibers (i.e., having substantially no fiber bundles). This can be done without having to drain the aqueous slurry from the machine or mixing tank in which the fibers are processed, which results in a substantial savings in time and cost.
  • a method for modifying the components in the aqueous slurry which includes the steps of providing an aqueous slurry containing a surfactant, a viscosity modifier and wet- chopped fibers, and adding a sufficient amount of a hydrophobic agent to cause the fibers to form a plurality of bundles.
  • a mat is then formed as described above by removing water from the fibers to form a web and applying a binder to the web.
  • the method may include the step of adding a sufficient amount of a surfactant to the existing slurry which causes the fibers to disperse.
  • a mat comprising dispersed fibers may then be produced by removing water from the fibers to form a web and applying a binder.
  • the surfactant is preferably added to the slurry in an amount so as to obtain a level of from about 30 ppm to about 200 ppm.
  • a complexing agent for the surfactant such as a polycarboxylate salt may be added to the slurry with the hydrophobic agent which aids in bundle formation as described above.
  • the slurry may be modified by the addition of a cationic polyacrylamide, which functions to remove the complexing agent and causes the fibers to disperse.
  • the cationic polyacrylamide is preferably added in an amount of from about 25 to about 50 ppm.
  • a method for forming a wet-laid glass fiber mat comprising the steps of adding chopped glass fibers to an aqueous slurry, adding a sufficient amount of a hydrophobic agent to the slurry to cause the chopped fibers to form a plurality of bundles, and forming a mat as described above.
  • the aqueous slurry does not contain a surfactant.
  • the hydrophobic agent added to the slurry may comprise a polyalkoxane defoaming agent, and is preferably added to the slurry in an amount of from about 50 to about 1000 ppm.
  • the slurry may also contain from about 30 to about 3000 ppm of a viscosity modifier selected from the group consisting of hydroxyethyl cellulose, anionic polyacrylamide, and polyethylene oxide.
  • the hydrophobic agent added to the slurry may comprise a viscosity modifier.
  • the viscosity modifier comprises an anionic polyacrylamide in the form of a water-in-oil emulsion, and is added to the slurry in an amount of from about 30 to about 1000 ppm. In this embodiment, it is the combination of the oil and emulsifier that causes bundle formation.
  • FIG. 1 is an enlarged perspective view of a glass fiber mat comprised of dispersed fibers
  • Fig. 2 is an enlarged perspective view of a glass fiber mat comprised of small bundles of fibers formed in accordance with the present invention.
  • Fig. 3 is an enlarged perspective view of a glass fiber mat comprised of large bundles of fibers formed in accordance with the present invention.
  • the process of the present invention provides many advantages over prior art mats which are formed by a dry-laid process.
  • the wet-laid process of the present invention provides a highly porous, thin, non-woven glass fiber mat which has greater uniformity of fiber distribution than mats produced in dry-laid processes.
  • the mat of the present invention can be produced at lower cost because it uses low-cost wet chopped fibers which are formed into bundles by altering the components of the slurry used in a normal wet-laid process.
  • the slurry components may be modified so as to produce mats comprising either bundles of fibers or dispersed fibers without having to replace the entire slurry.
  • the wet-laid mat of the present invention may be processed with the use of papermaking-type machines such as Fourdrinier, wire cylinder, Stevens Former, Roto Former, Inver Former and Venti Former machines.
  • the general procedure for preparing the glass fiber mat of the present invention is to form an aqueous slurry which contains the desired hydrophobic agent, and which may further contain a surfactant, a viscosity modifier, and a complexing agent.
  • the amount of water in the slurry may vary depending on the size of the equipment used. Typical volumes of water may range from 40,000 to 80,000 liters.
  • Wet chopped fibers are added to the slurry and agitated to form a thick stock. During agitation, the fibers begin to form bundles.
  • the concentration of fibers in the slurry is maintained at from about 0.2 % by weight to about 1% by weight.
  • the fiber-containing slurry is then passed to a conventional head box where the the slurry is deposited onto a moving wire screen and dewatered by suction or vacuum to form a web comprising bundles of fibers.
  • the web is coated with a binder by conventional means and then passed through a drying oven which dries the mat and cures the binder.
  • a binder is an emulsion of a copolymer of ethylene and vinyl acetate.
  • Any binder which is suitable for use in a wet-formed mat operation may be used in the present invention.
  • a preferred defoaming agent is Dispelair CF707, available from Blackburn Chemicals Ltd.
  • An alternative hydrophobic agent which may be used in embodiments where the slurry does not contain a surfactant is an anionic polyacrylamide viscosity modifier which is in the form of a water-in-oil emulsion.
  • An anionic polyacrylamide viscosity modifier is Magnifloc 1885A, available from Cytec Industries.
  • hydrophobic agents are preferred for use in the present invention, it should be appreciated that other hydrophobic agents may be used as long as they have the proper balance of hydrophilic and lipophilic properties.
  • the hydrophobic agent should be attracted to the fibers such that it coats the fibers and causes them to become hydrophobic and repel the water, gathering together to form bundles.
  • a preferred cationic surfactant is Aerosol C-61, available from Cytec Industries.
  • Aerosol C-61 available from Cytec Industries.
  • a suitable complexing agent is a polycarboxylate salt, available under the designation Dispex N40V from Allied Colloids.
  • the polycarboxylate salt functions to complex with the surfactant in the slurry so that the surfactant is prevented from emulsifying the hydrophobic agent. This, in turn, prevents the fibers from dispersing, thus aiding the hydrophobic agent in forming fiber bundles. It should be noted that while fiber bundles may be formed without the use of the polycarboxylate salt, much higher amounts of the hydrophobic agent would be required, i.e., about 3000 ppm to about 5000 ppm.
  • the complexing agent also works with the hydrophobic agent to control the size of the bundles formed. For example, when about 50 ppm of a polycarboxylate salt is added to the water slurry along with 300 ppm of a polyalkoxane defoaming agent, small bundles of fibers are formed as shown in Fig. 2. As the level of defoaming agent is increased from 300 ppm to about 700 ppm. the bundle size increases as shown in Fig. 3 to a maximum size that is reached with about 1000 ppm of the defoaming agent.
  • suitable viscosity modifiers include hydroxyethyl cellulose, anionic polyacrylamide, and polyethylene oxide.
  • a preferred viscosity modifier is Natrosol 250 HHBR (hydroxyethyl cellulose) available from Aqualon Co.
  • the chopped glass fibers used in the present invention are wet- chopped fibers having a length of from about 3 mm to about 50 mm. and more preferably, from about 25 mm to about 50 mm.
  • fibers which are too long in length tend to form strings, while fibers which are too short will not provide a strong enough web when the fibers are gathered.
  • the irregular shape of the bundles formed from such fibers may "print-through" the surface of the molded part, resulting in a nonuniform surface having visible fibers.
  • the fibers should preferably have a diameter of about 16 to about 25 microns. The diameter of the fiber determines the acceptable chop length, i.e., the larger the fiber diameter, the longer the acceptable chop length up to a maximum of 50 mm with 25 micron fibers.
  • a wide range of sizing agents may be used on the fibers. However, sufficient time must be allowed for the sizing to wash off the fibers when they are placed in the slurry. This time may vary depending on the temperature of the slurry and the degree of agitation of the slurry after fiber addition, as well as the composition of the sizing used on the fibers. For example, the temperature of the slurry is typically in the range of from about 20°C to about 40°C, and it usually takes from about 5 to 15 minutes for the size to wash off and for the bundles to form. When the temperature of the slurry is lower, the sizing usually takes longer to wash off.
  • the resulting mat comprising bundles of fibers may be used in a number of different applications.
  • the mat may be used in the reinforcement of polyurethane foam headliners.
  • the wet-laid mats may also be used in reinforced plastics applications such as in the production of boat hulls or food service trays.
  • the wet-laid process of the present invention provides an advantage in that the components in the aqueous slurry may be modified so as to produce mats comprised of either bundles or dispersed fibers without having to drain the slurry from the machine.
  • a sufficient amount of a surfactant may be added to the slurry which emulsifies the hydrophobic agent and allows the fibers to disperse.
  • the surfactant is preferably added to the slurry to obtain a level of about 30 to about 200 ppm.
  • the slurry may be modified by the addition of a cationic polyacrylamide.
  • the cationic polyacrylamide effectively removes the polycarboxylate salt from the slurry such that the surfactant can effectively disperse the fibers.
  • a preferred cationic polyacrylamide is Percol 1597 available from Allied Colloids.
  • the amount added to the slurry is preferably about 25 to about 50 ppm, but may be varied depending on how much of the polycarboxylate salt is present in the slurry. We have found that an excess of the cationic polyacrylamide may be added without adversely affecting the aqueous slurry.
  • a water slurry was formed in a wet-process pilot machine containing 2000 ppm of Natrosol 250 HHBR (hydroxyethyl cellulose viscosity modifier from Aqualon Co.). 75 ppm Aerosol C-61 surfactant (Cytec Industries), and 50 ppm of Dispelair CF-707 defoaming agent (Blackburn Chemicals Ltd.).
  • the viscosity was measured at 8.0 cps at a temperature of about 26°C. Throughout the formation of the mat, the viscosity was maintained in the range of 8.0 to 8.5 cps by periodic addition of a 0.5 percent solution of Natrosol 250 HHBR in water. The line speed was maintained at 9.1 m/min (30 fpm).
  • a binder comprising a vinyl acetate-ethylene emulsion Airflex 124 from Air Products
  • binder saturated sheet was then transferred to an oven where it was dried and the binder cured.
  • the resulting mat had a basis weight of 60 g/m 2 and a binder content of 14.4%.
  • the mat thickness was 0.6 mm.
  • Example 2 A slurry mix tank was charged with 2000 1 of the water slurry described in
  • Example 1 with an additional 50 ppm of Aerosol C-61 surfactant and 10 ppm of Dispelair defoaming agent. Ten (10) ppm of Dispex N40V (sodium salt of polycarboxylic acid from Allied Colloids) was then added. A 6590 g charge of wet-chopped fibers was then added and stirred for 15 minutes. A mat was then formed as described above. The resulting mat contained a combination of dispersed fibers and "strings”.
  • Example 3 Example 3
  • Example 2 Using the slurry of Example 2, the amount of Dispex in the slurry mix tank was increased to 50 ppm, with the other components remaining at the previous level. A mat was formed in which more strings appeared.
  • Example 4 Using the slurry of Example 3, the level of Dispelair was increased to 500 ppm, with the other components remaining at the same level. The resulting mat consisted entirely of small, slightly elongated fiber bundles. The resulting mat had a thickness of about 0.4 mm. had a basis weight of 90 g/m 2 , and a binder content of 10.2%.
  • Example 5 Using the slurry of Example 4, the amount of Dispelair was increased to

Abstract

L'invention porte sur un procédé d'obtention d'un mat de fibres de verre non tissées déposées par voie humide et comprenant un ensemble de faisceaux de fibres. Ledit procédé consiste à ajouter des fibres découpées à une boue aqueuse contenant une quantité suffisante d'un agent hydrophobe pour amener les fibres à former une série de faisceaux. Les fibres forment alors un mat pouvant servir à nombre d'applications de renfort. L'invention porte également sur un procédé modifiant les ingrédients de la boue aqueuse pour produire des mats comportant soit des faisceaux de fibres, soit des fibres dispersées.
EP97940900A 1996-09-12 1997-09-08 Procede d'obtention d'un mat de fibres de verre non tissees comprenant un ensemble de faisceaux de fibres Withdrawn EP0929715A4 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US71271196A 1996-09-12 1996-09-12
US712711 1996-09-12
PCT/US1997/015804 WO1998011299A1 (fr) 1996-09-12 1997-09-08 Procede d'obtention d'un mat de fibres de verre non tissees comprenant un ensemble de faisceaux de fibres

Publications (2)

Publication Number Publication Date
EP0929715A1 true EP0929715A1 (fr) 1999-07-21
EP0929715A4 EP0929715A4 (fr) 1999-11-03

Family

ID=24863229

Family Applications (1)

Application Number Title Priority Date Filing Date
EP97940900A Withdrawn EP0929715A4 (fr) 1996-09-12 1997-09-08 Procede d'obtention d'un mat de fibres de verre non tissees comprenant un ensemble de faisceaux de fibres

Country Status (3)

Country Link
EP (1) EP0929715A4 (fr)
BR (1) BR9711748A (fr)
WO (1) WO1998011299A1 (fr)

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6054022A (en) * 1996-09-12 2000-04-25 Owens-Corning Veil U.K. Ltd. Method for producing a non-woven glass fiber mat comprising bundles of fibers
US6008147A (en) * 1998-05-28 1999-12-28 Johns Manville International, Inc. Fiber glass mat for laminating to foam, foam laminate precursor, foam laminate, and methods of making the mat and the foam laminate
US6251224B1 (en) * 1999-08-05 2001-06-26 Owens Corning Fiberglass Technology, Inc. Bicomponent mats of glass fibers and pulp fibers and their method of manufacture
US6291552B1 (en) 1999-10-29 2001-09-18 Owens Corning Fiberglas Technology, Inc. Method for producing a glass mat
US6488811B1 (en) 2001-04-30 2002-12-03 Owens Corning Fiberglas Technology, Inc. Multicomponent mats of glass fibers and natural fibers and their method of manufacture
US20080142178A1 (en) * 2006-12-14 2008-06-19 Daphne Haubrich Wet layed bundled fiber mat with binder fiber
US9506194B2 (en) 2012-09-04 2016-11-29 Ocv Intellectual Capital, Llc Dispersion of carbon enhanced reinforcement fibers in aqueous or non-aqueous media
CN105040513B (zh) * 2015-06-26 2017-06-20 陕西科技大学 一种玻璃纤维增强纸张的制备方法
EP4134230A1 (fr) 2021-08-09 2023-02-15 URSA Insulation, S.A. Panneau d'isolation

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4112174A (en) * 1976-01-19 1978-09-05 Johns-Manville Corporation Fibrous mat especially suitable for roofing products

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4118272A (en) * 1977-03-03 1978-10-03 Gaf Corporation Continuous wet-laid process for making high-strength glass fiber mats
US4242404A (en) * 1979-05-16 1980-12-30 Gaf Corporation High-strength glass fiber mat particularly useful for roofing products

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4112174A (en) * 1976-01-19 1978-09-05 Johns-Manville Corporation Fibrous mat especially suitable for roofing products

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of WO9811299A1 *

Also Published As

Publication number Publication date
WO1998011299A1 (fr) 1998-03-19
EP0929715A4 (fr) 1999-11-03
BR9711748A (pt) 2000-01-18

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