EP3990687A1 - Mat non tissé souple - Google Patents

Mat non tissé souple

Info

Publication number
EP3990687A1
EP3990687A1 EP20743911.8A EP20743911A EP3990687A1 EP 3990687 A1 EP3990687 A1 EP 3990687A1 EP 20743911 A EP20743911 A EP 20743911A EP 3990687 A1 EP3990687 A1 EP 3990687A1
Authority
EP
European Patent Office
Prior art keywords
mat
binder
bonded
amount
present
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.)
Granted
Application number
EP20743911.8A
Other languages
German (de)
English (en)
Other versions
EP3990687B1 (fr
Inventor
Xin Wang
Paul Geel
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 Intellectual Capital LLC
Original Assignee
Owens Corning Intellectual Capital LLC
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Filing date
Publication date
Application filed by Owens Corning Intellectual Capital LLC filed Critical Owens Corning Intellectual Capital LLC
Publication of EP3990687A1 publication Critical patent/EP3990687A1/fr
Application granted granted Critical
Publication of EP3990687B1 publication Critical patent/EP3990687B1/fr
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions

Definitions

  • the present invention relates to non-woven fibrous mats with an enhanced combination of strength and flexibility, and methods of manufacturing such non-woven fibrous mats.
  • Non-woven mats include a web of fibers bound together by a suitable resinous binder.
  • Reinforcement fibers such as glass fibers, are useful in a variety of technologies, and may be used in the form of continuous or chopped filaments, strands, rovings, woven fabrics, nonwoven fabrics, meshes, and scrims (also called mats and veils), useful for reinforcing a number of materials.
  • Fibrous glass mats provide good insulative properties and dimensional stability as they generally do not shrink or stretch in response to changes in atmospheric conditions. Further, glass fibers have high tensile strength, heat resistance, moisture resistance, and high thermal conductivity. These properties make glass fiber mats a common choice for insulation of equipment that is exposed to changes in heat and/or humidity, such as HVAC ductwork.
  • the resinous binders that are commonly used to manufacture such duct insulation can substantially alter the ability of the fibrous mat to withstand the environmental fluctuations associated with HVAC applications.
  • HVAC duct work can take many unique configurations, the fibrous mat must balance flexibility and strength, while continuing to provide excellent insulation.
  • a fibrous mat comprising a binder composition with a combination of a thermoset(ting) resin and a thermoplastic resin can provide a nonwoven mat having an enhanced combination of flexibility, strength, and heat/humidity resistance.
  • the binder composition is applied to the nonwoven mat in one or more stages including a first binder composition providing one or more of tensile strength, heat resistance, and hot water resistance, and a second binder composition providing one or more of flexibility and smoothness to the ultimate product.
  • the second binder composition may form a“shell” around the“core” first binder composition.
  • a first binder composition (also referred to as a precursor binder) is applied to a nonwoven mat to form a precursor mat, followed by application of a second binder composition (also referred to as a coating binder), wherein the resin that forms the first binder composition is selected from a thermoset polymer a thermoplastic polymer, and combinations thereof, and wherein, when the first resin comprises a thermoset polymer the second binder resin comprises a thermoplastic polymer and when the first resin comprises a thermoplastic polymer the second binder resin comprises a thermoset polymer.
  • thermosetting material is applied to a nonwoven mat, followed by application of a thermoplastic material.
  • the physical properties of a non-woven fibrous mat are improved by formulating a binder composition combining a binder that provides heat and hot water resistance with a binder that provides enhanced flexibility.
  • a bonded non-woven mat comprising: a nonwoven fiber web; and a binder composition comprising a mixture of a thermoset material and a thermoplastic material.
  • the thermoset material is present in an amount of 5% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 95% by weight of the total binder composition.
  • the bonded non-woven mat has a Gurley stiffness of 500 mg to 2000 mg.
  • a method of forming a bonded non-woven mat comprises providing a fibrous web; applying a precursor binder composition to the fibrous web to form a precursor web, applying a coating binder composition to the precursor web; and allowing the nonwoven mat to cure; wherein the bonded nonwoven mat has a Gurley stiffness of 500 mg to 2000 mg.
  • At least one of the precursor binder and the coating binder is a thermoset material and at least one of the precursor binder and the coating binder is a thermoplastic material.
  • the thermoset material is present in an amount of 5% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 95% by weight of the total binder composition.
  • the first resin comprises a thermoset polymer (material)
  • the second binder resin comprises a thermoplastic polymer (material)
  • the first resin comprises a thermoplastic polymer
  • the second binder resin comprises a thermoset polymer.
  • Figure 1 shows an illustration of a core/shell binder combination, in principle.
  • surface modifier and “modifying agent” are used interchangeably and refer to a chemical agent applied to the surface of a glass fiber in the absence of a binder.
  • the surface modifier is provided generally to protect the surface of the glass from unwanted physical and/or chemical interaction.
  • binder formulation refers to a combination of a first binder resin and a second binder resin, according to the general inventive concepts. In certain embodiments, the term refers to the total binders including thermoset (one or more) resin(s) and thermoplastic (one or more) resin(s).
  • thermoplastic material refers to resins or binders that, after curing, become pliable or moldable when heated above a certain temperature. Suitable thermoplastic resins for use according to the general inventive concepts include those having a glass transition temperature of -30 °C to 40 °C.
  • thermoplastic material provides the softness needed for flexible mats.
  • thermoset material refers to resins or resins or binders that are irreversibly hardened by curing.
  • suitable resins include: acrylic resins, Joncryl 540, Joncryl 1540, Luhydran A 848 S, Acordur 950L, Acrodur DS3515 from BASF; Aquaset 100 , QR-1629S from Dow chemical.
  • a fibrous mat also called a bonded fibrous mat
  • a binder formulation with a combination of thermoplastic resin(s) and thermosetting resin(s) can provide a nonwoven mat having an enhanced combination of flexibility, strength, and heat/humidity resistance.
  • the binder composition is applied to the nonwoven mat in one or more stages. When applied in stages, the second binder composition may form a“shell” around the“core” first binder composition.
  • the general inventive concepts relate to a flexible non-woven fibrous mat (generally, the non-woven mat) with improved properties.
  • the flexible non-woven mat demonstrates improved mechanical strength, such as high tensile strength, while also showing improved flexibility and smoothness.
  • the softness and flexibility of the inventive non-woven mats facilitate its use in duct board (e.g., HVAC) and related applications.
  • the glass fibers used to form the inventive mats may be made of any suitable raw materials.
  • the glass fibers may be produced from a variety of natural minerals or manufactured chemicals such as silica sand, limestone, and soda ash. Other ingredients may include calcined alumina, borax, feldspar, nepheline syenite, magnesite, and kaolin clay.
  • the method of forming the fibers from the raw glass material (fiberization) is generally known in the art. The fibers once formed, may be pulverized, cut, chopped or broken into suitable lengths for various applications.
  • the fibrous mats according to the general inventive concepts may take a variety of forms according to their intended use.
  • the fibrous mats may comprise only one type of fiber.
  • the fibrous mat according to the general inventive concepts is formed with a mixture of two types of fiber, including glass fibers.
  • the fibrous mat is formed by a combination of fiberglass having a diameter of 12-14 micron and a fiberglass having a diameter of 9-11 microns.
  • the fibrous mat is formed by a combination of fiberglass having a diameter of 13 microns and a fiberglass having a diameter of 9-11 microns.
  • the fibrous mat is formed by a combination of fiberglass having a diameter of 12-14 micron and a fiberglass having a diameter of 11 microns. In certain exemplary embodiments, the fibrous mat is formed by a combination of fiberglass having a diameter of 12-14 micron and a fiberglass having a diameter of 10 microns. In certain exemplary embodiments, the fibrous mat may comprise the combination of fiberglass in a ratio of 10: 1 to 1 : 10 by weight, including a ratio of about 1 : 1 by weight.
  • the flexible non-woven mats of the present invention may comprise a plurality of fibers, including any of glass fibers, synthetic fibers, or a blend thereof.
  • the mats include only glass fibers.
  • the glass fibers can be made from any type of glass. Examples of glass fibers include A-type glass fibers, C-type glass fibers, E-type glass fibers, S-type glass fibers, ECR-type glass fibers (e.g., Advantex ® glass fibers commercially available from Owens Corning), Hiper-tex TM , wool glass fibers, and combinations thereof.
  • the use of other reinforcing fibers such as mineral fibers, carbon fibers, ceramic fibers, natural fibers (e.g., cellulosic), and/or synthetic fibers in the non- woven mat is also considered to be within the purview of the general inventive concepts.
  • the glass fibers may be formed by conventional methods known to those skilled in the art.
  • the glass fibers may be formed by a continuous manufacturing process in which molten glass passes through the holes of a“bushing,” the streams of molten glass thereby formed are solidified into filaments, and the filaments are combined together to form a fiber,“roving,”“strand,” or the like.
  • an aqueous sizing composition (also referred to as a size) may optionally be applied to the fibers.
  • the sizing composition is not limited, and may be any sizing known to those of skill in the art.
  • Generally sizing compositions contain a lubricant to protect the fibers from damage by abrasion.
  • the sizing composition may be applied by conventional methods such as by an application roller or by spraying the size directly onto the fibers.
  • the size protects the glass fibers from breakage during subsequent processing, helps to retard interfilament abrasion, ensures the integrity of the strands of glass fibers, promotes the interconnection of the glass filaments that form the strand, etc.
  • the glass fibers may be chopped for subsequent processing into a wet-laid, non-woven mat as described below.
  • the chopped fibers may have a length from about 0.2 to about 2.0 inches, including from about 0.6 to about 1.5 inches.
  • the chopped fibers may have varying lengths from each other within the non-woven mat.
  • first binder composition to form a fiberglass mat (also called a precursor binder composition and the resulting precursor mat) that can then pass to a coating station (the term coating also encompasses impregnation) with a second binder composition (i.e., a coating binder composition) detailed below.
  • a first binder composition also called a precursor binder composition and the resulting precursor mat
  • a second binder composition i.e., a coating binder composition
  • the flexible non-woven mat may be formed by a variety of processes, including dry-laid and wet-laid processes.
  • the non-woven mat is formed by a wet-laid process, which involves forming an aqueous dispersion or slurry of discrete fibers in a mix tank filled with various components (sometimes referred to as white water), such as water, surfactants, viscosity modifiers, defoaming agents, lubricants, biocides, and/or other chemical agents, along with agitation, to form a glass fiber slurry. It is desirable that the slurry is agitated sufficiently to provide a uniform or nearly uniform dispersion of fibers.
  • the aqueous fiber dispersion or slurry may then be processed into a wet-laid mat according to any number of conventional methods known in the art.
  • the aqueous fiber slurry is deposited onto a moving screen or conveyor, on which the majority of the water drains through, leaving a randomly oriented fiber web.
  • the fiber web may be further dried by a vacuum slot or other drying means to provide a fiber web.
  • a first binder composition (also referred to herein as a precursor binder) may then be applied to the fiber web in a conventional manner, such as by curtain coating, spraying, a twin wire dip bath, a two roll padder, and the like. Water, excess binder, and excess coupling agent may then be removed by a vacuum or other water removal means.
  • the precursor composition also includes a mixture of components that impart additional functional and/or aesthetic features to the final fibrous mat. These include pigments, flame retardants, fillers, etc.
  • the binder-coated fiber web or mat may be dried and allowed to cure. In certain instances, the binder is cured by means of an oven. This dried and cured fibrous mat is referred to herein as a precursor mat.
  • the first binder composition comprises only one binder resin.
  • the first binder composition may comprise more than one type of binder resin (e.g., both a thermosetting resin and a thermoplastic resin, or more than one thermosetting resin).
  • the precursor binder composition comprises a thermoset material and a thermoplastic material in a ratio of 5: 1 to 1 :5 by weight, including a ratio of 2: 1 to 1 :2.
  • the precursor binder composition is present in the bonded fibrous mat in an amount of 2 g/m 2 to 6 g/m 2 .
  • the precursor binder composition is present in the bonded fibrous mat in an amount of 2.5 g/m 2 to 5 g/m 2 . In certain exemplary embodiments, the precursor binder composition is present in the bonded fibrous mat in an amount of 3 g/m 2 to 4 g/m 2 .
  • binder composition that incorporates binder resins with differing functionalities (e.g., thermoset and thermoplastic) may impart improved properties to the bonded fibrous mat.
  • the combination of such properties may allow the non-woven mats to be used in challenging applications, such as applications where exposure to high temperature and humidity are common.
  • a second binder composition (also referred to as a coating binder composition) may then be applied to the precursor mat in an appropriate manner, including a process similar to that discussed for the first binder composition.
  • the coating is a mixture of components that impart additional functional and/or aesthetic features to the final fibrous mat. These include pigments, flame retardants, viscosity modifiers (for improved application of the coating), biocides, etc, and generally include an additional adhesive or binder to adhere the impregnation components to the mat.
  • One form of a coating composition is an impregnation.
  • the second binder composition comprises only one binder resin.
  • the second binder composition may comprise more than one binder resin (e.g., both a thermosetting binder and a thermoplastic resin, or more than one thermosetting binder).
  • the coating binder composition is present in the bonded fibrous mat in an amount of 2 g/m 2 to 8 g/m 2 .
  • the coating binder composition is present in the bonded fibrous mat in an amount of 3 g/m 2 to 6 g/m 2 .
  • the coating binder composition is present in the bonded fibrous mat in an amount of 3.5 g/m 2 to 5.5 g/m 2 .
  • the binder formulation is formulated such that once the binder is cured, it is able to impart enhanced mechanical strength (e.g., total tensile strength), coupled with excellent flexibility (e.g., Gurley stiffness of less than 2000 mg), among other desirable properties.
  • enhanced mechanical strength e.g., total tensile strength
  • excellent flexibility e.g., Gurley stiffness of less than 2000 mg
  • the general inventive concepts are based, in part, on the discovery that the enhanced combination of flexibility and strength may be attained by tuning the amount of thermoplastic material (i.e., coating or impregnation binder) relative to thermoset material (e.g., precursor binder). While not wishing to be bound by theory, it is believed that the thermoset resin provides excellent stiffness and heat resistance, while the thermoplastic resin provides flexibility and smoothness.
  • the binder formulation comprises a mixture of a thermoset material and a thermoplastic material, wherein the thermoplastic material is present in an amount of greater than 50% of the total binder formulation.
  • the binder formulation comprises a mixture of a thermoset material and a thermoplastic material, wherein the thermoset material is present in an amount of 5% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 95% by weight of the total binder formulation.
  • the binder formulation comprises a thermoset material in an amount of 10% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 90% by weight of the total binder formulation.
  • the binder formulation comprises a thermoset material in an amount of 20% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 80% by weight of the total binder formulation. In certain exemplary embodiments, the binder formulation comprises a thermoset material in an amount of 30% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 70% by weight of the total binder formulation. In certain exemplary embodiments, the binder formulation comprises a thermoset material in an amount of 40% to 49% by weight of the total binder formulation and the thermoplastic material is present in an amount of 51% to 60% by weight of the total binder formulation.
  • the thermoset material may comprise, for example, an acrylic material.
  • the acrylic material is Joncryl 540, Joncryl 1540, Luhydran A 848 S, Acordur 950L, Acrodur DS3515 from BASF; Aquaset 100, QR-1629S from Dow chemical.
  • the thermoset material once cured, provides good tensile performance and heat/water resistance helping maintain mat integrity in different applications.
  • the thermoplastic material provides good flexibility and smoothness helping maintain desirable aesthetic and functional characteristics in different applications.
  • the thermoplastic material may include any thermoplastic material having a low Tg (i.e., below 10 °C), for example, below 0°C.
  • the general inventive concepts contemplate a non-woven mat having improved mechanical strength.
  • the flexible non-woven mats have an average tensile strength of at least 70 N/50 mm in the machine direction (MD) and at least 35 N/50mm in the cross direction (CD).
  • the flexible non-woven mats have a machine direction tensile strength of at least 90 N/50mm and a cross-direction tensile strength of at least 54 N/50 mm.
  • the flexible non-woven mats may further have a total tensile strength (machine direction + cross-direction) of at least 105 N/50mm, or at least 23 lb/2 inch.
  • the general inventive concepts contemplate a flexible non-woven mat.
  • the non-woven mats demonstrate a Gurley stiffness of less than 2000 mg, including 500 to 2000, and including 1000 mg to 2000 mg.
  • the binder formulation may optionally include additional components, for example, coupling agents, dyes, oils, fillers, colorants, aqueous dispersions, UV stabilizers, lubricants, biocide, wetting agents, surfactants, viscosity modifiers, and/or antistatic agents.
  • the aqueous dispersions may include antioxidant dispersions, which counter the effects of oxidation by the binder composition due to aging.
  • the binder formulation further includes water to dissolve or disperse the components for application onto the reinforcement fibers Water may be added in an amount sufficient to dilute the aqueous binder composition to a viscosity that is suitable for its application to the fiber web.
  • the bonded fibrous mats of the present invention may have an average thickness of between about 0.25 and 1.00 millimeters, or from about 0.50 to about 0.70 millimeters.
  • the bonded nonwoven fibrous mats according to the general inventive concepts can be formulated to have a variety of properties such as total weight.
  • the bonded non-woven fibrous mat has a total weight of between 30 g/m 2 and 100 g/m 2 .
  • the bonded non-woven fibrous mat has a total weight of between 55 g/m 2 and 75 g/m 2 .
  • the bonded non- woven fibrous mat has a total weight of about 62 g/m 2 .
  • the total weight of glass fibers in the bonded non-woven fibrous mat is between 25 g/m 2 and 80 g/m 2 .
  • the total weight of glass fibers in the bonded non-woven fibrous mat is between 40 g/m 2 and 55 g/m 2 . In certain exemplary embodiments, the total weight of glass fibers in the bonded non-woven fibrous mat is about 48 g/m 2 .
  • incorporación of a soft, but strong binder composition in combination with the proper blend of glass, produces a flexible non-woven mat with an improved combination of flexibility and strength.
  • the flexible non-woven mats may be used in a variety of downstream processes to form a variety of end products.
  • the flexible non-woven mat is used to form a composite product or an insulation board, for example.
  • Non-woven mats were made by a conventional wet laid coating process in which chopped glass fibers, after being deposited onto a moving screen in the form of an aqueous slurry, were coated with an aqueous dispersion of a binder composition (also referred to as a precursor binder) and then dried and cured. All mats were made with 0.75” K fiber (13 micrometer diameter) and cured at 210 °C. The machine direction (MD) and cross direction (CD) tensile strengths of the nonwovens were tested using an Instron machine.
  • MD machine direction
  • CD cross direction
  • Dow 1- TS and Dow 2 - TS are thermosetting resins supplied from Dow Chemical.
  • BASF 1 - TP is thermoplastic resin (Tg 23 °C) supplied by BASF.
  • each mat in Table 1 was made with the same precursor binder weight and glass weight. (Precursor binder weight and glass weight were calculated from base weight and Loss on ignition (LOI)). As shown in Table 1, non-woven mats with 100% thermosetting resin (Sample 1 and Sample 2) showed Gurley stiffness around 1100 mg. To reduce Gurley stiffness, 25% of thermoplastic resin (BASF 1 - TP) was blended with 75% of thermosetting resin (Dow 2 - TS). However, Sample 3 mats with this blended precursor binder option did not show Gurley stiffness reduction.
  • Precursor binder weight and glass weight were calculated from base weight and Loss on ignition (LOI)).
  • LOI Loss on ignition
  • Table 2 shows the results of physical property characteristics for two samples made with thermosetting materials.
  • precursor binder weights were decreased from 4.5 g/m 2 to 3.5 g/m 2 .
  • Dow 1- TS and Dow 2 - TS were used as precursor binder for sample 4 and sample 5, respectively.
  • Gurley stiffness went down with reduction of binder weight.
  • Gurley stiffness reduced from 1101 mg to 758 mg, when binder weight of Dow 2 - TS decreased from 5.0 g/m 2 (Sample 2) to 3.5 g/ m 2 (Sample 5).
  • Tensile strengths were also decreased as expected, due to binder reduction.
  • Example 2 (Samples prepared by lab scale impregnator)
  • Non-woven mat with Dow 2 - TS (Sample 5) in Table 2 served as precursor for the study of impregnation binders.
  • a lab scale impregnator was used in this study.
  • Thermoplastic resins with varying glass transition temperature (Tg) were selected as impregnation formulation (Table 3).
  • Impregnated non-woven veils were dried/cured at 150 C for 3 min.
  • Gurley stiffness values decrease along with Tg of the impregnation resins. This is an important feature. By adjusting the impregnation formulation by varying the Tg of resins, the stiffness of impregnated non-woven veils can be tuned (from 810 to 1625 mgf). Tensile strengths for sample 6 to sample 9 are all higher than sample 5 (precursor non-woven mat with Dow 2 - TS ACR) due to impregnation resins. This suggests that impregnated non- woven veils can be adjusted to designed range of Gurley stiffness and tensile strength by changing types and add-on weights of thermoplastic resins.
  • Example 3 (Samples prepared by production run)
  • thermoset(ting) and thermoplastic materials e.g., resins
  • carbon black and aluminum trihydrate (ATH) were added into mat recipes as colorant and flame retardant, respectively.
  • Colorant and flame retardant can be blend with either precursor binder or impregnation formulation
  • Sample 10 was made in a single-step preparation (no impregnation). To prepare Sample 10, thermoplastic material (Tg 10 °C), carbon black and ATH were blended together as precursor formulation, which applied through wet laid coating process. In sample 11 and sample 12, thermosetting material functionalized as precursor formulation applied to glass fiber by wet laid coating process, while thermoplastic material, colorant and flame retardant are blended together as impregnation formulation, which applied by impregnation process.
  • thermoplastic material Tg 10 °C
  • carbon black and ATH were blended together as precursor formulation, which applied through wet laid coating process.
  • thermosetting material functionalized as precursor formulation applied to glass fiber by wet laid coating process while thermoplastic material, colorant and flame retardant are blended together as impregnation formulation, which applied by impregnation process.
  • Hot-wet tensile test Samples were immerged in 80°C water for 10 min. Take samples out and dry them by paper towel, following by tensile test.
  • Sample 10 (Current version -1)100% thermoplastic material (Tg 10 °C) blended with carbon black and ATH
  • Sample 11 (Current version -2) >50% of thermosetting binder as precursor binder; ⁇ 50% of thermoplastic material (Tg -20 °C) blended with carbon black and ATH
  • Sample 12 (New version) ⁇ 50% of thermosetting binder as precursor binder; >50% of thermoplastic material (Tg -20 °C) blend with carbon black and ATH
  • Sample 10 and Sample 12 showed similar Gurley stiffness (need to control thermosetting material ⁇ 50%, if not, such as Sample 11 showing higher Gurley stiffness).
  • Sample 12 (and Sample 11) showed better performance for hot-dry and hot-wet tensile strengths vs. Sample 10 because of thermosetting material in recipes.
  • the fiberglass compositions, and corresponding manufacturing methods of the present disclosure can comprise, consist of, or consist essentially of the essential elements and limitations of the disclosure as described herein, as well as any additional or optional ingredients, components, or limitations described herein or otherwise useful in fiberglass composition applications.
  • the fiberglass compositions of the present disclosure may also be substantially free of any optional or selected essential ingredient or feature described herein, provided that the remaining fiberglass composition still contains all of the required ingredients or features as described herein.
  • the term“substantially free” means that the selected composition contains less than a functional amount of the optional ingredient, typically less than 0.1% by weight, and also including zero percent by weight of such optional or selected essential ingredient.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Dispersion Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

L'invention concerne un mat fibreux non tissé qui comprend un mélange d'une résine thermodurcissable et d'une résine thermoplastique. Il a été découvert que les propriétés physiques (par exemple, flexibilité, résistance à la traction) d'un mat non tissé peuvent être améliorées en formulant une composition de liant comprenant des rapports variables du matériau thermodurcissable et du matériau thermoplastique. De cette manière, un mat non tissé lié peut être obtenu en ayant une combinaison souhaitable de résistance et de flexibilité, tout en conservant une bonne résistance à la chaleur et à l'eau.
EP20743911.8A 2019-06-28 2020-06-26 Mat non tissé souple Active EP3990687B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201962868211P 2019-06-28 2019-06-28
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CA (1) CA3144982A1 (fr)
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US4255485A (en) * 1979-11-08 1981-03-10 Owens-Corning Fiberglas Corporation Binder for glass fiber mat
JPS5870760A (ja) * 1981-10-15 1983-04-27 旭フアイバ−グラス株式会社 硝子短繊維用バインダ−並びに硝子短繊維マツトの製造方法
JP5961162B2 (ja) * 2011-03-31 2016-08-02 ダイワボウホールディングス株式会社 セパレータ材料及びそれを用いた電池、並びにセパレータ材料用熱接着性複合繊維
EP3058126B1 (fr) * 2013-10-16 2017-09-06 OCV Intellectual Capital, LLC Non-tissé flexible
EP3259790A4 (fr) * 2015-02-19 2019-01-16 Hollingsworth & Vose Company Séparateurs de batteries comprenant des additifs chimiques et/ou d'autres constituants
EP3135649A1 (fr) * 2015-08-28 2017-03-01 Rockwool International A/S Produit de laine minérale
US10252200B2 (en) * 2016-02-17 2019-04-09 Hollingsworth & Vose Company Filter media including a filtration layer comprising synthetic fibers
RU2742893C2 (ru) * 2016-09-06 2021-02-11 ОСВ ИНТЕЛЛЕКЧУАЛ КЭПИТАЛ, ЭлЭлСи Коррозионно-стойкий нетканый материал для трубопровода и применений в пултрузии
CN109056185A (zh) * 2018-08-02 2018-12-21 中材金晶玻纤有限公司 一种可热态连续生产隔音板的玻璃纤维毡、轻质隔音复合板及其制备方法

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FI3990687T3 (fi) 2024-02-06
PL3990687T3 (pl) 2024-04-15
CA3144982A1 (fr) 2020-12-30
EP3990687B1 (fr) 2023-11-15
WO2020264416A1 (fr) 2020-12-30
MX2021015913A (es) 2022-03-22
US20220356618A1 (en) 2022-11-10

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