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Non-woven felt with reduced transmittance and increased caliper size

A non-woven, low-density technology, applied in the field of non-woven mats, can solve the problems of increasing the production cost of non-woven glass mats, increasing costs, increasing the basis weight of non-woven glass mats, etc.

Pending Publication Date: 2022-07-22
OWENS CORNING INTELLECTUAL CAPITAL LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

[0005] However, applying the coating to the nonwoven glass mat requires additional raw materials to form the coating material and additional processing equipment, both of which increase the production cost of the nonwoven glass mat
In addition, the application of the coating increases the basis weight of the nonwoven glass mat, which further increases the costs associated with the coated nonwoven glass mat (e.g., shipping costs)

Method used

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Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0069] In this example, a nonwoven mat according to the invention (Sample Mat 1) and a control nonwoven mat (Control Mat 1) were formed and compared. Both Sample Mat 1 and Control Mat 1 contained a blend of 60 wt % 13 μm glass fibers and 40 wt % 10 μm fibers (based on the total weight of glass fibers). In addition, the basis weight of each of Sample Felt 1 and Control Felt 1 is 1.5 lbs / 100 ft 2 and LOI is 22%. The adhesive composition used to form Sample Mat 1 contained 5% by weight (on a dry basis) of polymeric microspheres (Expancel 551WU40). The adhesive composition used to form Control Felt 1 was otherwise identical to the adhesive composition used to form Sample Felt 1 but did not contain any polymer microspheres. The adhesive compositions used for both Control Felt 1 and Sample Felt 1 were based on QR1629S from Dow Chemical (Philadelphia, PA, USA).

[0070] Sample Felt 1 and Control Felt 1 were tested for air permeability according to ASTM D737—Standard Test Method fo...

Embodiment 2

[0072] In this example, a nonwoven felt according to the invention (Sample Felt 2) and a control nonwoven felt (Control Felt 2) were formed and compared. Both sample mat 2 and control mat 2 contained a blend (percentage) of 60 wt% 13 μm glass fibers (average length 19.05 mm (0.75 in)) and 40 wt % 10 μm fibers (average length 10 mm (0.39 in)) is based on the total weight of glass fibers). Additionally, the basis weight of each of Sample Felt 2 and Control Felt 2 was approximately 1.5 lbs / 100 ft 2 and LOI is about 21%. The adhesive composition used to form Sample Mat 2 contained 10% by weight (on a dry weight basis) of polymeric microspheres (Expancel 551WU40). The adhesive composition used to form Control Felt 2 was otherwise identical to the adhesive composition used to form Sample Felt 2 but did not contain any polymer microspheres. The binder compositions for both Control Felt 2 and Sample Felt 2 were based on QR 1629S from Dow Chemical (Philadelphia, PA, USA) and contain...

Embodiment 3

[0076] In this example, nonwoven mats according to the invention (Sample Felt 3 and Sample Felt 4) and a control nonwoven mat (Control Felt 3) were formed and compared. All mats were formed using 10 μm glass fibers with a length of 10 mm. Additionally, the basis weight of all felts is approximately 1.5lbs / 100ft 2 and LOI is about 24%. The adhesive composition used to form Sample Mat 3 was based on QR1629S from Dow Chemical (Philadelphia, PA, USA) and contained 5 wt% (on a dry basis) of polymeric microspheres (Expancel 551WU40) and 2 wt% (on a dry basis) microfibrillated cellulose fibers. The adhesive composition used to form Sample Felt 4 was the same as Sample Felt 3, but a different grade of polymer microspheres (Expancel 043WU80) was used. The adhesive composition used to form Control Felt 3 was otherwise identical to the adhesive composition used to form Sample Felts 3 and 4 but did not contain any polymer microspheres.

[0077] The caliper dimensions of each felt were...

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PUM

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Abstract

A non-woven mat and a method of making a non-woven mat are provided. The non-woven felt comprises reinforcing fibers and a binder composition comprising a polycarboxylic polymer and polymeric microspheres. The binder composition may also include low density fibers, such as microfibrillated cellulosic fibers. The polymeric microspheres have a thermoplastic shell encapsulating a blowing agent. The thermoplastic shell has magnesium hydroxide on its outer surface. The components of the adhesive composition interact with each other and / or with the reinforcing fibers to form a non-woven mat with fewer permeable structures and higher caliper sizes.

Description

[0001] Cross-referenced related applications [0002] This application claims priority to and the entire benefit of US Provisional Patent Application 62 / 946,464, filed December 11, 2019, the entire contents of which are incorporated herein by reference. technical field [0003] The present invention relates to nonwoven mats, and more particularly to nonwoven mats having less permeable structure and higher caliper size, which are components present in the binder compositions used to form the nonwoven mats the result of the interaction. The nonwoven felt can be used in a variety of applications and products, such as as a facing for gypsum board, office wallboard and / or polyisocyanurate foam board. Background technique [0004] Glass nonwovens (eg, mats, curtains, nets) are used in a variety of applications. For example, nonwoven glass mats are used as facings for gypsum boards and polyisocyanurate ("polyiso") boards. One problem associated with the use of nonwoven glass mat...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): D04H1/587C08K5/00C08K7/22C08K9/10C08L33/00E04B1/74E04C2/26D04H1/64D04H1/4218B32B5/02B32B5/24C08K3/22
CPCD04H1/587D04H1/64D04H1/4218B32B5/022B32B5/245B32B13/14B32B2262/101B32B2262/108B32B2262/105B32B2262/02B32B2260/021B32B2260/046B32B2419/00C08L33/04C08K3/20C08K7/10C08L2205/18D04H1/4242D10B2101/06D10B2101/08D10B2101/12
Inventor 吴剑辉
Owner OWENS CORNING INTELLECTUAL CAPITAL LLC