Two-part sizing composition for reinforcement fibers

a technology of sizing composition and reinforcement fiber, which is applied in the direction of fibre treatment, textiles and papermaking, transportation and packaging, etc., to achieve the effects of improving hydrolysis resistance, high loss-on-ignition (loi), and improving mechanical properties of dry as-molded

Inactive Publication Date: 2007-07-05
OCV INTELLECTUAL CAPITAL LLC
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  • Summary
  • Abstract
  • Description
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AI Technical Summary

Benefits of technology

[0011] It is an advantage of the present invention that a high loss-on-ignition (LOI) of the high acid number maleic anhydride copolymer, ethylene maleic acid copolymer, or polycarboxylic acid in the sizing composition provides for improved dry-as-molded mechanical properties and improved hydrolysis resistance.
[0012] It is another advantage of the present invention that polyurethane film formers present in the sizing composition demonstrate good compatibility with polyamide matrices, which helps to improve the dispersion of the reinforcement fiber bundles in the melt (e.g., in extrusion process or injection molding process) when forming a composite article. This increased fiber dispersion may cause a reduction of defects such as visual defects in the final product, a reduction in processing breaks, and / or low mechanical properties in the final article.
[0013] It is a further advantage of the present invention that the polyurethane dispersion present in the sizing composition improves the compatibility of the sizing composition with the di-cationic species containing polymer to improve the dispersion of the fibers during further processing to form a composite article.
[0014] It is yet another advantage that the present invention imparts improved physical properties such as improved dry-as-molded (DaM) mechanical properties of the composite part or after aging the composite part in severe hydrolysis conditions to composites formed from industrially processable and easily dispersible pellets.
[0015] It is also an advantage of the present invention that the two-part sizing formulation has improved stability over conventional sizing formulations that contain an aminosilane and a polyacid in the same mixture.
[0016] The foregoing and other objects, features, and advantages of the invention will appear more fully hereinafter from a consideration of the detailed description that follows.

Problems solved by technology

In addition, applying the binder composition separately from the size composition outside the fiber-forming environment permits the inclusion of materials that are not desirably applied during the fiber-forming process because of safety, flammability, irritation, stability, low compatibility with aminosilanes, viscosity, toxicity, cleanliness, odor, cost, and / or shear sensitivity.

Method used

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  • Two-part sizing composition for reinforcement fibers
  • Two-part sizing composition for reinforcement fibers
  • Two-part sizing composition for reinforcement fibers

Examples

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examples

[0079] Two-Part Sizing Formulations

TABLE 2Ex.Ex.Ex. 1Ex. 2Ex. 3Ex. 4Ex. 5Ex. 6Ex. 7Ex. 8Ex. 91011Size CompositionAX-1100 Silane(a)0.070.070.070.040.040.040.040.040.070.060.06Lubesize K-12(b)0.02Zonyl FS-300(c)0.005Baybond PU403(d)0.310.310.310.310.18Witcobond 296B(e)0.530.530.53Baybond XP-2602(f)0.160.16Binder CompositionGlascol E5(g)0.280.400.650.950.14Glascol C95(h)0.040.12ZeMac E400(i)0.300.240.470.38ZeMac E60(j)0.40AmmoniaBaybond PU-403(d)0.40Baybond XP-2602(e)0.21Aquathane 518(k)0.19AX-1100 Silane(a)0.02Jeffamine ED2003(l)0.09Pluronic F-77(m)0.0008Pluronic PE-103(n)0.0022Pluronic L-101(o)0.0009Triton X-100(p)0.0022Polyacid LOI0.000.280.300.000.400.650.950.280.610.400.50Total LOI (%)0.600.880.900.750.750.951.300.650.860.830.72

(a)AX-1100 Silane γ-aminopropyltriethoxysilane (GE Silicones)

(b)K12 Lubesize tetraethylenepentamine reacted with stearic acid (AOC)

(c)Zonyl FS-300 fluoroalkyl alcohol substituted polyethylene glycol (DuPont)

(d)Baybond PU-403 blocked isocyanate polyuret...

preparation of examples 1-3

of Table 2

[0081] In Examples 1-3, the components of Table 3 were mixed to prepare the size composition. The size composition was applied to 10 μm Advantex® glass fibers to achieve a strand Loss-On-Ignition (LOI) of 0.60% on the glass fibers. A conventional loss on ignition (LOI) method, ASTM 2854, was used to determine how much of the applied size composition was on the glass fibers. The glass fibers were then collected into a strand and chopped wet in-line by a chopper into segments of approximately 4 mm in length.

TABLE 3ComponentAmount of ComponentWitcobond 296B(a) 78.4 kg as received in 400 L of deionized waterAX-1100 Silane(b)19.91 kg as received in 500 L of deionized waterDeionized Waterto 1000 L

(a)blocked polyurethane dispersion (Baxenden Chemicals)

(b)γ-aminopropyltriethoxysilane (GE Silicones)

[0082] The chopped segments were then collected and approximately 1-2 days later treated under rotation in a lab pelletizer where the corresponding binder set forth in Table 2 was sp...

preparation of examples 4-7

of Table 2

[0083] In Examples 4-7, the components of Table 4 were mixed to prepare the size composition. The size composition was applied to 10 μm Advantex® glass fibers to achieve a strand Loss-On-Ignition (LOI) of 0.35% on the glass fibers. A conventional loss on ignition (LOI) method, ASTM 2854, was used to determine how much of the applied size composition was on the glass fibers. The glass fibers were then collected into a strand and chopped wet in-line by a chopper into segments of approximately 4 mm in length.

TABLE 4ComponentAmount of ComponentBaybond PU-403(a)160.20 kg as received in 450 L of deionized waterAX-1100 Silane(b) 14.5 kg as received hydrolyzed in 65 L ofdeionized waterDeionized Waterto 1400 L

(a)blocked isocyanate polyurethane dispersion (Bayer Corp.)

(b)γ-aminopropyltriethoxysilane (GE Silicones)

[0084] The chopped segments were then collected and approximately 1-2 days later treated under rotation in a lab pelletizer where the corresponding binder set forth in ...

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Abstract

A two-part sizing formulation that imparts improved strength of reinforced composites including a size composition and a binder composition is provided. The size composition may include one or more coupling agents and one or more film forming agents. The binder composition includes a high acid number copolymer formed from the polymerization of maleic anhydride or maleic acid and at least one other desired monomer and / or a high acid number polycarboxylic acid. In a preferred embodiment, the binder composition includes an ethylene-maleic acid copolymer formed by the hydrolysis of an ethylene-maleic anhydride copolymer. The size composition may be applied to a reinforcing fiber material before the binder size material is applied. The two-part size composition may be applied to a reinforcing fiber material to form a reinforcing fiber product which may then be densified or compacted to form a densified reinforcing fiber product, such as a pellet.

Description

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION [0001] The present invention relates generally to a sizing composition for a reinforcing fiber material, and more particularly, to a two-part sizing formulation that imparts improved strength to reinforced composites which includes a size composition and a binder composition. A composite article formed from a reinforcing fiber material sized with a two-part sizing formulation is also provided. BACKGROUND OF THE INVENTION [0002] Glass fibers are useful in a variety of technologies. For example, glass fibers are commonly used as reinforcements in polymer matrices to form glass fiber reinforced plastics or composites. Glass fibers have been used in the form of continuous or chopped filaments, strands, rovings, woven fabrics, nonwoven fabrics, meshes, and scrims to reinforce polymers. It is known in the art that glass fiber reinforced polymer composites possess higher mechanical properties compared to unreinforced polymer com...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D04H1/00
CPCC03C25/285C03C25/50C08L77/00D06M13/192D06M15/263C08L2666/04Y10T428/249924C03C25/24C03C25/28
Inventor COSSEMENT, MARC R.HENRION, JEAN-MARC P.
Owner OCV INTELLECTUAL CAPITAL LLC
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