Ceiling paneling

Abstract

A method for forming rotating fibers (e.g., glass fibers) with a more uniform or constrained distribution of fiber diameter and / or length is disclosed. Rotating fibers with an improved property distribution across the fiber volume facilitate the formation of improved nonwoven fiber mats and products formed from these mats (e.g., ceiling panel finishes). Ceiling panel finishes can have fewer visual defects due to the more uniform / consistent nonwoven mat.

Description

[0001] Cross-references to related applications

[0002] This application claims priority and any benefit to International Application No. PCT / US2023 / 084218, filed on December 15, 2023, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] The general concept of the present invention relates to apparatus and methods for fiberizing mineral fibers (such as glass fibers) from molten mineral materials using a rotary process, as well as articles relating to the fibers themselves and the fibers bonded together. Background Technology

[0004] The production of mineral fibers, such as glass fibers, via a rotary process is well known. See, for example, U.S. Patents 5,582,841; 7,856,853; 8,087,265; and 8,250,884, the entire disclosures of which are incorporated herein by reference. In such processes, molten glass is fed at high temperature into a metal rotator rotating at high speed. The rotator has a peripheral wall containing multiple orifices. The molten glass flows through the orifices by centrifugal force, forming a small-diameter stream of molten glass. The stream is directed downward toward a collection surface by an annular blower surrounding the rotator. The airflow generated by the blower fines the molten glass stream to an even finer diameter and cools the stream to form glass fibers. An annular burner is also positioned around the rotator, and combustion gases and heat from the burner are directed downward to provide a fiber-refining environment suitable for allowing the initial glass stream to be fined to the desired final diameter. The downward annular flow of hot gas facilitates the refining of the molten mineral material flow into mineral fibers by the blower, and also keeps the rotator at a temperature suitable for fiberization.

[0005] As an example, such as Figure 1 As shown, the fiber manufacturing apparatus or fiber generator 10 includes a centrifuge or rotator 12 fixed to a rotatable hollow shaft or mandrel 14. Specifically, the rotator 12 is fixed to a hub 54 of a sleeve 64 at the lower end of the rotatable shaft or mandrel 14. Rotating the rotator 12 by rotating the mandrel 14 is known in the art. The rotator 12 includes a base 16 extending from the hub 54 to a peripheral wall 18. A plurality of holes 20 are provided around the outer periphery of the peripheral wall 18 for centrifuging fibers 22 of a molten material (e.g., glass).

[0006] Molten glass stream 78 is supplied to the rotator 12. Conventional supply equipment 82 can be used to supply molten glass stream 78. Such molten glass supply equipment is well known in industry and will not be discussed in detail herein. The glass in stream 78 falls into chamber 42 of rotator 12 and is guided by centripetal force against the peripheral wall 18 and flows outward to form a glass deposit or head 90. The glass then flows through orifice 20 to form primary fibers 22, which are heated and stretched by burner 24 and annular blower 28.

[0007] Rotation of rotator 12 (e.g.) Figure 1 (As depicted by the circular arrow (a)) the molten glass is centrifuged through holes 20 in the rotator's peripheral wall 18 to form primary fibers 22. The primary fibers 22 are kept in a soft, available state by the heat from the annular burner 24. An annular blower 28 uses guided air through channels 30 to draw the primary fibers 22 and further refine them into secondary fibers 32 suitable for products such as wool insulation. The secondary fibers 32 are then collected on a conveyor (not shown) to form products such as glass wool bundles.

[0008] The hollow sleeve 64 is pressure-fitted into a drilled hole formed through the center of the hub 54 and locked in place by three circumferentially spaced locking pins 66. The upper end of the sleeve 64 is threaded into the lower end of the hollow tie rod 68. Preferably, the sleeve 64 is further cooled by water, which circulates through an annular cooling jacket 70 disposed around the mandrel 14 and the sleeve 64 and located above the hub 54. The sleeve 64 and the hub 54 are preferably made of a low thermal expansion alloy to minimize the difference in thermal expansion between them.

[0009] The radiation shield 52 may include multiple individual plates 52a, 52b, 52c. The plates may be connected to the hub 54 of the sleeve 64. The plates suppress convection from the base of the rotator and suppress the escape of infrared energy from the base of the rotator 12, and reduce the thermal gradient along the height of the peripheral sidewall 18, thereby suppressing devitrification within the glass head 90 and controlling the temperature of the glass as it passes through the aperture 20 at the lower edge of the peripheral sidewall 18. The uppermost shield 52a is preferably frustoconical to conform to the bottom wall 16 of the rotator 12. The lower shields 52b, 52c may be frustoconical or planar to allow space between the shields. The shield 52 may be formed of stainless steel or a refractory metal, such as Hastelloy alloy, a high-temperature alloy based on the transition metal nickel. A particularly suitable material for the shield is Hastelloy X alloy, which is available from Haines International (Kokomo, Indiana (USA)). HASTELLOY X alloy contains 47 wt% Ni, 22 wt% Cr, 18 wt% Fe, 9 wt% Mo, 1.5 wt% W, 0.1 wt% C, 1 wt% Mn (max), 1 wt% Si (max) and 0.008 wt% B (max).

[0010] The rotator 12 is clamped to the hub 54 (at the lower end of the mandrel 14) on the sleeve 64 by clamping ring 55. The sleeve disc 67 can be located below the radiant shield 52 to provide a stable flow pattern for the airflow containing the refined fibers. In this way, a more stable "veil" (i.e., annular flow of fibers and air downwards away from the rotator 12) is maintained. The sleeve disc 67 can have any shape sufficient to cover the bottom of the rotator 12 and a considerable portion of the radiant shield 52. Similar to the rotator 12, the sleeve disc 67 can be mounted on the hub 54.

[0011] Despite these (and other) advances in rotator technology, reliably and consistently forming glass fibers with desired fiber diameters and / or lengths via rotational forming processes remains a challenge. By way of example, the fiber diameter distributions of various conventional rotationally formed glass fibers are shown in... Figures 2A to 2D In addition, Figure 2E shows the fiber diameter distribution of a conventional non-rotationally formed glass fiber to illustrate that an undesirable wide (constant volume) fiber diameter distribution typically does not occur in the case of composite (i.e., stencil formed) glass fibers.

[0012] exist Figure 2A Figure 210 shows a graph illustrating the fiber diameter distribution of commercially available unbonded loosely filled (ULF) glass fiber materials. ULF fibers are rotationally shaped fibers that are not typically held together by adhesives. ULF fibers are commonly used in building insulation applications.

[0013] Referring to Figure 210, Table 1 shows various properties of this first ULF material.

[0014]

[0015] Table 1

[0016] In Table 1, “Peak Index” refers to the peak identifier from left to right, where peaks are shown with dashed lines; “Peak Type” refers to the type of model used to fit the data; “Area Intg” refers to the integral area of ​​the fitted peak; “Area IntgP” refers to the percentage of the total integral area of ​​each fitted peak; “Center Grvty” refers to the center of the fitted peak; “Maximum Height” refers to the maximum value of the fitted peak; and “FWHM” refers to the width of the peak at half its maximum height.

[0017] exist Figure 2A In graph 210, rotating fibers with a target diameter of approximately 3.1 μm are produced, as measured using a known airflow method. Graph 210 represents the fiber diameter distribution measured and plotted as a percentage of fiber volume using a method conforming to ISO 13322-2. The data measured according to the ISO 13322-2 method (Camsizer) was analyzed using Peak Deconvolution App (v2.00) and OriginPro 2023 (constant baseline; fitting until convergence to obtain displayed results). OriginPro 2023 is data analysis software sold by OriginLab Corp. (Northampton, Massachusetts).

[0018] Ideally, 100% of the produced fibers would have a fiber diameter of approximately 3.1 μm. However, rotary fiber production is a complex process with many variables, only a few of which can be controlled. Therefore, the fiber diameter distribution (i.e., the area under the graph) shows that a large number of fibers have a diameter greater than 3.1 μm, with some fibers measured to have diameters approaching 25 μm. This wide variation in fiber diameter (e.g., from approximately 1 μm to approximately 25 μm) (where most fibers have a diameter greater than 6 μm) is less than ideal for a target fiber diameter of 3.1 μm. In other words, for many applications, reducing the variation in fiber diameter relative to the target fiber diameter and / or increasing the volume of fibers with diameters closer to the target fiber diameter can result in improved products / applications using the fiber.

[0019] exist Figure 2BFigure 220 shows a graph illustrating the fiber diameter distribution of another commercially available unbonded loosely filled (ULF) glass fiber material. ULF fibers are rotationally shaped fibers that are not typically held together by adhesives. ULF fibers are commonly used in building insulation applications.

[0020] Referring to Figure 220, Table 2 shows various properties of this second ULF material.

[0021]

[0022] Table 2

[0023] In Table 2, “Peak Index” refers to the peak identifier from left to right, where peaks are shown with dashed lines; “Peak Type” refers to the type of model used to fit the data; “Area Intg” refers to the integral area of ​​the fitted peak; “Area IntgP” refers to the percentage of the total integral area of ​​each fitted peak; “Center Grvty” refers to the center of the fitted peak; “Maximum Height” refers to the maximum value of the fitted peak; and “FWHM” refers to the width of the peak at half its maximum height.

[0024] exist Figure 2B In plot 220, as measured using a known airflow method, the rotating fibers were measured to have an effective fiber diameter between 2.8 μm and 3 μm. Plot 220 represents the fiber diameter distribution when measured using a method conforming to ISO 13322-2 and plotted as a percentage of fiber volume. The data measured according to the ISO 13322-2 method (Camsizer) was analyzed using Peak Deconvolution App (v2.00) and OriginPro 2023 (constant baseline; fit until convergence to obtain displayed results). OriginPro 2023 is data analysis software sold by OriginLab Corp. (Northampton, Massachusetts).

[0025] Ideally, 100% of the produced fibers would have a fiber diameter within this effective range. However, rotary fiber production is a complex process with many variables, some of which can be controlled. Therefore, the fiber diameter distribution (i.e., the area under the graph) shows that a large number of fibers have diameters greater than this range (i.e., much greater than 3µm), with some fibers measured to have diameters close to 24µm. This wide variation in fiber diameter (e.g., from about 1µm to about 24µm) (where most fibers have a diameter greater than 6µm) is less than ideal for a target fiber diameter of 2.9µm (i.e., between 2.8µm and 3µm). In other words, for many applications, reducing the variation in fiber diameter relative to the target fiber diameter and / or increasing the volume of fibers with diameters closer to the target fiber diameter can result in improved products / applications using the fiber.

[0026] exist Figure 2C Figure 230 shows the fiber diameter distribution of another commercially available unbonded loosely filled (ULF) glass fiber material. ULF fibers are rotationally shaped fibers that are not typically held together by adhesives. ULF fibers are commonly used in building insulation applications.

[0027] Referring to Figure 230, Table 3 shows the various properties of this third ULF material.

[0028]

[0029] Table 3

[0030] In Table 3, “Peak Index” refers to the peak identifier from left to right, where peaks are shown with dashed lines; “Peak Type” refers to the type of model used to fit the data; “Area Intg” refers to the integral area of ​​the fitted peak; “Area IntgP” refers to the percentage of the total integral area of ​​each fitted peak; “Center Grvty” refers to the center of the fitted peak; “Maximum Height” refers to the maximum value of the fitted peak; and “FWHM” refers to the width of the peak at half its maximum height.

[0031] exist Figure 2CIn plot 230, as measured using a known airflow method, the rotating fibers were measured to have an effective fiber diameter between 2.8 μm and 3 μm. Plot 230 represents the fiber diameter distribution when measured using a method conforming to ISO 13322-2 and plotted as a percentage of fiber volume. The data measured according to the ISO 13322-2 method (Camsizer) was analyzed using Peak Deconvolution App (v2.00) and OriginPro 2023 (constant baseline; fit until convergence to obtain displayed results). OriginPro 2023 is data analysis software sold by OriginLab Corp. (Northampton, Massachusetts).

[0032] Ideally, 100% of the produced fibers would have a fiber diameter within this effective range. However, rotary fiber production is a complex process with many variables, some of which can be controlled. Therefore, the fiber diameter distribution (i.e., the area under the graph) shows that a large number of fibers have diameters greater than this range (i.e., much greater than 3µm), with some fibers measured to have diameters of 25µm or greater. This wide variation in fiber diameter (e.g., from about 1µm to about 25µm) (where most fibers have a diameter greater than 6µm) is less than ideal for a target fiber diameter of 2.9µm (i.e., between 2.8µm and 3µm). In other words, for many applications, reducing the variation in fiber diameter relative to the target fiber diameter and / or increasing the volume of fibers with diameters closer to the target fiber diameter can result in improved products / applications using the fiber.

[0033] exist Figure 2D Figure 240 shows a graph 240 illustrating the fiber diameter distribution of a commercially available specialty material in the form of chopped glass microfibers. These specialty glass fibers are rotationally shaped fibers that are chopped to shorten their length. The specialty glass fibers are not held together by adhesives. These specialty glass fibers can be used as reinforcing agents or filler materials.

[0034] Referring to Figure 240, Table 4 shows the various properties of this special glass fiber material.

[0035]

[0036] Table 4

[0037] In Table 4, “Peak Index” refers to the peak identifier from left to right, where peaks are shown with dashed lines; “Peak Type” refers to the type of model used to fit the data; “Area Intg” refers to the integral area of ​​the fitted peak; “Area IntgP” refers to the percentage of the total integral area of ​​each fitted peak; “Center Grvty” refers to the center of the fitted peak; “Maximum Height” refers to the maximum value of the fitted peak; and “FWHM” refers to the width of the peak at half its maximum height.

[0038] exist Figure 2D In plot 240, the swirled fibers were marketed as having an effective fiber diameter of approximately 3.2 μm. Plot 240 represents the fiber diameter distribution measured using a method conforming to ISO 13322-2 and plotted as a percentage of fiber volume. The data measured according to the ISO 13322-2 method (Camsizer) was analyzed using Peak Deconvolution App (v2.00) and OriginPro 2023 (constant baseline; fit until convergence to obtain displayed results). OriginPro 2023 is data analysis software sold by OriginLab Corp. (Northampton, Massachusetts).

[0039] Ideally, 100% of the produced fibers would have a fiber diameter of approximately 3.2 μm. However, rotary fiber production is a complex process with many variables, only a few of which can be controlled. Therefore, the fiber diameter distribution (i.e., the area under the graph) shows that a large number of fibers have a diameter greater than 3.2 μm, with some fibers measured to have diameters approaching 24 μm. This wide variation in fiber diameter (e.g., from approximately 1 μm to approximately 24 μm) (where most fibers have a diameter greater than 5 μm) is less than ideal for a target fiber diameter of 3.2 μm. In other words, for many applications, reducing the variation in fiber diameter relative to the target fiber diameter and / or increasing the volume of fibers with diameters closer to the target fiber diameter can result in improved products / applications using the fiber.

[0040] As described above, Figure 2E shows a graph 250 illustrating the fiber diameter distribution of conventionally prepared wet-cut chopped strands (WUCS) glass fiber material. WUCS fibers are chopped from longer, non-rotationally formed (i.e., composite) glass fibers with a target diameter of 3.5 μm. These composite fibers are drawn / extracted from molten glass flowing through holes formed in the bottom side of a fixed stencil. Therefore, such composite fibers do not suffer from the wide fiber diameter variation problem described herein. The composite fibers shown in graph 250 have the following values: d10 = 3.70 µm; d50 (median) = 4.32 µm; d90 = 5.11 µm; mean = 4.40 µm; and standard deviation = 0.72 µm.

[0041] In view of the above, there is an unmet need for a rotary fiber production method capable of producing glass fibers with improved fiber diameter and / or length distribution, a collection of fibers with improved distribution, and products / applications using said fibers. Summary of the Invention

[0042] In view of the above, modifications to the rotatable fiber forming process allow for the production of fibers with a more uniform fiber diameter and / or length distribution. The general concept of the present invention includes this new method for producing rotatable fibers, the new rotatable fibers themselves, adhesive formulations suitable for the new rotatable fibers, packaging of the rotatable fibers (e.g., with improved fiber distribution), nonwoven mats made from the new rotatable fibers, and downstream applications of the mats (e.g., ceiling panel finishes).

[0043] In one exemplary embodiment, a method for manufacturing mineral fibers is disclosed. The method includes: rotating a rotator having a peripheral wall including a plurality of holes; supplying molten mineral material to the rotating rotator to centrifuge the molten mineral material stream through the holes; mixing combustion air and combustion gas and supplying the mixture to an annular burner positioned around the rotator; generating an annular guide airflow in a channel positioned between the annular burner and an annular blower; directing the hot gas and the annular guide airflow from the annular burner toward the rotator and the molten mineral material stream to heat the rotator and refine the molten mineral material stream into multiple mineral fibers; and directing a source of cooling air through a hollow sleeve extending through the rotator to a sleeve disk positioned below the rotator, wherein the cooling air is delivered to the sleeve disk at a rate of about 30 cubic feet per minute to about 60 cubic feet per minute.

[0044] In some exemplary embodiments, the sleeve plate is cooled to a temperature below 750℉.

[0045] In some exemplary embodiments, the method further includes controlling the rotator to rotate at a rate of about 900 rpm to about 2,400 rpm. In some exemplary embodiments, the method further includes controlling the rotator to rotate at a rate of about 1,800 rpm to about 2,400 rpm.

[0046] In some exemplary embodiments, hot gas from the annular burner is directed toward the rotator and the flow of molten mineral material at a rate of about 240 cubic feet per minute to about 300 cubic feet per minute.

[0047] In some exemplary embodiments, the annular blower outputs approximately 410 cubic feet per minute of air to generate an annular guide airflow.

[0048] In some exemplary embodiments, the mineral fiber is glass fiber.

[0049] In some exemplary embodiments, the mineral fibers have an average diameter of less than 6 µm. In some exemplary embodiments, the mineral fibers have an average diameter of less than 5 µm. In some exemplary embodiments, the mineral fibers have an average diameter of less than 4 µm. In some exemplary embodiments, the mineral fibers have an average diameter of less than 3 µm.

[0050] In some exemplary embodiments, the mineral fiber comprises at least 10,000 different fibers; wherein the mineral fiber has an average fiber diameter x; and wherein x is less than the median fiber diameter of the mineral fiber.

[0051] In some exemplary embodiments, the mineral fiber comprises at least 10,000 different fibers; wherein the mineral fiber has a target production fiber diameter y; wherein the mineral fiber has an average fiber diameter x; and wherein y < 2x.

[0052] In some exemplary embodiments, the mineral fiber comprises at least 10,000 different fibers; wherein the mineral fiber has a target production fiber diameter of less than 6.5 µm; wherein the mineral fiber has an average fiber diameter x; and wherein the standard deviation from x is less than 3.5 µm.

[0053] In some exemplary embodiments, the standard deviation from x is less than 3.0 μm. In some exemplary embodiments, the standard deviation from x is less than 2.5 μm.

[0054] In some exemplary embodiments, the mineral fiber comprises at least 10,000 different fibers; wherein the mineral fiber has a fiber diameter distribution with two Gaussian peaks; wherein the two Gaussian peaks represent ≥85% of the mineral fiber volume; and wherein ≥40% of the mineral fiber volume is represented by a Gaussian peak corresponding to the smallest diameter of the mineral fiber.

[0055] In some exemplary embodiments, the mineral fibers do not contain any fibers with a diameter greater than 22 μm. In some exemplary embodiments, the mineral fibers do not contain any fibers with a diameter greater than 20 μm. In some exemplary embodiments, the mineral fibers do not contain any fibers with a diameter greater than 16 μm. In some exemplary embodiments, the mineral fibers do not contain any fibers with a diameter greater than 15 μm. In some exemplary embodiments, the mineral fibers do not contain any fibers with a diameter greater than 14 μm.

[0056] In some exemplary embodiments, the mineral fibers have an average formed (i.e., non-reduced) length greater than 50.8 mm (2 inches). In some exemplary embodiments, the mineral fibers have an average formed length ranging from about 76.2 mm (3 inches) to about 304.8 mm (12 inches). In some exemplary embodiments, the mineral fibers have an average formed length ranging from greater than 50.8 mm (2 inches) to less than or equal to 152.4 mm (6 inches).

[0057] In one exemplary embodiment, a package of rotationally molded fibers is disclosed. The package includes at least 10,000 different fibers, wherein the fibers have an average fiber diameter x; and wherein the fiber diameter distribution of the fibers has a standard deviation from x of less than 3.5 μm.

[0058] In some exemplary embodiments, the standard deviation from x is less than 3.0 μm. In some exemplary embodiments, the standard deviation from x is less than 2.5 μm.

[0059] In some exemplary embodiments, the fibers have an average diameter of less than 5 µm. In some exemplary embodiments, the fibers have an average diameter of less than 4 µm. In some exemplary embodiments, the fibers have an average diameter of less than 3 µm.

[0060] In some exemplary embodiments, the mineral fibers have an average formed (i.e., non-reduced) length greater than 50.8 mm (2 inches). In some exemplary embodiments, the mineral fibers have an average formed length ranging from about 76.2 mm (3 inches) to about 304.8 mm (12 inches). In some exemplary embodiments, the mineral fibers have an average formed length ranging from greater than 50.8 mm (2 inches) to less than or equal to 152.4 mm (6 inches).

[0061] In some exemplary embodiments, the average aspect ratio of the fibers is in the range of 850 to 5,000. In some exemplary embodiments, the average aspect ratio of the fibers is in the range of 850 to 2,000.

[0062] In some exemplary embodiments, x is less than the median fiber diameter.

[0063] In some exemplary embodiments, 90% of the fibers have a diameter of ≤ 1.525x.

[0064] In some exemplary embodiments, the fiber has a curvature greater than 0.043.

[0065] In some exemplary embodiments, the fiber has a curvature of at least 0.055.

[0066] In some exemplary embodiments, the fiber has a curvature in the range of 0.050 to 0.060.

[0067] In some exemplary embodiments, the fiber is glass fiber.

[0068] In some exemplary embodiments, the mineral fiber comprises at least 10,000 different fibers; wherein the mineral fiber has a fiber diameter distribution having a first Gaussian peak and a second Gaussian peak; and wherein the first Gaussian peak and the second Gaussian peak represent ≥85% of the mineral fiber volume.

[0069] In some exemplary embodiments, ≥40% of the mineral fiber volume is represented by the first Gaussian peak corresponding to the minimum diameter of the mineral fiber.

[0070] In some exemplary embodiments, the fiber includes an adhesive composition applied to the surface of the fiber; and the adhesive composition is an aqueous composition comprising water, a silane coupling agent, at least one organic acid and a cationic surfactant.

[0071] In some exemplary embodiments, the fiber includes an adhesive composition applied to the surface of the fiber; and the adhesive composition is an aqueous composition consisting essentially of water, a silane coupling agent, at least one organic acid and a cationic surfactant, or the like.

[0072] In some exemplary embodiments, the adhesive composition does not contain a film-forming agent.

[0073] In some exemplary embodiments, the adhesive composition has an active solids content of less than 5%.

[0074] In some exemplary embodiments, the adhesive composition (applied to mineral fibers) is substantially colorless, wherein ΔL The value ranges from -5 to +5.

[0075] In some exemplary embodiments, at least one organic acid is selected from acetic acid, succinic acid, citric acid, and combinations thereof.

[0076] In some exemplary embodiments, the amount of viscose composition applied to the fibers is from about 0.05% by weight to about 2% by weight, based on the total weight of the sizing fibers.

[0077] In one exemplary embodiment, a package of rotationally molded fibers is disclosed. The package includes: at least 10,000 different fibers, wherein the fibers have an average fiber diameter x; wherein the fiber diameter distribution of the fibers has a standard deviation from x of less than 3.5 μm; wherein the mineral fibers have a fiber diameter distribution having a first Gaussian peak and a second Gaussian peak; and wherein the first Gaussian peak and the second Gaussian peak represent ≥85% of the mineral fiber volume.

[0078] In one exemplary embodiment, a package of rotationally molded fibers is disclosed. The package includes: at least 10,000 different fibers, wherein the fibers have an average fiber diameter x; wherein the fiber diameter distribution of the fibers has a standard deviation from x of less than 3.5 μm; wherein the mineral fibers have a fiber diameter distribution having a first Gaussian peak and a second Gaussian peak; wherein the first and second Gaussian peaks represent ≥85% of the mineral fiber volume; and wherein ≥40% of the mineral fiber volume is represented by the first Gaussian peak corresponding to the minimum diameter of the mineral fiber.

[0079] In one exemplary embodiment, an adhesive composition for application to rotationally formed glass fibers is disclosed. The adhesive composition comprises, or is substantially composed of, water, a silane coupling agent, at least one organic acid and a cationic surfactant.

[0080] In some exemplary embodiments, at least one organic acid is selected from acetic acid, succinic acid, citric acid, and combinations thereof.

[0081] In some exemplary embodiments, the adhesive composition has a pH in the range of about 3.0 to about 7.5. In some exemplary embodiments, the adhesive composition has a pH in the range of about 4.5 to about 5.5.

[0082] In some exemplary embodiments, the adhesive composition has an active solids content of less than 5%.

[0083] In some exemplary embodiments, the cationic surfactant accounts for about 25% to about 90% by weight of the dry solids of the adhesive composition.

[0084] In some exemplary embodiments, the silane coupling agent accounts for about 15% to about 45% by weight of the solids of the adhesive composition; the organic acid accounts for about 1% to about 20% by weight of the solids of the adhesive composition; and the cationic surfactant accounts for about 35% to about 75% by weight of the solids of the adhesive composition.

[0085] In some exemplary embodiments, water comprises about 80% to about 99.9% by weight of the adhesive composition.

[0086] In one exemplary embodiment, a nonwoven mat is disclosed. The nonwoven mat includes: a plurality of first fibers; a plurality of second fibers; and an adhesive that holds the first and second fibers together in an alternating arrangement; wherein the first fibers have an average fiber diameter greater than about 7 μm; wherein the second fibers have an average fiber diameter x less than about 6 μm; and wherein the fiber diameter distribution of the second fibers has a standard deviation of less than 3.5 μm from x.

[0087] In some exemplary embodiments, the standard deviation from x is less than 3.0 μm. In some exemplary embodiments, the standard deviation from x is less than 2.5 μm.

[0088] In some exemplary embodiments, the second fiber has an average diameter of less than 5 µm. In some exemplary embodiments, the second fiber has an average diameter of less than 4 µm. In some exemplary embodiments, the second fiber has an average diameter of less than 3 µm.

[0089] In some exemplary embodiments, the second fiber has an average forming length greater than 50.8 mm (2 inches).

[0090] In some exemplary embodiments, the second fiber has an average forming length ranging from about 76.2 mm (3 inches) to about 304.8 mm (12 inches).

[0091] In some exemplary embodiments, the second fiber has an average forming length ranging from greater than 50.8 mm (2 inches) to less than or equal to 152.4 mm (6 inches).

[0092] In some exemplary embodiments, x is less than the median fiber diameter of the second fiber.

[0093] In some exemplary embodiments, 90% of the second fibers have a diameter of ≤ 1.525x.

[0094] In some exemplary embodiments, the second fiber has a curvature greater than 0.043.

[0095] In some exemplary embodiments, the second fiber has a curvature of at least 0.055.

[0096] In some exemplary embodiments, the second fiber has a curvature in the range of 0.050 to 0.060.

[0097] In some exemplary embodiments, the first fiber is glass fiber.

[0098] In some exemplary embodiments, the second fiber is glass fiber.

[0099] In some exemplary embodiments, the second fiber is a rotationally molded fiber.

[0100] In some exemplary embodiments, based on the weight of the nonwoven mat, the nonwoven mat contains at least 1% by weight of the second fiber. In some exemplary embodiments, based on the weight of the nonwoven mat, the nonwoven mat contains at least 10% by weight of the second fiber. In some exemplary embodiments, based on the weight of the nonwoven mat, the nonwoven mat contains at least 20% by weight of the second fiber.

[0101] In some exemplary embodiments, the second fiber includes an adhesive composition applied to the surface of the second fiber; wherein the adhesive composition is an aqueous composition comprising, substantially comprising, or comprises of, water, a silane coupling agent, at least one organic acid and a cationic surfactant.

[0102] In some exemplary embodiments, the amount of adhesive composition applied to the second fiber is from about 0.05% by weight to about 2% by weight, based on the total weight of the second fiber to which the adhesive is applied.

[0103] In some exemplary embodiments, the sizing composition is applied at a concentration of less than 4 mg / cm³. 2 The amount is applied to the second fiber.

[0104] In some exemplary embodiments, the sizing composition is an aqueous composition comprising water, 15% to 45% by weight solids of a silane coupling agent, 1% to 20% by weight solids of at least one organic acid, and 35% to 75% by weight solids of a cationic surfactant.

[0105] In some exemplary embodiments, the adhesive composition does not contain a film-forming agent.

[0106] In some exemplary embodiments, the adhesive composition has an active solids content of less than 5%.

[0107] In some exemplary embodiments, the adhesive composition (applied to mineral fibers) is substantially colorless, wherein ΔL The value ranges from -5 to +5.

[0108] In some exemplary embodiments, at least one organic acid is selected from acetic acid, succinic acid, citric acid, and combinations thereof.

[0109] In some exemplary embodiments, the adhesive includes polyvinyl alcohol.

[0110] In some exemplary embodiments, the nonwoven mat also includes inorganic fillers.

[0111] In some exemplary embodiments, the average fiber diameter of the first fiber is in the range of about 10 µm to about 11 µm; and the average fiber diameter of the second fiber is in the range of about 3 µm to about 4 µm.

[0112] In some exemplary embodiments, the second fiber does not contain any fibers with a diameter greater than 22 μm. In some exemplary embodiments, the second fiber does not contain any fibers with a diameter greater than 20 μm. In some exemplary embodiments, the second fiber does not contain any fibers with a diameter greater than 16 μm. In some exemplary embodiments, the second fiber does not contain any fibers with a diameter greater than 15 μm. In some exemplary embodiments, the second fiber does not contain any fibers with a diameter greater than 14 μm.

[0113] In some exemplary embodiments, the nonwoven mat has a first surface and a second surface opposite to the first surface, and each surface contains less than about 100 fibrous particles per 1,000 m³. 2 Nonwoven mat. In some exemplary embodiments, each surface of the nonwoven mat has less than about 50 fuzz particles per 1,000 m². 2 Nonwoven mat. In some exemplary embodiments, each surface of the nonwoven mat has less than about 25 fibrous particles per 1,000 m². 2 Nonwoven mat. In some exemplary embodiments, each surface of the nonwoven mat has less than about 15 flocs / 1,000 m². 2 Nonwoven mat.

[0114] In some exemplary embodiments, the average fiber diameter of the first fiber is in the range of about 8µm to about 13µm.

[0115] In some exemplary embodiments, the average fiber diameter of the second fiber is in the range of about 3µm to about 3.5µm.

[0116] In some exemplary embodiments, the first fiber accounts for about 10% to about 50% of the total weight of the first and second fibers; and the second fiber accounts for about 50% to about 90% of the total weight of the first and second fibers.

[0117] In some exemplary embodiments, the nonwoven mat contains more first fibers by weight percentage than the second fibers, based on the total weight of the first and second fibers.

[0118] In one exemplary embodiment, the ceiling panel includes a finish on at least one of its main surfaces, the finish including a nonwoven pad, wherein the nonwoven pad includes: a plurality of first fibers; a plurality of second fibers; and an adhesive holding the first and second fibers together in an alternating arrangement; wherein the first fibers have an average fiber diameter greater than about 7 μm; wherein the second fibers have an average fiber diameter x less than about 6 μm; and wherein the fiber diameter distribution of the second fibers has a standard deviation from x of less than 3.5 μm.

[0119] In one exemplary embodiment, a method for manufacturing a nonwoven fiber mat is disclosed. The method includes: (i) dispersing a plurality of first fibers in a first aqueous solution to form a first slurry; (ii) dispersing a plurality of second fibers in a second aqueous solution to form a second slurry; (iii) mixing the first slurry, the second slurry, and a water-soluble or water-dispersible binder to form a third slurry; (iv) depositing the third slurry to form a wet-laid fiber web comprising the first fibers, the second fibers, and the binder; and (v) drying the wet-laid fiber web to form a nonwoven fiber mat, wherein the first fibers have an average fiber diameter in the range of about 6.5 μm to about 15 μm; wherein the second fibers have an average fiber diameter x of less than 6.0 μm; wherein the fiber diameter distribution of the second fibers has a standard deviation of less than 3.5 μm from x; and wherein the nonwoven mat has a first surface and a second surface opposite the first surface, wherein each surface has less than 100 flocs / 1,000 m². 2 Nonwoven mat.

[0120] In some exemplary embodiments, an adhesive is added to the first slurry.

[0121] In some exemplary embodiments, an adhesive is added to the second slurry.

[0122] In one exemplary embodiment, a nonwoven mat for use as a finish on a ceiling panel is disclosed. The nonwoven mat includes: a plurality of first fibers; a plurality of second fibers; and an adhesive that holds the first and second fibers together in an alternating arrangement; wherein the first fibers have an average fiber diameter greater than about 6 μm; wherein the second fibers have an average fiber diameter x less than about 4 μm; wherein the second fibers constitute y% by weight of the mat; wherein y / x < 10; and wherein the mat has a turbidity rating of 15 or less in the range of 19 mm to 42 mm when measured with a cloud runner device.

[0123] In one exemplary embodiment, the ceiling panel includes a finish on at least one of its main surfaces, the finish comprising a nonwoven pad, wherein the nonwoven pad comprises: a plurality of first fibers; a plurality of second fibers; and an adhesive holding the first and second fibers together in an alternating arrangement; wherein the first fibers have an average fiber diameter greater than about 6 μm; wherein the second fibers have an average fiber diameter x less than about 4 μm; wherein the second fibers constitute y% by weight of the pad; wherein y / x < 10; and wherein, when measured with a cloudiness testing apparatus, the pad has a turbidity grade of 15 or less in the range of 19 mm to 42 mm.

[0124] In one exemplary embodiment (i.e., embodiment A), the nonwoven mat used as a finish for a ceiling panel comprises: a plurality of first fibers; a plurality of second fibers; and an adhesive that holds the first and second fibers together in an alternating arrangement; wherein the first fibers have an average fiber diameter greater than about 6 μm; wherein the second fibers have an average fiber diameter x less than about 4 μm; wherein the second fibers constitute y% by weight of the mat; wherein y / x < 10; and wherein, when measured with a cloudiness tester, the mat has a turbidity rating of 15 or less in the range of 19 mm to 42 mm.

[0125] In some embodiments of implementation scheme A, the fiber diameter distribution of the second fiber has a standard deviation from x of less than 3.5 μm, preferably less than 3.0 μm, and even more preferably less than 2.5 μm.

[0126] In some embodiments of implementation scheme A, the second fiber has an average diameter of less than 5 μm, preferably less than 4 μm, and even more preferably less than 3 μm.

[0127] In some embodiments of implementation scheme A, the second fiber has an average forming length greater than 50.8 mm, preferably in the range of about 76.2 mm to about 304.8 mm.

[0128] In some implementation schemes of scheme A, x is less than the median fiber diameter of the second fiber.

[0129] In some implementation schemes of scheme A, 90% of the second fibers have an average fiber diameter of ≤ 1.525x.

[0130] In some implementation schemes of scheme A, the first fiber is glass fiber.

[0131] In some embodiments of implementation scheme A, the second fiber is glass fiber.

[0132] In some embodiments of implementation scheme A, the second fiber is a rotationally formed fiber.

[0133] In some embodiments of implementation scheme A, the nonwoven mat comprises at least 1% by weight, preferably at least 10% by weight, and even more preferably at least 20% by weight of a second fiber based on the weight of the nonwoven mat.

[0134] In some embodiments of implementation scheme A, the adhesive includes polyvinyl alcohol.

[0135] In some implementation schemes of scheme A, the nonwoven mat also includes inorganic fillers.

[0136] In some embodiments of implementation A, the average fiber diameter of the first fiber is in the range of about 8 μm to about 13 μm, preferably in the range of about 10 μm to about 11 μm; and the average fiber diameter of the second fiber is in the range of about 3 μm to about 4 μm, preferably in the range of about 3 μm to about 3.5 μm.

[0137] In some embodiments of implementation scheme A, the second fiber does not contain any fiber with a diameter greater than 22 μm, preferably does not contain any fiber with a diameter greater than 20 μm, more preferably does not contain any fiber with a diameter greater than 16 μm, even more preferably does not contain any fiber with a diameter greater than 15 μm, and especially does not contain any fiber with a diameter greater than 14 μm.

[0138] In some embodiments of implementation scheme A, the nonwoven mat has a first surface and a second surface opposite to the first surface, and each surface contains less than about 100 flocs / 1,000 m². 2 Nonwoven mat, preferably less than about 50 lint particles per 1,000 m² 2 Nonwoven mats, more preferably less than about 25 lint particles per 1,000 m² 2 Nonwoven mats, and especially those with less than about 15 lint particles per 1,000 m². 2 Nonwoven mat.

[0139] In some embodiments of implementation scheme A, the first fiber accounts for about 10% to about 50% of the total weight of the first and second fibers; and the second fiber accounts for about 50% to about 90% of the total weight of the first and second fibers.

[0140] In one exemplary embodiment (i.e., embodiment B), the ceiling panel includes a finish on at least one of its main surfaces, which comprises a nonwoven mat according to any aspect of embodiment A.

[0141] Other aspects and features of the overall inventive concept will become more apparent to those skilled in the art after reviewing the following description of various exemplary embodiments in conjunction with the accompanying drawings. Attached Figure Description

[0142] The overall inventive concept, its embodiments, and advantages are described in more detail below with reference to the accompanying drawings, by way of example:

[0143] Figure 1 This is a partial cross-sectional view of a rotary fiber forming apparatus to illustrate various aspects of a conventional rotary fiber production method.

[0144] Figure 2A This is a graph showing the fiber diameter distribution of a certain volume of glass fiber produced by a conventional rotary fiber production method.

[0145] Figure 2B This is a graph showing the fiber diameter distribution of a certain volume of glass fiber produced by another conventional rotary fiber production method.

[0146] Figure 2C It is a graph showing the fiber diameter distribution of a certain volume of glass fiber produced by yet another conventional rotary fiber production method.

[0147] Figure 2D It is a graph showing the fiber diameter distribution of a certain volume of glass fiber produced by yet another conventional rotary fiber production method.

[0148] Figure 3 This is a partial cross-sectional view of a rotary fiber forming apparatus according to an exemplary embodiment, illustrating various aspects of a rotary fiber production method.

[0149] Figure 4 It shows through Figure 3 A curve showing the fiber diameter distribution of a certain volume of glass fiber produced by the rotary fiber manufacturing method.

[0150] Figure 5 This is a graph showing the zeta potential (relative to pH) of several glass adhesive formulations.

[0151] Figure 6 This is a diagram showing three different simulated perspectives of the cloud spot tester device.

[0152] Figure 7 A is a graph showing the cloud-like size measurements of ceiling panel finishes across a series of percentages, including different types of fibers (rotation-to-composite) and different fiber diameters (3.5 μm vs. 6.5 μm).

[0153] Figure 7 B is a graph showing the cloud-like size measurements of ceiling panel finishes with a series of percentages across the fine fibers, including different types of fibers (rotational pair composite) and the same fiber diameter (3.5 μm).

[0154] Figure 8This is a graph showing the cloud-like size measurements of ceiling panel finishes that include fine rotating fibers of varying percentages and diameters.

[0155] Figure 9A This is a graph showing the cloud-like size measurement results of ceiling panel finishes including different 6.5μm WUCS glass fibers and 3.5μm of the rotating glass fiber of the present invention.

[0156] Figure 9B This is a graph showing the cloud-like size measurement results of ceiling panel finishes including different 6.5μm WUCS glass fibers and 6.5μm of the rotating glass fiber of the present invention.

[0157] Figure 10 This is an illustration showing exemplary nonwoven mat portions having and not having fibrous material.

[0158] Figure 11 This is a graph showing the “conversion value” between measuring the fiber diameter of various WUCS fibers with different fiber diameters using a SEM microscopy-based method and the method described herein in accordance with ISO 13322-2.

[0159] Figure 12 This is an illustration showing an exemplary treatment of the rotating fibers of the present invention before they are mixed with other fibers in a wet web forming process.

[0160] Figures 13A to 13C This is a scanning electron microscope (SEM) image of an exemplary nonwoven mat made of fiber blends, in which fiber curvature was measured. Detailed Implementation

[0161] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. As used herein, the term “about” to modify any numerical value covers the specific numerical value without any modification, and reasonable deviations from it, such as those attributable to the method of measurement or limitations.

[0162] Several exemplary embodiments will be described in detail. It should be understood that this disclosure is merely illustrative of the general inventive concept. Embodiments covering the general inventive concept may take various forms, and the general inventive concept is not intended to be limited to the specific embodiments described herein.

[0163] In view of the above, modifications to the rotatable fiber forming process allow for the production of fibers with a more uniform fiber diameter and / or length distribution. The general concept of the present invention includes this new method for producing rotatable fibers, the new rotatable fibers themselves, adhesive formulations suitable for the new rotatable fibers, packaging of the rotatable fibers (e.g., with improved fiber distribution), nonwoven mats made from the new rotatable fibers, and downstream applications of the mats (e.g., ceiling panel finishes).

[0164] Rotational forming method / system

[0165] Nonwoven materials formed from glass fibers are known. For example, composite materials consisting of reinforced glass fiber mats (called, for example, veil, fiber web, finish) are used in a variety of applications.

[0166] One method of forming glass fibers involves passing molten glass through holes in the bottom of a fixed spinneret, where the molten glass flow thins into fibers as it cools. See, for example, US 3,653,860; US 3,972,702; and US 4,207,086. Another method of forming glass fibers involves passing molten glass through holes in the outer wall of a rotator (via centrifugal force), where the molten glass flow thins into fibers as it cools. See, for example, US 5,582,841. For rotationally formed fibers, heated air can be used to pull the fibers downward, which helps in the thinning and collection of the fibers.

[0167] The spinneret-formed glass fibers can then be chopped to form wet-cut chopped strands (WUCS) with relatively consistent average fiber diameter and average fiber length. However, due to health concerns associated with their non-biological solubility, spinneret-formed glass fibers are typically limited to fiber diameters of 6.5 μm or larger. Furthermore, the production of spinneret-formed glass fibers can be relatively more expensive than rotationally formed glass fibers due to factors such as raw material costs and production (melting) costs.

[0168] Therefore, for many applications, rotationally formed glass fibers are used instead of stencil-formed glass fibers, or rotationally formed glass fibers are used in addition to stencil-formed glass fibers. Due to their biosoluble formulation, rotationally formed glass fibers can have fiber diameters much smaller than 6.5 μm. Compared to WUCS fibers, these so-called “microfibers” can provide improved properties with a lower added weight. However, it has proven difficult to produce rotationally formed glass fibers with a consistent average fiber diameter and / or average fiber length.

[0169] One method for measuring the average fiber diameter (such as the average fiber diameter described herein) involves: (1) subjecting the sample to sufficient heat to burn off any surface chemicals without affecting the underlying fiber morphology; and (2) determining the average fiber diameter of that quantity of fibers by measuring the airflow / pressure drop across the given quantity of fibers, as is commonly performed in the insulation and fiber industries (e.g., Micronaire). Instruments used to measure fiber diameter via airflow resistance are based on theories by Darcy, Les Fontaines Publiques de la Ville de Dijon (1856); Kozeny, Uber Kapillare Leitung des Wassers im Boden (1927); and Carman, Flow of Gases Through PorousMedia (1956), etc. The instrument works by measuring the airflow resistance through a known mass of material; as the fiber diameter decreases, the specific surface area increases, which increases the airflow resistance. The higher the airflow resistance, the smaller the effective fiber diameter, thus implying that if all fibers had the same diameter, the fiber diameter would be expected to produce the same resistance. Unless otherwise specified, this is the primary technique (referred to as the airflow resistance method) for obtaining the effective fiber diameter value (as an estimate of the average fiber diameter) presented herein (including in the claims).

[0170] However, the aforementioned airflow resistance method is not suitable for determining the distribution of individual fibers (e.g., fibers with different diameters) from a given amount of fiber or from values ​​calculated from the distribution (e.g., mean, median, standard deviation). Therefore, another method for measuring fiber diameter in the context of the overall fiber distribution (such as the fiber diameter distribution described herein) involves: (1) subjecting the sample to sufficient heat to burn off any surface chemicals without affecting the underlying fiber morphology; (2) dispersing the ordinary fibers in water using a high-speed blender; (3) diluting the dispersed fibers in water to an acceptable concentration suitable for image analysis; and (4) measuring the fiber diameter distribution using image analysis (e.g., conforming to ISO 13322-2). Image analysis can be performed using a device in which the particles (i.e., the dispersed fibers) pass through the focal plane of two cameras, having an image rate of 300 images / second and a resolution of 0.8 μm / pixel. The device used to obtain the data described herein is a Camsizer X2 with an X-Flow module, manufactured by Microtrac MRB (Osaka, Japan). The measured data can be filtered to remove non-fibrous particles (e.g., particles with an aspect ratio (L / D) of less than 5). Generally, at least 10,000 fibers are measured to ensure proper distribution assessment. The reported results are the Martin minimum diameter, binned in 0.1 micrometer increments, and plotted based on volume (not counted), where volume requires measurement of the average diameter and average length of each fiber. Unless otherwise noted, this image processing-based method (generally referred to herein as the method conforming to ISO 13322-2) is the primary technique for obtaining the average fiber diameter values ​​presented herein (including in the claims).

[0171] As is commonly used herein (including in the claims), unless the context otherwise requires, the term “average fiber diameter” encompasses both the effective fiber diameter and the average fiber diameter of the sample.

[0172] It should be noted that other methods exist for identifying the average fiber diameter and other distribution-related properties of fiber assemblies, such as counting-based methods for observing individual fibers identified using scanning electron microscopy (SEM). While these other methods are not directly related to the values ​​presented herein, it has been determined that measurements obtained by one method can be readily converted to the method disclosed herein by multiplying these values ​​by a constant transformation value. For example, as... Figure 11As shown in Figure 1100, various samples made of non-rotating WUCS fibers with different fiber diameters were measured using both the SEM microscopy-based method and the ISO 13322-2 compliant method described herein (referred to as the Camsizer in Figure 1100). The conversion between the SEM microscopy-based method value (α) and the ISO 13322-2 compliant method value (β) was determined by calculating the “fit line” between the various measurements, as follows: α = 0.76 × β.

[0173] In light of the above, modifications to the rotational fiber forming process allow for the production of fibers with a more uniform fiber diameter and / or length distribution. Therefore, the main disadvantages of rotationally formed fibers are mitigated, and the downstream processing of rotationally formed fibers is improved.

[0174] This will refer to conventional fiber manufacturing equipment or fiber forming equipment, such as Figure 1 The fiber-forming device 10 describes an improved rotary fiber forming method 300 (although the radiation shield 52 disclosed therein is an optional component). For example... Figure 3 As shown, the rotary fiber forming method 300 includes multiple aspects AE, which can be modified to produce fibers with a more uniform fiber diameter and / or length distribution. The general inventive concept covers an improved rotary fiber forming method 300 that uses any or more of these aspects AE to obtain a quantity of fibers (produced together) with a more uniform fiber diameter and / or length distribution. The general inventive concept covers any combination of these aspects (e.g., A, A+B, A+C, A+B+C, A+D, A+B+D, A+B+C+D, A+E, etc.). Furthermore, the general inventive concept is not necessarily limited to these aspects, and in some exemplary embodiments, other features of the invention, such as the adhesive formulations described herein, may also contribute to the improved fiber diameter and / or length distribution.

[0175] During conventional processing, the surface of the sleeve disk 67 of the fiber-forming unit 10 can become hot enough to melt the fibers in contact with the sleeve disk 67. In one aspect A of the improved rotary fiber forming method 300, the amount of cooling air introduced through the hollow sleeve 64 is increased, which lowers the temperature of the sleeve disk 67. By way of example, the conventional rotary fiber forming method would use an airflow of approximately 5 cubic feet per minute (CFM) to 15 cubic feet per minute (CFM) to cool the sleeve disk 67 to a temperature temp. conv The rotary fiber forming method of the present invention (e.g., method 300) uses an airflow of approximately 30 CFM to 60 CFM to cool the sleeve disk 67 to a temperature temp. inv Therefore, although temp conv Typically much higher than 1,100℉ (e.g., ≥1200℉), but tempinv Keep below 1,100℉. Therefore, the forming fibers in contact with the sleeve disk 67 are unlikely to fuse with the sleeve disk (or with other fibers fused to the sleeve disk) in a way that could damage the fibers or cause fiber agglomeration (e.g., flocculent material), both of which could deform the intended fiber diameter and / or length distribution.

[0176] In another aspect B of the improved rotary fiber forming method 300, the rotational speed of the rotator 12 (via the rotating mandrel 14) is reduced, which decreases the likelihood of fibers contacting the surface of the blower 28. For example, a conventional rotary fiber forming method would operate the rotator 12 at 2,500 to 3,000 rpm, while the rotary fiber forming method of the present invention (e.g., method 300) would operate the same rotator 12 at 1,800 to 2,400 rpm. These ranges may vary for rotators with different sizes / geometries, but the reduction in rotational speed in the improved rotary fiber forming method will be maintained relative to the conventional rotary fiber forming method. Therefore, the formed fibers are less likely to fuse with (or with other fibers fused to them) in a manner that could damage the fibers or cause fiber agglomeration (e.g., flocculent material), both of which could distort the intended fiber diameter and / or length distribution.

[0177] In another aspect C of the improved rotary fiber forming method 300, the amount of heated air generated by the burner 24 is reduced. For example, a conventional rotary fiber forming method would use a mixed gas flow of approximately 360 cubic feet per minute (CFM), while the rotary fiber forming method of the present invention (e.g., method 300) would use a mixed gas flow of approximately 240-300 CFM. While reducing the gas flow at C helps lower the temperature within method 300, this must be balanced against the tendency for lower temperatures to result in larger diameter fibers due to reduced thinning. Therefore, in some exemplary embodiments, the improved rotary fiber forming method 300 may have a lower limit in its ability to produce fibers of smaller diameter and / or length. For example, the lower limit of the effective fiber diameter (using the airflow method) would be in the range of 2.5 μm to 3.0 μm, where this lower limit is limited by the ability to maintain sufficient temperature to thin the molten glass into fibers.

[0178] In another aspect D of the improved rotary fiber forming method 300, the amount of air introduced by the blower 28 through the channel 30 is controlled to promote improved thinning of the primary fiber 22 into the secondary fiber 32. In some exemplary embodiments of the rotary fiber forming method of the present invention (e.g., method 300), the blower 28 outputs approximately 410 cubic feet per minute (CFM), which in turn causes “guide air” to flow through the channel 30. Here, “improved thinning” can be considered as achieving a reduction in the occurrence of fused fibers and other defects (e.g., slag balls, flocculent material), as described herein. Similarly, this improved thinning (and the resulting reduction in fused fibers) is demonstrated by an improved fiber diameter and / or length distribution, such as… Figure 4 The curve is shown in graph 400.

[0179] The aforementioned aspect AD is particularly important relative to aspect E of the improved rotary fiber forming method 300, which represents the "refinement region" of the secondary fiber 32. The refinement region E is the area around the fiber generator 10 where the temperature is sufficiently high to fuse the fiber 32. The improved rotary fiber forming method 300 attempts to minimize collisions between the two individual fibers 32 and / or between the fiber 32 and components of the fiber forming device until the fiber 32 has cooled below its glass transition temperature T. g And therefore unlikely to fuse afterward. For example, for glass fibers with a Tg in the range of 1,000℉ to 1,250℉, the improved rotary fiber forming method 300 will attempt to minimize fiber collisions until the fibers have cooled to a temperature below 1,100℉.

[0180] In addition to producing a certain amount of fibers with a fiber diameter and / or length distribution that is closer to the target fiber diameter and / or length, the improved rotary fiber forming method 300 produces a certain amount of fibers with improved overall quality (e.g., longer length) compared to conventional rotary fibers by reducing the number of fibers that fuse and / or are damaged during the production process.

[0181] Furthermore, the fibers produced by the improved rotary fiber forming process 300 can be further processed downstream of method 300, such as by grinding / cutting / shredding the fibers to lengths that are easier to process. For example, the fibers can be ground to have a reduced length ranging from 1 / 8 inch (3.25 mm) to 1 inch (25.4 mm), which is beneficial for the use of the fibers in wet web forming methods. Similarly, other applications / methods can benefit from fibers with longer lengths. Therefore, because the fibers produced by the improved rotary fiber forming method 300 have a longer initial (forming) length than conventional rotary-formed fibers, the fibers are more likely to start at a length greater than the target length, which in turn provides greater flexibility in reducing the fibers to the target (processing) length and provides greater uniformity in products made from such fibers.

[0182] In this way, a wider range of aspect ratios can be obtained from the processed fibers, wherein the processed fibers have a more uniform distribution relative to the target aspect ratio. For example, the rotating fibers of the present invention can be processed to have an average aspect ratio in the range of 850 to 5,000 or in the range of 850 to 2,000. When blended with non-rotating fibers (e.g., WUCS fibers) having an aspect ratio of less than 2,000, the combined average aspect ratio of the fiber blend is less than about 1,000. The combined average aspect ratio is calculated as: Average aspect ratio = (weight % of fiber 1) (Aspect ratio of fiber 1) + (Weight % of fiber 2) The aspect ratio of fiber 2). In addition, as described herein, when used to form nonwoven mats, the average aspect ratio of the fibers will typically be low (e.g., in the range of 150 to 500) due to breakage during the nonwoven fabric forming process.

[0183] Improved rotational molding fibers

[0184] exist Figure 4 The diagram 400 shows a graph of the fiber diameter distribution of a glass fiber material according to an exemplary embodiment. The glass fiber material comprises rotationally formed fibers not held together by an adhesive. The glass fiber material is formed by an improved rotational fiber forming method (e.g., method 300).

[0185] Referring to graph 400, various properties of the glass fiber material of the present invention are shown in Table 5.

[0186]

[0187] Table 5

[0188] In Table 5, “Peak Index” refers to the peak identifier from left to right, where peaks are shown with dashed lines; “Peak Type” refers to the type of model used to fit the data; “Area Intg” refers to the integral area of ​​the fitted peak; “Area IntgP” refers to the percentage of the total integral area of ​​each fitted peak; “Center Grvty” refers to the center of the fitted peak; “Maximum Height” refers to the maximum value of the fitted peak; and “FWHM” refers to the width of the peak at half its maximum height.

[0189] exist Figure 4In plot 400, the rotating fibers were produced with a target diameter of approximately 3.5 μm, as measured using a known airflow method. Plot 400 represents the fiber diameter distribution measured and plotted as a percentage of fiber volume using a method conforming to ISO 13322-2. The data measured according to the ISO 13322-2 method (Camsizer) was analyzed using Peak Deconvolution App (v2.00) and OriginPro 2023 (constant baseline; fitting until convergence to obtain displayed results). OriginPro 2023 is data analysis software sold by OriginLab Corp. (Northampton, Massachusetts).

[0190] Ideally, 100% of the produced fibers would have a fiber diameter of approximately 3.5 μm. However, rotary fiber production is a complex process with many variables, only some of which can be controlled. As described herein, improved rotary fiber forming methods (e.g., method 300) identify and control one or more production variables to obtain fibers with improved properties compared to conventional rotary fibers.

[0191] and Figures 2A to 2D Compared to conventional spun fibers shown in the curve graph, the spun fibers shown in curve 400 exhibit a more pronounced bimodal distribution. Specifically, curve 400 shows two distinct peaks, each with a apex exceeding 15% / μm within the distribution. Furthermore, the fiber diameter distribution (i.e., the area below the curve) shows that larger-volume fibers are closer to the target fiber diameter (i.e., 3.5 μm), with almost no fibers measuring diameters greater than 14 μm. This narrower variation in fiber diameter (e.g., from about 1.5 μm to about 13.5 μm) for the target fiber diameter of 3.5 μm is closer to ideal than that achieved by conventional spun fibers, where most fibers have a diameter less than 6 μm. In other words, the spun fibers of the present invention result in improved products / applications due to the reduced variation in fiber diameter relative to the target fiber diameter and / or the increased volume of fibers with diameters closer to the target fiber diameter.

[0192] In Table 6, the additional properties of the glass fiber material of the present invention (shown in graph 400) are compared with those of various conventional fiber materials (shown in graphs 210, 220, 230, and 240).

[0193]

[0194] Table 6

[0195] Wherein: d10 means that 10% of all particles in the sample are less than or equal to the d10 value; d50 means that 50% of all particles in the sample are less than or equal to the d50 value (also known as the median particle size); d90 means that 90% of all particles in the sample are less than or equal to the d90 value; the sample mean refers to the average particle size of the sample; and the standard deviation refers to the standard deviation from the mean.

[0196] Compared to the values ​​shown in Table 6, although the rotationally formed glass fibers of the present invention do not have a lower median fiber diameter (d50) than all sampled conventional rotationally formed glass fibers, they do have a lower average value than all sampled conventional rotationally formed glass fibers. This indicates that the rotationally formed glass fibers of the present invention contain less material with larger diameters (i.e., larger than the target fiber diameter), which can... Figure 2A , Figure 2B , Figure 2C , Figure 2D and Figure 4 As seen in the graph, a smaller standard deviation value also indicates that the rotationally formed glass fibers of this invention have a more uniform fiber diameter distribution, as described herein.

[0197] In addition, the present invention produces a rotating fiber with an increased fiber length compared to conventional rotating fibers.

[0198] By way of example, conventional rotary fiber forming methods produce rotary fibers (from fiber former 10) with lengths ranging from approximately 12.7 mm (0.5 inches) to 50.8 mm (2 inches), while the rotary fiber forming method of the present invention (e.g., method 300) produces rotary fibers (from fiber former 10) with lengths ranging from approximately 76.2 mm (3 inches) to 304.8 mm (12 inches). In some exemplary embodiments, the rotary fiber forming method of the present invention produces rotary fibers with an average forming length ranging from greater than 50.8 mm (2 inches) to less than or equal to 152.4 mm (6 inches). The ability to produce longer fibers provides increased flexibility in downstream fiber processing and greater control over the properties of the final product.

[0199] Furthermore, the rotating fibers of the present invention contain fewer fused fibers, clumps (e.g., flocs) or threads, thus enabling more uniform fiber dispersion when producing nonwoven products, as described herein. As used herein, the term "flocs" refers to loosely aggregated clumps of fibers visible to the naked eye. Figure 10As shown in Figure 1000, a sample portion of nonwoven mat 1010 is substantially free of any flocculent material 1002 on one side 1012 and / or on the side opposite to side 1012 (not shown), however, a sample portion of another nonwoven mat 1020 includes a number of flocculent materials 1002 on one side 1022 and / or on the side opposite to side 1022 (not shown).

[0200] In some exemplary embodiments, the rotatable fibers have an average fiber diameter of less than 6.5 µm. In some exemplary embodiments, the rotatable fibers have an average fiber diameter of less than 5.5 µm. In some exemplary embodiments, the rotatable fibers have an average fiber diameter of less than 4.5 µm.

[0201] In some exemplary embodiments, the rotating fiber has a fiber diameter distribution with one or two Gaussian peaks, the Gaussian peaks representing ≥85% of the fiber volume / mass, wherein ≥40% of the volume / mass is located at the peak representing the smallest diameter fiber.

[0202] In some exemplary embodiments, the rotating fibers are substantially free of any fibers with a diameter greater than 15 μm.

[0203] In some exemplary embodiments, as they are formed (e.g., leaving the fiber generator 10), the rotating fibers are substantially free of or significantly reduced in any unfibered or poorly fiberized material (often referred to as “slag balls”), fused fibers, agglomerated fibers (e.g., flocculent material), and / or other forms of defective fibers, which can contribute to the improved fiber diameter distribution described herein.

[0204] In some exemplary embodiments, the rotating fibers are made of a biosoluble composition.

[0205] While non-rotating fibers (e.g., WUCS fibers) are inherently straight during formation, rotating fibers, in general, have curvature due to the glass fibers being cooled in a less controlled environment. This curvature can also impart beneficial effects to products made from the rotating fibers of this invention, such as reducing visual defects in ceiling panels (e.g., cloudiness / spots; directionality) caused by more random scattering of light and the fibers not aligning with each other.

[0206] like Figures 13A to 13C As shown, several nonwoven mat samples were prepared using a wet web-forming process, which combined fiber blends comprising: (i) 11 μm diameter, 6 mm long WUCS fibers as the first fiber (fiber 1) and (i) 6.5 μm diameter, 6 mm long WUCS fibers as the second fiber. Figure 13A The second fiber (fiber 2) in the middle; (ii) Figure 2C The conventional ULF fiber shown is as Figure 13BThe second fiber (fiber 2) in; and (iii) described herein and Figure 4 The rotating fiber of the present invention shown is as Figure 13C The second fiber (fiber 2) in the middle.

[0207] Figure 13A The image includes a SEM image of a nonwoven mat 1300 made by a wet web forming process from a combination of 85% first WUCS fiber (fiber 1) and 15% second WUCS fiber (fiber 2) by weight of the glass fiber. The first WUCS fiber has an average fiber diameter of 11 μm and a processing length of 6 mm, and the second WUCS fiber has an average fiber diameter of 6.5 μm and a processing length of 6 mm. Figure 13B The image includes a SEM image of a nonwoven mat 1302 made by a wet web forming process from a combination of 85% first WUCS fibers (fiber 1) and 15% second ULF fibers (fiber 2) by weight of the glass fiber. The first WUCS fibers have an average fiber diameter of 11 μm and a processing length of 6 mm, and the second ULF fibers have an average fiber diameter in the range of 2.8 μm to 3 μm and a processing length in the range of 1 mm to 6 mm. Figure 13C The image includes a SEM image of a nonwoven mat 1304 made by a wet web forming process from a combination of 85% first WUCS fibers (fiber 1) and 15% second inventive rotating fibers (fiber 2) by weight of the glass fiber. The first WUCS fibers have an average fiber diameter of 11 μm and a processing length of 6 mm, and the second inventive rotating fibers have an average fiber diameter of 3.5 μm and a processing length in the range of 1 mm to 6 mm.

[0208] Pads 1300, 1302, and 1304 were imaged using a scanning electron microscope to produce, respectively Figures 13A to 13C The SEM images shown are illustrated. These SEM images were analyzed using the open-source software ImageJ version 1.54f, where the Kappa Curvature Analysis plugin (Gary Brouhard, 2016) approximates the curvature of the second fiber (fiber 2) in each of pads 1300, 1302, and 1304. The WUCS fiber (fiber 2) in pad 1300 was found to have a curvature of 0.004. The ULF fiber (fiber 2) in pad 1302 was found to have a curvature of approximately 0.043. The inventive rotating fiber (fiber 2) in pad 1304 was found to have a curvature of approximately 0.055.

[0209] In some exemplary embodiments, rotating fibers, all produced by one or more fiber generators having substantially the same operating parameters (and possibly substantially simultaneously), are packaged together. In some exemplary embodiments, the rotating fibers may undergo processing (e.g., milling to reduce length to “processed length”) prior to packaging. As described herein, the rotating fibers in the package may include an adhesive composition applied thereto. As described herein, the package of rotating fibers will have an improved fiber diameter and / or length distribution.

[0210] adhesive preparations

[0211] When the spun fibers of the present invention are formed, or shortly thereafter, an aqueous viscose composition may be applied thereto. For example, the viscose composition may be sprayed onto the fibers using an annular ring with a nozzle surrounding a downward-pointing fiber curtain. The surface chemical properties imparted to the spun fibers by the viscose composition can protect the fibers and facilitate their downstream processing.

[0212] In one exemplary embodiment, an adhesive composition is provided. This adhesive composition comprises water, a silane coupling agent, at least one organic acid, and a cationic surfactant, wherein the adhesive composition has an active solids content of less than 5% and is substantially "colorless". Surprisingly, the subject adhesive compositions comprising reduced quantities of components have been found particularly suitable for the fibers of the present invention compared to conventional adhesive compositions (e.g., conventional adhesive compositions used with WUCS fibers). Specifically, various exemplary aspects of the adhesive compositions disclosed herein do not contain film-forming agents. In some aspects, the reduced quantity of components results in a more cationic adhesive composition than conventional adhesive compositions, which provides improved dispersion of the sizing fibers in aqueous white water during the formation of a pad made from the rotating fibers of the present invention.

[0213] The exemplary adhesive composition includes at least a silane coupling agent, at least one organic acid, and a cationic surfactant. In any of the embodiments, the adhesive composition may consist substantially of, or consist of, a silane coupling agent, at least one organic acid, and a cationic surfactant.

[0214] Silane coupling agents

[0215] Silane coupling agents can be in a partially or completely hydrolyzed state, or in a non-hydrolyzed state. Silane coupling agents can also exist in monomeric, oligomeric, or polymeric form before, during, or after their use.

[0216] Suitable silane coupling agents for the viscose compositions disclosed herein are organosilanes having silanol functional groups that are well bonded to glass (e.g., after hydrolysis of alkoxy groups). Silane coupling agents also contribute to processability, such as by reducing the level of broken fiber filaments during subsequent processing.

[0217] The silane coupling agent that can be used in the adhesive compositions of the present invention is characterized by functional groups of amino, methacrylate, epoxy, azide, vinyl, methacryloxy, urea, and isocyanate. Preferably, the organosilane has functional groups that are linked to silicon atoms by non-hydrolyzable bonds.

[0218] Organosilanes used in adhesive compositions include silanes containing the structure Si(OR)3, wherein R is an organic group, such as an alkyl group. Lower alkyl groups, such as methyl, ethyl, and isopropyl, are preferred. Examples of specific silane coupling agents suitable for adhesive compositions include, but are not limited to, γ-aminopropyltriethoxysilane (A-1100), γ-ureidopropyltrimethoxysilane (A-1524), 3-aminopropyltriethoxysilane (KBE-903), γ-glycidoxypropyltrimethoxysilane (A-187), γ-methacryloyloxypropyltrimethoxysilane (A-174), n-β-aminoethyl-γ-aminopropyltrimethoxysilane (A-1120), and methyl-trichlorosilane (A-...). 154), methyltrimethoxysilane (A-163), γ-mercaptopropyltrimethoxysilane (A-189), γ-chloropropyltrimethoxysilane (A-143), vinyltriethoxysilane (A-151), vinyltri-(2-methoxyethoxy)silane (A-2171), vinyltriacetoxysilane (A-188), octyltriethoxysilane (A-137), methyltriethoxysilane (A-162), and methyltrimethoxysilane (A-1630). All silane coupling agents listed herein are available as Silquest. ™ The product is commercially available from Momentive Performance Materials, Inc. (Waterford, New York). In some exemplary embodiments, the silane coupling agent is selected from γ-aminopropyltriethoxysilane, γ-ureidopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, and combinations thereof.

[0219] In one exemplary embodiment, the adhesive composition comprises Silquest ® Y-9669, purchased from Momentive, is N-phenyl-γ-aminopropyltriethoxysilane with a solids content of 82%, and is similar to Silquest. ®A-1120 is N(β-aminoethyl)γ-aminopropyltrimethoxysilane with a solids content of 81%. An exemplary methacrylate-functionalized silane for use in the adhesive compositions disclosed herein is γ-methacryloyloxypropylmethoxysilane (A-174), commercially available from Momentive Performance Materials, Inc. (Waterford, New York). In another exemplary embodiment, the silane coupling agent component of the adhesive compositions disclosed herein comprises Silquest. ® Y-9669 and A-174.

[0220] In some exemplary embodiments, the adhesive composition includes a silane coupling agent in an amount such that the silane coupling agent accounts for 1% to 60% by weight of the solids content of the adhesive composition. In some exemplary embodiments, based on the total solids content of the adhesive composition, the silane coupling agent comprises 5% to 50% by weight of solids, including, for example, 15% to 45% by weight, and further comprises 25% to 35% by weight of solids. In some exemplary embodiments, the silane coupling agent has an active solids content of 25%-80%, including 40%-70% and 60%-65%.

[0221] organic acids

[0222] As described above, the exemplary adhesive compositions disclosed herein include at least one organic acid. The organic acid is used to adjust the pH to enable the hydrolysis of the silane coupling agent. The organic acids disclosed herein comprise at least one weak acid. Examples of suitable weak acids that can be used in the adhesive compositions disclosed herein include, but are not limited to, acetic acid, succinic acid, citric acid, and combinations thereof. In some exemplary embodiments, the weak acid component comprises or is composed of acetic acid. The adhesive compositions disclosed herein have a pH of about 3.0 to about 7.5, preferably about 4.5 to about 5.5.

[0223] In some exemplary embodiments, the adhesive composition includes an organic acid in an amount such that the organic acid accounts for 0.01% to 50% by weight of the solids content of the adhesive composition. For example, based on the total solids of the adhesive composition, the organic acid accounts for 0.05% to 40% by weight of the solids content of the adhesive composition, including 0.1% to 30% by weight, 0.5% to 25% by weight, 0.75% to 22% by weight, 1.0% to 20% by weight, 1.5% to 18% by weight, and 2.0% to 15% by weight. In some exemplary embodiments, the organic acid has 25% to 99%, including 40% to 90% and 70% to 85% of active solids content. In some exemplary embodiments, the organic acid has about 80% + / - 3% of active solids content.

[0224] cationic surfactants

[0225] The exemplary adhesive compositions disclosed herein also include cationic surfactants. The cationic surfactants act as “wet lubricants” and are used to increase the dispersibility of the glass fibers in an aqueous white solution during the formation of a pad made from the rotating fibers of the present invention.

[0226] Suitable examples of cationic surfactants include, but are not limited to, imidazoline and alkyl imidazoline derivatives, aminoethyl imidazoline, stearic acid alcohol amides such as Lubesize K-12 (Alpha / Owens Corning (Ontario, Canada)), polyamides of acetic acid, C5-C9 carboxylic acids, and diethylenetriamine-ethyleneimine, which can be used as Katax ® 6760L (Pulcra Chemicals) is commercially available. A preferred cationic softener is the acetate of the reaction product of tetraethylenepentamine and stearic acid, which is converted to approximately 91% imidazoline groups and is commercially available as LUBESIZE K-12.

[0227] Imidazolines are thermally stable organic nitrogenous bases. Unneutralized imidazolines are lipophilic and generally soluble in nonpolar solvents and mineral oils, but tend to be dispersible only in aqueous systems. The ability of imidazolines to form cations allows them to strongly adsorb onto negatively charged surfaces of metals, fibers, plastics, glass, and minerals, thereby converting these hydrophilic surfaces into hydrophobic ones. Imidazoline salts tend to be more hydrophilic than their bases and are used as acid-stable detergents with good wetting properties. The compatibility of imidazolines in aqueous systems can be improved by using suitable solubilizers.

[0228] In some exemplary embodiments, the adhesive composition includes a cationic surfactant in an amount such that the cationic surfactant accounts for 25% to 90% by weight of the total solids content of the adhesive composition. In some exemplary embodiments, based on the total solids content of the adhesive composition, the cationic surfactant comprises 30% to 80% by weight of solids, including, for example, 35% to 75% by weight, 37% to 72% by weight, and 40% to 70% by weight of solids, including all endpoints and subranges between the two. In some exemplary embodiments, the cationic surfactant has an active solids content of 0.5% to 20%, including 1% to 15% and 5% to 10%. In some exemplary embodiments, the cationic surfactant has an active solids content of about 9% + / - 3%.

[0229] As described above, the adhesive compositions disclosed herein can be formed in the absence of a film-forming agent material, which may comprise polymeric materials such as, for example, amide-based polymers, acrylic-based polymers, polyester-based polymers, epoxide-based polymers, etc. Traditionally, film-forming agents are included to aggregate and form a film on fibers during the drying of the adhesive composition. Film-forming agents serve to protect the fibers from damage during processing and to impart compatibility with other end-use materials. However, the adhesive compositions disclosed herein are formed using reduced amounts of chemicals and provide sufficient fiber protection without the use of a film-forming agent. However, various aspects of the exemplary adhesive compositions disclosed herein may optionally include a film-forming agent.

[0230] The exemplary adhesive compositions disclosed herein also include water. The adhesive composition contains an amount of water sufficient to dilute the solids of the adhesive composition to a viscosity suitable for application onto rotating fibers. According to some exemplary embodiments, the adhesive composition contains 80% to 99.9% by weight, including, for example, 85% to 98% by weight, or 90% to 99.5% by weight, of water based on the total weight of the adhesive composition. The total solids content of the adhesive composition can be from 0.5% to about 20% by weight, including 2% to 10% by weight. Preferably, the adhesive composition has a total solids content of 3% to 6% by weight, and more preferably about 5% by weight.

[0231] In some exemplary embodiments, the adhesive composition comprises, substantially comprises, or comprises the following: 25% to 35% by weight of a silane coupling agent, about 2% to 20% by weight of an organic acid, and 50% to 70% by weight of a cationic surfactant, based on the total solids content of the adhesive composition. In any of the exemplary embodiments, the adhesive composition may comprise or comprises: 25% to 35% by weight of a γ-aminopropyltriethoxysilane coupling agent, 2% to 20% by weight of acetic acid, and 50% to 70% by weight of an imidazoline derivative coupling agent, based on the total solids content of the adhesive composition.

[0232] The exemplary adhesive compositions disclosed herein may also include other components conventionally used in adhesive compositions. For example, the adhesive composition may optionally include wetting agents, surfactants, lubricants, antioxidants, dyes, oils, fillers, heat stabilizers, defoamers, dust suppressants, antimicrobial agents, antistatic agents, fungicides, biocides, film-forming agents, shredding aids, thickeners, and / or other conventional additives. Based on the dry solids content of the adhesive composition, the amount of the aforementioned optional components in the adhesive composition may range from 0% by weight to 90% by weight, including, for example, 0% by weight to 50% by weight, or 0% by weight to 30% by weight.

[0233] The exemplary adhesive compositions disclosed herein can be prepared by combining their components according to any method known to those skilled in the art. In some exemplary embodiments, the viscosity of the white water at room temperature is preferably greater than 2.0 cps, more preferably between 2.0 cps and 5 cps, and even more preferably about 3.0 cps to 3.5 cps.

[0234] Exemplary adhesive composition ranges are provided in Table 7 below. It should be understood that any of the disclosed ranges of adhesive compositions AC in Table 7 may be used in combination with any other disclosed composition ranges herein, and is not limited to the specific combinations of the ranges provided herein.

[0235]

[0236] Table 7

[0237] In some exemplary embodiments, the adhesive composition is essentially cationic. The charge of the adhesive composition can be described by its zeta potential over a pH range. Zeta potential is the charge generated at the interface between a solid surface (such as particulate material) and its liquid medium. The adhesive composition of the present invention has a zeta potential with an absolute value at least 20 greater than the pH. Specifically, the adhesive composition has a zeta potential with an absolute value greater than 30 in a pH range between 2 and 4. The adhesive composition has a zeta potential with an absolute value greater than 20 in a pH range between 2 and 6.

[0238] For illustrative purposes, the adhesive formulation (IF) of the present invention, which is formed according to the concept of the invention and has a cationic surfactant comprising about 70% by weight of solids, is compared with a first conventional reference adhesive formulation (RF-1) applied to an equivalent fiber and a second conventional reference adhesive formulation (RF-2) applied to another equivalent fiber. Both RF-1 and RF-2 contain about 20% to 40% by weight of cationic lubricant. In each case, the specific adhesive formulation is applied to conventional WUCS fibers at the same or lower weight percentage using a roll coating technique. Figure 5In the figure, a graph of the zeta potential for each formulation was plotted relative to pH. Generally speaking, the higher the magnitude of the zeta potential, the more cations in the formulation.

[0239] As shown in graph 500, the larger zeta potential of IF at both high and low pH indicates that the sizing fiber exhibits amphipathic behavior, meaning it can act as either an acid or a base. This characteristic indicates that fibers sizing with IF disperse well in both acidic and alkaline environments. To achieve a suitable dispersion, a zeta potential with an absolute value greater than 20 is generally desirable at pH levels between 2 and 6.

[0240] In addition, the total composition of adhesive chemicals (such as IF) contains more cationic lubricants, approximately 70% by weight solids, than that of conventional adhesive chemicals (such as RF-1, RF-2), which typically range from 0% to 40% by weight solids.

[0241] Compared to conventional adhesive compositions, the exemplary adhesive compositions disclosed herein can be substantially "colorless". In exemplary embodiments, the adhesive compositions disclosed herein exhibit a ΔL of -5 to +5 on fibers. Value. In some exemplary embodiments, the viscose compositions disclosed herein exhibit a ΔL value of 0 to +2.5 on fibers. Values, including +2 ΔL Value. In an exemplary embodiment, the adhesive composition disclosed herein exhibits a Δa value of -10 to +10 on fibers. Value. In some exemplary embodiments, the viscose compositions disclosed herein exhibit a Δa value of -8 to +2 on fibers. Values, including approximately -6 Δa Value. In an exemplary embodiment, the adhesive composition disclosed herein exhibits a Δb value of -10 to +10 on fibers. Value. In some exemplary embodiments, the adhesive compositions disclosed herein exhibit a Δb value of -5 to +5 on fibers. Values, including approximately 0 for Δb value.

[0242] The viscose composition can be applied to the fiber such that it is present on the fiber in an amount of 0.05 wt% to 2 wt% based on the total weight of the sizing fiber. The amount of viscose composition present on the fiber is also referred to as the "twist solids content". In some exemplary embodiments, the viscose composition is present on the fiber in an amount of 0.08 wt% to 1.0 wt% based on the total weight of the sizing fiber, including 0.1 wt% to 0.8 wt%, 0.2 wt% to 0.6 wt%, and further including an amount of 0.35 wt% to 0.55 wt% based on the total weight of the sizing fiber. This can be determined by the loss on ignition (LOI) of the sizing fiber, which is the weight reduction experienced by the sizing fiber after heating it to a temperature sufficient to cause the viscose composition to burn or pyrolyze from the fiber.

[0243] When evaluated based on the surface area of ​​the fibers, the adhesive compositions of the present invention can also be applied at lower levels. For example, the rotary fibers of the present invention described herein can have a surface area of ​​less than about 4 mg / cm² when applied thereon. 2 Including, for example, 0.5 mg / cm³ 2 -3.8mg / cm 2 0.75 mg / cm 2 -3.4mg / cm 2 1mg / cm 2 -3mg / cm 2 Or 1.15 mg / cm 2 -2.5mg / cm 2 The strand solid, however, conventional WUCS fibers can have a 4 mg / cm² applied to them. 2 -24mg / cm 2 The solid strand.

[0244] In an exemplary embodiment, the moisture content of the sizing fiber is less than 10%, including a final moisture content of less than 7%, less than 6%, and less than or equal to 5%. A reduction in the final moisture content (i.e., an increase in fiber dryness) can provide beneficial effects such as reduced transportation costs, while reducing / avoiding the need for antimicrobial agents in the viscose composition.

[0245] nonwoven mat

[0246] The rotating fibers of this invention can be used to form other materials, such as nonwoven mats. Fiber mats can be formed by known methods, such as wet web forming processes. In a wet web forming process, discrete fibers are dispersed in an aqueous slurry containing surfactants, thickeners, defoamers, and / or other chemical reagents. The water and chemical components are commonly referred to as a “white water” solution. The slurry containing the fibers is then stirred in a mixing tank, causing the fibers to disperse throughout the slurry. The slurry containing the dispersed fibers is deposited onto a moving screen, where a significant portion of the water is removed to form a fiber web of randomly oriented fibers. A binder is applied to the fiber assembly, which is then passed through an oven to dry the fibers (i.e., remove any residual water from the fibers) and cure the binder to form a mat. In addition to being applied in an aqueous form, the binder can also be applied in a dry (powdered) form. For example, swellable polyvinyl alcohol (PVA) powder can be added to the fiber mixture, where the PVA binder effectively binds the fibers as they pass through the oven / dryer.

[0247] Generally, any adhesive suitable for forming conventional nonwoven fiber mats can be used. Exemplary adhesive compositions that can be used to produce nonwoven mats include formaldehyde-free (or formaldehyde-free (“NAF”)) adhesives, such as carboxyl-based adhesive compositions, polyvinyl alcohol-based adhesive compositions, carbohydrate-based adhesive compositions, etc. Such formaldehyde-free adhesives are environmentally friendly, i.e., “green.” In some embodiments, the adhesive may comprise one or more bio-based materials. However, in some exemplary embodiments, the adhesive composition may comprise a formaldehyde system, such as a urea-formaldehyde system.

[0248] The adhesive may include thermosetting or thermoplastic adhesives. For example, the adhesive may comprise a thermosetting adhesive, wherein at least one polycarboxylic acid polymer is used as the thermosetting adhesive resin. Polycarboxylic acid polymers include organic polymers or oligomers containing more than one side carboxyl group. The polycarboxylic acid adhesive may be a homopolymer or copolymer prepared from one or more unsaturated carboxylic acids, including, but not limited to, acrylic acid, methacrylic acid, crotonic acid, isocrotonic acid, maleic acid, cinnamic acid, 2-methylmaleic acid, itaconic acid, 2-methylitaconic acid, α,β-methyleneglutaric acid, etc. Alternatively, the polycarboxylic acid adhesive may be prepared from unsaturated acid anhydrides, including but not limited to maleic anhydride, itaconic anhydride, acrylic anhydride, methacrylic anhydride, etc., and mixtures thereof. The polymerization of these acids and anhydrides is considered to be within the capabilities of those skilled in the art.

[0249] In some exemplary embodiments, the adhesive composition comprises a thermosetting acrylic package comprising a blend of a thermosetting hydrophilic acrylic adhesive material and a thermosetting hydrophobic acrylic adhesive material. The thermosetting acrylic package may include, but is not limited to, acrylic emulsions, acrylic solutions, or mixtures thereof. The thermosetting nature of the acrylic package reduces the tackiness of the adhesive and thus reduces adhesion of the adhesive to processing equipment during manufacturing. In some embodiments, the thermosetting acrylic package comprises a mixture of an acrylic homopolymer and a styrene-acrylic latex. Based on the total weight of the precursor adhesive solids, the acrylic homopolymer may be present in an amount of about 50% to about 80% by weight, or about 60% to about 75% by weight. Based on the total weight of the adhesive solids, the styrene-acrylic latex may be present in an amount of about 20% to about 45% by weight, or about 25% to about 40% by weight.

[0250] The adhesive composition may optionally include a defoamer. In some exemplary embodiments, the defoamer includes one or more of siloxanes, mineral oils, and polyoxyethylenes, but any defoamer may alternatively be used. Exemplary defoamers include polyether siloxanes, such as Tego. ® Foamex 1488 (available commercially from Evonik). In some exemplary embodiments, the defoamer is present in the binder composition in an amount from about 0.001% to about 1.0% by weight, including from about 0.01% to about 0.25% by weight, based on the total solids weight in the precursor binder composition.

[0251] In some embodiments, the adhesive composition may optionally contain at least one coupling agent. In some embodiments, the coupling agent is a silane coupling agent. The coupling agent may be present in the adhesive composition in amounts of 0.01% to 5% by weight (based on dry weight), 0.01% to 2.5% by weight (based on dry weight), 0.1% to 0.5% by weight (based on dry weight), or 0.15% to 0.25% by weight (based on dry weight).

[0252] Non-limiting examples of silane coupling agents that can be used in adhesive compositions may be characterized by functional groups, including but not limited to alkyl, aryl, amino, epoxy, vinyl, methacryloxy, urea, isocyanate, and mercapto groups. In some embodiments, the silane coupling agent comprises a silane containing one or more nitrogen atoms, the silane having one or more functional groups such as amines (primary, secondary, tertiary, and quaternary amines), amino, imino, amide, imide, urea, or isocyanate groups. Specific, non-limiting examples of suitable silane coupling agents include, but are not limited to, aminosilanes (e.g., γ-aminopropyltriethoxysilane and γ-aminopropyltrihydroxysilane), epoxytrialkoxysilanes (e.g., 3-glycidoxypropyltrimethoxysilane and 3-glycidoxypropyltriethoxysilane), methacryloxytrialkoxysilanes (e.g., 3-methacryloyloxypropyltrimethoxysilane and 3-methacryloyloxypropyltriethoxysilane), hydrocarbontrialkoxysilanes, aminotrihydroxysilanes, epoxytrihydroxysilanes, methacryloxytrihydroxysilanes, and / or hydrocarbontrihydroxysilanes.

[0253] The binder composition may also contain one or more additional additives, such as extenders, catalysts, processing aids, dust suppressants, viscosity modifiers, pH adjusters, crosslinking density enhancers, deodorizers, antioxidants, moisture-proofing agents, or combinations thereof. Optionally, the binder may contain, but is not limited to, dyes, pigments, additional fillers, colorants, UV stabilizers, heat stabilizers, emulsifiers, preservatives (e.g., sodium benzoate), corrosion inhibitors, and mixtures thereof. Other additives may be added to the binder composition to improve process and product performance. Such additives include lubricants, wetting agents, antistatic agents, and / or waterproofing agents. Additives may be present in trace amounts (such as about 0.1% or less by weight of the binder composition) up to about 10% by weight of the total solids in the binder composition in the precursor binder composition.

[0254] In some exemplary embodiments, the adhesive may constitute a filled adhesive that includes one or more primary fillers (e.g., mineral fillers). In this case, the primary filler may be present in the filled adhesive composition at a maximum of about 50% by weight of the total solids in the filled adhesive composition.

[0255] The binder composition includes water to dissolve or disperse active solids for application onto fibers. The amount of water added is sufficient to dilute the aqueous binder composition to a viscosity suitable for its application onto the fibers and to achieve the desired solids content on the fibers.

[0256] In some exemplary embodiments, the adhesive composition is included in the fiber mat in amounts ranging from about 10% to about 30% by weight, including between about 15% and about 27% by weight, and between about 16% and about 25% by weight.

[0257] Uniform fiber arrangement in nonwoven sheet-like fiber mats contributes to the mat's strength and the final product. Other beneficial effects, such as improved aesthetics, can also be achieved through increased fiber uniformity. One problem in preparing uniform fiber mats from aqueous dispersions is the difficulty in dispersing fibers (e.g., glass fibers) in the aqueous medium. This difficulty in dispersing fibers initially occurs when the fibers are added to water. Dispersibility is further complicated by the tendency of fibers that are slightly dispersed in the aqueous medium to re-agglomerate to some extent. Re-agglomerated fibers are very difficult to redisperse. The lack of good fiber dispersion in the aqueous medium hinders the formation of uniform mats and adversely affects the properties (e.g., strength, appearance) of the resulting sheet-like mat or the final product incorporating such a mat. This dispersion problem can be exacerbated when smaller diameter fibers (e.g., rotating fibers) are mixed with larger diameter fibers (e.g., non-rotating fibers, such as WUCS).

[0258] A well-dispersed aqueous mixture can be obtained by any suitable means, provided that a uniform or substantially uniform distribution of two (or more) different sets of glass fibers is achieved in the aqueous medium. In some exemplary embodiments, a uniform distribution of two different sets of glass fibers is achieved. In some exemplary embodiments, a substantially uniform distribution of two sets of glass fibers is achieved. The dispersion can be obtained by high-shear mixing equipment, such as a rotor / stator mixer. Not wishing to be bound by theory, the inventors believe that highly dispersed and distributed mixing contributes to the production of fibrous nonwoven mats that have substantially no or only a small amount of undispersed or partially dispersed fibers (e.g., flocculent material) on each surface of the bonded nonwoven mat.

[0259] In some exemplary embodiments, the majority (e.g., at least 10% by weight) of the fibers used to form the nonwoven mat are, but not all, the rotationally formed fibers of the present invention described herein. In some exemplary embodiments, the nonwoven mat is formed from a blend of a first fiber and a second fiber (i.e., the rotationally formed fibers of the present invention), wherein the first fiber has an average diameter >6.5 μm and the second fiber has an average diameter <6.5 μm. In some exemplary embodiments, the first fiber has an average diameter in the range of about 6.5 µm to about 15 µm. In some exemplary embodiments, the second fiber has an average diameter in the range of about 1 µm to about 6 µm. In some exemplary embodiments, both the first and second fibers are glass fibers. In some exemplary embodiments, the first fiber is not a rotationally formed fiber.

[0260] In some exemplary embodiments, the rotating fibers of the present invention undergo pretreatment before being introduced into the mixing tank (along with other fibers) of a wet web forming process. Pretreatment can be used to convert the fibers from a stored (e.g., compressed) form to a form more suitable for wet web forming, to adjust the fibers (e.g., to promote dispersibility) for wet web forming, to assess fiber defects (e.g., to remove fibrous material or potential fibrous material), etc.

[0261] To illustrate, the reference Figure 12 Figure 1200 illustrates a pretreatment associated with the production of nonwoven yarn via a wet web forming process involving the blending of the rotatable fibers of the present invention with wet-laid chopped strands (WUCS) of glass. In this example, the rotatable fibers of the present invention are ultimately blended with WUCS in a slurry, wherein the percentage of rotatable fibers in the total glass fiber blend can vary between 1 wt% and 99 wt%. Prior to using this blend of two glass-based fibers in the wet web forming process to produce the nonwoven yarn, the rotatable fibers are wetted and dispersed in a separate process before being blended with the WUCS.

[0262] In the first step 1202, a certain amount of rotating fibers is loaded onto the conveyor to feed into the mixing tank.

[0263] In the next step 1204, the rotating fibers are fed into a mixing tank containing an aqueous solution of surfactants, viscosity modifiers, polymer binders, and other process chemical additives. The rotating fibers are added gradually to the mixing tank to ensure that each fiber is individually wetted by the aqueous solution. The shape of the agitator and the tank is designed to provide sufficient shear energy input and volumetric displacement rate while also disrupting any continuous eddies that may form. The rotating fibers, with their large surface area to mass ratio, are thoroughly wetted by the aqueous solution. The dosage level of the rotating fibers in the mixing tank varies between 5 g / L and 50 g / L.

[0264] In the next step 1206, after sufficient dispersion, the rotating fiber aqueous suspension is pumped through a screening unit to remove any potentially large impurities from the raw material. The screening device can be modified according to the required fineness of the rotating fiber suspension.

[0265] The rotating fiber raw material may contain agglomerates of fibers that are difficult to thoroughly wet and disperse using the initial mixing method (step 1204). These agglomerates may manifest as defects in the nonwoven mat (e.g., "flocculents"). Therefore, in the next (optional) step 1208, a device such as a high-shear mixer may be employed to break up these fiber flocculents. In the high-shear mixer, the fiber suspension passes through a slotted rotor / stator system that homogenizes the fiber suspension, thereby facilitating the breaking up of the fiber flocculents.

[0266] Finally, in step 1210, the pretreated rotating fibers are delivered to the mixing tank of the wet web forming process, where the rotating fibers can be more effectively dispersed together with other fibers in the white aqueous solution.

[0267] In view of the above, in one method of producing nonwoven mats using a fiber blend comprising the rotating fibers of the present invention (wherein the percentage of the rotating fibers in the total glass fiber blend can vary between 1 wt% and 99 wt%), the method comprises dispersing the rotating fibers in a first white aqueous solution and then adding the dispersed rotating fibers to a second white aqueous solution containing non-rotating fibers. In some exemplary embodiments, the non-rotating fibers are WUCS fibers. In some exemplary embodiments, the non-rotating fibers have a larger average fiber diameter than the rotating fibers.

[0268] In some exemplary embodiments, separate aqueous mixtures of a first group of glass fibers and a second group of glass fibers are prepared and then combined under stirring (e.g., high-intensity mixing) to provide a homogeneous or nearly homogeneous dispersion of the fiber blend.

[0269] In some exemplary embodiments, a first group of glass fibers and a second group of glass fibers are combined to form a dry mixture of glass fibers. The dry mixture is then formed into an aqueous mixture under stirring (e.g., high-intensity mixing) to provide a homogeneous or substantially homogeneous dispersion of the fiber blend.

[0270] Because the rotating fibers of the present invention (e.g., made by method 300 or similar methods) can be substantially free of or have significantly reduced amounts of any unfibered or poorly fiberized material (commonly referred to as “slag balls”), fused fibers, agglomerated fibers (e.g., flocculents) and / or other forms of defective fibers, as described above, nonwoven mats made from the rotating fibers of the present invention (e.g., nonwoven mats comprising portion 1010) can also have fewer defects and thus have improved properties (e.g., surface smoothness, surface appearance).

[0271] For example, the nonwoven mat has a first surface 1012 and a second surface (not shown) opposite to the first surface 1012. In some exemplary embodiments, at least one surface of the nonwoven mat has less than about 100 fuzz particles per 1,000 m³. 2 Nonwoven mat. In some exemplary embodiments, each surface of the nonwoven mat has less than about 100 fuzz particles per 1,000 m². 2 Nonwoven mat. In some exemplary embodiments, at least one surface of the nonwoven mat has less than about 50 fibrous particles per 1,000 m². 2Nonwoven mat. In some exemplary embodiments, each surface of the nonwoven mat has less than about 50 fuzz particles per 1,000 m². 2 Nonwoven mat. In some exemplary embodiments, at least one surface of the nonwoven mat has less than about 25 flocs / 1,000 m². 2 Nonwoven mat. In some exemplary embodiments, each surface of the nonwoven mat has less than about 25 fibrous particles per 1,000 m². 2 Nonwoven mat. In some exemplary embodiments, at least one surface of the nonwoven mat has less than about 15 flocculent particles per 1,000 m². 2 Nonwoven mat. In some exemplary embodiments, each surface of the nonwoven mat has less than about 15 flocs / 1,000 m². 2 Nonwoven mat.

[0272] In some exemplary embodiments, at least one surface of the nonwoven mat is substantially free of any fibrous material / 1,000 m 2 Nonwoven mat. In some exemplary embodiments, each surface of the nonwoven mat is substantially free of any lint / 1,000 m². 2 Nonwoven mat.

[0273] One method for assessing or otherwise estimating the amount of fibrous material in a nonwoven mat is (1) unrolling a roll of the nonwoven mat, which represents approximately 500 m... 2 (1) the total surface area, (2) manually counting the mass of loosely aggregated fibers visible to the naked eye under standard or ambient lighting, and (3) converting (extrapolating) the counting results to a larger surface area (e.g., 1,000 m²). 2 The amount of flocculent material in a given surface area can be calculated. Other suitable methods for counting the amount of flocculent material in a given surface area are also conceivable. For example, image processing techniques can be used to generate the amount of flocculent material corresponding to relatively large portions of a nonwoven mat (e.g., ≥ 500 m²). 2 The image is then automatically evaluated to identify examples of fibrous material within it. Generally, smaller portions (e.g., < 500 m²) of the nonwoven mat material are identified for evaluation. 2 This produces less reliable estimates of flocculent counts, likely because the flocculent material is typically distributed over a larger portion of the resulting pad (roll).

[0274] Generally, nonwoven mats are designed to have sufficient strength to withstand the processing steps and speeds required to produce nonwoven mats for a variety of end uses. Furthermore, the strength of the nonwoven mat must be sufficient to allow it to be stored in any desired form and for potentially extended periods without loss of its cohesive properties. The improved fiber diameter and / or fiber length distribution of the rotating fibers of this invention is intended to enhance the structure and homogeneity or uniformity of the glass fiber arrangement in the nonwoven mat, which should result in more consistent and defined strength properties of the mat.

[0275] Exemplary Applications

[0276] There are numerous applications for nonwoven fiber mats produced using the rotating fibers of the present invention described herein. Generally, any conventional nonwoven mat can be replaced by the nonwoven mat of the present invention, provided improved properties (e.g., surface smoothness, mechanical strength). Examples of potential uses include, but are not limited to, roofing materials (e.g., roof panels), surface coverings for composite materials, ceiling panels, building panels, filter media, flooring applications, wall covering materials, and battery separators.

[0277] One such application is as a finishing material (“finishing”) for ceiling panels. The finishing is intended to be bonded to or otherwise joined to a core substrate (e.g., gypsum board, polyisocyanurate board, mineral wool insulation). Further processing of the finishing substrate (e.g., by painting) forms the ceiling panel.

[0278] Typically, nonwoven mats (as “base mats”) are impregnated with inorganic fillers (e.g., calcium carbonate (CaCO3), alumina trihydrate (ATH), kaolin) and auxiliary binders to form “impregnated mats”. The selection and application of fillers are controlled to achieve desired aesthetic properties (e.g., color, smoothness) while still maintaining necessary sound insulation properties (e.g., porosity).

[0279] In various exemplary embodiments, the rotating fibers of the present invention described herein are used to form base mats and / or impregnated mats. In some exemplary embodiments, a blend of WUCS glass fibers (as the first fiber) and rotating glass fibers (as the second fiber) is used to form base mats and / or impregnated mats.

[0280] Generally, the average diameter of the second fiber is smaller than that of the first fiber, and the average (processed, e.g., ground) length of the second fiber is smaller than that of the first fiber (processed, e.g., chopped) length. Furthermore, as described herein, the average fiber diameter distribution and / or average fiber length distribution of the rotating fibers of the present invention are more compact (by volume) around the target fiber diameter and / or target fiber length than those of conventional rotating fibers.

[0281] In some exemplary embodiments of the nonwoven mat of the present invention, the average fiber diameter of the first fiber is in the range of 10µm to 11µm; and the average fiber diameter of the second fiber is in the range of 3µm to 4µm. In some embodiments, the average processed fiber length of the first fiber is approximately 6mm; and the average processed fiber length of the second fiber is in the range of 1mm to 6mm. For reference, relatively small fiber diameter values ​​are typically expressed in micrometers (μm) or thousandths of an inch (HT), where 1 HT = 0.254 μm / micrometer (or 1 μm / micrometer = 3.937 HT).

[0282] By way of example, conventional rotary fiber forming methods produce rotary fibers (from fiber former 10) with lengths ranging from approximately 12.7 mm (0.5 inches) to 50.8 mm (2 inches), while the rotary fiber forming method of the present invention (e.g., method 300) produces rotary fibers (from fiber former 10) with lengths ranging from approximately 76.2 mm (3 inches) to 304.8 mm (12 inches). In some exemplary embodiments, the rotary fiber forming method of the present invention produces rotary fibers with an average forming length ranging from greater than 50.8 mm (2 inches) to less than or equal to 152.4 mm (6 inches). The ability to produce longer fibers provides increased flexibility in downstream fiber processing and greater control over the properties of the final product.

[0283] In some exemplary embodiments of the nonwoven mat of the present invention, the first fiber and the second fiber are bonded together by a polyvinyl alcohol (PVOH) adhesive.

[0284] The nonwoven felt of the present invention may or may not include a coating (i.e., an impregnating agent) that penetrates into the felt. The coating may be considered as a combination of inorganic mineral fillers (e.g., alumina trihydrate and / or calcium carbonate), auxiliary binders (i.e., PVOH and / or acrylic emulsions) and other additives (e.g., defoamers, dispersants, waterproofing agents).

[0285] In one exemplary embodiment, the nonwoven mat is an unfilled product comprising first fibers (with an average diameter in the range of 10 μm to 11 μm and an average processed length of about 6 mm), second fibers (with an average diameter in the range of 3 μm to 4 μm and an average processed length in the range of 1 mm to 6 mm), and PVOH binder, without any coating / impregnation applied as described above. In this embodiment, the mat comprises approximately 64 wt% of the first fibers, approximately 21 wt% of the second fibers, and approximately 15 wt% of the binder.

[0286] In another exemplary embodiment, the nonwoven mat is a low-filling product comprising a first fiber (with an average diameter in the range of 10 μm to 11 μm and an average processing length of about 6 mm), a second fiber (with an average diameter in the range of 3 μm to 4 μm and an average processing length in the range of 1 mm to 6 mm), and a PVOH binder, as described above, with any coating / impregnation applied thereto. In this embodiment, the mat comprises approximately 32 wt% of the first fiber, approximately 11 wt% of the second fiber, and approximately 7 wt% of the primary PVOH binder, and approximately 50 wt% of the coating (i.e., 47 wt% of inorganic filler and approximately 3 wt% of auxiliary binder).

[0287] In another exemplary embodiment, the nonwoven mat is a highly filled product comprising a first fiber (with an average diameter in the range of 10 μm to 11 μm and an average processing length of about 6 mm), a second fiber (with an average diameter in the range of 3 μm to 4 μm and an average processing length in the range of 1 mm to 6 mm), and a PVOH binder, as described above, with any coating / impregnation applied thereto. In this embodiment, the mat comprises approximately 13% by weight of the first fiber, approximately 4% by weight of the second fiber, and approximately 3% by weight of the primary PVOH binder, as well as approximately 80% by weight of the coating (i.e., 75% by weight of inorganic filler and approximately 5% by weight of auxiliary binder).

[0288] As described above, a common application of the base pads and impregnated pads of the present invention is in ceiling panel finishes. The pads of the present invention are expected to contribute to the functionality and / or customer acceptance of finished ceiling panels, at least due to the inclusion of the rotating fibers of the present invention. These properties may include reduced turbidity, increased opacity, and improved directionality. Directionality refers to the phenomenon that a ceiling panel has different perceived visual effects when rotated 90 degrees. Furthermore, the pads of the present invention can have a smoother surface, which reduces the amount of coating required to achieve the desired aesthetics. Additionally, the pads of the present invention can have a desired surface porosity, allowing the ceiling panel to exhibit acceptable acoustic performance.

[0289] By way of example, it has been shown that ceiling panels made with a finish formed from the nonwoven pad of the present invention as described herein exhibit reduced turbidity compared to similar finishes made with conventional nonwoven pads.

[0290] To assess the turbidity of ceiling panels facing nonwoven fiber mats, a device controlled by a cloud-runner speckle meter (“cloud tester” device) manufactured by BYK-Gardner GmbH (Geretsried, Germany), known as a paint speckle tester, was used. Cloud testers are typically sold to the automotive industry for measuring paint spots (e.g., spots, blemishes, clouding) on ​​automotive topcoats. The cloud tester device measures irregular brightness variations by simulating visual evaluation at three different viewing angles, such as… Figure 6 As shown in Figure 600, the cloud / spot is characterized by its size and visibility. In this way, the cloud tester device has proven to be an effective tool for quantifying and ranking the turbidity of ceiling panel surfaces.

[0291] The cloud spot tester can measure "cloud spots" of different sizes (i.e., color changes / deviations) and provide a numerical rating / value indicating the turbidity of the sample. As shown in Table 8, each cloud spot range requires a minimum scan length for measurement. The cloud spot tester supports scan lengths from 10 cm to 100 cm, selectable in 1 cm increments.

[0292]

[0293] Table 8

[0294] To evaluate ceiling panel finish products, cloudiness within Md, Me, Mf, and Mg was measured. Data were collected using a cloudiness testing apparatus with a scan length set to 23 cm. At this scan length, five passes were performed across the width or length of a sample with dimensions set to A3 (297 mm × 420 mm) or A4 (210 mm × 297 mm) to obtain one measurement result. Unpainted and unfilled sample sheets were measured against a black background.

[0295] like Figure 7As shown in plot 700, the effect of adding a certain percentage of finer (i.e., smaller diameter) glass fibers (x-axis) to a certain amount of larger diameter (i.e., 10 μm) glass fibers on the “turbidity” grade (y-axis) of the nonwoven fiber pads was evaluated. Specifically, a series of nonwoven sample pads were prepared using different blend ratios (0% to 40%) of 6.5 μm non-rotational WUCS glass fibers added to 10 μm WUCS glass fibers; and a series of nonwoven sample pads were also prepared using different blend ratios (0% to 40%) of 3.5 μm rotationally formed glass fibers of the present invention added to 10 μm WUCS glass fibers. In this way, samples comprising 6.5 μm non-rotational WUCS glass fibers were compared with samples comprising 3.5 μm rotationally formed glass fibers of the present invention at different loading percentages (%) and across all three viewing angles (15°, 45°, and 60°) of the clouding tester apparatus. It can be seen that the 3.5 μm rotating fibers of the present invention are more effective than the 6.5 μm WUCS fibers in reducing the turbidity grades of smaller (9 mm to 13 mm and 11 mm to 24 mm) and larger (19 mm to 42 mm and 33 mm to 72 mm) cloud spots in reducing the turbidity grades of both smaller and larger cloud spots. For example, while the 3.5 μm rotating fibers of the present invention reduce the turbidity grades of both smaller and larger cloud spots, the 6.5 μm WUCS fibers have little effect on larger cloud spots. Furthermore, compared to the 6.5 μm WUCS fibers, the 3.5 μm rotating fibers of the present invention show a more dramatic reduction in turbidity grades relative to the loading level (%). Specifically, at a 40% loading, the 3.5 μm rotating fibers of the present invention show a reduction in turbidity grades of 9 mm to 13 mm cloud spots by approximately 35%, while the 6.5 μm WUCS fibers show only a reduction in turbidity grades of approximately 18% relative to cloud spots in the same size range at the same loading %. Furthermore, at a 40% load, the 3.5μm rotating fibers of the present invention showed a reduction of approximately 45% in turbidity grade for cloud spots ranging from 33mm to 72mm, while the 6.5μm WUCS fibers showed no significant reduction (0%) in cloud spots relative to this size range at the same load % . Therefore, due to its increased effectiveness in producing ceiling panel finishes with a reduced number of cloud spots, ceiling panels with acceptable aesthetic properties can be achieved at a lower fiber load compared to 6.5μm WUCS fibers.

[0296] like Figure 7As shown in plot 710 of B, the effect of adding a certain percentage of finer (i.e., smaller diameter) glass fibers (x-axis) to a certain amount of larger diameter (i.e., 10 μm) glass fibers on the “turbidity” grade (y-axis) of the nonwoven fiber pads was also evaluated. The finer fibers varied depending on their type (i.e., rotational molding versus non-rotational molding (i.e., composite material)) but otherwise had the same target diameter of 3.5 μm. Similarly, a series of nonwoven sample pads were prepared using different blend ratios (0% to 40%) of 3.5 μm non-rotational WUCS glass fibers added to 10 μm WUCS glass fibers; and a series of nonwoven sample pads were also prepared using different blend ratios (0% to 40%) of 3.5 μm rotational molded glass fibers of the present invention added to 10 μm WUCS glass fibers. In this way, samples comprising 3.5 μm non-rotating WUCS glass fibers were compared with samples comprising 3.5 μm rotationally formed glass fibers of the present invention at different loading percentages (%) and across all three viewing angles (15°, 45°, and 60°) used in the cloud spot tester apparatus. It can be seen that, across all viewing angles, as the loading of the 3.5 μm non-rotating fibers increases, the rate of turbidity reduction decreases, eventually reaching a state where minimal (if any) additional turbidity reduction is observed. This is shown in graph 710, where the 3.5 μm non-rotating fibers exhibit a clear point of curvature. Conversely, it can be seen that, across all viewing angles, as the loading of the 3.5 μm rotationally formed fibers of the present invention increases, the rate of turbidity reduction remains essentially constant, where a continuous decrease in turbidity values ​​is observed. This is shown in graph 710, where the 3.5 μm rotationally formed fibers of the present invention are a relatively straight line. Therefore, as Figure 7 As shown in B, reducing turbidity in nonwoven mats is affected not only by fiber diameter but also by fiber type, wherein the 3.5μm swirl fiber of the present invention has different properties than the 3.5μm composite fiber. For example, it is believed that the 3.5μm swirl fiber of the present invention has a greater curvature than the 3.5μm composite fiber.

[0297] In another experiment, such as Figure 8As shown in graph 800, the effect of adding a certain percentage (x-axis) of smaller (i.e., 3.5 μm), medium (i.e., 6.5 μm), and larger (i.e., 10 μm) of the inventive rotating glass fiber to a certain amount of 10 μm to 11 μm WUCS glass fiber on the “turbidity” grade (y-axis) of the nonwoven fiber mat was also evaluated. This experiment evaluated the effect of increasing the average fiber diameter of the inventive rotating glass fiber on the turbidity grade (y-axis) found in ceiling panel finishes made using each fiber blend. Specifically, each of the smaller, medium, and larger diameter inventive rotating glass fibers was added at different loading percentages (%) to 10 μm to 11 μm WUCS glass fiber to produce ceiling panel finish samples, which were measured across all three viewing angles (15°, 45°, and 60°) of the cloud spot tester apparatus. It can be seen that the 3.5 μm of the rotating glass fiber of the present invention resulted in a relatively large reduction in the turbidity level in the sample ceiling panel finish (e.g., 37% to 50%), the 6.5 μm of the rotating glass fiber of the present invention resulted in a more moderate reduction in the turbidity level in the sample ceiling panel finish (e.g., about 26%), and the 10 μm of the rotating glass fiber of the present invention did not result in a significant reduction in the turbidity level in the sample ceiling panel finish (e.g., 0%).

[0298] Furthermore, when comparing the cloudiness tester data of the 3.5μm rotating glass fiber of the present invention with that of the 6.5μm WUCS glass fiber ( Figure 7 As can be seen, for cloud spots in the ranges of 9mm to 13mm, 11mm to 24mm, 19mm to 42mm, and 33mm to 72mm, the 3.5μm rotating glass fiber of this invention performs better than the 6.5μm WUCS glass fiber. For a 60° viewing angle of the cloud spot testing device, and for the smallest (9mm to 13mm) and largest (33mm to 72mm) cloud spots, subsets of this comparison result are also... Figure 9A The curve is shown in 900. Note that 60° is the widest support angle, where cloud-like patterns on the ceiling panel are best observed under oblique light.

[0299] Furthermore, when 6.5 μm of the rotating glass fiber of this invention ( Figure 8 ) with 6.5μm WUCS glass fiber ( Figure 7When comparing data from the cloud spot tester, it can be seen that for cloud spots in the ranges of 9mm to 13mm (both achieving approximately 18% reduction), 11mm to 24mm, and 19mm to 42mm, the performance of the 6.5μm rotating glass fiber of this invention is comparable to that of the 6.5μm WUCS glass fiber. However, for cloud spots in the range of 33mm to 72mm, the performance of the 6.5μm rotating glass fiber of this invention is superior to that of the 6.5μm WUCS glass fiber (a 20% reduction compared to 0%). This comparison also shows that the cloud spot tester device has a 45° viewing angle. Figure 9B The curve is shown in graph 910.

[0300] Tests using a cloud spot testing device revealed that for smaller cloud spots (i.e., those in the range of 9 mm to 13 mm), conventional ceiling panel finishes typically exhibit a turbidity rating of 27 or higher. However, by replacing approximately 8% of the conventional fibers with 3.5 μm spun glass fibers of the present invention, a turbidity rating of less than 27 can be easily obtained (see [link to original text]). Figure 9A Furthermore, by using more 3.5 μm rotating glass fibers of the present invention, the turbidity level of these smaller cloud spots can be easily reduced to about 17 or less (see [reference]). Figure 9A ).

[0301] Tests using a cloud spot testing device revealed that for larger cloud spots (i.e., those in the range of 33 mm to 72 mm), conventional ceiling panel finishes typically exhibit a turbidity rating of 19 or higher. However, by replacing approximately 3% of conventional fibers with 3.5 μm spun glass fibers of the present invention, a turbidity rating of less than 19 can be easily obtained (see [link to original text]). Figure 9A Furthermore, by using more 3.5 μm rotating glass fibers of the present invention, the turbidity level of these smaller cloud spots can be easily reduced to about 9 or less (see [reference]). Figure 9A ).

[0302] The ability of the rotating glass fiber of the present invention to reduce turbidity in nonwoven fiber mats can yield other advantages. For example, the effect of using conventional ULF microfibers (effective fiber diameter of approximately 3.00 μm) in nonwoven mats on the rotating fiber of the present invention (effective fiber diameter of approximately 3.56 μm) was evaluated. Specifically, for large cloud spots (considered to be cloud spots in the range of 19 mm-42 mm) and a target turbidity level of 15, it was determined that 40.58 wt% of the mat would need to be conventional microfibers to achieve the target, while it was determined that 31.88 wt% of the mat would need to be the microfiber of the present invention to achieve the target. Therefore, the rotating fiber of the present invention is more effective than other microfibers in reducing large cloud spots. Based on the above measurements, it was determined that 13.54 wt% of mat / μm of conventional microfibers was needed to achieve the target, while 8.96 wt% of mat / μm of the microfiber of the present invention was needed to achieve the target. Therefore, if conventional microfibers and the microfiber of the present invention have the same average fiber diameter, the rotating fiber of the present invention will require less material to impart the same turbidity reduction.

[0303] In some embodiments, various inventive concepts can be utilized in combination with each other. Furthermore, any specific ingredient described in a particular disclosed embodiment should be understood to be applicable to all disclosed embodiments unless the introduction of such a specific ingredient would contradict the terminology expressed in that embodiment. The scope of the general inventive concept presented herein is not intended to be limited to the specific exemplary embodiments shown and described herein. Based on the given disclosure, those skilled in the art will not only understand the general inventive concept and its accompanying advantages, but will also discover various obvious changes and modifications thereto. For example, although exemplary embodiments generally disclose the use of glass fibers, the general inventive concept may cover fibers made of materials other than glass, such as mineral wool or asbestos. Therefore, it is sought to cover all such changes and modifications and any equivalents that fall within the spirit and scope of the general inventive concept described and / or claimed herein.

Claims

1. A nonwoven mat used as a finish for a ceiling panel, said nonwoven mat comprising: Multiple first fibers; Multiple secondary fibers; and An adhesive that holds the first and second fibers together in an alternating arrangement; The first fiber has an average fiber diameter greater than approximately 6 μm; The second fiber has an average fiber diameter of less than approximately 4 μm (xµm); The second fiber constitutes y% by weight of the pad. Where y / x < 10; and When measured with a cloud spot tester, the pad has a turbidity level of 15 or lower in the range of 19 mm to 42 mm.

2. The nonwoven mat according to claim 1, wherein the fiber diameter distribution of the second fiber has a standard deviation from x of less than 3.5 μm.

3. The nonwoven mat according to claim 1, wherein the fiber diameter distribution of the second fiber has a standard deviation from x of less than 3.0 μm.

4. The nonwoven mat according to claim 1, wherein the fiber diameter distribution of the second fiber has a standard deviation from x of less than 2.5 μm.

5. The nonwoven mat according to any one of claims 1 to 4, wherein the second fiber has an average diameter of less than 5 μm.

6. The nonwoven mat according to any one of claims 1 to 4, wherein the second fiber has an average diameter of less than 4 μm.

7. The nonwoven mat according to any one of claims 1 to 4, wherein the second fiber has an average diameter of less than 3 μm.

8. The nonwoven mat according to any of the preceding claims, wherein the second fiber has an average forming length greater than 50.8 mm (2 inches).

9. The nonwoven mat according to any of the preceding claims, wherein the second fiber has an average forming length in the range of about 76.2 mm (3 inches) to about 304.8 mm (12 inches).

10. The nonwoven mat according to any of the preceding claims, wherein x is less than the median fiber diameter of the second fiber.

11. The nonwoven mat according to any of the preceding claims, wherein 90% of the second fibers have a diameter of ≤1.525x.

12. The nonwoven mat according to any of the preceding claims, wherein the first fiber is glass fiber.

13. The nonwoven mat according to any of the preceding claims, wherein the second fiber is glass fiber.

14. The nonwoven mat according to any of the preceding claims, wherein the second fiber is a rotationally molded fiber.

15. The nonwoven mat according to any of the preceding claims, wherein, based on the weight of the nonwoven mat, the nonwoven mat comprises at least 1% by weight of the second fiber.

16. The nonwoven mat according to any of the preceding claims, wherein, based on the weight of the nonwoven mat, the nonwoven mat comprises at least 10% by weight of the second fiber.

17. The nonwoven mat according to any of the preceding claims, wherein, based on the weight of the nonwoven mat, the nonwoven mat comprises at least 20% by weight of the second fiber.

18. The nonwoven mat according to any of the preceding claims, wherein the adhesive comprises polyvinyl alcohol.

19. The nonwoven mat according to any of the preceding claims, wherein the nonwoven mat further comprises an inorganic filler.

20. The nonwoven mat according to any of the preceding claims, wherein the average fiber diameter of the first fiber is in the range of about 10 µm to about 11 µm; and The average fiber diameter of the second fiber is in the range of about 3 μm to about 4 μm.

21. The nonwoven mat according to any one of claims 1 to 20, wherein the second fiber does not contain any fiber with a diameter greater than 22 μm.

22. The nonwoven mat according to any one of claims 1 to 20, wherein the second fiber does not contain any fiber with a diameter greater than 20 μm.

23. The nonwoven mat according to any one of claims 1 to 20, wherein the second fiber does not contain any fiber with a diameter greater than 16 μm.

24. The nonwoven mat according to any one of claims 1 to 20, wherein the second fiber does not contain any fiber with a diameter greater than 15 μm.

25. The nonwoven mat according to any one of claims 1 to 20, wherein the second fiber does not contain any fiber with a diameter greater than 14 μm.

26. The nonwoven mat according to any of the preceding claims, wherein the nonwoven mat has a first surface and a second surface opposite to the first surface, and each surface contains less than about 100 fibrous particles per 1,000 m³. 2 Nonwoven mat.

27. The nonwoven mat of claim 26, wherein each surface of the nonwoven mat has less than about 50 flocs per 1,000 m². 2 Nonwoven mat.

28. The nonwoven mat of claim 26, wherein each surface of the nonwoven mat has less than about 25 flocs / 1,000 m 2 Nonwoven mat.

29. The nonwoven mat of claim 26, wherein each surface of the nonwoven mat has less than about 15 flocs / 1,000 m 2 Nonwoven mat.

30. The nonwoven mat according to any of the preceding claims, wherein the average fiber diameter of the first fiber is in the range of about 8 µm to about 13 µm.

31. The nonwoven mat according to any of the preceding claims, wherein the average fiber diameter of the second fiber is in the range of about 3µm to about 3.5µm.

32. The nonwoven mat according to any of the preceding claims, wherein the first fiber accounts for about 10% to about 50% of the total weight of the first fiber and the second fiber; and The second fiber accounts for approximately 50% to approximately 90% of the total weight of the first fiber and the second fiber.

33. The nonwoven mat according to any of the preceding claims, wherein, based on the total weight of the first fiber and the second fiber, the nonwoven mat comprises more of the first fiber by weight percentage than the second fiber.

34. A ceiling panel comprising a finish on at least one of its main surfaces, the finish comprising a nonwoven mat according to any one of claims 1 to 33.

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