Cross-linked non-woven mat

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Solution Overview

Problem

Formaldehyde-free non-woven fiber mats used in roofing applications often lack sufficient hot-wet tensile strength retention due to moisture absorption, failing to meet performance requirements.

Innovation Solution

A cross-linked non-woven fibrous mat is developed with a core layer of fibers bound by a formaldehyde-free binder composition containing hydroxyl or carboxylic acid functional groups and a cross-linker, such as isocyanate or melamine, applied as a protective coating to enhance hot-wet retention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If formaldehyde-free binder composition is used, then environmental safety is improved, but hot-wet tensile strength retention deteriorates

Engineering Contradiction:

Improveformaldehyde emissionVSAvoidhot-wet tensile strength retention

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent combines formaldehyde-free binder composition with silane cross-linking agents to create a composite binder system. The silane-modified binder forms a cross-linked network structure that significantly improves hot-wet tensile strength retention while maintaining the formaldehyde-free advantage, achieving both environmental safety and performance reliability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the chemical parameters of the binder composition by introducing silane functional groups and controlling the cross-linking reaction conditions. This parameter change transforms the binder's molecular structure to enhance its resistance to moisture and heat, thereby improving hot-wet tensile strength retention without compromising environmental safety.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If cross-linker is added to improve hot-wet retention, then hot-wet tensile strength retention is improved, but binder composition complexity increases

Engineering Contradiction:

Improvehot-wet tensile strength retentionVSAvoidbinder composition complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the binder composition and cross-linking agent into an integrated system where the silane-modified binder and cross-linker work synergistically. This combination achieves improved hot-wet retention while managing composition complexity through coordinated formulation and processing parameters.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The cross-linked mat achieves hot-wet retention of at least 25%, significantly improving durability and performance in roofing applications by reducing moisture absorption and maintaining tensile strength.

Implementation Method 1

a cross-linker disposed on at least one surface of the core layer. The cross-linker comprises one or more of isocyanate, polyol, and melamine functional groups

Methodology Applied

Scientific EffectCross-linking: Chemical Bonding

Data Source

PatentUS12152324B2Cross-linked non-woven mat

Publication Date: 2024.11.26 OWENS CORNING INTELLECTUAL CAPITAL LLC

AI summary

A cross-linked nonwoven fibrous mat is disclosed comprising a core layer including a fibrous precursor mat bound with a formaldehyde-free core binder composition and a cross-linker disposed on at least one surface of the core layer, said cross-linker comprising one or more of isocyanate, polyol, and melamine functional groups. The cross-linked nonwoven mat has a hot-wet retention of at least 25%.