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  Fiber mat and process for making sameUSPTO Application #: 20070111622Title: Fiber mat and process for making same Abstract: A fiber mat comprises fibers; a resinous fiber binder; and a binder modifier which is a methacrylate/C1-2 succinate/hydroxyacrylate copolymer. (end of abstract)
Agent: Gaf Materials Corporation Attn: William J. Davis, Esq. - Wayne, NJ, US Inventors: Linlin Xing, William Bittle USPTO Applicaton #: 20070111622 - Class: 442180000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Coated Or Impregnated Woven, Knit, Or Nonwoven Fabric Which Is Not (a) Associated With Another Preformed Layer Or Fiber Layer Or, (b) With Respect To Woven And Knit, Characterized, Respectively, By A Particular Or Differential Weave Or Knit, Wherein The Coating Or Impregnation Is Neither A Foamed Material Nor A Free Metal Or Alloy Layer, Coated Or Impregnated Inorganic Fiber Fabric, Coated Or Impregnated Glass Fiber Fabric The Patent Description & Claims data below is from USPTO Patent Application 20070111622. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates generally to a fiber mat and a process of making the same, and, more particularly, to a glass fiber mat comprising fibers, a binder and a defined binder modifier. Embodiments of the present invention can have desired characteristics, such as, for example, improved wet web strength, as compared with a conventional mat where no such defined binder modifier is employed, and can be suitable for use in building materials. [0003] 2. Description of the Prior Art [0004] High strength fiber mats are increasingly used in the building materials industry, most commonly in roofing shingles. Fiber mats have numerous other material applications, including use in roofing, siding and floor underlayment; insulation facers; floor and ceiling tile; and vehicle parts. [0005] Various fiber mats and methods of making the same have been described previously. For example, U.S. Pat. Nos. 4,135,029; 4,258,098; 5,914,365; and 6,642,299, describe glass fiber mats made by a wet-laid process formed from glass fibers held together by a binder material. Typically, in wet processed glass fiber mats, the binder is applied in liquid form and dispersed onto the glass fibers by an applicator. Conventional wet processes strive to produce a uniform coating of binder on the glass fibers. After the binder and glass fibers have been dried and cured, the glass fiber mat is cut as desired. [0006] A major problem in the manufacturing process and use of some known fiber mats is inadequate wet web strength. The wet web strength of wet glass mat has significant impact on glass mat production and mat properties. In order to prevent the mat web from breaking during production, the speed of the production line has to be adjusted (reduced) to the low wet web strength of the wet glass mat before curing. Also, a lower wet web strength requires a higher vacuum drawing to support the wet web and to minimize web breaking. However, a higher vacuum drawing will lead to undesired mat properties, for example, a high mat tensile ratio. SUMMARY OF THE INVENTION [0007] Responsive to the foregoing challenges, an improved fiber mat for use in a building materials component has been developed. In one embodiment, the invention fiber mat includes a plurality of fibers; a resinous fiber binder, the fibers being fixedly distributed in the binder; and a binder modifier which is a methacrylates/C1-2 succinates/hydroxyacrylates copolymer. By "fixedly distributed", it is meant chemically bonded with binder. The binder modifier comprises 0.1 wt. % to 50 wt. %, based on the weight of the binder. [0008] The present invention also relates to a binder composition which includes a blend of a resinous fiber binder and a binder modifier which is a methacrylates/C1-2 succinates/hydroxyacrylates copolymer. [0009] In addition to the above, the present invention also provides a process for making an improved fiber mat. In one embodiment, the process comprises the steps of: forming an aqueous fiber slurry; removing water from the fiber slurry to form a wet fiber mat; saturating the wet fiber mat with an aqueous solution of a fiber binder and binder modifier, and forming, via drying and curing, a fiber mat product from the wet fiber mat. [0010] The fiber mats in accordance with the embodiments of the present invention are particularly suitable for use as a component of building materials. In addition, the process of making fiber mats in accordance with the embodiments of the present invention can provide an improved wet web strength to an uncured mat. [0011] In this invention, the glass mats made from resin binder and the acrylate copolymer binder modifier exhibits improved wet web strength. [0012] Additional advantages of embodiments of the present invention are set forth, in part, in the description which follows and, in part, will be apparent to one of ordinary skill in the art from the description and/or from the practice of the invention. DETAILED DESCRIPTION OF THE INVENTION [0013] As stated above, the fiber mat of the present invention comprises a plurality of fibers fixedly distributed in a fixative composition. The fixative composition comprises 0.05 wt. % to 45 wt. % of fiber binder, based on the weight of the fiber mat product, and 0.1 wt. % to 50 wt. % of the binder modifier based on the binder weight. [0014] The preferred binder modifier of the invention is a methacrylates/C1-2 succinates/hydroxyacrylates copolymer available commercially as Allianz.TM. LT-120 (International Specialty Products). Allianz.TM. LT-120 is a low viscosity acrylate-based, aqueous emulsion polymer. The polymer architecture is a random, linear copolymer derived from methacrylic acid, alkene succinic acids, alkyl and hydroxyl alkyl esters of acrylic and methacrylic acid. [0015] Structurally, Allianz.TM. LT-120 can be represented as: R.sub.1,2.dbd.CH.sub.3 R.sub.3.dbd.H or CH.sub.3 R.sub.4=Alkylene R.sub.5=Alkyl R.sub.6,7=Acid Group a,b,c and d are independently 1-5. [0016] In one embodiment of the present invention, the fiber binder comprises a formaldehyde type resin. The fiber binder can include, but is not limited to, a urea/formaldehyde resin, a phenol/formaldehyde resin, a melamine/formaldehyde resin, and/or a mixture thereof. It is contemplated, however, that other binders, such as, for example, ethylene vinyl acetate, and other known resins adapted for binding mat fibers, can be used without departing from the scope and spirit of the present invention. [0017] In one embodiment of the present invention, the urea-formaldehyde resin is a commercially available material, such as, for example, GP2997 supplied by Georgia Pacific Resins, Inc.; Dyneae 246 from Dynea Co.; and Borden FG.RTM. 486D and Borden 607A; from Borden Chemical Inc. Other commercial formaldehyde resins, such as, for example, S-370I-C supplied by Pacific Resins and Chemicals, Inc.; and PR-913-23, supplied by Borden Chemical, Inc.; may be used as well. As will be apparent to those of ordinary skill in the art, other commercially or non-commercially available binders can be used without departing from the scope and spirit of the present invention. [0018] In one embodiment of the present invention, the resinous fiber binder can contain methylol groups which, upon curing, form methylene or ether linkages. These methylols can include, for example, N,N'-dimethylol; dihydroxymethylolethylene; N,N'-bis(methoxymethyl), N,N'-dimethylolpropylene; 5,5-dimethyl-N,N'-dimethylolpropylene; N,N'-dimethylolethylene; N,N'-dimethylolethylene and the like. [0019] In one embodiment, the weight ratio of resinous fiber binder to polymer binder modifier is 200:1 to 4:1. In one embodiment of the present invention, the weight ratio is more particularly 99:1 to 9:1. [0020] The fiber binder and binder modifier are adapted to be compatible. These components can be intimately admixed in an aqueous medium to form a stable emulsion which does not become overly gummy, or gel, even after prolonged storage, e.g., for a period of a year or longer. This stability factor is advantageous in commercial use of the invention composition. [0021] In one embodiment of the present invention, the fibers comprise glass fibers. The glass fibers can comprise individual fiber filaments having an average length in the range of, but not limited to: from about 1/4 inch to about 3 inches, and an average diameter in the range of, but not limited to: from about 1 to about 50 microns (.mu.). It is contemplated, however, that the glass fibers can be in another form, such as, for example, a continuous strand or strands. In an alternative embodiment of the present invention, the fibers can comprise other fibers, including, but not limited to: wood, polyethylene, polyester, nylon, polyacrylonitrile, and/or a mixture of glass and one or more of the other fibers. In one embodiment, the fiber mat can further comprise a small amount of filler, e.g., less than about 0.5%, based on the fiber weight. A fiber mixture can be optional for construction material applications, such as, for example, roofing and siding, because an excessive amount of filler can reduce porosity and vapor ventability of the fiber mat. Continue reading... Full patent description for Fiber mat and process for making same Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Fiber mat and process for making same patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Fiber mat and process for making same or other areas of interest. ### Previous Patent Application: Armor including a strain rate hardening elastomer Next Patent Application: Pull mat Industry Class: Fabric (woven, knitted, or nonwoven textile or cloth, etc.) ### FreshPatents.com Support Thank you for viewing the Fiber mat and process for making same patent info. 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