Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H13/00—Other non-woven fabrics
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/002—Inorganic yarns or filaments
  • D04H3/004—Glass yarns or filaments
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4209—Inorganic fibres
  • D04H1/4218—Glass fibres
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/20—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
  • Y10T442/2926—Coated or impregnated inorganic fiber fabric
  • Y10T442/2934—Coating or impregnation contains vinyl polymer or copolymer
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/20—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
  • Y10T442/2926—Coated or impregnated inorganic fiber fabric
  • Y10T442/2992—Coated or impregnated glass fiber fabric

Definitions

• the present invention relates to a method for manufacturing a mat consisting of glass strands and the product resulting therefrom.
• glass mat is understood to mean a product formed from glass strands (cut or continuous), the constituent filaments of which remain linked to each other, thus being distinguished from glass veils formed by the association of dispersed glass filaments.
• main problems to be resolved include the choice of the nature of the binder which will make it possible to give the mat its cohesion, the form in which the binder will be used and the process which will ensure the contact of the binder with the mat.
• the binder can be used as a powder, suspension, emulsion or solution.
• the liquid with which it is associated is, more and more often, water in order to avoid the difficulties always presented by the use of organic solvents.
• the application methods are also very varied.
• the deposit of the binder in the form of a dry powder avoids the use of a liquid which it will be necessary to eliminate later, it is difficult to distribute it uniformly within the mass of the mat.
• the binder grains sometimes remain in the composite reinforced with the mat, which gives it an irregular surface condition.
• the deposition of a binder in the form of an emulsion or solution in water or in an organic solvent gives good cohesion to the mat because, most often, it sticks at least partially to the glass strands.
• this advantage may turn out to be less advantageous when the mat must be combined with a product which it must reinforce, whether it is organic or mineral.
• the binder when the binder remains on the glass strands during this association phase, it can constitute an obstacle to the good wetting of said strands by said product. This is particularly the case when the mat must be combined with a resin which is in the form of a dispersion or suspension in water or with a mixture based on cement and water. This results in a decrease in mechanical properties and in a poor surface condition of the final composite part.
• the subject of the present invention is a manufacturing process making it possible to obtain a mat of glass strands which has good cohesion and which is easily wetted by resins, in particular by resins in an aqueous medium, in particular in aqueous solution, dispersion or suspension. or by a mixture based on cement and water.
• the subject of the present invention is a manufacturing process which makes it possible to uniformly distribute the binder throughout the thickness of the mat.
• the present invention also relates to a process for manufacturing a mat of glass strands which allows continuous recycling of the binder used.
• a manufacturing process which consists of continuously depositing on a sheet of glass strands, distributed on a moving conveyor, a binder whose viscosity during deposition is less than about 40 mPa.s, said binder being formed of an aqueous solution of polyvinyl alcohol (s).
• the polyvinyl alcohol (s) used in the context of the invention preferably have a degree of polymerization of less than around 1000.
• the binder is deposited on the sheet of glass strands in the form of a liquid sheet or of a curtain of liquid nets which fall transversely over the entire width of said layer of wires.
• the binder thus deposited, and thanks to its relatively low viscosity, penetrates and crosses the entire layer of wires, -. distributing throughout the volume of said sheet.
• the binder is retained essentially on a large part of the contact points of the crossing wires.
• the binder is deposited when its temperature is greater than approximately 10 ° C. and most generally between 20 and 60 ° C.
• the flow rate of binder thus deposited is in particular a function of the speed of the conveyor and the quantity of glass deposited per square meter on said conveyor This flow rate of binder is determined so as to obtain between approximately 3 and 15% by weight of binder to the state of dry matter relative to the weight of glass.
• the binder can be deposited, in part, on the surface of the sheet of wires, upstream of the zone where it is deposited in the form of nets or of a liquid sheet.
• the binder can, for example, be sprayed upstream, which has the effect of lightly packing the layer of wires and moistening its surface layer, thus promoting the penetration of the binder deposited downstream.
• a fraction of the binder thus deposited completely crosses the sheet of yarns and can be recovered under the conveyor.
• One of the advantages of the binder used is that it is stable over time, even after being heated to a temperature above about 30 ° C, unlike binders whose composition contains at least one component which promotes its crosslinking.
• the binder used in the context of the invention can thus be directly recycled, which constitutes an economic advantage.
• the layer of threads passes through an oven in a manner known per se, then optionally through a calender.
• the method according to the invention is applicable to mats of glass strands obtained by all known means, whether continuous or indirect processes
• the first type of process is used to manufacture mats of continuous glass strands. It consists, most often, of drawing a multiplicity of filaments from molten glass flowing from the orifices of several dies, of bringing these filaments together at the rate of at least one yarn per die and of mechanically distributing the yarns thus obtained on a conveyor moving below said dies
• the second type of process is generally used to fabricate chopped glass strands. It consists in extracting from a multiplicity of continuous wire windings, to cut them simultaneously and to distribute them on a moving conveyor
• the second type of process can also be used to manufacture mats of continuous threads when the extraction of the threads from their winding is immediately FOLLOWED by their distribution on the conveyor
• the mat used can be reinforced by continuous glass strands arranged longitudinally over at least part of its width. This is particularly the case when the mat is intended to be combined with a cement-based mixture. This mat is obtained, for example, by simultaneously distributing on the moving conveyor the cut wires and the continuous wires, the latter being extracted from a series of windings.
• the average diameter of the filaments constituting the threads is between approximately 9 and 30 micrometers.
• the length of said strands is generally greater than 20 millimeters.
• This solution was obtained by dissolving in water brought to 80 ° C. a polyvinyl alcohol characterized by a degree of polymerization of 530 and a hydrolysis rate of 88%.
• This polyvinyl alcohol is marketed under the reference F 1 05 by the LAMBERTI Company This solution is poured onto the layer of wires at an hourly flow rate of 3 cubic meters. The excess solution is sucked under the conveyor and recycled
• the layer of son thus treated then passes into a hot air oven inside which it is subjected to a temperature of the order of 200 ° C for about 50 seconds.
• the sheet of wires is calendered and cooled before being wound on a rotary mandrel
• the mat obtained has a binder rate of 8% and has a surface mass of 250 grams per square meter. Its cohesion is good as shown by its tensile strength which, measured according to the ISO 3342 method, is on average 40 decanewtons. In comparison, a mat which has the same characteristics, but the binder content of which is 4.5%, this binder being plasticized polyvinyl acetate, has a tensile strength, measured by the same method, of less than 20 decanewtons.
• the binder used in the present invention also offers the advantage of being partially dissolved in the presence of water.
• the following test makes it possible to observe this. a series of samples of 1,00 x 1,25 millimeters are cut from the mat, the manufacturing process of which has been described previously. These samples are immersed in water at 20 ° C. and subjected to a load of 1,00 grams. The partial elimination of the binder in the water and the effect of the filler cause the mat to tear into two parts after an average time of 25 seconds. This time is very short for this kind of test. In fact, the tearing of the mat bound with plasticized polyvinyl acetate, mentioned above, takes place, under the same conditions, only after an average time greater than 5 minutes.
• Cement plates are produced by using on the one hand a mixture based on cement and cut glass yarns called premix, on the other hand of mat according to the invention or, for comparison, of a known mat.
• the mat according to the invention has a surface mass of 120 grams per square meter, it is made up of cut threads of 50 millimeters in length, the title of which is 38 tex and which are made up of a multiplicity of filaments of a average diameter of 1 4 micrometers. Its binder rate is 1 0%
• the mat used for comparison has the same characteristics, except for the level of binder, which is 4.5%, and the binder itself, which is plasticized polyvinyl acetate.
• the glass used to obtain these mats is an alkali-resistant glass sold under the brand CEMFIL.
• a first layer of mat is deposited at the bottom of a mold and covered with a layer of premix uniformly distributed by subjecting said mold to vibrations.
• a second layer of mat identical to the first is deposited on the premix, then applied against the premix by means of a roller in order to impregnate it.
• the plate thus formed is kept for 24 hours in the mold, then stored in an enclosure maintained at 20 ° C. in an atmosphere at 50% relative humidity.
• MOR, LOP and EPS respectively denote the modulus of rupture, the limit of proportionality or elasticity and the deformation at break during the bending test.
• the percentage of reinforcement in the premix is 2% by weight relative to the composite for the two kinds of plates, the percentage of reinforcement due to the mat itself being 1, 4% for the plate reinforced by the mat according to the invention and for the plate reinforced with known mat
• association with resins in an aqueous medium can also be carried out by any means known to those skilled in the art.

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Inorganic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Dispersion Chemistry (AREA)
• General Chemical & Material Sciences (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Nonwoven Fabrics (AREA)
• Laminated Bodies (AREA)
• Surface Treatment Of Glass Fibres Or Filaments (AREA)
• Paper (AREA)
• Extrusion Moulding Of Plastics Or The Like (AREA)
• Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
• Glass Compositions (AREA)
• Adhesives Or Adhesive Processes (AREA)

Applications Claiming Priority (3)

Publications (2)

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ID=9485698

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• 1995
  • 1995-12-12 FR FR9515113A patent/FR2742172B1/fr not_active Expired - Fee Related
• 1996
  • 1996-12-09 IN IN2119CA1996 patent/IN191056B/en unknown
  • 1996-12-12 US US08/875,924 patent/US6034006A/en not_active Expired - Lifetime
  • 1996-12-12 SK SK1074-97A patent/SK284976B6/sk not_active IP Right Cessation
  • 1996-12-12 AR ARP960105630A patent/AR005045A1/es active IP Right Grant
  • 1996-12-12 KR KR1019970705455A patent/KR100410713B1/ko not_active IP Right Cessation
  • 1996-12-12 CA CA002212921A patent/CA2212921C/fr not_active Expired - Fee Related
  • 1996-12-12 AT AT96942392T patent/ATE232247T1/de not_active IP Right Cessation
  • 1996-12-12 RU RU97115106/12A patent/RU2171322C2/ru not_active IP Right Cessation
  • 1996-12-12 JP JP9521808A patent/JPH11500795A/ja not_active Ceased
  • 1996-12-12 DE DE69626106T patent/DE69626106D1/de not_active Expired - Lifetime
  • 1996-12-12 EP EP96942392A patent/EP0819189B1/de not_active Expired - Lifetime
  • 1996-12-12 PL PL96321732A patent/PL186513B1/pl not_active IP Right Cessation
  • 1996-12-12 ES ES96942392T patent/ES2191780T3/es not_active Expired - Lifetime
  • 1996-12-12 CZ CZ0248897A patent/CZ297438B6/cs not_active IP Right Cessation
  • 1996-12-12 BR BR9607736-0A patent/BR9607736A/pt not_active IP Right Cessation
  • 1996-12-12 CN CN96193072A patent/CN1083028C/zh not_active Expired - Fee Related
  • 1996-12-12 WO PCT/FR1996/001988 patent/WO1997021861A2/fr active IP Right Grant
• 1997
  • 1997-01-22 TW TW086100679A patent/TW340833B/zh not_active IP Right Cessation
  • 1997-08-11 NO NO973682A patent/NO973682L/no not_active Application Discontinuation

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