Glass chopped strand mat, glass chopped strand mat roll, method for manufacturing glass chopped strand mat and automotive molded ceiling material

Patent metadata

Field	Value
Publication number	US-10160403-B2
Application number	US-201415124299-A
Country	US
Kind code	B2
Filing date	Dec 24, 2014
Priority date	Mar 10, 2014
Publication date	Dec 25, 2018
Grant date	Dec 25, 2018

Abstract

In a glass chopped strand mat, a short chopped strand layer having first glass chopped strands with an average length of 25.4 to 76.2 mm and a long chopped strand layer having second glass chopped strands with an average length of 76.2 to 203.2 mm are laminated, a difference between the average length of the first glass chopped strands and that of the second glass chopped strands is 25.4 mm or greater, the short chopped strand layer occupies 50 to 70 parts by mass, and the long chopped strand layer occupies 30 to 50 parts by mass with respect to 100 parts by mass of the glass chopped strand mat, a mass per unit area of the glass chopped strand mat is 180 g/m 2 or lower, and a loss on ignition of the glass chopped strand mat measured on the basis of JIS R 3420 is lower than 10%.

First claim

The invention claimed is:

1. A glass chopped strand mat in which glass chopped strands are deposited in a sheet shape and are bound together by a binder made of a thermoplastic resin,
wherein a short chopped strand layer having first glass chopped strands with an average length of 25.4 mm to 76.2 mm and a long chopped strand layer having second glass chopped strands with an average length of 76.2 to 203.2 mm are laminated,
a difference between the average length of the first glass chopped strands and the average length of the second glass chopped strands is 25.4 mm or greater,
with respect to 100 parts by mass of the glass chopped strand mat, the short chopped strand layer occupies 50 to 70 parts by mass, and the long chopped strand layer occupies 30 to 50 parts by mass,
a mass per unit area of the glass chopped strand mat is 180 g/m 2 or lower, and
a loss on ignition of the glass chopped strand mat measured on the basis of JIS R 3420 is lower than 10%.

2. The glass chopped strand mat according to claim 1 ,
wherein, with respect to 100 parts by mass of the binder present in the glass chopped strand mat, the binder present in the short chopped strand layer occupies 20 to 40 parts by mass, and the binder present in the long chopped strand layer occupies 60 to 80 parts by mass.

3. A glass chopped strand mat roll in which the glass chopped strand mat according to claim 2 is wound around a winding core into a roll shape,
wherein the long chopped strand layer is disposed on an inside.

4. A glass chopped strand mat roll in which the glass chopped strand mat according to claim 1 is wound around a winding core into a roll shape,
wherein the long chopped strand layer is disposed on an inside.

5. A method for manufacturing a glass chopped strand mat of claim 1 , the method comprising:
a first deposition process of forming first glass chopped strands having an average length of 25.4 to 76.2 mm by cutting the glass chopped strands using a first cutter, and forming a short chopped strand layer by depositing the first glass chopped strands to be deposited in a sheet shape;
a second deposition process of forming second glass chopped strands having an average length of 76.2 to 203.2 mm by cutting the glass chopped strands using a second cutter, and forming a long chopped strand layer by depositing the second glass chopped strands on the short chopped strand layer in a sheet shape;
a binder spraying process of spraying the binder made of the thermoplastic resin onto a laminate in which the short chopped strand layer and the long chopped strand layer are laminated;
a heating process of heating the binder present in the laminate so as to be melted; and
a cooling process of cooling the binder to bind the glass chopped strands after the heating process,
wherein a difference between the average length of the first glass chopped strands and the average length of the second glass chopped strands is 25.4 mm or greater,
with respect to 100 parts by mass of the glass chopped strand mat, the short chopped strand layer occupies 50 to 70 parts by mass, and the long chopped strand layer occupies 30 to 50 parts by mass,
a mass per unit area of the glass chopped strand mat is 180 g/m 2 or lower, and
a loss on ignition of the glass chopped strand mat measured on the basis of JIS R 3420 is lower than 10%.

6. The method for manufacturing a glass chopped strand mat according to claim 5 , further comprising:
a winding process of winding the glass chopped strands around a winding core into a roll shape after the cooling process,
wherein, in the winding process, the glass chopped strands are wound such that the long chopped strand layer is disposed on an inside.

7. The glass chopped strand mat according to claim 1 , wherein the yarn counts of the first glass chopped strands and the second glass chopped strands are the same.

Assignees

• Nitto Boseki Co Ltd

Inventors

• OMIYA Mitsuhiro
• Suzuki Masatoshi

Classifications

• D04H1/58

  by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives (in combination with needling D04H1/488) · CPC title

• D04H1/4374

  using different kinds of webs, e.g. by layering webs · CPC title

• B32B2260/046

  Synthetic resin · CPC title

• B32B5/24

  one layer being a fibrous or filamentary layer · CPC title

• D04H1/593

  to layered webs · CPC title