Nonwoven with two-part binder system

Patent metadata

Field	Value
Publication number	US-11959210-B2
Application number	US-201917056074-A
Country	US
Kind code	B2
Filing date	Apr 16, 2019
Priority date	May 18, 2018
Publication date	Apr 16, 2024
Grant date	Apr 16, 2024

Abstract

Disclosed herein is a binder system for nonwoven fiber mats that provides desirable properties to the nonwoven mat including desirable porosity, desirable surface properties e.g., desirable wettability and/or moisture resistance, and enhanced tensile strength. The system includes a two-part binder that includes (1) a formaldehyde-free carbohydrate-based binder and (2) a formaldehyde-free hydrophobic acrylic-based hinder.

First claim

What is claimed is:

1. A nonwoven fiber mat comprising:
randomly oriented fibers; and
a two-part binder system applied to at least a portion of the randomly oriented fibers, wherein the binder system comprises:
a formaldehyde-free carbohydrate-based binder, and
a formaldehyde-free hydrophobic acrylic-based binder,

wherein the formaldehyde-free hydrophobic acrylic-based binder is applied over the formaldehyde-free carbohydrate-based binder,
and wherein the formaldehyde-free acrylic-based binder is impregnated within the nonwoven fiber mat.

2. The nonwoven fiber mat of claim 1 , wherein the mat has a basis weight of about 0.012 to about 0.018 lb/ft 2 (about 60 to about 88 gsm).

3. The nonwoven fiber mat of claim 1 , wherein the nonwoven fiber mat comprises from about 10% to about 30% by weight solids of the two-part binder system based on the total weight of the nonwoven fiber mat.

4. The nonwoven fiber mat of claim 1 , wherein the carbohydrate-based binder comprises a carbohydrate and a crosslinking agent.

5. The nonwoven fiber mat of claim 4 , wherein the carbohydrate comprises a polysaccharide having a dextrose equivalence of 2 to 20.

6. The nonwoven fiber mat of claim 4 , wherein the carbohydrate comprises a water soluble polysaccharide.

7. The nonwoven fiber mat of claim 4 , wherein the carbohydrate comprises maltodextrin, dextrin, starch, modified starch, starch derivative, or combinations thereof.

8. The nonwoven fiber mat of claim 4 , wherein the carbohydrate-based binder comprises from about 30% to about 60% by weight solids of carbohydrate.

9. The nonwoven fiber mat of claim 4 , wherein the crosslinking agent comprises a polycarboxylic acid, a salt of polycarboxylic acid, an anhydride, a polyacrylic acid, a salt of polyacrylic acid, a polyacrylic acid-based resin, or combinations thereof.

10. The nonwoven fiber mat of claim 4 , wherein the carbohydrate-based binder further comprises a coupling agent.

11. The nonwoven fiber mat of claim 1 , wherein the acrylic-based binder has acrylic and/or acrylonitrile functionality.

12. The nonwoven fiber mat of claim 1 , wherein the acrylic-based binder is applied as an emulsion or latex.

13. The nonwoven fiber mat of claim 1 , wherein the hydrophobic acrylic-based binder has a glass transition temperature (Tg) of greater than 20° C.

14. The nonwoven fiber mat of claim 1 , wherein the randomly oriented fibers comprise glass fibers, synthetic polymer fibers, natural fibers, or combinations thereof.

15. The nonwoven fiber mat of claim 1 , wherein the mat has a Frazier permeability of about 690 to about 710 CFM (about 19.5 to about 20.1 m 3 /min).

16. A facer for a construction board comprising the nonwoven fiber mat of claim 1 and a facer coating applied to at least a portion of the nonwoven fiber mat, when the facer has a basis weight of about 0.05 to about 0.08 lb/ft 2 (about 244 to about 391 gsm) and about 10% to about 30% by weight solids of the two-part binder system and facer coating based on the total weight of the facer, the facer has an average Gurley gas permeability of about 1400 s to about 2150 s.

17. The facer of claim 16 , wherein the facer has a basis weight of about 0.065 lb/ft 2 (about 317 gsm).

18. A foam insulation board comprising at least one facer of claim 16 disposed adjacent to a foam core.

19. The foam insulation board of claim 18 , wherein the foam core is selected from the group consisting of polyurethane, polyisocyanurate, polyurethane modified polyisocyanurate, and phenolic resin.

20. A gypsum board comprising at least one facer of claim 16 disposed adjacent to a gypsum core.

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Wu Tony

Classifications

• D04H1/587 Primary

  characterised by the bonding agents used · CPC title

• B32B5/022

  Non-woven fabric · CPC title

• B32B5/245

  another layer next to it being a foam layer · CPC title

• B32B13/14

  next to a fibrous or filamentary layer · CPC title

• D04H1/4218

  Glass fibres · CPC title