Binder composition

Patent metadata

Field	Value
Publication number	US-9803116-B2
Application number	US-201013496271-A
Country	US
Kind code	B2
Filing date	Sep 24, 2010
Priority date	Oct 8, 2009
Publication date	Oct 31, 2017
Grant date	Oct 31, 2017

Abstract

The invention relates to a new binder composition which is particularly suitable for the manufacture of composite materials utilizing such new binder composition in the required nonwoven materials. Composite materials using such new binder composition in their nonwoven part are suitable, in particular, for composites materials for interior construction, for linings, floor coverings, and for the manufacture of furniture and similar products.

First claim

The invention claimed is:

1. A method for the manufacture of a semi-finished textile structure comprising the measures:
supplying a textile
applying a binder composition comprising a B-stage binder and an emulsion, wherein the emulsion comprises a polyolefin compound, and wherein the emulsion is a thermoplastic emulsion that does not have three-dimensional crosslinking, and
drying the textile structure so that the B-stage binder is at least partially cured and being in the B-stage state.

2. The method as claimed in claim 1 , wherein the polyolefin compound of the emulsion comprises polypropylene.

3. The method as claimed in claim 1 , wherein the textile structure has received a pre-strengthening.

4. The method as claimed in claim 1 , further comprising applying a functional material to the textile structure.

5. The method as claimed in claim 1 , wherein the emulsion is present at between about 0.1% and about 35% of the total solid content of the binder composition.

6. The method as claimed in claim 1 , wherein the emulsion is present at between about 5% and about 10% of the total solid content of the binder composition.

7. The method as claimed in claim 1 , wherein the binder composition is present in a total amount of 10% to 80% by weight of the textile.

8. The method as claimed in claim 1 , wherein the textile structure includes at least one type of fiber selected from the group consisting of natural fibers, fibers of synthesized polymers, fibers of natural polymers, ceramic fibers, mineral fibers, and glass fibers.

9. The method as claimed in claim 1 , wherein the textile structure includes at least one material selected from the group consisting of a tissue, laying, multiaxial fabric, knitted fabric, woven fabric, non-woven fabric, and paper.

10. A method for the manufacture of a semi-finished textile structure, the method comprising:
providing a textile structure;
applying a B-stage binder composition to the textile structure to form a B-staged textile structure, wherein the B-stage binder composition comprises:
(i) a B-stage polymerizable composition, and
(ii) a thermoplastic emulsion comprising a polyolefin compound, wherein the thermoplastic emulsion does not have three-dimensional crosslinking; and
partially curing the B-staged textile structure to form the semi-finished textile structure.

11. The method of claim 10 , wherein the textile structure is selected from the group consisting of a nonwoven material, a woven fabric, and a paper.

12. The method of claim 10 , wherein the textile structure comprises at least one type of fiber selected from the group consisting of natural fibers, polymer fibers, ceramic fibers, mineral fibers, and glass fibers.

13. The method of claim 10 , wherein the textile structure comprises a nonwoven material containing glass fibers.

14. The method of claim 13 , wherein the glass fibers comprise:
(i) an average fiber length between 5 mm and 120 mm, and
(ii) an average fiber diameter between 5 μm and 30 μm.

15. The method of claim 13 , wherein the nonwoven material further comprises reinforcement threads.

16. The method of claim 13 , wherein the glass fibers are selected from the group consisting of A-glass, C-glass, E-glass, S-glass, T-glass, and R-glass.

17. The method of claim 13 , wherein the method further comprises:
applying a pre-strengthening binder composition to the textile structure.

18. The method of claim 17 , wherein the textile structure comprises 40 wt. % or less of the pre-strengthening binder composition.

19. The method of claim 17 , wherein the textile structure comprises 10 wt. % to 30 wt. % of the pre-strengthening binder composition.

20. The method of claim 10 , wherein the B-stage binder composition comprises 25 wt. % to 85 wt. % of the B-staged textile structure.

21. The method of claim 10 , wherein the B-stage binder composition comprises 50 wt. % to 80 wt. % of the B-staged textile structure.

22. The method of claim 10 , wherein the thermoplastic emulsion comprises 0.1 wt % to 35 wt. % of the B-stage binder composition.

23. The method of claim 10 , wherein the thermoplastic emulsion comprises 1 wt % to 10 wt. % of the B-stage binder composition.

24. The method of claim 10 , wherein the thermoplastic emulsion comprises 1 wt % to 5 wt. % of the B-stage binder composition.

25. The method of claim 10 , wherein the polyolefin compound comprises a polypropylene polymer.

26. The method of claim 10 , wherein the B-stage binder composition further comprises a hardening catalyst.

27. The method of claim 26 , wherein the hardening catalyst comprises up to 10 wt. % of the B-stage binder composition.

28. The method of claim 10 , wherein the method further comprises applying a functional material to the B-staged textile structure.

29. The method of claim 28 , wherein the functional material includes at least one material selected from the group consisting of a flame-proofing agent, a material for discharging electrostatic charges, a material for screening off electromagnetic rays, an organic or inorganic pigment, material that increases resistance to wear or slippage, and a decorative layer.

30. The method of claim 10 , wherein the B-stage binder composition comprises a functional material.

31. The method of claim 26 , wherein the hardening catalyst comprises maleic acid.

32. The method of claim 13 , wherein the glass fibers comprise glass microfibers having an average fiber diameter between 0.1 μm and 5 μm.

33. The method of claim 10 , wherein the B-stage polymerizable composition can be hardened.

34. The method of claim 10 , wherein the B-stage polymerizable composition can be hardened in multiple stages.

Assignees

• Gleich Klaus Friedrich
• Miele Philip Francis
• Ketzer Michael
• Johns Manville

Inventors

• Gleich Klaus Friedrich
• Miele Philip Francis
• Ketzer Michael

Classifications

• C08L2666/20

  Macromolecular compounds having nitrogen in the main chain according to C08L75/00 - C08L79/00; Derivatives thereof · CPC title

• C09J161/00 Primary

  Adhesives based on condensation polymers of aldehydes or ketones (with polyalcohols C09J159/00; with polynitriles C09J177/00); Adhesives based on derivatives of such polymers · CPC title

• Y10T442/2975

  Coated or impregnated ceramic fiber fabric · CPC title

• 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 · CPC title

• C08L2666/06

  Homopolymers or copolymers of unsaturated hydrocarbons; Derivatives thereof · CPC title