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CN115836148A - 含有阻燃矿物质和折射粒子的玻璃纤维罩幕以及含有此类罩幕的高光泽度和/或阻燃和/或非可燃层压板 - Google Patents

含有阻燃矿物质和折射粒子的玻璃纤维罩幕以及含有此类罩幕的高光泽度和/或阻燃和/或非可燃层压板 Download PDF

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CN115836148A
CN115836148A CN202180049233.9A CN202180049233A CN115836148A CN 115836148 A CN115836148 A CN 115836148A CN 202180049233 A CN202180049233 A CN 202180049233A CN 115836148 A CN115836148 A CN 115836148A
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component
flame retardant
mask
present
veil
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CN115836148B (zh
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F·泰兰
A·L·卡拉默
D·R·格林
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Diller Corp
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Diller Corp
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Abstract

描述了非织造玻璃纤维罩幕及由所述非织造玻璃纤维罩幕制造的层压板，所述非织造玻璃纤维罩幕包含：多根玻璃纤维；树脂组分；阻燃组分；和颗粒组分，所述颗粒组分包含折射率高于所述阻燃组分的折射率且平均粒度为约0.1至约0.5pm的无机粒子；其中所述阻燃组分和所述颗粒组分基于所述罩幕的总重量以按重量计约50％至约90％的组合量存在，并且其中所述阻燃组分和所述颗粒组分按重量比以约95:5至约50:50存在。

Description

含有阻燃矿物质和折射粒子的玻璃纤维罩幕以及含有此类罩 幕的高光泽度和/或阻燃和/或非可燃层压板
相关申请的交叉引用
本申请案要求于2020年7月17日申请的美国临时专利申请案第63/053,016号的权益，所述申请案的全部内容以引用方式并入本文中。
背景技术
复合材料是已知的。各种复合材料由于其强度、重量和机械性质的组合而被用于层压的多层建筑材料中。例如，玻璃纤维垫或罩幕已用于使用各种树脂进行层压的材料中以产生建筑面板。
通常，对于某些用途而言，可能重要的是为此类复合面板提供安全特征，包括例如耐火性。因此，例如，可以将阻燃材料并入到玻璃纤维垫和罩幕中。
通常，可能希望在表面上提供具有装饰性方面的此类面板。然而，玻璃纤维面板在地形方面通常是粗糙的。纤维含量和布置的变化可以显示在垫的暴露表面上，并且可以在所得的层压板中放大。在此类表面上包括装饰性覆盖层可以进一步放大此类表面粗糙度的视觉化。
另外，此类表面粗糙度和不规则性导致不能在此类表面上以可接受的图像质量和高光泽度印刷装饰性图像。
发明内容
大体来说，本发明涉及玻璃纤维罩幕，且特别来说涉及提供具有改善的表面光滑度、规则性和光泽度性质的层压板的玻璃纤维罩幕。更具体来说，本发明的各个方面和实施方案涉及玻璃纤维罩幕，所述玻璃纤维罩幕包括玻璃纤维、树脂组分、阻燃组分和额外的颗粒组分。本文中公开的各种实施方案可包括非织造玻璃纤维罩幕，所述罩幕涂有或饱含有浆料，所述浆料含有分散在水性树脂粘合剂系统中的阻燃粒子组分和低的表面积与体积比的粒子组分(即，光散射组分，其具有高于阻燃组分的折射率的折射率)。树脂粘合剂可以与用于形成待用公开的浆料处理的玻璃纤维罩幕的树脂粘合剂相同或不同。各种实施方案还可包括着色添加剂(例如，颜料、染料等)。本文中公开的各种实施方案可包括在例如湿法成网工艺中形成的非织造玻璃纤维罩幕，其中用于形成罩幕的树脂粘合剂体系包括分散在树脂粘合剂中的阻燃粒子组分和低的表面积与体积比的粒子组分。
本发明的各种实施方案包括多层层压板，其中至少一个层是根据本文中公开的玻璃纤维罩幕。本发明的实施方案可包括由根据本文中公开的若干层玻璃纤维罩幕组成的层压板。各种实施方案可包括具有额外装饰性层或覆盖层的层压板。根据本发明的层压板可以包括外部装饰层，所述外部装饰层是根据本公开的玻璃纤维罩幕。因此，本发明的各种实施方案可与装饰性表面层结合地使用，或可饱含装饰性表面层。在本发明的各种实施方案中，玻璃纤维罩幕可以用作印刷装饰性设计的基材。本发明的各种实施方案可用于产生高光泽度产品，以及满足从阻燃到不可燃的各种国家阻燃标准的产品。本发明的各种实施方案可用作白色屏障以为浅色、低基重装饰性层提供不透明性。本发明的各种实施方案可以提供抗微生物性质。本发明的各种实施方案可用于内部和外部等级应用，并且可与其他芯体材料结合使用以达成所需的最终性质。
本发明的一个实施方案包括一种非织造玻璃纤维罩幕，其包含：多根玻璃纤维；树脂组分；阻燃组分；和颗粒组分，所述颗粒组分包含折射率高于阻燃组分的折射率且平均粒度为约0.1至约0.5μm的无机粒子；其中阻燃组分和颗粒组分基于罩幕的总重量以按重量计约50％至约90％的组合量存在，并且其中阻燃组分和颗粒组分按重量比以约95:5至约50:50存在。
在本发明的各种优选实施方案中，阻燃组分包含选自以下各者中的至少一种：三水合铝、氧化锌、氢氧化镁、碳酸钙、碳酸钙镁石和水菱镁石、硫酸钡、氧化锑、硅酸镁、粘土和硼酸盐。在本发明的各种优选实施方案中，阻燃组分包含三水合铝。在本发明的各种优选实施方案中，颗粒组分包含二氧化钛。在本发明的各种优选实施方案中，树脂组分包含热固性树脂。在本发明的各种实施方案中，玻璃纤维罩幕包含预先形成的玻璃纤维罩幕，所述玻璃纤维罩幕随后涂布有或饱含有在树脂体系中含有阻燃组分和颗粒组分的浆料，其中用于形成初始玻璃纤维罩幕的树脂和用于形成阻燃/颗粒浆料的树脂包含相同树脂。在各种实施方案中，使用树脂粘合剂体系形成玻璃纤维罩幕，所述树脂粘合剂体系含有本文所述数量的阻燃和颗粒组分。
本发明的另一个实施方案包括一种非织造玻璃纤维罩幕，其包含：多根玻璃纤维；热固性树脂组分；三水合铝；和二氧化钛，二氧化钛包含具有低的表面积与体积比和约0.1至约0.5μm的平均粒度的金红石二氧化钛；其中三水合铝和二氧化钛基于罩幕的总重量以约60重量％至约80重量％的组合量存在，并且其中阻燃组分和颗粒组分以按重量计约75:25至约55:45的比率存在。
本发明的另一实施方案包括一种多层装饰性层压板，所述层压板包含为非织造玻璃纤维罩幕的至少一个层，所述非织造玻璃纤维罩幕包含：多根玻璃纤维；树脂组分；阻燃组分；和颗粒组分，所述颗粒组分包含具有低的表面积与体积比且平均粒度为约0.1至约0.5μm的无机粒子；其中阻燃组分和颗粒组分基于罩幕的总重量以按重量计约50％至约90％的组合量存在，并且其中阻燃组分和颗粒组分按重量比以约95:5至约50:50存在。各种额外实施方案包括多层装饰性层压板，其中为非织造玻璃纤维罩幕的至少一个层是装饰性元件。各种额外的实施方案包括多层装饰性层压板，其中为装饰性元件的非织造玻璃纤维罩幕提供层压板的外部可视表面，所述外部可视表面具有约80至约120的60°光泽度值、约35至约99的图像清晰度、小于约20的雾度值及约30至约110的峰值镜面反射率。
其他方面、特征和优点将从以下公开内容，包括详细描述、优选实施方案和所附权利要求中显而易见。
附图说明
当结合附图阅读时，将更好地理解前述概述内容以及以下对本发明的优选实施方案的详细描述。为了说明本发明，在附图中示出了当前优选的实施方案。然而，应当理解，本发明不限于所示出的精确布置和手段。
在附图中：
图1是根据本发明的实施方案的样品的光泽度特性的图形表示；
图2是根据本发明的实施方案的样品的孔隙空间特性的图形表示；
图3a到3e是根据本发明的实施方案的各种样品的横截面扫描电子显微照片的图像；且
图4a到4e是图3a到3e中成像的各种样品的表面视图扫描电子显微照片的图像。
具体实施方式
如本文中所使用，单数术语“一个”和“该”与“一个或多个”和“至少一个”同义并可互换地使用，除非语言和/或上下文清楚地另有指示。因此，例如，本文或所附权利要求书中提及“一层”或“该层”可指单层或多于一层。此外，除非另有特别注解，否则所有数值均应理解为由“大约”一词修饰。
为了说明简单且清楚，图中的元件不一定按比例绘制，并且不同图中的相同参考数字意指相同元件。为了附图清楚，元件被图示为具有大体直线边缘和精确的角度隅角。然而，本领域的技术人员应理解，边缘不需要为直线，且隅角不需要是精确的角度。
某些术语仅为了方便在以下描述中使用且并非限制性的。词语“右”、“左”、“下”和“上”指明经参考的附图中的方向。词语“向内”和“向外”分别指朝向和远离描述对象的几何中心及其指定部分的方向。术语包括上面特别提到的词语、其派生词和类似含义的词。
本发明的各种实施方案涉及包括阻燃组分和颗粒组分的纤维罩幕。在各种实施方案中，此类纤维罩幕可包括玻璃纤维罩幕。换句话说，在各种实施方案中，以随机或有序的方式取向的无机纤维罩幕分散在粘合剂中。合适的无机纤维包括玻璃，但可以由本领域已知的各种其他材料制成。在根据本发明的各种优选实施方案中，使用玻璃纤维，并且罩幕包含玻璃纤维罩幕。纤维罩幕且优选地玻璃纤维罩幕可以通过使用例如纤维和粘合剂的任何合适的技术，包括湿法成网技术制造，那些技术和材料在美国专利第4,129,674号、第4,112,174号、第4,681,802号、第4,810,576号、第5,484,653号、第6,187,697号和第8,084,378号中描述，前述各案的全部公开内容均通过引用方式并入本文中。例如，通常，玻璃纤维的浆料可以通过以下操作来制造：在碎浆机中将短切玻璃纤维添加到水性粘合剂树脂(根据本发明任选地含有阻燃组分和颗粒组分)中以将纤维分散在树脂中，并将此浆料供给到移动的倾斜筛网上从而形成线以脱水并形成湿的非织造纤维网。
根据本文中公开的各种实施方案，适用于玻璃纤维罩幕的玻璃纤维依据众所周知的罩幕所需的强度和其他性质可具有各种纤维直径和长度。适用于本发明的玻璃纤维可由任何类型的玻璃形成。在根据本发明的各种优选实施方案中，可以使用E型玻璃纤维。适用于本发明的各种实施方案的玻璃纤维可具有约3微米(μm)到约25微米的直径。在各种优选实施方案中，玻璃纤维的直径在8到20微米的范围内，且更优选地8到12微米的范围内，更优选为约10微米。适用于本发明的各种实施方案的玻璃纤维依据所需的机械性能可以具有任何长度。在各种优选实施方案中，可使用约8mm到约20mm的纤维长度。所使用的玻璃纤维都可以具有大约相同的长度，但是也可以使用不同长度和直径的纤维而以已知的方式获得不同的特性。
在本发明的各种实施方案中，适用的树脂包含热固性树脂。通常，可使用任何合适的热固性树脂，所述树脂包括但不限于丙烯酸树脂、乙烯基树脂(例如，聚乙酸乙烯酯和聚乙烯醇)、聚酯、聚氨酯、酚醛塑料、氨基塑料、己二烯酞酸酯、环氧化物、聚酰胺、氰酸酯和聚氰脲酸酯，或其共聚物、三元共聚物或组合。在本发明的各种优选实施方案中，合适树脂可以包括酚醛树脂和/或环氧树脂。在本发明的各种优选实施方案中，树脂包含三聚氰胺树脂或酚醛树脂。通常，优选具有较低燃烧热值的树脂。
在根据本发明的各种实施方案中，纤维罩幕可以根据任何上述工艺形成，例如湿法成网技术，并随后用含有树脂、阻燃组分和颗粒组分的浆料进行处理。替代地，纤维罩幕最初可通过此类技术形成，其中在湿法成网技术中使用的浆料含有阻燃组分和颗粒组分。在各种实施方案中，玻璃纤维罩幕可经形成，且随后由含有树脂、阻燃组分及颗粒组分的浆料进行处理。例如，在各种实施方案中，可商购的玻璃纤维罩幕，例如以商品名JohnsManville 7610、Ahlstrom GFT-25G10-60和Ahlstrom GFT-255M18-80可获得的那些罩幕可以用含有树脂、阻燃组分和颗粒组分的浆料进行处理。形成为具有最小表面不规则性的玻璃纤维罩幕为优选的。使用本领域已知的湿法成网或干法成网工艺制备的玻璃纤维罩幕在用含有阻燃组分和颗粒组分的浆料处理之前通常可具有约20gsm到约110gsm且优选约30gsm到约90gsm的基重，其中纤维经随机取向并用粘合剂树脂以及各种其他可选组分结合在一起，并且玻璃纤维罩幕可以用浆料处理以形成根据本发明的各种实施方案的玻璃纤维罩幕。在起始玻璃纤维罩幕用浆料处理以形成经处理的罩幕的本发明的各种优选实施方案中，起始玻璃纤维罩幕可具有约50gsm到约70gsm的基重。
可以任何已知的方式将含有阻燃组分和颗粒组分的浆料施加到玻璃纤维罩幕上，所述方式包括例如浸入浆料浴或辊涂。在各种实施方案中，玻璃纤维罩幕可以作为连续网状物从一卷材料提供并穿过树脂浴中的具有树脂、阻燃组分和颗粒组分的浆料，随后通过适当的计量方法去除多余的浆料，随后在例如热风烘箱中至少部分干燥。替代地，例如，含有树脂、阻燃组分和颗粒组分的浆料可以使用辊涂机被施加到玻璃纤维罩幕，且接着经平滑化，且使用绕线计量棒(也称为Mayer棒或杆)来对适当基重进行计量。接着，可以在热风烘箱中干燥涂布的罩幕以去除挥发性组分。玻璃纤维罩幕可以用浆料处理一次或多次，优选地是一次或两次涂布。
在本发明的各种实施方案中，阻燃组分包含矿物阻燃粒子。各种阻燃组分可以适用于本发明的各种实施方案，只要阻燃组分不与树脂体系反应且不可压缩即可。因此，矿物类阻燃粒子适用于本发明的各种实施方案中。在本发明的各种优选实施方案中，阻燃组分包含选自以下的组分：三水合铝(aluminum trihydrate，ATH)、氧化锌、碳酸钙、硫酸钡、氢氧化镁和粘土。在各种优选实施方案中，阻燃组分包含三水合铝。例如，在根据本发明的各种优选实施方案中，阻燃组分包括作为Polyfill 301从佐治亚州Chatsworth的CustomGrinders采购的三水合铝。在本发明的各种实施方案中，阻燃组分的平均粒度可为约5微米到约20微米。在根据本发明的各种优选实施方案中，阻燃组分的平均粒度可为约9微米到约11微米。在根据本发明的各种优选实施方案中，阻燃组分的pH值可为约9到约10。
根据本发明的各种实施方案的玻璃纤维罩幕含有颗粒组分。适用于本发明的各种实施方案的颗粒组分通常具有具低的表面积与体积比的形状或晶体结构。适用于本发明的各种实施方案的颗粒组分通常应具有比所用阻燃组分的折射率高的折射率。适用于本发明的各种实施方案的颗粒组分优选地具有约0.1μm到约0.5μm的平均粒度。如上文所提及，适用于本发明的各种实施方案的颗粒组分通常具有具低的表面积与体积比的形状。换言之，各种颗粒组分的粒子具有形状，所述形状具有对于给定体积具有最低或接近最低可能表面积的表面积。通常，包括球形、椭球形、椭圆形、圆形粒子。也可以包括立方体和最小狭长的立方体形状，只要所述形状具有低纵横比，例如小于约10:1，更优选小于约5:1且更优选小于约2.5:1的纵横比。
适用于本发明的各种实施方案的颗粒组分通常应具有比所用阻燃组分的折射率高的折射率。适用于本发明的各种实施方案的颗粒组分可包括二氧化钛、氧化锌、硫酸钡、硫化锌或类似等同物，其包括折射率高于所用阻燃组分的折射率的无机粒子。例如，ATH的折射率约为1.57。在本发明的各种优选实施方案中，颗粒组分可包含二氧化钛。优选地，二氧化钛是金红石二氧化钛。在各种优选的实施方案中，颗粒组分包含金红石二氧化钛，所述金红石二氧化钛具有大于99％，更优选大于99.9％，甚至更优选大于99.99％的TiO2含量。在各种实施方案中，二氧化钛粒子的平均粒度为约0.1μm到约0.5μm。
根据本发明的各种实施方案的玻璃纤维罩幕包括(a)玻璃纤维，(b)树脂组分，(c)阻燃组分，和(d)颗粒组分。在本发明的各种实施方案中，玻璃纤维罩幕可以按罩幕的组合成分(a)到(d)的重量计约5％到约15％的量含有玻璃纤维。在本发明的各种优选实施方案中，玻璃纤维罩幕可以按罩幕的组合成分(a)到(d)的重量计约5％到约8％的量含有玻璃纤维。在本发明的各种实施方案中，罩幕可以按罩幕的组合组分(a)到(d)的重量计约5％到约30％的量含有树脂组分。前述公开量的树脂可由用于制备未处理的起始玻璃纤维罩幕的树脂和通过提供阻燃组分和颗粒组分的处理浆料引入的后续树脂组成。替代地，此量的树脂可以是在湿法成网或其他工艺中形成玻璃纤维罩幕的结果，其中在最初形成罩幕的工艺中提供阻燃组分和颗粒组分。在本发明的各种实施方案中，罩幕可以按罩幕的组合成分(a)到(d)的重量计约25％到约80％的量含有阻燃组分。在本发明的各种实施方案中，罩幕可以按罩幕的组合成分(a)到(d)的重量计约4％到约50％的量含有颗粒组分。
在本发明的各种实施方案中，阻燃组分和颗粒组分可以以约95:5至约50:50的重量比存在。即，在本发明的各种实施方案中，例如三水合铝和例如二氧化钛可以以约95:5到约50:50的ATH:TiO2的重量比存在于根据本文公开的各种实施方案的玻璃纤维罩幕中。在各种优选实施方案中，阻燃组分和颗粒组分可以以如下各者的重量比存在：约90:10到约55:45、约85:15到约55:45、约80:20到约55:45、约80:20到约60:40、约75:25到约60:40、约80:20到约65:35、约75:25到约65:35。在各种优选实施方案中，阻燃组分和颗粒组分以约80:20或约70:30或约60:40的重量比存在。在某些优选实施方案中，阻燃组分和颗粒组分以80:20或70:30或60:40的重量比存在，每一比率的每一值变化范围为±5％、更优选±2％且甚至更优选±1％。在各种优选实施方案中，前述重量比中的每一个可以关于彼此具体地应用于每一种公开的阻燃组分和每一种公开的颗粒组分。
根据本发明的各种实施方案的处理浆料可以另外添加一种或多种任选的添加剂，例如表面活性剂、消泡剂、流变改性剂、防阻断剂、加味剂、驱虫剂、抗微生物剂、染料、颜料及本领域已知的用于包括在玻璃纤维罩幕或垫处理中的类似添加剂。
根据本发明的各种实施方案，用于将阻燃组分和颗粒组分施加到预成型玻璃纤维罩幕的处理浆料可具有约57到约76％，并且优选地约65到约75％的固体含量。根据本发明的各种实施方案，用于将阻燃组分和颗粒组分施加到预成型玻璃纤维罩幕的处理浆料制备为所选树脂或树脂体系、阻燃组分、颗粒组分以及如上文所提及的任何可选成分的水性混合物。根据本发明的各种实施方案使用的处理浆料经混合以达成均匀的浆料并避免凝聚和膨胀流变。浆料粘度通常应>400cP(Brookfield 50rpm主轴03，25℃)以达成恰当的浆料涂层重量并避免沉降。
根据本发明的各种实施方案的玻璃纤维罩幕可用作多层装饰性层压板产品中的一或多个层。在根据本发明的各种实施方案中，层压板可包含根据本发明的多层玻璃纤维罩幕。在根据本发明的各种实施方案中，层压板可包含不含有阻燃组分和颗粒组分两者的多层玻璃纤维罩幕，在所述多层玻璃纤维罩幕上安置至少一个上层，所述上层包含根据本发明的实施方案的玻璃纤维罩幕。在根据本发明的各种实施方案中，层压板根据任一前述实施方案可以包含多个玻璃纤维罩幕层，并且还包括一个或多个覆盖层，所述覆盖层可以包括本领域已知的装饰性层和保护性覆盖层。在额外实施方案中，根据本发明的各种实施方案的玻璃纤维罩幕可以用作多层防弹层压产品或隔音板产品中的一层或多层。其中防弹面板包括根据本发明的实施方案的玻璃纤维罩幕的各种实施方案可以进一步包括环氧树脂或粘弹性材料，以及可选的一种或多种防弹布材料，例如芳族聚酰胺纤维(例如，凯夫拉尔(Kevlar))。
可以使用任何层压方法制备根据本发明的各种实施方案的层压板，所述方法包括例如高压层压(HPL)、连续压力层压(CPL)、热熔三聚氰胺(TFM)方法和其他已知方法。合适的温度、压力和保持时间条件可以根据本领域已知的参数而变化。可以使用本领域已知的各种压板和设备。在根据本发明的各种实施方案中，使用高压层压生产的层压板可为较佳的。
根据本发明的各种实施方案的玻璃纤维罩幕可以为层压板提供不可燃和阻燃的材料。如本文所用，“不可燃”是指A2或更高的阻燃等级(根据EN ISO 1716和EN 13823)。如本文中所使用，“阻燃”是指B或更高的阻燃等级(根据EN 13823和EN 11925-2)。
因此，例如，取决于所得经处理玻璃纤维罩幕的所需基重，以及在用含有阻燃组分和颗粒组分的浆料处理之前玻璃纤维的起始基重，A2级和阻燃处理过的罩幕可以运用如下表1和表2所示的所得组分含量(表1以重量百分比表示，且表2以gsm表示)获得。表1和表2中所示的量是非限制性的，且仅是合适配方的示例。在下表中，最左侧一列中的基重是指处理过的玻璃纤维罩幕的最终基重。“粘合剂+树脂”是指来自预成型罩幕的粘合剂和来自处理浆料的树脂的组合量。
表1.
Figure BDA0004046826300000111
表2.
Figure BDA0004046826300000112
现在将参照以下非限制性实施例更详细地描述本发明。
实施例
实施例1a至1f：
具有60gsm的基重、从Ahlstrom获得的GFT-25G10-60纤维玻璃罩幕使用三聚氰胺树脂用含有不同量的三水合铝(购自Chatsworth Custom Grinders的Polyfill 301)和金红石二氧化钛的六种不同浆料处理。
使用带有迈尔棒的双程反向辊涂将浆料涂覆到每个罩幕。根据六种不同的浆料配方中的每一种的四个玻璃纤维罩幕经堆叠，并在约130℃的温度和1300psi的压力下进行高压层压约半小时。
如以下表3(按重量百分比)和表4(gsm)所示，所得层压板使用厚度测量仪(Rhopoint)IQ(测角光度计)针对60°光泽度、图像清晰度(“DOI”)、峰值镜面反射率和雾度进行评估。这些分析的结果在图2中予以阐述。表面光泽度值是在压制层压板的表面装饰性三聚氰胺层上进行测试。
表3.
Figure BDA0004046826300000121
表4.
Figure BDA0004046826300000122
从图1中可以看出，相对于阻燃组分和颗粒组分的组合总量以增大的数量包括颗粒组分(本例中为金红石二氧化钛)提供显著增加和改善的DOI、改善的峰值镜面反射率和更好的雾度特性，同时保持极高的60°光泽度值。
如图2中所示，孔隙空间通过TiO2的包括而减小。使用实施例1a至1e中制备的样品和成像技术(参见下面的实施例3和4)，确定孔隙空间。对应于实施例1a到1e的样品中针对0％的TiO2的孔隙空间值使用来自以下实施例2的值进行近似。使用较高基重材料的0％的TiO2样品中的实际孔隙空间甚至更高，为22％。随着TiO2内含物增加，取代阻燃粒子，孔隙空间减小，从而达成接近50％的近似稳定水平。
实施例2：
从Ahlstrom获得的基重为80gsm的GFT-255M18-80玻璃纤维罩幕在0和34％ TiO2(％ATH被TiO2取代)两者下进行处理，其他方面与实施例1a至1f中描述的样式相同。就压制后的横截面孔隙空间而言，我们看到添加TiO2后从22％减少到13％。此情形转译成DOI从55到91的改善。还将使用80gsm玻璃纤维和0％和34％的二氧化钛制备的层压板与竞争产品进行了比较。与不含二氧化钛的玻璃纤维产品以及CGS层压产品和MDF漆产品两者相比，包含二氧化钛可产生更优的DOI、雾度和峰值反射率(Rspec)。结果汇总在以下表5中。
表5.
60°光泽度 DOI 雾度 峰值反射率
0％的TiO2 115 55 3.9 49
34％的TiO2 115 91 5.6 60
MDF漆 91 89 5 44
CGS层压板 110 47 13 26
实施例3与4：
根据实施例1a至1e制备的层压板的扫描电子显微照片，包括横截面图和表面视图绘示于图3a到3e(横截面)和图4a到4e(表面视图)中。如可看出，孔隙空间随着二氧化钛替代ATH的数量而减小。
另外还发现，本发明的各种实施例可以提供这种均匀、低孔隙的基材，收缩纸具有更少的孔隙缺陷以放大，且因此即使在纸比玻璃纤维收缩更多的加速干燥条件下，带有装饰性纸覆盖层的层压玻璃纤维表面不会因纸张收缩而出现放大的缺陷。TiO2的添加进一步改善了具有装饰性纸表面的玻璃纤维芯体的外观，此情形又为100％纸类产品上的改善。
本领域的技术人员将理解，可以对上述实施例进行改变而不脱离其广泛的发明概念。因此，应理解，本发明不限于所公开的特定实施例，而是旨在涵盖在由所附权利要求书限定的本发明的精神和范围内的修改。

Claims (20)

1.一种非织造玻璃纤维罩幕，其包含：多根玻璃纤维；树脂组分；阻燃组分；和颗粒组分，所述颗粒组分包含折射率高于所述阻燃组分的折射率且平均粒度为约0.1至约0.5μm的无机粒子；其中所述阻燃组分和所述颗粒组分基于所述罩幕的总重量以按重量计约50％至约90％的组合量存在，并且其中所述阻燃组分和所述颗粒组分按重量比以约95:5至约50:50存在。
2.根据权利要求1所述的非织造玻璃纤维罩幕，其中阻燃组分包含选自由以下组成的组中的一种或多种：三水合铝、氧化锌、氢氧化镁、碳酸钙、碳酸钙镁石和水菱镁石、硫酸钡、氧化锑、硅酸镁、粘土和硼酸盐。
3.根据权利要求1所述的非织造玻璃纤维罩幕，其中所述颗粒组分包含二氧化钛。
4.根据权利要求3所述的非织造玻璃纤维罩幕，其中所述二氧化钛包含金红石二氧化钛。
5.根据权利要求1所述的非织造玻璃纤维罩幕，其中所述树脂组分包含热固性树脂。
6.根据权利要求1所述的非织造玻璃纤维罩幕，其中所述多根玻璃纤维随机取向并且具有约8μm至约20μm的平均纤维直径和约8mm至约20mm的平均纤维长度。
7.根据权利要求1所述的非织造玻璃纤维罩幕，其中所述玻璃纤维罩幕的基重为约200gsm至约1200gsm。
8.根据权利要求1所述的非织造玻璃纤维罩幕，其中所述阻燃组分和所述颗粒组分基于所述罩幕的所述总重量以按重量计约60％至约80％的组合量存在。
9.根据权利要求1所述的非织造玻璃纤维罩幕，其中所述阻燃组分和所述颗粒组分基于所述罩幕的所述总重量以按重量计约65％至约75％的组合量存在。
10.根据权利要求1所述的非织造玻璃纤维罩幕，其中所述阻燃组分和所述颗粒组分以约80:20到约50:50的重量比存在。
11.根据权利要求1所述的非织造玻璃纤维罩幕，其中所述阻燃组分和所述颗粒组分以约75:25到约55:45的重量比存在。
12.根据权利要求1所述的非织造玻璃纤维罩幕，其中所述阻燃组分和所述颗粒组分以约70:30到约60:40的重量比存在。
13.一种非织造玻璃纤维罩幕，其包含：多根玻璃纤维；热固性树脂组分；三水合铝；和二氧化钛，所述二氧化钛包含具有低的表面积与体积比和约0.1至约0.5μm的平均粒度的金红石二氧化钛；其中所述三水合铝和所述二氧化钛基于所述罩幕的总重量以按重量计约60％至约80％的组合量存在，并且其中所述阻燃组分和所述颗粒组分以约75:25至约55:45的重量比存在。
14.根据权利要求13所述的非织造玻璃纤维罩幕，其中所述罩幕的基重为约700gsm至约800gsm。
15.一种多层装饰性层压板，其包含为根据权利要求1所述的非织造玻璃纤维罩幕的至少一个层。
16.一种多层装饰性层压板，其包含为根据权利要求13所述的非织造玻璃纤维罩幕的至少一个层。
17.根据权利要求15所述的多层装饰性层压板，其中为非织造玻璃纤维罩幕的所述至少一个层是装饰性元件。
18.根据权利要求17所述的多层装饰性层压板，其中所述层压板的所述外部可视表面具有约80至约120的60°光泽度值、约35至约99的图像清晰度、小于约20的雾度值及约30至约110的峰值镜面反射率。
19.根据权利要求17所述的多层装饰性层压板，其中所述层压板的所述外部可视表面具有约100至约120的60°光泽度值、约60至约99的图像清晰度、小于约15的雾度值及小于40的峰值镜面反射率与所述60°光泽度值之间的差。
20.根据权利要求19所述的多层装饰性层压板，其中为非织造玻璃纤维罩幕的所述至少一个层是外表面层。
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US11866561B2 (en) 2024-01-09
BR112022027041A2 (pt) 2023-01-31

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