[go: up one dir, main page]

WO2025137029A1 - Mat fibreux non tissé revêtu - Google Patents

Mat fibreux non tissé revêtu Download PDF

Info

Publication number
WO2025137029A1
WO2025137029A1 PCT/US2024/060656 US2024060656W WO2025137029A1 WO 2025137029 A1 WO2025137029 A1 WO 2025137029A1 US 2024060656 W US2024060656 W US 2024060656W WO 2025137029 A1 WO2025137029 A1 WO 2025137029A1
Authority
WO
WIPO (PCT)
Prior art keywords
binder
glass fibers
mat
composition
range
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2024/060656
Other languages
English (en)
Inventor
Robert Huusken
Gerard van den Berk
Gregory Godard
Thomas QUERETTE
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Owens Corning Intellectual Capital LLC
Original Assignee
Owens Corning Intellectual Capital LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Owens Corning Intellectual Capital LLC filed Critical Owens Corning Intellectual Capital LLC
Publication of WO2025137029A1 publication Critical patent/WO2025137029A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

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
    • 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
    • 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
    • D04H1/587—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 characterised by the bonding agents used
    • 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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78—Heat insulating elements
    • E04B1/80—Heat insulating elements slab-shaped

Definitions

  • Glass veils also known as mats, non-wovens, or webs
  • ETICs external thermal insulation composite systems
  • the glass veils are currently impregnated with poly- or per-fluoroalkyl substances (PFAS).
  • PFAS poly- or per-fluoroalkyl substances
  • the PFAS- impregnated glass veils prevent bleed-through of polyisocyanurate foam during the manufacture of the insulation boards.
  • the glass veil contains the expanding polyisocyanurate foam (made from a mixture of isocyanate and polyol) without going through the glass veil because it would soil the conveyor of the production line.
  • the PFAS-impregnated glass veils typically are porous. Despite their open structure, they have highly repellent properties to the foam due to the hydrophobic and oleophobic qualities introduced to the glass veil by the PFAS.
  • PFAS will be banned under European legislation in the near future, and as a result, more sustainable PFAS-free glass veils have been developed.
  • These include a heavy, mineral-coated glass non-woven.
  • the coated glass facers have a very low porosity and work as facers in the polyisocyanurate process because the surface is physically closed due to the thick mineral coating.
  • the thick coating on top of the glass nonwoven makes it a vulnerable design for especially the ETICS application.
  • the ETICS render applied to the mineral coating of the coated glass facer does not adhere well and gives a significantly higher risk in long term weathering and durability performance.
  • the point of attachment of a repeat unit, moiety, or substituent is represented by For example, - COOH is attached through the carbon atom.
  • the term “about” or “approximately” means an acceptable error for a particular value as determined by a person of ordinary skill in the art, which depends in part on how the value is measured or determined.
  • the term “about” or “approximately” may mean within 1 , 2, 3 or 4 standard deviations.
  • the term “about” or “approximately” may mean within 30%, 25%, 20%, 15%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1 %, or 0.5% of a given value or range.
  • Alkyl refers to a straight-chain, branched, or cyclic saturated hydrocarbon group.
  • the alkyl group may have from 5-20 carbon atoms, for example from 7-17 carbon atoms, such as 10-15 carbon atoms.
  • the alkyl group may be unsubstituted. Alternatively, the alkyl group may be substituted. Unless otherwise specified, the alkyl group may be attached at any suitable carbon atom and, if substituted, may be substituted at any suitable atom.
  • Aryl refers to an aromatic carbocylic group or aromatic heterocarbocyclic group.
  • the aryl group may have a single ring or multiple condensed rings.
  • the aryl group can have from 5-20 carbon atoms, for example from 6-20 carbon atoms, such as 6-12 carbon atoms.
  • the aryl group may be unsubstituted. Alternatively, the aryl group may be substituted. Unless otherwise specified, the aryl group may be attached to any suitable carbon atom and, if substituted, may be substituted at any suitable atom. Examples of aryl groups include, but are not limited to, phenyl, tolyl (o-, m-, or p-), naphthyl, anthracenyl, and the like.
  • aryl group is an aromatic heterocarbocyclic group
  • one or more (e.g. 1 , 2, 3, or more) of the carbon atoms in an aromatic carbocylic group is independently substituted with a heteroatom provided aromaticity is maintained.
  • An aromatic heterocarbocyclic group may also be known as a heteroaryl group.
  • the heteroaryl group may have a single ring or multiple condensed rings.
  • the or each heteroatom may be independently selected from the group consisting of nitrogen, oxygen, phosphorus, sulfur.
  • the or each heteroatom may be selected from nitrogen.
  • the heteroaryl group may have from 4-20 carbon atoms, for example from 5-20 carbon atoms, such as from 5-15 carbon atoms.
  • the heteroaryl group may be unsubstituted.
  • the heteroaryl group may substituted. Unless otherwise specified, the heteroaryl group may be attached at any suitable atom and, if substituted, may be substituted at any suitable atom.
  • heteroaryl groups include but are not limited to thienyl, furanyl, pyrrolyl, imidazolyl, pyrazolyl, thiazolyl, isothiazolyl, oxazolyl, isoxazolyl, triazolyl, thiadiazolyl, thiophenyl, oxadiazolyl, pyridinyl, pyrimidyl, benzoxazolyl, benzthiazolyl, benzimidazolyl, indolyl, quinolinyl, and the like.
  • PFAS poly- or per-fluoroalkyl substances
  • room temperature is about 20 °C.
  • Viscosity is a function of the rate of shear. A decrease in the viscosity of a composition with increasing rate of shear is called “shear thinning”, and an increase in the viscosity of a composition is called “shear thickening”.
  • substantially free means that the selected composition contains less than a functional amount of the stated ingredient or component, typically less than about 0.1 wt%, such as less than about 0.05 wt%, for example, less than about 0.03 wt% of the total composition.
  • “Substituted” refers to a group in which one or more (e.g. 1 , 2, 3, 4, or 5) hydrogen atoms are each independently replaced with substituents which may be the same or different.
  • the substituent may be any group which does not adversely affect the aqueous composition of the invention, the coating of the coated non-woven mat of the invention, the coated non-woven mat of the invention, or the precursor mat. Examples of substituents include, but are not limited to, -R a , -O-R a , -NR a R b , -CN, -COOR a , and -CONR a R b , preferably -R a .
  • R a and R b are independently selected from the groups consisting of H, alkyl, and aryl, such as phenyl, tolyl (o-, m-, or p-), naphthyl, anthracenyl, methyl, ethyl, n-propyl, i- propyl, n-butyl, i-butyl, t-butyl, pentyl, cyclo-pentyl, hexyl, cyclo-hexyl and the like.
  • aryl such as phenyl, tolyl (o-, m-, or p-), naphthyl, anthracenyl, methyl, ethyl, n-propyl, i- propyl, n-butyl, i-butyl, t-butyl, pentyl, cyclo-pentyl, hexyl, cyclo-hexyl and the
  • Figure 1 shows a representative photograph of a coated non-woven fibrous mat coated with a 10 wt% solution of Mowiol® 28-99 (sold by Kuraray) using an RK laboratory multicoater. Description of the Invention
  • the present invention provides to a coated non-woven fibrous mat, the coated non-woven fibrous mat comprising:
  • the coating comprises a second binder, wherein the second binder is a polyvinyl alcohol binder with a weight average molecular weight in the range of about 100000 g/mole to about 500000 g/mol; wherein: the coated non-woven fibrous mat has an air permeability of ⁇ about 70 L/m 2 /s as measured according to ASTM D737.
  • the coated non-woven fibrous mat comprises a precursor mat.
  • the precursor mat has a first major surface and a second major surface opposite to the first major surface.
  • the coating may be applied to the first or second major surfaces.
  • the coating may not comprise poly- or per-fluoroalkyl substances (PFAS) i.e. the coating is PFAS-free.
  • PFAS per-fluoroalkyl substances
  • the coating may be prepared from e.g. tap water, which may contain PFAS as an impurity or residue.
  • a PFAS-free coating therefore may comprise trace quantities of PFAS introduced as an impurity or residue.
  • the coating comprises a second binder.
  • the second binder is a polyvinyl alcohol (PVOH) binder with a weight average molecular weight in the range of about 100000 g/mole to about 500000 g/mol.
  • PVOH polyvinyl alcohol
  • Specific polyvinyl alcohol binders chosen according to the invention produce a lightweight and low air permeability mat, which makes the mat suitable for use as a facer for construction boards, in particular polyisocyanurate foam boards.
  • the performance of the resulting board is good in terms of stability towards humidity and moisture.
  • the coated non-woven fibrous mats may be used in polyisocyanurate foam boards in external thermal insulation composite systems, the foam boards will be exposed to rain, snow, and humidity before a render is applied on top of it. It is of benefit therefore for the coated non-woven fibrous mat to exhibit sufficient resistance to these weather conditions.
  • the binder is a polyvinyl alcohol binder with a weight average molecular weight (Mw) in the range of about 100000 g/mole to about 500000 g/mol.
  • Mw weight average molecular weight
  • the weight average molecular weight of the polyvinyl alcohol binder may be > about 100000 g/mol.
  • the weight average molecular weight of the polyvinyl alcohol binder may be > about 105000 g/mol.
  • the weight average molecular weight of the polyvinyl alcohol binder may be > about 110000 g/mol.
  • the weight average molecular weight of the polyvinyl alcohol binder may be > about 115000 g/mol.
  • the weight average molecular weight of the polyvinyl alcohol binder may be > about 120000 g/mol.
  • the weight average molecular weight of the polyvinyl alcohol binder may be > about 125000 g/mol.
  • the weight average molecular weight of the polyvinyl alcohol binder may be > about 130000 g/mol.
  • the weight average molecular weight of the polyvinyl alcohol binder may be > about 135000 g/mol.
  • the weight average molecular weight of the polyvinyl alcohol binder may be ⁇ about 500000 g/mol.
  • the weight average molecular weight of the polyvinyl alcohol binder may be ⁇ about 450000 g/mol.
  • the weight average molecular weight of the polyvinyl alcohol binder may be ⁇ about 350000 g/mol.
  • the weight average molecular weight of the polyvinyl alcohol binder may be ⁇ about 300000 g/mol.
  • the weight average molecular weight of the polyvinyl alcohol binder may be ⁇ about 250000 g/mol.
  • the weight average molecular weight of the polyvinyl alcohol binder may be > about 140000 g/mol to ⁇ about 150000 g/mol.
  • the weight average molecular weight of the polyvinyl alcohol binder may be measured by gel permeation chromatography.
  • the polyvinyl alcohols are commercially available, and may be produced by hydrolysing polyvinyl acetate (PVA). The amount of hydroxylation determines its physical and mechanical properties.
  • the dry polymer is a hard, colorless, and odorless crystalline thermoplastic with a Tg of about 375 K (about 102 °C). It is highly water soluble, fully biodegradable but resistant to organic solvents and oils, with high tensile strength, and elasticity.
  • Polyvinyl acetate may be hydrolysed to a high degree (e.g. greater than 85 mol%). In this instance, the resulting polyvinyl alcohols become more difficult to solubilize and films on drying become more resistant to humidity and rain because of an increasing level of hydrogen bonding occurring between intra- and intermolecular hydroxyl groups.
  • the degree of hydrolysis of the polyvinyl alcohol may be > about 85 mol%.
  • the degree of hydrolysis of the polyvinyl alcohol may be > about 88 mol%.
  • the degree of hydrolysis of the polyvinyl alcohol may be > about 90 mol%.
  • the degree of hydrolysis of the polyvinyl alcohol may be > about 92 mol%.
  • the degree of hydrolysis of the polyvinyl alcohol may be > about 94 mol%.
  • the degree of hydrolysis of the polyvinyl alcohol may be > about 95 mol%.
  • the degree of hydrolysis of the polyvinyl alcohol may be > about 96 mol%.
  • the degree of hydrolysis of the polyvinyl alcohol may be > about 97 mol%.
  • the degree of hydrolysis of the polyvinyl alcohol may be > about 98 mol%.
  • the degree of hydrolysis can be measured by titration with a base, typically a strong base. This method is well known from the skilled in the art for measuring saponification index.
  • the polyvinyl alcohol may have a viscosity measured at 4 wt% in water at room temperature with a Brookfield synchronized-motor rotary viscometer that is > about 25 mPa.s. It may be > about 28 mPa.s.
  • the polyvinyl alcohol may have a viscosity measured at 4 wt% of said polyvinyl alcohol in water at room temperature with a Brookfield synchronized-motor rotary viscometer of > about 25 mPa.s and ⁇ about 60 mPa.s.
  • the polyvinyl alcohol binder binder may have a viscosity of about 28 mPa.s to about 40 mPa.s when measured with a 4% aqueous solution at room temperature (about 20°C) with a Brookfield synchronized-motor rotary viscometer, and a degree of hydrolysis of about 99 mol%.
  • the coated non-woven fibrous mat is asymmetric.
  • asymmetric we mean that the aqueous composition of the present invention does not completely penetrate through the entire thickness of the precursor mat. Instead, the aqueous composition coats or sits solely on one side of the precursor mat after application i.e. on one major surface of the precursor mat. In this respect, the aqueous composition will be detectable on the coated side of the precursor mat but will not be detectable on the other (uncoated) side of the mat. Likewise, the coating (i.e. the aqueous composition after being dried) will be detectable on the coated side of the precursor mat but will not be detectable on the other (uncoated) side of the mat.
  • the coating may penetrate the precursor mat between > about 0.1 % to ⁇ about 50% of the thickness of the precursor mat.
  • the thickness of the precursor mat and/or coated non-woven fibrous mat may be measured in accordance with ASTM D1777.
  • the coating may penetrate the precursor mat ⁇ about 45% of the thickness of the precursor mat.
  • the coating may penetrate the precursor mat ⁇ about 40% of the thickness of the precursor mat.
  • the coating may penetrate the precursor mat ⁇ about 35% of the thickness of the precursor mat.
  • the coating may penetrate the precursor mat ⁇ about 30% of the thickness of the precursor mat.
  • the coating may penetrate the precursor mat ⁇ about 25% of the thickness of the precursor mat.
  • the coating may penetrate the precursor mat ⁇ about 20% of the thickness of the precursor mat.
  • the coating may penetrate the precursor mat ⁇ about 15% of the thickness of the precursor mat.
  • the coating may penetrate the precursor mat ⁇ about 10% of the thickness of the precursor mat.
  • the coating may penetrate the precursor mat between > about 0.5% to ⁇ about 30% of the thickness of the precursor mat, such as about > about 0.5% to ⁇ about 20% of the thickness of the precursor mat, for example > about 0.5% to ⁇ about 10% of the thickness of the precursor mat.
  • the precursor mat comprises (a) a non-woven web of fibers comprising glass fibers and optionally polyester fibers, and (b) a first binder, or combination thereof.
  • the precursor mat may not comprise poly- or per-fluoroalkyl substances (PFAS) i.e. the precursor mat is PFAS-free.
  • PFAS per-fluoroalkyl substances
  • the precursor mat may be prepared using e.g. tap water, which may contain PFAS as an impurity or residue.
  • a PFAS-free precursor mat therefore may comprise trace quantities of PFAS introduced as an impurity or residue.
  • the precursor mat may comprise a non-woven web of fibers comprising glass fibers i.e. the precursor mat does not contain polyester fibers.
  • the precursor mat may comprise a non-woven web of fibers comprising glass fibers and polyester fibers.
  • the glass fibers may comprise one or more (e.g. 2, 3, 4, or 5) groups of glass fibers.
  • the glass fibers may comprise a single group of fibers.
  • the glass fibers may comprise more than one (e.g. two or more, optionally two) groups of glass fibers.
  • the glass fibers may be (a) manufactured from the same type of glass but have differing dimensions (average diameter and/or average length), (b) manufactured from different types of glass but have the same or similar dimensions within manufacturing tolerances, or (c) manufactured from different types of glass and having differing dimensions (average diameter and/or average length).
  • the glass fibers After the glass fibers are treated with the sizing composition, they may be chopped for subsequent processing into a wet-laid, non-woven mat as described below.
  • the glass fibers may have a mean fiber diameter as described below and a mean fiber length as described below.
  • the glass fibers may have a mean fiber diameter in the range of > about 5 pm and ⁇ about 20 pm.
  • the glass fibers may have a mean fiber diameter in the range of > about 6 pm and ⁇ about 17 pm.
  • the glass fibers may have a mean fiber diameter in the range of > about 7 pm and ⁇ about 15 pm.
  • the glass fibers may have a mean fiber diameter of > about 6 pm.
  • the glass fibers may have a mean fiber diameter of > about 6.5 pm.
  • the glass fibers may have a mean fiber diameter of > about 7 pm.
  • the glass fibers may have a mean fiber diameter of > about 8.5 pm.
  • the glass fibers may have a mean fiber diameter of > about 9 pm.
  • the glass fibers may have a mean fiber diameter of > about 9.5 pm.
  • the glass fibers may have a mean fiber diameter of ⁇ about 17 pm.
  • the glass fibers may have a mean fiber diameter ⁇ about 16.5 pm.
  • the glass fibers may have a mean fiber diameter of ⁇ about 16 pm.
  • the glass fibers may have a mean fiber diameter of ⁇ about 15.5 pm.
  • the glass fibers may have a mean fiber diameter of ⁇ about 15 pm.
  • the glass fibers may have a mean fiber diameter of ⁇ about 14.5 pm.
  • the glass fibers may have a mean fiber diameter of ⁇ about 14 pm.
  • the glass fibers may have a mean fiber diameter of ⁇ about 13.5 pm.
  • the glass fibers may have a mean fiber diameter of ⁇ about 13 pm.
  • the glass fibers may have a mean fiber diameter of ⁇ about 12.5 pm.
  • the glass fibers may have a mean fiber diameter of ⁇ about 12 pm.
  • the glass fibers may have a mean fiber diameter of ⁇ about 11 .5 pm.
  • the glass fibers may have a mean fiber diameter of ⁇ about 11 pm.
  • the glass fibers may have a mean fiber diameter of ⁇ about 10.5 pm.
  • the glass fibers may have a mean fiber diameter of about 10 pm.
  • the glass fibers may have a mean fiber length of > about 3 mm.
  • the glass fibers may have a mean fiber length of > about 3.5 mm.
  • the glass fibers may have a mean fiber length of > about 4 mm.
  • the glass fibers may have a mean fiber length of > about 4.5 mm.
  • the glass fibers may have a mean fiber length of > about 5 mm.
  • the glass fibers may have a mean fiber length of > about 5.5 mm.
  • the glass fibers may have a mean fiber length ⁇ about 10 mm.
  • the glass fibers may have a mean fiber length of ⁇ about 9.5 mm.
  • the glass fibers may have a mean fiber length of ⁇ about 9 mm.
  • the glass fibers may have a mean fiber length of ⁇ about 8.5 mm.
  • the glass fibers may have a mean fiber length of ⁇ about 8 mm.
  • the glass fibers may have a mean fiber length of ⁇ about 7.5 mm.
  • the glass fibers may have a mean fiber length of ⁇ about 7 mm.
  • the glass fibers may have a mean fiber length of ⁇ about 6.5 mm.
  • the glass fibers may have a mean fiber length of about 6 mm.
  • the glass fibers may further comprise glass fibers having a smaller average diameter than those described above.
  • the glass fibers therefore may be a mixture or blend of two groups of fibers, in which one group of fibers has a larger average diameter than the other group of fibers.
  • the second group of glass fibers may have a mean fiber diameter ⁇ about 5 pm.
  • the second group of glass fibers may have a mean fiber diameter in the range of > about 1 pm and ⁇ about 5 pm, such as about > about 1 pm and ⁇ about 4.5 pm, for example, about > about 1 .5 pm and ⁇ about 4 pm.
  • the second group of glass fibers may have a mean fiber length in the range of > about 1 mm and ⁇ about 20 mm.
  • the second group of glass fibers may have a mean fiber length in the range of > about 2 mm and ⁇ about 15 mm.
  • the second group of glass fibers may have a mean fiber length in the range of > about 3 mm and ⁇ about 10 mm.
  • the second group of glass fibers may have a mean fiber length of > about 3 mm.
  • the second group of glass fibers may have a mean fiber length of > about 3.5 mm.
  • the second group of glass fibers may have a mean fiber length of > about 4 mm.
  • the second group of glass fibers may have a mean fiber length of > about 4.5 mm.
  • the second group of glass fibers may have a mean fiber length of > about 5 mm.
  • the second group of glass fibers may have a mean fiber length of > about 5.5 mm.
  • the second group of glass fibers may have a mean fiber length of about 6 mm.
  • any suitable wt% ratio of glass fibers may be used provided the final coated non-woven fibrous mat retains its low air permeability and performance in the final application, notably in terms of resistance to rain and humidity.
  • the ratio of the first group of glass fibers (having a larger average fiber diameter than the other group) : the second group of glass fibers (having a smaller average fiber diameter than the other group) may be in the range of about 5 : about 95 wt% to about 95 : about 5 wt%.
  • the ratio of the first group of glass fibers : the second group of glass fibers may be about 10 : about 90 wt%.
  • the ratio of the first group of glass fibers : the second group of glass fibers may be about 20 : about 80 wt%.
  • the ratio of the first group of glass fibers : the second group of glass fibers may be about 30 : about 70 wt%.
  • the ratio of the first group of glass fibers : the second group of glass fibers may be about 40 : about 60 wt%.
  • the ratio of the first group of glass fibers : the second group of glass fibers may be about 50 : about 50 wt%.
  • the ratio of the first group of glass fibers : the second group of glass fibers may be about 60 : about 40 wt%.
  • the ratio of the first group of glass fibers : the second group of glass fibers may be about 70 : about 30 wt%.
  • the ratio of the first group of glass fibers : the second group of glass fibers may be about 80 : about 20 wt%.
  • the ratio of the first group of glass fibers : the second group of glass fibers may be about 10 : about 90 wt%.
  • the glass fibers may comprise
  • the glass fibers may comprise SiO2 in a range from about 50 to about 65 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise SiO2 in a range from about 51 to about 62 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise SiO2 in a range from about 52 to about 62 wt% of the total wt% of the glass composition, such as about 52 to about 56 wt% of the total wt% of the glass composition or about 55 wt% to about 60.4 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise SiO2 in a range from about 54 to about 62 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise SiO2 in about 58 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise SiO2 in about 59 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise SiO2 in about 60 wt% of the total wt% of the glass composition, such as about 60.1 wt%.
  • the glass fibers may comprise AI2O3 in a range from about 7 to about 25 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise AI2O3 in a range from about 7 to about 20 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise AI2O3 in a range from about 19 to about 25 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise AI2O3 in a range from about 9 to about 15 wt% of the total wt% of the glass composition.
  • the glass fibers may contain B2O3 i.e. the glass fibers are boron-containing glass fibers.
  • the glass fibers may comprise B2O3 in a range from about 1 wt% to about 12 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise B2O3 in a range from about 4 to about 6 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise B2Os in a range from about 5 to about 10 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise B2Os in a range from about 7 to about 12 wt% of the total wt% of the glass composition.
  • boron-containing glass fibers typically have lower softening points than boron-free glass fibers.
  • the process for preparing the fibers typically utilise less energy than the boron-free fibers (because the glass melt typically has a lower softening point).
  • the lower softening point of the boron-containing glass fibers may be of use in the application of the fibers.
  • the glass fibers may comprise substantially no B2O3 i.e. the glass fibers may be substantially boron- free fibers.
  • the glass fibers may contain less than 0.2 wt% B2O3 of the total wt% of the glass composition.
  • the glass fibers may comprise no B2O3 i.e. the glass fibers may be boron-free fibers.
  • boron-free or substantially boron-free glass fibers are more environmentally friendly than the boron-containing glass fibers as melts from which the fibers are made do not emit boron into the environment during processing.
  • the fibers themselves typically have higher softening points than boron-containing fibers which may be of use in the application of the fibers.
  • the glass fibers may comprise CaO in a range from about 7 to about 30 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise CaO in a range from about 7 to about 12 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise CaO in a range from about 12 to about 30 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise CaO in a range from about 16 to about 25 wt% of the total wt% of the glass composition, such as about 17 to about 25 wt% of total wt% of the glass composition.
  • the glass fibers may comprise CaO in a range from about 21 to about 23 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise CaO in a range from about 24 to about 30 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise CaO in about 21 .7 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise CaO in about 22 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise CaO in about 22.1 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise CaO in about 22.6 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise MgO in a range from about 0.1 to about 15 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise MgO in a range from about 0.1 to about 8 wt% of the total wt% of the glass composition, such as about 0.1 to about 4 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise MgO in a range from about 8 to about 15 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise MgO in a range from about 0.1 to about 5 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise substantially no MgO i.e. the glass fibers may be substantially magnesium-free fibers.
  • the glass fibers may comprise no MgO i.e. the glass fibers may be magnesium- free fibers.
  • the glass fibers may comprise ZnO in a range from about 0.1 to about 4 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise ZnO in a range from about 0.5 to about 1 wt% of the total wt% of the glass composition, such as about 1 wt%.
  • the glass fibers may comprise ZnO in a range from about 2 to about 5 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise ZnO in a range from about 1 to about 4 wt% of the total wt% of the glass composition, such as about 1.1 to about 3 wt%.
  • the glass fibers may comprise ZnO in about 2.9 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise substantially no ZnO i.e. the glass fibers may be substantially zinc-free fibers.
  • the glass fibers may comprise no ZnO i.e. the glass fibers may be zinc-free fibers.
  • the glass fibers may comprise BaO in a range from about 0.1 to about 3 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise BaO in a range from about 0.5 to about 1 wt% of the total wt% of the glass composition, such as about 1 wt%.
  • the glass fibers may comprise BaO in a range from about 1 to about 3 wt% of the total wt% of the glass composition, such as about 1 .1 to about 3 wt%.
  • the glass fibers may comprise substantially no BaO i.e. the glass fibers may be substantially barium- free fibers.
  • the group of glass fibers may comprise no BaO i.e. the glass fibers may be barium-free fibers.
  • the glass fibers may comprise IJ2O in a range from about 0.1 to about 1 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise IJ2O in a range from about 0.1 to about 0.4 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise IJ2O in a range from about 0.5 to about 1 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise substantially no IJ2O i.e. the glass fibers may be substantially lithium- free fibers.
  • the glass fibers may contain less than 0.2 wt% U2O of the total wt% of the glass composition.
  • the glass fibers may comprise no IJ2O i.e. the glass fibers may be lithium-free fibers.
  • the glass fibers may comprise Na2 ⁇ D and K2O in a range from about 0.1 to about 5 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise Na2 ⁇ D and K2O in a range from about 0.1 to about 4 wt% of the total wt% of the glass composition, such as about 0.5 to about 4 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise a total of Na2 ⁇ D and K2O in a range from about 0.1 to about 2 wt% of the total wt% of the glass composition, such as about 0.1 to about 1 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise a total of Na2 ⁇ D and K2O in a range from about 0.1 to about 0.3 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise Na2 ⁇ D and K2O in about 0.1 to about 0.2 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise Na2 ⁇ D and K2O in about 0.9 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise Na2 ⁇ D and K2O in about 0.8 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise Na2 ⁇ D and K2O in about 1 .2 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise substantially no Na2 ⁇ D or K2O i.e. the glass fibers may be substantially sodium- and potassium-free fibers.
  • the glass fibers may comprise no Na2 ⁇ D or K2O i.e. the glass fibers may be sodium- and potassium-free fibers.
  • the glass fibers may comprise TiO2 in a range from about 0.1 to about 5 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise TiO2 in a range from about 0.1 to about 4 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise T1O2 in a range from about 0.1 to about 0.2 wt% of the total wt% of the glass composition, such as about 0.1 to about 1 .5 wt%.
  • the glass fibers may comprise TiO2 in a ange from about 0.2 to about 0.5 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise TiO2 in about 0.5 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise TiO2 in about 1.5 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise TiO2 in about 2.5 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise substantially no TiO2 i.e. the glass fibers may be substantially titanium- free fibers.
  • the glass fibers may comprise no TiO2 i.e. the glass fibers may be titanium-free fibers.
  • the glass fibers may comprise ZrO2 in a range from about 0.1 to about 1 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise ZrO2 in a range from about 0.1 to about 0.4 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise ZrO2 in a range from about 0.5 to about 1 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise substantially no Fe2 ⁇ D3 i.e. the glass fibers may be substantially iron-free fibers.
  • the glass fibers may comprise no Fe2 ⁇ D3 i.e. the glass fibers may be iron-free fibers.
  • the glass fibers may comprise F2 in a range from about 0.1 to about 2 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise F2 in a range from about 0.1 to about 1 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise F2 in a range from about 0.2 to about 0.7 wt% of the total wt% of the glass composition.
  • the glass fibers may comprise F2 in about 0.1 wt% of the total wt% of the glass composition.
  • the precursor mat may be PFAS-free.
  • the glass fibers in the precursor mat may comprise F2 but the precursor mat may still be PFAS-free.
  • the glass fibers may comprise substantially no F2 i.e. the glass fibers may be substantially fluoride-free fibers.
  • the glass fibers may contain less than 0.2 wt% F2 of the total wt% of the glass composition.
  • the glass fibers may comprise no F2 i.e. the glass fibers may be fluoride-free fibers.
  • fluoride-free or substantially fluoride-free fibers are more environmentally friendly than fluoride-containing fibers.
  • composition of ECR-glass may comprise:
  • SiO2 in an amount from 55.0 to 60.4% by weight
  • the combined amounts in H glass of MgO and CaO is less than 22% by weight.
  • H glass of Fe20s, TiO2, K2O, and Na2O is below 1 .5% by weight.
  • composition of H glass is free or substantially free of B2O3.
  • composition of H glass is free of IJ2O.
  • the polyester fibers may have a mean fiber diameter in the range of > about 1 pm and ⁇ about 15 pm.
  • the polyester fibers may have a mean fiber diameter in the range of > about 3 pm and ⁇ about 10 pm.
  • the polyester fibers may have a mean fiber diameter of > about 3.5 pm.
  • the polyester fibers may have a mean fiber diameter of > about 4 pm.
  • the polyester fibers may have a mean fiber diameter of > about
  • the polyester fibers may have a mean fiber diameter of > about 5 pm.
  • the polyester fibers may have a mean fiber diameter of > about 5.5 pm.
  • the polyester fibers may have a mean fiber diameter of > about 6 pm.
  • the polyester fibers may have a mean fiber diameter ⁇ about 9.5 pm.
  • the polyester fibers may have a mean fiber diameter of ⁇ about 9 pm.
  • the polyester fibers may have a mean fiber diameter of ⁇ about
  • the polyester fibers may have a mean fiber diameter of ⁇ about 8 pm.
  • the polyester fibers may have a mean fiber diameter of ⁇ about 7.5 pm.
  • the polyester fibers may have a mean fiber diameter of ⁇ about 7 pm.
  • the polyester fibers may have a mean fiber diameter of about 6 to about 7 pm, such as about 6 pm.
  • the polyester fibers may have a mean fiber length in the range of > about 1 mm and ⁇ about 15 mm.
  • the polyester fibers may have a mean fiber length in the range of > about 3 mm and ⁇ about 10 mm.
  • the polyester fibers may have a mean fiber length of > about 3.5 mm.
  • the polyester fibers may have a mean fiber length of > about 4 mm.
  • the polyester fibers may have a mean fiber length of > about 4.5 mm.
  • the polyester fibers may have a mean fiber length of > about 5 mm.
  • the polyester fibers may have a mean fiber length of > about 5.5 mm.
  • the polyester fibers may have a mean fiber length of > about 6 mm.
  • any suitable wt% ratio of glass fibers : polyester fibers may be used provided the final coated nonwoven fibrous mat retains its low air permeability and performance in the final application, notably in terms of resistance to rain and humidity.
  • the ratio of glass fibers : polyester fibers may be in the range of about 50 : about 50 wt% to about 90 : about 10 wt%.
  • the ratio of glass fibers : polyester fibers may be about 55 : about 45 wt%.
  • the ratio of glass fibers : polyester fibers may be about 60 : about 40 wt%.
  • the ratio of glass fibers : polyester fibers may be about 65 : about 35 wt%.
  • the ratio of glass fibers : polyester fibers may be about 70 : about 30 wt%.
  • the ratio of glass fibers : polyester fibers may be about 80 : about 20 wt%.
  • the ratio of glass fibers : polyester fibers may be about 85 : about 15 wt%.
  • the ratio of glass fibers : polyester fibers may be about 90 : about 10 wt%.
  • the ratio of glass fibers : polyester fibers may be about 75 : about 25 wt%.
  • the total wt% of the glass fibers and the polyester fibers adds up to 100 wt%.
  • the first binder may be selected from one or more (e.g. 1 , 2, 3, 4, 5, or more) urea formaldehyde resins, such as modified urea formaldehyde resins.
  • the first binder may be selected from a formaldehyde-free (or no-added formaldehyde (“NAF”)) binder. Binders which are free of added formaldehyde are environmentally friendly i.e. “green”.
  • formaldehyde-free (or no-added formaldehyde (“NAF”) binders which are free of added formaldehyde are environmentally friendly i.e. “green”.
  • the first binder may be selected from one or more (e.g. 1 , 2, 3, 4, 5, or more) polycarboxylic acid binders, polyvinyl alcohol binders, or combination thereof.
  • the first binder may be a water-soluble or water-dispersible binder.
  • the binder may be a water-soluble binder.
  • the binder may be a water-dispersible binder.
  • the binder composition may comprise one or more of any water-based emulsion or solution.
  • the polycarboxylic acid binder may be a homopolymer or copolymer prepared from one or more (e.g. 1 , 2, 3, 4, 5 or more) unsaturated carboxylic acid compounds including but not necessarily limited to, acrylic acid, methacrylic acid, crotonic acid, isocrotonic acid, maleic acid, cinnamic acid, 2-methylmaleic acid, itaconic acid, 2-methylitaeonic acid, a,p-methyleneglutaric acid, and the like. Methods for polymerising these acids are known to the skilled person.
  • the polycarboxylic acid binder is a homopolymer or copolymer comprising at least one or more (e.g. 1 , 2, 3, 4, or 5) repeat units, and the or each repeat unit comprises a -COOH group.
  • the polycarboxylic acid binder may be prepared from unsaturated anhydrides including, but not necessarily limited to, maleic anhydride, methacrylic anhydride, and the like, as well as mixtures thereof. Methods for polymerising these anhydrides are known to the skilled person.
  • the polycarboxylic acid binder is a homopolymer or copolymer comprising at least one or more (e.g. 1 , 2, 3, 4, or 5) repeat units, and the or each repeat unit comprises a -CO-O-CO- group.
  • the polycarboxylic acid binder may comprise a homopolymer or copolymer prepared from one or more (e.g. 1 , 2, 3, 4, 5 or more) unsaturated carboxylic acid ester compounds including, but not necessarily limited to, methyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, methyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, glycidyl methacrylate, vinyl acetate, and the like. Methods for preparing these polymers are known to the skilled person.
  • the polycarboxylic acid binder is a homopolymer or copolymer comprising at least one or more (e.g. 1 , 2, 3, 4, or 5) repeat units, and the or each repeat unit comprises a -COOR group, and R is selected from the group consisting of methyl, ethyl, butyl (n-, i-, or t-), and 2,3-epoxypropyl as appropriate.
  • the wt% ratio of the polymer of the unsaturated carboxylic acid to the polymer of the unsaturated carboxylic acid ester may be in the range of about 1 : about 0.1 wt% to about 1 : about 0.8 wt% of the total solids in the binder composition.
  • the wt% ratio of the polymer of the unsaturated carboxylic acid to the polymer of the unsaturated carboxylic acid ester may be in the range of about 1 : about 0.2 wt% to about 1 : about 0.5 wt% of the total solids in the binder composition.
  • the wt% ratio of the polymer of the unsaturated carboxylic acid (e.g. polyacrylic acid binder) to the polymer of the unsaturated carboxylic acid ester (e.g. polymethyl methacrylate) may be about 1 : about 0.4 wt% of the total solids in the binder composition.
  • the polycarboxylic acid binder may be a homopolymer or copolymer of polyacrylic acid.
  • the polycarboxylic acid binder is a homopolymer of polyacrylic acid i.e. the polymer is synthesised from acrylic acid.
  • the weight average molecular weight (Mw) of the polycarboxylic acid binder such as polyacrylic acid binder or polymethyl methacrylate binder, may be less than 10000 g/mole, such as less than 5000 g/mole, and for example about 3000 g/mole or less, e.g. about 2000 g/mole.
  • the polycarboxylic acid binder may comprise polymethyl methacrylate.
  • the polycarboxylic acid binder may comprise polyacrylic acid and polymethyl methacrylate.
  • the pH of the first binder may be low, for example, about 3 or less, such as about 2.5 or less, e.g. about 2 or less.
  • the pH of the binder can be adjusted by adding a suitable acid, such as sulfuric acid.
  • the low pH of the binder can provide processing advantages. An example of the processing advantages include a reduction in cure temperature or time.
  • the pH of the first binder may be about pH 2 to about pH 3.
  • the first binder, or combination thereof, may additionally contain a polyol containing at least two hydroxyl groups.
  • a polyol containing at least two hydroxyl groups.
  • Any suitable polyol may be used provided the polyol is sufficiently non-volatile such that it will substantially remain available for reaction with the polyacid in the composition during heating and curing operations.
  • the polyol may be a compound with a molecular weight less than about 1000 and bearing at least two hydroxyl groups such as ethylene glycol, glycerol, penta erythritol, trimethylol propane, sorbitol, sucrose, glucose, resorcinol, catechol, pyrogallol, glycollated ureas, 1 ,4-cyclohexane diol, diethanolamine, or triethanolamine.
  • the polyol may be glycerol.
  • the wt% ratio of the unsaturated carboxylic acid polymer to polyol may be in the range of about 1 : about 0.01 wt% to about 1 : about 1 wt% of the total solids in the binder composition.
  • the wt% ratio of the unsaturated carboxylic acid polymer to polyol may be in the range of about 1 : about 0.1 wt% to about 1 : about 0.8 wt% of the total solids in the binder composition.
  • the wt% ratio of the unsaturated carboxylic acid polymer to polyol may be in the range of about 1 : about 0.2 wt% to about 1 : about 0.5 wt% of the total solids in the binder composition.
  • the wt% ratio of the unsaturated carboxylic acid polymer (e.g. polyacrylic acid binder) to polyol (e.g. glycerol) may be about 1 : about 0.3 wt% of the total solids in the binder composition, such as about 1 : 0.25 wt% of the total solids in the binder composition.
  • the first binder may be a combination of polyacrylic acid, polymethyl methacylate, and glycerol.
  • the first binder may be a combination of (a) polyacrylic acid and glycerol, and (b) polymethyl methacrylate latex.
  • the wt% ratio of polyacrylic acid : glycerol may be about 75% to about 25% of the total solids in the binder composition.
  • the ratio of (a) : (b) may be about 75% to about 25% of the total solids in the binder composition.
  • the final wt% ratio of polyacrylic acid : glycerol : polymethyl methacrylate overall may be about 56% : about 19% : about 25% of the total solids in the binder composition.
  • the polyol does not comprise a -hydroxyalkylamide group.
  • examples of such polyols include but are not limited to, bis[N,N-di(hydroxyethyl)]adipamide.
  • the first binder may be a polyvinyl alcohol binder. Suitable polyvinyl alcohol binders are as described herein with respect to the second binder.
  • the % hydrolysis may be > about 98 to 99%.
  • the polyvinyl alcohol binder has a high purity, and is particularly suitable for use in coated non-woven fibrous mats in polyisocyanurate foam boards.
  • the polyvinyl alcohol binder may be liquid or a solid. When the polyvinyl alcohol binder is a powder, it may be co-cast with the blend of glass fibers in the aqueous solution.
  • the polycarboxylic acid binder may be a copolymer prepared from one or more (e.g. 1 , 2, 3, 4, 5 or more) unsaturated carboxylic acid compounds and one or more (e.g. 1 , 2, 3, 4, 5 or more) aryl vinyl compounds.
  • the unsaturated carboxylic acid include but not necessarily limited to, acrylic acid, methacrylic acid, crotonic acid, isocrotonic acid, maleic acid, cinnamic acid, 2-methylmaleic acid, itaconic acid, 2-methylitaeonic acid, a,p-methyleneglutaric acid, and the like.
  • the aryl vinyl compounds include but are not limited to, styrene, methylstyrene (2-, 3-, or 4-), ethylstyrene (2-, 3-, or 4-), n- butylstyrene (2-, 3-, or 4-), iso-butylstyrene (2-, 3-, or 4-), tert-butylstyrene (2-, 3-, or 4-), a- methylstyrene (also known as isopropenylbenzene), p-methylstyrene (also known as propenylbenzene). Methods for preparing these copolymers are known to the skilled person.
  • the polycarboxylic acid binder is a copolymer comprising (a) a repeat unit comprising a - COOH group, and (b) a repeat unit comprising a substituted or unsubstituted styrenyl group.
  • the first binder may be styrene acrylic latex.
  • the copolymer is prepared from an unsaturated carboxylic acid which is acrylic acid, and an aryl vinyl compound which is styrene.
  • the wt% of the first binder, or combination thereof may be in the range of about 1 wt% to about 90 wt% of the total solids in the precursor mat, such as about 5 wt% to about 50 wt% of the total solids in the precursor mat.
  • the wt% of the first binder, or combination thereof may be in the range of about 10 wt% to about 40 wt% of the total solids in the precursor mat.
  • the wt% of the first binder, or combination thereof may be > about 10 wt% of the total solids in the precursor mat.
  • the wt% of the first binder, or combination thereof may be > about 11 wt% of the total solids in the precursor mat.
  • the wt% of the first binder, or combination thereof may be > about 12 wt% of the total solids in the precursor mat.
  • the wt% of the first binder, or combination thereof may be > about 13 wt% of the total solids in the precursor mat.
  • the wt% of the first binder, or combination thereof may be > about 14 wt% of the total solids in the precursor mat.
  • the wt% of the first binder, or combination thereof, may be in the range of about 15 wt% to about 25 wt% of the total solids in the precursor mat.
  • the weight of the precursor mat (i.e. the weight of the first binder, glass fibers and polyester fibers (if any)) may be in the range of about 30 to about 170 gsm (grams per square meter).
  • the weight of the precursor mat may be in the range of about 40 to about 150 gsm.
  • the weight of the precursor mat may be > about 40 gsm.
  • the weight of the precursor mat may be > about 45 gsm.
  • the weight of the precursor mat may be > about 50 gsm.
  • the weight of the precursor mat may be > about 55 gsm.
  • the weight of the precursor mat may be > about 60 gsm.
  • the weight of the precursor mat may be ⁇ about 170 gsm.
  • the weight of the precursor mat may be ⁇ about 165 gsm.
  • the weight of the precursor mat may be ⁇ about 160 gsm.
  • the weight of the precursor mat may be ⁇ about 155 gsm.
  • the weight of the precursor mat may be ⁇ about 150 gsm.
  • the weight of the precursor mat may be ⁇ about 140 gsm.
  • the weight of the precursor mat may be ⁇ about 135 gsm.
  • the weight of the precursor mat may be ⁇ about 130 gsm.
  • the dried composition may comprise the second binder in a range of about 50 wt% to about 100 wt% of the total solids in the dried composition.
  • the dried composition may comprise the second binder in an amount of > about 10 wt% total solids in the dried composition, such as > about 50 wt% total solids in the dried composition.
  • the dried composition may comprise the second binder in a range of about 52 wt% to about 95 wt% of the total solids in the dried composition.
  • the dried composition may comprise the second binder in an amount > 10 wt% of the total solids in the dried composition.
  • the dried composition may comprise the second binder in an amount > 20 wt% of the total solids in the dried composition.
  • the dried composition may comprise the second binder in an amount > 30 wt% of the total solids in the dried composition.
  • the dried composition may comprise the second binder in an amount > 40 wt% of the total solids in the dried composition.
  • the dried composition may comprise the second binder in an amount > 50 wt% of the total solids in the dried composition.
  • the dried composition may comprise the second binder in an amount > 54 wt% of the total solids in the dried composition.
  • the dried composition may comprise the second binder in an amount > 55 wt% of the total solids in the dried composition.
  • the dried composition may comprise the second binder in an amount > 60 wt% of the total solids in the dried composition.
  • the dried composition may comprise the second binder in an amount > 65 wt% of the total solids in the dried composition.
  • the dried composition may comprise the second binder in a range of about 50 wt% to about 70 wt%, such as about 65 wt% to about 75 wt%.
  • the dried composition may comprise the second binder in about 70 wt% of the total solids in the dried composition.
  • the dried composition may comprise the second binder in about 50 wt% of the total solids in the dried composition.
  • the coating composition may comprise a filler.
  • a filler may also be referred to as a mineral pigment or inorganic filler. Any suitable filler may be used. Examples of fillers suitable for making coated mats include, but are not limited to talc, aluminum trihydrate (ATH), magnesium hydroxide (Mg(OH)2), vermiculite, antimony oxide, titanium dioxide, aluminium oxide (AI2O3), calcium carbonate (CaCOs) or a combination of any two or more of these substances.
  • the filler may be a flame retardant, such as aluminum trihydrate (ATH), or magnesium hydroxide (Mg(OH)2).
  • ATH aluminum trihydrate
  • Mg(OH)2 magnesium hydroxide
  • a coated non-woven fibrous mat comprising a flame retardant is beneficial when the mat is used in polyisocyanurate foam boards.
  • ATH has fire retardant and smoke suppressing properties. It decomposes at about 220 °C, absorbing heat during the decomposition process while releasing water vapour.
  • the filler (such as ATH) may also be an opacity modifier i.e. the filler may make the coated non-woven fibrous mat less transparent and more opaque.
  • the opacity of the coated non-woven fibrous mat may be measured in accordance with TAPPI T425.
  • the filler may be calcium carbonate.
  • the dried composition may comprise an inorganic filler in a range of about 1 wt% to about 90 wt% total solids in the dried composition.
  • the dried composition may comprise the inorganic filler in a range of about 15 wt% to about 35 wt%, such as about 15 wt% or 30 wt% of the total solids in the dried composition.
  • the dried composition may comprise the inorganic filler in a range of about 25 wt% to about 35 wt%, such as about 30 wt% of the total solids in the dried composition.
  • the dried coating may further comprise at least one additive (e.g. 1 , 2, 3, 4, 5, or more) selected from the group consisting of a biocide, defoamer, pigment, preservative, emulsion stabilizer, wetting and levelling agent, cross-linker, and combinations thereof.
  • a biocide e.g. 1 , 2, 3, 4, 5, or more
  • Any suitable additive may be used provided the or each additive do not adversely affect the properties of the coated non-woven mat.
  • the or each additive shall not adversely affect the air permeability of the coated non-woven fibrous mat such that the coated non-woven fibrous mat exhibits an air permeability greater than 70 L/m 2 /s as measured according to ASTM D737.
  • a method for assessing the air permeability is provided in the Examples below.
  • the weight of the dried coating may be in the range of about 10 to about 50 gsm (grams per square meter).
  • the weight of the dried coating may be > about 11 gsm.
  • the weight of the dried coating may be > about 12 gsm.
  • the weight of the dried coating may be > about 13 gsm.
  • the weight of the dried coating may be > about 14 gsm.
  • the weight of the dried coating may be > about 15 gsm.
  • the weight of the dried coating may be ⁇ about 50 gsm.
  • the weight of the dried coating may be ⁇ about 45 gsm.
  • the weight of the dried coating may be ⁇ about 40 gsm.
  • the weight of the dried coating may be ⁇ about 39 gsm.
  • the weight of the dried coating may be ⁇ about 38 gsm.
  • the weight of the dried coating may be ⁇ about 37 gsm.
  • the weight of the dried coating may be ⁇ about 36 gsm.
  • the weight of the dried coating may be ⁇ about 35 gsm.
  • the weight of the dried coating may be in the range of about 15 to about 35 gsm, such as about 15 to about 25 gsm, or about 25 to about 35 gsm.
  • the coated non-woven mat of the present invention is lightweight.
  • the total weight of the (dried) coated non-woven fibrous mat may be in the range of about 40 to about 220 gsm (grams per square meter).
  • the total weight of the coated non-woven fibrous mat may be in the range of about 50 to about 200 gsm.
  • the total weight of the coated non-woven fibrous mat may be > about 51 gsm.
  • the total weight of the coated non-woven fibrous mat may be > about 57 gsm.
  • the total weight of the coated non-woven fibrous mat may be > about 63 gsm.
  • the total weight of the coated non-woven fibrous mat may be > about 69 gsm.
  • the total weight of the coated non-woven fibrous mat may be > about 75 gsm.
  • the total weight of the coated non-woven fibrous mat may be ⁇ about 220 gsm.
  • the total weight of the coated non-woven fibrous mat may be ⁇ about 210 gsm.
  • the total weight of the coated non-woven fibrous mat may be ⁇ about 200 gsm.
  • the total weight of the coated non-woven fibrous mat may be ⁇ about 193 gsm.
  • the total weight of the coated non-woven fibrous mat may be ⁇ about 188 gsm.
  • the total weight of the coated non-woven fibrous mat may be ⁇ about 177 gsm.
  • the total weight of the coated non-woven fibrous mat may be ⁇ about 171 gsm.
  • the total weight of the coated non-woven fibrous mat may be ⁇ about 165 gsm.
  • the total weight of the coated non-woven fibrous mat may be in the range of about 45 to about 165 gsm, such as about 45 to 155 gsm.
  • the total weight of the coated non-woven fibrous mat may be in the range of about 75 to about 150 gsm, such as about 90 to about 100 gsm.
  • the coated non-woven fibrous mat may have an air permeability as measured at 100 mbar in accordance with ASTM D737.
  • the coated non-woven fibrous mat of the present invention is highly air impermeable, which prevents foam bleed through during preparation of the polyisocyanurate foam boards.
  • the coated non-woven fibrous mat may have an air permeability ⁇ about 70 L.nrH.S’ 1 .
  • the coated nonwoven fibrous mat may have an air permeability ⁇ about 60 L.rr .s 1 .
  • the coated non-woven fibrous mat may have an air permeability ⁇ about 50 L.rrH.s 1 .
  • the coated non-woven fibrous mat may have an air permeability ⁇ about 40 L.rr .S' 1 .
  • the coated non-woven fibrous mat may have an air permeability ⁇ about 30 L.rr .s -1 .
  • the coated non-woven fibrous mat may have an air permeability ⁇ about 20 L.m _2 .s' 1 .
  • the coated non-woven fibrous mat may have an air permeability in the range of about 5 L.rr .s -1 to about 65 L.m _2 .s' 1 measured in accordance with ASTM D737, such as about 5 L.rrH.s -1 to about 20 L.rrr 2.S- 1 .
  • the present invention provides a method for manufacturing the coated non-woven fibrous mat of the present invention, the method comprising the steps of:
  • the aqueous composition comprises a second binder, wherein the second binder is a polyvinyl alcohol binder with a weight average molecular weight in the range of about 100000 g/mole to about 500000 g/mol; and
  • the precursor mat, glass fibers, polyester fibers (if any), first binder, second binder, polyvinyl alcohol binder, weight average molecular weight of the polyvinyl alcohol binder, filler (if any), coated non-woven fibrous mat, and air permeability are as described herein.
  • the polyvinyl alcohol binder has the advantage of being water-soluble on preparation of the aqueous composition that is coated onto at least one surface of the precursor veil. After drying, the aqueous composition forms a film that allows the coated non-woven fibrous mat to have a good performance in the targeted application, notably in terms of resistance to rain and humidity before render application.
  • the resulting coated non-woven fibrous mat therefore is suitable for use in external thermal insulation composite systems (ETICs).
  • a reverse roll technique is known to the skilled person.
  • three rollers are set up in parallel, and rotate in the same direction.
  • a metering roller is suitably aligned next to an application roller.
  • a support roller is suitably aligned next to the application roller.
  • the precursor mat passes through a predetermined gap between the application roller and the support roller.
  • the aqueous composition is deposited in the gap between the metering roller and the application roller. As the metering and application rollers rotate, the aqueous composition passes through a predetermined gap between the metering and application rollers, and adheres to the application roller.
  • the aqueous composition which is adhered to the application roller is then coated onto one major surface of the precursor mat as the precursor mat passes through the rotating application and support rollers.
  • a reverse roll coating technique is not an impregnation or classical size press method.
  • the aqueous composition as described herein is not impregnated through the precursor mat when using the reverse roll coating method.
  • the present invention provides an aqueous composition for coating a non-woven fibrous mat.
  • the aqueous composition comprises a binder.
  • the binder is described as a “second binder” in connection with the coated non-woven fibrous mat.
  • the second binder is a polyvinyl alcohol binder with a weight average molecular weight in the range of about 100000 g/mole to about 500000 g/mol.
  • the polyvinyl alcohol binder is as described above.
  • the viscosity of the aqueous composition is not particularly limiting provided (a) it is maintained high enough to ensure the reduction of the air permeability of the non-woven fibrous mat to ⁇ about 70 L/m 2 /s as measured according to ASTM D737, (b) it is maintained high enough to ensure that the aqueous composition does not penetrate through the entire thickness of the non-woven mat, and (c) it is maintained low enough such that the non-woven fibrous mat can be suitably coated using a reverse roll coating (or wire bar, kiss roll, knife-over-air, or knife-over-air) technique.
  • a reverse roll coating or wire bar, kiss roll, knife-over-air, or knife-over-air
  • the aqueous composition may have a viscosity in the range from > about 500 mPa.s to ⁇ about 5000 mPa.s (millipascal second) as measured at room temperature using a Brookfield synchronized-motor rotary viscometer.
  • the aqueous composition may have a viscosity > about 500 mPa.s as measured at room temperature using a Brookfield synchronized-motor rotary viscometer.
  • the aqueous composition may have a viscosity > about 600 mPa.s as measured at room temperature using a Brookfield synchronized-motor rotary viscometer.
  • the aqueous composition may have a viscosity > about 700 mPa.s as measured at room temperature using a Brookfield synchronized-motor rotary viscometer.
  • the aqueous composition may have a viscosity > about 800 mPa.s as measured at room temperature using a Brookfield synchronized-motor rotary viscometer.
  • the aqueous composition may have a viscosity > about 900 mPa.s as measured at room temperature using a Brookfield synchronized-motor rotary viscometer.
  • the aqueous composition may have a viscosity > about 1000 mPa.s as measured at room temperature using a Brookfield synchronized-motor rotary viscometer.
  • the aqueous composition may have a viscosity > about 1100 mPa.s as measured at room temperature using a Brookfield synchronized-motor rotary viscometer.
  • the aqueous composition may have a viscosity ⁇ about 5000 mPa.s as measured at room temperature using a Brookfield synchronized-motor rotary viscometer.
  • the aqueous composition may have a viscosity ⁇ about 4500 mPa.s as measured at room temperature using a Brookfield synchronized-motor rotary viscometer.
  • the aqueous composition may have a viscosity ⁇ about 4000 mPa.s as measured at room temperature using a Brookfield synchronized-motor rotary viscometer.
  • the aqueous composition may have a viscosity in the range from > about 1000 mPa.s and ⁇ about 5000 mPa.s as measured at room temperature using a Brookfield synchronized-motor rotary viscometer.
  • the aqueous composition exhibits shear thinning in the reverse roll coating technique (or other coating techniques described herein).
  • the viscosities provided above therefore are shear thinned viscosities.
  • the viscosity of the aqueous composition before it is exposed to the applied pressure of the rollers in the reverse roll technique may be greater than 2000 mPa.s, for example, the viscosity may be between 2000 mPa.s to about 5000 mPa.s.
  • the weight average molecular weight (Mw) of the polyvinyl alcohol binder is as described above.
  • the degree of hydrolysis of the polyvinyl alcohol binder is as described above.
  • Any suitable quantity of polyvinyl alcohol may be used in the aqueous composition provided sufficient polyvinyl alcohol is used to produce an aqueous composition having a suitable viscosity as described above.
  • the polyvinyl alcohol may be dissolved in water to provide the desired aqueous composition.
  • the water used may be demineralised. Alternatively, the water may be tap water.
  • the mixture of polyvinyl alcohol and water may be agitated and/or heated to facilitate dissolution.
  • the mixture may be agitated for any suitable period of time.
  • the mixture may be heated at a suitable temperature (e.g. about 92 °C, such as about 85 °C) for any suitable period of time (e.g. about 4 hours, such as about 3 hours), provided the aqueous solution of polyvinyl alcohol is not heated for so long that the aqueous solution is adversely affected.
  • the wt% of the polyvinyl alcohol binder may be in the range of about 5 wt% to about 15 wt% of the total weight of the aqueous composition.
  • the wt% of the polyvinyl alcohol binder may be > about 5.5 wt% of the total weight of the aqueous composition.
  • the wt% of the polyvinyl alcohol binder may be > about 6 wt% of the total weight of the aqueous composition.
  • the wt% of the polyvinyl alcohol binder may be > about 6.5 wt% of the total weight of the aqueous composition.
  • the wt% of the polyvinyl alcohol binder may be > about 7 wt% of the total weight of the aqueous composition.
  • the wt% of the polyvinyl alcohol binder may be > about 8 wt% of the total weight of the aqueous composition.
  • the wt% of the polyvinyl alcohol binder may be ⁇ about 15 wt% of the total weight of the aqueous composition.
  • the wt% of the polyvinyl alcohol binder may be ⁇ about 14 wt% of the total weight of the aqueous composition.
  • the wt% of the polyvinyl alcohol binder may be ⁇ about 13 wt% of the total weight of the aqueous composition.
  • the wt% of the polyvinyl alcohol binder may be ⁇ about 12 wt% of the total weight of the aqueous composition.
  • the wt% of the polyvinyl alcohol binder may be ⁇ about 11 wt% of the total weight of the aqueous composition.
  • the wt% of the polyvinyl alcohol binder may be in the range of about 8 wt% to about 11 wt% of the total weight of the aqueous composition, such as about 8 wt%, about 9 wt% about 10 wt%, or about 11 wt%, for example about 10 wt%.
  • the aqueous composition may comprise water in a range of about 75 wt% to about 95 wt% total weight of the aqueous composition.
  • the aqueous composition may comprise water in a range of about 80 wt% to about 90 wt% total weight of the aqueous composition.
  • the aqueous composition may consist essentially of:
  • a binder which is a polyvinyl alcohol binder with a weight average molecular weight in the range of about 100000 g/mole to about 500000 g/mol;
  • a binder which is a polyvinyl alcohol binder with a weight average molecular weight in the range of about 100000 g/mole to about 500000 g/mol;
  • the aqueous composition comprises a second binder, wherein the second binder is a polyvinyl alcohol binder with a weight average molecular weight in the range of about 100000 g/mole to about 500000 g/mol; and
  • a wire bar coating technique is known to the skilled person.
  • a wire bar is a cylindrical bar which has a wire tightly wound around the circumference of the bar for the majority of its length.
  • the wire bar is positioned at a predetermined distance above the precursor mat, or may be in contact with the precursor mat.
  • the aqueous composition is placed on the precursor mat in front of the wire bar in the direction of travel.
  • the wire bar is then moved at a predetermined speed over the precursor mat.
  • the aqueous composition is spread over one major surface of the precursor mat as the wire bar passes over the precursor mat to produce a uniform coating of the aqueous composition on the precursor mat.
  • Reverse roll coating is an industrial process which may not be easy to carry out on a smaller or laboratory scale.
  • a wire bar coating technique therefore may conveniently be used in a laboratory to simulate reverse roll coating.
  • the Examples below use an RK multicoater model no K303 Electric Drive as a wire bar coater.
  • a kiss roll coating technique is known to the skilled person.
  • a coating roller is typically positioned above a bath of aqueous composition and is partly submerged therein. As the coating roller rotates, the aqueous composition adheres to the coating roller and is transferred onto one major surface of the precursor mat as it passes over the coating roller.
  • the kiss roll coating technique may comprise two coating rollers.
  • One coating roller is positioned substantially above another coating roller.
  • the coating rollers rotate in the opposite direction to each other.
  • the lower coating roller is typically partly submerged in a bath of aqueous composition such that as it rotates, the aqueous composition adheres to it and is transferred firstly onto the upper coating roller and then onto one major surface of the precursor mat as the precursor mat passes over the upper coating roller.
  • the coating roller is set up such that it can rotate in the same direction of travel as the precursor mat as the precursor mat passes over the coating roller. Alternatively, the coating roller may rotate in the opposite direction of travel to the precursor mat as the precursor mat passes over the coating roller. In the first instance, a greater quantity of aqueous composition is typically coated onto the precursor mat than the second instance.
  • a kiss roll coating technique is not an impregnation or classical size press method.
  • the aqueous composition as described herein is not impregnated through the precursor mat in the wire bar coating method.
  • the present invention provides a method for manufacturing the coated non-woven fibrous mat of the present invention, the method comprising the steps of:
  • the aqueous composition comprises a second binder, wherein the second binder is a polyvinyl alcohol binder with a weight average molecular weight in the range of about 100000 g/mole to about 500000 g/mol; and
  • the precursor mat, glass fibers, polyester fibers (if any), first binder, second binder, aqueous composition, polyvinyl alcohol binder, weight average molecular weight of the polyvinyl alcohol binder, coated precursor mat, filler (if any), coated non-woven fibrous mat, and air permeability are as described herein.
  • the knife coating technique may be a knife-over-roll technique.
  • the knife coating technique may be a knife-over-air technique.
  • the knife-over-roll and knife-over-air techniques are known to the skilled person.
  • a knife In the knife-over-roll coating technique, a knife is positioned above a roller and the precursor mat passes between them. The roller rotates in the direction of travel of the precursor mat.
  • the precursor mat passes over two rollers, which rotate in the direction of travel of the precursor mat.
  • the knife in this instance is positioned above the precursor mat between the rollers i.e. there is no roller beneath the mat at the point of coating.
  • the aqueous composition is deposited onto precursor mat, and is coated onto the precursor mat as it passes between a predetermined gap between the knife blade and precursor mat.
  • the quantity of aqueous composition which is coated onto the precursor mat is influenced by the width of the predetermined gap. In this respect, the greater the width, the greater the quantity of aqueous composition coated.
  • a knife coating technique (such as knife-over-roll or knife-over-air) is not an impregnation or classical size press method.
  • the aqueous composition as described herein is not impregnated through the precursor mat in the wire bar coating method.
  • the precursor mat itself may be prepared in a method comprising the steps of:
  • the steps for forming the precursor mat may also be referred to as a “co-casting” method. This is because an aqueous mixture comprising the glass fibers is formed together with the first binder.
  • the precursor mat may be prepared in a method comprising the steps of:
  • the first binder may be applied to the web comprising glass fibers by a suitable binder applicator, such as a spray applicator or a curtain coater.
  • a suitable binder applicator such as a spray applicator or a curtain coater.
  • the dispersion of the aqueous mixture may be obtained by any suitable means provided a uniform or substantially uniform distribution of the glass fibers and optional polyester fibers in the aqueous medium is produced. A uniform distribution of the glass fibers and optional polyester fibers may be produced. Alternatively, a substantially uniform distribution of the glass fibers and optional polyester fibers may be produced.
  • the dispersion may be obtained by a high shear mixing apparatus, such as a rotor/stator mixer.
  • the first binder may optionally contain conventional additives as described above for the improvement of process and product performance such as dyes, oils, biocides, fillers, colorants, UV stabilizers, coupling agents (e.g., aminosilanes), lubricants, wetting agents, surfactants, and/or antistatic agents.
  • additives as described above for the improvement of process and product performance such as dyes, oils, biocides, fillers, colorants, UV stabilizers, coupling agents (e.g., aminosilanes), lubricants, wetting agents, surfactants, and/or antistatic agents.
  • the first binder (or combination thereof) may be added at any suitable point in the preparation of the aqueous mixture.
  • the binder (or combination thereof) may be added before, after, or at the same time as the glass fibers and polyester fibers (if any).
  • the first binder may be a liquid or solid.
  • the powdered binder may facilitate co-casting with the fibers in the aqueous solution.
  • the aqueous fiber dispersion or slurry may then be processed into a wet-laid mat according to any number of conventional methods known in the art.
  • the aqueous fiber dispersion or slurry is deposited onto a moving screen or conveyor, on which the majority of the water drains through, leaving a randomly oriented fiber web.
  • the water may be removed from the web by a conventional vacuum or air suction system.
  • the wetlaid web is passed through at least one drying oven to remove remaining water and cure the binder composition.
  • the fiber web may be further dried by a vacuum slot or other drying means to provide a fiber web.
  • the formed precursor mat that emerges from the oven is an assembly of randomly oriented, dispersed, individual fibers.
  • the fiber mat may be rolled onto a take-up roll for storage or later use.
  • the precursor mat is substantially or completely coated with the aqueous composition as defined above.
  • the aqueous composition of the present invention is prepared by any suitable method, such as mixing the polyvinyl alcohol binder, optional additives (if any), and water.
  • the coated non-woven fibrous mat is asymmetric.
  • asymmetric we mean that the aqueous composition of the present invention does not completely impregnate the precursor mat. Instead, the aqueous composition coats or sits solely on one side of the precursor mat. In this respect, the aqueous composition will be detectable on coated side of the precursor mat but will not be detectable on the other (uncoated) side of the mat.
  • the coated precursor mat is then dried to form the coated non-woven fibrous mat. Typically the coated precursor mat may be passed through at least one drying oven to remove any remaining water and to cure the binder. The mat may be further dried by a vacuum slot or other drying means to provide the coated non-woven fibrous mat as described above.
  • the drying conditions are maintained below the point at which any component of the coated precursor mat degrades (e.g. the first binder, second binder, filler, and/or optional additives (if any)). Therefore, when it is known that one or more components of the coated precursor mat degrades at a particular temperature or vacuum, the drying conditions should be maintained below the degradation temperature or vacuum. Likewise, when it is known that one or more components of the coated precursor mat degrades after drying for a particular period of time, the drying conditions should be maintained for a shorter period of time than the degradation time. With respect to PVOH, care should be taken not to over-dry the coated mats as the PVOH may lose its properties and turn yellow.
  • any component of the coated precursor mat degrades e.g. the first binder, second binder, filler, and/or optional additives (if any)
  • the resulting non-woven fibrous precursor mats typically have a smooth surface (the surface in contact with the moving screen or conveyor, and which may be referred to as the “wire side”) and a non-smooth surface (the surface not in contact with the moving screen or conveyor, and which may be referred to as the “top side”).
  • Either the smooth surface or the rough surface may be coated with the aqueous composition as described herein to form the coated non-woven fibrous mat of the invention.
  • the rough surface is the presentation surface.
  • the coated non-woven fibrous mat is attached to a construction board, the rough surface is faces into the room and the smooth surface attaches to the board.
  • the present invention provides a construction board comprising: a first surface and a second surface opposite the first surface, a coated non-woven fibrous mat adhered to the first surface, the second surface or both the first and second surfaces, wherein the coated non-woven fibrous mat is as described herein.
  • the construction board may be a polyisocyanurate foam board.
  • coated non-woven fibrous mat is as described herein.
  • the coated non-woven fibrous mat may be a facer in the construction board i.e. the facer is adhered to a first surface, a second surface or both first and second surfaces to form a construction board.
  • the construction board may further comprise a layer of ink as the outermost layer of the first surface, the second surface or both the first and second surfaces of the construction board.
  • PVOHs polyvinylalcohols
  • each powder is dissolved in 1 .8 L of demineralised water under stirring at 600 rpm for 4 hours at 85 °C with a VMI agitator.
  • the solutions are diluted with further demineralised water to adjust the solid content as appropriate.
  • A4 sized sheets of glass non-woven precursor are coated with each solution of PVOH using a wire bar coating method.
  • a laboratory RK multicoater model NO K303 Electric Drive is utilised.
  • the multicoater is fitted with a meter bar (meter bar 0) and each coating is applied at a coating speed of 10 meters per minute.
  • the precursor mat has a basis weight of 65g/m 2 and an air permeability of 1900L/m 2 /s before being coated.
  • the glass fibers in the precursor mat have a mean fiber diameter of about 10 pm, and a mean fiber length of about 6 mm.
  • Mowiol® 4-98, PovalTM 5-74, and PovalTM 95-88 are each applied to the precursor mat at a concentration of 10 wt%.
  • Mowiol® 28-99 is applied to the precursor mat at a concentration of 8 wt%.
  • PovalTM 56-98 is applied to the precursor mat at a concentration of 11 wt%.
  • Aqueous coating compositions comprising Mowiol® 28-99, PovalTM56-98, and 95-88 are according to the invention. These PVOHs are suitably viscous to close the precursor non-woven fibrous mat. When precursor mats are coated with aqueous compositions comprising these PVOHs, the dried coated nonwoven fibrous mats have low to very low air permeabilities i.e. the mats are very impermeable. Mats coated with these PVOHs therefore are suitable for use in the preparation of polyisocyanurate insulation boards.
  • Mowiol® 28-99 is dissolved in tap water to obtain a 10 wt% solution (coating 1).
  • Coatings 1-4 are individually applied to sheets of glass non-woven precursor using a wire bar coating method.
  • a laboratory RK multicoater model NO K303 Electric Drive is utilised.
  • the multicoater is fitted with a meter bar (meter bar 0) and each coating is applied at a coating speed of 10 meters per minute.
  • the target add-on for each sample is 25-35 g/m 2 .
  • This precursor mat has a basis weight of 65g/m 2 and an air permeability of 1900L/m 2 /s before being coated.
  • the glass fibers in the precursor mat have a mean fiber diameter of about 10 pm, and a mean fiber length of about 6 mm.
  • the coated non-woven fibrous mats are dried in an oven.
  • the oven temperature is about 170°C and the total drying time about 60 seconds. Care is taken not to over-dry the coated mats as the PVOH may lose its properties and turn yellow.
  • the coated non-woven fibrous mats are cut in to 10 x 10 cm samples.
  • the air permeabilities of the coated mats are determined using an air permeability tester FX3300 (TEXTEST Instruments). The air permeability is determined according to ASTM D737. The air flow is set at a pressure of 100 Pa.
  • Dried coated non-woven fibrous mats 1-4 have low to very low air permeabilities i.e. the mats are very impermeable.
  • the coated mats 1-4 therefore are suitable for use in the preparation of polyisocyanurate insulation boards.
  • coated mats 2-4 demonstrate that magnesium hydroxide and aluminium trihydrate can be incorporated into the coating of the coated non-woven fibrous mats as fire retardants.
  • Coated Mats 2- 4 retain their suitability for use in the preparation of polyisocyanurate insulation boards as they have average air permeabilities ⁇ 70 L/m 2 /s.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Dispersion Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Abstract

La présente invention concerne un mat fibreux non tissé revêtu, le mat fibreux non tissé revêtu comprenant : (a) un mat précurseur comprenant : une toile non tissée de fibres comprenant des fibres de verre, et un premier liant ; et (b) un revêtement qui recouvre le mat précurseur, le revêtement comprenant un second liant, le second liant étant un liant à base d'alcool polyvinylique ayant un poids moléculaire moyen en poids situé dans la plage allant d'environ 100 000 g/mol à environ 500 000 g/mol ; et le mat fibreux non tissé revêtu ayant une perméabilité à l'air ≤ à environ 70 L/m2/s telle que mesurée selon la norme ASTM D737. L'invention concerne également des procédés de fabrication du mat fibreux non tissé revêtu, et un panneau de construction comprenant le mat fibreux non tissé revêtu.
PCT/US2024/060656 2023-12-22 2024-12-18 Mat fibreux non tissé revêtu Pending WO2025137029A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP23220135 2023-12-22
EP23220135.0 2023-12-22

Publications (1)

Publication Number Publication Date
WO2025137029A1 true WO2025137029A1 (fr) 2025-06-26

Family

ID=89322009

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2024/060656 Pending WO2025137029A1 (fr) 2023-12-22 2024-12-18 Mat fibreux non tissé revêtu

Country Status (1)

Country Link
WO (1) WO2025137029A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2727891A1 (fr) * 2012-10-31 2014-05-07 Isover Saint-Gobain Produit en laine minérale réversible capable de fixer l'eau
WO2019074867A1 (fr) * 2017-10-09 2019-04-18 Owens Corning Intellectual Capital, Llc Compositions liantes aqueuses
WO2021183492A1 (fr) * 2020-03-09 2021-09-16 Owens Corning Intellectual Capital, Llc Formulation de revêtement pour le revêtement au rideau de mats non tissés fibreux
US11214512B2 (en) 2017-12-19 2022-01-04 Owens Coming Intellectual Capital, LLC High performance fiberglass composition
WO2022076731A1 (fr) * 2020-10-07 2022-04-14 Owens Corning Intellectual Capital, Llc Mat non tissé revêtu avec couche de revêtement

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2727891A1 (fr) * 2012-10-31 2014-05-07 Isover Saint-Gobain Produit en laine minérale réversible capable de fixer l'eau
WO2019074867A1 (fr) * 2017-10-09 2019-04-18 Owens Corning Intellectual Capital, Llc Compositions liantes aqueuses
US11214512B2 (en) 2017-12-19 2022-01-04 Owens Coming Intellectual Capital, LLC High performance fiberglass composition
WO2021183492A1 (fr) * 2020-03-09 2021-09-16 Owens Corning Intellectual Capital, Llc Formulation de revêtement pour le revêtement au rideau de mats non tissés fibreux
WO2022076731A1 (fr) * 2020-10-07 2022-04-14 Owens Corning Intellectual Capital, Llc Mat non tissé revêtu avec couche de revêtement

Similar Documents

Publication Publication Date Title
EP0991602B1 (fr) Procédé pour la fabrication des objets de construction couchés
CA3026634C (fr) Systeme de liant
AU2011271204B2 (en) Formaldehyde free coating for panels comprsing a polyacid copolymer and calcium aluminosilicate powder
EP3807364B1 (fr) Revêtement à base de borate et de silicate pour améliorer les performances acoustiques d'un panneau, et procédé de fabrication associé
EP2053083A1 (fr) Composition de revêtement ignifuge pour tapis fibreux
KR20070029697A (ko) 코팅 조성물, 코팅된 물품 및 이를 제조하기 위한 방법
WO2022144103A1 (fr) Système de façade et élément isolant pour un système de façade
US20220251779A1 (en) Walkable facer mats for roof insulation
CA3068735C (fr) Materiaux de construction a retardement de vapeur et procedes pour leur fabrication
US10457814B2 (en) Aqueous binder composition for fibres and fibrous products produced
WO2025137029A1 (fr) Mat fibreux non tissé revêtu
PL182483B1 (pl) Wodny klej dyspersyjny
US12428762B2 (en) Nonwoven mat with reduced permeability and increased caliper
WO2025064391A1 (fr) Composition aqueuse pour l'enduction de mat fibreux non tissé
WO2025064385A1 (fr) Composition aqueuse pour le revêtement d'un mat fibreux non tissé
EP3469165A1 (fr) Revêtements de surface et de bord de couleur à haute teneur en solides pour panneaux de construction
WO2025122417A1 (fr) Composition de revêtement utilisant des particules de verre en tant que charge, tapis non tissé revêtu, panneaux de construction et leurs procédés de production
CN114269843B (zh) 无机纤维用粘结剂及无机纤维垫
RU2800147C2 (ru) Боратное и силикатное покрытие для улучшения акустических характеристик панелей и способы его изготовления
JP2025010103A (ja) 全熱交換素子用仕切部材、それを用いた全熱交換素子、及び全熱交換素子用仕切部材の製造方法
WO2025128989A1 (fr) Parement non tissé rempli de microfibres
JPH0648149B2 (ja) 全熱交換素子

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 24837511

Country of ref document: EP

Kind code of ref document: A1