U.S. patent application number 10/055154 was filed with the patent office on 2002-11-07 for superabsorbent water-resistant coatings for fiber-reinforced articles.
Invention is credited to Flautt, Martin Charles, Hager, Thomas P., Priest, James Robert, Stotler, David V..
Application Number | 20020165312 10/055154 |
Document ID | / |
Family ID | 22703127 |
Filed Date | 2002-11-07 |
United States Patent
Application |
20020165312 |
Kind Code |
A1 |
Flautt, Martin Charles ; et
al. |
November 7, 2002 |
Superabsorbent water-resistant coatings for fiber-reinforced
articles
Abstract
A coating composition for forming a water-resistant coating on
fiber-reinforced articles such as rods or cables. The composition
comprises an aqueous solution of a superabsorbent water-soluble
polymer, a viscosity modifying agent, and optionally a lubricant.
The coating formed by applying the composition effectively prevents
the treated surface from water-permeation damage by absorbing water
that contacts the layer containing the superabsorbent
component.
Inventors: |
Flautt, Martin Charles;
(Granville, OH) ; Priest, James Robert; (Nashport,
OH) ; Stotler, David V.; (Newark, OH) ; Hager,
Thomas P.; (Westerville, OH) |
Correspondence
Address: |
OWENS CORNING
2790 COLUMBUS ROAD
GRANVILLE
OH
43023
US
|
Family ID: |
22703127 |
Appl. No.: |
10/055154 |
Filed: |
October 26, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10055154 |
Oct 26, 2001 |
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09190866 |
Nov 13, 1998 |
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6380298 |
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Current U.S.
Class: |
524/500 ;
524/507; 524/513; 524/522; 524/555; 524/556; 525/123; 525/185 |
Current CPC
Class: |
D06M 15/263 20130101;
D06M 2200/40 20130101; C08L 101/14 20130101; Y10T 428/2933
20150115; D06M 15/564 20130101; D06M 7/00 20130101; D06M 15/285
20130101 |
Class at
Publication: |
524/500 ;
524/507; 524/513; 524/522; 524/555; 524/556; 525/185; 525/123 |
International
Class: |
C08L 11/14 |
Claims
we claim:
1. A coating composition for a reinforcing article comprising a
superabsorbent water-soluble polymer precursor in aqueous
solution.
2. The coating composition of claim 1, wherein the superabsorbent
water-soluble polymer precursor is a polyacrylate.
3. The coating composition of claim 1, further comprising a
viscosity-modifying agent.
4. The coating composition of claim 3, wherein the
viscosity-modifying agent is an aqueous solution of a polymeric
material selected from the group consisting of polyacrylamides.
5. The coating composition of claim 1, further comprising a
lubricant.
6. The coating composition of claim 1, further comprising a
binder.
7. The coating composition of claim 6, wherein the binder is a
polyurethane.
8. A coating formed on the surfaces of a reinforcing article,
comprising a superabsorbent water-soluble polymer.
9. The coating of claim 8, wherein the superabsorbent water-soluble
polymer, after curing, absorbs up to about 400 times its initial
dry weight in water when immersed in an aqueous environment, and
desorbs water when the coating is dried.
10. The coating of claim 8, further comprising a
viscosity-modifying agent.
11. The coating of claim 8, further comprising a lubricant.
12. The coating of claim 11, wherein the article comprising a
reinforcing fiber material is a fiber strand selected from the
group consisting of glass, carbon, one or more polymers, natural
fibers and mixtures.
13. The coating of claim 12, having a swell rate of from about 300%
to about 2000% weight, based on the total weight of coated strand,
in the first minute.
14. A reinforcing article having a coating comprising: a
superabsorbent polymer; a viscosity modifying agent; and a
binder.
15. A method of forming a superabsorbent, water-resistant coating
on the surface of a reinforced fiber-containing article comprising:
a) preparing a liquid coating composition comprising a
superabsorbent water-soluble polymer that absorbs and desorbs water
when the coating is exposed to an aqueous or moisture-containing
environment and a viscosity modifying agent; b) applying the liquid
coating composition to the surface of the article to form a liquid
coating; and c) drying and curing the liquid coating to form a
water-absorbing, water-resistant coating layer on the surface of
the article.
16. The method of claim 15, wherein the step of applying the liquid
coating composition to the surface of the article comprises
contacting the liquid coating composition with the surface of the
article to form a layer of liquid coating over the entire surface
of the article.
17. An aqueous coating composition comprising: a superabsorbent
polymer precursor; a viscosity-modifying agent; and a binder.
18. The aqueous coating composition of claim 17, wherein the
superabsorbent polymer precursor is selected from the group
consisting of anionic alkali salts and alkali metal salts of said
superabsorbent polymer.
19. The aqueous coating composition of claim 17, wherein the
superabsorbent polymer precursor is a polyacrylate.
20. The aqueous coating composition of claim 17, wherein the
viscosity-modifying agent is selected from the group consisting of
alkyl celluloses, acrylamide polymers and mixtures thereof.
21. The aqueous coating composition of claim 20, wherein the
viscosity-modifying agent is a polyacrylamide.
22. The aqueous coating composition of claim 17, wherein the binder
is selected from the group consisting of polyesters, polyurethanes,
epoxies, latex and mixtures thereof.
23. The aqueous coating composition of claim 22, wherein the binder
is a film-forming polyurethane.
Description
[0001] The present invention relates to a high strength
superabsorbent coating capable of rapidly absorbing water, which is
suitable for coating reinforcing fibers, or for coating articles
comprising reinforcing fibers, such as reinforced rods and cables.
More specifically, the coating is formed from a composition
comprising a superabsorbent polymer precursor which, upon cure,
forms a polymer with a high water swelling ability; and a
film-forming polymer. As a modification to adapt the coating to
pultruded articles, the coating composition may also include a
viscosity-modifying agent.
[0002] The inventive concept also relates to articles coated with
the superabsorbent coating composition, such as glass rods; and
methods of applying such coatings. The novel coating of this
invention demonstrates a high level of water absorption in fresh
and salt-water environments, and excellent spreading and coating
ability when applied to a substrate.
BACKGROUND OF THE INVENTION
[0003] Deterioration caused by the invasion of moisture beneath the
exposed surfaces of articles used in outdoor environments is a
well-known problem. This deterioration includes oxidative
deterioration caused by reaction of water with the surfaces of
reinforcing fibers used in these articles, as well as water-induced
corrosion. In marine environments, the problems associated with
waterlogging are particularly compounded by the salinity of the
environment. The presence of salt in such aqueous environments
hastens the oxidative decomposition.
[0004] Articles affected by the deterioration described above
include reinforced fibers made of glass, carbon, polymer or
mixtures thereof, or items containing such reinforcing fibers. The
term "articles", as used herein, is specifically intended to
include reinforcing fiber materials known in the art, as well as
products made using one or more of these fibers collectively or
dispersed within a matrix of any type. The term also includes
articles manufactured using reinforced fiber products, such as
structural materials or in equipment. Examples of such articles
include such as reinforced rods and cables, such as fiber optic or
telecommunications cables. These telecommunications cables are
often used in situations where they are buried underground or
submerged in water over long periods. As such, protection from
water damage is critical to the structural integrity of these
cables and to the success of the functions they are intended to
perform. A telecommunications cable, for example, may include a
core comprising a glass rod that acts as a stiffening or
reinforcing member. This rod contributes to the rigidity of the
cable. When water penetrates to contact the core element of the
cable, corrosion or chemical deterioration of the cable
infrastructure may result.
[0005] In order to combat the problems associated with this
waterlogging damage, several strategies have been devised in an
attempt to provide water resistance to cables and other reinforced
articles, and to protect their sensitive inner surfaces from
contact with water or water vapor present in the surrounding
environment. These techniques for making water-repellent articles
have included wrapping the articles in a protective sheathing
material; or sealing the surface to be protected. Sealing
techniques may include chemically manipulating the surface layer of
the article to render it resistant to water-absorption, or applying
a repellent coating.
[0006] The technique of covering the surface with a protective
sheathing material is conventional. It includes for example, using
a wrap or tape made of an impervious polymer with water-blocking
ability, or treating the wrapping material with an emulsion or
solution of a water-blocking polymer. The sheathing process does
not require application of a chemical compound or treatment to the
surface of the article, rather the protection is derived only from
the coverage by the sheathing material.
[0007] Coatings used to repel water traditionally have been
composed of substances that are both insoluble and impenetrable to
water, and therefore presented a physical barrier to encroaching
moisture. Such barrier coatings have included materials such as
greases or gels. In the case of cables, for example, these coatings
are applied by extrusion under pressure. There are however, certain
drawbacks associated with this type of coating. Greases or gels are
difficult to handle because of their slipperiness, and they
contribute an unpleasant feel to the coated article. This is an
important factor to be considered in the manufacturing process,
particularly because it affects the ease of handling of the cable
during splicing operations. Greases and gels also undergo changes
in viscosity at low or high temperatures. These viscosity changes
may affect the freeze/thaw performance and therefore the stability
of the coating. Poor performance in these respects therefore
affects the stable performance of the cables.
[0008] More recently, greaseless, water-resistant dry coatings have
been devised which, of themselves, have some degree of
water-absorbing capacity. This ability to absorb water allows the
coating to absorb the moisture contacting the article, while
preventing direct contact with the sensitive surfaces. The
absorbent component in these dry waterblocking coatings is a dry,
granulated superabsorbent polymer that swells and absorbs upon
contact with water. The superabsorbent polymers are usually
characterized in terms of their swell rate, swell capacity and gel
strength. Traditional uses for these dry superabsorbent polymers
have primarily included personal hygiene product articles, food
packaging articles and chemical spill cleanup compositions, however
recent experimentation has included using these dry polymers to
form coatings for other articles such as reinforced cables. For
example, U.S. Pat. NO. 5,689,601 to Hager, herein incorporated by
reference, discloses a dry waterblocking coating for reinforcing
fiber articles using a powdered or granulated water-soluble dry
blocking ingredient encased in one or more thin layers of a
sheathing polymer. This casing restricts the degree of water
absorption that can be achieved by the granular polymer, and
accordingly the swell capacity of this coating is limited.
[0009] The superabsorbent polymers traditionally used in dry
waterblocking cable coating applications are dry, granular polymers
that are incorporated into various substrates such as yarn, binders
and tape. The substrates typically also contain glass fibers as a
form of reinforcement. However, as discussed above, the coatings
formed with dry granulated blocking agents suffer the limitations
of limited water swelling ability and swell rate as a necessary
consequence of optimizing the gel strength. In the context of
surface coatings, gel strength is defined as the ability to prevent
water from wicking down the cable axis, particularly when the
cables are used in aqueous environments where they are exposed to
elevated water pressures. The swelling ability is directly related
to the degree of cross-linking of the superabsorbent polymer. As
the degree of cross-linking increases, so does the gel strength,
but there is a related decrease in the swell rate and swell
capacity of the polymer. The swell rate defines the amount of water
that the coating absorbs over a fixed period of time. The swell
capacity denotes the maximum amount of water or fluid absorbed by
the coating, based on a measure of its dry weight. Consequently,
coatings made of dry, granular, water-insoluble polymer are limited
in their water-absorbing performance, as measured in terms of the
swell rate and swell capacity.
[0010] Generally, coatings for reinforced fibers, strands and
articles such as cables that are made from these fibrous materials
are applied to the surface of the fibrous material and then cured
before further processing, if any, occurs. The means of applying
coatings, in general, differs depending on whether a fluid coating
is used or whether a solid particulate coating is being
applied.
[0011] In the case of powdered coatings, the coating process using
granulated water-blocking agents involves several time-consuming
and labor- and equipment-intensive steps that are directly related
to the use of a granulated polymer. These steps include the need
for one or more treatments with a binding resin, and one or more
applications of powdered resin at the powder-coating stations using
apparatus such as a fluidized bed.
[0012] The means for applying fluid coatings may include flooding,
or dipping the fibers or cables, for example. in a resin bath and
then removing excess resin and form a consistent layer on the
treated surface. In the case of strands, rovings or cables, the
product is in the form of a continuous filament and therefore it
can be passed through a stripper die to remove the excess resin.
Alternatively, the coating may be sprayed onto the surface of the
article. In order to form a coating layer that is thick enough to
provide good coverage and protection from water penetration, the
coating composition must be thick enough that it can adequately
coat the article in one pass through the coating apparatus. In
addition to thickness however, the composition must also have
sufficient flowing ability to allow ready formation of a uniform
coating on the surface of the article, and to prevent clogging of
the coating apparatus, dye orifices or other machinery used to make
polymer-coated fibrous articles. Traditionally in the art, in order
to modify the viscosity of the fluid coating composition, dry
particulate ingredients such as a flocculent polymer or starch have
been used. The difficulty with such compositions is that the
resulting composition after this solid ingredient is added is not
homogenous. Rather, the composition contains varying levels of a
particulate material, which makes handling difficult and also
compromises the spreadability of the composition.
[0013] There exists in the art then, a need for a waterblocking
coating composition which possesses excellent gel strength and
wicking ability, as well as a high degree of water absorption and a
concurrent, rapid swell rate. At the same time, a further need
exists in the art for a coating composition that does not contain
powdered polymer, and which, as a result, would not require a
costly and labor intensive application process. At the same time it
is desired that such a coating composition exhibit good spreading
and surface performance characteristics.
SUMMARY OF THE INVENTION
[0014] It has now surprisingly been discovered that highly
absorbent waterblocking coatings having an excellent water swelling
capacity and a rapid swell rate can be formed by incorporating a
solution of a superabsorbent polymer precursor into an aqueous
solution used to coat glass fiber reinforced articles such as
cables or rods. The polymer precursor, when cured, forms a
superabsorbent polymer. The novel coatings containing this
superabsorbent polymer are capable of substantially instantaneous
water absorption when exposed to aqueous environments.
[0015] Depending on the intended application, the absorbent coating
may be enhanced by adding a viscosity-modifying agent. For example,
where the coating composition is applied to rods comprising glass,
carbon, polymer or mixtures thereof, including a viscosifier
imparts excellent spreading ability to the formulation. This
viscosity-modifying agent is not an insoluble powdered component,
rather it is a polymeric solution or dispersion that can be easily
incorporated into the coating composition. Hence, unlike
waterblocking coatings previously known in the art, the coating
composition of this invention is in the form of a true solution
having substantially no particulate components.
[0016] In one aspect, this invention also relates to a process of
forming a coating onto fibers or strands of a reinforcing material.
The process of coating may further be applied to products
containing reinforced fiber materials, such as rods or cables
formed from a composite making process such as pultrusion or
injection molding. Generally, this process includes the steps of
applying the coating composition to the surface of the fibers,
strands or articles, passing it through a stripper die to remove
excess coating, followed by a drying or curing step.
[0017] The inventive concept further relates to articles containing
reinforcing fibers made of glass, polymer, carbon or natural fibers
that are made using the water-absorbent coatings of the present
invention. Such articles include reinforcing fibers, strands, rods,
rovings etc., either in continuous form or as chopped fibers,
strands, or pellets; fabrics comprised of glass, polymer or natural
fibers; and pultruded articles such as rods or cables. The
pultruded articles may be comprised of glass, carbon, one or more
polymers, and mixtures thereof. Also, the coating can be applied to
corrugated metallic tubes and tapes used for rodent protection in
fiber optic cables.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE
INVENTION
[0018] The composition of this invention is suitable for forming a
superabsorbent coating on the surface of fiber reinforcements and
fibrous products or articles made using these reinforcements. The
products to which the composition may be applied can be divided
into the broad categories of fiber reinforcements, such as
continuous strands, or composited articles comprising fiber
reinforcements and one or more other components. The ingredients
included in the superabsorbent coating formulation depend on the
type of product to which the composition will be applied.
[0019] As one embodiment, examples of fibrous reinforcement
products in the first category mentioned above include strands or
rovings made from fiber-forming materials such as glass, carbon,
polymers or mixtures thereof. The coating formulation for these
products will preferably include a small amount of a lubricant.
[0020] In another embodiment, the composited articles in the second
category include articles that comprise a reinforcing fiber
material as at least one component thereof. Examples include
articles formed in a pultrusion operation. For example, the
coatings of this invention can be successfully applied to a
pultruded rod or cable comprised at least partially of reinforcing
glass fiber/polymer composite. The polymers that may be used to
form these pultruded articles include thermosetting resins, such as
epoxies, polyesters and vinyl esters. The polymer component of the
pultruded article may also be a thermoplastic resin that has been
heat-treated, however a thermosetting resin is preferred. As an
example, a thermosetting epoxy resin such as a vinyl ester may be
combined with glass strands in a pultrusion operation to form a rod
that can be used as the stiffening member in a telecommunications
cable.
[0021] The water resistant properties of the coatings of the
present invention are obtained by combining a solution of a
non-toxic, environmentally safe superabsorbent polymer precursor
with the binder resin used to coat the substrate articles. The
superabsorbent polymer formed by this precursor possesses a
surprisingly high capacity for absorbing water, and at the same
time maintains a high gel strength in the cured coating as a result
of increased cross-linking. As mentioned previously, this polymer
uniquely provides water resistance by absorbing large quantities of
water. As water contacts the coated surface of the article to be
protected, the coating absorbs water and swells in volume. By
absorbing the water, the coating effectively wicks away the
moisture and thus prevents it from contacting the inner surfaces of
the protected article. As a result, the sensitive inner surfaces
remain dry and are protected from waterlogging deterioration. The
coatings of this invention uniquely achieve water resistance
protection by absorbing water to prevent moisture penetration
beneath the coating layer. This function is distinctly different
from the type of protection accomplished by the barrier coatings
more commonly known in the art, which protect the substrate by
forming an impermeable barrier.
[0022] The non-toxic, environmentally safe superabsorbent polymer
precursor used in the coatings of this invention may be selected
from any such polymer capable of forming an aqueous solution for
use in the coating mixture, and which, upon cure, has a swell
capacity and swell rate that enables rapid absorption of large
amounts of water followed by desorption without loss of the polymer
itself when the coating is dried. A polymer precursor suitable for
use in the present coating will demonstrate a swell capacity of up
to about 400 times its initial dry weight when the coating is
applied to reinforcing fibers or strands and cured.
[0023] The superabsorbent polymer precursor for use in the present
invention may, for example, be selected from the group of
water-soluble polyacrylates possessing the required ability to
absorb and desorb large quantities of water, as has been previously
mentioned. The superabsorbent polymer precursor is preferably used
in its anionic form as a salt of a corresponding alkali or alkali
metal salt. The polymer salt is in the form of an aqueous solution
that is either clear or slightly cloudy in appearance. A desirable
solids content is in the range of from 30-35% weight. The solution
also has a specific gravity of about 1.1 grams per milliliter and a
viscosity of about 1000 mPas at about 20.degree. C. The solution is
typically slightly anionic, having a pH of from about 6 to about 8.
One example of an acceptable superabsorbent polymer precursor is a
water-soluble anionic polyacrylate in aqueous solution.
[0024] If the coating is to be applied to pultruded articles, a
viscosity-modifying agent may also be added to the coating
composition. The role of this viscosifier is to create a spreading
consistency that will enable adequate coating of the pultruded
article after it has been passed through a stripper die. The
viscosifier also provides good flowing ability and prevents
clogging of the coating apparatus and die orifices. Viscosity
modifying agents capable of forming a true solution, such as alkyl
cellulose or acrylamide polymers, may be used in the coatings of
this invention. A preferred viscosifier for use in the present
coatings is a polyacrylamide in aqueous solution. The
polyacrylamide solution is particularly suitable because of its
compatibility with the superabsorbent polymer precursor solution
and the film-forming binder component.
[0025] The binder component used in the coating compositions of
this invention can include any polymeric material customarily used
as a binder in coating compositions for reinforced fiber-containing
products. The binder preferably comprises a film-forming polymer or
polymer latex that is a thermosetting resin or a thermosetting
resin with some thermoplastic properties to enhance the flexibility
of the coating. The film-forming binder is also necessarily
compatible with the water-absorbing polymer and with the
viscosity-modifying agent, in that it promotes combination of the
ingredients in the coating composition, and also facilitates
adherence of the coating to the surface once it is applied. The
film-former further provides a tough film with preferably no
surface tackiness or flaking of the coating after it is cured. The
film-forming polymer comprised in the binder may for example be a
polyester, urethane, epoxy, latex or mixtures thereof. The latex
may in turn be selected from an acrylic latex, a styrene-butadiene
latex, or mixtures thereof. Preferably, the binder is a
film-forming urethane that promotes adherence of the
water-absorbing polymer to the treated surface after it is dried.
An example of a desirable film-forming binder is Witcobond W320,
which is a polyurethane film-former available from Witco Chemical
Co.
[0026] Optionally, the coating composition may also include one or
more additives selected from the group consisting of lubricants and
wetting agents. Lubricants are added to enhance the handling of the
polymer-impregnated strand in subsequent processing. Where the
coating is applied to fiber reinforcements such as glass strands, a
lubricant is preferably added to improve adherence of the coating
to the strand.
[0027] The wetting agent is added to facilitate contact between the
dispersion and the fiber surface. Any conventional wetting agent
that is compatible with the other ingredients of the sizing
composition can be used.
[0028] When the coatings of the invention are applied to the
surfaces of reinforcing fiber strands and cured, they demonstrate a
swell capacity of from about up to about 400 times the initial dry
weight of the water-swellable polymer. Preferably, the swell
capacity for this type of application is from about 200 to about
400 times the initial dry weight of the water-swellable polymer.
Where the coatings are applied and cured on the surface of articles
such as rods or cables, the swell capacity ranges up to 120 times
the initial dry weight of the water-swellable polymer. In this
context, preferably the swell capacity is from about 50 to about
100 times the initial dry weight of the water-swellable
polymer.
[0029] The swell rate of the coating should also be high. The
coatings of this invention demonstrate an exceptionally high swell
rate, in the order of from about 300% to about 2000% weight in the
first minute, based on the total weight of the polymer and the
fiber substrate. The rate of water uptake varies depending on the
salinity of the aqueous environment in which the coating is used.
In fresh water, the swell rate is higher than can be achieved in a
saline solution such as a marine environment. However, whether the
coating is used in either a fresh or salt-water environment, its
performance, as measured by the swell rate, is demonstrably higher
than has been previously achieved by dry waterblocking coatings
known in the art.
[0030] In the method of making the coating compositions of this
invention, the ingredients are combined in liquid form to prepare
the coating solution. A solution of the superabsorbent polymer
precursor is first stirred to ensure homogeneity, then added to a
mixing tank. Deionized water is then added to the tank, and the
lubricant, if desired, is then introduced. Next, the polyurethane
in the form of an aqueous emulsion is pumped into the tank. The
viscosity-modifying agent is first premixed to form a 1 % aqueous
solution, and a sufficient amount of this aqueous solution is added
to the mixing tank. As a final step, the mixture is then stirred,
without heating, and the resulting composition is ready for
application.
[0031] The composition is contacted with the surface of the
articles to be coated by a means suitable for applying a liquid
coating. For example, the coating composition can be applied by
passing reinforcing fiber strands through a resin bath.
Alternatively, the composition is applied to an article to be
coated by spraying, flooding, or by any other means which permits
the liquid coating to be contacted with the entire surface of the
article. A further processing means may then be used to ensure an
even and adequate distribution of the coating layer. For example,
fiber strands or rods are coated with the coating composition are
passed through a stripper die.
[0032] The coated articles are then dried and cured. The article
coated with the superabsorbent polymer precursor is heated to
212.degree. F. for a period sufficient to volatilize a substantial
portion of the water. The polymer precursor-coated article is then
heated to approximately 280.degree. F. to cure the polymer by
cross-linking. Typically, polymers heated to above approximately
300.degree. F. lose the desired superabsorbent quality. The
drying/curing step may be performed in an in-line oven. In a 25
foot long oven set to approximately 600.degree. F. the polymer is
cured at 380-490 feet per minute, and preferably at 440-465 feet
per minute.
[0033] Glass fiber reinforced articles having the water resistant
coating herein described may be used in applications where exposure
to water or water vapor is likely, and where the formation of a
durable, resilient, flexible coating with good waterproofing
properties is desired. The following examples are representative,
but are in no way limiting as to the scope of this invention.
EXAMPLES
[0034] Exemplary coating formulations were prepared by combining a
film-forming binder polymer, a water-absorbing polymer precursor
solution and a polyacrylamide solution. The coating compositions
were then applied to pultruded glass-vinyl ester rods using a
flooding process. After the coating composition was applied, the
rod was passed through a stripper of desired orifice size to
control the amount of coating composition deposited on the surface
of the rod. The rod was then heated to volatilize the water
component, then further heated to about 270.degree. F. to cure the
coating and activate the superabsorbent polymer precursor.
Example 1
[0035] In this example, a coating composition for treating
pultruded glass/polymer rods was formulated by mixing the
ingredients in the proportions listed below:
[0036] 33.3% weight of a superabsorbent polyacrylate precursor
solution (aqueous), available commercially as Stockhausen 63815
from Stockhausen Inc.;
[0037] 25.0% weight of a urethane film-forming polymer, Witcobond
W290H, available from Witco Chemical Co.; and
[0038] 41.7% weight of a 1 % aqueous acrylamide solution, Drewfloc
270, which is available commercially from Ashland Chemical Inc.
Example 2
[0039] In this coating composition for pultruded rods, the
ingredients were combined as follows:
[0040] 28.6% weight Stockhausen 63815 superabsorbent polyacrylate
precursor solution;
[0041] 35.7% weight urethane film-forming polymer, Witcobond W320,
available from Witco Chemical Co.; and
[0042] 35.7% weight of a 1% aqueous solution of Drewfloc 270.
Example 3
Water Resistance Testing
[0043] An exemplary coating composition was developed according to
the following formulation:
[0044] 40.0% weight Stockhausen 63815 superabsorbent polyacrylate
precursor solution;
[0045] 7.5% weight Witcobond W320polyurethane film-forming
polymer;
[0046] 2.0% weight Emerlube 7440, a sulfonated mineral oil
available from Henkel Corp.;
[0047] 2.0% weight of a 1% aqueous solution of Drewfloc 270;
and
[0048] 48.5% weight of deionized water.
[0049] The composition was applied to glass fiber reinforcement
strands designed for use in optical cables. The reinforcements were
then immersed in either deionized water or in a 1% saline solution.
The swell rate in both the fresh water and the marine environments
were determined by measuring the percentage swell or increase in
weight over time intervals ranging from 0-20 minutes. As a
comparison, strands coated with a dry waterblocking coating using
granulated polymer powder were also immersed in both the fresh and
salt-water environments for the same period of time.
[0050] The strands coated according to this invention and immersed
in deionized or fresh water showed a swell rate that was up to
seven times faster than the swell rate for the rods coated with the
dry, granulated polymer, within the first minute of exposure. The
swell capacity or the overall amount of swell was up to 270% higher
in comparison to the dry coating. In the salt-water environment,
the coating of this invention demonstrated a swell rate that was
more than 6 times faster than the dry granulated coating within the
first minute of exposure. The coating also showed up to 50% more
swell capacity than the dry coating.
[0051] These results clearly show that the coating solutions of the
present invention achieve superior water absorption, and
correspondingly, superior water resistance, when they are applied
to articles that are exposed over prolonged periods to an aqueous
fresh- or salt-water environment.
Examples 4-5
[0052] The coatings of the present invention were further
investigated to determine their efficacy when applied to
reinforcing fiber materials such as strands or rovings. Strands of
glass reinforcing fibers were coated with the invention and the
percentage swell over time, calculated based on the total weight of
coating and fiber was measured. In comparison, strands coated with
the dry, granular coatings were also tested to determine the swell
rate of the coating. In Example 4, the reinforcements were immersed
in deionized water. For Example 5, the reinforcements were exposed
to a 1% sodium chloride solution. The results obtained are included
in Table 1 and 2 below:
1TABLE 1 Example 4 - Water Absorption in Deionized Water Swell
Rate.sup.a (% swell/time) Time (minutes) Example 4 Comparison
Sample 0 0 0 0.033 612 86 0.0833 677 119 0.1666 730 168 0.25
nr.sup.1 210 0.333333 745 nr 0.5 751 264 0.666666 754 nr 0.83333
758 nr 1 762 336 1.5 770 nr 2 778 nr 5 810 480 10 865 575 20 975
650 .sup.1nr = not recorded .sup.aSwell rate was measured as the
percentage change in weight of the coated strand per unit time.
[0053]
2TABLE 2 Example 5 - Water Absorption in 1% Sodium Chloride
Solution Swell Rate.sup.a (% swell/time) Time (minutes) Example 5
Comparison Sample 0 0 0 0.030 225 38 0.0833 237 47 0.25 265 81 0.5
276 88 1 295 99 2 312 118 5 325 140 10 350 142 20 415 158
[0054] It is believed that Applicants' invention includes many
other embodiments which are not herein specifically described,
accordingly this disclosure should not be read as being limited to
the foregoing examples or preferred embodiments.
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