U.S. patent application number 13/699914 was filed with the patent office on 2013-05-09 for mat of polymer fibers containing a dihydrazide and use thereof.
This patent application is currently assigned to SAINT-GOBAIN ADFORS. The applicant listed for this patent is Benjamin Blanchard, Katarzyna Chuda, Boris Jaffrennou. Invention is credited to Benjamin Blanchard, Katarzyna Chuda, Boris Jaffrennou.
Application Number | 20130115447 13/699914 |
Document ID | / |
Family ID | 43307783 |
Filed Date | 2013-05-09 |
United States Patent
Application |
20130115447 |
Kind Code |
A1 |
Blanchard; Benjamin ; et
al. |
May 9, 2013 |
MAT OF POLYMER FIBERS CONTAINING A DIHYDRAZIDE AND USE THEREOF
Abstract
The present invention relates to a mat of polymer fibers capable
of trapping formaldehyde which contains at least one dihydrazide.
Another subject of the invention is the use of said mat, in
particular as a surface covering for thermal and/or sound
insulation products, in particular based on mineral wool,
polystyrene or on an organic or inorganic foam.
Inventors: |
Blanchard; Benjamin;
(Taverny, FR) ; Jaffrennou; Boris; (Paris, FR)
; Chuda; Katarzyna; (Asnieres Sur Seine, FR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Blanchard; Benjamin
Jaffrennou; Boris
Chuda; Katarzyna |
Taverny
Paris
Asnieres Sur Seine |
|
FR
FR
FR |
|
|
Assignee: |
SAINT-GOBAIN ADFORS
Chambery
FR
|
Family ID: |
43307783 |
Appl. No.: |
13/699914 |
Filed: |
May 13, 2011 |
PCT Filed: |
May 13, 2011 |
PCT NO: |
PCT/FR11/51074 |
371 Date: |
January 18, 2013 |
Current U.S.
Class: |
428/340 ;
181/294; 428/221 |
Current CPC
Class: |
B32B 27/308 20130101;
B32B 2260/048 20130101; B32B 2255/24 20130101; D02G 3/02 20130101;
B32B 2266/0228 20130101; B32B 5/26 20130101; B32B 27/281 20130101;
B32B 5/08 20130101; B27N 1/003 20130101; B27N 7/005 20130101; B32B
27/065 20130101; B32B 2262/0276 20130101; D06N 7/0002 20130101;
B32B 2255/02 20130101; B32B 2260/046 20130101; B32B 5/245 20130101;
B32B 27/40 20130101; B32B 2262/14 20130101; B32B 25/16 20130101;
B32B 27/42 20130101; B32B 2471/02 20130101; B32B 19/043 20130101;
B32B 27/302 20130101; B32B 2307/50 20130101; B32B 2262/101
20130101; B32B 2307/718 20130101; E04F 13/002 20130101; D06M 13/422
20130101; B32B 5/022 20130101; B32B 2260/021 20130101; B32B
2262/0284 20130101; B32B 2266/02 20130101; B32B 19/045 20130101;
B32B 25/12 20130101; B32B 27/30 20130101; B32B 27/38 20130101; B32B
2605/003 20130101; B32B 2266/04 20130101; B32B 25/20 20130101; B32B
2262/02 20130101; B32B 2262/0246 20130101; B32B 2250/20 20130101;
B32B 2262/0292 20130101; B32B 2419/06 20130101; E04B 1/74 20130101;
B32B 5/28 20130101; B32B 13/14 20130101; D06M 2101/32 20130101;
B32B 2262/0238 20130101; B32B 2262/0253 20130101; C08J 7/065
20130101; D02G 3/04 20130101; D04H 1/587 20130101; Y10T 428/27
20150115; B32B 27/36 20130101; B32B 5/10 20130101; B32B 5/18
20130101; B32B 27/32 20130101; E04F 15/18 20130101; D06M 13/402
20130101; B32B 27/28 20130101; B32B 2262/0223 20130101; B60R 13/02
20130101; E04B 1/8409 20130101; B32B 2262/0215 20130101; B32B
25/045 20130101; B32B 2307/304 20130101; B32B 21/10 20130101; B32B
27/12 20130101; B32B 2262/0261 20130101; B32B 2262/0269 20130101;
B32B 2307/102 20130101; C08J 2323/06 20130101; Y10T 428/249921
20150401; B32B 2601/00 20130101; B32B 19/06 20130101; B32B 2419/00
20130101; B32B 2419/04 20130101 |
Class at
Publication: |
428/340 ;
428/221; 181/294 |
International
Class: |
D02G 3/04 20060101
D02G003/04; E04B 1/84 20060101 E04B001/84; D02G 3/02 20060101
D02G003/02 |
Foreign Application Data
Date |
Code |
Application Number |
May 25, 2010 |
FR |
1054021 |
Claims
1. A mat of polymer fibers, comprising a dihydrazide.
2. The mat of claim 1, wherein the dihydrazide has formula (I):
H.sub.2N--NH--R--CO--NH--NH.sub.2 wherein R represents is: a linear
or branched alkylene radical, optionally substituted with a
hydroxyl radical; or an arylene radical optionally substituted by
with a hydroxyl radical, a halogen atom, or a linear or branched
alkyl radical comprising 1 to 4 carbon atoms.
3. The mat of claim 2, wherein, in formula (I) R is a
C.sub.1-C.sub.12 alkylene radical.
4. The mat of claim 3, wherein the dihydrazide is adipic acid
dihydrazide.
5. The mat of claim 1, wherein the amount of dihydrazide is from
0.1 to 50% of the weight of the mat.
6. The mat of claim 1, further comprising an anionic, cationic, or
nonionic surfactant.
7. The mat of claim 6, wherein the surfactant is less than 90% of
the weight of the dihydrazide.
8. The mat of claim 1, wherein the polymer fibers comprise an
organic polymer.
9. The mat of claim 8, wherein the organic polymer is a polyolefin,
a polyvinyl acetate, a polyvinyl alcohol, a polylactic acid, an
acrylonitrile, a polyoxyalkylene, a polyoxyphenylene, a
polyacrylic, a polyacrylate, a polyester, a polyamide, a polyimide,
a chlorinated and/or fluorinated polymer, a polysulfone, a
polyurethane, a polybenzimidazol; or an aramid.
10. The mat of claim 9, wherein the organic polymer is a
polyester.
11. The mat of claim 1, having a surface density in a range from 5
to 1000 g/m.sup.2.
12. The mat of claim 1, further comprising a binder comprising a
polymer capable of binding the fibers, of the same nature or of a
different nature to the polymer of the fibers.
13. The mat of claim 12, wherein the polymer capable of binding the
fibers is a thermoplastic, thermosetting or elastomeric polymer, or
a biopolymer.
14. The mat of claim 12, wherein the binder is 5 to 300% by weight
of the mat of polymer fibers.
15. A covering, comprising the mat of claim 1.
16. A surface or sealing covering, comprising the mat of claim
1.
17. A thermal and/or sound insulation product, comprising a surface
covering comprising the mat of claim 1.
18. The mat of claim 1, wherein the amount of dihydrazide is from
0.2 to 20% of the weight of the mat.
19. The mat of claim 1, wherein the amount of dihydrazide is from
0.3 to 10% of the weight of the mat.
20. The mat of claim 6, wherein the surfactant is from 20 to 80% of
the weight of the dihydrazide.
Description
[0001] The invention relates to a mat of polymer fibers which
contains a dihydrazide as an agent capable of trapping
formaldehyde.
[0002] Highly varied composite materials are used in the field of
the construction and fitting out of dwellings and offices, and also
of transportation vehicles. Some of these materials, such as sound
and/or thermal insulators, wooden panels, furniture parts and
decorative parts, use adhesives, paints and varnishes comprising
formaldehyde-based resins. The proportion of free formaldehyde in
these materials is kept at a very low level owing to the
incorporation of a small amount of agents capable of trapping
formaldehyde.
[0003] However, regulations regarding protection against
undesirable emissions of products, such as formaldehyde, which may
exhibit a risk to the health of the individual are becoming
stricter and require a further reduction in the amount of free
formaldehyde present in materials or capable of being emitted by
materials over time.
[0004] Means for reducing the content of formaldehyde inside
buildings are known.
[0005] The proposal has been made to include particles of
photocatalytic titanium oxide in a paint or material made of
plaster (US-A-2005/0226761), a paper or a textile, plastic or
wooden material (EP-A-1 437 397).
[0006] It is also known to use a hydrazide in a construction
material based on plaster or on cement (US-A-2004/0101695 and
JP-A-2004115340) or a carbodihydrazide in a fiberboard (EP 1 905
560).
[0007] The aim of the present invention is to reduce the amount of
formaldehyde present inside buildings, in particular dwellings, and
transportation vehicles.
[0008] To achieve this aim, the present invention provides a mat of
polymer fibers which contains at least one dihydrazide.
[0009] Another subject of the invention relates to the use of the
aforementioned mat, in particular as a surface covering for thermal
and/or sound insulation products based on mineral wool.
[0010] The dihydrazide in accordance with the present invention
corresponds to the following formula:
H.sub.2N--NH--CO--R--CO--NH--NH.sub.2
[0011] in which R represents [0012] a linear or branched alkylene
radical preferably containing 1 to 18 carbon atoms, optionally
substituted by one or more hydroxyl radicals; or [0013] an arylene,
preferably phenylene or biphenylene, radical optionally substituted
by one or more hydroxyl radicals, one or more halogen atoms,
especially F, Cl or Br, or one or more linear or branched alkyl
radicals containing 1 to 4 carbon atoms.
[0014] Advantageously, the dihydrazide is chosen from the
dihydrazides for which the radical R is a C.sub.1-C.sub.12,
preferably C.sub.1-C.sub.8 alkylene radical. The preferred
dihydrazide is adipic acid dihydrazide.
[0015] Preferably, the amount of dihydrazide represents 0.1 to 50%,
advantageously 0.2 to 20% and better still 0.3 to 10% of the weight
of the mat of polymer fibers.
[0016] Advantageously, the dihydrazide is used together with a
surfactant, the purpose of which is to increase the affinity of the
fibers for the dihydrazide. This results in a more homogeneous
distribution of the dihydrazide in the mat.
[0017] The surfactant in accordance with the invention may be an
anionic, cationic or nonionic surfactant. Anionic surfactants are
preferred and among these alkyl diphenyl oxide disulfonate.
[0018] The amount of surfactant generally represents less than 90%,
preferably from 20 to 80%, and advantageously from 55 to 65% of the
weight of the dihydrazide.
[0019] The mat in accordance with the invention is based on fibers
preferably constituted of an organic polymer.
[0020] As examples, mention may be made of fibers of polyolefin,
for example of polyethylene, of polypropylene, of polyisobutylene
and of polymethylpentene, of polyvinyl acetate (homopolymer or
copolymer), for example of ethylene/vinyl acetate (EVA), of
polyvinyl alcohol (homopolymer or copolymer), for example of
ethylene/vinyl alcohol, of polylactic acid, of acrylonitrile, for
example modacrylic (containing 35 to 85% of acrylonitrile units),
of polyoxyalkylene, for example of polyoxyethylene, of
polyoxyphenylene, of polyacrylic or of polyacrylate, for example of
polymethyl methacrylate (PMMA), of polyester, especially of
polyalkylene terephthalate, for example of polyethylene
terephthalate and polybutylene terephthalate, of polyamide, of
polyimide, of chlorinated and/or fluorinated polymer, for example
of polyvinyl chloride, of polychiorofluoroethylene, of
perfluoroethylene and of perfluoropropylene, of polysulfone, for
example polyethersulfone, of polyurethane, especially elastane (at
least 85% of thermoplastic polyurethane elastomer), of
polybenzimidazole and of aramid.
[0021] The preferred fibers are fibers of a thermoplastic polymer
since they can be obtained easily by conventional processes that
take place by spinning or cospinning of molten plastic, in
particular of polyester, advantageously of polyethylene
terephthalate.
[0022] The mat may be constituted of fibers constituted of a single
polymer or of a mixture of fibers of different polymers.
[0023] The mat of polymer fibers may be composed of continuous
filaments, or of discontinuous filaments having a length which may
reach 1000 mm, preferably that varies from 5 to 500 mm and
advantageously from 50 to 100 mm.
[0024] The linear density of the fibers may vary to a large extent,
for example up to 30 dtex, preferably is at least equal to 0.9
dtex, advantageously varies from 2 to 20 dtex and better still from
3 to 10 dtex.
[0025] Although the invention relates more particularly to a mat of
fibers of synthetic polymer, it also applies to fibers of a polymer
of natural origin containing, in particular, polysaccharides and/or
proteins, such as animal fibers (wool or silk) and plant fibers
(cotton, flax, hemp, sisal, coir, bamboo, etc.).
[0026] The mat in accordance with the invention may be constituted
of the aforementioned synthetic or natural fibers or of a mixture
of these fibers.
[0027] The mat of polymer fibers may also comprise reinforcing
elements in the form of fibers having a diameter greater than the
diameter of the polymer fibers that constitute the mat, or of
strands composed of a plurality of filaments, that have or have not
undergone twisting. The reinforcing elements may be constituted of
a polymer material identical to or different from that of the
fibers constituting the mat, or of another material, for example of
glass.
[0028] The proportion of the reinforcing elements in the mat of
polymer fibers remains low and generally represents at most 10% of
the weight of the polymer fibers.
[0029] The mat of polymer fibers in accordance with the present
invention has a surface density that varies from 5 to 1000
g/m.sup.2, preferably 10 to 800 g/m.sup.2, advantageously from 15
to 300 g/m.sup.2 and better still is at most equal to 100
g/m.sup.2.
[0030] Of course, higher surface densities may be obtained by
superposing several mats of polymer fibers in accordance with the
present invention.
[0031] The mat that can be used within the context of the present
invention may be manufactured according to known processes that
make it possible to obtain polymer fibers, in particular by dry
processes that take place by carding or by aerodynamic defibering
(airlaid processes), by molten processes that take place by direct
spinning (spunlaid processes) or by extrusion (spun bonding or melt
blowing processes), by wet processes that take place starting from
a suspension of fibers in water, similar to that used for obtaining
paper or by specific techniques, for example electrospinning and
flash spinning.
[0032] Conventionally, the mat of polymer fibers may also contain a
binder which binds said fibers and confers thereon mechanical
properties suitable for the desired use, especially a sufficient
stiffness in order to be able to be handled easily.
[0033] The binder generally comprises at least one polymer capable
of binding the fibers, said polymer possibly being of the same
nature or of a different nature from that constituting the
fibers.
[0034] This polymer may be a thermoplastic polymer, for example
styrene/acrylonitrile, acrylonitrile/butadiene/styrene, cellulose
(tri)acetate, expanded polystyrene, a polyolefin such as
polyethylene and polypropylene, a poly(meth)acrylate, a polyvinyl
acetate or a polyoxymethylene; a thermosetting polymer, for example
an unsaturated polyester, an epoxide, a phenolic resin such as a
novolac or a resol, in particular having a content of free
aldehyde(s) of less than 0.05%, a polyimide, a polyurethane, a
phenoplast or a biopolymer, for example a polysaccharide or a
protein; an elastomeric polymer, for example a fluoropolymer, in
particular based on vinylidene fluoride, neoprene, a polyacrylic, a
polybutadiene, a polyether amide, a silicone, a natural rubber or
styrene-butadiene rubber (SBR), or a biopolymer, for example a
polysaccharide or a protein.
[0035] The binder generally represents 5 to 300%, preferably less
than 100%, by weight of the mat of polymer fibers.
[0036] In this case, it is necessary to treat the mat of polymer
fibers at a sufficient temperature so that the binder can
crosslink. The treatment temperature depends on the polymer
constituting the fibers of the mat and on the polymer incorporated
into the composition of the binder: it must remain well below the
decomposition temperature of the polymer of the fibers in order to
prevent the destruction of the mat.
[0037] The application of the dihydrazide to the mat of polymer
fibers may be carried out by any known means, for example by
impregnation, coating or spraying a solution, dispersion or an
emulsion of said dihydrazide.
[0038] The liquid phase that can be used for dissolving, dispersing
or emulsifying the dihydrazide is generally water.
[0039] The liquid phase may also comprise a small proportion of a
water-miscible co-solvent that increases the wettability of the
polymer fibers.
[0040] The co-solvent is chosen from polar organic solvents such as
alcohols, in particular ethanol or propanol, and ketones, in
particular acetone.
[0041] As a general rule, the amount of co-solvent does not exceed
30% of the total weight of water and co-solvent, and preferably
remains less than 20%.
[0042] The mat of polymer fibers in accordance with the present
invention may be used in many applications, for example: [0043] in
construction, as a covering for walls, floors and/or ceilings,
surface or sealing covering for gypsum board or cement board, or
surface covering for thermal and/or sound insulation products, in
particular based on mineral wool, polystyrene or an organic or
inorganic foam intended in particular for roof-boarding
applications, [0044] in motor vehicles, as trim material or
decorative fabric (shelf, trunk, door, seat, floor carpet) or sound
damping material (hood, floor pan, roof lining), [0045] in the
geological field, as geotextiles, in particular covering for
asphalt or soil stabilization material, [0046] in industry, as
coated fabric, filter for gases (ventilation, air conditioning) or
liquids such as oils, covering for the protection of seeds and
cultures or covering for furnishings (wallpaper base or carpet
underlay).
[0047] The following example makes it possible to illustrate the
invention without however limiting it.
EXAMPLE 1
[0048] a) Obtaining the Mat
[0049] Into a container, 141.1 g of water, 5.9 g of adipic acid
dihydrazide and 3 g of alkyl diphenyl oxide disulfonate
(Dowfax.RTM. sold by Dow Chemical) are poured.
[0050] A mat of polyethylene terephthalate fibers (18 g/m.sup.2) is
immersed in the solution obtained, then it is withdrawn and dried
in an oven at 110.degree. C. for 1 minute.
[0051] The amount of adipic acid dihydrazide deposited on the mat
is equal to 4 g/m.sup.2.
[0052] b) Capacity to Trap Formaldehyde under Static Conditions
[0053] The mat (25 cm.times.5 cm) is placed in a container
containing a 0.4 g/l aqueous solution of formol. The mat is placed
above the solution so that it is not in contact with it. The
container is hermetically sealed, then it is placed in an oven at
50.degree. C. for 16 hours.
[0054] The mat is withdrawn and washed with water in order to
remove the formaldehyde that has not reacted with the adipic acid
dihydrazide.
[0055] The mat is then cut into several pieces which are placed in
a container containing 100 ml of distilled water, under stirring.
The container is heated at 60.degree. C. for 24 hours. The aqueous
phase is recovered, it is filtered and the amount of formaldehyde
that it contains is measured by spectrocolorimetry.
[0056] The capacity of the mat from Example 1 to trap formaldehyde
is equal to 930.44 mg/m.sup.2.
[0057] By comparison, an identical mat containing no adipic acid
dihydrazide, treated under the same conditions, is not capable of
trapping formaldehyde.
[0058] c) Capacity to trap formaldehyde under dynamic
conditions
[0059] A sample of the mat obtained under a) is placed in a device
in accordance with the ISO 16000-9 standard, modified in that the
specific ventilation flow rate is equal to 0.5 m.sup.3/(m.sup.2.h)
and the load factor is equal to 1 m.sup.2/m.sup.3.
[0060] 1--firstly, the test chamber of the device is fed with a
continuous stream of air containing 95 .mu.g/m.sup.3 of
formaldehyde over 8 days. The amount of formaldehyde in the air
entering and exiting is measured over a period of 8 days, and the
reduction in the amount of formaldehyde per unit volume of air is
calculated.
[0061] The formaldehyde is measured by liquid chromatography (HPLC)
under the conditions of the ISO 16000-3 standard.
[0062] In Table 1, the reduction in the amount of formaldehyde
carried out with the mat containing adipic acid dihydrazide is
indicated in comparison with a mat that contains no agent capable
of trapping the formaldehyde (Reference).
TABLE-US-00001 TABLE 1 Reduction of formaldehyde (.mu.g/m.sup.3)
Example Reference 1 day 32 0 2 days 23 0 8 days 19 0
[0063] 2--secondly, the chamber is supplied with air that contains
no formaldehyde for 7 days and the amount of formaldehyde present
in the air exiting the chamber is measured.
[0064] The formaldehyde is measured under the same conditions as in
paragraph 1.
[0065] The amount of formaldehyde emitted by the mat according to
the example in accordance with the invention is equivalent to that
which is measured when the chamber does not contain any mat. It can
be concluded therefrom that the formaldehyde is bonded to the
adipic acid dihydrazide in a strong and lasting manner.
EXAMPLE 2
[0066] The conditions from Example 1 were implemented, but modified
in that the polyester mat is immersed in a solution obtained by
mixing 121.9 g of water, 5.1 g of adipic acid dihydrazide, 20 g of
a solution of binding containing a thermosetting polymer
(Aquaset.RTM. TF 150 sold by Rohm & Haas; solids content: 54%)
and 3 g of alkyl diphenyl oxide disulfonate (Dowfax.RTM. sold by
Dow Chemical) and in that the drying is carried out at 210.degree.
C.
[0067] The amount of adipic acid dihydrazide deposited on the mat
is equal to 3 g/m.sup.2.
[0068] The capacity of the mat from Example 2 to trap formaldehyde
under static conditions of b), is equal to 694.44 mg/m.sup.2.
[0069] By comparison, an identical mat that contains no adipic acid
dihydrazide, treated under the same conditions, is not capable of
trapping formaldehyde.
* * * * *