U.S. patent application number 14/450465 was filed with the patent office on 2015-02-12 for fibre mat and products containing fibre mats.
The applicant listed for this patent is JOHNS MANVILLE. Invention is credited to Stephan Groger, Elvira Rempt.
Application Number | 20150044414 14/450465 |
Document ID | / |
Family ID | 51298512 |
Filed Date | 2015-02-12 |
United States Patent
Application |
20150044414 |
Kind Code |
A1 |
Rempt; Elvira ; et
al. |
February 12, 2015 |
FIBRE MAT AND PRODUCTS CONTAINING FIBRE MATS
Abstract
A hybrid fibre mat comprises glass fibres, polymer fibres and
binding agents, the glass fibres having a mean diameter of between
6 and 13 .mu.m and a mean length of between 6 and 15 mm, the
polymer fibres being staple fibres having a mean fineness of
between 0.2 and 0.6 dtex and a mean length of between 2 and 4 mm
and the percentage by weight of the polymer fibres being between 5
and 20% of the dry fibre mat. Such a hybrid fibre mat being
suitable in particular as a covering for interior elements, a
ceiling panel or other interior cladding elements and, provided
with an impregnation (for example plastisol), in particular as a
structural layer of a cushioned vinyl floor covering. For the
production thereof, preferably water which contains the glass
fibres and the polymer fibres is passed in a circuit through a band
screen, the fibre mixture in the form of a fibre layer with a
predetermined layer thickness is deposited on the band screen,
excess circuit water is removed from the fibre layer, binding agent
is added to the fibre layer and the fibre layer to which binding
agent has been added is dried.
Inventors: |
Rempt; Elvira; (Wertheim,
DE) ; Groger; Stephan; (Wertheim, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
JOHNS MANVILLE |
DENVER |
CO |
US |
|
|
Family ID: |
51298512 |
Appl. No.: |
14/450465 |
Filed: |
August 4, 2014 |
Current U.S.
Class: |
428/92 ;
264/86 |
Current CPC
Class: |
D21H 13/24 20130101;
D06N 2211/063 20130101; D04H 3/005 20130101; D04H 1/435 20130101;
D04H 1/64 20130101; D06N 7/006 20130101; D06N 2211/066 20130101;
D06N 3/0011 20130101; D21H 13/40 20130101; D04H 1/4218 20130101;
D04H 3/004 20130101; D04H 1/587 20130101; D06N 3/0022 20130101;
D21H 27/26 20130101; Y10T 428/23957 20150401; D06N 3/0036
20130101 |
Class at
Publication: |
428/92 ;
264/86 |
International
Class: |
D04H 3/004 20060101
D04H003/004; D04H 3/005 20060101 D04H003/005 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 9, 2013 |
DE |
102013013321.1 |
Claims
1. Fibre mat, namely hybrid fibre mat comprising glass fibres,
polymer fibres and binding agents having the following features:
the glass fibres have a mean diameter of between 6 and 13 .mu.m and
a mean length of between 6 and 15 mm; the polymer fibres are staple
fibres having a mean fineness of between 0.2 and 0.6 dtex and a
mean length of between 2 and 4 mm; the percentage by weight of the
polymer fibres is between 5 and 20% of the dry fibre mat.
2. Hybrid fibre mat according to claim 1, characterised in that the
percentage by weight of the binding agent is between 15 and 35% of
the dry fibre mat.
3. Hybrid fibre mat according to claim 2, characterised in that the
percentage by weight of the binding agent is between 20 and 30% of
the dry fibre mat.
4. Hybrid fibre mat according to claim 1, characterised in that the
polymer fibres have a mean fineness of between 0.3 and 0.4
dtex.
5. Hybrid fibre mat according to claim 1, characterised in that the
polymer fibres have a mean length of between 2.5 and 3.5 mm.
6. Hybrid fibre mat according to claim 1, characterised in that the
polymer fibres consist of PET.
7. Hybrid fibre mat according to claim 1, characterised in that the
glass fibres have a mean diameter of between 7 and 10 .mu.m.
8. Hybrid fibre mat according to claims 1, characterised in that
the diameter of the glass fibres is a maximum of 10 .mu.m and in
that the length of the glass fibres is a maximum of 15 mm.
9. Hybrid fibre mat according to claim 1, characterised in that the
glass fibres have a mean length of between 7 and 9 mm.
10. Hybrid fibre mat according to claim 1, characterised in that
the binding agent comprises urea resin, preferably a mixture of
urea resin and a polymer dispersion.
11. Hybrid fibre mat according to claim 1, characterised in that
the binding agent comprises polyacrylic acid binders, preferably a
mixture of polyacrylic acid binders and a polymer dispersion.
12. Hybrid fibre mat according to claim 1, characterised in that
the glass fibres consist of C-glass and/or E-glass.
13. Hybrid fibre mat according to claim 1, characterised in that it
has a surface weight of between 25 g/m.sup.2 and 80 g/m.sup.2,
preferably of between 40 g/m.sup.2 and 60 g/m.sup.2.
14. Hybrid fibre mat according to claim 1, characterised in that
the percentage by weight of the polymer fibres is between 10 and
15% of the dry fibre mat.
15. Hybrid fibre mat according to claim 1, characterised in that it
is provided with an additional impregnation.
16. Hybrid fibre mat according to claim 15, characterised in that
the impregnating agent is plastisol.
17. Cushioned vinyl floor covering having a useable layer and a
structural layer, the structural layer comprising a hybrid fibre
mat provided with an impregnation according to claim 15 or claim
16.
18. Use of a hybrid fibre mat according to claim 1, as a covering
for interior elements, in particular as a ceiling panel or other
interior cladding element.
19. Use of a hybrid fibre mat according to claim 1, as a surface
coating of a construction panel, in particular a mineral ceiling
panel or wall panel.
20. Use of a hybrid fibre mat according to claim 1, as a wall
covering.
21. Method for producing the hybrid fibre mat according to claim 1,
water, which contains the glass fibres and the polymer fibres,
being passed in a circuit through a band screen, the fibre mixture,
in this case in the form of a fibre layer with a predetermined
layer thickness, being deposited on the band screen, excess circuit
water being removed from the fibre layer, binding agent being added
to the fibre layer and the fibre layer to which binding agent has
been added being dried.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a fibre mat. The invention
further relates to products containing fibre mats, in particular a
cushioned vinyl floor covering which comprises a fibre mat as a
structural layer.
[0002] Fibre mats are known in many different embodiments and for
various applications. For example, glass fibre mats are widely
available. Different methods exist for the production thereof from
glass fibres and binding agents.
[0003] A principal application of fibre mats is the use as a
carrier material in floor coverings, namely in CV (cushioned vinyl)
floor coverings. The fibre mats used here typically consist of
glass fibres, the use of specific mixtures of different glass
fibres also being known for producing corresponding glass fibre mat
carriers (see DE 102011011056 A1, the disclosure thereof being made
for the contents of the present application).
BRIEF SUMMARY OF THE INVENTION
[0004] The object of the present invention is to provide a fibre
mat which is able to be produced in a cost-effective manner and
which, due to properties which in this respect are particularly
advantageous, is suitable, in particular, for the application as a
carrier material in floor coverings and in this application
advantageously influences the properties of the finished floor
covering.
DETAILED DESCRIPTION OF THE INVENTION
[0005] This object is achieved according to the present invention,
as set forth in claim 1, by a fibre mat which is designed as a
hybrid fibre mat, by said mat comprising glass fibres, polymer
fibres and binding agents, the glass fibres having a mean diameter
of between 6 and 13 .mu.m and a mean length of between 6 and 15 mm,
the polymer fibres being staple fibres having a mean fineness of
between 0.2 and 0.6 dtex and a mean length of between 2 and 4 mm
and the percentage by weight of the polymer fibres being between 5
and 20% of the dry fibre mat.
[0006] In other words, therefore, a specific combination of
synergistically interacting features is characteristic of the fibre
mat according to the invention, such that both with regard to the
material and with regard to the typical length and thickness
dimensions said fibre mat consists of various fibres connected
together by means of a binding agent, namely relatively short
and--in the polymers principally under consideration here for the
polymer fibres, with thicknesses of between approximately 1.2 and
1.6 g/cm.sup.3--thinner polymer fibres, on the one hand, and
relatively long and thicker glass fibres, on the other hand, the
percentage by weight of the polymer fibres being substantially less
than the percentage by weight of the glass fibres, the polymer
fibres only constituting between 5 and 20, preferably between 10
and 15 percentage by weight of the dry fibre mat. The ratio between
the percentage by weight of the glass fibres and that of the
polymer fibres in the fibre mat is typically between 5 and 8, for
example approximately 6.5--with a percentage by weight of the
binding agent of approximately between 20 and 30%.
[0007] Surprisingly, the hybrid fibre mat according to the
invention is characterised by a series of very advantageous
properties. Thus, due to the particular mixture of specific glass
fibres used and specific polymer fibres, physical properties
(mechanical strength, density, pore volume, hollow structure, etc.)
are produced, such that particularly thin hybrid fibre mats
according to the invention already satisfy the requirements which
are applicable, in particular, to the structural materials of floor
coverings. This is specifically an advantage which is not to be
underestimated, therefore, as in this manner (already due to the
reduced thickness of the fibre mat) the quantity of impregnating
agent with which the fibre mat is to be treated may be reduced.
This results in corresponding economic advantages relative to the
prior art and namely without adversely affecting the performance.
In contrast, the fibre mat according to the invention has a surface
structure of particular quality and homogeneity, such that a floor
covering produced by the application thereof is also characterised
by a particular surface quality. This is a great advantage for
surface finishing, namely by printing.
[0008] In other words, the present invention provides outstanding
fibre mats with regard to the properties thereof and namely--for
example an additional coating of the fibres, which is a drawback in
terms of material expenditure and complexity of method, may be
avoided--with minimal cost and without the use of respirable
micro-glass fibres which are dangerous to the health.
[0009] Although the use of the hybrid fibre mat according to the
invention is paramount when producing floor coverings, as far as
the particular suitability of the hybrid fibre mat according to the
invention is concerned, this does not constitute in any way the
only possible use. Various features set forth above which
characterise the hybrid fibre mat according to the invention are
also able to be used particularly advantageously for a series of
other applications. Here may be cited in particular the use as a
paintable ceiling and wall covering (corresponding to a
conventional wallpaper), in which due to the properties of the
hybrid fibre mat an excellent surface quality may be achieved with
a very small (subsequent) application of paint, moreover the
exceptionally low tendency for the paint to pass through the fibre
mat having a very advantageous effect on the adhesion of the hybrid
fibre mat as a ceiling covering and/or wall covering on the
relevant substrate. The fact that a very good surface quality may
be achieved with a very small quantity of wall and/or ceiling paint
is not only an economic aspect in this case. The weight of the
ceiling covering and wall covering, together with the coat of
paint, i.e. the painted ceiling covering and wall covering, also
remains relatively low, which in turn assists the adhesion of the
hybrid fibre mat onto the substrate. When using the hybrid fibre
mat according to the invention as a visible face of a ceiling
panel, a mineral coating is advantageously used.
[0010] These advantageous aspects apply in a very similar manner
when using the hybrid fibre mat according to the invention as a
surface coating of a construction panel, in particular a mineral
ceiling panel or wall panel, such that the hybrid fibre mat is
applied to the preformed panel in the factory (in particular by
adhesive bonding and/or laminating); the specific structure of the
hybrid fibre mat according to the invention thus prevents the
penetration of the adhesive from the rear face to the front
surface, i.e. the visible face, so that the surface quality of the
visible face and the paint adhesion are not adversely affected by
traces of adhesive. In addition, due to its advantageous
properties, as set forth, the hybrid fibre mat according to the
invention may be used particularly advantageously as a covering for
interior elements, in particular as a ceiling panel or other
interior cladding element.
[0011] With regard to production technology, it is advantageous if
the polymer fibres consist of a polymer with a density of
approximately 1.2 and 1.6 g/cm.sup.3. It is particularly
advantageous if the polymer fibres consist entirely or at least
substantially of PET (polyethylene terephthalate). When using such
a material for producing the polymer fibres, said polymer fibres
have such properties which are suitable for the production of the
mat, the production of pure glass fibre mats providing experience
thereof. In this sense, according to a preferred feature of the
present invention, the hybrid fibre mat according to the invention
is produced by the glass fibres and the water containing the
polymer fibres being passed in a circuit through a band screen, the
fibre mixture in the form of a fibre layer with a predetermined
layer thickness then being deposited on the band screen, excess
circuit water being removed from the fibre layer, binding agent
being added to the fibre layer and the fibre layer to which binding
agent has been added being dried.
[0012] The particular advantages set forth above of the glass fibre
mat according to the invention are particularly pronounced when the
mean fineness of the polymer fibres is between 0.3 and 0.4 dtex.
Excellent results may be achieved, for example, by using PET fibres
with a fineness of 0.33 dtex and a mean length of between 2.5 and
3.5 mm.
[0013] Moreover, according to a further preferred development of
the present invention, it is particularly advantageous if the mean
fibre diameter of the glass fibres is between 7 and 10 .mu.m and/or
the mean length of the glass fibres is between 7 and 9 mm.
Specifically in combination with the preferred dimensions of the
polymer fibres, as set forth above, particularly outstanding
material properties result, which make the corresponding hybrid
fibre mat particularly attractive for the applications set forth
above. For different applications it is advantageous if the glass
fibres are not longer than 15 mm and not thicker than 10 .mu.m;
since in the case of dimensions above these values the surface
properties of the hybrid fibre mat are impaired. Particularly
preferably, the glass fibres consist of C-glass and/or E-glass.
[0014] According to a further preferred development of the present
invention--for typical applications of the hybrid fibre mat
according to the invention--the surface weight of the glass fibre
mat is between 25 and 80 g/m.sup.2, particularly preferably between
40 and 60 g/m.sup.2. Once again, in this case quite particularly
advantageous properties of the hybrid fibre mat according to the
invention result, in particular with regard to the possible use
thereof as a carrier material in cushioned vinyl floor coverings
with outstanding properties.
[0015] There is considerable flexibility here as regards the
binding agent of the hybrid fibre mat according to the invention,
which in particular may take into account the subsequent use of the
hybrid fibre mat according to the invention. Particularly
advantageous binding agents are urea resins and polyacrylic acid
binders. The binding agent may, however, also comprise polyacrylic
acid. Outstanding properties result when the binding agent
comprises a mixture of urea resin and a polymer dispersion or a
mixture of polyacrylic acid binders and a polymer dispersion.
[0016] Likewise, there is considerable flexibility as regards the
percentage by weight of the binding agent in the hybrid fibre mat,
in this regard the specific binding agent respectively used and
also the use of the hybrid fibre mat also being able to play a
role. For the potential use as a carrier material of a cushioned
vinyl floor covering, which is paramount here, a percentage by
weight of the binding agent of between 15% and 35%, preferably
between 20% and 30% of the total weight of the hybrid fibre mat is
advantageous.
[0017] The binding agent, depending on the designated subsequent
use of the respective hybrid fibre mat according to the invention,
may contain an additive (or a plurality of additives) which may
constitute up to 50% of the total weight of the binding agent. The
additive(s) may in this case specifically modify and/or optimise
the properties of the binding agent with regard to the individual
purpose of the hybrid fibre mat. Typical additives are, for
example, kaolin and TiO.sub.2. However, additives are not only
capable of optimising the binding agent in technical terms but
additives are also capable of reducing costs by being able to
reduce the need for expensive binding agents.
[0018] The present invention according to the above embodiments
does not relate exclusively to the untreated hybrid fibre mat. On
the contrary, the invention also relates, in particular, to a
hybrid fibre mat pre-treated for subsequent specific further
processing, in particular provided with an additional impregnation,
the impregnating agent, in particular, being able to be plastisol
or another PVC-based agent. Moreover, the present invention also
extends to the finished cushioned vinyl floor covering produced
using the hybrid fibre mat according to the invention, said
cushioned vinyl floor covering comprising a useable layer and a
structural layer, the structural layer comprising a hybrid fibre
mat according to the invention provided with an impregnation (see
above).
* * * * *