Fibrous mats
AssigneeICI United States Inc.
InventorJoseph P. Burns
Life of this patent
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Abstract
Fibrous mats which are insoluble in styrene are disclosed. The mats comprise a fibrous material and a binder resin which is the reaction product of (a) a first monomer selected from the group consisting of styrene, lower alkyl acrylates, lower alkyl methacrylates, lower alkyl itaconates, lower alkyl maleates, lower alkyl fumarates, vinyl esters, and vinyl chloride; (b) a second monomer selected from the group consisting of acrylic acid, methacrylic acid, itaconic acid, maleic acid, fumaric acid, acrylamide, lower alkyl acrylamides, N-alkoxy modified acrylamides, diacetone acrylamide, maleamic acid, meleamide, furamide, N-monoalkyl/aryl substituted amides, hydroxyethyl acrylate, and hydroxypropyl methacrylate; and (c) a modifier selected from the group consisting of epoxy resins, melamine formaldehyde resins, and urea formaldehyde resins.
Claims8
A styrene insoluble fibrous mat comprising a fibrous material and a binder resin, said resin comprising the single step reaction product of
- a. a first alpha-beta ethylenically unsaturated monomer selected from the group consisting of styrene, vinyl esters, vinyl chloride, lower alkyl methacrylates, lower alkyl acrylates, lower alkyl itaconates, lower alkyl maleates, and lower alkyl fumarates;
- b. a second alpha-beta ethylenically unsaturated monomer selected from the group consisting of acrylic acid, methacrylic acid, itaconic acid, maleic acid, fumaric acid, maleamic acid, maleamide, furamide, N-monoalkyl/aryl substituted amides, hydroxyethyl acrylate, and hydroxypropyl methacrylate;
- and
- c. a modifier selected from the group consisting of epoxy resins, melamine formaldehyde resins, and urea formaldehyde resins;
- wherein the amount of binder resin is equal to from about 3 percent to about 8 percent by weight based on the total weight of said mat and said binder resin comprises from about 75% to about 98% by weight of said first monomer, from about 1% to about 10% by weight of said monomer, and from about 1% to about 15% by weight of said modifier.
A method of preparing a styrene insoluble fibrous mat, said method comprising
- a. preparing a mat comprising a fibrous material and a binder resin, wherein the amount of binder resin is equal to from about 3 percent to about 8 percent by weight based on the total weight of said mat, said resin comprising a mixture of
- i. from about 75% to about 98% by weight of a first alpha-beta ethylenically unsaturated monomer selected from the group consisting of styrene, vinyl esters, vinyl chloride, lower alkyl methacrylates, lower alkyl acrylates, lower alkyl itaconates, lower alkyl maleates, and lower alkyl fumarates;
- ii. from about 1% to about 10% by weight of a second alpha-beta ethylenically unsaturated monomer selected from the group consisting of acrylic acid, methacrylic acid, itaconic acid, maleic acid, fumaric acid, maleamic acid, maleamide, furamide, N-monoalkyl/aryl substituted amides, hydroxyethyl acrylate, and hydroxypropyl methacrylate;
- and
- iii. from about 1% to about 15% by weight of a modifier selected from the group consisting of epoxy resins, melamide formaldehyde resins, and urea formaldehyde resins;
- and
- b. heating said mat to a temperature of from 150.degree.C. to about 250.degree.C. for a time sufficient to cure said mat to a styrene insoluble state.
Dependencies are inferred from the claim text.