Fiber glass mat, method and laminate
AssigneeJohns Manville International, Inc.
InventorAlan Michael Jaffee
Life of this patent
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Abstract
A fiber glass mat containing a novolac resin having an acid solubility of at least about 35 wt. percent is especially useful for bonding to a light weight fibrous or foam web or board, such as a polymer fiber web. A method of making the mat by wet laying a slurry containing the fiber and the novolac resin particles and then further adding an aqueous solution or slurry containing a crosslinking agent for the novolac resin and a laminate containing the fiber glass mat are disclosed.
Claims14
A method of making a wet laid nonwoven mat bound with a novolac resin comprising the steps of:
- a) dispersing fibers and novolac resin particles in water to form a dilute slurry,
- b) flowing said slurry onto a moving first permeable belt to form a wet layer of wet nonwoven fibers and resin particles,
- c) transferring said wet layer off of said permeable belt onto a second moving permeable belt,
- d) saturating said wet layer with an aqueous solution or slurry containing a crosslinking agent and removing excess slurry or solution and excess crosslinking agent from said wet layer,
- e) transferring said wet layer off of said second permeable belt onto an oven belt, and
- f) drying said wet layer to form a dry mat, the improvement comprising that said resin is a novolac powder having an acetone solubility greater than 95 wt. percent, that the aqueous solution or slurry contains a hardening agent for the novolac, the amount of said resin and hardening agent in the finished dried mat is at least 10-65 wt. percent, and said novolac resin is in contact with the hardening agent and is cured sufficiently reduce the acetone solubility to between about 35 and about 95 weight percent to give sufficient strength to the mat for handling and further processing, but not so much that the mat looses its ability to conform to a desired shape and bond to another mat or different material under heat and pressure.
A laminate having a core selected from a group consisting of foam board, a web of intermingled polymer fibers and a fiber glass wool board with two opposed surfaces of the core being bonded to a mat comprising glass fibers bonded together at the locations where the fibers cross each other with up to about 60 weight percent, based on the dry weight of the mat, of novolac resin, said resin having an acetone solubility of at least 35 wt. percent, and at least about 3 weight percent hardening agent for said resin based on the weight of the mat, said hardening agent amounting to at least 7 weight percent of the weight of the novolac resin, said novolac resin being substantially in melted form bonding the fibers together.
Dependencies are inferred from the claim text.