RS53786B1 - GLASS FIBER NON-WOVEN TEXTILE AND ARTICLES CONTAINING GLASS-FIBER NON-WOVEN TEXTILE - Google Patents

Abstract

Glass fiber nonwovens comprising type 1 glass fibers, type 2 glass fibers and binder, characterized in that type 1 glass fibers are characterized by a mean fiber diameter of less than 6 μm in compliance with the EC Protocol "ECB / TM / 27 rev. 7" that the glass fibers of the second type are characterized by a mean fiber diameter greater than 6 μm, that the ratio between the weight fraction of glass fibers of the first type and the weight fraction of glass fibers of the second type is between 0.01 and 0.15; although the surface weight is between 25 g / m2 and 80 g / m2. The application contains 14 more patent claims.

Description

The subject invention relates to a non-woven textile (non-woven material/fleece/fleece) made of glass fibers. In a broader sense, it also includes products that contain non-woven textiles made of glass fibers, especially CV floor covering that includes non-woven textiles made of glass fibers as a structural layer.

Nonwoven textiles made of glass fibers are known in various designs and applications for different purposes. Conventional processes for the production of non-woven textiles from glass fibers and binders are also known. One significant application of non-woven glass fiber textiles is as a carrier material in floor coverings, namely CV floor coverings (Cushioned Vinyl coverings, inflated vinyl coverings). In the production of CV floor coverings, it is typical that non-woven glass fiber textiles are impregnated with PVC paste (especially Plastisol) in the first stage. In addition, it is customary to apply the PVC paste in a predetermined thickness, i.e., a predetermined surface weight (eg about 400 g/m<2>) using a suitable application tool to the non-woven glass fiber textile. After that, the next layer of PVC paste is applied to the glass fiber non-woven textile thus impregnated, with the surface weight of that second layer usually being of the same order of magnitude as the impregnating layer. This is followed by obtaining a foam background, i.e. application of an elastic, flexible layer to the back of a non-woven glass fiber textile. After that, the usable side (face) can be finished, for example, by applying a layer of colorless varnish or other special layers. This type of production of CV floor coverings has long been known in the PVC industry and is applied in various variants on a large scale.

At the same time, different requirements are set for the non-woven glass fiber textile that forms the supporting layer, which are partly in contradiction. According to them, non-woven textiles made of glass fibers should have good mechanical strength, both during processing and during the use of floor coverings produced by its application. Then it is important that the PVC paste as well as the foam backing have an optimal mechanical bond with the non-woven glass fiber textile to avoid separation of these layers from the non-woven glass fiber textile during the use of the floor covering. On the other hand, in any case, it must be avoided that the PVC paste which, as explained, is applied with a tool to the glass fiber non-woven textile penetrates into it, because if this happens on the back of the glass fiber non-woven textile, where the foam layer is later applied, more or less pronounced PVC lumps are formed, which fundamentally affect the comfort of walking on the CV floor covering. In addition, costs, as usual, have a certain role, both those related to the production of non-woven glass fiber textiles and those related to its impregnation with PVC paste, where the consumption of PVC paste for impregnation depends on the thickness and characteristics (pore volume, permeability, absorbency, pore size distribution) of the non-woven glass fiber textile.

The objective of the present invention is to make available a non-woven textile made of glass fibers that is exceptionally suitable for use as a carrier material in CV floor coverings, while in practice it meets all the previously given and explained requirements and which by its overall characteristics exceeds the state of the art.

This task is solved according to the present invention, as given in the first patent claim, with a non-woven glass fiber textile comprising glass fibers of the first type, glass fibers of the second type and a binder, wherein the glass fibers of the first type are characterized by a mean fiber diameter of less than 6 µm, as well as compliance with the EC protocol "ECB/TM/27 rev. 7" and the glass fibers of the second type are characterized by a mean fiber diameter greater than 6 in m, where the ratio of the weight share of glass fibers of the first type and the weight share of glass fibers of the second type is between 0.01 and 0.15 and the surface weight of the non-woven glass fiber textile is in the range of 25 g/m<2> and 80 g/m<2>.

For the non-woven glass fiber textile according to the invention, in this way and in other words, a characteristic specific combination of properties acting together is designed so that it consists of different glass fibers mutually connected by a binder, namely from relatively thin on the one hand, i.e. of glass fibers of the first type with a mean fiber diameter of less than 6 µm, and on the other hand of relatively thick ones, i.e. glass fibers of the second type with a mean fiber diameter greater than 6 µm, whereby the weight share of glass fibers of the first type in the glass fiber mixture is significantly lower than the weight share of glass fibers of the second type, where the ratio between the weight shares of glass fibers of the first type and glass fibers of the second type is in the range of 0.01 and 0.15, whereby the glass fibers of the first finger in terms of the criteria according to the EC protocol "ECB/TM/27 rev. 7" (Bioperistencia fibers, intratracheal instillation) are not biopersistent and the surface weight of non-woven glass fiber textiles is between 25 g/m<2> and 80 g/m<2>. The properties of the glass fiber non-woven textile thus described make it particularly suitable with regard to the application, which will be explained below, but in any case also enable the use of the glass fiber non-woven textile according to the invention with significant advantages for a whole range of other purposes in which similar requirements are set for the glass fiber non-woven textile (see below). A significant, completely surprising aspect in this regard consists in the fact that the nonwoven textile according to the invention despite its low surface weight of 25 g/m<2> to 80 g/m<2>, which is lower than the usual surface weights of known glass fiber nonwoven textiles, which are suitable for and used for similar purposes and do not contain microfibres, and thanks to this and despite the difference from the usual glass fiber nonwoven textiles which have a reduced proportion of only one type of thicker glass fibers, does not show any significant defects in relation to mechanical properties, especially strength, while at the same time the risk of PVC paste penetrating into the non-woven textile of glass fibers and forming lumps on the back is significantly reduced (during the primary application explained in more detail above), compared to the current state of the art. At the same time, when applying the non-woven glass fiber textile according to the invention, and compared to the state of the art, the upper surface of the finished floor covering can be improved, by maximally reducing unevenness on the useful surface. It should be pointed out that in the application of the non-woven glass fiber textile according to the invention, the consumption of PVC paste, which is necessary for impregnating the non-woven glass fiber textile, can be reduced, in such a way that the adhesion between the non-woven glass fiber textile and the impregnation material is not affected. Since microfiber, i.e. glass fibers of the first type, which have a mean fiber diameter of less than 6 µm, are not biopersistent (see above), non-woven glass fiber textiles according to the invention, as well as the products obtained by its application are harmless from a health point of view, because glass fibers released especially during processing (especially on cut edges) cannot be harmful in the human body, because they either cannot enter the lungs (this applies to glass fibers of another type) or are decomposed in the body body fluids (this refers to glass fibers of the first type). In this sense, fiberglass of another kind cannot be biopersistent, and they do not have to be, which is also an important aspect from the point of view of flexibility, which refers to the type of glass used for glass fibers of another kind, as well as the cost of production.

Although the previous, in the introduction, the application of the non-woven glass fiber textile according to the invention, which relates to the production of floor coverings, is in the foreground when considering what the non-woven glass fiber textile is suitable for, it is by no means the only possible application. In contrast to the previously described characteristics of the non-woven textile according to the invention, it is suitable for a whole range of other applications with special advantages. In particular, it should be mentioned here (similar to ordinary wallpaper) the application as coverings for ceilings and walls, which can be whitewashed, when thanks to the properties of non-woven textiles made of glass fibers with a very thin (subsequent) application of paint, an extremely high-quality surface is obtained, with the extremely small possibility that the color will penetrate through the non-woven textiles, it has a very favorable effect on the adhesion of non-woven textiles made of glass fibers as coverings for the ceiling, i.e. the wall to the appropriate substrate. The fact that with a very small amount of paint for the ceiling, that is, the wall, a very good surface quality is obtained is not only an economic aspect. In this way, the weight of the ceiling, i.e. wall covering, including the coating with paint, i.e. relatively small painted ceiling or wall covering, which in turn contributes to the adhesion of non-woven glass fiber textiles to the substrate. In a very similar way, these convenient aspects of the invention also apply when applying non-woven glass fiber textiles as a surface layer of a construction panel, especially mineral panels for the ceiling or wall, so that the non-woven glass fiber textile is placed on a pre-formed panel with the working side (especially by gluing or lamination), because the specific structure of the non-woven glass fiber textile prevents the penetration of glue from the back to the front upper surface, i.e. the visible page, so that the quality of the surface of the visible page and the adhesion of the paint are not affected by traces of glue. The non-woven glass fiber textile according to the invention is, due to its favorable described properties, also applicable and with particularly good characteristics as a cover layer for elements for the interior space, especially in motor vehicles, and especially as a cover plate or other type of upholstery for the interior space.

The previously described particular advantages of the non-woven glass fiber textile according to the invention are particularly pronounced when the mean fiber diameter of the glass fiber of the first type is between 0.5 µm and 6 µm, preferably between 0.6 µm and 3.0 µm, and particularly preferably between 0.6 µm and 1.5 µm.

In addition, according to another preferred embodiment of the present invention, it is particularly suitable that the mean fiber diameter of the glass fibers of the second type is between 6 µm and 13 µm. Namely, in combination with the previously given primary dimensions of glass fibers of the first type, particularly excellent material characteristics are obtained, which make the appropriate non-woven textile from glass fibers extremely attractive for the previously described applications.

Of particular advantage is that the glass fibers are of a different type from C-glass and/or E-glass, and T-glass for different types of glass fibers is also very suitable for different applications. It is particularly advantageous when the glass fibers of the second type consist of a mixture of at least two different types of glass fibers. If the mixture of glass fibers of another type, in this sense, includes glass fibers of both C-glass and E-glass, then it is advantageous that the proportion of glass fibers of C-glass in the mixture of glass fibers of the other type be greater than the proportion of glass fibers of E-glass, whereby the proportion of glass fibers of C-glass in the mixture of glass fibers of the other type within the scope of the present invention can be significantly higher than the proportion of glass fibers of E-glass. The aforementioned relationship can also be advantageous from the point of view of the above-described special properties of the non-woven glass fiber textiles according to the invention, where they are particularly useful in floor covering applications. However, for other applications, different ratios may be advantageous, for example, up to a proportion of 100% glass fibers from E-glass to fibers of another type.

According to another aspect of the present invention, it is particularly advantageous that the glass fibers of the second type have an average length/diameter ratio between 500 and 2000. This proportion of the glass fibers of the second type is in a specific relationship with their special function within the non-woven glass fiber textile, especially with regard to mechanical strength (see above).

According to another preferred embodiment of the subject invention, for typical cases of application of non-woven glass fiber textiles according to the invention, the ratio between the weight fraction of glass fibers of the first type and the weight fraction of glass fibers of the second type is primarily between 0.03 and 0.08, and particularly preferably between 0.04 and 0.06. It is convenient for the ratio to be less than 0.055, and ideally less than 0.048. Again, in this case, particularly favorable properties of the non-woven glass fiber textile according to the invention are obtained, especially from the point of view of its possible application as a carrier material in CV floor coverings with outstanding properties. From this point of view, it is advantageous for typical cases of application that the surface weight of the non-woven glass fiber textile is between 40 g/m<2> and 60 g/m<2>. However, for specific application cases, very good results could be achieved with values deviating from those listed, e.g. with the ratio between the weight fraction of glass fibers of the first type and the weight fraction of glass fibers of the second type less than 0.03.

Regarding the binder for the non-woven glass fiber textile according to the invention, there is a wide range to choose from, where particular care should be taken in the subsequent application of the non-woven glass fiber textile according to the invention. Of particular advantage are carbamide resin binders and polyacrylic acid-based binders. The binder may also contain polyacrylic acid. Excellent characteristics are obtained when the binder contains a mixture of carbamide resin and polymer dispersion or a mixture of binder based on polyacrylic acid and polymer dispersion.

There is also a wide area of choice when it comes to the weight share of the binder in the glass fiber non-woven textile, whereby the specific binder used and the application of the glass fiber non-woven textile can also play a certain role. For the possible application which is in the foreground here as a carrier material in a CV floor covering, it is advantageous for the weight share of the binder to be between 15% and 35%, preferably between 20% and 30% of the total weight of the glass fiber non-woven textile.

The binder, depending on the subsequent application for which the corresponding non-woven glass fiber textile according to the invention is intended, may also contain one additive (or more additives), which can make up to 50% of the total weight of the binder. The additive (or additives) can modify or optimize the characteristics of the binder in a specific way in connection with the individual purpose of the non-woven glass fiber textile. Common additives are, for example, kaolin and TiC>2. In any case, additives can not only technically optimize the binder, but additives are also suitable for reducing costs, because they can be used to dilute expensive binders.

Considering the other relationships described above, it is advantageous for a common application when the porosity of the glass fiber non-woven textile is within the range of about 1000 l/m2s and about 3000 l/m<2>s, with porosity between 1500 l/m<2>s and 2500 l/m<2>s being particularly suitable. The above values for favorable porosity are based on the measurement standard DIN EN IS09237 for a pressure difference of 100 Pa.

The subject invention according to the above explanations does not only relate to unprocessed non-woven glass fiber textiles. The invention is much more related in particular to non-woven textiles made of glass fibers treated later by specific processing, in particular treated by additional impregnation, and when it comes to the impregnation agent, it can be Plastisol or another agent based on PVC. The subject invention also extends to finished CV floor coverings, obtained by applying non-woven glass fiber textiles according to the invention, where they have one useful layer and one structural layer, whereby the structural layer includes impregnated non-woven glass fiber textiles (see above) according to the invention.

Claims (15)

1. Non-woven textile from glass fibers, which includes glass fibers of the first type, glass fibers of the second type and a binder, indicated by which are glass fibers of the first type characterized by a mean fiber diameter of less than 6 µm with respect to the EC Protocol "ECB/TM/27 rev. 7"; which are glass fibers of a different type characterized by a mean fiber diameter greater than 6fxm; that the ratio between the weight share of glass fibers of the first type and the weight share of glass fibers of the second type is between 0.01 and 0.15; and which surface weight is between 25 g/m<2> and 80 g/m<2>. 2. Non-woven textile from glass fibers according to claim 1, characterized by the fact that the binder contains carbamide resin or binder based on polyacrylic acid, and primarily a mixture of polymer dispersion and carbamide resin or binder based on polyacrylic acid. 3. Glass fiber non-woven textile according to claim 1 or claim 2, characterized by the fact that the average fiber diameter of the glass fibers of the first type is between 0.5 µm and 6 µm, preferably between 0.6 µm and 3 µm, and particularly preferably between 0.6 µm and 1.5 µm and that the average fiber diameter of the glass fibers of the second type is between 6 µm and 13 µm. 4. A non-woven glass fiber textile according to one of claims 1 to 3, characterized in that the glass fibers of the second type have an average length/diameter ratio between 500 and 2000. 5. Non-woven glass fiber textile according to one of claims 1 to 4, characterized in that the glass fibers are of a different type than C-glass, E-glass and/or T-glass. 6. Non-woven textile from glass fibers according to one of the requirements from 1 to 5, indicated by the fact that the glass fibers of the second type are a mixture of at least two different types of glass fibers, whereby the primary mixture of glass fibers of the second type includes glass fibers both from C-glass and also from E-glass, especially with a higher proportion of glass fibers from C-glass compared to the proportion of glass fibers from E-glass. 7. Non-woven textile from glass fibers according to one of the requirements from 1 to 6, characterized by the fact that the ratio between the weight share of glass fibers of the first type and the weight share of glass fibers of the second type is between 0.03 and 0.08, and primarily between 0.04 and 0.06. 8. A non-woven glass fiber textile according to one of claims 1 to 7, characterized in that it has a surface weight between 40 g/m and 60 g/m. 9. Non-woven textile from glass fibers according to one of the requirements from 1 to 8, characterized by the fact that the weight share of the binder is between 15% and 35%, preferably between 20% and 30%. 10. Non-woven glass fiber textile according to one of the requirements from 1 to 9, characterized by the fact that the porosity is from 1000 to 3000 l/m<2>s, and primarily from 1500 to 2500 l/m<2>s. 11. Non-woven textile from glass fibers according to one of the requirements from 1 to 10, indicated by the fact that it has additional impregnation. 12. Non-woven glass fiber textile according to claim 11, characterized in that the impregnation agent is Plastisol. 13. CV floor covering with one useful layer and one structural layer, wherein the structural layer comprises an impregnated non-woven glass fiber textile according to claim 11 or claim 12. 14. Use of a non-woven textile made of glass fibers according to one of claims 1 to 11 for covering the surfaces of construction boards, especially mineral boards for ceilings or walls. 15. Use of a non-woven glass fiber textile according to one of claims 1 to 11 for wall covering.