Meta- and para-aramid pulp and processes of making same

1. A process for making a meta- and para-aramid pulp for use as reinforcement material, comprising:

(a) combining pulp ingredients including:

(1) pieces of fibrous meta-aramid material, wherein the fibrous meta-aramid material is uncalendered paper having a thickness of 2 to 40 mils and a density of 0.1 to 0.4 g/cm 3 , being 10 to 90 wt % of the total solids in the ingredients, and having an average maximum dimension of no more than 50 mm;

(2) para-aramid fiber being 10 to 90 wt % of the total solids in the ingredients, and having an average length of no more than 10 cm; and

(3) water being 95 to 99 wt % of the total ingredients;

(b) mixing the ingredients to a substantially uniform slurry;

(c) co-refining the slurry by simultaneously:

(1) breaking apart the fibrous meta-aramid material pieces, and cutting and/or masticating the meta-aramid material, into fibril free, fibrous and non fibrous, meta-aramid particles;

(2) fibrillating, cutting and masticating the para-aramid fiber to irregularly shaped fibrillated fibrous structures; and

(3) dispersing all solids such that the refined slurry is substantially uniform; and

(d) removing water from the refined slurry to no more than 60 total wt % water, thereby producing a meta- and para-aramid pulp with the para-aramid fibrous structures contacting and wrapped partially around at least some of the meta-aramid particles.

2. The process of claim 1 , wherein the fibrous meta-aramid material comprises pieces of fibrous meta-aramid paper which comprise paper components including:

(i) meta-aramid fiber being 10 to 90 wt % of the paper, and having a length of 2 to 25 mm; and

(ii) non granular, fibrous or film-like, meta-aramid fibrids being 90 to 10 wt % of the paper, and having an average maximum dimension of 0.2 to 1 mm, an aspect ratio of 5:1 to 10:1, and a thickness of no more than 2 microns.

3. The process of claim 1 , wherein the ingredients further comprise:

substantially or completely fibril-free, granular, para-aramid particles being no more than 50 wt % of the total solids in the ingredients, and having an average maximum dimension of 50 to 2000 microns; and in the refining step, masticating at least some of the para-aramid particles into smaller, rounder, substantially fibril-free, particles, whereby in the produced meta- and para-aramid pulp, the para-aramid fibrous structures contact and are wrapped partially around at least some of the rounder, substantially fibril-free, para-aramid particles.

4. A process for making a meta- and para-aramid pulp for use as reinforcement material, comprising:

(a) combining ingredients including water and a first material of the group:

(1) pieces of fibrous meta-aramid material, wherein the fibrous meta-aramid material is uncalendered paper having a thickness of 2 to 40 mils and a density of 0.1 to 0.4 g/cm 3 , being 10 to 90 wt % of the total solids in the pulp, and having an average maximum dimension of no more than 50 mm; and

(2) para-aramid fiber being 10 to 90 wt % of the total solids in the pulps, and having an average length of no more than 10 cm;

(b) mixing the ingredients to a substantially uniform suspension;

(c) refining the mixed suspension by:

(1) breaking apart at least some of the fibrous meta-aramid material pieces, and cutting and/or masticating at least some of the meta-aramid material, into fibril free, meta-aramid particles; or

(2) fibrillating, cutting and masticating at least some of the para-aramid fiber to irregularly shaped fibrillated fibrous structures;

(d) combining ingredients including the refined suspension, the second material of the group of (a) (1 and 2), and water, if necessary, to increase the water concentration to 95-99 wt % of the total ingredients;

(e) mixing the ingredients, if necessary, to form a substantially uniform slurry;

(f) co-refining the slurry by simultaneously:

(1) breaking apart at least some of the fibrous meta-aramid material pieces and/or cutting and/or masticating at least some of the meta-aramid material, such that all or substantially all of the fibrous meta-aramid material pieces are converted into fibril free, meta-aramid particles; and

(2) fibrillating, cutting and masticating at least some of the para-aramid fiber such that all or substantially all of the para-aramid fiber is converted to irregularly shaped fibrillated fibrous structures; and

(3) dispersing all solids such that the refined slurry is substantially uniform; and

(g) removing water from the refined slurry to no more than 60 total wt % water, thereby producing a meta- and para-aramid pulp with the para-aramid fibrous structures contacting and wrapped partially around at least some of the meta-aramid particles.

5. The process of claim 4 , wherein the fibrous meta-aramid material comprises pieces of fibrous meta-aramid paper which comprise paper components including:

(i) meta-aramid fiber being 5 to 97 wt % of the paper, and having a linear density of 1 to 10 dtex and a length of 2 to 25 mm; and

(ii) non granular, fibrous or film-like, meta-aramid fibrids being 95 to 3 wt % of the paper, and having an average maximum dimension of 0.2 to 1 mm, an aspect ratio of 5:1 to 10:1, and a thickness of no more than 1 micron.

6. The process of claim 4 , wherein the ingredients further comprise:

substantially or completely fibril-free, granular, para-aramid particles being no more than 50 wt % of the total solids in the ingredients, and having an average maximum dimension of 50 to 2000 microns; and in either the first or second refining step, masticating at least some of the para-aramid particles into smaller, rounder, substantially fibril-free, particles, whereby in the produced meta- and para-aramid pulp, the para-aramid fibrous structures contact and are wrapped partially around at least some of the rounder, substantially fibril-free, para-aramid particles.