Para-aramid pulp including meta-aramid fibrids and processes of making same

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

(a) combining pulp ingredients including:

(1) never-dried meta-aramid fibrids having an average maximum dimension of 0.2 to 1 mm, a ratio of maximum to minimum dimension of 5:1 to 10:1, and a thickness of no more than 2 micrometers, and being a 10 to 90 weight percent of the total solids in the ingredients;

(2) para-aramid fiber being 10 to 90 weight percent 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 weight percent of the total ingredients;

(b) mixing the ingredients to a substantially uniform slurry, wherein random samples of the slurry contain the same wt % of the concentration of each of the starting ingredients as in the total ingredients in the combination step plus or minus 10 wt %

(c) co-refining the slurry by simultaneously:

(1) shearing and/or masticating the meta-aramid fibrids into fibril-free refined meta-aramid fibrids having an average maximum dimension of 0.1 to 0.5 mm;

(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,

thereby producing a meta- and para-aramid pulp with the para-aramid fibrous structures contacting and wrapped partially around at least some of the refined meta-aramid fibrids.

2. The process of claim 1 , wherein in the combining step, the never-dried meta-aramid fibrids are 25 to 60 weight percent of the total solids.

3. The process of claim 1 , wherein in the combining step, the irregularly shaped, para-aramid, fibrous structures are 40 to 75 weight percent of the total solids.

4. The process of claim 1 , wherein after the removing step, the pulp has a Canadian Standard Freeness (CSF) of 100 to 700 ml.

5. The process of claim 1 , wherein the refining step comprises passing the mixed slurry through a series of disc refiners.

6. The process of claim 1 , wherein after the removing step, the meta-aramid refined fibrids and the masticated irregularly shaped para-aramid fibrous structures have a length weighted average length of no more than 1.3 mm.

7. A process for making a para-aramid pulp including meta-aramid fibrids for use as reinforcement material, comprising:

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

(1) never-dried meta-aramid fibrids having an average maximum dimension of 0.2 to 1 mm, a ratio of maximum to minimum dimension of 5:1 to 10:1, and a thickness of no more than 2 micrometers and being 10 to 90 weight percent of the total solids in the pulp; and

(2) para-aramid fiber being 10 to 90 weight percent 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, wherein random samples of the slurry contain the same wt % of the concentration of each of the starting ingredients as in the total ingredients in the combination step plus or minus 10 wt %;

(c) refining the mixed suspension by:

(1) shearing and/or masticating at least some of the meta-aramid fibrids; 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 weight percent of the total ingredients;

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

(f) co-refining the slurry by simultaneously:

(1) shearing and/or masticating at least some of any remaining never-dried meta-aramid fibrids 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 micrometers, such that all or substantially all of the never-dried meta-aramid fibrids are size-reduced into fibril free, meta-aramid refined fibrids having an average maximum dimension of 0.1 to 0.5 mm 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,

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 refined fibrids.

8. The process of claim 7 , wherein after the removing step, the meta-aramid refined fibrids are about 25 to 60 weight percent of the total solids.

9. The process of claim 7 , wherein after the removing step, the irregularly shaped, para-aramid, fibrous structures are 40 to 75 weight percent of the total solids.

10. The process of claim 7 , wherein the first refining step comprises passing the mixed suspension through a first disc refiner and the second refining step comprises passing the mixed slurry through a second disc refiner.

11. The process of claim 7 , wherein after the removing step, the meta-aramid refined fibrids and the irregularly shaped para-aramid fibrous structures having a length weighted average length of no more than 1.3 mm.