Glass fiber mat with low-density fibers
A binder composition for use in the manufacture of a nonwoven mat including a low-density fiber, and nonwoven mats made with the binder, are disclosed. The low-density fiber is able to reduce the acoustic openness of the nonwoven mats made therefrom while also capable of being delivered with existing binder technology and equipment.
1. A curable composition for an article made of nonwoven fibers, the curable composition comprising:
water;
a binder component; and
a plurality of low-density fibers;
wherein the plurality of low-density fibers have an average length of 50 microns to 1 mm and an average diameter of 0.5 to 20 micron,
wherein the plurality of low-density fibers are present in an amount of 0.01% to 25% by weight of the curable composition
wherein the binder component is selected from the group consisting of acrylic binders, urea-formaldehyde binders (UF), polyvinyl alcohol, polyvinylacetate, carbohydrate-based binders, and combinations thereof.
2. The curable composition of claim 1 , wherein the plurality of low-density fibers are selected from the group consisting of microfibrillated cellulose (MFC), carbon fibers, mica, micro-clay, micro-HBN, kevlar micropulp, and combinations thereof.
3. The curable composition of claim 1 , wherein the plurality of low-density fibers have an average length of 200 microns to 1 mm.
4. The curable composition of claim 1 , wherein the plurality of low-density fibers have an average diameter of 0.5 to 1 micron.
5. The curable composition of claim 1 , wherein the plurality of low-density fibers are present in an amount of 5% to 25% by weight of the curable composition.
6. A nonwoven article comprising:
a nonwoven web layer having a first major surface and a second major surface defining a thickness therebetween, wherein said nonwoven web layer comprises:
a plurality of inorganic fibers present in an amount of 50% to 90% by weight of the nonwoven article, and
a plurality of low-density fibers present in an amount of 0.01% to 10% by weight of the nonwoven article,
wherein the low-density fibers are present in the nonwoven web layer as a gradient that decreases from the first major surface through at least a portion of the thickness of the nonwoven web layer.
7. The nonwoven article of claim 6 , wherein the inorganic fibers are glass fibers.
8. The nonwoven article of claim 6 , wherein the plurality of low-density fibers are selected from the group consisting of microfibrillated cellulose (MFC), carbon fibers, mica, micro-clay, micro-HBN, kevlar micropulp, and combinations thereof.
9. The nonwoven article of claim 6 , wherein the plurality of low-density fibers have an average length of 50 microns to 1 mm.
10. The nonwoven article of claim 6 , wherein the plurality of low-density fibers have an average diameter of less than 1 micron.
11. A method of forming the nonwoven article of claim 6 , the method comprising:
mixing glass fibers having a discrete length in a dispersion substrate;
depositing the glass fibers on a processing line to form a wet laid mat having a first major surface and a second major surface;
applying a binder composition to at least one of the first major surface and the second major surface; and
allowing the binder composition to cure to form a nonwoven mat,
wherein the binder composition comprises a binder component and at least one low-density fiber.
12. The method of claim 11 , wherein the binder component is selected from the group consisting of acrylic binders, urea-formaldehyde binders (UF), polyvinyl alcohol, polyvinylacetate, carbohydrate-based binders, and combinations thereof.
13. The method of claim 11 , further comprising application of at least one additional material to a major surface of the nonwoven article, wherein the at least one additional material enhances a property selected from: electrical conductivity/resistance, flexibility, durability, weathering, moisture repellency, corrosion resistance, rigidity, porosity, aesthetics, fire or smoke resistance, puncture resistance, tensile strength, tear strength, and combinations thereof.
14. A composite panel comprising:
a substrate; and
a nonwoven article having a first major surface and a second major surface defining a thickness therebetween, wherein said nonwoven article comprises:
a plurality of inorganic fibers present in an amount of 60% to 80% by weight of the nonwoven article, and
a plurality of low-density fibers present in an amount of 0.01% to 5% by weight of the nonwoven article,
wherein the low-density fibers are present in the nonwoven article as a gradient that decreases from the first major surface through at least a portion of the thickness of the nonwoven article.
15. The composite panel of claim 14 , wherein the plurality inorganic fibers are glass fibers.
16. The composite panel of claim 14 , wherein the plurality of low-density fibers is selected from the group consisting of microfibrillated cellulose (MFC), carbon fibers, mica, micro-clay, micro-HBN, kevlar micropulp, and combinations thereof.
17. The composite panel of claim 14 , wherein the plurality of low-density fibers have an average length of 50 microns to 1 mm.
18. The composite panel of claim 14 , wherein the plurality of low-density fibers have an average diameter of less than 1 micron.
19. The composite panel of claim 14 , wherein the substrate is selected from gypsum, a foam, or combinations thereof.