Corrosion-resistant non-woven for pipe liner pultrusion applications
A non-woven chopped fiber mat includes a mixture of glass fibers and synthetic fibers. The non-woven mat is formed using a binder composition that includes a binder resin, a coupling agent, and a corrosion inhibitor. The non-woven mat is non-corrosive and resistant to volatile unsaturated monomers such as styrene, but still remains fully compatible with solvent-containing polyester resins, such that it can be used in various pultruded products.
1. A pultruded composite product comprising:
at least one roving impregnated with a thermosetting resin; and
a non-woven mat comprising:
at least one of glass fibers and synthetic fibers; and
a binder composition comprising a binder resin, a coupling agent, and a corrosion inhibitor,
wherein the binder composition is non-corrosive,
wherein the binder resin comprises a thermoset material, a thermoplastic material, or a combination thereof, and
wherein the non-woven mat exhibits a tensile strength of at least 1.0 lb/ft after being soaked in a 100% styrene monomer for 10 minutes.
2. The pultruded composite product of claim 1 , wherein the plurality of reinforcing fibers is glass fibers.
3. The pultruded composite product of claim 1 , wherein the plurality of reinforcing fibers is a mixture of chopped glass fibers and synthetic fibers.
4. The pultruded composite product of claim 3 , wherein the non-woven mat comprises from 10.0 to 100 wt. % of the chopped glass fibers and from 0 to 90.0 wt. % of the synthetic fibers.
5. The pultruded composite product of claim 1 , wherein the corrosion inhibitor is an organic corrosion inhibitor.
6. The pultruded composite product of claim 1 , wherein the corrosion inhibitor is triethanolamine.
7. The pultruded composite product of claim 1 , wherein the corrosion inhibitor is present in the binder composition from 0.05 to 15.0 wt. %, based on the total solids in the binder composition.
8. The pultruded composite product of claim 1 , wherein the binder composition further comprises a defoamer.
9. The pultruded composite product of claim 8 , wherein the defoamer is present in the binder composition from 0.01 to 10.0 wt. %, based on the total solids in the binder composition.
10. The pultruded composite product of claim 1 , wherein the coupling agent comprises a silane coupling agent.
11. The pultruded composite product of claim 1 , wherein the coupling agent is present in the binder composition from 0.05 to 10.0 wt. %, based on the total solids in the binder composition.
12. The pultruded composite product of claim 1 , wherein the thermoset material comprises at least one of an acrylic material and a urea formaldehyde material.
13. The pultruded composite product of claim 12 , wherein the acrylic material is polyacrylic acid.
14. The pultruded composite product of claim 13 , wherein the polyacrylic acid has a molecular weight at or below 10,000.
15. The pultruded composite product of claim 1 , wherein the thermoplastic material comprises ethylene vinyl acetate.
16. The pultruded composite product of claim 1 , wherein the binder resin comprises from 50.0 to 100 wt. % of the thermoplastic material and from 0 to 50.0 wt. % of the thermoset material, based on the total binder resin.
17. The pultruded composite product of claim 1 , wherein the binder resin comprises from 70.0 to 85.0 wt. % of the thermoplastic material and from 15.0 to 30.0 wt. % of the thermoset material, based on the total binder resin.
18. The pultruded composite product of claim 1 , wherein the non-woven mat exhibits a tensile strength of at least 2.5 lbs/ft after being soaked in the 100% styrene monomer for 10 minutes.
19. The pultruded composite product of claim 1 , wherein the non-woven mat does not exhibit any fiber whitening after curing, as compared to an otherwise identical non-woven mat without the corrosion inhibitor.
20. A pultruded composite product comprising:
at least one roving impregnated with a thermosetting resin; and
a non-woven mat comprising:
at least one of glass fibers and synthetic fibers; and
a binder composition comprising a binder resin, a silane coupling agent, a defoamer, and an organic corrosion inhibitor,
wherein the binder composition is non-corrosive,
wherein the binder resin comprises a thermoset material, a thermoplastic material, or a combination thereof,
wherein the thermoset material comprises at least one of an acrylic material and a urea formaldehyde material, and
wherein the non-woven mat exhibits a tensile strength of at least 1.0 lb/ft after being soaked in a 100% styrene monomer for 10 minutes.