Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – At least one aryl ring which is part of a fused or bridged...
Patent
1997-01-28
1998-12-22
Cain, Edward J.
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
At least one aryl ring which is part of a fused or bridged...
524494, 524541, 524542, C08L 5100
Patent
active
058521020
DESCRIPTION:
BRIEF SUMMARY
This application is a 371 of PCT/EP95/01643 filed Apr. 29, 1995.
FIELD OF THE INVENTION
The invention relates to a special binder composition for preparing fibre mats and a method for its preparation. The prepregs produced from the fibre mats and binders are also described.
BACKGROUND OF THE INVENTION
Moulded articles based on fibre mats are used extensively in industry. These consist of a matting made of fibres of various kinds which can be mixed with binder. Intermediates can then be produced from these fibre mats, so-called prepregs, which are then moulded with the appropriate processing mould, cured and optionally backed. Likewise, it is also possible to prepare corresponding continuous fibre mats directly from the fibres and binder powders. These moulded articles or sheet products are used in a wide range of areas. In the automobile industry, for example, these products are used as moulded articles, e.g. as insulating material for engine bonnets, as wheel arches or as boot insulation. Another field of use is application as sheet products, e.g. as insulation in washing machines, tumble-driers or loud speakers, in sound-absorbing walls. They may also be provided with further coatings, e.g. by flock spraying, backing or laminating. These moulded articles or sheet parts thus provided with an optically stable and decorative surface coating can then be used e.g. as door side panels, as rear parcel shelves or as roof panels in the automobile industry.
The methods for preparing fibre mats and for mixing these mats with binder powder are known. In these, the fibrous material is homogenised, e.g. in a fibre mixing chamber, and laid out as a loose fibrous layer on a conveyer belt.
The binder mixture is then applied to the fibrous material, e.g. with feed rolls or vibrating chutes. Then the fibre/binder mixture is swirled using a current of air in a sealed system and homogenously mixed. The homogeneous mixture of fibres and binder powder is laid out to give a continuous mat. The components in this mixture may then either be stuck together by slightly warming and then cooling, wherein prepregs are produced, or produced as sheet or rolled up products which are already fully cured. The prepregs are not finally cured but they are storage-stable. After processing in the final mould, these prepregs are thermally cross-linked under the effects of heat, at up to 210.degree. C., wherein three-dimensional thermoset moulded articles are obtained.
The demands placed on these moulded articles with respect to surface structure and colour are variable, but adequate mechanical stability must be provided at elevated temperature or under long-term stress. A binder must be used when preparing them, however, which binds together the fibre mats used so well that a stable moulded article is obtained after the final moulding and curing procedures. The binders currently used are relatively expensive. In addition, phenol resins are hazardous to health. The industry is extremely interested in reducing the costs. Alternatives to the expensive, technically pure resins are being sought in particular for the moulded articles described above such as insulating materials for car bonnets, for wheel arches and for other insulating materials.
SUMMARY OF THE INVENTION
The present invention provides a binder mixture for producing fibre matting moulded articles in which a considerable part of the conventionally used pure resins can be replaced by another component which nevertheless leads to stable, reactive binder mixtures which are suitable for producing fibre matting prepregs or cured fibre mats. The invention also provides a reduction in the proportion of substances hazardous to health. These binder mixtures have to satisfy the conventional requirements for the production of fibre matting moulded articles and thus produce cured, stable moulded articles which can be adapted to a wide variety of applications.
It has been shown that this object can be achieved by the use of powder coating waste as or in binders for producing moulded article
REFERENCES:
International Search Report
Cain Edward J.
Teodur N.V.
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