Claims
- 1. A process for producing a resin composition with wet-laid nonwoven mat comprising the steps of;providing a slurry of glass fibers and polymeric binder to form a resin composition; dewatering the slurry to form a base mat; heating the base mat to fuse the polymeric binder to the glass fibers; saturating the mat with the secondary water-based binder, wherein said secondary binder is soluble in or plasticized by said resin composition; removing excess water from the saturated mat; drying and curing the mat to form a finished nonwoven mat; and plasticizing or dissolving said secondary water-based binder of said finished nonwoven mat in said resin composition.
- 2. A process according to claim 1 wherein the polymeric binder includes vinyl chloride polymer.
- 3. The process according to claim 2, wherein the vinyl chloride polymer is a powder having a particle size of about 50 to about 250 μm.
- 4. A process according to claim 1 wherein the polymeric binder includes bicomponent binder fibers with a polyolefin sheath and polyester core.
- 5. A process according to claim 1 wherein the slurry additionally contains poly(vinyl alcohol) powder or fiber.
- 6. A process according to claim 1 wherein the secondary binder is selected from the group consisting of acrylic copolymers, styrene-acrylic copolymers, vinyl acetate-acrylic copolymers, styrene-butadiene copolymers, vinyl acetate-ethylene copolymers, and vinyl acetate homopolymers.
- 7. A process according to claim 1 wherein the secondary binder is a styrene-acrylate copolymer.
- 8. A process according to claim 1 wherein the secondary binder is a styrene-butadiene copolymer.
- 9. A process according to claim 1 wherein the secondary binder is a vinyl acetate-ethylene copolymer.
- 10. A process according to claim 1 wherein the steps of applying the secondary water-based binder to the mat; removing excess water from the saturated mat; and drying and curing the mat to form a finished nonwoven mat are performed in an off-line process.
- 11. The process of claim 1, further comprising the step of applying polymeric binder powder directly to said mat prior to curing said mat.
CROSS-REFERENCE TO RELATED APPLICATION
This application is a division of application Ser. No. 09/231,068, filed Dec. 16, 1998, now U.S. Pat. No. 6,267,843 which is a continuation of Ser. No. 08/619,785, filed Mar. 20, 1996, abandoned the contents of which are incorporated herein by reference.
US Referenced Citations (31)
Foreign Referenced Citations (2)
Number |
Date |
Country |
1154753 |
Apr 1958 |
FR |
9735056 |
Sep 1997 |
WO |
Non-Patent Literature Citations (1)
Entry |
Parrinello, Nonwovens Conference, Fiber Geometry Effects on Physical Properties of Chopped Fiber Composites, (Jan. 10, 1990). |
Continuations (1)
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Number |
Date |
Country |
Parent |
08/619785 |
Mar 1996 |
US |
Child |
09/213068 |
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US |