Fiber mat and process of making same

Abstract

A fiber mat of improved tensile strength and a process of making same is disclosed. The fiber mat comprises: fibers; a resinous fiber binder; and a binder modifier comprising a dibasic unsaturated acid.

1 . A fiber mat for use in a building material, said mat comprising: 
 a plurality of fibers;    a resinous fiber binder coating said fibers; and    a binder modifier comprising a carboxylic acid.    
     
     
         2 . The fiber mat of  claim 1 , wherein said resinous fiber binder comprises a formaldehyde type binder.  
     
     
         3 . The fiber mat of  claim 2 , wherein said formaldehyde type binder is selected from the group consisting of: a urea/formaldehyde binder, a phenol/formaldehyde binder, and a melamine/formaldehyde binder.  
     
     
         4 . The fiber mat of  claim 1 , wherein the concentration of said fibers in said mat is between about 55 wt. % and about 98 wt. %.  
     
     
         5 . The fiber mat of  claim 1 , wherein said fibers comprise glass fibers.  
     
     
         6 . The fiber mat of  claim 1 , wherein the carboxylic acid is maleic acid or citric acid.  
     
     
         7 . The fiber mat of  claim 1 , wherein the carboxylic acid is selected from the group consisting of: formic acid, acetic acid, propionic acid, benzoic acid, butyric acid, acrylic acid, lactic acid, glycolic acid malic acid, all amino acids, oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, and salicylic acid.  
     
     
         8 . The fiber mat of  claim 7 , wherein said formaldehyde type binder is selected from the group consisting of: a urea/formaldehyde binder, a phenol/formaldehyde binder, and a melamine/formaldehyde binder.  
     
     
         9 . The fiber mat of  claim 6 , wherein the concentration of said fibers in said mat is between about 55 wt. % and about 98 wt. %.  
     
     
         10 . The fiber mat of  claim 6 , wherein said fibers comprise glass fibers.  
     
     
         11 . The fiber mat of  claim 1  further comprising of a secondary binder modifier selected from the group of polyurethane, styrenebutadiene, and acrylic.  
     
     
         12 . A fiber mat for use in a building material, comprising: 
 a plurality of glass fibers; and    a fixative composition comprising a fiber binder and between about 0.05 wt. % and about 20 wt. % binder modifier, based on the weight of the binder, wherein the binder modifier comprises a carboxylic acid.    
     
     
         13 . The fiber mat of  claim 12 , wherein the concentration of the fiber binder, based on the weight of the fibrous mat, is in the range of from about 5 wt. % and about 30 wt. %.  
     
     
         14 . The fiber mat of  claim 12 , wherein said glass fibers comprise a plurality of glass filaments having an average length of from about 0.25 to about 3 inches and a diameter of from about 5 to about 50 micrometers.  
     
     
         15 . The fiber mat of  claim 14 , wherein the concentration of said glass filaments is between about 55 and about 98 wt. %.  
     
     
         16 . The fiber mat of  claim 12 , wherein said fiber binder comprises a formaldehyde type binder selected from the group consisting of: a urea/formaldehyde binder, a phenol/formaldehyde binder, and a melamine/formaldehyde binder.  
     
     
         17 . The fiber mat of  claim 12 , wherein the carboxylic acid is maleic acid or citric acid.  
     
     
         18 . The fiber mat of  claim 17 , wherein the concentration of the fiber binder, based on the weight of the fibrous mat, is in the range of from about 5 wt. % and about 30 wt. %.  
     
     
         19 . The fiber mat of  claim 17 , wherein said glass fibers comprise a plurality of glass filaments having an average length of from about 0.25 to about 3 inches and a diameter of from about 5 to about 50 micrometers.  
     
     
         20 . The fiber mat of  claim 17 , wherein the concentration of said glass filaments is between about 55 and about 98 wt. %.  
     
     
         21 . The fiber mat of  claim 17 , wherein said fiber binder comprises a formaldehyde type binder selected from the group consisting of: a urea/formaldehyde binder, a phenol/formaldehyde binder, and a melamine/formaldehyde binder.  
     
     
         22 . The fiber mat of  claim 12 , wherein the carboxylic acid is selected from the group consisting of: formic acid, acetic acid, propionic acid, benzoic acid, butyric acid, acrylic acid, lactic acid, glycolic acid malic acid, all amino acids, oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, and salicylic acid.  
     
     
         23 . The fiber mat of  claim 12  further comprising of a secondary binder modifier selected from the group of polyurethane, styrenebutadiene, and acrylic.  
     
     
         24 . A process of making a fiber mat for use in a building material, said process comprising the steps of: 
 (a) forming an aqueous fiber slurry;    (b) removing water from the fiber slurry to form a wet fiber mat;    (c) saturating the wet fiber mat with an aqueous solution of a fiber binder; (d) spraying the wet fiber mat with a binder modifier comprising a carboxylic acid, and    (d) drying and curing the wet fiber mat to form a fiber mat product.    
     
     
         25 . The process of  claim 24 , wherein the aqueous fiber slurry further comprises a fiber dispersing agent.  
     
     
         26 . The process of  claim 24 , wherein the binder modifier is maleic acid or citric acid.  
     
     
         27 . The process of  claim 24 , wherein the binder modifier is selected from the group consisting of: formic acid, acetic acid, propionic acid, benzoic acid, butyric acid, acrylic acid, lactic acid, glycolic acid malic acid, all amino acids, oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, and salicylic acid.  
     
     
         28 . The process of  claim 24 , wherein the aqueous fiber slurry further comprises a fiber dispersing agent.  
     
     
         29 . The process of claim of  claim 24 , wherein the binder modifier further comprises of a secondary binder modifier selected from the group of polyurethane, styrenebutadiene, and acrylic.