Fiber mat and process for making same

Abstract

A fiber mat comprises fibers; a resinous fiber binder; and a binder modifier which is a functional silane monomer or polymer.

1 . A fiber mat comprising a plurality of fibers, a resinous fiber binder, said fibers fixedly distributed in said binder; and a binder modifier which is a functional silane monomer or polymer, in an amount of 0.1 wt. % to 50 wt. %, based on the weight of said binder.  
     
     
         2 . A fiber mat of  claim 1 , wherein said binder modifier contains an amino, epoxy vinyl, methacryloxy, mercapto, isocyanates, glycidoxy or uveido functionality.  
     
     
         3 . A fiber mat of  claim 2  wherein said functionality is an amino functionality.  
     
     
         4 . A fiber mat of  claim 3  wherein said aminosilane is a homopolymer.  
     
     
         5 . A fiber mat of  claim 3  wherein said aminosilane is a diaminofunctional silane monomer.  
     
     
         6 . A fiber mat of  claim 1 , wherein said resinous fiber binder comprises a formaldehyde type binder.  
     
     
         7 . A fiber mat of  claim 6 , wherein said formaldehyde type binder is selected from the group consisting of urea/formaldehyde, a phenol/formaldehyde, and melamine/formaldehyde.  
     
     
         8 . A fiber mat of  claim 1 , wherein the weight ratio of resinous fiber binder to said binder modifier is in the range from 200:1 to 4:1.  
     
     
         9 . A fiber mat of  claim 1 , wherein said mat contains 55 wt. % to 98 wt. % of fibers and 0.05 wt. % to 45 wt. % of resinous fiber binder.  
     
     
         10 . A fiber mat of  claim 1 , wherein said fibers are glass fibers.  
     
     
         11 . A fiber mat of  claim 1 , wherein said mat contains 55 wt. % to 98 wt. % glass fibers and 15 wt. % to 30 wt. % of resinous fiber binder.  
     
     
         12 . A binder composition comprising a resinous fiber binder and a binder modifier which is a functional silane monomer or polymer.  
     
     
         13 . A binder composition of  claim 12 , wherein said binder modifier contains an amino, epoxy vinyl, methacryloxy, mercapto, isocyanates, glycidoxy or uveido functionality.  
     
     
         14 . A binder composition of  claim 12  wherein said binder modifier contains an amino functionality.  
     
     
         15 . A binder composition of  claim 12  wherein said binder modifier is an aminosilane homopolymer.  
     
     
         16 . A binder composition of  claim 12  wherein said binder is an aminosilane is a diaminofunctional silane monomer.  
     
     
         17 . A binder composition of  claim 12 , wherein the weight ratio of said resinous fiber binder to said binder modifier is 200:1 to 4:1.  
     
     
         18 . A binder composition of  claim 12 , wherein said resinous fiber binder is a formaldehyde type binder.  
     
     
         19 . A binder composition of  claim 18 , 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.