Elastomeric coating composition for glass fibers and coated glass fibers made from same

Claim 2

Glass fiber strand coated with the dried residue of an elastomeric coating composition for glass fibers to yield coated glass fiber strands of medium thickness having improved weaveability by having an increased knot tensile strength, wherein the aqueous elastomeric coating composition, comprises: (a) an elastomeric latex in an amount in the range of about 30 to about 70 weight percent on a dry solids basis of the composition, (b) an external plasticizer soluble, dispersible or emulsifiable into the latex but not incorporable into the polymer backbone of the elastomer in an amount in the range of about 10 to about 50 weight percent on a dry solids basis of the composition, (c) an antioxidant for elastomeric latices in an amount in the range of about 0.05 to about 2 weight percent on a dry solids basis of the coating composition, (d) an elastomeric latex curing agent in an amount in the range of about 0.3 to about 2.5 weight percent on a dry solids basis of the coating composition, (e) water in an amount sufficient to obtain a percent solids of the coating composition to allow for coating the glass fiber strand.

Claim 3

Coated glass fiber strand according to claim 1 wherein the strand has an amount of the aqueous elastomeric coating in the range of about 8 to about 20 weight percent pickup.

Claim 4

Coated glass fiber strand according to claim 1 wherein the elastomer is selected from the group consisting of butadiene-styrene latices and carboxylated derivatives thereof and neoprene and mixtures thereof.

Claim 5

Coated glass fiber strand according to claim 3 wherein a portion of butadiene-styrene latex is replaced with a less conductive butadiene-styrene latex.

Claim 6

Coated glass fiber strand according to claim 1 wherein one or more emulsifiers are added to the composition to emulsify the plasticizer.

Claim 7

Coated glass fiber strand according to claim 5 wherein the emulsifiers are non-ionic emulsifiers selected from the group consisting of ethylene oxide derivatives of sorbitol esters.

Claim 8

The coated glass fiber strand according to claim 1 wherein the antioxidant is a polymeric hindered phenol.

Claim 9

Coated glass fiber strand according to claim 1 wherein the filler is added in an amount in the range of about 0.1 to about 15 weight percent on a dry solids basis of the coating.

Claim 10

Coated glass fiber strand according to claim 8 wherein the filler is dextrin.

Claim 11

Coated glass fiber strand according to claim 1 wherein a melamine formaldehyde polymer is added to the coating in an amount in the range of about 0.1 to about 5.0 weight percent of the coating.

Claim 12

Coated glass fiber strand according to claim 10 wherein the melamine aldehyde polymer is a melamine formaldehyde polymer.

Claim 13

Coated glass fiber strand according to claim 11 wherein the melamine aldehyde polymer is a hexamethoxymethylolmelamine.

Claim 14

Coated glass fiber strand according to claim 1 wherein the curing agent is sulfur dispersion.

Claim 15

Coated glass fiber strand according to claim 1 wherein an elastomeric latex accelerator is in an amount in the range of about 0.01 to about 1.5 weight percent of the coating on a dry solids basis.

Claim 16

Coated glass fiber strand according to claim 14 wherein the accelerator is mercaptobenzothiozole.

Claim 17

Glass fiber strand coated with the dried residue of an elastomeric coating composition for glass fibers to yield coated glass fiber strands of medium thickness having improved weaveability by having increased knot tensile strength, wherein the aqueous elastomeric coating composition, comprises: (a) a butadiene-styrene latex in the range of about 30 to about 70 weight percent of the coating composition on a dry solids basis, (b) a light petroleum oil plasticizer emulsion in an amount in the range of about 10 to about 66 weight percent of the coating composition on a dry solids basis and comprising: (1) a light petroleum oil external plasticizer in an amount in the range of about 10 to about 50 weight percent on a dry solids basis of the coating composition, and (2) one or more emulsifying agents of the group consisting of polyoxyethylene sorbitan monolaurate and polyoxyethylene sorbitan trioleate and mixtures thereof in an amount of about 1 to about 16 weight percent on a dry solids basis of the coating composition, (c) a polymeric hindered phenol antioxidant in an amount in the range of about 0.05 to about 2 weight percent of the coating on a dry solids basis, (d) a filler in an amount in the range of about 0.1 to about 1.5 weight percent of the coating composition on a dry solids basis, (e) melamine formaldehyde resin in an amount in the range of about 0.1 to about 5.0 weight percent of the coating on a dry solids basis, (f) a sulfur dispersion in an amount in the range of about 0.3 to about 2.5 weight percent of the coating composition on a dry solids basis, (g) mercaptobenzothiozole in an amount in a range of about 0.01 to about 1.5 weight percent of the coating composition on a dry solids basis, and (h) water in sufficient amounts to bring the percent solids of the coating composition in the range of about 10 percent to about 40 weight percent.

Claim 18

Glass fiber strand coated with the dried residue of an elastomeric coating composition for glass fibers to yield coated glass fiber strands of medium thickness having improved weaveability by having increased knot tensile strength, wherein the aqueous elastomeric coating composition, comprises: (a) a butadiene-styrene latex in the range of about 30 to about 70 weight percent of the coating composition on a dry solids basis, (b) a light petroleum oil plasticizer emulsion in an amount in the range of about 10 to about 66 weight percent of the coating composition on a dry solids basis and comprising: (1) a light petroleum oil external plasticizer in an amount in the range of about 10 to about 50 weight percent on a dry solids basis of the coating composition, and (2) one or more emulsifying agents of the group consisting of polyoxyethylene sorbitan monolaurate and polyoxyethylene sorbitan trioleate and mixtures thereof in an amount of about 1 to about 16 weight percent on a dry solids basis of the coating composition, (c) a polymeric hindered phenol antioxidant in an amount in the range of about 0.05 to about 2 weight percent of the coating on a dry solids basis, (d) a filler in an amount in the range of about 0.1 to about 1.5 weight percent of the coating composition on a dry solids basis, (e) melamine formaldehyde resin in an amount in the range of about 0.1 to about 5.0 weight percent of the coating on a dry solids basis, (f) a sulfur dispersion in an amount in the range of about 0.3 to about 2.5 weight percent of the coating composition on a dry solids basis, (g) mercaptobenzothiozole in an amount in a range of about 0.01 to about 1.5 weight percent of the coating composition on a dry solids basis, and (h) water in sufficient amounts to bring the percent solids of the coating composition in the range of about 10 percent to about 40 weight percent.

Claim 19

Coated glass fiber strand according to claim 16 wherein the strand has an amount of the aqueous elastomeric coating in the range of about 8 to about 20 weight percent pickup.

Claim 20

The coated glass fiber strand according to claim 1 or 16 wherein the strand is comprised of glass fibers produced by drawing glass filaments from molten cones of glass at a high rate of speed, applying to the filaments during formation an aqueous glass fiber size composition having a film former, and a lubricant, and gathering the filaments into a strand and winding the strand up on a rapidly rotating forming tube and unwinding the strand from the forming tube to be coated with the elastomeric coating composition wherein the filaments have a diameter of around 5.25±0.25×10 -4 inches.

Claim 21

An article of manufacture for use in producing woven carpets that can be used as the weft between which the carpet pile is woven comprising: (a) coated glass fiber strand produced by drawing glass filament from molten cones of glass at a high rate of speed, applying to the filaments during formation an aqueous glass fiber size composition having a film-former, a lubricant, and gathering the filaments into a strand and winding the strand up on a rapidly rotating forming tube and unwinding the strand from the forming tube to be coated with an elastomeric composition, comprising (1) an elastomeric latex in an amount of about 30 to about 70 weight percent on a dry solids basis of the composition, (b) an external plasticizer, soluble, dispersible or emulsifiable into the latex but not incorporatable into the polymer backbone of the elastomer in an amount in the range of about 10 to about 50 weight percent on a dry solids basis of the composition, (c) an antioxidant for elastomeric latices in an amount in the range of about 0.05 to about 2 weight percent on a dry solids basis of the coating composition, (d) an elastomeric latex curing agent in an amount in the range of about 0.3 to about 2.5 weight percent of the coating composition, and (e) water in an amount sufficient to obtain a percent solids on the coating composition to allow for the coating of glass fibers and drying to obtain the dried residue of the elastomeric coating composition.

Claim 22

An article of manufacture for use in producing woven carpets that can be used as the weft between which the carpet pile is woven comprising: (a) coated glass fiber strand produced by drawing glass filament from molten cones of glass at a high rate of speed, applying to the filaments during formation an aqueous glass fiber size composition having a film-former, a lubricant, and gathering the filaments into a strand and winding the strand up on a rapidly rotating forming tube and unwinding the strand from the forming tube to be coated with an elastomeric composition, comprising (1) an elastomeric latex in an amount of about 30 to about 70 weight percent on a dry solids basis of the composition, (b) an external plasticizer, soluble, dispersible or emulsifiable into the latex but not incorporatable into the polymer backbone of the elastomer in an amount in the range of about 10 to about 50 weight percent on a dry solids basis of the composition, (c) an antioxidant for elastomeric latices in an amount in the range of about 0.05 to about 2 weight percent on a dry solids basis of the coating composition, (d) an elastomeric latex curing agent in an amount in the range of about 0.3 to about 2.5 weight percent of the coating composition, and (e) water in an amount sufficient to obtain a percent solids on the coating composition to allow for the coating of glass fibers and drying to obtain the dried residue of the elastomeric coating composition.

Claim 23

The article of claim 19 wherein the glass filaments have a diameter of around 5.25±0.25×10 -4 inches.