CROSS-REFERENCE TO THE RELATED APPLICATION The present application claims the benefit of the provisional patent application Ser. No. 61/739,376, filed Dec. 19, 2012, which is incorporated herein by reference.
BACKGROUND The subject matter disclosed herein relates generally to non-woven matrices and, more particularly, to cotton shoddy and/or natural fiber matrices and systems and methods for producing cotton shoddy matrices.
Commercially available technology exists today for the purpose of applying liquids to a non-woven matrix, such as a matrix constructed from natural fiber and/or cotton shoddy. One technology includes dipping a continuous feed of a non-woven matrix into a tank of emulsion resin, then squeezing the resin-saturated matrix to remove excess content, while a second technology includes converting emulsion resin into a dense foam using a foam generating system, and injecting the foam into the matrix under pressure using a specially designed application head made for this purpose. While both of these technologies may work to some degree for certain natural fiber non-woven matrices, neither is well suited to resin-saturate cotton shoddy.
Several disadvantages exist with conventional foam injection processes. Foam injection requires a continuous feed of a non-woven matrix. After foam is injected into the non-woven matrix, the non-woven matrix is cut to appropriate size requirements and dried prior to final processing. Further, foam injection requires a wider matrix than an actual foam application area. This excess material provides an edge seal to prevent foam from escaping from an edge area of the continuously moving matrix during foam impregnation. This process does not allow the recycling of the excess of material after cutting to size before resin impregnation. In addition, only one side of the continuously feed matrix can be injected with foam having a certain desired uniformity of application. This, therefore, requires two passes of the non-woven matrix through the foam injection applicator in order to completely resonate the non-woven matrix. Foam injection also tends to be expensive. Capital costs are higher, process application of resonating matrix is slower, and therefore this is an undesirable means of applying a liquid resin into non-woven matrix.
Several disadvantages also exist with conventional dip and squeeze processes. The conventional dip and squeeze process is often undesirable because of problems associated with accuracy of application. However, dip and squeeze may have a better throughput capability than conventional foam injection processes. Similar to the foam injection process, conventional dip and squeeze technology requires the product to be run using a continuous feed of non-woven matrix. It does not allow the recycling of the excess material after cutting to size before resin impregnation.
It is desirable to develop an application system that utilizes the simplicity of a dip and squeeze process or applying the resin on a scrim and then laminating the scrim on a matrix made of thermoplastic and cotton shoddy and/or natural fibers, and achieves the accuracy results of a foam injection process, while doing so with a feed of precut matrix blanks as opposed to roll goods required for existing technology.
SUMMARY In one aspect, a process system incorporates a modified dip and squeeze process system combined with a modified injection system that pumps non-foam resin directly into a non-woven matrix while the non-woven matrix remains substantially submerged in a resin contained within a resin tank.
In another aspect, a method for producing cotton shoddy and/or natural fiber matrices includes a modified dip and squeeze process combined with a modified injection process that pumps non-foam resin directly into the non-woven matrix while the non-woven matrix remains substantially submerged in a resin contained within a resin tank.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic view of an exemplary device for impregnating a matrix blank with a resin;
FIG. 2A is a schematic view of the device shown in FIG. 1, with the framing and support structure removed for clarity;
FIG. 2B is a schematic view of an exemplary device for impregnating a matrix blank with a resin including a plurality of compression squeeze rolls;
FIG. 3 is a schematic view of an exemplary application line including the device shown in FIGS. 1 and 2A, coupled to a microwave forced air drying oven; and
FIG. 4 is a schematic view of an exemplary application line including the device shown in FIGS. 1 and 2A, coupled to a hot air drying oven.
DETAILED DESCRIPTION The embodiments described herein are directed to a non-woven matrix, such as a non-phenol formaldehyde cotton shoddy matrix, for example, and a process system for the application of a suitable emulsify resin, such as an Acrodur™ resin available from BASF Aktiengesellschaft Corp., Ludwigshafen am Rhein, Germany, for example, that substantially completely saturates the cotton shoddy matrix through a thickness of the cotton shoddy matrix. In certain embodiments, the process system is scalable to meet any application requirement. In addition and for means of practicality, in certain embodiments the system design intent includes the ability to resonate individual cut sheet sizes without the need for a continuous feed of matrix. This will facilitate recycling the excess of material after cutting to size before resin impregnation.
In the following description, the embodiments are described in relation to a cotton shoddy matrix. This is by way of example only, it being understood that the embodiments may be implemented for use with suitable natural fiber non-woven matrices.
In one embodiment, the process system incorporates a modified dip and squeeze process system combined with a modified injection system that pumps non-foam resin directly into the non-woven matrix while the non-woven matrix remains substantially submerged in a resin contained within a resin tank, as described in greater detail below with reference to FIGS. 1-4. Unlike conventional dip and squeeze systems, the process system described herein allows for the use of precut matrix blanks prior to resonating. In a particular embodiment, the process system includes two open weave, glass fiber belts coated with a Teflon™ coating to carry each matrix blank through the resin application process to significantly reduce the strain on the non-woven matrix blank during saturation, and further reduce or eliminate any tensile pull on the matrix blank during the process, an undesirable affect caused by conventional systems. This system allows to dip and squeeze material in both directions (machine direction and cross-machine direction) which is not reasonably possible in conventional foam injection and continuous dip and squeeze systems.
Resonating cotton shoddy with a liquid resin product is virtually impossible to achieve using existing dip and squeeze technology. A cotton shoddy non-woven matrix does not have sufficient tensile strength to carry the matrix through a conventional dip and squeeze system without tearing under the nominal tensile pulls that are typically exerted on a product during a resin application and post-matrix drying. Additionally, the wet pick up rate (the rate of added weight of resin and water to fully impregnate the cotton shoddy matrix) adds more than 110% additional weight to a pre-resonated matrix weight. The additional weight, in addition to the weak strengths of short fiber cotton shoddy, renders existing technologies impractical to adopt for this purpose.
Referring to FIGS. 1-4, an exemplary process system 10 includes a resin application station 12, a drying station 14 and a palletizing station 16 operatively coupled in series. Referring further to FIGS. 1, 2A and 2B, resin application station 12 includes a tank, such as a stainless steel tank 20 configured to contain a suitable amount of an aqueous solution of a resin material and water. In a particular embodiment, the aqueous solution comprises an Acrodur™ resin and water. A first or lower carrying belt 22 is operatively coupled to and supported by a frame 24. In one embodiment, lower carrying belt 22 is a fiberglass-reinforced, Teflon™ coated open webbing belt, although other belts can be used as lower carrying belt 22. As shown in FIG. 1, frame 24 is a stainless steel construction frame configured to support the associated components of resin application station 12, for example, associated belts, bearings, and drives. Resin application station 12 also includes one or more belt rolls 26 and a fixed compression roll 28 to further support lower carrying belt 22, and a bottom belt drive unit 30 configured to drive lower carrying belt 22 about belt rolls 26. In one embodiment, belt drive unit 30 includes a PLC-controlled, AC inverter drive with gear reductions for lower carrying belt 32, as well as for a cooperating upper carrying belt 32.
In one embodiment, upper carrying belt 32 is a fiberglass-reinforced, Teflon™ coated open webbing belt, as described above with reference to lower carrying belt 22, although other belts can be used as upper carrying belt 32. In other embodiments, upper carrying belt 32 may be the same as or different than lower carrying belt 22. Upper carrying belt 32 is operatively coupled to and supported by stainless steel frame 24, one or more belt rolls 36, and an adjustable compression roll 38. A belt drive unit 40 is configured to drive upper carrying belt 32 about belt rolls 36. In one embodiment, belt drive unit 40 includes a PLC-controlled, AC inverter drive with gear reductions for upper carrying belt 32. Alternatively, belt drive unit 30 may include a PLC-controlled, AC inverter drive with gear reductions for upper carrying belt 32, as well as for lower carrying belt 22.
Referring again to FIG. 1, a level 42 of the aqueous solution is maintained in tank 20 to sufficiently submerge a matrix blank 43, securely positioned between lower carrying belt 22 and upper carrying belt 32, in the aqueous solution. In one embodiment, level 42 is maintained by using a sonic level control device or other suitable level control device, which adds a desired amount of pre-mixed aqueous solution to tank 20 as required.
In one embodiment, electrically-driven screw jacks 44, shown in FIG. 1, are configured to move or urge adjustable compression roll 38 with respect to fixed compression roll 28. In a particular embodiment, screw jacks 44 are activated to move adjustable compression roll 38 to a predetermined point with respect to an outer surface of fixed compression roll 28 to define a gap 46, shown in FIG. 2A, through which lower carrying belt 22 and upper carrying belt 32 carry matrix blank 43 saturated with resin. A gap clearance is adjustable through the activation of screw jacks 44 to set a compression force applied to the saturated matrix blank 43 as matrix blank 43 is carried by lower carrying belt 22 and upper carrying belt 32 through gap 46. As the saturated matrix blank 43 moves continuously through gap 46 under a desired compression force applied by the cooperating adjustable compression roll 38 and fixed compression roll 28, excess resin and water is flushed from the saturated matrix blank 43 providing an impregnated matrix blank 43 having an amount of resin/water solution equal to a total wet pickup required to achieve a desired percentage of resin dry solids add-on. As shown in FIG. 2B, in one embodiment, resin application system 12 includes a plurality of adjustable compression roll sets, such as a series of three adjustable compression roll sets 38A, 38B, and 38C, to facilitate removing excess resin and water from the saturated matrix blank 43.
Referring to FIG. 3, the impregnated matrix blank 43 is transferred from resin application station 12 to drying station 14 by a transfer belt 50. In this embodiment, drying station 14 includes a microwave drying oven 60 having an air suction fan 62 configured to remove water vapor as means to accelerate drying time. Drying oven size depends on dimensions, such as a width, of matrix blanks 43 being dried, as well as a linear flow speed of matrix blanks 43 through drying oven 60. In a particular embodiment, drying oven 60 is a 75 Kw magnetron microwave drying oven capable of drying resonated matrix blanks 43 having a width of 1.5 meters traveling through drying oven 60 at linear flow speed of 5 meters per minute. Microwave drying oven 60, as described herein, provides for an overall size reduction in the line foot print of process system 10 and a reduction in energy cost to remove excess water, for example, when compared with conventional drying stations. Once the impregnated matrix blank 43 is dried, the impregnated matrix blank 43 is transferred from an outlet of drying oven 60 to an automatic stacking device 70 of palletizing station 16 by a dry matrix blank conveyor 72 to form a stack of dry matrix blanks 43.
Alternatively, referring to FIG. 4, the impregnated matrix blank 43 is transferred from resin application station 12 to drying station 14 by a transfer belt 50. In this embodiment, drying station 14 includes a hot air drying oven 80. Like microwave drying oven 60 described above, hot air drying oven size depends on dimensions, such as a width, of matrix blanks 43 being dried, as well as a linear flow speed of matrix blanks 43 through drying oven 60. Once the impregnated matrix blank 43 is dried, the impregnated matrix blank 43 is transferred from an outlet of hot air drying oven 80 to an automatic stacking device 70 of palletizing station 16 by a dry matrix blank conveyor 72 to form a stack of dry matrix blanks 43.
Process system 10 as described with reference to drying station 14 shown in FIGS. 3 and 4 can be utilized with either pre-cut matrix blanks 43 or a matrix roll 82 of desired material, as shown in FIG. 4. With process system 10 operating with matrix roll 82 to supply a continuous feed of material, a guillotine cross-cutter 84 cuts matrix blanks 43 from the continuously fed matrix prior to palletizing, for example, as the continuous feed of matrix material exits drying oven 80 onto conveyor 72, as shown in FIG. 4.
Referring again to FIGS. 1-4, a method for forming impregnated matrix blanks 43 with process system 10 as described herein includes, in one embodiment, placing a precut matrix blank 43 of cotton shoddy, or another suitable fibrous non-woven matrix that will absorb an aqueous resin solution, on a top surface of lower carrying belt 22 coated with a suitable coating, such as a Teflon™ coating. Lower carrying belt 22 moves at a speed equal to a speed at which upper cooperating carrying belt 32 moves. In this embodiment, upper carrying belt 32 is also coated with a suitable coating, such as a Teflon™ coating.
Lower carrying belt 22 and upper carrying belt 32 meet to secure or trap the precut matrix blank 43 between lower carrying belt 22 and upper carrying belt 32 prior to or as matrix blank 43 enters tank 20 containing a liquid resin, such as an aqueous solution of a resin and water. As lower carrying belt 22 and upper carrying belt 32 move through tank 20, matrix blank 43 secured between opposing and cooperating lower carrying belt 22 and upper carrying belt 32 is submerged into the aqueous solution contained within tank 20 at a suitable speed to ensure that matrix blank 43 is submerged in the aqueous solution for a sufficient exposure time so that full saturation of the resin throughout matrix blank 43 is achieved. For highly absorbent and dense products, such as cotton shoddy, lower carrying belt 22 and upper carrying belt 32 slide between two stainless steel spring loaded plates that cover a full width of the belts and at least 24 inches of a running length of the belts at any time. One or more nozzles are positioned in a middle portion of each plate in a machine direction, and run across the width of the each plate. Resin is pumped through the one or more nozzles at a predetermined velocity to force resin into a center of matrix blank 43 while matrix blank 43 moves in the machine direction. An added length of the plates ensures that pressure is focused in a desired treatment area. Pre-load spring pressure is sufficient to keep the nozzles and pressure plates compressed to each belt, thereby forming a seal to prevent resin blow by. Resin is forced under pressure into matrix blank 43 to facilitate accelerating absorption of the resin to a center core of matrix blank 43. Other matrices can be resonated similarly to accelerate the resonating speed, but this is the only process which ensures cotton shoddy is fully resonated throughout a Z dimension.
At the end of the submersion process, lower carrying belt 22 and upper carrying belt 32 carrying the resin impregnated non-woven matrix blank 43 tum 90 degrees upwards ascending above tank 20 and entering a squeeze process to remove excess liquid resin to achieve the desired application rate. Using cooperating fixed compression roll 28 and adjustable compression roll 38, with lower carrying belt 22 and upper carrying belt 32 securing matrix blank 43 therebetween, matrix blank 43 moves into and through the squeeze rolls. In one embodiment, three compression roll sets are used, one above the other, to facilitate extracting excess resin from the resonated matrix blank. Each of the three vertical compression rolls, as shown in FIG. 2B, is set at a particular gap to provide less strain on matrix blank 43, and at the same time applying three different rates of pressure on the wetted matrix blank 43 to optimize solution extraction. (FIG. 1 shows only one set of such compression rolls). This squeeze action allows excess resin to flush out of matrix blank 43, flowing equally on opposing sides of the incoming pre-squeezed matrix blank 43 to maintain consistent and uniform liquid exposure equally to opposing sides of matrix blank 43. Exiting squeeze rolls, upper carrying belt 32 separates from matrix blank 43 to allow lower carrying belt 22 to deliver matrix blank 43 into a drying oven for downstream final processing.
EXAMPLES Example of formulation for application of liquid resin is as follows.
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- Resonated cotton shoddy matrix at desired dry weight=1000 gsm.
- Based weight of composite matrix pre-resonating=770 gsm at 0% moisture. Active resin required to meet resonated gram weight of matrix=230 gsm. Acrodur™ resin as supplied by BASF=50% water, 50% active dry solids resin. Required active dry solids solution to apply resin to cotton shoddy=25%.
- True wet pick required to apply 230 gsm dry solids resin=(100/25)=3×230=690 gsm or 89%.
Wet pick up for cotton shoddy to fully wet out matrix blank during solution application is greater than 125% or 1250 gsm of aqueous solution, pick up during dipping matrix in solution or 55%′ greater dilution in solution mix in order to apply 230 gsm dry solids resin. Therefore the aqueous solution mix needs to be further diluted to (100/18)=5.55×230=1276 gsm.
After resin impregnation, the impregnated matrix blank 43 is dried of excess water prior to use. Because the rate of water evaporation is very high compared to the final matrix blank weight (up to 70%), conventional technology using air impingement driers to perform this task requires ovens lengths often exceeding 50 feet and normally greater than 100 feet in length to run at any appreciable speed. This large foot print takes up valuable floor space and, as a means of energy utilization for drying, is one of the least efficient means to control drying costs. Based on test results, adopting microwave technology in the processing line reduces operating costs and reduces floor space requirements. Microwave oven technology works on the principal of exciting water molecules through energy waves causing the water molecules to vibrate rapidly. Further, microwave technology works on the mass inside out, a more desirable drying method than conventional air impingement ovens that work through transpiration or wicking water from the inside to the drier outside. Because final moisture content is critical to thermal processing (Acrodur™ resin requires moisture to be present in a sufficient quantity to cross-link resin), microwave heating and the ability to precisely control the amount of applied energy allows the process system to deliver matrix blank 43 having a desired pre-set moisture content exiting the drying oven without overheating matrix blank 43. Also, due to the intense focused energy microwave technology offers, the footprint required for oven drying is reduced by 75% over conventional hot air impingement-type drying. Therefore, in contrast to a conventional air oven that must be about 100 feet long to dry matrix blanks, a microwave drying oven, such as described herein, may be less than 25 feet in length. With the use of focused energy, the amount of energy required to dry the same material in the same time cycle is also greatly reduced.
In certain embodiments, cotton shoddy was formulated to include, without limitation, the following: cotton shoddy comprising cotton shoddy ranging from 10% to 90% of dry composite matrix weight, and hi-component polyester fiber ranging from 10% to 90% of composite matrix weight, and natural fiber comprising one or more of the following: jute, tossa, hemp, cori, sisal, curaua, kenaf and other similar fibers ranging from 5% to 90% of composite matrix weight, and polyester fiber ranging from 10% to 90% of matrix weight.
An exemplary Composite Matrix Weight 770 gsm, comprises the following:
10% hi-component polyester=(770×0.10)=77 grams. 1.
35% natural fiber of any fiber type above=(770×0.35)=269.5 grams. 2
55% cotton shoddy=(770×0.55)=432.5 grams. 3
Another exemplary Composite Matrix has the same weight as follows:
10% bi-component polyester=(770×0.10)=77 grams. 1
90% cotton shoddy=(770×0.90)=693 grams. 2
Yet another exemplary Composite Matrix has the same weight as follows:
10% hi-component polyester=(770×0.10)=77 grams. 1
35% polyester fiber of any fiber type above=(770×0.35)=269.5 grams. 2
55% cotton shoddy=(770×0.55)=432.5 grams. 3
Yet another exemplary Composite Matrix has the same weight as follows:
10% bi-component polyester=(770×0.10)=77 grams. 1
20% polyester fiber of any fiber type above=(770×0.20)=154 grams. 2
45% cotton shoddy=(770×0.45)=346.5 grams. 3
25% natural fiber of any fiber type above=(770×0.25)=192.5 grams. 4
The combination of fiber types used can be in any percent always requiring two or more of the above fiber types. The percentage and combination of blends is dependent on the application requirements.
This combination of systems provides a unique opportunity to apply liquid resins to a fibrous matrix, such as a cotton shoddy matrix, that is sensitive to line process strain and resistant to absorption due to density. The system viewed in whole, may include one or more of the following in various embodiments.
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- 1. Resonating matrix blanks of non-woven matrix, which can include matrix made with one or more of the following materials: cotton shoddy, natural bast fiber including, but not limited to, jute, kenaf, curaua, hemp, and other similar cellulous fibers.
- 2. Using twin belts to carrying matrix blanks into a resin tank.
- 3. Using twin belts to limit any strain associated with a dip and squeeze or direct injection application of any liquid including resins, adhesives or other such products used as a binder in matrix.
- 4. Twin plate injection system spring load to apply predetermined load during direct liquid injection.
- 5. Flow design of system, including upper and lower belts, belt types and direction of flow.
- 6. Direct pump resin system.
- 7. Parallel resin flow back under squeeze rolls to keep resin contact equally on both sides.
Additional Data is attached as Appendix A, noting the following:
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- 1. Sample A, B, C, D, E & L are made with 90% cotton Shoddy and 10% Bico
- 2. Sample F, G and H are made with 20% Hemp+25% Regenerated Polyester+10% Bico+45% Cotton Shoddy
- 3. Sample I & J are made with 50% PP+40% shoddy+10% Bico
- 4. All the samples with Jute (K samples) are from old runs and they are all made with 90% Jute (coffee bag)+10% Shoddy.
The described system and methods are not limited to the specific embodiments described herein. In addition, components of each system and/or steps of each method may be practiced independent and separate from other components and method steps, respectively, described herein. Each component and method also can be used in combination with other systems and methods.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
APPENDIX A
Sample 1*& 2* cut to size 20″ × 65¼″
1* 1014.1 0.0894 923.43 11.00% 60 3680 2585.92 2.55 284.45 1207.88 30.80% 23.55% 1413 1329
2* 1053.4 0.0894 959.24 11.00% 60 3550 2496.59 2.37 274.62 1233.86 28.63% 22.26% 1444 1357
Sample D10 cut to size 20″ × 65½″
D10* 1043 841.8 0.0894 766.56 7.00% 60 3150 2308.18 2.7419 161.57 928.13 21.08% 17.41% 1086 1021
Sample E10 cut to size 20″ × 65-½″
E10* 946 743.4 0.0894 676.91 11.00% 60 3000 2256.63 3.0357 248.23 925.14 36.67% 26.83% 1082 1018
Sample L cut to size 20″ × 65½″
Dry to Dry to
17% 10% Dry to 5%
L1 0.0 1038.6 0.0894 945.73 11.00% 60 3500 2461.42 2.37 270.76 1216.48 28.63% 22.26% 1423 1338 1277
L2 1170.2 0.0894 1065.60 11.00% 60 3850 2679.79 2.29 294.78 1360.37 27.66% 21.67% 1592 1496 1428
L3 983.1 0.0894 895.25 11.00% 60 3500 2516.85 2.56 276.85 1172.11 30.92% 23.62% 1371 1289 1231
L4 1014.5 0.0894 923.80 11.00% 60 3500 2485.51 2.45 273.41 1197.20 29.60% 22.84% 1401 1317 1257
L5 1116.1 0.0894 1016.29 11.00% 60 3750 2633.93 2.36 289.73 1306.03 28.51% 22.18% 1528 1437 1371
L6 1038.6 0.0894 945.73 11.00% 60 3500 2461.42 2.37 270.76 1216.48 28.63% 22.26% 1423 1338 1277
Dry to Dry to Weight after
17% 10% Drying
Sample L6 cut to size 12″ × 12″
L6
1 0.0 114.2 0.0894 104.03 11.00% 60 385 270.76 2.37 29.78 133.81 28.63% 22.26% 157 147 159
2 103.9 0.0894 94.57 11.00% 60 350 246.14 2.37 27.08 121.65 28.63% 22.26% 142 134 144
3 114.2 0.0894 104.03 11.00% 60 385 270.76 2.37 29.78 133.81 28.63% 22.26% 157 147 151
4 101.5 0.0894 92.41 11.00% 60 342 240.52 2.37 26.46 118.87 28.63% 22.26% 139 131 142
5 108.9 0.0894 99.17 11.00% 60 367 258.10 2.37 28.39 127.56 28.63% 22.26% 149 140 148
Sample L5 cut to size 12″ × 12″
L5
1 0.0 109.5 0.0894 99.73 11.00% 60 368 258.48 2.36 28.43 128.16 28.51% 22.18% 150 141 150
2 116.7 0.0894 106.24 11.00% 60 392 275.33 2.36 30.29 136.52 28.51% 22.18% 160 150 156
3 112.5 0.0894 102.44 11.00% 60 378 265.50 2.36 29.21 131.65 28.51% 22.18% 154 145 148
4 127.4 0.0894 115.99 11.00% 60 428 300.62 2.36 33.07 149.06 28.51% 22.18% 174 164 166
5 131.8 0.0894 120.06 11.00% 60 443 311.15 2.36 34.23 154.29 28.51% 22.18% 181 170 169
Sample L4 cut to size 12″ × 12″
L4
1 0.0 84.1 0.0894 76.54 11.00% 60 290 205.94 2.45 22.65 99.20 29.60% 22.84% 116 109 125
2 89.0 0.0894 81.03 11.00% 60 307 218.01 2.45 23.98 105.01 29.60% 22.84% 123 116 126
3 100.6 0.0894 91.59 11.00% 60 347 246.42 2.45 27.11 118.69 29.60% 22.84% 139 131 137
4 95.4 0.0894 86.84 11.00% 60 329 233.64 2.45 25.70 112.54 29.60% 22.84% 132 124 135
5 113.0 0.0894 102.94 11.00% 60 390 276.96 2.45 30.47 133.40 29.60% 22.84% 156 147 157
Sample L3 cut to size 12″× 12″
L3
1 0.0 91.0 0.0894 82.87 11.00% 60 324 232.99 2.56 25.63 108.50 30.92% 23.62% 127 119 140
2 104.5 0.0894 95.15 11.00% 60 372 267.51 2.56 29.43 124.58 30.92% 23.62% 146 137 151
3 99.4 0.0894 90.55 11.00% 60 354 254.56 2.56 28.00 118.55 30.92% 23.62% 139 130 138
4 96.6 0.0894 87.99 11.00% 60 344 247.37 2.56 27.21 115.20 30.92% 23.62% 135 127 135
5 103.4 0.0894 94.13 11.00% 60 368 264.63 2.56 29.11 123.24 30.92% 23.62% 144 136 144
Sample L2 cut to size 12″ × 12″
L2
1 0.0 109.4 0.0894 99.64 11.00% 60 360 250.58 2.29 27.56 127.20 27.66% 21.67% 149 140 147
2 107.6 0.0894 97.98 11.00% 60 354 246.40 2.29 27.10 125.08 27.66% 21.67% 146 138 144
3 110.6 0.0894 100.75 11.00% 60 364 253.36 2.29 27.87 128.62 27.66% 21.67% 150 141 148
4 115.5 0.0894 105.18 11.00% 60 380 264.50 2.29 29.09 134.27 27.66% 21.67% 157 148 154
5 115.5 0.0894 105.18 11.00% 60 389 264.50 2.29 29.09 134.27 27.66% 21.67% 157 148 162
Dry to Weight after
17% Drying
Jute Fiber samples K2 & K3 cut to size 12″ × 12″
K3
1 0.0 120.5 0.06 113.23 11.00% 60 418 297.54 2.47 32.73 145.96 28.90% 22.42% 171 173
2 113.5 0.06 106.73 11.00% 60 394 280.46 2.47 30.85 137.58 28.90% 22.42% 161 157
3 117.0 0.06 109.98 11.00% 60 406 289.00 2.47 31.79 141.77 28.90% 22.42% 166 163
4 115.9 0.06 108.90 11.00% 60 402 286.15 2.47 31.48 140.38 28.90% 22.42% 164 159
5 111.8 0.06 105.11 11.00% 60 388 276.18 2.47 30.38 135.49 28.90% 22.42% 159 155
6 119.3 0.06 112.15 11.00% 60 414 294.69 2.47 32.42 144.57 28.90% 22.42% 169 169
7 112.4 0.06 105.65 11.00% 60 390 277.61 2.47 30.54 136.19 28.90% 22.42% 159 140
8 117.0 0.06 109.98 11.00% 60 400 289.00 2.47 31.79 141.77 28.90% 22.42% 166 153
9 110.1 0.06 103.48 11.00% 60 382 271.91 2.47 29.91 133.39 28.90% 22.42% 156 155
10 108.9 0.06 102.40 11.00% 60 378 269.07 2.47 29.60 131.99 28.90% 22.42% 154 145
11 123.3 0.06 115.94 11.00% 60 428 304.66 2.47 33.51 149.45 28.90% 22.42% 175 170
12 113.5 0.06 106.73 11.00% 60 394 280.46 2.47 30.85 137.58 28.90% 22.42% 161 161
13 114.7 0.06 107.82 11.00% 60 398 283.30 2.47 31.16 138.98 28.90% 22.42% 163 161
14 121.0 0.06 113.78 11.00% 60 420 298.96 2.47 32.89 146.66 28.90% 22.42% 172 171
15 131.4 0.06 123.53 11.00% 60 456 324.59 2.47 35.70 159.23 28.90% 22.42% 186 189
K2
1 0.0 123.1 0.06 115.73 11.00% 60 426 302.88 2.46 33.32 149.05 28.79% 22.35% 174 175
2 122.5 0.06 115.19 11.00% 60 424 301.46 2.46 33.16 148.35 28.79% 22.35% 174 174
3 130.1 0.06 122.25 11.00% 60 450 319.94 2.46 35.19 157.45 28.79% 22.35% 184 185
4 119.1 0.06 111.93 11.00% 60 412 292.92 2.46 32.22 144.15 28.79% 22.35% 169 168
5 115.6 0.06 108.67 11.00% 60 400 284.39 2.46 31.28 139.95 28.79% 22.35% 164 161
6 121.4 0.06 114.10 11.00% 60 420 298.61 2.46 32.85 146.95 28.79% 22.35% 172 170
7 122.0 0.06 114.65 11.00% 60 422 300.03 2.46 33.00 147.65 28.79% 22.35% 173 173
8 122.5 0.06 115.19 11.00% 60 424 301.46 2.46 33.16 148.35 28.79% 22.35% 174 173
9 113.9 0.06 107.04 11.00% 60 394 280.13 2.46 30.81 137.85 28.79% 22.35% 161 161
10 120.2 0.06 113.02 11.00% 60 416 295.77 2.46 32.53 145.55 28.79% 22.35% 170 171
11 104.0 0.06 97.80 11.00% 60 360 255.95 2.46 28.15 125.96 28.79% 22.35% 147 146
12 115.0 0.06 108.13 11.00% 60 398 282.97 2.46 31.13 139.25 28.79% 22.35% 163 164
13 123.1 0.06 115.73 11.00% 60 426 302.88 2.46 33.32 149.05 28.79% 22.35% 174 174
14 121.4 0.06 114.10 11.00% 60 420 298.61 2.46 32.85 146.95 28.79% 22.35% 172 170
15 126.6 0.06 118.99 11.00% 60 438 311.41 2.46 34.26 153.25 28.79% 22.35% 179 182
Acrodur dry Acrodur dry
solid Resin solid Resin
950 L Post weight rate weight rate
Acrodur Mat weight Squeeze Dry Resin based on dry based on dry
Base weight Nominal Dry Base Solids Ratio Soak Time after Wet Pickup % solution Solids Pickup Mat Dry base weight Mat weight Weight after
SAMPLE # GSM Weight (gr) Mositure (%) Weight (gr) to Water (%) (sec) squeeze (gr) Rate (gr) pick up rate Rate (gr) Weight (gr) (gr) (gr) Drying
TEST # 01 (A) (90% Shoody + 10% Bico)
A2 1134 1700 0.0894 1548.02 11.00% 60 6200 4500 264.71% 495 2043.02 31.98% 24.23% 2200
A5 1161 1750 0.0894 1593.55 11.00% 60 6250 4500 257.14% 495 2088.55 31.06% 23.70% 2300
A6 1117 1650 0.0894 1502.49 11.00% 60 6100 4450 269.70% 489.5 1991.99 32.58% 24.57% 2200
A8 1069 1600 0.0894 1456.96 11.00% 60 6100 4500 281.25% 495 1951.96 33.97% 25.36% 2100
A10 1140 1700 0.0894 1548.02 11.00% 60 6200 4500 264.71% 495 2043.02 31.98% 24.23% 2250
TEST # 02 (B) (90% Shoody + 10% Bico)
B3 1172 1750 0.0894 1593.55 7.00% 60 6300 4550 260.00% 318.5 1912.05 19.99% 16.66% 2100
B4 1229 1800 0.0894 1639.08 7.00% 60 6450 4650 258.33% 325.5 1964.58 19.86% 16.57% 2200
B6 1203 1800 0.0894 1639.08 7.00% 60 6450 4650 258.33% 325.5 1964.58 19.86% 16.57% 2150
B7 1225 1850 0.0894 1684.61 7.00% 60 6600 4750 256.76% 332.5 2017.11 19.74% 16.48% 2250
B8 1184 1750 0.0894 1593.55 7.00% 60 6400 4650 265.71% 325.5 1919.05 20.43% 16.96% 2150
TEST # 03 (C) (90% Shoody + 10% Bico)
C2 1274 1850 0.0894 1684.61 5.00% 60 6550 4700 254.05% 235 1919.61 13.95% 12.24% 2150
C3 1251 1850 0.0894 1684.61 5.00% 60 6450 4600 248.65% 230 1914.61 13.65% 12.01% 2100
C4 1274 1900 0.0894 1730.14 5.00% 60 6550 4650 244.74% 232.5 1962.64 13.44% 11.85% 2150
C5 1255 1850 0.0894 1684.61 5.00% 60 6500 4650 251.35% 232.5 1917.11 13.80% 12.13% 2100
C6 1263 1900 0.0894 1730.14 5.00% 60 6350 4450 234.21% 222.5 1952.64 12.86% 11.39% 2100
TEST # 04 (D) (90% Shoody + 10% Bico)
D5 1046 1550 0.0894 1411.43 7.00% 60 5850 4300 2.77 301 1712.43 21.33% 17.58% 1900
D6 1013 1550 0.0894 1411.43 7.00% 60 5950 4400 2.84 308 1719.43 21.82% 17.91% 1850
D7 1009 1500 0.0894 1365.9 7.00% 60 5800 4300 2.87 301 1666.9 22.04% 18.06% 1850
D8 1042 1550 0.0894 1411.43 7.00% 60 5900 4350 2.81 304.5 1715.93 21.57% 17.75% 1900
D9 1002 1500 0.0894 1365.9 7.00% 60 5650 4150 2.77 290.5 1656.4 21.27% 17.54% 1800
TEST # 05 (E) (90% Shoody + 10% Bico)
E1 971 1450 0.0894 1320.37 11.00% 60 5900 4450 3.07 489.5 1809.87 37.07% 27.05% 2000
E2 994 1450 0.0894 1320.37 11.00% 60 5650 4200 2.90 462 1782.37 34.99% 25.92% 2000
E3 993 1450 0.0894 1320.37 11.00% 60 5750 4300 2.97 473 1793.37 35.82% 26.37% 2000
E5 908 1350 0.0894 1229.31 11.00% 60 5700 4350 3.22 478.5 1707.81 38.92% 28.02% 1900
E6 921 1350 0.0894 1229.31 11.00% 60 5750 4400 3.26 484 1713.31 39.37% 28.25% 1900
TEST # 06 (F) (45% Shoody + 25% PET + 20% Hemp + 10% Bico)
F3 1028 1546 0.05 1468.7 11.00% 60 6450 4904 3.17 539.44 2008.14 36.73% 26.86% 2150
F4 1033 1554 0.05 1476.3 11.00% 60 6450 4896 3.15 538.56 2014.86 36.48% 26.73% 2150
F7 993 1510 0.05 1434.5 11.00% 60 6200 4690 3.11 515.9 1950.4 35.96% 26.45% 2100
F9 1025 1550 0.05 1472.5 11.00% 60 6250 4700 3.03 517 1989.5 35.11% 25.99% 2100
F10 990 1476 0.05 1402.2 11.00% 60 5850 4374 2.9634 481.14 1883.34 34.31% 25.55% 2050
TEST # 07 (G) (45% Shoody + 25% PET + 20% Hemp + 10% Bico)
G3 1092 1642 0.05 1559.9 7.00% 60 6300 4658 2.84 326.06 1885.96 20.90% 17.29% 2000
G4 1114 1676 0.05 1592.2 7.00% 60 6100 4424 2.64 309.68 1901.88 19.45% 16.28% 2050
G6 1166 1754 0.05 1666.3 11.00% 60 6650 4896 2.79 538.56 2204.86 32.32% 24.43% 2400
G8 1145 1722 0.05 1635.9 11.00% 60 6600 4878 2.83 536.58 2172.48 32.80% 24.70% 2350
G9 1162 1748 0.05 1660.6 11.00% 60 6550 4802 2.75 528.22 2188.82 31.81% 24.13% 2300
TEST # 08 (H) (45% Shoody + 25% PET + 20% Hemp + 10% Bico)
H2 1390 2090 0.05 1985.5 5.00% 60 6950 4860 2.33 243 2228.5 12.24% 10.90% 2450
H4 1388 2088 0.05 1983.6 5.00% 60 7250 5162 2.47 258.1 2241.7 13.01% 11.51% 2450
H5 1400 2106 0.05 2000.7 5.00% 60 7050 4944 2.35 247.2 2247.9 12.36% 11.00% 2400
50% PP + 40% Shoddy + 10% Bico
Test # 09 (I) Test # 09 (J)
Sample # GSM weight (gr) Sample # GSM weight (gr)
I-1 1247 1896 J-1 1444 2302
I-2 1150 1748 J-2 1438 2292
I-3 1171 1780 J-3 1435 2288
I-4 1168 1776 J-4 1292 2060
I-5 1253 1904 J-5 1355 2160
I-6 1154 1754 J-6 1413 2252
I-7 1167 1774 J-7 1395 2224
I-8 1238 1882 J-8 1359 2166
I-9 1132 1720 J-9 1403 2236
I-10 1151 1749 J-10 1408 2244
Dry Acrodur dry Acrodur dry
Dry Resin Mat solid Resin solid Resin Weight cible Weight cible
Base Nominal Base 950 L Acrodur Soak Mat weight Post Squeeze Solids Dry weight rate weight rate after drying = after drying =
SAMPLE GSM weight Mositure Weight Solids Ratio to Time after squeeze Wet Pickup Rate % solution pick Pickup Weight based on dry based on dry 1.17 × dry mat 1.10 × dry mat
# Weight (gr) (%) (gr) Water (%) (sec) (gr) (gr) up rate Rate (gr) (gr) base weight (gr) Mat weight (gr) weight (gr) weight (gr)
M1-1 1500 0.06 1410 6.00% 30 6000 4500 300.00% 270 1680 19.15% 16.07% 1965.6 1848
M1-2 1450 0.06 1363 6.00% 30 5950 4500 310.34% 270 1633 19.81% 16.53% 1910.61 1796.3
M1-3 1350 0.06 1269 6.00% 30 5900 4550 337.04% 273 1542 21.51% 17.70% 1804.14 1696.2
M1-4 1450 0.06 1363 6.00% 30 5950 4500 310.34% 270 1633 19.81% 16.53% 1910.61 1596.3
M1-5 1350 0.06 1269 6.00% 30 5850 4500 333.33% 270 1539 21.28% 17.54% 1800.63 1692.9
M1-6 1700 0.06 1598 6.00% 30 6400 4700 276.47% 282 1880 17.65% 15.00% 2199.6 2068
M1-7 1550 0.06 1457 6.00% 30 6150 4600 296.77% 276 1733 18.94% 15.93% 2027.61 1906.3
M1-8 1700 0.06 1598 6.00% 30 6350 4650 273.53% 279 1877 17.46% 14.86% 2196.09 2064.7
M1-9 1500 0.06 1410 6.00% 30 6200 4700 313.33% 282 1692 20.00% 16.67% 1979.64 1861.2
M1-10 1700 0.06 1598 6.00% 30 6350 4650 273.53% 279 1877 17.46% 14.86% 2196.09 2064.7
Acrodur %
Test # Recipe Target GSM
1 Jute FR 35% 12% 1000
Bico 20%
Shoddy 45%
Acudur Test May 31, 2011
Acrodure Solution used: 3515 25% Resine
75% H2O
Drying Process Convection
Temp (C.) = 121
1A
Dipping and squeezing process
sample Exit Airlay Conditions wet Pad Sol Acr (g) Resine H2O
ID Composition Weight (g) gsm (g) W (g) % Pick-up W (g) % W (g) %
1-A 100% polyester 109 1214 256 147 135% 37 14% 110 43%
2-A 90% jute + 10Bico 83 921 280 197 237% 49 18% 148 53%
3-A 90% shoddy + 10% Bico 98 1086 248 150 153% 38 15% 113 45%
4-A* 63% shoddy + 20% Hollow + 17% Bico 134 1486 339 205 153% 51 15% 154 45%
5-A** 62% shoddy + 20% Hollow + 18% Bico 133 1473 331 198 149% 50 15% 149 45%
6-A 90% cotton + 10% Bico 69 767 204 135 196% 34 17% 101 50%
*Rieter Tilsonburg
**Rieter Oregon
2A
Dipping and squeezing process
sample Exit Airlay Conditions wet Pad Sol Acr (g) Resine H2O
ID Composition Weight (g) gsm Dray Pad (g) W (g) % Pick-up W (g) % W (g) %
4-A* 63% shoddy + 20% Hollow + 17% Bico 134 1486 122.02 339 205 153% 51 15% 154 45%
Test Date: May 31, 2011
Drying process
Dry Pad Resine H2O Drying H2Oevp % H2O
(g) W (g) % W (g) % (min) (g) evp
1B
178 37 21% 32 18% 25 78 71%
160 49 31% 28 17% 29 120 81%
157 38 24% 22 14% 17 91 81%
224 51 23% 39 17% 26 115 75%
224 50 22% 42 19% 23 107 72%
125 34 27% 22 18% 10 79 78%
2B
224 51 23% 39 17% 26 115 75%
3A
Post
950 L Squeeze Dry
Acrodur Wet Resin Mat
Nominal Solids Ratio Soak Mat weight Pickup Solids Dry
Base weight Mositure Dry Base to Water Time after Rate % solution Pickup Weight
SAMPLE # GSM Weight (gr) (%) Weight (gr) (%) (sec) squeeze (gr) (gr) pick up rate Rate (gr) (gr)
4-A* 1486 134 0.0894 122.02 25.0% 60 339 205 153.0% 51.25 173.3
4-A* 1486 134 0.05 127.3 25.0% 60 339 205 153.0% 51.25 178.6
4-A* 1486 134 0.13 116.58 25.0% 60 339 205 153.0% 51.25 167.8
4-A* 1486 134 0.135 115.91 25.0% 60 339 205 153.0% 51.25 167.2
5-A** 1374 133 0.135 115.045 25.0% 60 331 198 148.9% 49.5 164.5
3A 1086 98 0.135 84.77 25.0% 60 248 150 153.1% 37.5 122.3
3A 1086 98 0.0895 89.229 25.0% 60 248 150 153.1% 37.5 126.7
3A 1086 98 0.05 93.1 25.0% 60 248 150 153.1% 37.5 130.6
1-A 1214 109 0 109 25.0% 60 265 156 143.1% 39 148
3B
Weight Weight
Acrodur Acrodur cible cible
dry solid dry solid after after
Resin Resin drying = drying =
weight weight 1.17 × 1.10 ×
rate based rate based dry dry
on dry on dry mat mat
base Mat weight weight
weight (gr) weight (gr) (gr) (gr)
42.00% 29.58% 202.7 191
40.26% 28.70% 208.9 196
43.96% 30.54% 196.4 185
44.22% 30.66% 195.6 184
43.03% 30.08% 192.5 181
44.24% 30.67% 143.1 134
42.03% 29.59% 148.3 139
40.28% 28.71% 152.8 144
35.78% 26.35% 173.2 163
Acrodur Samples Jun. 22, 2010
1A
TEST # 01 (A)
Acrodur dry Acrodur dry
solid Resin solid Resin Weight cible
950 L Post weight rate weight rate after drying =
Acrodur Mat weight Squeeze Dry Resin based on dry based on dry 1.10 × dry
SAMPLE GSM Base weight Nominal Dry Base Solids Ratio Soak Time after Wet Pickup % solution pick up Solids Pickup Mat Dry base weight Mat weight mat weight
# Weight (gr) Mositure (%) Weight (gr) to Water (%) (sec) squeeze (gr) Rate (gr) rate Rate (gr) Weight (gr) (gr) (gr) (gr)
A1 1082 1600 0.0894 1456.96 11.00% 60 6000 4400 275.00% 484 1940.96 33.22% 24.94% 2135.056
A2 1134 1700 0.0894 1548.02 11.00% 60 6200 4500 264.71% 495 2043.02 31.98% 24.23% 2247.322
A3 1096 1600 0.0894 1456.96 11.00% 60 6150 4550 284.38% 500.5 1957.46 34.35% 25.57% 2158.206
A4 1088 650 0.0894 1502.49 11.00% 60 6150 4500 272.73% 49% 997.49 32.95% 24.78% 2297.239
A5 1161 1750 0.0894 1593.55 11.00% 60 6250 4500 257.14% 495 2088.55 31.06% 23.70% 2297.405
A6 1117 1650 0.0894 1502.49 11.00% 60 6100 4450 269.70% 489.5 1991.99 32.58% 24.57% 2191.189
A7 1096 1650 0.0894 1502.49 11.00% 60 6200 4550 275.76% 500.5 2002.99 33.31% 24.99% 2203.289
A8 1069 1600 0.0894 1456.96 11.00% 60 6100 4500 281.25% 495 1951.96 33.97% 25.36% 2147.156
A9 1115 1700 0.0894 1548.02 11.00% 60 6250 4550 267.65% 500.5 2048.52 32.33% 24.43% 2253.372
A10 1140 1700 0.0894 1548.02 11.00% 60 6200 4500 264.71% 495 2043.02 31.98% 24.23% 2247.322
SOLUTION to prepare 11% solid acrodur
3 × total solution 91 liter solution acrodur 950 L (50% resine) = 20 liter water = 3 × 71 liter
1B
2100 −35.056 −1.54% 8.46%
2200 −47.322 −1.98% 8.02%
2200 46.794 2.04% 12.04%
2182 −16.239 −0.65% 9.35%
2300 2.595 0.11% 10.11%
2200 8.811 0.38% 10.38%
2200 −3.289 −0.14% 9.86%
2100 −47.156 −2.06% 7.94%
2200 −53.372 −2.23% 7.77%
2250 2.678 0.11% 10.11%
2A
TEST # 01 (A)
Acrodur dry Acrodur dry
solid Resin solid Resin Weight cible Weight cible
950 L Post weight rate weight rate after drying = after drying =
Base Nominal Acrodur Mat weight Squeeze % solution Dry Resin based on dry based on dry 1.17 × dry 1.10 × dry
SAMPLE GSM weight Mositure Dry Base Solids Ratio Soak Time after Wet Pickup pick up Solids Pickup Mat Dry base weight Mat weight mat weight mat weight
# Weight (gr) (%) Weight (gr) to Water (%) (sec) squeeze (gr) Rate (gr) rate Rate (gr) Weight (gr) (gr) (gr) (gr) (gr)
A1 1082 1600 0.05 1520 11.00% 60 6000 4400 275.00% 484 2004 31.84% 24.15% 2344.68 2204.4
A2 1134 1700 0.05 1615 11.00% 60 6200 4500 264.71% 495 2110 30.65% 23.46% 2468.7 2321
A3 1096 1600 0.05 1520 11.00% 60 6150 4550 284.38% 500.5 2020.5 32.93% 24.77% 2363.985 2222.55
A4 1088 1650 0.05 1567.5 11.00% 60 6150 4500 272.73% 495 2062.5 31.58% 24.00% 2413.125 2268.75
A5 1161 1750 0.05 1662.5 11.00% 60 6250 4500 257.14% 495 2157.5 29.77% 22.94% 2524.275 2373.25
A6 1117 1650 0.05 1567.5 11.00% 60 6100 4450 269.70% 489.5 2057 31.23% 23.80% 2406.69 2262.7
A7 1096 1650 0.05 1567.5 11.00% 60 6200 4550 275.76% 500.5 2068 31.93% 24.20% 2419.56 2274.8
A8 1069 1600 0.05 1520 11.00% 60 6100 4500 281.25% 495 2015 32.57% 24.57% 2357.55 2216.5
A9 1115 1700 0.05 1615 11.00% 60 6250 4550 267.65% 500.5 2115.5 30.99% 23.66% 2475.135 2827.05
A10 1140 1700 0.05 1615 11.00% 60 6200 4500 264.71% 495 2110 30.65% 23.46% 2468.7 2821
Acrodur Solid base dry weight
12.00 88 13.64%
13.00 87 14.94%
14.00 86 16.28%
15.00 85 17.65%
16.00 84 19.05%
17.00 83 20.48%
18.00 82 21.95%
19.00 81 23.46%
20.00 80 25.00%
21.00 79 26.58%
22.00 78 28.21%
23.00 77 29.87%
24.00 76 31.58%
25.00 75 33.33%
26.00 74 35.14%
27.00 73 36.99%
28.00 72 38.89%
29.00 71 40.85%
30.00 70 42.86%
31.00 69 44.93%
32.00 68 47.06%
2B
2100 −104.4 −4.45% 5.55% 2104.2
2200 −121 −4.90% 5.10%
2200 −22.55 −0.95% 9.05%
2182 −86.75 −3.59% 6.41% 2182
2300 −73.25 −2.90% 7.10%
2200 −62.7 −2.61% 7.39%
2200 −74.8 −3.09% 6.91%
2100 −116.5 −4.94% 5.06%
2200 −127.05 −5.13% 4.87%
2250 −71 −2.88% 7.12%
3A
33.00 67 49.25%
34.00 66 51.52%
35.00 65 53.85%
A4 1088 1650 0.135 1427.25 11.00% 60 6150 4500 272.73% 495 1922.25 34.68% 25.75% 2249.033 2114.475
A4 1088 1650 0.14 1419 11.00% 60 6150 4500 272.73% 495 1914 34.88% 25.86% 2239.38 2105.4
3B
2400 150.9675 6.71% 23.71%
2400 160.62 7.17% 24.17%
Impregnation Acrodur November 2011
Acrodur dry Acrodur dry
% Dry Resin solid Resin solid Resin Weight cible Weight cible
Base Nominal Dry Base 950 L Acrodur Soak Mat weight Post Squeeze solution Solids Mat Dry weight rate weight rate after drying = after drying =
SAMPLE GSM weight Mositure Weight Solids Ratio to Time after squeeze Wet Pickup Rate pick Pickup Weight based on dry based on dry 1.17 × dry mat 1.10 × dry mat
# Weight (gr) (%) (gr) Water (%) (sec) (gr) (gr) up rate Rate (gr) (gr) base weight (gr) Mat weight (gr) weight (gr) weight (gr)
M1-1 1500 0.06 1410 6.00% 30 6000 4500 300.00% 270 1680 19.15% 16.07% 1965.6 1848
M1-2 1450 0.06 1363 6.00% 30 5950 4500 310.34% 270 1633 19.81% 16.53% 1910.61 1793.3
M1-3 1350 0.06 1269 6.00% 30 5900 4550 337.04% 273 1542 21.51% 17.70% 1804.14 1696.2
M1-4 1450 0.06 1363 6.00% 30 5950 4500 310.34% 270 1633 19.81% 16.53% 1910.61 1796.3
M1-5 1350 0.06 1269 6.00% 30 5850 4500 333.33% 270 1539 21.28% 17.54% 1800.63 1692.9
M1-6 1700 0.06 1598 6.00% 30 6400 4700 276.47% 282 1880 17.65% 15.00% 2199.6 2068
M1-7 1550 0.06 1457 6.00% 30 6150 4600 296.77% 276 1733 18.94% 15.93% 2027.61 1906.3
M1-8 1700 0.06 1598 6.00% 30 6350 4650 273.53% 279 1877 17.46% 14.86% 2196.09 2064.7
M1-9 1500 0.06 1410 6.00% 30 6200 4700 313.33% 282 1692 20.00% 16.67% 1979.64 1861.2
M1-10 1700 0.06 1598 6.00% 30 6350 4650 273.53% 279 1877 17.46% 14.86% 2196.09 2064.7
Acrodur %
Test # Recipe Target GSM
1 Jute FR 35% 12% 1000
Bico 20%
Shoddy 45%
Summary - Samples July 2011
Acrodur dry Acrodur dry
solid Resin solid Resin
950 L Post weight rate weight rate
Acrodur Mat weight Squeeze Dry Resin based on dry based on dry
Base weight Nominal Dry Base Solids Ratio Soak Time after Wet Pickup % solution Solids Pickup Mat Dry base weight Mat weight Weight after
SAMPLE # GSM Weight (gr) Mositure (%) Weight (gr) to Water (%) (sec) squeeze (gr) Rate (gr) pick up rate Rate (gr) Weight (gr) (gr) (gr) Drying
TEST # 01 (A) (90% Shoody + 10% Bico)
A2 1134 1700 0.0894 1548.02 11.00% 60 6200 4500 264.71% 495 2043.02 31.98% 24.23% 2200
A5 1161 1750 0.0894 1593.55 11.00% 60 6250 4500 257.14% 495 2088.55 31.06% 23.70% 2300
A6 1117 1650 0.0894 1502.49 11.00% 60 6100 4450 269.70% 489.5 1991.99 32.58% 24.57% 2200
A8 1069 1600 0.0894 1456.96 11.00% 60 6100 4500 281.25% 495 1951.96 33.97% 25.36% 2100
A10 1140 1700 0.0894 1548.02 11.00% 60 6200 4500 264.71% 495 2043.02 31.98% 24.23% 2250
TEST # 02 (B) (90% Shoody + 10% Bico)
B3 1172 1750 0.0894 1593.55 7.00% 60 6300 4550 260.00% 318.5 1912.05 19.99% 16.66% 2100
B4 1229 1800 0.0894 1639.08 7.00% 60 6450 4650 258.33% 325.5 1964.58 19.86% 16.57% 2200
B6 1203 1800 0.0894 1639.08 7.00% 60 6450 4650 258.33% 325.5 1964.58 19.86% 16.57% 2150
B7 1225 1850 0.0894 1684.61 7.00% 60 6600 4750 256.76% 332.5 2017.11 19.74% 16.48% 2250
B8 1184 1750 0.0894 1593.55 7.00% 60 6400 4650 265.71% 325.5 1919.05 20.43% 16.96% 2150
TEST # 03 (C) (90% Shoody + 10% Bico)
C2 1274 1850 0.0894 1684.61 5.00% 60 6550 4700 254.05% 235 1919.61 13.95% 12.24% 2150
C3 1251 1850 0.0894 1684.61 5.00% 60 6450 4600 248.65% 230 1914.61 13.65% 12.01% 2100
C4 1274 1900 0.0894 1730.14 5.00% 60 6550 4650 244.74% 232.5 1962.64 13.44% 11.85% 2150
C5 1255 1850 0.0894 1684.61 5.00% 60 6500 4650 251.35% 232.5 1917.11 13.80% 12.13% 2100
C6 1263 1900 0.0894 1730.14 5.00% 60 6350 4450 234.21% 222.5 1952.64 12.86% 11.39% 2100
TEST # 04 (D) (90% Shoody + 10% Bico)
D5 1046 1550 0.0894 1411.43 7.00% 60 5850 4300 2.77 301 1712.43 21.33% 17.58% 1900
D6 1013 1550 0.0894 1411.43 7.00% 60 5950 4400 2.84 308 1719.43 21.82% 17.91% 1850
D7 1009 1500 0.0894 1365.9 7.00% 60 5800 4300 2.87 301 1666.9 22.04% 18.06% 1850
D8 1042 1550 0.0894 1411.43 7.00% 60 5900 4350 2.81 304.5 1715.93 21.57% 17.75% 1900
D9 1002 1500 0.0894 1365.9 7.00% 60 5650 4150 2.77 290.5 1656.4 21.27% 17.54% 1800
TEST # 05 (E) (90% Shoody + 10% Bico)
E1 971 1450 0.0894 1320.37 11.00% 60 5900 4450 3.07 489.5 1809.87 37.07% 27.05% 2000
E2 994 1450 0.0894 1320.37 11.00% 60 5650 4200 2.90 462 1782.37 34.99% 25.92% 2000
E3 993 1450 0.0894 1320.37 11.00% 60 5750 4300 2.97 473 1793.37 35.82% 26.37% 2000
E5 908 1350 0.0894 1229.31 11.00% 60 5700 4350 3.22 478.5 1707.81 38.92% 28.02% 1900
E6 921 1350 0.0894 1229.31 11.00% 60 5750 4400 3.26 484 1713.31 39.37% 28.25% 1900
TEST # 06 (F) (45% Shoody + 25% PET + 20% Hemp + 10% Bico)
F3 1028 1546 0.05 1468.7 11.00% 60 6450 4904 3.17 539.44 2008.14 36.73% 26.86% 2150
F4 1033 1554 0.05 1476.3 11.00% 60 6450 4896 3.15 538.56 2014.86 36.48% 26.73% 2150
F7 993 1510 0.05 1434.5 11.00% 60 6200 4690 3.11 515.9 1950.4 35.96% 26.45% 2100
F9 1025 1550 0.05 1472.5 11.00% 60 6250 4700 3.03 517 1989.5 35.11% 25.99% 2100
F10 990 1476 0.05 1402.2 11.00% 60 5850 4374 2.9634 481.14 1883.34 34.31% 25.55% 2050
TEST # 07 (G) (45% Shoody + 25% PET + 20% Hemp + 10% Bico)
G3 1092 1642 0.05 1559.9 7.00% 60 6300 4658 2.84 326.06 1885.96 20.90% 17.29% 2000
G4 1114 1676 0.05 1592.2 7.00% 60 6100 4424 2.64 309.68 1901.88 19.45% 16.28% 2050
G6 1166 1754 0.05 1666.3 11.00% 60 6650 4896 2.79 538.56 2204.86 32.32% 24.43% 2400
G8 1145 1722 0.05 1635.9 11.00% 60 6600 4878 2.83 536.58 2172.48 32.80% 24.70% 2350
G9 1162 1748 0.05 1660.6 11.00% 60 6550 4802 2.75 528.22 2188.82 31.81% 24.13% 2300
TEST # 08 (H) (45% Shoody + 25% PET + 20% Hemp + 10% Bico)
H2 1390 2090 0.05 1985.5 5.00% 60 6950 4860 2.33 243 2228.5 12.24% 10.90% 2450
H4 1388 2088 0.05 1983.6 5.00% 60 7250 5162 2.47 258.1 2241.7 13.01% 11.51% 2450
H5 1400 2106 0.05 2000.7 5.00% 60 7050 4944 2.35 247.2 2247.9 12.36% 11.00% 2400
50% PP + 40% Shoddy + 10% Bico
Test # 09 (I) Test # 09 (J)
Sample # GSM weight (gr) Sample # GSM weight (gr)
I-1 1247 1896 J-1 1444 2302
I-2 1150 1748 J-2 1438 2292
I-3 1171 1780 J-3 1435 2288
I-4 1168 1776 J-4 1292 2060
I-5 1253 1904 J-5 1355 2160
I-6 1154 1754 J-6 1413 2252
I-7 1167 1774 J-7 1395 2224
I-8 1238 1882 J-8 1359 2166
I-9 1132 1720 J-9 1403 2236
I-10 1151 1749 J-10 1408 2244
indicates data missing or illegible when filed
