Formaldehyde-free binder compositions and methods of making the binders under controlled acidic conditions
AssigneeJohns Manville
InventorsKiarash Alavi, Uranchimeg Lester, Jawed Asrar
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Abstract
Formaldehyde-free binder compositions are described that include an aldehyde or ketone, a reaction product between a polyamine and an organic anhydride, and an acidic compound. The acidic compound may be an organic acid, an acidic catalyst, or both. The acidic compound is supplied in quantities that lower the pH of the binder composition to about 5 or less. The binder compositions may be used in methods of binding fiberglass and the resulting fiberglass products have an improved tensile strength due to the addition of the acidic compound.
Claims26
A method of making a fiberglass product, the method comprising:
- combining a binder composition and glass fibers, wherein the binder composition includes:
- an aldehyde or ketone,
- an amino-amide compound that consists of a reaction product of a diamine and a carbonyl compound, wherein the diamine is selected from the group consisting of 1,2-ethylenediamine, 1,3-propanediamine, 1,4-butanediamine, 1,5-pentadiamine, and 1,6-hexanediamine, and
- a catalyst for catalyzing a reaction between (i) the aldehyde or ketone and (ii) the amino-amide compound;
- forming the combination of the binder composition and the glass fibers into an uncured fiberglass mat or batt;
- and
- heating the uncured fiberglass mat or batt into the fiberglass product.
A method of making a fiberglass product, the method comprising:
- combining a binder composition and glass fibers, wherein the binder composition includes:
- an aldehyde or ketone, and
- an amino-amide compound comprising a reaction product of a diamine and a carbonyl compound, wherein the diamine is selected from the group consisting of 1,2-ethylenediamine, 1,3-propanediamine, 1,4-butanediamine, 1,5-pentadiamine, and 1,6-hexanediamine,
- forming the combination of the binder composition and the glass fibers into an uncured fiberglass mat or batt;
- and
- heating the uncured fiberglass mat or batt at a temperature of 200° C. to 300° C. for 20 minutes or more to form the fiberglass product.
Dependencies are inferred from the claim text.