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US 11,697,729 B2Granted
Modified urea-formaldehyde binders for non-woven fiber glass mats
AssigneeJohns Manville
InventorsGuodong Zheng, Mingfu Zhang, Luke Weith, Jawed Asrar
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Abstract
A method of forming a binder composition includes providing a urea-formaldehyde resin and combining one or more starch compounds with the urea-formaldehyde resin to form a starch modified urea-formaldehyde resin. The one or more starch compounds may be combined with the urea-formaldehyde resin so that the starch modified urea-formaldehyde resin includes about 1 wt. % to about 10 wt. % of the one or more starch compounds.
Claims15
A method of forming a binder composition comprising:
- providing an aqueous solution of formaldehyde and urea;
- initiating synthesis of a urea-formaldehyde resin from the aqueous solution of formaldehyde and urea;
- and
- combining one or more starch compounds with the urea-formaldehyde resin by adding a starch slurry to the aqueous solution of formaldehyde and urea during synthesis of the urea-formaldehyde resin to form a starch modified urea-formaldehyde resin;
- wherein the one or more starch compounds are combined with the urea-formaldehyde resin so that the starch modified urea-formaldehyde resin includes about 1 wt. % to about 10 wt. % of the one or more starch compounds;
- and
- wherein the one or more starch compounds have a weight average molecular weight of between about 100,000 g/mol to about 2,000,000 g/mol.
4 more elements
A method of forming a non-woven fiber mat comprising:
- providing a binder composition that includes a urea-formaldehyde resin and about 1 wt. % to about 10 wt. % of a starch, wherein providing the binder composition comprises:
- providing an aqueous solution of formaldehyde and urea;
- initiating synthesis of the urea-formaldehyde resin;
- and
- combining a starch slurry with the aqueous solution of formaldehyde and urea during synthesis of the urea-formaldehyde resin, the starch slurry comprising one or more starch compounds having a weight average molecular weight of between about 100,000 g/mol to about 2,000,000 g/mol;
- applying the binder composition to a wet laid fiber mesh;
- drying the wet laid fiber mesh;
- and
- curing the binder composition to bond fibers of the wet laid fiber mesh and thereby form the non-woven fiber mat.
6 more elements
Dependencies are inferred from the claim text.