Formaldehyde-free cyclic urea reactive additives for exotherm suppressant compositions
AssigneeJohns Manville
InventorsUranchimeg Lester, Ameya Natu, Kiarash Alavi
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Abstract
Exotherm suppressant compositions are described that include a resin, such as a thermoset or thermoplastic resin, and at least one cyclic urea compound. Such compositions have no free formaldehyde, contain no antimony and are halogen free, for example. As described, such compositions can be used as binders, for example, to bind organic, inorganic fibers, and/or minerals. Also described are binder-containing fiberglass products that include glass fibers and a binder. The binder-containing fiberglass products have reduced formaldehyde emissions.
Claims20
An exotherm suppressant composition, comprising:
- a thermoset or thermoplastic resin polymeric matrix;
- and
- a cyclic urea compound in an amount from 1 wt. % to 50 wt. %, based on the weight of the exotherm suppressant composition, incorporated into the polymeric matrix of the thermoset or thermoplastic resin,
- wherein the composition has no free formaldehyde, and
- wherein the cyclic urea compound has the formula:
- wherein R1, R2, R3, and R4 are independently selected from a hydrogen, a hydroxyl group, and an alcohol group, and
- wherein R5 and R6 are independently selected from a hydroxyl group and an alcohol group.
A fiberglass insulation composition, comprising:
- glass fibers;
- and
- a binder, wherein the binder comprises:
- a thermoset or thermoplastic resin polymeric matrix;
- and
- at least one cyclic urea compound in an amount from 1 wt. % to 50 wt. %, based on the weight of the binder, incorporated into the polymeric matrix of the thermoset or thermoplastic resin,
- wherein the composition has no free formaldehyde, and
- wherein the at least one cyclic urea compound has the formula:
- wherein R1, R2, R3, and R4 are independently selected from a hydrogen, a hydroxyl group and an alcohol group, and
- wherein R5 and R6 are independently selected from a hydroxyl group and an alcohol group.
A method of making a fiberglass insulation product, the method comprising:
- forming a binder composition comprising:
- a thermoset or thermoplastic resin polymeric matrix;
- and
- at least one cyclic urea compound in an amount from 1 wt. % to 50 wt. %, based on the weight of the binder, incorporated into the polymeric matrix of the thermoset or thermoplastic resin;
- contacting the binder composition with glass fibers to form an amalgam of the binder composition and glass fibers;
- heating the amalgam of the binder composition and the glass fibers to form a mat of glass fibers and binder;
- and
- processing the mat of glass fibers and binder into the fiberglass insulation product;
- wherein the binder composition is formaldehyde free, and
- wherein the at least one cyclic urea compound has the formula:
- wherein R1, R2, R3, and R4 are independently selected from a hydrogen, a hydroxyl group and an alcohol group, and
- wherein R5 and R6 are independently selected from a hydroxyl group and an alcohol group.
Dependencies are inferred from the claim text.