Urea-glyoxal crosslinking compounds for phenolic binder compositions
AssigneeJohns Manville
InventorsKiarash Alavi, Ameya Natu
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Abstract
Binder compositions are described that include a phenol, a urea compound, formaldehyde, and at least one cyclic urea-dialdehyde compound. The cyclic urea-dialdehyde compound forms crosslinking bonds between polymers of phenol-urea-formaldehyde when the binder composition is cured. Also described are methods of making fiberglass insulation products using the above-described binder compositions. The methods may include contacting the binder composition with glass fibers and forming an amalgam of the binder composition and the glass fibers. The amalgam may be heated to form mats of the glass fibers and binder. The mats may be processed into the fiberglass insulation products.
Claims16
A method of making a fiberglass insulation product, the method comprising:
- forming an aqueous phenol-formaldehyde mixture;
- adding urea and a cyclic urea-dialdehyde crosslinking compound to the aqueous phenol-formaldehyde mixture to form a phenol-urea-formaldehyde pre-reaction composition;
- adding a polyol to the phenol-urea-formaldehyde pre-reaction composition to form a binder composition, wherein the polyol is added in an amount from 10 wt % to 30 wt. % of total solids in the binder composition;
- contacting the binder composition with glass fibers and forming 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.
Dependencies are inferred from the claim text.