# US 2017/0335153 A1 · New binder composition > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2017/0335153 A1 - Document ID: US20170335153A1 - Status: Published application - Kind: A1 - Application number: 15/666,160 - Filed: 2017-08-01 - Published: 2017-11-23 - Earliest claimed: 2009-10-08 - Assignees: Johns Manville - Applicants: Johns Manville - Inventors: Klaus Friedrich Gleich; Philip Francis Miele; Michael Ketzer - Web page: https://patentgrep.com/patent/US20170335153A1 ## CPC - C09J 161/00: Adhesives based on condensation polymers of aldehydes or ketones (with polyalcohols C09J159/00; with polynitriles C09J177/00); Adhesives based on derivatives of such polymers - C08L 23/04: Homopolymers or copolymers of ethene - C08L 23/06: Polyethylene - C08L 23/10: Homopolymers or copolymers of propene - C08L 23/12: Polypropene - C09J 161/06: of aldehydes with phenols - C09J 161/28: with melamine - C08L 23/00: Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers - C08L 75/04: Polyurethanes - C08L 2666/06: Homopolymers or copolymers of unsaturated hydrocarbons; Derivatives thereof - C08L 2666/20: Macromolecular compounds having nitrogen in the main chain according to C08L75/00 - C08L79/00; Derivatives thereof - Y10T 428/24149: Honeycomb-like - Y10T 428/31993: Of paper - Y10T 442/20: Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer - Y10T 442/2762: Coated or impregnated natural fiber fabric [e.g., cotton, wool, silk, linen, etc.] - Y10T 442/2861: Coated or impregnated synthetic organic fiber fabric - Y10T 442/2975: Coated or impregnated ceramic fiber fabric - Y10T 442/2992: Coated or impregnated glass fiber fabric - C09J: ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES (preparation of glue or gelatine C09H) - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract The invention relates to a new binder composition which is particularly suitable for the manufacture of composite materials utilizing such new binder composition in the required nonwoven materials. Composite materials using such new binder composition in their nonwoven part are suitable, in particular, for composites materials for interior construction, for linings, floor coverings, and for the manufacture of furniture and similar products. ## Claims ### Claim 1 A semi-finished product comprising: a textile structure; and a binder, wherein the binder is made from a binder composition comprising: a B-stage binder composition, and an emulsion, wherein the semi-finished product can undergo further hardening of the binder. ### Claim 2 (depends on 1) The semi-finished product of claim 1, wherein the textile structure comprises at least one type of fiber selected from the group consisting of natural fibers, fibers of synthesized polymers, fibers of natural polymers, ceramic fibers, mineral fibers, and glass fibers. ### Claim 3 (depends on 1) The semi-finished product of claim 1, wherein the textile structure comprises at least one material selected from the group consisting of a tissue, laying, multiaxial fabric, knitted fabric, woven fabric, non-woven fabric, and paper. ### Claim 4 (depends on 1) The semi-finished product of claim 1, wherein the B-stage binder composition comprises a thermoset binder composition. ### Claim 5 (depends on 1) The semi-finished product of claim 1, wherein the B-stage binder composition comprises a formaldehyde-free binder composition. ### Claim 6 (depends on 1) The semi-finished product of claim 1, wherein the B-stage binder composition comprises at least one binder composition selected from the group consisting of furfuryl alcohol formaldehyde, phenol formaldehyde, melamine formaldehyde, and urea formaldehyde. ### Claim 7 (depends on 1) The semi-finished product of claim 1, wherein the emulsion comprises a thermoplastic emulsion. ### Claim 8 (depends on 1) The semi-finished product of claim 1, wherein the emulsion comprises a polyolefin emulsion. ### Claim 9 (depends on 1) The semi-finished product of claim 1, wherein the polyolefin emulsion comprises polypropylene. ### Claim 10 (depends on 1) The semi-finished product of claim 1, wherein the emulsion is 0.1 wt. % to 35 wt. % based on a total solids content of the binder composition. ### Claim 11 (depends on 1) The semi-finished product of claim 1, wherein the emulsion is not a thermoset emulsion that has three-dimensional crosslinking. ### Claim 12 (depends on 1) The semi-finished product of claim 1, wherein the binder composition further comprises a hardening catalyst for the B-stage binder composition. ### Claim 13 (depends on 12) The semi-finished product of claim 12, wherein the hardening catalyst is selected from the group consisting of ammonium nitrate, p-toluene sulfonic acid, and maleic acid. ### Claim 14 (depends on 12) The semi-finished binder product of claim 12, wherein the hardening catalyst comprises 0.25 wt. % to 7 wt. % relative to the total binder content. ### Claim 15 (depends on 1) The semi-finished binder product of claim 1, wherein the binder is 10 wt. % to 30 wt. % of a weight of the textile structure. ### Claim 16 (depends on 1) The semi-finished binder product of claim 1, wherein the semi-finished binder product further comprises at least one functional material selected from the group consisting of a flame proofing agent, a material to discharge electrostatic charge, a material to screen off electromagnetic rays, a filler, a pigment, a material to increase resistance to wear, a material to increase resistance to slippage, and a decorative element. ### Claim 17 A semi-finished binder product comprising: a textile fabric; and a partially-cured binder, wherein the partially-cured binder comprises a partially-polymerized thermoset polymer and a thermoplastic polymer selected from polyolefins and polyurethanes, and wherein the thermoplastic polymer does not have three-dimensional crosslinking. ### Claim 18 (depends on 17) The semi-finished binder product of claim 17, wherein the textile fabric comprises at least one type of fiber selected from the group consisting of natural fibers, fibers of synthesized polymers, fibers of natural polymers, ceramic fibers, mineral fibers, and glass fibers. ### Claim 19 (depends on 18) The semi-finished binder product of claim 18, wherein the textile fabric comprises glass fibers, and wherein the glass fibers comprise one or more types of glass selected from the group consisting of A-glass, C-glass, E-glass, S-glass, T-glass, and R-glass. ### Claim 20 (depends on 18) The semi-finished binder product of claim 18, wherein the textile fabric comprises fibers of synthesized polymers, and wherein the fibers of synthesized polymers comprise one or more types of synthesized polymers selected from the group consisting of polyamides, polyesters, polyethylene, polypropylene, and polybenzimidazoles. ### Claim 21 (depends on 17) The semi-finished binder product of claim 17, wherein the partially-polymerized thermoset polymer comprises a formaldehyde-free polymer. ### Claim 22 (depends on 17) The semi-finished binder product of claim 17, wherein the partially-polymerized thermoset polymer is selected from the group consisting of furfuryl alcohol formaldehyde, phenol formaldehyde, melamine formaldehyde, and urea formaldehyde. ### Claim 23 (depends on 17) The semi-finished binder product of claim 17, wherein the thermoplastic polymer comprises polypropylene. ### Claim 24 (depends on 17) The semi-finished binder product of claim 17, wherein the partially-cured binder further comprises a hardening catalyst for the partially-polymerized thermoset polymer, and wherein the hardening catalyst is selected from the group consisting of ammonium nitrate, p-toluene sulfonic acid, and maleic acid. ### Claim 25 (depends on 17) The semi-finished binder product of claim 17, wherein the semi-finished binder product further comprises at least one functional material selected from the group consisting of a flame proofing agent, a material to discharge electrostatic charge, a material to screen off electromagnetic rays, a filler, a pigment, a material to increase resistance to wear, a material to increase resistance to slippage, and a decorative element. ### Claim 26 A semi-finished binder product comprising: a textile structure; and a B-stage binder, wherein the B-stage binder comprises a B-stage thermoset polymer, and a polyolefin polymer derived from a polyolefin emulsion that does not have three-dimensional crosslinking. ### Claim 27 (depends on 26) The semi-finished product of claim 26, wherein the textile structure comprises at least one type of fiber selected from the group consisting of natural fibers, fibers of synthesized polymers, fibers of natural polymers, ceramic fibers, mineral fibers, and glass fibers. ### Claim 28 (depends on 26) The semi-finished product of claim 26, wherein the B-stage thermoset polymer comprises a formaldehyde-free polymer. ### Claim 29 (depends on 26) The semi-finished product of claim 26, wherein the B-stage thermoset polymer is selected from the group consisting of furfuryl alcohol formaldehyde, phenol formaldehyde, melamine formaldehyde, and urea formaldehyde. ### Claim 30 (depends on 26) The semi-finished product of claim 26, wherein the polyolefin polymer comprises a polypropylene polymer.