Use of polyacrylic acid and other polymers as additives in fiberglass formaldehyde based binders
AssigneeSchuller International, Inc.
InventorsThomas J. Taylor, Paul Nedwick
Life of this patent
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Abstract
A process for preparing binder-coated fiber-glass products employs as a binder aqueous polymer systems comprising a nitrogenous formaldehyde resin such as a urea-extended alkaline phenol/formaldehyde resole together with an acidic polyacrylate which cocure to form a thermoset polymer while synergistically reducing ammonia emissions which normally occur during cure of the nitrogenous formaldehyde resin. The polymer system may be used in applications other than fiberglass where reduced emissions are desired.
Claims30
A low total emission process for preparation of a binder-coated fiberglass product, comprising:
- (a) selecting as one component of said binder, an aqueous phenol/formaldehyde resin which has been extended with a nitrogenous compound to form an extended phenol/formaldehyde resin;
- (b) adding to said extended phenol/formaldehyde resin an amount of a non-curable acidic polyacrylate effective to reduce ammonia emissions during cure of the combination (a) and (b) below that produced during the cure of (a) alone;
- (c) applying an aqueous mixture comprising (a) and (b) to fiberglass in need of binder-coating to form a binder-containing fiberglass;
- (d) curing said binder-containing fiberglass at elevated temperature to form a binder-coated fiberglass product.
A low total emission process for preparation of a binder-coated fiberglass product, comprising:
- (a) selecting as one component of said binder, an aqueous phenol/formaldehyde alkaline resole resin which has been extended with a nitrogenous compound to form an extended phenol/formaldehyde resin;
- (b) adding to said extended phenol/formaldehyde resin an amount of a water soluble non-curable acidic polyacrylate effective to reduce ammonia emissions during cure of the combination (a) and (b) below that produced during the cure of (a) alone;
- (c) applying an aqueous mixture comprising (a) and (b) to fiberglass in need of binder-coating to form a binder-containing fiberglass;
- (d) curing said binder-containing fiberglass at elevated temperature to form a binder-coated fiberglass product, wherein said acidic polyacrylate is a polyacrylate copolymer greater than 50 mol % of moieties derived from acrylic acid, methacrylic acid and maleic acid, optionally containing acrylonitrile and styrene comonomers.
A heat-curable aqueous resin system with reduced emission of ammonia upon cure, comprising:
- (a) from 40% to about 95% by weight based on the sum of (a) and (b) of a nitrogenous formaldehyde resin prepared by reacting formaldehyde with a nitrogenous monomer selected from the group consisting of urea, dicyandiamide, melamine, and mixtures thereof, optionally also with phenol, said nitrogenous formaldehyde resin one which emits ammonia upon curing at elevated temperature;
- (b) from 60% to about 5% by weight of a noncurable, acidic polyacrylate,
- wherein total ammonia emissions of said resin system are less than that which may be calculated based upon the ammonia emission of (a) alone when diluted with (b).
A binder-coated fiberglass product, comprising:
- (a) glass fibers
- (b) a cured binder composition comprising the co-cured reaction product of:
- i) a nitrogenous formaldehyde resin in an amount of from 40 to about 95% by weight based on the weight of (b)(i) and (b)(ii), and
- ii) from 60% to about 5% based on the weight of (b)(i) and (b)(ii) of a non-curable water-soluble acidic polyacrylate.
Dependencies are inferred from the claim text.