Water-soluble sulfonated melamine-formaldehyde resins
AssigneeGeorgia-Pacific Resins, Inc.
InventorKim K. Tutin
Life of this patent
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Abstract
The present invention relates to a sulfonated water-soluble melamine-formaldehyde resin, to a method of manufacturing the resin, and to insulation products prepared using the resin. The resin is particularly useful for making thermal insulation having low moisture adsorption, high tensile strength and low formaldehyde emissions.
Claims20
A water-soluble sulfonated melamine-formaldehyde resin prepared by
- reacting melamine and formaldehyde at an initial F/M mole ratio of about 2.0 to 3.0 in the presence of a polyhydroxy compound and under an alkaline condition to form an initial melamine-formaldehyde resin;
- sulfonating the initial resin with sodium bisulfite or metabisulfite;
- polymerizing the sulfonated melamine-formaldehyde resin by heating;
- adding additional melamine to reduce the cumulative F/M mole ratio to about 1.6 to 1.7 and produce a final sulfonated melamine-formaldehyde resin;
- and
- adjusting the pH of the final resin, as necessary, to about 9.0 to 10.0,
- wherein sufficient sodium bisulfite or metabisulfite is added to provide a bisulfite/melamine mole ratio of about 0.05 to 1.5 based on the total amount of melamine.
A method of producing a water-soluble sulfonated melamine-formaldehyde resin comprising
- reacting melamine and formaldehyde at an initial F/M mole ratio of about 2.0 to 3.0 in the presence of a polyhydroxy compound and under an alkaline condition to form an initial melamine-formaldehyde resin;
- sulfonating the initial resin with sodium bisulfite or metabisulfite;
- polymerizing the sulfonated melamine-formaldehyde resin by heating;
- adding additional melamine to reduce the cumulative F/M mole ratio to about 1.6 to 1.7 and produce a final sulfonated melamine-formaldehyde resin;
- and
- adjusting the pH of the final resin, as necessary, to about 9.0 to 10.0,
- wherein sufficient sodium bisulfite or metabisulfite is added to provide a bisulfite/melamine mole ratio of about 0.05 to 1.5 based on the total amount of melamine.
Thermal insulation treated with a binder containing a water-soluble sulfonated melamine-formaldehyde resin prepared by dissolving the resin in water and applying to the thermal insulation;
- wherein the resin is prepared by
- reacting melamine and formaldehyde at an initial F/M mole ratio of about 2.0 to 3.0 in the presence of a polyhydroxy compound and under an alkaline condition to form an initial melamine-formaldehyde resin;
- sulfonating the initial resin with sodium bisulfite or metabisulfite;
- polymerizing the sulfonated melamine-formaldehyde resin by heating;
- adding additional melamine to reduce the cumulative F/M mole ratio to about 1.6 to 1.7 and produce a final sulfonated melamine-formaldehyde resin;
- and
- adjusting the pH of the final resin, as necessary, to about 9.0 to 10.0,
- wherein sufficient sodium bisulfite or metabisulfite is added to provide a bisulfite/melamine mole ratio of about 0.05 to 1.5 based on the total amount of melamine.
Dependencies are inferred from the claim text.