Back to results
US 6,194,512 B1Granted
Phenol/formaldehyde and polyacrylic acid co-binder and low emissions process for making the same
AssigneeOwens Corning Fiberglas Technology, Inc.
InventorsLiang Chen, Richard Wolever
Life of this patent
Estimating the term…
Abstract
An aqueous phenol/formaldehyde resole resin is disclosed having improved speciation. An aqueous extended phenol/formaldehyde and polycarboxylic acid co-binder and low emissions process for making the same are also disclosed. Glass fiber products may be prepared using the co-binder.
Claims42
A method of making binder-coated glass fibers, comprising:
- providing an initial charge of phenol (P);
- providing formaldehyde (F) at a F:P molar ratio of from about 2:1 to about 6:1;
- reacting said phenol and said formaldehyde in the presence of an effective amount of an alkaline methylolation catalyst to form a phenolic resole resin;
- reacting some of the excess, unreacted formaldehyde in said phenolic resole resin with a formaldehyde scavenger under alkaline conditions to form a reaction pre-mix;
- combining said reaction pre-mix with an effective amount of a base neutralizing salt;
- combining an effective amount of a polycarboxylic acid polymer containing pendant carboxylic acid groups, a polyhydroxy tertiary alkanolamine and a thermoset catalyst with at least one of said phenolic resole resin, extended resole resin, and reaction pre-mix, to form a co-binder solution, wherein said polycarboxylic acid polymer forms a thermoset polymer in the presence of said polyhydroxy tertiary alkanolamine and said thermoset catalyst;
- applying said co-binder solution to glass fibers;
- and
- curing said co-binder solution.
6 more elements
A method of making a phenolic/polyacrylic acid-cobinder comprising:
- providing a phenolic resole resin containing an effective amount of an organic hydroxyl-group containing amine;
- combining a polycarboxylic acid polymer with said organic hydroxyl group containing amine and a thermoset catalyst in the presence of said phenolic resole resin to form a co-binder solution;
- and
- curing said co-binder solution to form said cured co-binder.
1 more element
A heat-curable aqueous composition comprising:
- formaldehyde;
- phenolic compound;
- methylolated phenolic species;
- alkanolamine crosslinking agent;
- thermoset catalysts;
- and
- polyacrylic acid.
4 more elements
A binder-coated glass fiber comprising:
- a glass fiber;
- and
- a cured reaction product of:
- a urea-extended phenol-formaldehyde resole resin;
- polyacrylic acid;
- alkanolamine crosslinking agent;
- and
- a sodium hypophosphate thermoset catalyst.
5 more elements
A glass fiber mat comprising:
- a plurality of randomly oriented glass fibers;
- and
- a cured binder composition that is the reaction product of:
- a urea-extended phenol-formaldehyde resole resin;
- polyacrylic acid;
- alkanolamine crosslinking agent;
- and
- a sodium hypophosphate thermoset catalyst.
5 more elements
Dependencies are inferred from the claim text.