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US 6,307,009 B1Granted
High catalyst phenolic resin binder system
AssigneeOwens Corning Fiberglas Technology, Inc.
InventorJianjun Li
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Abstract
An aqueous binder composition suitable for use as a binder in making wool and board products including fiberglass insulation comprising a phenolic resole resin binder made from phenol and formaldehyde by using an excess amount of a basic catalyst.
Claims6
A method of preparing water soluble phenolic binders for use in making wool and board products comprising;
- preparing an aqueous mixture including a formaldehyde, a phenol and a basic catalyst, said catalyst being present in an amount of at least 20% based on the weight of phenol;
- the mol ratio of formaldehyde to phenol ratio being between about 3.0/1 and 4.5/1;
- heating said mixture;
- maintaining the mixture for a time and a temperature so that the free formaldehyde content of the mixture falls to a predefined level and the free phenol level is less than 1% ;
- neutralizing the catalyst with an acid, said acid reacting with the basic catalyst so as to form a salt that precipitates from the mixture;
- and separating the salt from the mixture.
3 more elements
Dependencies are inferred from the claim text.