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US 6,646,094 B1Granted
Low emission formaldehyde resin and binder for mineral fiber insulation
AssigneesCertainTeed Corporation, Borden Chemical, Inc.
InventorsVinay Malhotra, Wayne Walliser, Susan G. Watson, Pierre C. Herault, Domenic Tessari, Philippe Espiard, Serge Tetart, Bruno Malhieuxe
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Abstract
A phenol-formaldehyde resole resin is prepared using a high level of catalyst at a polymerization temperature of about 63° C. The endpoint, measured by salt water tolerance, is selected so that the resulting resin has a water dilutability of 20:1 at neutral pH after storage for three weeks at a temperature of about 13° C., with a free phenol level of no more than 0.50 percent.
Claims62
A process for preparing a water-soluble resin for mineral fibers, the process comprising reacting three components:
- (1) at least one hydroxy-functional aromatic compound, (2) at least one reactive aldehyde, and (3) at least one basic polymerization catalyst;
- the process including:
- a) preparing an initial aqueous mixture including at least one hydroxy-functional aromatic compound and a second component selected from the group comprising (1) at least one reactive aldehyde and (2) at least one basic polymerization catalyst;
- b) feeding the third component to the initial aqueous mixture while the temperature of the aqueous mixture is maintained from about 50° C. to about 75° C.;
- the mole ratio of total catalyst to hydroxy-functional aromatic compound being at least 17 moles catalyst per 100 moles hydroxy-functional aromatic compound;
- c) maintaining the temperature of the aqueous mixture in a range from about 50° C. to about 75° C. until a predetermined endpoint is achieved;
- and
- d) cooling the aqueous mixture.
5 more elements
A phenol-formaldehyde resole resin, having
- (a) a mole ratio of formaldehyde to phenol is from 2.0:1 to 5.0:1;
- (b) a pH from 5 to 9;
- (c) sufficient water solubility so that it can be diluted with water to a ratio of 20:1 at neutral pH after at least three weeks storage at a temperature of about 13° C.;
- and
- (d) a free phenol content no more than 0.50 percent by weight of the liquid resin.
2 more elements
A process for preparing a phenolic binder for mineral fibers, the process comprising reacting three components:
- (1) at least one hydroxy-functional aromatic compound, (2) at least one reactive aldehyde, and (3) at least one basic polymerization catalyst;
- the process including
- a) preparing a water-soluble resin by:
- 1) preparing an initial aqueous mixture including at least one hydroxy-functional aromatic compound and a second component selected from the group comprising (1) at least one reactive aldehyde and (2) at least one basic polymerization catalyst;
- 2) feeding the third component to the initial aqueous mixture while the temperature of the aqueous mixture is maintained from about 50° C. to about 75° C.;
- the mole ratio of total catalyst to hydroxy-functional aromatic compound being at least 17 moles catalyst per 100 moles hydroxy-functional aromatic compound;
- 3) maintaining the temperature of the aqueous mixture between in a range from about 50° C. to about 75° C. until a predetermined endpoint is achieved;
- and
- 4) cooling the aqueous mixture;
- b) subsequently completing preparation of the binder by adding a catalyst for curing the resole resin.
7 more elements
A binder for mineral fibers comprising
- (a) a water-soluble phenol-formaldehyde resole resin having:
- (1) a mole ratio of formaldehyde to phenol is from 2.0:1 to 5.0:1;
- (2) a pH from 5 to 9;
- (3) sufficient water solubility so that it can be diluted with water to a ratio of 20:1 at neutral pH after at least three weeks storage at a temperature of about 13° C.;
- (4) a free phenol content no more than 0.50 percent by weight of the liquid resin;
- and
- (b) a catalyst for curing the resole resin.
4 more elements
A process for preparing a mineral fiber mat product, the process comprising:
- a) preparing a phenolic binder for mineral fibers by a process comprising
- 1) preparing a water-soluble resin by a process comprising reacting three components:
- (1) at least one hydroxy-functional aromatic compound, (2) at least one reactive aldehyde, and (3) at least one basic polymerization catalyst;
- the process including:
- A) preparing an initial aqueous mixture including at least one hydroxy-functional aromatic compound and a second component selected from the group comprising (1) at least one reactive aldehyde and (2) at least one basic polymerization catalyst;
- B) feeding a third component to the initial aqueous mixture while the temperature of the aqueous mixture is maintained from about 50° C. to about 75° C.;
- the mole ratio of total catalyst to hydroxy-functional aromatic compound at least 17 moles catalyst per 100 moles hydroxy-functional aromatic compound;
- C) maintaining the temperature of the aqueous mixture between in a range from about 50° C. to about 75° C. until a predetermined endpoint is achieved;
- D) cooling the aqueous mixture;
- and
- E) neutralizing the aqueous mixture to a pH between 5 and 9;
- 2) subsequently completing preparation of the binder by adding a catalyst for curing the resin;
- b) applying the binder to a mineral fiber mat;
- and
- c) curing the binder comprising the resin and the cure catalyst.
12 more elements
Dependencies are inferred from the claim text.