Binder compositions for fiber mats, and fiber mats and articles comprising them
AssigneeGeorgia-Pacific Chemicals LLC
InventorKelly A. Shoemake
Life of this patent
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Abstract
Aqueous binder compositions for fiber mats include a urea-formaldehyde resin and an aqueous emulsion of a copolymer prepared by polymerization of a monomer mixture including styrene, an alkyl(meth)acrylate, acrylonitrile, and an unsubstituted or substituted acrylamide. Even when used in relatively low concentration, the copolymer provides improved physical properties to the fiber mat. The fiber mats can be used in composite flooring, asphalt roofing shingles, siding, and dry wall.
Claims22
An aqueous binder composition for use in making fiber mats, the binder composition comprising:
- a urea-formaldehyde resin;
- and
- an aqueous emulsion of a copolymer prepared by polmerization of a mixture comprising about 20 wt % to about 60 wt % styrene, about 20 wt % to about 50 wt % of an alkyl (meth)acrylate, about 5 wt % to about 30 wt % acrylonitrile, and about 1 wt % to about 15 wt % of an unsubstituted or substituted acrylamide, where all weight percents are based on a total weight of the mixture.
A non-woven fiber mat, comprising:
- reinforcing fibers;
- and
- a cured product of a curable binder composition comprising:
- a urea-formaldehyde resin;
- and
- an aqueous emulsion of a copolymer prepared by polymerization of a mixture comprising about 20 wt % to about 60 wt % styrene, about 20 wt % to about 50 wt % of an alkyl (meth)acrylate, about 5 wt % to about 30 wt % acrylonitrile, and about 1 wt % to about 15 wt % of an unsubstituted or substituted acrylamide, where all weight percents are based on a total weight of the mixture.
A fiber mat faced gypsum wall board, comprising:
- a gypsum core having a planar first face and a planar second face;
- and
- a coated non-woven glass fiber mat facing material adhered to and covering at least one of the planar first face and the planar second face;
- wherein the non-woven glass fiber mat facing material comprises a coating comprising a cured product of a curable binder composition comprising:
- a urea-formaldehyde resin;
- and
- an aqueous emulsion of a copolymer prepared by polymerization of a mixture comprising about 20 wt % to about 60 wt % styrene, about 20 wt % to about 50 wt % of an alkyl (meth)acrylate, about 5 wt % to about 30 wt % acrylonitrile, and about 1 wt % to about 15 wt % of an unsubstituted or substituted acrylamide, where all weight percents are based on a total weight of the mixture.
Dependencies are inferred from the claim text.