Urea-formaldehyde resin composition and process for making fiber mats
AssigneeGeorgia-Pacific Chemicals LLC
InventorsMark Poggi, Kelly Shoemake
Life of this patent
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Abstract
A thermosetting urea-formaldehyde (UF) resin composition containing a rheological-enhancing amount of a thickening agent, the use of the resin composition for formulating an adhesive binder for preparing fiber mats and the fiber mats made using the adhesive binder, wherein improved mat properties and faster cure speeds can be obtained.
Claims19
A fiber mat adhesive comprising a thermosetting urea-formaldehyde resin and a thickening agent, wherein the adhesive contains about 5 to about 35% solids by weight of the urea-formaldehyde resin, wherein the thickening agent is selected from the group consisting of:
- polyacrylamides;
- polyvinyl alcohols;
- and mixtures thereof, and wherein the thickening agent is present in an amount of about 0.005 to about 0.3 pounds per hundred pounds of the urea-formaldehyde resin solids.
A fiber mat comprising fibers bound together through a full thickness of the fiber mat with a cured adhesive comprising thermoset urea-formaldehyde resin solids and a thickening agent, wherein the thickening agent is selected from the group consisting of:
- polyacrylamides;
- polyvinyl alcohols;
- and mixtures thereof, and wherein the thickening agent is present in an amount of about 0.005 to about 0.3 pounds per hundred pounds of the urea-formaldehyde resin solids.
A fiber mat comprising fibers bound together through a full thickness of the fiber mat with a cured adhesive, wherein the cured adhesive consists essentially of thermoset urea-formaldehyde resin solids and a thickening agent, wherein the thickening agent is selected from the group consisting of:
- polyacrylamides;
- polyvinyl alcohols;
- and mixtures thereof, and wherein the thickening agent is present in an amount of about 0.005 to about 0.3 pounds per hundred pounds of the urea-formaldehyde resin solids.
A process for making a non-woven fiber mat comprising:
- forming an aqueous dispersion of fibers;
- passing the dispersion through a mat forming screen to form a wet non-woven mat;
- and
- applying an adhesive to the wet non-woven mat at a mat speed of at least 10 feet per second using a curtain coater, the adhesive comprising a thermosetting urea-formaldehyde resin and a thickening agent, wherein the adhesive contains about 5 to about 35% solids by weight of the urea-formaldehyde resin, wherein the thickening agent is selected from the group consisting of:
- polyacrylamides;
- polyvinyl alcohols;
- and mixtures thereof, and wherein the thickening agent is present in an amount of about 0.005 to about 0.3 pounds per hundred pounds of the urea-formaldehyde resin solids.
Dependencies are inferred from the claim text.