Disclosed are binders including urea-extended phenol-formaldehyde alkaline resole resins to which melamine-containing resin has been added, and non-woven fiber compositions made therewith. The disclosed binders may be cured to low formaldehyde-emission and low trimethylamine-emission, water-resistant thermoset binders.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an exemplary schematic that depicts one way of disposing a binder of the present invention onto fibers.
Claims
1. A method for preparing an aqueous binder, said method comprising:
(a) selecting an aqueous resole resin having a pH greater than about 7, said resin prepared by reacting phenol with excess formaldehyde under alkaline conditions;(b) adding to said aqueous resole resin and reacting therewith aqueous urea in an amount to produce a premix containing about 70 parts by weight of resole resin solids and about 30 parts by weight of urea solids; and(c) mixing into said premix a melamine-containing resin and aqueous urea such that resole resin solids, urea solids, and melamine solids are present in said aqueous binder in the range from about 45 to about 50 parts by weight, about 35 to about 45 parts by weight, and about 10 to about 15 parts by weight, respectively, based on the total of resole resin solids, urea solids, and melamine solids.
2. The method of claim 1, wherein the premix contains about 50 weight percent solids.
3. The method of claim 1, wherein the free formaldehyde content of the resole resin is about 7.5% by weight, based on the total weight of the resole resin.
4. The method of claim 1, wherein the free formaldehyde content of the premix is about 0.5% by weight, based on the total weight of the premix.
5. The method of claim 1, further comprising:
(d) mixing into said premix a latent acid catalyst, wherein said catalyst is generated in situ in said premix from aqueous ammonia and an aqueous organic acid.
6. The method of claim 5, wherein the aqueous organic acid is selected from the group consisting of para-toluenesulfonic acid, sulfuric acid, methanesulfonic acid, and phenylsulfonic acid.
7. A binder prepared by the method of claim 6.
8. The binder of claim 7, wherein the resole solids, urea solids, and melamine solids are present in about 44 parts by weight, about 45 parts by weight, and about 11 parts by weight, respectively.
9. The binder of claim 7, wherein the resole solids, urea solids, and melamine solids are present in about 52 parts by weight, about 35 parts by weight, and about 13 parts by weight, respectively.
10. A method for binding glass fibers, said method comprising:
(a) contacting said fibers with the binder of claim 7; and(b) removing water from the binder in contact with said fibers to dehydrate the binder.
11. A fiberglass composition prepared by the method of claim 10.
12. The method of claim 10, further comprising:
(c) heating the dehydrated binder in contact with said fibers at a temperature sufficient to cure the binder and produce a water-resistant thermoset binder.
13. A fiberglass composition prepared by the method of claim 12.
14. The method of claim 12, wherein the heating is conducted under pressure.
15. A fiberglass composition prepared by the method of claim 14.
Patent Application
20070191574
