Urea-formaldehyde binder composition and process

• US 20050070186A1
• Filed: 09/29/2003
• Published: 03/31/2005
• Est. Priority Date: 09/29/2003
• Status: Abandoned Application

• Current Assignee: Georgia-Pacific Chemicals LLC (KOCH Industries Incorporated)
• Original Assignee: Georgia-Pacific Resins, Inc. (KOCH Industries Incorporated)
• Inventors: Shoemake, Kelly, Rivers, Jason, Thompson, John Everett, Breyer, Robert A.
• Application Number:
  US10/671,884
• Publication Number:
  US 20050070186A1
• Time in Patent Office: Days
• US Class Current: 442/176
• CPC Class Codes: C08J 2361/24 with urea or thiourea
• CPC Class Codes: C08J 5/04 Reinforcing macromolecular compounds with loose or coherent fibrous material
• CPC Class Codes: C08L 2666/26 Natural polymers, natural resins or derivatives thereof according to C08L1/00 - C08L5/00, C08L89/00, C08L93/00, C08L97/00 or C08L99/00
• CPC Class Codes: C08L 61/24 with urea or thiourea
• CPC Class Codes: C08L 61/32 Modified amine-aldehyde condensates
• CPC Class Codes: D04H 1/587 characterised by the bonding agents used
• CPC Class Codes: Y10T 442/20 Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
• CPC Class Codes: Y10T 442/2959 Coating or impregnation contains aldehyde or ketone condensation product
• CPC Class Codes: Y10T 442/2992 Coated or impregnated glass fiber fabric

Abstract

An aqueous binder composition containing a urea-formaldehyde resin modified with a protein, preferably with a source of soy protein and the use of the binder for preparing fiber mats, especially glass fiber mats.

Claims

1. A binder composition comprising a urea-formaldehyde resin, prepared at a formaldehyde to urea mole ratio in the range of about 2.1:

1 to 3.2;

1, modified with a protein, said protein provided in an amount of 0.1% to 10% by weight of urea-formaldehyde resin solids.

2. The binder composition of claim 1 wherein the protein is a vegetable protein.

3. The binder of claim 2 wherein the vegetable protein is a soy protein.

4. The binder of claim 3 wherein the soy protein is a soy flour and having a final formaldehyde to urea mole ratio in the range of about 1.4:

1 to about 2.3;

1.

5. The binder of claim 4 having the soy flour in an amount of about 0.2% to about 7% by weight of urea-formaldehyde resin solids.

6. The binder of claim 1 comprising a binder modifier selected from the group consisting of a styrene-maleic anhydrde copolymer;

a non-ionic amine oxide, optionally with a latex or a water-soluble polymer;

a water-insoluble anionic phosphate ester and a fatty alcohol; and

a styrene/acrylate/acrylonitrile polymer, supplemented with a polysiloxane.

7. A fiber mat bonded with a binder composition comprising a urea-formaldehyde resin modified with a protein, said protein provided in an amount of 0.1% to 10% by weight of resin solids.

8. The fiber mat of claim 7 wherein the protein is a vegetable protein.

9. The fiber mat of claim 8 wherein the vegetable protein is a soy protein.

10. The fiber mat of claim 9 wherein the soy protein is a soy flour.

11. The fiber mat of claim 10 having the soy flour in an amount of about 0.2% to about 7% by weight of urea-formaldehyde resin solids.

12. The fiber mat of claim 11 made using glass fibers.

13. The fiber mat of claim 7 wherein the binder comprises a binder modifier selected from the group consisting of a styrene-maleic anhydrde copolymer;

a non-ionic amine oxide, optionally with a latex or a water-soluble polymer;

a water-insoluble anionic phosphate ester and a fatty alcohol; and

a styrene/acrylate/acrylonitrile polymer, supplemented with a polysiloxane.

14. A process for making a fiber mat comprising (a) forming an aqueous dispersion of fibers;

(b) passing the dispersion through a mat forming screen to form a wet non-woven mat and (c) applying a binder composition to the wet non-woven mat, the binder composition comprising a urea-formaldehyde resin modified with a protein, said protein provided in an amount of 0.1% to 10% by weight of resin solids.

15. The process of claim 14 wherein the protein is a vegetable protein.

16. The process of claim 15 wherein the vegetable protein is a soy protein.

17. The process of claim 16 wherein the soy protein is a soy flour.

18. The process of claim 17 having the soy flour in an amount of about 0.2% to about 7% by weight of urea-formaldehyde resin solids

19. The process of claim 18 wherein the fibers are glass fibers.

20. The process of claim 14 wherein the binder comprises a binder modifier selected from the group consisting of a styrene-maleic anhydrde copolymer;

a non-ionic amine oxide, optionally with a latex or a water-soluble polymer;

a water-insoluble anionic phosphate ester and a fatty alcohol; and

a styrene/acrylate/acrylonitrile polymer, supplemented with a polysiloxane.