Curable fiberglass binder comprising salt of inorganic acid

Patent metadata

Field	Value
Publication number	US-10099959-B2
Application number	US-201715433180-A
Country	US
Kind code	B2
Filing date	Feb 15, 2017
Priority date	Aug 11, 2009
Publication date	Oct 16, 2018
Grant date	Oct 16, 2018

Abstract

A curable formaldehyde-free binding composition for use with fiberglass is provided. Such curable composition comprises an aldehyde or ketone and an amine salt of an inorganic acid. The composition when applied to fiberglass is cured to form a water-insoluble binder which exhibits good adhesion to glass. In a preferred embodiment the composition when applied to fiberglass provides a sufficient blackness required in facer products.

First claim

That which is claimed is:

1. A facer material comprising:
a curable composition, and
a non-woven web, wherein:
the curable composition comprises an aldehyde or ketone and an amine salt of an inorganic acid,
the non-woven web is bonded to the curable composition,
the amine salt is an organic amine salt,
the molar ratio of the amine salt to the aldehyde or ketone is 1:3 to 1:10,
the composition is formaldehyde-free,
the aldehyde or ketone is present in a saccharide, and
the amine of the amine salt is a diamine having at least one primary amine group.

2. The facer material of claim 1 , wherein the non-woven web comprises chopped glass fibers.

3. The facer material of claim 2 , wherein at least about 90 percent of the chopped glass fibers have a fiber diameter in the range from 1 to 30 μm.

4. The facer material of claim 1 , wherein the non-woven web has a total weight from 20 to 200 g/m2.

5. The facer material of claim 1 , wherein:
the non-woven web is a first non-woven web, and
the facer material comprises a second non-woven web.

6. The facer material of claim 5 , wherein:
the first non-woven web comprises glass fibers having a diameter in the range from 1 to 10 μm, and
the second non-woven web comprises glass fibers having a diameter in the range from 12 to 30 μm.

7. The facer material of claim 1 , wherein:
the non-woven web comprises a first portion of chopped fibers having a diameter in the range from 1 to 30 μm,
the non-woven web comprises a second portion of chopped fibers having a diameter less than about 5.5 μm, and
the second portion is present in about 1 to 30 weight percent of the dry weight of the non-woven web.

8. The facer material of claim 1 , wherein:
the non-woven web comprises chopped fibers, and
the majority of the chopped fibers have a length in the range from 0.20 inches to 1.5 inches.

9. The facer material of claim 1 , further comprising a water repellant.

10. The facer material of claim 1 , further comprising fillers or pigments.

11. The facer material of claim 10 , wherein the fillers or pigments are distributed throughout the facer material.

12. The facer material of claim 10 , wherein the fillers or pigments are concentrated on a surface of the facer material.

13. The facer material of claim 1 , wherein:
the non-woven web comprises a first portion of chopped glass fibers,
the non-woven web comprises a second portion of fibers that are not glass fibers, and
the first portion is greater than the second portion.

14. The facer material of claim 1 , wherein the inorganic acid is phosphoric acid.

15. The facer material of claim 1 , wherein the amine salt is an amine-acid salt.

16. The facer material of claim 15 , wherein the amine is selected from the group consisting of ethylene diamine, 1,3-propanediamine, 1,4-butanediamine, 1,5-pentanediamine, 1,6-hexanediamine, α,α′-diaminoxylene, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, diamino benzene, and mixtures thereof.

17. The facer material of claim 1 , wherein the aldehyde is used with the amine salt.

18. The facer material of claim 1 , wherein the ketone is used with the amine salt.

19. The facer material of claim 1 , wherein the saccharide is selected from the group consisting of dextrose, fructose, galactose, xylose, and ribose.

Assignees

• Johns Manville

Inventors

• Christensen Bernd
• Alavi Kiarash
• Nandi Souvik
• Asrar Jawed
• Zhang Mingfu

Classifications

• C03C25/246

  Chemistry & Metallurgy · mapped topic

• C03C25/1095

  to obtain coated fabrics · CPC title

• C03C2217/29

  Mixtures · CPC title

• C03C25/42

  Coatings containing inorganic materials · CPC title

• C03C25/34 Primary

  Condensation polymers of aldehydes, e.g. with phenols, ureas, melamines, amides or amines · CPC title