Modified urea-formaldehyde binders for non-woven fiber glass mats

Patent metadata

Field	Value
Publication number	US-10119020-B2
Application number	US-201113300841-A
Country	US
Kind code	B2
Filing date	Nov 21, 2011
Priority date	Nov 21, 2011
Publication date	Nov 6, 2018
Grant date	Nov 6, 2018

Abstract

Urea-formaldehyde (UF) resin binder compositions modified with a starch are described. The binder compositions may include about 1 wt. % to about 10 wt. % of a starch. In addition, fiber reinforced composites are described. The composites may include organic or inorganic fibers and a polymer matrix formed from a binder composition. The binder composition may include a UF resin and about 1 wt. % to about 10 wt. % of a starch.

First claim

What is claimed is:

1. A binder composition comprising:
a urea-formaldehyde resin;
about 1 wt. % to about 10 wt. % of a starch crosslinking agent selected from the group consisting of a native starch, a cationically modified starch, and an anionically modified starch, wherein hydroxyl functional groups on the starch bond to reactive functional groups on the urea-formaldehyde resin; and
wherein the binder composition lacks a styrene-containing, petroleum-based modifier,
wherein the urea-formaldehyde resin and the starch crosslink to increase a hot/wet tensile strength of a fiber-reinforced composite formed with the binder composition by 5% to 35% compared to a comparative fiber-reinforced composite made with an unmodified urea-formaldehyde binder composition that lacks the starch.

2. The binder composition of claim 1 , wherein the binder composition comprises about 1 wt. % to about 2.5 wt. % of the starch.

3. The binder composition of claim 1 , wherein the binder composition has a solids content of greater than 35 wt. %.

4. The binder composition of claim 1 , wherein the binder composition has a solids content of about 45 wt. % to about 70 wt. %.

5. The binder composition of claim 1 , wherein the binder composition further comprises water.

6. The binder composition of claim 5 , wherein the binder composition has a solids content of about 5 to 35 wt. %.

7. The binder composition of claim 1 , wherein the pH of the composition is between about 7.0 and 9.0.

8. The binder composition of claim 1 , wherein the binder composition comprises between about 45% to about 75% by weight nonvolatiles.

9. A fiber reinforced composite comprising:
a polymer matrix formed from a binder composition that comprises:
a urea-formaldehyde resin;
about 1 wt. % to about 10 wt. % of a starch crosslinking agent selected from the group consisting of a native starch, a cationically modified starch, and an anionically modified starch, wherein hydroxyl functional groups on the starch bond to reactive functional groups on the urea-formaldehyde resin; and
wherein the binder composition lacks a styrene-containing, petroleum-based modifier,
organic or inorganic fibers,
wherein the urea-formaldehyde resin and the starch are crosslinked to increase a hot/wet tensile strength of the fiber-reinforced composite by 5% to 35% compared to a comparative fiber-reinforced composite made with an unmodified urea-formaldehyde binder composition that lacks the starch.

10. The fiber reinforced composite of claim 9 , wherein the organic or inorganic fibers comprise glass fibers.

11. The fiber reinforced composite of claim 9 , wherein the composite comprises a non-woven glass-fiber reinforced mat.

12. The fiber reinforced composite of claim 11 , wherein the non-woven glass-fiber reinforced mat forms part of a roofing shingle.

13. The fiber reinforced composite of claim 9 , wherein a weight ratio of the starch to the petroleum-based modifier is about 0.1:1 or more.

14. A binder composition consisting of:
a urea-formaldehyde resin; and
about 1 wt. % to about 10 wt. % of a starch crosslinking agent selected from a native starch, a cationically modified starch, and an anionically modified starch wherein the starch does not substantially increase a viscosity of the binder composition, and wherein the binder composition lacks a styrene-containing, petroleum-based modifier, and
wherein the urea-formaldehyde resin and the starch crosslink to increase a hot/wet tensile strength of a fiber-reinforced composite formed with the binder composition by 5% to 35% compared to a comparative fiber-reinforced composite made with an unmodified urea-formaldehyde binder composition that lacks the starch.

15. The binder composition of claim 14 , wherein the binder composition comprises about 1 wt. % to about 2.5 wt. % of the starch.

16. The binder composition of claim 14 , wherein the binder composition has a solids content of greater than 35 wt. %.

17. The binder composition of claim 14 , wherein the binder composition has a solids content of about 45 wt. % to about 70 wt. %.

18. The binder composition of claim 14 , wherein the urea-formaldehyde resin is an aqueous urea-formaldehyde resin.

19. The binder composition of claim 18 , wherein the binder composition has a solids content of about 5 to 35 wt. %.

Assignees

• Zheng Guodong
• Zhang Mingfu
• Weith Luke Saylor
• Asrar Jawed
• Johns Manville

Inventors

• Zheng Guodong
• Zhang Mingfu
• Weith Luke Saylor
• Asrar Jawed

Classifications

• C08L61/00 Primary

  Compositions of condensation polymers of aldehydes or ketones (with polyalcohols C08L59/00; with polynitriles C08L77/00); Compositions of derivatives of such polymers · CPC title

• C08L61/24

  with urea or thiourea · CPC title

• Y10T442/2992

  Coated or impregnated glass fiber fabric · CPC title

• C08J2361/24

  with urea or thiourea · CPC title

• C08J5/043

  with glass fibres · CPC title