Methacrylic acid polymer extended urea-formaldehyde resin composition for making fiberglass products

Patent metadata

Field	Value
Publication number	US-9962731-B2
Application number	US-201414501638-A
Country	US
Kind code	B2
Filing date	Sep 30, 2014
Priority date	Sep 30, 2013
Publication date	May 8, 2018
Grant date	May 8, 2018

Abstract

The present invention provides methacrylic acid polymer modified aqueous urea formaldehyde resin (UF resin) binder compositions useful in making a treated glass mat, e.g. for roofing shingles, wherein the methacrylic acid polymer comprises the reaction product of at least 50 wt. %, based on the total weight of monomers used to make the methacrylic acid polymer, of methacrylic acid or its salts, or mixtures thereof, a water-soluble phosphorous or sulfur containing compound and the remainder of a carboxylic acid group containing monomer, such as acrylic acid. The methacrylic acid polymers have at least one of a phosphite group, hypophosphite group, phosphinate group, diphosphinate group, and/or sulfonate group and enable modified UF resins to have early strength development even when the binder compositions comprise from 0.1 to less than 5 wt. % of the polymer modifier, based on total solids of the UF resin and the polymer modifier.

First claim

We claim:

1. An aqueous urea formaldehyde resin (UF resin) binder composition comprising the UF resin and from 0.1 to less than 5 wt. % of at least one polymer modifier, based on total solids of the UF resin and the polymer, wherein the polymer modifier is a methacrylic acid polymer that contains at least one acid group which is other than a carboxylic acid group and which is chosen from a phosphite group, hypophosphite group, phosphinate group, diphosphinate group, sulfonate group and combinations thereof, wherein the methacrylic acid polymer is the reaction product of 50 wt. % or more of methacrylic acid, a salt thereof, or mixtures thereof, based on the total weight of monomers used to make the methacrylic acid polymer up to 40 wt %, based on the total weight of monomers used to make the methacrylic acid polymer, of a carboxylic acid group containing monomer group consisting of acrylic acid, itaconic acid and maleic acid or its anhydride, and 4.0 to 25 wt %, based on total weight of monomer used to make the methacrylic acid polymer, of a water soluble phosphorous containing compound having an oxidation state of +3 or +1 or sulfur containing compounds having an oxidation state +4 or +1; and,
further wherein the at least one polymer modifier has a weight average molecular weight of from 2,000 to 16,000.

2. The aqueous urea formaldehyde resin (UF resin) binder composition as claimed in claim 1 , wherein the methacrylic acid polymer is the reaction product of 60 wt. % or more of methacrylic acid, a salt thereof, or mixtures thereof, based on the total weight of monomers used to make the methacrylic acid polymer.

3. The aqueous urea formaldehyde resin (UF resin) binder composition as claimed in claim 1 , wherein the at least one polymer modifier has a weight average molecular weight of from 5,000 to 12,000.

4. The aqueous urea formaldehyde resin (UF resin) binder composition as claimed in claim 1 , wherein the at least one polymer modifier is a methacrylic acid copolymer wherein the at least one acid group which is other than a carboxylic acid group is chosen from a group wherein a phosphorous atom is bound to two carbon atoms along the carbon chain, a terminal group, a pendant alkyl phosphinate, a pendant alkyl phosphonate, and combinations thereof.

5. A method of making an aqueous urea formaldehyde resin (UF resin) binder composition comprising the UF resin and from 0.1 to less than 5 wt. % of at least one methacrylic acid polymer modifier, based on total solids of the UF resin and the polymer modifier, wherein the polymer modifier is a methacrylic acid polymer that contains at least one acid group which is other than a carboxylic acid group and which is chosen from a phosphite group, hypophosphite group, phosphinate group, diphosphinate group, sulfonate group and combinations thereof, comprising;
polymerizing in aqueous media a mixture of 50 wt. % or more of methacrylic acid or its salt, based on the total weight of monomers used to make the methacrylic acid polymer, up to 40 wt %, based on the total weight of monomer used to make the methacrylic acid polymer, of a carboxylic acid group containing monomer selected from a group consisting of acrylic acid, itaconic acid and maleic acid or its anhydride, and from 4.0 to 25.0 wt. %, based on the total weight of monomers used to make the methacrylic acid polymer, of at least one of a water-soluble compound chosen from a phosphorous containing compound in which the phosphorous is in the oxidation state of +3, a phosphorous containing compound in which the phosphorous is in the oxidation state of +1, a sulfur containing compound in which the sulfur is in the oxidation state of +4, a sulfur containing compound in which the sulfur is in the oxidation state of +1, and their salts; and,
combining the result of the polymerization with urea formaldehyde resin.

6. The method of making an aqueous urea formaldehyde resin (UF resin) binder composition as claimed in claim 5 , wherein the amount of the water-soluble compound ranges from 6.0 wt. % to 20 wt. %.

7. The method of making an aqueous urea formaldehyde resin (UF resin) binder composition as claimed in claim 5 , wherein the water-soluble compound is chosen a hypophosphite compound, a bisulfite, a metabisulfite, and salts thereof.

8. The method of making an aqueous urea formaldehyde resin (UF resin) binder composition as claimed in claim 5 , wherein the amount of the methacrylic acid polymer modifier ranges from 0.5 to less than 5 wt. % of at least one polymer modifier, based on total solids of the UF resin and the polymer modifier.

9. A method of using the aqueous urea formaldehyde resin (UF resin) binder composition as claimed in claim 1 , comprising;
applying the aqueous urea formaldehyde resin binder composition to or treating with the aqueous urea formaldehyde resin composition a wet laid continuous glass fiber mat; and,
heating to cure the aqueous urea formaldehyde resin composition to form a treated glass mat.

10. A treated glass mat made by the method as claimed in claim 9 .

Assignees

• Rohm & Haas

Inventors

• Finch William C
• Kelly Michael D
• Mulik Sudhir M
• Rodowski C Damien

Classifications

• C08L61/24

  with urea or thiourea · CPC title

• B05D3/007 Primary

  After-treatment · CPC title

• C08L33/14

  of esters containing halogen, nitrogen, sulfur, or oxygen atoms in addition to the carboxy oxygen · CPC title

• Y10T442/2959

  Coating or impregnation contains aldehyde or ketone condensation product · CPC title

• C08L33/02

  Homopolymers or copolymers of acids; Metal or ammonium salts thereof · CPC title