U.S. patent application number 10/715087 was filed with the patent office on 2004-08-05 for surfactant-containing insulation binder.
Invention is credited to Dobrowolski, Richard.
Application Number | 20040152824 10/715087 |
Document ID | / |
Family ID | 25357505 |
Filed Date | 2004-08-05 |
United States Patent
Application |
20040152824 |
Kind Code |
A1 |
Dobrowolski, Richard |
August 5, 2004 |
Surfactant-containing insulation binder
Abstract
A fiberglass insulation binder composition made from a
polycarboxy polymer, a polyhydroxy crosslinking agent, and a
cationic surfactant, amphoteric surfactant, nonionic surfactant, or
mixture thereof. Also, a process for manufacturing a fiberglass
insulation product, which involves a step of applying the binder
composition onto a fiberglass substrate and curing the fiberglass
substrate so treated. Binders produced in accordance with the
present invention are characterized by improved atomization,
improved binder dispersion and fiber wetting properties, and
improved protection of individual fibers during processing.
Inventors: |
Dobrowolski, Richard;
(Cheltenham, PA) |
Correspondence
Address: |
ROHM AND HAAS COMPANY
PATENT DEPARTMENT
100 INDEPENDENCE MALL WEST
PHILADELPHIA
PA
19106-2399
US
|
Family ID: |
25357505 |
Appl. No.: |
10/715087 |
Filed: |
November 17, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10715087 |
Nov 17, 2003 |
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09871467 |
May 31, 2001 |
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Current U.S.
Class: |
524/494 ; 252/62;
524/474; 65/450; 65/465 |
Current CPC
Class: |
C03C 25/285 20130101;
C08K 5/06 20130101; C08L 33/02 20130101; C08K 5/06 20130101 |
Class at
Publication: |
524/494 ;
065/465; 065/450; 252/062; 524/474 |
International
Class: |
E04B 001/74; C08K
003/40; C08K 005/01 |
Claims
What is claimed is:
1. A fiberglass insulation binder composition comprising a
polycarboxy polymer, a polyhydroxy crosslinking agent, a mineral
oil dust suppressing agent, a surfactant selected from the group
consisting of cationic surfactants, amphoteric surfactants,
nonionic surfactants, and mixtures thereof, and sufficient water to
provide a mixture comprising up to 98 wt-% water based on the total
weight of solids in the mixture.
2. The fiberglass insulation binder composition of claim 1, wherein
the surfactant is a nonionic surfactant selected from the group
consisting of: ethylene oxide and propylene oxide condensates which
include straight and branched chain alkyl and alkaryl polyethylene
glycol and polypropylene glycol ethers and thioethers;
alkylphenoxypoly(ethyleneoxy)- -ethanols having alkyl groups
containing 7 to 18 carbon atoms and having 4 to 240 ethyleneoxy
units; polyoxyalkylene derivatives of hexitol; partial long-chain
fatty acids esters; condensates of ethylene oxide with a
hydrophobic base formed by condensing propylene oxide with
propylene glycol; sulfur containing condensates prepared by
condensing ethylene oxide with higher alkyl mercaptans or with
alkylthiophenols wherein the alkyl group contains 6 to 15 carbon
atoms; ethylene oxide derivatives of long-chain carboxylic acids or
oleic acids or mixtures of acids; ethylene oxide derivatives of
long-chain alcohols; and ethylene oxide/propylene oxide
copolymers.
3. The fiberglass insulation binder composition of claim 2, wherein
the surfactant is an ethoxylated
2,4,7,9-tetramethyl-5-decyn-4,7-diol surfactant.
4. The fiberglass insulation binder composition of claim 1, wherein
the polycarboxy polymer is a polyacrylic acid polymer.
5. A process for producing a fiberglass insulation binder
comprising the steps of preparing a mixture of a polycarboxy
polymer, a polyhydroxy crosslinking agent, a mineral oil dust
suppressing agent, a surfactant selected from the group consisting
of cationic surfactants, amphoteric surfactants, nonionic
surfactants, and mixtures thereof, and sufficient water to provide
a mixture comprising up to 98 wt-% water based on the total weight
of solids in the mixture, and blending the mixture to form a
polymeric composition useful as a fiberglass insulation binder.
6. The process of claim 5, wherein the amount of surfactant
employed ranges from about 0.01 to about 10 weight percent based on
the total weight of binder solids.
7. The process of claim 6, wherein the amount of surfactant
employed ranges from about 0.2 to about 5 weight percent based on
the total weight of binder solids.
8. The process of claim 5, wherein a pre-mixture containing the
polymer and crosslinking agent comprises about 50 to 60 wt-%
water.
9. The process of claim 5, further comprising the step of adding a
hydrolyzed silane coupling agent to the mixture.
10. The process of claim 9, wherein the weight of hydrolyzed silane
coupling agent added is from 0.01 to 10 wt-% based upon the weight
of the mixture.
11. The process of claim 1, wherein the weight of mineral oil dust
suppressing agent added is up to 20 wt-% based upon the weight of
the mixture.
12. The process of claim 5, wherein the polycarboxy polymer is a
polyacrylic acid polymer.
13. The product of the process of claim 5.
14. A process for manufacturing a fiberglass insulation product,
comprising: (a) applying onto a fiberglass substrate, a binder
composition comprising a polycarboxy polymer, a polyhydroxy
crosslinking agent, a mineral oil dust suppressing agent, a
surfactant selected from the group consisting of cationic
surfactants, amphoteric surfactants, nonionic surfactants, and
mixtures thereof, and sufficient water to provide a mixture
comprising up to 98 wt-% water based on the total weight of solids
in the mixture and (b) curing the treated fiberglass substrate.
15. The process of claim 14, wherein curing is carried out in a
curing oven at a temperature from 200.degree. C. to 350.degree. C.
for 30 seconds to 3 minutes.
16. The product of the process of claim 14.
17. A process for manufacturing a fiberglass insulation product,
comprising: (a) supplying melted glass to a fiber forming device;
(b) blowing said melted glass downwardly within a forming chamber
of said forming device to attenuate glass fibers; (c) applying the
binder composition of claim 1 onto said glass fibers; (d)
depositing said glass fibers onto a foraminous forming conveyor
within said forming chamber; (e) gathering and forming said glass
fibers into a mat on said conveyor using a vacuum drawn through
said mat from below said forming conveyor, wherein residual heat
contained in said glass fibers and said vacuum volatizes said
water; and (f) curing the mat so treated.
18. The process of claim 17, wherein curing is carried out in a
curing oven at a temperature from 200.degree. C. to 350.degree. C.
for 30 seconds to 3 minutes
19. The product of the process of claim 17.
Description
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION
[0001] The present invention relates to fiberglass insulation. More
specifically, the present invention provides a means for obtaining
improved performance of polyacrylic acid and similar fiberglass
insulation binders.
BACKGROUND OF THE INVENTION
[0002] Polyacrylic acid-based fiberglass insulation binders are
typically manufactured with a low molecular weight polyacrylic
acid, a polyhydroxy crosslinking agent, and a cure accelerator,
such as sodium hypophosphite. Typical embodiments include QRXP-1564
and QRNT-1513, produced by Rohmn & Haas. QRXP-1564 is a blend
of Acuner 1020 (71.6 wt-%), glycerol (21.8 wt-%), sodium
hypophosphite (5.6 wt-%), and a small amount of corrosion
inhibitor. Water is added as a diluent. QRXP-1513 is a blend of
Acumer 1020, triethanolamine, and sodium hypophosphite. Water is
added as a diluent. Acumer 1020 is a polyacrylic acid produced from
acrylic acid monomer and a sodium bisulfite reactant. Acumer 1020
has a molecular weight of approximately 2000 and a sulfur content
of about 3.4 wt-%. U.S. Pat. Nos. 5,340,868, 5,661,213, and
5,763,524, as well as PCT publications WO 100 699 A2 and WO 9 961
384 A1, disclose conventional sulfur-containing polyacrylic
acid-based fiberglass insulation binders. See also U.S. Pat. No.
5,318,990.
[0003] Recently, insulation binders, produced by polymerizing
acrylic acid monomer in water in the presence of a cure accelerator
comprising an alkali metal salt of a phosphorous-containing
inorganic acid to form a low molecular weight polyacrylic acid and
subsequently reacting the low molecular weight polyacrylic acid
with a polyhydroxy crosslinking agent in a crosslinkng step in the
absence of added catalyst, were described by Chen and Downey in an
application entitled "Low Odor Insulation Binder from Phosphite
Terminated Polyacrylic Acid" that was filed on Mar. 21, 2001 as
Ser. No. 09/814,034.
[0004] It has been discovered that when polycarboxy polymer-based
binders, such as polyacrylic acid-based binders, are applied to
fiberglass in the course of manufacturing insulation products, the
binder is not spread on the glass fiber as well as are
conventionally employed phenol formaldehyde based insulation
binders. This poor interfacing/wetting between glass and the
polyacrylic acid binder is believed to result from high surface
tension due to the strong hydrogen bond of the acid and the acidity
of the binder versus the alkalinity of the glass surface. Such high
surface tension binders prevent efficient atomization when the
binder is applied by spraying it onto glass fibers e.g. in a
forming hood, resulting in undesirable droplet size and binder
distribution. Once the binder is on the glass fiber, its acidity
and high surface tension result in poor wetting and reduced binder
flow to fiber-fiber junctions. The poor wetting and reduced bonding
efficiency decreases protection of individual glass fibers and
results in increased fiber damage during processing. As a result,
product properties, including pack integrity and dusting, are
adversely impacted.
[0005] A recently issued U.S. Pat. No. 6,171,654 (Seydel Research)
discloses the incorporation of ethyoxylated tallow amine
surfactants into binder made from terephthalate polymers. The
Seydel Research patent does not purport to address the above-noted
problems.
SUMMARY OF THE INVENTION
[0006] It has now been found that if an appropriate surfactant is
added to the polycarboxy polymer binder composition, the surface
tension of the polycarboxy polymer binder composition is reduced,
enabling a great improvement in binder wetting and in the
distribution of the binder into the fiberglass matrix. Thus the
present invention provides better fiber protection, less fiber
damage, better product performance, and a more environmentally
friendly manufacturing operation.
[0007] One embodiment of this invention is a fiberglass insulation
binder composition comprising a polycarboxy polymer (especially a
polyacrylic acid polymer), a polyhydroxy crosslinking agent, and a
surfactant selected from the group consisting of cationic
surfactants, amphoteric surfactants, nonionic surfactants, and
mixtures thereof.
[0008] Another embodiment of this invention is a process for
producing a fiberglass insulation binder. The process includes the
preparation of a mixture of a polycarboxy (e.g., polyacrylic acid)
polymer, a polyhydroxy crosslinking agent, a surfactant as
described above, and sufficient water to provide a mixture
comprising up to 98 wt-% water based on the total weight of solids
in the mixture, and blending the mixture to form a polymeric
composition useful as a fiberglass insulation binder. In this
process, the amount of surfactant employed can ranges from about
0.01 to about 10 weight percent, preferably from about 0.2 to about
5 weight percent, based on the total weight of binder solids. This
process can make use of a pre-mixture containing the polymer and
crosslinking agent that comprises about 50 to 60 wt-% water. A
hydrolyzed silane coupling agent can also be added to the mixture,
for example in an amount of from 0.01 to 10 wt-% based upon the
weight of the mixture. Likewise, a mineral oil dust suppressing
agent to the mixture, for example in an amount of up to 20 wt-%
based upon the weight of the mixture. The product of this process
is also one aspect of the present invention.
[0009] Another important embodiment of the present invention is a
process for manufacturing a fiberglass insulation product. This
process comprises the step of applying a binder composition as
described above onto a fiberglass substrate, and curing the
fiberglass substrate so treated. The fiberglass insulation product
so produced is yet another embodiment of the present invention.
[0010] Advantages of the present invention will become more
apparent from the detailed description given hereinafter. However,
it should be understood that the detailed description and specific
examples, while indicating preferred embodiments of the invention,
are given by way of illustration only. Based upon this detailed
description, various changes and modifications within the spirit
and scope of this invention will become apparent to those skilled
in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The drawings accompanying this application are presented by
way of illustration only and are not intended to limit the present
invention.
[0012] FIG. 1 is a Scanning Electron Microscope (SEM) photograph
showing poor binder dispersion in a Prior Art context.
[0013] FIGS. 2 and 3 are SEM photographs showing good binder
dispersion obtained in accordance with the present invention.
DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS OF THE INVENTION
[0014] As described hereinbelow, compositions of this invention are
prepared by polymerization of monomers emulsified in water using
conventional emulsion polymerization procedures. Suitable
surface-active agents ("surfactants") are used for emulsification
of the monomers. Suitable surfactants include cationic, amphoteric,
and nonionic surfactants, or mixtures thereof, with nonionic
surfactants being preferred. Unless otherwise noted all percentages
are weight percent.
[0015] The primary solids component of the binder of this invention
is preferably acrylic acid, but may be any polycarboxy polymer.
Thus the binder of the present invention comprises an organic
polymer or oligomer containing a plurality of pendant carboxy
groups. The polycarboxy polymer may be a homopolymer or copolymer
prepared from unsaturated carboxylic acids including acrylic acid,
methacrylic acid, crotonic acid, isocrotonic acid, maleic acid,
cinnamic acid, 2-methylmaleic acid, itaconic acid, 2-methylitaconic
acid, and the like. Alternatively, the polycarboxy polymer may be
prepared from unsaturated anhydrides including maleic anhydride,
itaconic anhydride, acrylic anhydride, methacrylic anhydride, and
the like, as well as mixtures thereof. Methods for polymerizing
these acids and anhydrides are well known in the chemical arts.
[0016] The low molecular weight polycarboxy polymer produced in the
first step of the process of the present invention is reacted with
a polyhydroxy crosslinking agent, such as triethanolamine,
glycerol, trimethylolpropane, 1,2,4-butanetriol, ethyleneglycol,
1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, pentaerythritol,
sorbitol, and the like. No catalyst is necessary in this
crosslinking step.
[0017] The polycarboxy polymer, polyhydroxy crosslinking agent and
surfactant may be mixed in a conventional mixing device. The
polycarboxy polymer may be present at a concentration from about 5%
to about 50% by weight, preferably from about 10% to about 30% by
weight, based on the total weight of the mixture. It will be
readily apparent to those skilled in the art that the concentration
ranges for the polycarboxy polymer and other binder components may
vary over wide limits and are not sharply critical to the
successful practice of the present invention. Water may be added to
the solids mixture in any amount which would produce an aqueous
binder having a viscosity and flow rate suitable for its
application to a forming fibrous glass mat by any convenient
method, such as by spraying. Conveniently, water may comprise up to
about 98% by weight of the binder.
[0018] Examples of useful cationic surfactants include alkylamine
salts such as laurylamine acetate, quaternary ammonium salts such
as lauryl trimethyl ammonium chloride and alkyl benzyl
dimethylammonium chlorides, and polyoxyethylenealkylarnines.
Examples of the amphoteric surfactants are alkylbetaines such as
lauryl-betaine.
[0019] Examples of nonionic surfactants which can be used in this
invention are polyethers, e.g., ethylene oxide and propylene oxide
condensates which include straight and branched chain alkyl and
alkaryl polyethylene glycol and polypropylene glycol ethers and
thioethers; alkylphenoxypoly(ethyleneoxy)ethanols having alkyl
groups containing from about 7 to about 18 carbon atoms and having
from about 4 to about 240 ethyleneoxy units, such as
heptylphenoxypoly(ethyleneoxy) ethanols,
nonylphenoxypoly(ethyleneoxy) ethanols; the polyoxyalkylene
derivatives of hexitol including sorbitans, sorbides, mannitans,
and mannides; partial long-chain fatty acids esters, such as the
polyoxyalkylene derivatives of sorbitan monolaurate, sorbitan
monopalmitate, sorbitan monostearate, sorbitan tristearate,
sorbitan monooleate, and sorbitan trioleate; the condensates of
ethylene oxide with a hydrophobic base, said base being formed by
condensing propylene oxide with propylene glycol; sulfur containing
condensates, e.g., those prepared by condensing ethylene oxide with
higher alkyl mercaptans, such as nonyl, dodecyl, or tetradecyl
mercaptan, or with alkylthiophenols wherein the alkyl group
contains from about 6 to about 15 carbon atoms; ethylene oxide
derivatives of long-chain carboxylic acids, such as lauric,
myristic, palmitic, or oleic acids or mixtures of acids, such as
tall oil fatty acids; ethylene oxide derivatives of long-chain
alcohols such as octyl, decyl, lauryl, or cetyl alcohols; and
ethylene oxide/propylene oxide copolymers.
[0020] Particularly preferred surfactants include SURFYNOL 420,
440, and 465, which are ethoxylated
2,4,7,9-tetramethyl-5-decyn4,7-diol surfactants produced by Air
Products and Chemicals, Inc. of Allentown, Pa.
[0021] The amounts of surfactants employed in the emulsion
polymerization process will range from about 0.01 to about 10
weight percent, preferably about 0.2 to about 5 weight percent
based on the total weight of monomers and water.
[0022] The binders of the present invention may optionally contain
conventional adjuvants such as, for example, coupling agents, dyes,
oils, fillers, thermal stabilizers, flame retarding agents,
lubricants, and the like, in conventional amounts generally not
exceeding 20% of the weight of the binder.
[0023] The polyacrylic acid and the polyhydroxy crosslinking agent
may be mixed with water in a conventional mixing device. Water may
be added to the mixture of acrylic acid monomer and polyhydroxy
crosslinking agent in any amount which produces an aqueous binder
mixture having a viscosity and flow rate suitable for application
to a forming fibrous glass mat by any convenient method, e.g.,
spraying. Water may comprise up to about 98% by weight of the
binder mixture.
[0024] In use, the polyacrylic acid-based binder produced as
described above is applied onto fiberglass, and the fiberglass so
treated is cured and formed into, e.g., an insulation blanket. More
specifically, the binder is applied to glass fibers as they are
being produced and formed into a mat, water is volatilized from the
binder, and the resulting high solids binder-coated fibrous glass
mat is heated to cure the binder, thereby producing a finished
fibrous glass bat. These cured fiberglass bats may be used as
thermal or acoustical insulation products, reinforcement for
subsequently produced composites, and so on.
[0025] It is generally well known in the art to produce a porous
mat of fibrous glass by fiberizing molten glass and immediately
forming a fibrous glass mat on a moving conveyor. Glass is melted
in a tank and supplied to a fiber forming device such as a spinner
or a bushing. Fibers of glass are attenuated from the device and
are blown generally downwardly within a forming chamber. The glass
fibers typically have a diameter from about 2 to about 9 microns
and have a length from about 1/4 inch to about 3 inches.
Preferably, the glass fibers range in diameter from about 3 to
about 6 microns, and have a length from about 1/2 inch to about 1
1/2 inches. The glass fibers are deposited onto a perforated,
endless forming conveyor. The binder is applied to the glass fibers
as they are being formed by means of suitable spray applicators so
as to result in a distribution of the binder throughout the formed
mat of fibrous glass. The glass fibers, having the uncured resinous
binder adhered thereto, are gathered and formed into a mat on the
endless conveyor within the forming chamber with the aid of a
vacuum drawn through the mat from below the forming conveyor. The
residual heat contained in the glass fibers as well as the air flow
through the mat causes a majority of the water to volatilize from
the mat before it exits the forming chamber.
[0026] In more detail, application of the binder may proceed as
follows. Melted glass is supplied to a fiber forming device such as
a spinner or a bushing. Fibers of glass are attenuated from the
device and are blown generally downwardly within a forming chamber.
The glass fibers typically have a diameter of about 2 to 9 microns
and a length of about 1/4 to 3 inches. The glass fibers are
deposited onto a foraminous forming conveyor. Binder mixture is
applied to the glass fibers as they are being formed, e.g. by means
of spray applicators, so as to distribute the binder throughout the
formed mat of fibrous glass. The glass fibers, having the uncured
resinous binder adhered thereto, are gathered and formed into a mat
on the conveyor within the forming chamber with the aid of a vacuum
drawn through the mat from below the forming conveyor. The residual
heat contained in the glass fibers, as well as air flow through the
mat, causes much of the water to volatilize from the mat before it
exits the forming chamber.
[0027] The mat is then conveyed through a curing oven, typically at
a temperature from 200 to 325.degree. C. for from 1/2 to 3 minutes,
wherein heated air is passed through the mat to cure the resin.
Fibrous glass having a cured, rigid binder matrix emerges from the
oven in the form of a bat, which may be processed and utilized in
manners well known to those skilled in the art.
EXAMPLES
[0028] The present invention is illustrated by the following
non-limiting specific Examples.
Example 1
[0029] Surface Tension
[0030] A polyacrylic acid based binder having a solids content of
2.8 weight-% was prepared by diluting QRXP 1564 with water,
followed by the addition of amino silane and oil emulsion. To make
binder products of the present invention, small amounts (0.1
weight-% and 0.2 weight-%) of Surfynol 465 were blended into the
binder composition.
[0031] Surface tensions of the polyacrylic acid based binder
compositions of this invention and of two reference binder
compositions were measured using a Surface Tensionmeter 6000,
produced by the SensaDyne Instrument Division of the Chem-Dyne
Research Group. The instrument was calibrated with deionized water.
The data were taken every 5 seconds. After the testing started and
the system stabilized, the average value over a one-minute testing
period was obtained for each sample. The results are reported in
Table 1.
1 TABLE 1 Surface Tension Binder Description (dyne/cm) QRXP 1564
2.8% solid 70.94 QRXP 1564 2.8% + 0.1% S-465 62.87 QRXP 1564 2.8% +
0.2% S-465 60.54 Phenolic Binder 2.8% 65.75
[0032] As can be seen from the reported data, the compositions in
accordance with the present invention (QRXP 1564 2.8%+0.1% S-465
and QRXP 1564 2.8%+0.2% S-465) had surface tensions that were lower
not only than that of a similar conventional polyacrylic acid
binder (QRXP 1564 2.8%) but also than that of a traditional phenol
formaldehyde binder.
Example 2
[0033] Binding Strength
[0034] A polyacrylic acid binder premix was prepared composed on
74.25 parts by weight (pbw) of Acumer 9932 (a 46% solids
polyacrylic acid from Robm & Haas), 10.40 pbw glycerol, 0.45
pbw corrosion inhibitor, and 14.90 pbw water, to provide a 45%
solids premix. The premix was added along with silane and oil
emulsion to water to provide a 3.5% solids polyacrylic acid
glycerol binder (PAG+).
[0035] Surfynol 465 surfactant was added to this polyacrylic acid
glycerol binder at various % levels based on the binder solids.
These binder compositions were sprayed onto fiberglass as in a
typical fiberglass insulation binder application to obtain a Loss
On Ignition (LOI) of 1.9%. The binder fiberglass was formed into
insulation blankets, conveyed to an oven, and cured therein at
temperatures ranging from 350 to 590.degree. F. The bond strength,
a measure of mechanical strength, of the cured bindered insulation
products was measured and is reported in Table 2.
2 TABLE 2 Bond Strength Binder Description (average) PAG+ 3.64 PAG+
with 0.025% S-465 3.70 PAG+ with 0.05% S-465 3.65 PAG+ with 0.1%
S-465 3.42 PAG+ with 0.15% S-465 3.60
[0036] This data indicates that the addition of surfactant to
polyacrylic acid insulation binders in accordance with the present
invention provides acceptable mechanical properties that are
generally equivalent to those obtained without surfactant
addition.
Example 3
[0037] SEM Examination
[0038] Scanning Electron Microscope imaging reveals structural
details relating to the manner in which binder is distributed in a
fiberglass matrix. SEM provides insight into such details as
droplet size, wetting performance, and fiber-fiber junctions. FIG.
1 shows fiberglass insulation produced with no surfactant added to
the polyacrylic acid binder. This sample shows poor binder
dispersion and poor atomization. This "prior art" binder is poorly
distributed throughout the pack and even forms some binder "nests".
FIGS. 2 and 3 show fiberglass insulation produced with surfactant
added in accordance with this invention. In these products, the
binder was much more uniformly distributed throughout the matrix,
the binder showed much better wetting on the glass fiber surface,
and more and better fiber-fiber junctions were observed. Thus the
present invention significantly improves binder atomization, binder
distribution, and binder wetting.
[0039] Fiberglass insulation products manufactured in accordance
with the present invention have better binder coverage and
protection, less glass fiber damage, and provide better working
environment and better product performance than do similar products
made with previously known polyacrylic acid binder systems.
Example 4
[0040] Insulation
[0041] The surfactant-activated polyacrylic acid-based aqueous
binder of this invention is applied onto fiberglass, and the
fiberglass so treated is cured and formed into an insulation
blanket. The molten glass is supplied to a rotary fiber forming
device--spinner. Fibers of glass are attenuated from the device and
are blown generally downwardly within a forming chamber. The
surfactant-activated polyacrylic acid-based binder is sprayed
through nozzles attached to a binder ring by liquid or air
atomization. The binder flow rate and solid content are determined
by the product design.
[0042] The binder is applied at ambient temperature and most of the
water in the binder is volatized as the atomized binder travels
through the hot forming air flow and makes contact with the heated
glass fiber. The bindered glass fiber blanket is conveyed through a
curing oven at a temperature from 200.degree. C. to 350.degree. C.
for 1/2 to 3 minutes. The cured fiber glass blanket can be used as
is or can be fabricated to customer demand.
[0043] It is understood that the foregoing description and specific
embodiments shown herein are merely illustrative of the invention
and its principles. Modifications and additions to the invention
may readily be made by those skilled in the art without departing
from the spirit and scope of the invention, which is therefore
understood to be limited only by the scope of the appended
claims.
[0044] Patent publications cited hereinabove are hereby
incorporated by reference in their entirety and for all
purposes.
* * * * *