U.S. patent application number 14/021262 was filed with the patent office on 2015-10-08 for dedusting agents for fiberglass products and methods for making and using same.
This patent application is currently assigned to Georgia-Pacific Chemicals LLC. The applicant listed for this patent is Georgia-Pacific Chemicals LLC. Invention is credited to Lisa M. Arthur, Phillip W. Hurd, Michael C. Peck, Kelly A. Shoemake, Brian L. Swift, Kim Tutin.
Application Number | 20150284561 14/021262 |
Document ID | / |
Family ID | 43649656 |
Filed Date | 2015-10-08 |
United States Patent
Application |
20150284561 |
Kind Code |
A9 |
Tutin; Kim ; et al. |
October 8, 2015 |
DEDUSTING AGENTS FOR FIBERGLASS PRODUCTS AND METHODS FOR MAKING AND
USING SAME
Abstract
Dedusting agents for fiberglass products and methods for making
and using the same are provided. The composition can include a
binder and a dedusting agent. The dedusting agent can include an
emulsion comprising one or more pitches, one or more fatty acids,
one or more rosins, or any combination thereof.
Inventors: |
Tutin; Kim; (East Point,
GA) ; Hurd; Phillip W.; (Conyers, GA) ;
Shoemake; Kelly A.; (Atlanta, GA) ; Swift; Brian
L.; (Oxford, GA) ; Peck; Michael C.;
(Snellville, GA) ; Arthur; Lisa M.; (Conyers,
GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Georgia-Pacific Chemicals LLC |
Atlanta |
GA |
US |
|
|
Assignee: |
Georgia-Pacific Chemicals
LLC
Atlanta
GA
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20140001396 A1 |
January 2, 2014 |
|
|
Family ID: |
43649656 |
Appl. No.: |
14/021262 |
Filed: |
September 9, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12875064 |
Sep 2, 2010 |
8551355 |
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14021262 |
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12533726 |
Jul 31, 2009 |
8133408 |
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12875064 |
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61239161 |
Sep 2, 2009 |
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61085840 |
Aug 2, 2008 |
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Current U.S.
Class: |
252/62 ;
252/88.1 |
Current CPC
Class: |
C08L 61/06 20130101;
C09K 3/22 20130101; D04H 3/004 20130101 |
International
Class: |
C08L 61/06 20060101
C08L061/06 |
Claims
1. A composition, comprising: a binder; and a dedusting agent
comprising: at least one pitch, and at least one additive
comprising one or more fatty acids, one or more rosins, or a
mixture of one or more fatty acids and one or more rosins, wherein
the pitch is present in an amount of about 10 wt % to about 80 wt
%, based on the combined weight of the pitch and the additive.
2. The composition of claim 1, wherein the additive is provided in
the form of crude tall oil, tall oil fatty acids, distilled tall
oil, tall oil rosins, or any mixture thereof.
3. The composition of claim 1, wherein the dedusting agent further
comprises at least one base compound in an amount of about 0.1 wt %
to about 5 wt %, based on the combined weight of the pitch, the
additive, and the base compound.
4. The composition of claim 1, wherein the pitch is present in an
amount of about 20 wt % to about 80 wt %, based on the combined
weight of the pitch and the additive.
5. The composition of claim 1, wherein the pitch is present in an
amount of about 35 wt % to about 80 wt %, based on the combined
weight of the pitch and the additive.
6. The composition of claim 1, wherein the pitch is present in an
amount of about 50 wt % to about 80 wt %, based on the combined
weight of the pitch and the additive.
7. The composition of claim 1, wherein the dedusting agent is in
the form of an emulsion.
8. The composition of claim 1, wherein the pitch comprises a tall
oil pitch.
9. The composition of claim 1, further comprising one or more oils
selected from the group consisting of mineral oils, soy bean oil,
rapeseed oil, sunflower oil, corn oil, peanut oil, cotton oil,
palm, oil, palm kernel oil, coconut oil, and mixtures thereof.
10. The composition of claim 1, wherein the composition dries to a
film that is tack free, according to ASTM 1640-03.
11. The composition of claim 1, wherein the dedusting agent further
comprises water and at least one base compound, and wherein: the
water is present in an amount of about 20 wt % to about 80 wt %,
based on the weight of the dedusting agent; the base compound is
present in an amount of about 0.1 wt % to about 5 wt %, based on
the combined weight of the pitch, the additive, and the base
compound; the additive comprises the fatty acids; and the fatty
acids are present in an amount of about 10 wt % to about 40 wt %,
based on the combined weight of the pitch, the additive, and the
base compound.
12. The composition of claim 1, wherein the binder comprises an
aldehyde based resin, a copolymer of one or more vinyl aromatic
derived units and at least one of maleic anhydride and maleic acid,
a mixture of Maillard reactants, or any mixture thereof.
13. The composition of claim 1, wherein the binder comprises an
aldehyde based resin, and wherein the aldehyde based resin
comprises a urea-formaldehyde polymer, a phenol-formaldehyde
polymer, a melamine-formaldehyde polymer, or any mixture
thereof.
14. The composition of claim 1, wherein the composition further
comprises one or more mineral oils, a copolymer of styrene and
acrylic acid, a copolymer of styrene and maleic anhydride, a
copolymer of styrene and maleic acid, a copolymer of styrene and
butadiene, a copolymer of styrene and isoprene, or any mixture
thereof.
15. A method for making a fiberglass product, comprising:
contacting a plurality of fibers with a composition, the
composition comprising: a binder; and a dedusting agent comprising:
at least one pitch, and at least one additive comprising one or
more fatty acids, one or more rosins, or a mixture of one or more
fatty acids and one or more rosins, wherein the pitch is present in
an amount of about 10 wt % to about 80 wt %, based on the combined
weight of the pitch and the additive; and heating the contacted
fibers to at least partially cure the composition.
16. The method of claim 15, wherein the pitch is present in an
amount of about 20 wt % to about 80 wt %, based on the combined
weight of the pitch and the additive.
17. The method of claim 15, wherein the composition further
comprises one or more mineral oils, a copolymer of styrene and
acrylic acid, a copolymer of styrene and maleic anhydride, a
copolymer of styrene and maleic acid, a copolymer of styrene and
butadiene, a copolymer of styrene and isoprene, or any mixture
thereof.
18. A fiberglass product, comprising: a plurality of fibers; and an
at least partially cured composition, wherein the composition,
prior to curing, comprises: a binder; and a dedusting agent
comprising: at least one pitch, and at least one additive
comprising one or more fatty acids, one or more rosins, or a
mixture of one or more fatty acids and one or more rosins, wherein
the pitch is present in an amount of about 10 wt % to about 80 wt
%, based on the combined weight of the pitch and the additive.
19. The fiberglass product of claim 18, wherein the pitch is
present in an amount of about 20 wt % to about 80 wt %, based on
the combined weight of the pitch and the additive.
20. The fiberglass product of claim 18, wherein the composition
further comprises one or more mineral oils, a copolymer of styrene
and acrylic acid, a copolymer of styrene and maleic anhydride, a
copolymer of styrene and maleic acid, a copolymer of styrene and
butadiene, a copolymer of styrene and isoprene, or any mixture
thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 12/875,064, filed Sep. 2, 2010, which claims
priority to U.S. Provisional Patent Application having Ser. No.
61/239,161, filed Sep. 2, 2009, each of which is incorporated by
reference herein.
BACKGROUND
[0002] 1. Field
[0003] Embodiments described herein generally relate to dedusting
agents for compositions. More particularly, such embodiments relate
to dedusting agents for use in compositions for making fiberglass
products.
[0004] 2. Description of the Related Art
[0005] Fiber insulation, e.g. fiber batting, is well known in the
construction industry and is generally installed in floors,
ceilings, and walls. In addition to insulation in the form of
batting, fiber insulation can be installed by blowing fiber
insulation into an enclosed or open wall, ceiling, and/or floor
space. When the fiber insulation is handled or installed, the
fibers break causing fiber dust or particles to be suspended in the
air. These suspended particles cause physical discomfort to persons
handling the fiber insulation. For example, the suspended particles
can cause difficulty in breathing, irritation of the eyes, and the
like.
[0006] Binders are typically applied to the fiber insulation
product in order to hold or contain the fibers together. The
binders include dedusting agents that reduce the generation of dust
when the fiber insulation products are installed or otherwise
handled. Conventional dedusting agents, however, utilize petroleum
based oils, such as mineral oil, that is emulsified in water using
an emulsifier such as casein. These conventional dedusting agents
are not bio-based, which for some applications can be preferable
over petroleum based oils. Additionally, casein is a milk based
emulsifier that has a very limited shelf life and as the product
ages the casein causes the product to develop an undesirable
odor.
[0007] There is a need, therefore, for new dedusting agents for use
with binders for making fiberglass products.
SUMMARY
[0008] Dedusting agents for fiberglass products and methods for
making and using the same are provided. In at least one specific
embodiment, a composition can include a binder and a dedusting
agent. The dedusting agent can include an emulsion comprising one
or more pitches, one or more fatty acids, one or more rosins, or
any combination thereof.
[0009] In at least one specific embodiment, a fiberglass product
can include a plurality of fibers and a composition. The
composition can include can include a binder and a dedusting agent.
The dedusting agent can include an emulsion comprising one or more
pitches, one or more fatty acids, one or more rosins, or any
combination thereof. The composition can be at least partially
cured.
[0010] In at least one specific embodiment, a process for preparing
a fiberglass product can include contacting a plurality of fibers
with a composition. The composition can include can include a
binder and a dedusting agent. The dedusting agent can include an
emulsion comprising one or more pitches, one or more fatty acids,
one or more rosins, or any combination thereof. The process can
also include collecting the contacted fibers to form a non-woven
mat. The non-woven mat can be heated to at least partially cure the
composition.
DETAILED DESCRIPTION
[0011] In one or more embodiments, a dedusting agent can be
combined with a binder to provide a composition or "binder
composition." The dedusting agent can include an emulsion
comprising one or more pitches, one or more fatty acids, one or
more rosins, or any combination thereof. It has been surprisingly
and unexpectedly discovered that when the dedusting agents provided
herein are combined with a binder, a composition is formed that can
be applied to a fiberglass substrate that reduces the amount of
dust that is generated from the substrate when manipulated, for
example, during handling, relative to a composition not containing
the dedusting agent.
[0012] Suitable pitches can include, bio-based or bio-derived
pitches, petroleum based or petroleum derived pitches, or a
combination thereof. Illustrative bio-based pitches can include,
but are not limited to, tall oil pitch, natural resins such as
shellac, gilsonite, copal, lignin, and wood tar, or any combination
thereof. Illustrative petroleum based pitches can include, but are
not limited to, coal tar pitch, asphalts such as bitumen, heavy
crude oil, heavy petroleum distillates, tar-like, low volatility
Fischer-Tropsch products, or any combination thereof.
[0013] Tall oil pitch is derived from crude tall oil (CTO). Crude
tall oil is recovered as a byproduct in the Kraft pulping process
in which wood is digested with alkali and sulfide, producing tall
oil soap and crude sulfate turpentine as by-products. Acidification
of the tall oil soap produces the crude tall oil. Prior to
refining, crude tall oil can include a mixture of rosins or rosin
acids, fatty acids, and neutral materials. As used herein, the term
"neutral materials" refers to unsaponifiable material that
typically includes sterols, higher-molecular weight alcohols and
other alkyl chain materials. Crude tall oil is a known material of
commerce. The CAS number for crude tall oil (CTO) is 8002-26-4.
[0014] Crude tall oil can have a fatty acids concentration ranging
from a low of about 15 wt %, about 20 wt %, or about 25 wt % to a
high of about 50 wt %, about 60 wt %, or about 70 wt %. Crude tall
oil can have a rosin concentration ranging from a low of about 15
wt %, about 20 wt %, or about 25 wt % to a high of about 60 wt %,
about 70 wt %, or about 75 wt %. Crude tall oil can have a neutral
materials concentration ranging from a low of about 15 wt %, about
20 wt % or about 30 wt % to a high of about 35 wt %, about 40 wt %,
or about 45 wt %. Illustrative fatty acids can include, but are not
limited to, oleic acid, linoleic acid, conjugated linoleic acid,
lauric acid, ricinoleic acid, stearic acid, palmitic acid,
linolenic acid, palmitoleic acid, myristic acid, arachidic acid,
behenic acid, and any combination thereof. Illustrative rosin acids
or rosins can include abietic acid, dehydroabietic acid, isopimaric
acid and pimaric acid.
[0015] Crude tall oil can have an acid value ranging from a low of
about 100, about 110, or about 120 to a high of about 165, about
175, or about 180. The acid value can be determined by dissolving a
known weight of the material into an organic solvent, e.g. toluene,
and then titrating a measured amount of methanolic potassium
hydroxide (KOH) solution into the material. The titration is
complete when a pH of about 7 is obtained. The acid value of the
material is equal to the amount of KOH, in mg, that was used in the
titration, divided by the weight of the material, in grams, of the
sample that was titrated. In other words, the acid value is equal
to the milligrams of KOH needed to neutralize 1 gram of
material.
[0016] Crude tall oil can have a specific gravity ranging from a
low of about 0.9, about 0.95, or about 1 to a high of about 1.2,
about 1.25, or about 1.3. Crude tall oil can have a saponification
number ranging from a low of about 115, about 120, or about 125 to
a high of about 175, about 180, or about 195. Crude tall oil can
have an iodine number ranging from about 135, about 138, or about
140 to a high of about 148, about 150, or about 155. Crude tall oil
can have a flash point ranging from a low of about 300.degree. C.,
about 325.degree. C., or about 350.degree. C. to a high of about
375.degree. C., about 400.degree. C., or about 425.degree. C.
[0017] The crude tall oil can be distilled to provide several
different products in addition to tall oil pitch, which can
include, but are not limited to, heads or lights, fatty acids or
tall oil fatty acids (TOFA), distilled tall oil (DTO), and rosin
acids or rosins (tall oil rosins). Tall oil pitch is a known
material of commerce. The CAS number for tall oil pitch is
8016-81-7. In one or more embodiments, the tall oil pitch in the
dedusting agent can be provided in the form of crude tall oil. In
other words, crude tall oil can be used as the source of tall oil
pitch.
[0018] The precise composition of tall oil pitch depends, at least
in part, on the particular process by which the tall oil pitch is
isolated and/or the particular source(s) of wood from which the
crude tall oil is produced. At room temperature, tall oil pitch is
a semi-solid, tar-like material. Tall oil pitch is a hydrophobic
material. The tall oil pitch can include, but is not limited to,
fatty acids, esters of fatty acids, rosin or rosin acids, esters of
rosin acids, and neutral materials. The fatty acids, the rosin
acids, or both can be chemically modified. For example, chemically
modified rosins can retain some polar groups like carboxylic acid
or a polar group that has been added like an amine (rosin amine),
polyethylene glycol chain (as a non-ionic emulsifier) or additional
acid functionality through a Diels Alder reaction with fumaric or
maleic acid/anhydride. Accordingly, chemically modified rosins
include disproportionated rosin acids, maleated rosin acids,
diethylene tetramine amido amines of rosin acids, amine-modified
rosin acids, rosin salts, rosin ethoxylates, phenolic modified
rosins, dimerized rosins, rosin-formaldehyde adducts, hydrogenated
rosin, or any combination thereof.
[0019] The tall oil pitch can have a concentration of fatty acids
and esters of fatty acids ranging from a low of about 5 wt %, about
7 wt %, or about 9 wt % to a high of about 20 wt %, about 30 wt %,
about 40 wt %, about 50 wt %, or about 55 wt %. The tall oil pitch
can have a concentration of rosin acids and esters of rosin acids
ranging from about 5 wt %, about 7 wt %, or about 9 wt % to a high
of about 20 wt %, about 25 wt %, about 30 wt %, or about 35 wt %.
The tall oil pitch can have a concentration of neutral materials
ranging from a low of about 30 wt %, about 40 wt %, or about 50 wt
% to a high of about 70 wt %, about 80 wt %, or about 90 wt %.
Dimerized rosin and dimerized fatty acid also can also be found in
tall oil pitch. The tall oil pitch can have a moisture or water
content of less than about 1 wt %, less than about 0.5 wt %, less
than about 0.1 wt %, or less than about 0.05 wt %.
[0020] The tall oil pitch can have an acid value ranging from a low
of about 20, about 25, or about 30 to a high of about 40, about 45,
or about 50. The tall oil pitch can have a viscosity (centipoise at
85.degree. C.) ranging from a low of about 20 centipoise (cP),
about 40 cP, or about 60 cP to a high of about 110 cP, about 130
cP, or about 150 cP. The tall oil pitch can have a density ranging
from a low of about 900 g/L, about 910 g/L, or about 920 g/L to a
high of about 940 g/L, about 950 g/L, or about 960 g/L. The tall
oil pitch can have a softening temperature ranging from a low of
about 15.degree. C., about 20.degree. C., or about 25.degree. C. to
a high of about 40.degree. C., about 50.degree. C., or about
60.degree. C. The tall oil pitch can have an energy or heating
value of about 10,000 BTU/lb, about 12,000 BTU/lb, about 14,000
BTU/lb, about 16,000 BTU/lb, about 18,000 BTU/lb, about 20,000
BTU/lb, about 22,000 BTU/lb, or about 25,000 BTU/lb.
[0021] Suitable tall oil pitches are commercially available from a
variety of sources including Georgia-Pacific Chemicals LLC, e.g.,
XTOL.RTM. Tall Oil Pitch. Typical properties of XTOL.RTM. Tall Oil
Pitch include a viscosity of about 450 cps at a temperature of
85.degree. C., a concentration of rosin acids of about 9 wt %, a
concentration of fatty acids of about 9 wt %, an acid value of 35
mg KOH/g, and an energy value of about 17,000 BTU/lb.
[0022] Another suitable pitch can include coal tar pitch, which is
a byproduct of coke production and coal gasification. Coal tar
pitch is a mixture containing polycyclic aromatic hydrocarbons and
heterocyclic compounds. Another suitable pitch can include one or
more asphalts (bitumens), which is a sticky, black, and highly
viscous liquid or semi-solid that is present in most crude
petroleums and in some natural deposits sometimes termed asphaltum.
Asphalt (bitumen) pitch is also commercially available from a wide
range of sources. Other suitable sources of pitch can include heavy
crude oil, heavy petroleum distillates, and tar-like, low
volatility Fischer-Tropsch products. As such, the pitch can be or
include tall oil pitch, coal tar pitch, heavy crude oil, heavy
petroleum distillates, Fischer-Tropsch products, asphalt (bitumen),
or any combination thereof.
[0023] The fatty acids and rosin acids can be derived from any
suitable source. For example, the fatty acids and rosins can be
recovered as products from the distillation of crude tall oil.
Suitable sources of fatty acids and/or rosins can include distilled
tall oil (DTO), tall oil fatty acids (TOFA), rosin acids (tall oil
rosins), or any combination thereof, derived from crude tall oil,
such as by the distillation of crude tall oil. In another example,
the fatty acids and/or rosins can be provided in the form of crude
tall oil. In other words, the fatty acids and/or rosins can be used
as present in crude tall oil. The fatty acids and/or rosins can
also be or include crude tall oil and a combination of one or more
products derived from crude tall oil.
[0024] Distilled tall oil (DTO) is an intermediate fraction that
can be produced from the distillation of crude tall oil and
includes a mixture of various components. For example, distilled
tall oil can include a mixture of fatty acids, fatty acid esters,
rosins, rosin esters, and minor or trace amounts of neutral
materials. The distilled tall oil can have a fatty acids and esters
of fatty acids concentration ranging from a low of about 55 wt %,
about 60 wt %, or about 65 wt % to a high of about 85 wt %, about
90 wt %, or about 95 wt %. The distilled tall oil can have a rosin
acids or rosins concentration ranging from a low of about 5 wt %,
about 10 wt %, or about 15 wt % to a high of about 30 wt %, about
35 wt %, or about 40 wt %. The distilled tall oil can have a
neutral materials concentration ranging from a low of about 0.1 wt
%, about 1 wt %, or about 1.5 wt % to a high of about 2 wt %, about
3.5 wt %, or about 5 wt %.
[0025] The distilled tall oil can have an acid value ranging from a
low of about 20, about 25, or about 30 to a high of about 40, about
45, or about 50. The distilled tall oil can have a viscosity
(centipoise at 85.degree. C.) ranging from a low of about 10 cP,
about 20 cP, about 30 cP, or about 40 cP to a high of about 100 cP,
about 120 cP, about 135 cP, or about 150 cP. The distilled tall oil
can have a density ranging from a low of about 840 g/L, about 860
g/L, or about 880 g/L to a high of about 900 g/L, about 920 g/L, or
about 935 g/L. The distilled tall oil can have a saponification
number ranging from a low of about 180, about 185, or about 190 to
a high of about 200, about 205, or about 210. The distilled tall
oil can have an iodine value ranging from a low of about 115, about
117, or about 120 to a high of about 130, about 135, or about
140.
[0026] The rosin acids derived from crude tall oil (tall oil rosin)
are also an intermediate fraction that can be produced from the
distillation of crude tall oil. The tall oil rosin can have a
concentration of rosin acids ranging from a low of about 80 wt %,
about 85 wt %, or about 90 wt % to a high of about 93 wt %, about
95 wt %, or about 99 wt %. Illustrative rosin acids can include,
but are not limited to, abietic acid, dehydroabietic acid,
isopimaric acid and pimaric acid. For example, the tall oil rosin
can have a concentration of abietic acid ranging from a low of
about 35 wt %, about 40 wt %, or about 43 wt % to a high of about
50 wt %, about 55 wt %, or about 60 wt %. The tall oil rosin can
have a concentration of dehydroabietic acid ranging from a low of
about 10 wt %, about 13 wt %, or about 15 wt % to a high of about
20 wt %, about 23 wt %, or about 25 wt %. The tall oil rosin can
have a concentration of isopimaric acid of about 10 wt % or less,
about 8 wt % or less, about 5 wt % or less, or about 3 wt % or
less. The tall oil rosin can have a concentration of pimaric acid
of about 10 wt % or less, about 8 wt % or less, about 5 wt % or
less, or about 3 wt % or less. The tall oil rosins can have a fatty
acids concentration ranging from a low of about 0.5 wt %, about 1
wt %, or about 2 wt % to a high of about 3 wt %, about 5 wt %, or
about 10 wt %. The tall oil rosin can have a concentration of
neutral materials ranging from a low of about 0.5 wt %, about 1 wt
%, or about 2 wt % to a high of about 3 wt %, about 5 wt %, or
about 10 wt %. The tall oil rosin can have a density ranging from a
low of about 960 g/L, about 970 g/L, or about 980 g/L to a high of
about 1,000 g/L, about 1,010 g/L, or about 1,020 g/L. The tall oil
rosin can have an acid value ranging from a low of about 150, about
160, or about 165 to a high of about 170, about 175, or about
180.
[0027] The tall oil fatty acids (TOFA) is also an intermediate
fraction that can be produced from the distillation of crude tall
oil and includes a mixture of various fatty acids, fatty acid
esters, and minor amounts of rosin, rosin esters, and neutral
materials. The tall oil fatty acids can have an oleic acid ranging
from a low of about 30 wt %, about 35 wt %, or about 40 wt % to a
high of about 45 wt %, about 50 wt %, or about 55 wt %. The tall
oil fatty acids can have a linoleic acid concentration ranging from
a low of about 30 wt %, about 35 wt %, or about 40 wt % to a high
of about 45 wt %, about 50 wt %, or about 55 wt %. The tall oil
fatty acids can have a concentration of stearic acid ranging from a
low of about 0.5 wt %, about 1 wt %, or about 1.5 wt % to a high of
about 2 wt %, about 3 wt %, or about 5 wt %. The tall oil fatty
acids can have a concentration of conjugated linoleic acid ranging
from a low of about 0.5 wt %, about 1 wt %, or about 1.5 wt % to a
high of about 2 wt %, about 3 wt %, or about 5 wt %. The tall oil
fatty acids can have a combined concentration of palmitic acid,
linolenic acid, and palmitoleic acid ranging from a low of about
0.5 wt %, about 1 wt %, or about 1.5 wt % to a high of about 2 wt
%, about 3 wt %, or about 5 wt %. The tall oil fatty acids can have
a concentration of rosins of less than about 5 wt %, less than
about 3 wt %, less than about 2 wt %, less than about 1 wt %, or
less than about 0.5 wt %. The tall oil fatty acids can have a
concentration of neutral materials of less than about 5 wt %, less
than about 3 wt %, less than about 2 wt %, less than about 1 wt %,
or less than about 0.5 wt %.
[0028] The tall oil fatty acids can have an acid value ranging from
a low of about 180, about 190, or about 195 to a high of about 200,
about 205, or about 210. The tall oil fatty acids can have a
density ranging from a low of about 840 g/L, about 860 g/L, or
about 880 g/L to a high of about 920 g/L, about 940 g/L, or about
960 g/L. The tall oil fatty acids can have a saponification number
ranging from about 190 to about 210. The tall oil fatty acids can
have an iodine value ranging from about 120 to about 135.
[0029] Suitable products derived from crude tall oil (CTO) are
commercially available from a variety of sources including
Georgia-Pacific Chemicals LLC. Representative distilled tall oil
(DTO), tall oil fatty acids (TOFA), and/or tall oil rosin products
can include, but are not limited to, XTOL.RTM. 100, XTOL.RTM. 101,
XTOL.RTM. 300, XTOL.RTM. 304, XTOL.RTM. 520, XTOL.RTM. 530,
XTOL.RTM. 540, XTOL.RTM. 542, XTOL.RTM. 656, XTOL.RTM. 690,
XTOL.RTM. 692, XTOL.RTM. MTO, LYTOR.RTM. 100, LYTOR.RTM. 105,
LYTOR.RTM. 105K, LYTOR.RTM. 110 and LYTOR.RTM. 307.
[0030] Processes for producing tall oil pitch, distilled tall oil,
tall oil fatty acids, tall oil rosin acids, and other products
derived from crude tall oil can be as discussed and described in
U.S. Pat. Nos. 3,943,117, 4,075,188; 4,154,725; 4,238,304;
4,308,200; 4,495,095; 4,524,024; 5,132,399; 5,164,480; and,
6,469,125; and U.S. Patent Application Publication Nos.
2005/0268530; and 2010/0025625. It also is understood by those
skilled in the art that because crude tall oil, and, as such, tall
oil pitch, distilled tall oil, tall oil fatty acids, tall oil
rosins, and other crude tall oil derived products are derived from
natural sources, the compositions can vary among the various
sources.
[0031] In preparing the emulsion that includes the one or more
pitches, fatty acids, and/or rosins, one or more base compounds can
be used. The one or more base compounds can be or include any
alkaline material. An aqueous emulsion can be prepared by combining
the one or more pitches, fatty acids, and/or rosins and the one or
more base compounds. Illustrative base compounds can include, but
are not limited to, hydroxides, carbonates, ammonia, amines, or any
combination thereof. Illustrative hydroxides can include, but are
not limited to, sodium hydroxide, potassium hydroxide, ammonium
hydroxide (e.g., aqueous ammonia), lithium hydroxide, and cesium
hydroxide. Illustrative carbonates can include, but are not limited
to, sodium carbonate, potassium carbonate, and ammonium carbonate.
Illustrative amines can include, but are not limited to,
alkanolamines, polyamines, aromatic amines, and any combination
thereof. Illustrative alkanolamines can include, but are not
limited to, monoethanolamine (MEA), diethanolamine (DEA),
triethanolamine (TEA), or any combination thereof. An alkanolamine
is defined as a compound that has both amino and hydroxyl
functional groups as illustrated by diethanolamine,
triethanolamine, 2-(2-aminoethoxy)ethanol, aminoethyl ethanolamine,
aminobutanol and other aminoalkanols. Illustrative aromatic amines
can include, but are not limited to, benzyl amine, aniline, ortho
toludine, meta toludine, para toludine, n-methyl aniline,
N--N'-dimethyl aniline, di- and tri-phenyl amines, 1-naphthylamine,
2-naphthylamine, 4-aminophenol, 3-aminophenol and 2-aminophenol.
Illustrative polyamines can include, but are not limited to,
diethylenetriamine (DETA), triethylenetetramine (TETA),
tetraethylenepentamine (TEPA). Other polyamines can include, for
example, 1,3-propanediamine, 1,4-butanediamine, polyamidoamines,
and polyethylenimines.
[0032] In one or more embodiments, the one or more emulsifiers or
emulsifying agents that can be used to prepare the emulsion can
include any emulsifier or combination of emulsifiers. Different
classes of emulsifiers can include cationic emulsifiers such as
alkyltrimethylammonium salts, polyethoxylated tallow amines,
anionic emulsifiers such as alkyl sulfates, alkyl benzene
sulfonates, alkyl carboxylates, nonionic emulsifiers such as fatty
alcohols, ethoxylated alkylphenols, and amphoteric emulsifiers such
as amino acids, betaines, or any combination thereof.
[0033] In one or more embodiments, the emulsifier can be or include
protein-based emulsifiers and/or other natural emulsifiers.
Illustrative protein-based emulsifiers can include, but are not
limited to, soy-protein based materials, gelatin, phospholipids
such as lecithin and casein, and the like. Alkali salts, e.g.,
sodium and/or ammonium salts of casein, can also be used. An alkali
caseinate can be pre-formed or it can be formed in situ when
preparing the emulsion, for example by mixing casein with an alkali
hydroxide during the preparation of the emulsion. Other natural
emulsifiers can include, but are not limited to, Gum Arabic, Guar
gum, and starches such as corn starch and potato starch.
[0034] Other emulsifiers can include nonylphenol ethoxylates of
various ethoxylate chain lengths, alkyl succinate salts, resinous
soaps and resinous emulsions such as fatty acid based materials and
rosin acid based materials. A suitable nonylphenol ethyoxylate
commercially available can be or include Tergitol NP-70 (available
from Dow Chemical Company). Suitable emulsifiers can also include
fatty acid based materials and rosin acid based materials derived
from crude tall oil, distilled tall oil, tall oil fatty acids,
chemically modified tall oil (including products identified as
dimer acids, oxidized tall oil, maleated tall oil, oxidized and
maleated tall oil and chemically-modified versions thereof), tall
oil rosins, chemically modified tall oil rosins, or any combination
thereof. Illustrative maleated, oxidized, maleated and oxidized,
and/or derivatives thereof can include those compositions discussed
and described in U.S. Patent Application Publication Nos.
2008/0179570, 2008/0194795, 2009/0065736, and 2009/0194731. In one
or more embodiments, the emulsifier can be or include one or more
Maillard reaction products. Illustrative Maillard reaction products
can include, but are not limited to, an adduct of an amine reactant
and a reducing sugar, a reducing sugar equivalent, or a mixture
thereof. Suitable Maillard reaction products can be as discussed
and described in U.S. Patent Application Publication No.
2009/0301972. In one or more embodiments, fatty acid based and/or
rosin acid based emulsifiers can be partially neutralized.
[0035] Other fatty acids and chemically modified fatty acids can
include straight-chain or branched, saturated, mono- or
polyunsaturated fatty acid radicals having 8 to 24 carbon atoms, in
particular 12 to 22 carbon atoms, or any combination thereof.
Representative fatty acids include oleic acid, lauric acid,
linoleic acid, linolenic acid, palmitic acid, stearic acid,
ricinoleic acid, myristic acid, arachidic acid, behenic acid and
mixtures thereof.
[0036] Other fatty acids-based products suitable for use as the
emulsifier can include fatty acids derived (saponified) from animal
or plant derived oils and their derivatives. Through the use of
known saponification techniques, a number of animal and/or
vegetable oils (triglycerides), such as linseed (flaxseed) oil,
castor oil, tung oil, soybean oil, cottonseed oil, olive oil,
canola oil, corn oil, sunflower seed oil, peanut oil, coconut oil,
safflower oil, palm oil, or any combination thereof, can be used as
a source of fatty acid(s) for making an emulsifier.
[0037] In one or more embodiments, the amount of the emulsifier or
the presence of an emulsifier can depend, at least in part, on the
particular emulsifier and/or the particular components of the
emulsion to be formed. For example, if the emulsion consists of
tall oil pitch, an emulsifier is preferably used to produce the
emulsion. In another example, if the emulsion includes crude tall
oil, distilled tall oil, tall oil rosins, and/or tall oil fatty
acids, an emulsifier can be present or absent in the emulsion. In
other words, if crude tall oil and/or one or more products derived
from crude tall oil are present in the emulsion, the fatty acids
can act as emulsifiers. The suitability of any particular
emulsifier and an appropriate quantity to use in the emulsification
of a particular emulsion composition can be selected following
routine testing.
[0038] In one or more embodiments, the concentration of pitch(es)
in the emulsion can range from about 5 wt % to about 80 wt %, based
on the combined weight of any pitch(es), fatty acid(s), rosin(s),
base compound(s), and/or emulsifier(s) in the emulsion. For
example, the concentration of the pitch(es) in the emulsion can
range from a low of about 10 wt %, about 20 wt %, about 30 wt %, or
about 35 wt % to a high of about 50 wt %, about 60 wt %, about 70
wt %, or about 75 wt %, based on the combined weight of any
pitch(es), fatty acid(s), rosin(s), base compound(s), and/or
emulsifier(s) in the emulsion.
[0039] In one or more embodiments, the concentration of fatty
acid(s) in the emulsion can range from about 1 wt % to about 45 wt
%, based on the combined weight of any pitch(es), fatty acid(s),
rosin(s), base compound(s), and/or emulsifier(s) in the emulsion.
For example, the concentration of the fatty acid(s) in the emulsion
can range from a low of about 1 wt %, about 5 wt %, about 10 wt %,
about 20 wt %, or about 25 wt % to a high of about 30 wt %, about
35 wt %, about 37 wt %, or about 40 wt %, based on the combined
weight of any pitch(es), fatty acid(s), rosin(s), base compound(s),
and/or emulsifier(s) in the emulsion.
[0040] In one or more embodiments, the concentration of rosin(s) in
the emulsion can range from about 1 wt % to about 40 wt %, based on
the combined weight of any pitch(es), fatty acid(s), rosin(s), base
compound(s), and/or emulsifier(s) in the emulsion. For example, the
concentration of the fatty acid(s) in the emulsion can range from a
low of about 1 wt %, about 5 wt %, about 15 wt %, or about 20 wt %
to a high of about 25 wt %, about 30 wt %, about 35 wt %, or about
40 wt, based on the combined weight of any pitch(es), fatty
acid(s), rosin(s), base compound(s), and/or emulsifier(s) in the
emulsion.
[0041] In one or more embodiments, the concentration of the base
compound(s) in the emulsion can range from about 0.1 wt % to about
5 wt %, based on the combined weight of any pitch(es), fatty
acid(s), rosin(s), base compound(s), and/or emulsifier(s) in the
emulsion. For example, the concentration of the base compound(s) in
the emulsion can range from a low of about 0.5 wt %, about 0.8 wt
%, or about 1 wt % to a high of about 2 wt %, about 3 wt %, or
about 4 wt %, based on the combined weight of any pitch(es), fatty
acid(s), rosin(s), base compound(s), and/or emulsifier(s) in the
emulsion.
[0042] The dedusting agent can also include one or more oils. The
one or more oils can be petroleum based or petroleum derived oils,
bio-based or bio-derived oils, synthetic-based or
synthetically-derived oils, or any combination thereof. In one or
more embodiments, the oil can be or include mineral oils, glycols
such as ethylene glycol, motor oils, hydraulic oils, soybean oil,
rapeseed oil, sunflower oil, corn oil, peanut oil, cotton oil,
palm, oil, palm kernel oil, coconut oil, or any combination
thereof. Suitable oils can include hydrocarbons that contain from
about 10 carbon atoms to about 100 carbon atoms. For example, the
number of carbon atoms in the oil can range from a low of about 10,
about 15, about 20, about 25 or about 30 to a high of about 40,
about 60, about 70, about 80, about 90, or about 100. Motor oils
can include those oils conventionally or typically used to
lubricate moving components in internal combustion engines, for
example.
[0043] The one or more oils can have any number of desired
properties or combination of properties. For example, the one or
more oils can have flash point of greater than about 200.degree.
C., greater than about 250.degree. C., greater than about
300.degree. C., greater than about 350.degree. C., greater than
about 400.degree. C., greater than about 450.degree. C., greater
than about 500.degree. C., greater than about 550.degree. C., or
greater than about 600.degree. C. In another example, the one or
more oils can have a flash point between about 275.degree. C. and
about 600.degree. C., between about 300.degree. C. and about
550.degree. C., between about 350.degree. C. and about 500.degree.
C., or between about 400.degree. C. and about 600.degree. C. In one
or more embodiments, the flash point of the oil can be greater than
a temperature the composition can be subjected to when used to
produce a fiberglass product. In another example, the one or more
oils can have a flash point ranging from a low of about 200.degree.
C., about 225.degree. C., about 250.degree. C., about 275.degree.
C., or about 300.degree. C. to a high of about 350.degree. C.,
about 375.degree. C., about 400.degree. C., about 425.degree. C.,
about 450.degree. C., about 475.degree. C., about 500.degree. C.,
about 525.degree. C., or about 550.degree. C.
[0044] Considering mineral oil in more detail, the mineral oil can
include from about 15 to about 40 carbon atoms. The mineral oil can
include paraffinic hydrocarbons, naphthenic hydrocarbons, aromatic
hydrocarbons, or any combination thereof. Mineral oil can also be
referred to as "brightstock."
[0045] In one or more embodiments, the amount of oil(s) relative to
the emulsion can vary between wide limits. For example, for a
dedusting agent that includes an emulsion containing one or more
pitches, the dedusting agent can have a concentration of the oil(s)
ranging from a low of about 1 wt %, about 5 wt %, or about 10 wt %
to a high of about 30 wt %, about 40 wt %, or about 50 wt % based
on the weight of the one or more pitches. In another example, for a
dedusting agent that includes an emulsion containing one or more
pitches, the dedusting agent can have a concentration of the oil(s)
ranging from about 1 wt % to about 50 wt %, from about 5 wt % to
about 25 wt %, from about 5 wt % to about 20 wt %, or from about 1
wt % to about 25 wt %, based on the weight of the one or more
pitches.
[0046] In one or more embodiments, for a dedusting agent that
includes an emulsion containing one or more pitches and one or more
fatty acids and one or more rosins, the dedusting agent can have a
concentration of the oil(s) ranging from a low of about 1 wt %,
about 5 wt %, or about 10 wt %, or about 20 wt % to a high of about
50 wt %, about 60 wt %, about 70 wt %, about 80 wt %, about 90 wt
%, or about 100 wt %, based on the combined weight of the pitches,
fatty acids, and rosins. In one or more embodiments, an emulsion
containing the one or more pitches and one or more fatty acids
and/or one or more rosins, the dedusting agent can have a
concentration of the oil(s) ranging from a low a low of about 1 wt
%, about 5 wt %, or about 10 wt %, or about 20 wt % to a high of
about 50 wt %, about 60 wt %, about 70 wt %, about 80 wt %, about
90 wt %, or about 100 wt %, based on the combined weight of the
pitches, fatty acids, and rosins.
[0047] The dedusting agent can also include one or more film
forming polymers. The film forming polymer can include any film
forming polymer or combination of film forming polymers. Preferably
the film forming polymer(s) does not interfere with the stability
of the emulsion that includes one or more pitches, fatty acids,
rosin acids, or any combination thereof. Suitable film forming
polymers can be identified using only routine testing. The film
forming polymer(s) can be water soluble. The film forming polymers
can be capable of forming a latex.
[0048] Suitable film forming polymers can include, but are not
limited to, copolymers of styrene and acrylic acid; copolymers of
styrene-acrylate; copolymers of styrene and maleic anhydride;
copolymers of styrene and maleic acid; copolymers of styrene
butadiene; copolymers of styrene isoprene; polyolefins;
polyacrylates and other acrylate copolymers; polystyrene;
polystyrene copolymers; polyurethanes; polyamides; polyesters
including alkyd resins; modified rosin salts; polycarbonates;
polyacrylamides; vinyl chloride and/or vinyledene chloride
homopolymers and copolymers; polyterpenes; resins based on
aldehydes (formaldehyde) with phenolics, melamine, and/or urea;
polyimides; polysiloxanes; polyvinylpyrolidone; aliphatic
hydrocarbon resins; aromatic hydrocarbon resins; polyvinyl alcohol;
polyethylene glycol; polyethylene imines; polyethylene oxides;
lignosulfonates; water soluble gums; water soluble starches;
microcrystalline waxes; petroleum; hydroxymethyl cellulose;
carboxymethylcellulose; rubber and modified rubber latexes;
humates; tallow; shellac and gilsonite. The film forming polymers
can be derived from natural sources. The film forming polymers can
be synthetically produced. As used herein, the terms "acrylic" and
"acrylate" are also intended to include alkylacrylics and
alkylacrylates, such as methacrylic and methacrylate.
[0049] In one or more embodiments, the film forming polymer can
include functional groups or segments capable of interacting both
with an aqueous phase and with the pitch. As such, in one or more
embodiments the film forming polymer can include both hydrophilic
and hydrophobic groups or segments. For interacting with an aqueous
phase, the film forming polymer can include hydrophilic groups such
as carboxyl or hydroxyl groups. For interacting with the pitch, the
film forming polymer can include groups or segments that are
hydrophobic, such as hydrocarbon groups. Illustrative hydrophilic
groups or segments can include, but are not limited to, polymerized
maleic anhydride (maleic acid), acrylic acid, methacrylic acid,
hydroxyethylacrylic acid, hydroxyethylmethacrylic acid,
hydroxymethylacrylate, hydroxyethylacrylate, hydroxyethyl
methacrylate, ethylene oxide, hydrolyzed vinylacetate, or any
combination thereof. Illustrative hydrophobic groups or segments
can include, but are not limited to, polymerized ethylene,
propylene, butylene, styrene, halogenated olefins such as
tetrafluoroethylene, chlorotrifluoroethylene, acrylates of alcohols
having about 1-20 carbon atoms, or any combination thereof. Methods
for making such film forming polymers are well known and such
materials are widely available commercially.
[0050] In one or more embodiments, suitable film forming polymers
can have a sufficiently high molecular weight so that at their
level of use they can form, in cooperation with the pitch (if
present), a film having both a reduced tack and a sufficient
integrity to reduce the generation of fugitive dust on the surface
of the solids to which the dedusting composition has been applied.
In one or more embodiments, the molecular weight of the film
forming polymer can range from a low of about 1,000, about 5,000,
about 10,000, about 15,000, or about 20,000 to a high of about
100,000, about 200,000, about 300,000, about 400,000, or about
500,000. In one or more embodiments, the molecular weight of the
film forming polymer can range from about 10,000 to about 300,000,
from about 10,000 to about 200,000, or from about 10,000 to about
180,000.
[0051] In at least one specific embodiment, the film forming
polymer can be or include styrene maleic anhydride (acid) (SMA).
The molecular weight of the SMA copolymer can vary within wide
limits. The SMA copolymer can have a weight average molecular
weight (Mw) of between about 1,000 and about 500,000. For example,
the SMA copolymer can have a Mw ranging from a low of about 1,000,
about 5,000, about 10,000, about 15,000, or about 20,000 to a high
of about 100,000, about 200,000, about 300,000, about 400,000, or
about 500,000. In another example, the Mw of the SMA copolymer can
range from a low of about 1,000, about 5,000, or about 10,000 to a
high of about 400,000, or about 350,000, or about 300,000, or about
250,000, or about 200,000, or about 175,000, or about 150,000, or
about 120,000, or about 100,000, or about 90,000, or about 80,000,
or about 70,000, or about 60,000, or about 50,000, or about 40,000,
or about 30,000, or about 20,000.
[0052] In one or more embodiments, the amount of film forming
polymer(s) relative to the emulsion can vary between wide limits.
The film forming polymer can be present in the dedusting
composition in an amount sufficient to reduce the tack of the
emulsion and/or an at least partially dried emulsion. For example,
for a dedusting agent that includes an emulsion containing one or
more pitches, the dedusting agent can have a concentration of the
film forming polymer(s) ranging from a low of about 1 wt %, about 5
wt %, or about 10 wt % to a high of about 30 wt %, about 40 wt %,
or about 50 wt % based on the weight of the one or more pitches. In
another example, for a dedusting agent that includes an aqueous
emulsion containing one or more pitches, the dedusting composition
can have a concentration of the film forming polymer(s) ranging
from a low of about 1 wt %, about 5 wt %, or about 10 wt % to a
high of about 30 wt %, about 40 wt %, or about 50 wt % based on the
weight of the one or more pitches. In another example, for a agent
composition that includes an aqueous emulsion containing one or
more pitches, the dedusting composition can have a concentration of
the film forming polymer(s) ranging from about 1 wt % to about 50
wt %, from about 5 wt % to about 25 wt %, from about 5 wt % to
about 20 wt %, or from about 1 wt % to about 25 wt %, based on the
weight of the one or more pitches.
[0053] The dedusting agent can have any desired concentration of
solids. The solids can be or include the one or more pitches, fatty
acids, rosins, and/or emulsifier. For example, the dedusting agent
can have a solids concentration ranging from a low of about 10 wt
%, about 20 wt %, about 30 wt %, or about 40 wt % to a high of
about 50 wt %, about 55 wt %, or about 60 wt %, based on the weight
of the dedusting agent. In another example, the dedusting agent can
have a solids concentration of about 35 wt % to about 50 wt %,
about 40 wt % to about 50 wt %, or about 35 wt % to about 45 wt %,
based on the weight of the dedusting agent. In another example, the
dedusting agent can have a solids concentration of about 37 wt % to
about 43 wt %, from about 47 wt % to about 53 wt %, or from about
37 wt % to about 53 wt %, based on the weight of the dedusting
agent. The dedusting composition can have a water concentration
ranging from a low of about 10 wt %, about 20 wt %, about 20 wt %,
or about 50 wt % to a high of about 60 wt %, about 70 wt %, or
about 80 wt %, based on the weight of the dedusting agent.
[0054] The solids in the dedusting agent can have any desired size.
For example, the solids in the dedusting agent can have an average
size ranging from about 0.1 .mu.m to about 20 .mu.m. In another
example, the size of the solids in the dedusting agent can be less
than about 10 .mu.m, less than about 8 .mu.m, less than about 5
.mu.m, less than about 4 .mu.m, less than about 3 .mu.m, less than
about 2 .mu.m, less than about 1 .mu.m, or less than about 0.5
.mu.m. In another example, the size of the solids in the dedusting
agent can range from about 0.5 .mu.m to about 3.5 .mu.m, from about
1 .mu.m to about 3 .mu.m, or from about 0.5 .mu.m to about 3
.mu.m.
[0055] Returning to the composition, the dedusting agent can be
mixed, blended, or otherwise combined with one or more binders to
produce the composition. Illustrative binders can include, but are
not limited to aldehyde containing or aldehyde based polymers, a
mixture of Maillard reactants, a copolymer of one or more vinyl
aromatic derived units and at least one of maleic anhydride and
maleic acid, or any combination thereof.
[0056] Illustrative aldehyde containing or aldehyde based polymers
can include, but are not limited to, urea-aldehyde polymers,
melamine-aldehyde polymers, phenol-aldehyde polymers, or
combinations thereof. Combinations of aldehyde based polymers can
include, for example, melamine-urea-aldehyde, phenol-urea-aldehyde,
and phenol-melamine-aldehyde.
[0057] The aldehyde component of the aldehyde-containing polymers,
e.g., urea-aldehyde polymers, melamine-aldehyde polymers, and/or
phenol-aldehyde polymers can include any suitable aldehyde. The
aldehyde component can include a variety of substituted and
unsubstituted aldehyde compounds. Illustrative aldehyde compounds
can include the so-called masked aldehydes or aldehyde equivalents,
such as acetals or hemiacetals. Specific examples of suitable
aldehyde compounds can include, but are not limited to,
formaldehyde, acetaldehyde, propionaldehyde, butyraldehyde,
furfuraldehyde, benzaldehyde, or any combination thereof. As used
herein, the term "formaldehyde" can refer to formaldehyde,
formaldehyde derivatives, other aldehydes, or combinations thereof.
Preferably, the aldehyde component is formaldehyde.
[0058] Formaldehyde for making suitable formaldehyde containing
polymers is available in many forms. Paraform (solid, polymerized
formaldehyde) and formalin solutions (aqueous solutions of
formaldehyde, sometimes with methanol, in 37%, 44%, or 50%
formaldehyde concentrations) are commonly used forms. Formaldehyde
gas is also available. Any of these forms is suitable for use in
preparing a formaldehyde containing polymer.
[0059] The urea component of a urea-aldehyde polymer can be
provided in many forms. For example, solid urea, such as prill,
and/or urea solutions, typically aqueous solutions, are commonly
available. Further, the can may be combined with another moiety,
for example, formaldehyde and/or urea-formaldehyde adducts, often
in aqueous solution. Any form of urea or urea in combination with
formaldehyde (or any other aldehyde or combinations thereof) can be
used to make a urea-aldehyde polymer. For example, both urea prill
and combined urea-formaldehyde products can be used. Suitable
urea-formaldehyde polymers can be prepared from urea and
formaldehyde monomers or from urea-formaldehyde precondensates in
manners well known to those skilled in the art. Illustrative
urea-formaldehyde products can include, but are not limited to,
Urea-Formaldehyde Concentrate (UFC). These types of products can be
as discussed and described in U.S. Pat. Nos. 5,362,842 and
5,389,716, for example. Any of these forms of urea, alone or in any
combination, can be used to prepare a urea-aldehyde polymer.
[0060] Urea-formaldehyde polymers can include from about 45% to
about 70%, and preferably, from about 55% to about 65%
non-volatiles, generally have a viscosity of about 50 cps to about
600 cps, preferably about 150 to about 400 cps, normally exhibit a
pH of about 7 to about 9, preferably about 7.5 to about 8.5, and
often have a free formaldehyde level of not more than about 3.0%,
and a water dilutability of about 1:1 to about 100:1, preferably
about 5:1 and above. Many suitable urea-formaldehyde polymers are
commercially available. Urea-formaldehyde polymers such as the
types sold by Georgia Pacific Resins, Inc. (e.g., GP-2928 and
GP-2980) for glass fiber mat applications, those sold by Hexion
Specialty Chemicals, and by Arclin Company can be used.
[0061] In preparing a urea-aldehyde polymer, the aldehyde and the
urea component can be reacted in an aqueous mixture under alkaline
conditions using known techniques and equipment. For example, a
urea-formaldehyde polymer can be made using a molar excess of
formaldehyde (along with any other reactive aldehyde component(s))
relative to the urea component. The molar ratio of formaldehyde to
urea (F:U) in the urea-formaldehyde polymer can range from about
1.1:1 to about 6:1, from about 1.3 to about 5:1, or from about
1.5:1 to about 4:1. When synthesized, such polymers typically
contain a low level of residual "free" urea component and a much
larger amount of residual "free" formaldehyde i.e. unreacted
formaldehyde. Prior to any formaldehyde scavenging, the
urea-formaldehyde polymer can be characterized by a free
formaldehyde content ranging from about 0.2 wt % to about 18 wt %
of the aqueous urea-formaldehyde resin.
[0062] The phenol component of a phenol-aldehyde polymer can
include a variety of substituted phenolic compounds, unsubstituted
phenolic compounds, or any combination of substituted and/or
unsubstituted phenolic compounds. For example, the phenol component
can be phenol itself (i.e. mono-hydroxy benzene). Examples of
substituted phenols can include, but are not limited to,
alkyl-substituted phenols such as the cresols and xylenols;
cycloalkyl-substituted phenols such as cyclohexyl phenol;
alkenyl-substituted phenols; aryl-substituted phenols such as
p-phenyl phenol; alkoxy-substituted phenols such as
3,5-dimethyoxyphenol; aryloxy phenols such as p-phenoxy phenol; and
halogen-substituted phenols such as p-chlorophenol. Dihydric
phenols such as catechol, resorcinol, hydroquinone, bis-phenol A
and bis-phenol F also can also be used.
[0063] Specific examples of suitable phenolic compounds (phenol
components) for replacing a portion or all of the phenol used in
preparing a phenol-aldehyde polymer can include, but are not
limited to, bis-phenol A, bis-phenol F, o-cresol, m-cresol,
p-cresol, 3,5-5 xylenol, 3,4-xylenol, 3,4,5-trimethylphenol,
3-ethyl phenol, 3,5-diethyl phenol, p-butyl phenol, 3,5-dibutyl
phenol, p-amyl phenol, p-cyclohexyl phenol, p-octyl phenol, 3,5
dicyclohexyl phenol, p-phenyl phenol, p-phenol, 3,5-dimethoxy
phenol, 3,4,5 trimethoxy phenol, p-ethoxy phenol, p-butoxy phenol,
3-methyl-4-methoxy phenol, p-phenoxy phenol, naphthol, anthranol
and substituted derivatives thereof. Preferably, about 80 wt % or
more, about 90 wt % or more, or about 95 wt % or more of the phenol
component comprises phenol (monohydroxybenzene).
[0064] In preparing a phenol-aldehyde polymer, the aldehyde
component and the phenol component can be reacted in an aqueous
mixture under alkaline conditions using known techniques and
equipment. For example, a phenol-formaldehyde polymer can be made
using a molar excess of formaldehyde (along with any other reactive
aldehyde component(s)) relative to the phenol component, e.g.,
phenol. The molar ratio of formaldehyde to phenol (F:P) in the
phenol-formaldehyde polymer can range from about 1.1:1 to about
6:1, from about 1.3 to about 5:1, or from about 1.5:1 to about 4:1.
When synthesized, such polymers typically contain a low level of
residual "free" phenol component and a much larger amount of
residual "free," i.e. unreacted formaldehyde. Prior to any
formaldehyde scavenging, the phenol-formaldehyde polymer can be
characterized by a free formaldehyde content ranging from about 0.2
wt % to about 18 wt % of the aqueous phenol-formaldehyde
polymer.
[0065] Suitable phenol-formaldehyde polymers can be as discussed
and described in U.S. Patent Application Publication Nos.
2008/0064799 and 2008/0064284. In these published patent
applications, the formation of tetradimer is suppressed by the
addition of a sulfite source during the preparation of the
phenol-formaldehyde polymer. Other phenol-formaldehyde resins can
be prepared under acidic reaction conditions, such as novolac
resins and inverted novolac resins. Suitable novolac resins and
inverted novolac resins can be as discussed and described in U.S.
Pat. Nos. 5,670,571 and 6,906,130 and U.S. Patent Application
Publication No. 2008/0280787.
[0066] The melamine component of a melamine-aldehyde polymer can be
provided in many forms. For example, solid melamine, such as prill,
and/or melamine solutions can be used. Although melamine is
specifically mentioned, the melamine can be totally or partially
replaced with other aminotriazine compounds. Other suitable
aminotriazine compounds can include substituted melamines, or
cycloaliphatic guanamines, or mixtures thereof. Substituted
melamines include the alkyl melamines and aryl melamines which can
be mono-, di-, or tri-substituted. In the alkyl substituted
melamines, each alkyl group can contain 1-6 carbon atoms and,
preferably 1-4 carbon atoms. Typical examples of some of the
alkyl-substituted melamines are monomethyl melamine, dimethyl
melamine, trimethyl melamine, monoethyl melamine, and
1-methyl-3-propyl-5-butyl melamine. In the aryl-substituted
melamines, each aryl group can contain 1-2 phenyl radicals and,
preferably, 1 phenyl radical. Typical examples of aryl-substituted
melamines include monophenyl melamine and diphenyl melamines.
[0067] In preparing a melamine-aldehyde polymer, the aldehyde and
the melamine component can be reacted in an aqueous mixture under
alkaline conditions using known techniques and equipment. For
example, a melamine-formaldehyde polymer can be made using a molar
excess of formaldehyde (along with any other reactive aldehyde
component(s)) relative to the melamine component, e.g., melamine
The molar ratio of formaldehyde to melamine (F:M) in the
melamine-formaldehyde polymer can range from about 1.1:1 to about
6:1, from about 1.3 to about 5:1, or from about 1.5:1 to about 4:1.
When synthesized, such polymers typically contain a low level of
residual "free" melamine component and a much larger amount of
residual "free," i.e. unreacted formaldehyde. Prior to any
formaldehyde scavenging, the melamine-formaldehyde polymer can be
characterized by a free formaldehyde content ranging from about 0.2
wt % to about 18 wt % of the aqueous melamine-formaldehyde
resin.
[0068] Similar to urea-formaldehyde polymers, melamine-formaldehyde
and phenol-formaldehyde polymers can be prepared from melamine or
phenol monomers and formaldehyde monomers or from
melamine-formaldehyde or phenol-formaldehyde precondensates. Phenol
and melamine reactants, like the urea and formaldehyde reactants
are commercially available in many forms and any form that can
react with the other reactants and does not introduce extraneous
moieties deleterious to the desired reaction and reaction product
can be used in the preparation of the polymers.
[0069] Suitable phenol-formaldehyde resins and
melamine-formaldehyde resins can include those sold by Georgia
Pacific Resins, Inc. (e.g. GP-2894 and GP-4878, respectively).
These polymers are prepared in accordance with well known methods
and contain reactive methylol groups which upon curing form
methylene or ether linkages. Such methylol-containing adducts may
include N,N'-dimethylol, dihydroxymethylolethylene; N,N'
bis(methoxymethyl), N,N'-dimethylolpropylene; 5,5-dimethyl-N,N'
dimethylolethylene; N,N'-dimethylolethylene; and the like.
[0070] If urea is added to the aldehyde-containing polymer(s), any
form or combination of forms of urea can be used. For example, an
aqueous urea solution containing about 40 wt % urea can be added to
the aldehyde-containing polymer(s) to form the premix. The premix
can have a ratio of urea to the aldehyde-containing polymer(s)
ranging from a low of about 1:10, about 1:8, or about 1:6 to a high
of about 1:4, about 1:3, or about 1:2.
[0071] The mixture of Maillard reactants can include, but is not
limited to, a source of a carbohydrate (carbohydrate reactant) and
an amine reactant capable of participating in a Maillard reaction
with the carbohydrate reactant. In another example, the mixture of
Maillard reactants can include a partially pre-reacted mixture of
the carbohydrate reactant and the amine reactant. The extent of any
pre-reaction can preserve the ability of the mixture of Maillard
reactants to be blended with the dedusting agent and with any other
components desired to be added into composition.
[0072] The source of the carbohydrate can include one or more
reactants having one or more reducing sugars, one or more reactants
that yields one or more reducing sugars under thermal curing
conditions, or a combination thereof. A reducing sugar can be a
sugar that contains aldehyde groups, or can isomerize, i.e.
tautomerize, to contain aldehyde groups. Such aldehyde groups are
reactive with an amino group (amine reactant) under Maillard
reaction conditions. Usually such aldehyde groups can also be
oxidized with, for example, Cu.sup.+2 to afford carboxylic acids.
The carbohydrate reactant can optionally be substituted with other
functional groups, such as with hydroxy, halo, alkyl, alkoxy, and
the like. The carbohydrate source can also possess one or more
chiral centers. The carbohydrate source can also include each
possible optical isomer at each chiral center. Various mixtures,
including racemic mixtures, or other diastereomeric mixtures of the
various optical isomers of any such carbohydrate source, as well as
various geometric isomers thereof, can be used.
[0073] The carbohydrate source can be nonvolatile. Nonvolatile
carbohydrate sources can increase or maximize the ability of the
carbohydrate reactant to remain available for reaction with the
amine reactant under Maillard reaction conditions, including the
curing conditions for curing the composition. Partially
pre-reacting the mixture of the source of the carbohydrate and the
amine reactant can expand the list of suitable carbohydrate
sources. The carbohydrate source can be a monosaccharide in its
aldose or ketose form, including a triose, a tetrose, a pentose, a
hexose, or a heptose; or a polysaccharide, or any combination
thereof.
[0074] If a triose serves as the carbohydrate source, or is used in
combination with other reducing sugars and/or a polysaccharide, an
aldotriose sugar or a ketotriose sugar can be utilized, such as
glyceraldehyde and dihydroxyacetone, respectively. If a tetrose
serves as the carbohydrate source, or is used in combination with
other reducing sugars and/or a polysaccharide, aldotetrose sugars,
such as erythrose and threose; and ketotetrose sugars, such as
erythrulose, can be utilized. If a pentose serves as the
carbohydrate source, or is used in combination with other reducing
sugars and/or a polysaccharide, aldopentose sugars, such as ribose,
arabinose, xylose, and lyxose; and ketopentose sugars, such as
ribulose, arabulose, xylulose, and lyxulose, can be utilized. If a
hexose serves as the carbohydrate source, or is used in combination
with other reducing sugars and/or a polysaccharide, aldohexose
sugars, such as glucose (i.e., dextrose), mannose, galactose,
allose, altrose, talose, gulose, and idose; and ketohexose sugars,
such as fructose, psicose, sorbose and tagatose, can be utilized.
If a heptose serves as the carbohydrate source, or is used in
combination with other reducing sugars and/or a polysaccharide, a
ketoheptose sugar such as sedoheptulose can be utilized. Other
stereoisomers of such carbohydrate sources not known to occur
naturally are also contemplated to be useful in preparing the
compositions. If a polysaccharide serves as the carbohydrate
source, or is used in combination with monosaccharides, then
sucrose, lactose, maltose, starch, and cellulose can be
utilized.
[0075] The carbohydrate reactant can also be used in combination
with a non-carbohydrate polyhydroxy reactant. Examples of
non-carbohydrate polyhydroxy reactants can include, but are not
limited to, trimethylolpropane, glycerol, pentaerythritol,
polyvinyl alcohol, partially hydrolyzed polyvinyl acetate, fully
hydrolyzed polyvinyl acetate, and mixtures thereof. The
non-carbohydrate polyhydroxy reactant can be sufficiently
nonvolatile to maximize its ability to remain available for
reaction with other components during curing. Partially
pre-reacting the mixture of the source of the carbohydrate
(carbohydrate reactant) and the amine reactant can expand the list
of suitable non-carbohydrate polyhydroxy reactants. The
hydrophobicity of the non-carbohydrate polyhydroxy reactant can be
a factor in determining the physical properties of the
composition.
[0076] The amine reactant capable of participating in a Maillard
reaction with the source of the carbohydrate can be a compound
possessing an amino group. The compound can be present in the form
of an amino acid. The free amino group can also be derived from a
protein where the free amino groups are available in the form of,
for example, the .epsilon.-amino group of lysine residues, and/or
the .alpha.-amino group of the terminal amino acid. The amine
reactant can also be formed separately or in situ by using a
polycarboxylic acid ammonium salt reactant. Ammonium salts of
polycarboxylic acids can be generated by neutralizing the acid
groups of a polycarboxylic acid with an amine base, thereby
producing polycarboxylic acid ammonium salt groups. Complete
neutralization, i.e. about 100%, calculated on an equivalents
basis, can eliminate any need to titrate or partially neutralize
acid groups in the polycarboxylic acid(s) prior to binder
formation. However, it is expected that less-than-complete
neutralization also would not inhibit formation of the composition.
To reiterate, neutralization of the acid groups of the
polycarboxylic acid(s) can be carried out either before or after
the polycarboxylic acid(s) is mixed with the carbohydrate(s).
[0077] Suitable polycarboxylic acids can include dicarboxylic
acids, tricarboxylic acids, tetracarboxylic acids, pentacarboxylic
acids, and the like, monomeric polycarboxylic acids, anhydrides,
and any combination thereof, as well as polymeric polycarboxylic
acids, anhydrides, and any combination thereof. Preferably, the
polycarboxylic acid ammonium salt reactant is sufficiently
non-volatile to maximize its ability to remain available for
reaction with the carbohydrate reactant of a Maillard reaction.
Again, partially pre-reacting the mixture of the source of the
carbohydrate and the amine reactant can expand the list of suitable
amine reactants, including polycarboxylic acid ammonium salt
reactants. In another example, polycarboxylic acid ammonium salt
reactants can be substituted with other chemical functional
groups.
[0078] Illustrative monomeric polycarboxylic acids can include, but
are not limited to, unsaturated aliphatic dicarboxylic acids,
saturated aliphatic dicarboxylic acids, aromatic dicarboxylic
acids, unsaturated cyclic dicarboxylic acids, saturated cyclic
dicarboxylic acids, hydroxy-substituted derivatives thereof, and
the like. Other suitable polycarboxylic acids can include
unsaturated aliphatic tricarboxylic acids, saturated aliphatic
tricarboxylic acids such as citric acid, aromatic tricarboxylic
acids, unsaturated cyclic tricarboxylic acids, saturated cyclic
tricarboxylic acids, hydroxy-substituted derivatives thereof, and
the like. It is appreciated that any such polycarboxylic acids can
be optionally substituted, such as with hydroxy, halo, alkyl,
alkoxy, and the like. Other suitable polycarboxylic acids can
include, but are not limited to, aconitic acid, adipic acid,
azelaic acid, butane tetracarboxylic acid dihydride, butane
tricarboxylic acid, chlorendic acid, citraconic acid,
dicyclopentadiene-maleic acid adducts, diethylenetriamine
pentaacetic acid, adducts of dipentene and maleic acid,
ethylenediamine tetraacetic acid (EDTA), fully maleated rosin,
maleated tall-oil fatty acids, fumaric acid, glutaric acid,
isophthalic acid, itaconic acid, maleated rosin oxidized with
potassium peroxide to alcohol then carboxylic acid, maleic acid,
malic acid, mesaconic acid, biphenol A or bisphenol F reacted via
the Kolbe-Schmidt reaction with carbon dioxide to introduce 3-4
carboxyl groups, oxalic acid, phthalic acid, sebacic acid, succinic
acid, tartaric acid, terephthalic acid, tetrabromophthalic acid,
tetrachlorophthalic acid, tetrahydrophthalic acid, trimellitic
acid, trimesic acid, and the like, and anhydrides, and any
combination thereof.
[0079] Suitable polymeric polycarboxylic acids can include organic
polymers or oligomers containing more than one pendant carboxy
group. The polymeric polycarboxylic acid can be a homopolymer or
copolymer prepared from unsaturated carboxylic acids that can
include, but are not limited to, acrylic acid, methacrylic acid,
crotonic acid, isocrotonic acid, maleic acid, cinnamic acid,
2-methylmaleic acid, itaconic acid, 2-methylitaconic acid,
.alpha.,.beta.-methyleneglutaric acid, and the like. The polymeric
polycarboxylic acid can also be prepared from unsaturated
anhydrides. Unsaturated anhydrides can include, but are not limited
to, 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 art.
[0080] Preferred polymeric polycarboxylic acids can include
polyacrylic acid, polymethacrylic acid, polymaleic acid, and the
like. Examples of commercially available polyacrylic acids include
AQUASET.RTM. 529 (Rohm & Haas, Philadelphia, Pa., USA),
CRITERION.RTM. 2000 (Kemira, Helsinki, Finland, Europe), NF1 (H. B.
Fuller, St. Paul, Minn., USA), and SOKALAN.RTM. (BASF,
Ludwigshafen, Germany, Europe). With respect to SOKALAN.RTM., this
is believed to be a water-soluble polyacrylic copolymer of acrylic
acid and maleic acid, having a molecular weight of approximately
4,000. AQUASET.RTM. 529 is understood to be a composition
containing polyacrylic acid cross-linked with glycerol, also
containing sodium hypophosphite as a catalyst. CRITERION.RTM. 2000
is thought to be an acidic solution of a partial salt of
polyacrylic acid, having a molecular weight of approximately 2,000.
NF1 is believed to be a copolymer containing carboxylic acid
functionality and hydroxy functionality, as well as units with
neither functionality; NF1 is also thought to contain chain
transfer agents, such as sodium hypophosphite or organophosphate
catalysts.
[0081] The amine base for reaction with the polycarboxylic acid can
include, but is not limited to, ammonia, a primary amine, i.e.,
NH.sub.2R.sup.1, and a secondary amine, i.e., NHR.sup.1R.sup.2,
where R.sup.1 and R.sup.2 are each independently selected from the
group consisting of: an alkyl, a cycloalkyl, an alkenyl, a
cycloalkenyl, a heterocyclyl, an aryl, and a heteroaryl group. The
amine base can be volatile or substantially non-volatile under
conditions sufficient to promote reaction among the mixture of
Maillard reactants during any partial pre-reaction or during
thermal cure of the composition. Suitable amine bases can include,
but are not limited to, a substantially volatile base, a
substantially non-volatile base, or a combination thereof.
Illustrative substantially volatile bases can include, but are not
limited to, ammonia, ethylamine, diethylamine, dimethylamine,
ethylpropylamine, or any combination thereof. Illustrative
substantially non-volatile bases can include, but are not limited
to, aniline, 1-naphthylamine, 2-naphthylamine, para-aminophenol, or
any combination thereof.
[0082] One particular example of the mixture of Maillard reactants
can include a mixture of aqueous ammonia, citric acid, and dextrose
(glucose). It is believed that the mixture of aqueous ammonia,
citric acid, and dextrose is representative of Knauf Insulation's
ECOSE.RTM. Technology. In this mixture, the ratio of the number of
molar equivalents of acid salt groups present on the
polycarboxylic, citric acid reactant (produced upon neutralization
of the --COOH groups of the citric acid by ammonia) to the number
of molar equivalents of hydroxyl groups present on the carbohydrate
reactant(s) can range from about 0.04:1 to about 0.15:1. After
curing, this formulation results in a water-resistant, cured
thermoset binder. Thus, in one embodiment, the number of molar
equivalents of hydroxyl groups present on the dextrose,
carbohydrate reactant can be about twenty five-fold greater than
the number of molar equivalents of acid salt groups present on the
polycarboxylic, citric acid reactant. In another embodiment, the
number of molar equivalents of hydroxyl groups present on the
dextrose carbohydrate reactant is about ten-fold greater than the
number of molar equivalents of acid salt groups present on the
polycarboxylic citric acid reactant. In yet another embodiment, the
number of molar equivalents of hydroxyl groups present on the
dextrose carbohydrate reactant is about six-fold greater than the
number of molar equivalents of acid salt groups present on the
polycarboxylic citric acid reactant.
[0083] As noted above, the mixture of Maillard reactants can
include a source of a carbohydrate and an amine reactant capable of
participating in a Maillard reaction therewith. Also, as noted
above, the mixture of Maillard reactants can include a partially
reacted mixture of a source of a carbohydrate and an amine
reactant. For example, the source of a carbohydrate can be mixed
with an amine reactant capable of participating in a Maillard
reaction with the source of the carbohydrate and the mixture can be
heated to about 90.degree. C. for a time sufficient to initiate the
Maillard reaction(s), but not allow the reaction(s) to proceed to
completion, before finally formulating the composition.
[0084] As the case with the aldehyde based polymers, a binder that
includes a mixture of Maillard reactants can also include other
ingredients commonly used in such compositions such as an extender,
e.g., urea, one or more catalysts for accelerating the cure of the
resin such as sodium or ammonium sulfate, melamine,
melamine-formaldehyde adducts, silicon-based coupling or
compatibilizing agents, corrosion inhibitors, dispersants,
biocides, viscosity modifiers, pH adjusters, surfactants,
lubricants, defoamers, and the like, and any combination
thereof.
[0085] The binder can be or include a copolymer of one or more
vinyl aromatic derived units and at least one of maleic anhydride
and maleic acid. The vinyl aromatic derived units can include, but
are not limited to, styrene, alpha-methylstyrene, vinyl toluene,
and combinations thereof. Preferably, the vinyl aromatic derived
units are derived from styrene and/or derivatives thereof.
[0086] In one or more embodiments, the copolymer comprising one or
more vinyl aromatic derived units and maleic anhydride (maleic
acid). Such copolymer can include of from about 7 mol % to about 50
mol % maleic anhydride and conversely of from about 50 mol % to
about 93 mol % vinyl aromatic derived units. In one or more
embodiments, the copolymer can include from about 20 mol % to about
40 mol % maleic anhydride and conversely of from about 60 mol % to
about 80 mol % vinyl aromatic derived units. In one or more
embodiments, the maleic anhydride (maleic acid) can be present in
an amount ranging from a low of about 7 mol %, about 10 mol %,
about 12 mol %, or about 15 mol % to a high of about 30 mol %,
about 35 mol %, about 40 mol %, or about 45 mol %, based on the
total weight of the maleic anhydride and the one or more vinyl
derived units. In one or more embodiments, the vinyl aromatic
derived units can be present in an amount ranging from a low of
about 50 mol %, about 55 mol %, about 60 mol %, or about 65 mol %
to a high of about 75 mol %, about 80 mol %, about 85 mol %, or
about 90 mol %, based the total weight of the maleic anhydride and
the one or more vinyl derived units.
[0087] The copolymer can contain a minor amount (less than 50 mol
%, or less than about 40 mol %, or less than about 30 mol %, or
less than about 20 mol %, based on the amount of maleic anhydride
(maleic acid)) of another unsaturated carboxylic acid monomer such
as aconitic acid, itaconic acid, acrylic acid, methacrylic acid,
crotonic acid, isocrotonic acid, citraconic acid, and fumaric acid
and the mixtures thereof. The copolymer can also contain a minor
amount (less than 50 mol %, or less than about 40 mol %, or less
than about 30 mol %, or less than about 20 mol %, based on the
amount of the vinyl aromatic derived units) of another hydrophobic
vinyl monomer. Another "hydrophobic vinyl monomer" is a monomer
that typically produces, as a homopolymer, a polymer that is
water-insoluble or capable of absorbing less than 10% by weight
water. Suitable hydrophobic vinyl monomers are exemplified by (i)
vinyl esters of aliphatic acids such as vinyl acetate, vinyl
propionate, vinyl butyrate, vinyl caproate, vinyl 2-ethylhexanoate,
vinyl laurate, and vinyl stearate; (ii) diene monomers such as
butadiene and isoprene; (iii) vinyl monomers and halogenated vinyl
monomers such as ethylene, propylene, cyclohexene, vinyl chloride
and vinylidene chloride; (iv) acrylates and alkyl acrylates, such
as methyl acrylate, ethyl acrylate, n-propyl acrylate, isopropyl
acrylate, n-butyl acrylate, isobutyl acrylate, tert-butyl acrylate,
n-hexyl acrylate, cyclohexyl acrylate, and 2-ethylhexyl acrylate;
and (v) nitrile monomers such as acrylonitrile and
methacrylonitrile and mixtures thereof.
[0088] In at least one specific embodiment, the copolymer can be a
copolymer of styrene and maleic anhydride (acid) (SMA). The
molecular weight of the SMA copolymer can vary within wide limits.
The SMA copolymer can have a weight average molecular weight (Mw)
of between about 1,000 and about 500,000. For example, the SMA
copolymer can have a Mw ranging from a low of about 1,000, about
5,000, about 10,000, about 15,000, or about 20,000 to a high of
about 100,000, about 200,000, about 300,000, about 400,000, or
about 500,000. In another example, the Mw of the SMA copolymer can
range from a low of about 1,000, about 5,000, or about 10,000 up to
about 400,000, or about 350,000, or about 300,000, or about
250,000, or about 200,000, or about 175,000, or about 150,000, or
about 120,000 or about 100,000, or about 90,000, or about 80,000,
or about 70,000, or about 60,000, or about 50,000, or about 40,000,
or about 30,000, or about 20,000.
[0089] In one or more embodiments, the SMA copolymers can be
partially esterified. For example, the SMA copolymers can be
partially esterified and can still contain some anhydride groups.
The partial esters of the SMA copolymers can be prepared in
conventional manners from alkanols of about 3 to 20 carbon atoms,
preferably from hexanol or octanol. The extent of the
partial-esterification of the SMA copolymers can range from about 5
to 95%, from about 10% to about 80%, from about 20% to about 50%,
or from about 15% to about 40%. The esterification can be effected
by simply heating a mixture of the appropriate quantities of the
SMA copolymers with the alcohol at elevated temperatures, e.g.,
from about 100.degree. C. to about 200.degree. C. In one or more
embodiments, the benzene ring of the SMA copolymers can be
substituted with one or more groups. For example, the benzene ring
of the SMA copolymers can contain one or more sulfonate groups.
[0090] Suitable SMA copolymers are commercially available from
numerous companies. For example, suitable SMA copolymers can be
purchased from, among others, Polyscope Polymers BV, Sartomer USA,
LLC, Hercules, Inc., and Georgia-Pacific Chemical LLC.
[0091] In one or more embodiments, the binder comprising the
copolymer of maleic anhydride and one or more vinyl aromatic
derived units can further include one or more carbohydrates. The
one or more carbohydrates can be present in an amount ranging from
a low of about 1 wt %, about 3 wt %, or about 5 wt % to a high of
about 70 wt %, about 80 wt %, or about 90 wt %, based on the total
weight of the binder. In one or more embodiment, the binder can
include from about 5 wt % to about 50 wt % carbohydrate(s), based
on the total weight of the binder. In one or more embodiments, the
binder can include of from about 7.5 wt % to about 15 wt %
carbohydrate(s), based on the total weight of the binder. In one or
more embodiments, the binder can include from about 5 wt % to about
30 wt % carbohydrate(s), based on the total weight of the
binder.
[0092] The one or more carbohydrates can include one or more
monosaccharides, disaccharides, oligosaccharides, polysaccharides,
or any combinations thereof. In one or more embodiments, the one or
more carbohydrates can include one or more aldose sugars. In one or
more embodiments, the monosaccharide can be or include D-Glucose
(dextrose monohydrate), L-Glucose, or a combination thereof. Other
carbohydrate aldose sugars can include, but are not limited to,
glyceraldehyde, erythrose, threose, ribose, deoxyribose, arabinose,
xylose, lyxose, allose, altrose, gulose, mannose, idose, galactose,
talose, and any combination thereof.
[0093] In one or more embodiments, the binder comprising the
copolymer of maleic anhydride and one or more vinyl aromatic
derived units can be modified by reaction with one or more amines.
Illustrative amines can include, but are not limited to,
alkanolamines, polyamines, aromatic amines, and any combination
thereof. Illustrative alkanolamines can include, but are not
limited to, monoethanolamine (MEA), diethanolamine (DEA),
triethanolamine (TEA), or any combination thereof. Preferably, the
alkanolamine is a tertiary alkanolamine or more preferably
triethanolamine (TEA). An alkanolamine is defined as a compound
that has both amino and hydroxyl functional groups as illustrated
by diethanolamine, triethanolamine, 2-(2-aminoethoxy)ethanol,
aminoethyl ethanolamine, aminobutanol and other aminoalkanols.
Illustrative aromatic amines can include, but are not limited to,
benzyl amine, aniline, ortho toludine, meta toludine, para
toludine, n-methyl aniline, N--N'-dimethyl aniline, di- and
tri-phenyl amines, 1-naphthylamine, 2-naphthylamine, 4-aminophenol,
3-aminophenol and 2-aminophenol. Illustrative polyamines can
include, but are not limited to, diethylenetriamine (DETA),
triethylenetetramine (TETA), tetraethylenepentamine (TEPA). Other
polyamines can include, for example, 1,3-propanediamine,
1,4-butanediamine, polyamidoamines, and polyethylenimines.
[0094] Other suitable amines can include, but are not limited to,
primary amines (NH.sub.2R.sub.1), secondary amines
(NHR.sub.1R.sub.2), and tertiary amines (NR.sub.1R.sub.2R.sub.3),
where each R.sub.1, R.sub.2, and R.sub.3 can be independently
selected from alkyls, cycloalkyls, heterocycloalkyls, aryls,
heteroaryls, and substituted aryls. The alkyl can include branched
or unbranched alkyls having from 1 to 15 carbon atoms or more
preferably from 1 to 8 carbon atoms. Illustrative alkyls can
include, but are not limited to, methyl, ethyl, n-propyl,
isopropyl, n-butyl, sec butyl, t-butyl, n-pentyl, n-hexyl, and
ethylhexyl. The cycloalkyls can include from 3 to 7 carbon atoms.
Illustrative cycloalkyls can include, but are not limited to,
cyclopentyl, substituted cyclopentyl, cyclohexyl, and substituted
cyclohexyl. The term "aryl" refers to an aromatic substituent
containing a single aromatic ring or multiple aromatic rings that
are fused together, linked covalently, or linked to a common group
such as a methylene or ethylene moiety. More specific aryl groups
contain one aromatic ring or two or three fused or linked aromatic
rings, e.g., phenyl, naphthyl, biphenyl, anthracenyl,
phenanthrenyl, and the like. In one or more embodiments, aryl
substituents can have from 1 to about 20 carbon atoms. The term
"heteroatom-containing," as in a "heteroatom-containing cycloalkyl
group," refers to a molecule or molecular fragment in which one or
more carbon atoms is replaced with an atom other than carbon, e.g.,
nitrogen, oxygen, sulfur, phosphorus, boron, or silicon. Similarly,
the term "heteroaryl" refers to an aryl substituent that is
heteroatom-containing. The term "substituted," as in "substituted
aryls," refers to a molecule or molecular fragment in which at
least one hydrogen atom bound to a carbon atom is replaced with one
or more substituents that are functional groups such as hydroxyl,
alkoxy, alkylthio, phosphino, amino, halo, silyl, and the like.
Illustrative primary amines can include, but are not limited to,
methylamine and ethylamine. Illustrative secondary amines can
include, but are not limited to, dimethylamine and diethylamine.
Illustrative tertiary amines can include, but are not limited to,
trimethylamine and triethylamine.
[0095] The addition of one or more carbohydrates to the binder
containing the copolymer of maleic anhydride (acid) and one or more
vinyl aromatic derived units and/or modifying the binder comprising
the copolymer of maleic anhydride and one or more vinyl aromatic
derived units can be as discussed and described in U.S. Provisional
Patent Application having Ser. No. 61/265,956, filed on Dec. 2,
2009.
[0096] In one or more embodiments, the binder can be or include one
or more latexes. Illustrative latexes can include, but are not
limited to, styrene/acrylic acid ester copolymer, styrene-butadiene
rubber, acrylonitrile butadiene styrene, acrylic polymers,
polyvinyl acetate, or any combination thereof. The latexes can be
prepared using any suitable process. For example, the
styrene/acrylic acid ester copolymer (SAE) can be the reaction
product of a hydrophobic styrene-based monomer and acrylic acid
ester co-polymerized in an emulsion. A suitable SAE copolymer can
be prepared as discussed and described in U.S. Pat. No. 6,734,232.
A suitable, commercially available SAE can include NOVACOTE.RTM.
PS, available from Georgia-Pacific Resins, Inc.
[0097] In one or more embodiments, the binder can be or include an
adduct or polymer of styrene, at least one of maleic anhydride and
maleic acid, and at least one of an acrylic acid and an acrylate.
Any suitable acrylic acid or acrylate can be used such as methyl
methacrylate, butyl acrylate, methacrylate, or any combination
thereof. Preferably, the acrylate is methyl methacrylate (MMA). The
adduct can be combined with the aldehyde based polymer, the
Maillard reactants, or a combination thereof. In another example,
the components of the adduct can be mixed with the aldehyde based
polymer, the mixture of Maillard reactants, or a combination
thereof.
[0098] The adduct can be prepared by dissolving the components of
the adduct in a suitable solution. Illustrative solutions can
include, but are not limited to, aqueous solutions of sodium
hydroxide, ammonium hydroxide, potassium hydroxide, and
combinations thereof. The solution can be heated to a temperature
of about 70.degree. C. to about 90.degree. C. The solution can be
held at the elevated temperature until the components are all at
least partially in solution. The solution can then be added to the
phenol-aldehyde resin, the mixture of Maillard reactants, or the
combination of the phenol-aldehyde resin and the mixture of
Maillard reactants.
[0099] The adduct can be prepared by combining styrene, at least
one of maleic anhydride and maleic acid, and at least one of an
acrylic acid and an acrylate to form a terpolymer. The amount of
styrene in the adduct can range from a low of about 50 wt %, about
55 wt %, or about 60 wt % to a high of about 75 wt %, about 80 wt
%, or about 85 wt %, based on the total weight of the adduct. The
amount of the maleic anhydride and/or maleic acid in the adduct can
range from a low of about 15 wt %, about 20 wt %, or about 25 wt %
to a high of about 40 wt %, about 45 wt %, or about 50 wt %, based
on the total weigh of the adduct. The amount of the acrylic acid
and/or the acrylate in the adduct can range from a low of about 1
wt %, about 3 wt % or about 5 wt % to a high of about 10 wt %,
about 15 wt %, or about 20 wt %, based on the total weight of the
adduct.
[0100] In another example, the acrylic acid or acrylate can be
combined with the copolymer of one or more vinyl aromatic derived
units and at least one of maleic anhydride and maleic acid to
provide the modifier. For example, combining the acrylic acid or
acrylate with SMA can form a styrene maleic anhydride
methyl-methacrylate terpolymer. In another example, the modifier
can also include a physical mixture of styrene acrylic acid and/or
styrene-acrylate copolymer and a SMA copolymer. The adduct or
polymer of styrene, at least one of maleic anhydride and maleic
acid, and at least one of an acrylic acid and an acrylate and the
physical mixture of styrene acrylic acid and/or styrene-acrylate
copolymer and a SMA copolymer can be prepared according to the
processes discussed and described in U.S. Pat. No. 6,642,299.
[0101] In one or more embodiments, the binder can be or include one
or more polyacrylic acid based polymers. The polyacrylic acid based
binder can include an aqueous solution of a polycarboxy polymer, a
monomeric trihydric alcohol, a catalyst, and a pH adjuster. The
polycarboxy polymer can include an organic polymer or oligomer
containing more than one pendant carboxy group. The polycarboxy
polymer can be a homopolymer or copolymer prepared from unsaturated
carboxylic acids including, but not limited to, acrylic acid,
methacrylic acid, crotonic acid, isocrotonic acid, maleic acid,
cinnamic acid, 2-methylmaleic acid, itaconic acid, 2-methylitaconic
acid, .alpha.,.beta.-methyleneglutaric acid, and the like. Other
suitable polycarboxy polymers can be prepared from unsaturated
anhydrides including, but not limited to, maleic anhydride,
itaconic anhydride, acrylic anhydride, methacrylic anhydride, and
the like, as well as mixtures thereof.
[0102] Illustrative trihydric alcohols can include, but are not
limited to, glycerol, trimethylolpropane, trimethylolethane,
triethanolamine, 1,2,4-butanetriol, and the like. The one or more
trihydric alcohols can be mixed with other polyhydric alcohols.
Other polyhydric alcohols can include, but are not limited to,
ethylene, glycol, 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol,
2-butene-1, erythritol, pentaerythritol, sorbitol, and the like.
The catalyst can include an alkali metal salt of a
phosphorous-containing organic acid; particularly alkali metal
salts of phosphorous acid, hypophosphorous acid, and polyphosphoric
acids. Illustrative catalysts can include, but are not limited to,
sodium, sodium phosphite, potassium phosphite, disodium
pyrophosphate, tetrasodium pyrophosphate, sodium tripolyphosphate,
sodium hexametaphosphate, potassium phosphate, potassium
polymetaphosphate, potassium polyphosphate, potassium
tripolyphosphate, sodium trimetaphosphate, and sodium
tetrametaphosphate, or any combination thereof. Illustrative
polyacrylic acid based polymers can be as discussed and described
in U.S. Pat. No. 7,026,390.
[0103] In one or more embodiments, the aldehyde based binders
and/or the Maillard reactant based binders can include one or more
modifiers. The modifier can be or include the copolymer comprising
one or more vinyl aromatic derived units and at least one of maleic
anhydride and maleic acid. In another example, the modifier can be
or include the adduct of styrene, at least one of maleic anhydride
and maleic acid, and at least one of an acrylic acid and an
acrylate. In another example, the modifier can be or include the
one or more latexes. In another example, the modifier can include
two or more of: (1) a copolymer comprising one or more vinyl
aromatic derived units and at least one of maleic anhydride and
maleic acid; (2) an adduct of styrene, at least one of maleic
anhydride and maleic acid, and at least one of an acrylic acid and
an acrylate; and (3) one or more latexes. The addition of the one
or more modifiers to the aldehyde based binder and/or the Maillard
reactant based binder can be as discussed and described in U.S.
patent application Ser. No. 12/860,446, filed on Aug. 20, 2010.
[0104] In one or more embodiments, the binder can be extended using
any suitable material. For example, the binder can be extended
through the addition of urea. In one or more embodiments, the
binder can be extended with urea such that the binder has a urea
concentration ranging from about 1 wt % to about 50 wt %, based on
the combined weight of the binder and the added urea. In another
example, the binder extended with urea can have a urea
concentration ranging from a low of about 5 wt %, about 15 wt %, or
about 25 wt % to a high of about 35 wt %, about 40 wt %, or about
45 wt %, based on the combined weight of the binder and the added
urea. In at least one specific embodiment, the aldehyde based
binder, the Maillard reactants binder, the copolymer of one or more
vinyl aromatic derived units and at least one of maleic anhydride
and maleic acid, or any combination thereof, can be extended with
urea.
[0105] In one or more embodiments, the optional urea can be added
to the binder by mixing, blending, or any other process to produce
a "premix." The premix can be agitated to homogeneity. After
forming the premix, the premix can be allowed to react or prereact
for a period of time. For example, the premix can be allowed to
react for about 5 hours or more, about 10 hours or more, about 15
hours or more, about 20 hours or more, or about 25 hours or more,
after which time it can be stored at 65.degree. F. and used to
prepare a composition for up to approximately four days. Premixing
the urea with aldehyde-based binders, for example, can reduce the
level of free aldehydes, such as formaldehyde, in the aldehyde
based binder to a level that does not increase the ammonia demand
of binder solutions prepared with the premix.
[0106] Other suitable extenders can include, but are not limited
to, polysaccharides, sulfonated lignins, and the like. Illustrative
polysaccharides can be include, but are not limited to, starch,
cellulose, gums, such as guar and xanthan, alginates, pectin,
gellan, or any combination thereof. Suitable polysaccharide
starches can include, for example maize or corn, waxy maize, high
amylose maize, potato, tapioca and wheat starch. Other starches
such as genetically engineered starches can include, high amylose
potato and potato amylopectin starches. Illustrative sulfonated
lignins can include, but are not limited to, sodium lignosulfonate
and ammonium lignodulfonate.
[0107] In one or more embodiments above or elsewhere herein, the
binder can further include one or more oils, one or more film
forming polymers, or a combination thereof. Suitable oils and film
forming polymers can be as discussed and described above or
elsewhere herein.
[0108] In one or more embodiments above or elsewhere herein, the
binder can further include any combination of two or more binders.
As such, a composition that includes a first binder and a second
binder can be prepared. In one or more embodiments, the first
binder can be present in an amount of from about 1 wt % to about 99
wt %, based on the combined weight of the first binder and the
second binder. For example, the first binder can be present in an
amount ranging from a low of about 5 wt %, about 15 wt %, about 25
wt %, or about 35 wt % to a high of about 65 wt %, about 75 wt %,
about 85 wt %, or about 95 wt %, based on the combined weight of
the first binder and the second binder. When three or more binders
are combined to provide the binder used in the composition, the
three or more binders can be present in any amount. For example,
for a combination of three binders, the first binder can be present
in an amount of from about 1 wt % to about 98 wt %, the second
binder can be present in an amount of from about 1 wt % to about 98
wt %, and the third binder can be present in an amount of from
about 1 wt % to about 98 wt %, based on the combined weight of the
first, second, and third binders.
[0109] In one or more embodiments, the binder can include a
combination of the one or more aldehyde based polymers and/or the
Maillard reactants and the copolymer comprising one or more vinyl
aromatic derived units and at least one of maleic anhydride and
maleic acid. In one or more embodiments, the binder can include a
combination of the one or more aldehyde based polymers and/or the
Maillard reactants and an adduct of styrene, at least one of maleic
anhydride and maleic acid, and at least one of an acrylic acid and
an acrylate. In one or more embodiments, the binder can include a
combination of the one or more aldehyde based polymers and/or the
Maillard reactants; and one or more latexes.
[0110] The binder can have a solids concentration ranging from a
low of about 1 wt %, about 5 wt % or about 10 wt % to a high of
about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about
40 wt %, about 45 wt %, or about 50 wt %. For example, the binder
can have a solids concentration of from about 5 wt % to about 20 wt
%, about 10 wt % to about 30 wt %, about 30 wt % to about 40 wt %,
or about 10 wt % to about 25 wt %.
[0111] Any one or more of the binders can be blended, mixed, or
otherwise combined with the dedusting agent to form or produce the
composition. The mixing procedure can be carried out at ambient
temperature or at a temperature greater than ambient temperature,
for example about 50.degree. C. The composition can be used
immediately or stored for a period of time and may be diluted with
water to a concentration suitable for the desired method of
application, such as by a curtain coater onto the glass fibers.
[0112] The composition can have a concentration of the dedusting
agent ranging from a low of about 0.1 wt %, about 1 wt %, about 3
wt %, or about 5 wt % to a high of about 10 wt %, about 15 wt %,
about 20 wt %, about 25 wt %, about 30 wt %, about 35 wt %, about
40 wt %, about 45 wt %, or about 50 wt %, based on the combined
weight of the solid components in the composition. For example, the
composition can have a concentration of the dedusting agent ranging
from about 1 wt % to about 40 wt %, about 2 wt % to about 30 wt %,
about 5 wt % to about 40 wt %, or about 10 wt % to about 35 wt %,
based on the combined weight of the solid components in the
composition.
[0113] The composition can have a concentration of the dedusting
agent ranging from about 1 wt % to about 50 wt % or from about 1 wt
% to about 30 wt %, or from about 1 wt % to about 20 wt %, based on
the combined weight of the binder and the dedusting agent. The
composition can have a concentration of the dedusting agent ranging
from a low of about 0.1 wt %, about 1 wt %, about 3 wt %, about 5
wt %, or about 7 wt % to a high of about 10 wt %, about 13 wt %,
about 15 wt %, about 17 wt %, about 20 wt %, about 23 wt %, or
about 25 wt %, based on the combined weight of the binder and the
dedusting agent. For example, the composition can have a
concentration of the dedusting agent ranging from about 1 wt % to
about 20 wt %, about 5 wt % to about 20 wt %, about 3 wt % to about
15 wt %, or from about 10 wt % to about 20 wt %, based on the
combined weight of the binder and the dedusting agent.
[0114] The components of the composition, e.g., an
aldehyde-containing polymer, the dedusting agent, and any
additional additives or ingredients can be combined in any order or
sequence. For example, all the components of the composition can be
simultaneously mixed, blended, or otherwise combined with one
another. In another example, the components can be added one after
another, with mixing or blending occurring between the addition of
components. In another example, some of the components can be mixed
or blended together and then other components can be added, e.g.,
one after another or at the same time, and the mixture can be
further mixed to form the composition.
[0115] The composition can be applied as a dilute solution to a
plurality of fibers. The composition solution can be an aqueous
solution. In at least one embodiment, the aqueous solution can be
basic, i.e. having a pH of at least 7, such as a pH of 8 or above.
The pH can also range from a low of about 6, 7, or 8 to a high of
about 9, 10, 11, or 12.
[0116] One or more additives can be added to the binder, the
dedusting agent, and/or the composition. For example, one or more
catalysts for accelerating the cure of the binder such as sodium or
ammonium sulfate, melamine, melamine-formaldehyde adducts,
silicon-based coupling or compatibilizing agents, corrosion
inhibitors, dispersants, biocides, viscosity modifiers, pH
adjusters, surfactants, lubricants, defoamers, and any combination
thereof can be added to the composition. Other additives or
ingredients commonly used in compositions for preparing fiber
products can include, but are not limited to, dispersants,
biocides, viscosity modifiers, pH adjusters, coupling agents,
surfactants, lubricants, defoamers, and the like. For example, the
composition can be added to an aqueous solution (white water) of
polyacrylamide (PAA), amine oxide (AO), or hydroxyethylcellulose
(HEC). In another example, a coupling agent (e.g., a silane
coupling agent, such as an organo silicon oil) can also be added to
the solution.
[0117] In one or more embodiments above or elsewhere herein, the
composition can be at least partially cured as a consequence of
cross-linking, esterification reactions between pendant carboxyls
and hydroxyl groups on the solubilized (hydrolyzed) modified
copolymer chains. The composition can further include one or more
polyols to increase the crosslink density of the cured binder.
Suitable polyols can include, but are not limited to, ethylene
glycol, diethylene glycol, triethylene glycol, polyethylene oxide
(hydroxy terminated), glycerol, pentaerythritol, trimethylol
propane, diethanolamine, triethanolamine, ethyl diethanolamine,
methyl diethanolamine, sorbitol, monosaccharides, such as glucose
and fructose, disaccharides, such as sucrose, and higher
polysaccharides such as starch and reduced and/or modified
starches, polyvinyl alcohols, resorcinol, catechol, pyrogallol,
glycollated ureas, and 1,4-cyclohexane diol, lignin, or any
combination thereof.
[0118] As used herein, the terms "curing," "cured," and similar
terms are intended to embrace the structural and/or morphological
change that occurs in an aqueous (or solvent based) composition,
such as by covalent chemical reaction (crosslinking), ionic
interaction or clustering, improved adhesion to the substrate,
phase transformation or inversion, and/or hydrogen bonding when the
composition is dried and heated to cause the properties of a
flexible, porous substrate, such as a mat or blanket of fibers,
especially glass fibers, to which an effective amount of the
composition has been applied, to be altered.
[0119] As used herein, the term "cured binder" refers to the cured
product of the composition and any added polyol, such that the
cured product bonds the fibers of a fibrous product together.
Generally, the bonding occurs at the intersection of overlapping
fibers.
[0120] As used herein, the terms "fiber," "fibrous," "fiberglass,"
"fiber glass," "glass fibers," and the like are refer to materials
that have an elongated morphology exhibiting an aspect ratio
(length to thickness) of greater than 100, generally greater than
500, and often greater than 1000. Indeed, an aspect ratio of over
10,000 is possible. Suitable fibers can be glass fibers, natural
fibers, synthetic fibers, mineral fibers, ceramic fibers, metal
fibers, carbon fibers, or any combination thereof. Illustrative
glass fibers can include, but are not limited to, A-type glass
fibers, C-type glass fibers, E-type glass fibers, S-type glass
fibers, ECR-type glass fibers, wool glass fibers, and any
combination thereof. The term "natural fibers," as used herein
refers to plant fibers extracted from any part of a plant,
including, but not limited to, the stem, seeds, leaves, roots, or
phloem. Illustrative natural fibers can include, but are not
limited to, cotton, jute, bamboo, ramie, bagasse, hemp, coir,
linen, kenaf, sisal, flax, henequen, and any combination thereof.
Illustrative synthetic fibers can include, but are not limited to,
synthetic polymers, such as polyester, polyamide, aramid, and any
combination thereof. In at least one specific embodiment, the
fibers can be glass fibers that are wet use chopped strand glass
fibers (WUCS). Wet use chopped strand glass fibers can be formed by
conventional processes known in the art. The WUCS can have a
moisture content ranging from a low of about 5%, about 8%, or about
10% to a high of about 20%, about 25%, or about 30%.
[0121] Prior to using the fibers to make a fiberglass product, the
fibers can be allowed to age for a period of time. For example, the
fibers can be aged for a period of a few hours to several weeks
before being used to make a fiberglass product. For fiberglass mat
products the fibers can typically be aged for about 3 to about 30
days. Ageing the fibers includes simply storing the fibers at room
temperature for the desired amount of time prior to being used in
making a fiberglass product.
[0122] In one or more embodiments, a method for binding loosely
associated, non-woven mat or blanket of fibers can include, but is
not limited to (1) contacting the fibers with the composition and
(2) heating the curable composition to an elevated temperature,
which temperature is sufficient to at least partially cure the
composition. Preferably, the composition is cured at a temperature
ranging from about 75.degree. C. to about 400.degree. C., usually
at a temperature between about 200.degree. C. and up to a
temperature of about 350.degree. C. The composition can be cured at
an elevated temperature for a time ranging from about 1 second to
about 15 minutes. The particular curing time can depend, at least
in part, on the type of oven or other heating device design and/or
production or line speed.
[0123] As noted above, in the making of non-woven fiber products,
such as a fiberglass mat and fiberglass insulation, the composition
can be formulated into a dilute aqueous solution and then applied,
such as by a curtain coating, spraying, or dipping, onto fibers,
such as glass fibers. The aqueous solution can be fresh water,
process water, or a combination thereof. Compositions containing
somewhere between about 1 wt % and about 50 wt % solids are
typically used for making fiber products, including glass fiber
products. For example, the aqueous composition can have a solids
concentration ranging from a low of about 10 wt %, about 13 wt %,
about 15 wt %, or about 18 wt % to a high of about 22 wt %, about
26 wt %, about 30 wt %, or about 33 wt %.
[0124] The amount of composition applied to the fiberglass product,
e.g., a fiberglass mat product, can vary considerably. Loadings
typically can range from about 3 wt % to about 45 wt %, about 10 wt
% to about 40 wt %, or from about 15 wt % to about 30 wt %, of
non-volatile composition based on the dry weight of the bonded
fiberglass product. For inorganic fibrous mats, the amount of
composition applied to a fiberglass product can normally be
confirmed by measuring the percent loss on ignition (% LO") of the
fiber mat product. The percent loss on ignition can be measured by
weighing a sample of the fiberglas product, ashing the sample at a
high temperature, e.g., 650.degree. C., and then re-weighing the
residue.
[0125] Fiberglass mats can be manufactured in a wet-laid or
dry-laid process. In a wet-laid process, chopped bundles of fibers,
having suitable length and diameter, can be introduced to an
aqueous dispersant medium to produce an aqueous fiber slurry, known
in the art as "white water." The white water can typically contain
about 0.5 wt % fibers. The fibers can have a diameter ranging from
about 0.5 .mu.m to about 30 .mu.m and a length ranging from about 5
mm to about 50 mm, for example. In another example, the fibers can
have a diameter ranging from a low of about 1 .mu.m, about 5 .mu.m,
or about 10 .mu.m to a high of about 20 .mu.m, about 40 .mu.m,
about 50 .mu.m, or about 60 .mu.m. The fibers can be sized or
unsized and wet or dry, as long as the fibers can be suitably
dispersed within the aqueous fiber slurry.
[0126] One or more dispersing agent(s) such as polyacrylamide can
be present in an amount ranging from about 10 ppm to about 8,000
ppm, about 100 ppm to about 5,000 ppm, or from about 200 ppm to
about 1,000 ppm. The introduction of one or more viscosity
modifiers can reduce settling time of the fibers and can improve
the dispersion of the fibers in the aqueous solution. The amount of
viscosity modifier used can be effective to provide the viscosity
needed to suspend the fibers in the white water as needed to form
the wet laid fiber product. The optional viscosity modifier(s) can
be introduced in an amount ranging from a low of about 1 cP, about
1.5 cP, or about 2 cP to a high of about 8 cP, about 12 cP, or
about 15 cP. For example, optional viscosity modifier(s) can be
introduced in an amount ranging from about 1 cP to about 12 cP,
about 2 cP to about 10 cP, or about 2 cP to about 6 cP. In one or
more embodiments, the fiber slurry can include of from about 0.03
wt % to about 25 wt % solids. The fiber slurry can be agitated to
produce a uniform dispersion of fibers having a suitable
consistency.
[0127] The fiber slurry, diluted or undiluted, can be introduced to
a mat-forming machine that can include a mat forming screen, e.g.,
a wire screen or sheet of fabric, which can form a fiber product
and can allow excess water to drain therefrom, thereby forming a
wet or damp fiber mat. The fibers can be collected on the screen in
the form of a wet fiber mat and excess water is removed by gravity
and/or by vacuum assist. The removal of excess water via vacuum
assist can include one or a series of vacuums.
[0128] As discussed above, an at least partially curable
composition can be provided as a liquid and applied onto the
dewatered wet fiber mat. Application of the composition can be
accomplished by any conventional means, such as by soaking the mat
in an excess of binder solution or suspension, a falling film or
curtain coater, dipping, or the like. The composition can include,
for example, from about 5 wt % to about 45 wt % solids. Excess
composition can be removed, for example under vacuum.
[0129] The composition, after it is applied to the glass fibers,
can be at least partially cured. For example, the fiberglass
product can be heated to effect final drying and full curing. The
duration and temperature of heating can affect the rate of
processability and handleability, degree of curing and property
development of the treated substrate. The curing temperature can be
within the range of from about 50.degree. C. to about 400.degree.
C., preferably within the range of from about 90.degree. C. to
about 350.degree. C. and the curing time will usually be somewhere
between 1 second to about 15 minutes.
[0130] On heating, water (or other volatiles) present in the
composition evaporates, and the composition undergoes curing. These
processes can take place in succession or simultaneously. Curing in
the present context is to be understood as meaning the chemical
alteration of the composition, for example crosslinking through
formation of covalent bonds between the various constituents of the
composition, especially the esterification reaction between pendant
carboxyl (--COOH) of modified copolymer and the hydroxyl (--OH)
moieties both of the modified copolymer and any added polyol(s),
the formation of ionic interactions and clusters, and formation of
hydrogen bonds.
[0131] Alternatively or in addition to heating the fiberglass
product catalytic curing can be used to cure the fiberglass
product. Catalytic curing of the fiberglass product can include the
addition of an acid catalyst. Illustrative acid catalysts can
include, but are not limited to, ammonium chloride or
p-toluenesulfonic acid.
[0132] In one or more embodiments, the drying and curing of the
composition can be conducted in two or more distinct steps. For
example, the composition may be first heated at a temperature and
for a time sufficient to substantially dry but not to fully or
completely cure the composition and then heated for a second time
at a higher temperature and/or for a longer period of time to
effect curing (cross-linking to a thermoset structure). Such a
preliminary procedure, referred to as "B-staging", may be used to
provide a binder-treated product, for example, in roll form, which
may at a later stage be fully cured, with or without forming or
molding into a particular configuration, concurrent with the curing
process. This makes it possible, for example, to use fiberglass
products which can be molded and cured elsewhere.
[0133] The fiberglass product can be formed as a relatively thin
product having a thickness of about 0.1 mm to about 6 mm, can be
formed. In another example, a relatively thick fiberglass product
having a thickness of about 10 cm to about 50 cm, or about 15 cm to
about 30 cm, or about 20 cm to about 30 cm can be formed. In
another example, the fiberglass product can have a thickness
ranging from a low of about 0.1 mm, about 1 mm, about 1.5 mm, or
about 2 mm to a high of about 5 mm, about 1 cm, about 5 cm, about
10 cm, about 20 cm, about 30 cm, about 40 cm, or about 50 cm.
Depending on formation conditions, the density of the product can
also be varied from a relatively fluffy low density product to a
higher density of about 6 pounds to about 10 pounds per cubic foot
or higher. In one or more embodiments, the fiber mat product can
have a basis weight ranging from a low of about 0.1 pound, about
0.5 pounds, or about 0.8 pounds to a high of about 3 pounds, about
4 pounds, or about 5 pounds per 100 square feet. For example, the
fiber mat product can have a basis weight of from about 0.6 pounds
per 100 square feet to about 2.8 pounds per 100 square feet, about
1 pound per 100 square feet to about 2.5 pounds per 100 square
feet, or about 1.5 pounds per 100 square feet to about 2.2 pounds
per 100 square feet. In at least one specific embodiment, the fiber
mat product can have a basis weight of about 1.2 pounds per 100
square feet, about 1.8 pounds per 100 square feet, or about 2.4
pounds per 100 square feet.
[0134] The fibers can represent the principal material of the
non-woven fiber products, such as a fiberglass mat product. For
example, 60 wt % to about 90 wt % of the fiberglass product, based
on the combined amount of binder and fibers can be composed of the
fibers. The composition can be applied in an amount such that the
cured binder constitutes from about 1 wt % to about 40 wt % of the
finished glass fiber product. The composition can be applied in an
amount such that the cured binder constitutes a low of from about 1
wt %, about 5 wt %, or about 10 wt % to a high of about 15 wt %,
about 20 wt %, or about 25 wt %.
[0135] Fiberglass products may be used by themselves or
incorporated into a variety of products. For example, fiberglass
products can be used as or incorporated into insulation batts or
rolls, composite flooring, asphalt roofing shingles, siding, gypsum
wall board, roving, microglass-based substrate for printed circuit
boards, battery separators, filter stock, tape stock, carpet
backing, and as reinforcement scrim in cementitious and
non-cementitious coatings for masonry.
[0136] In one or more embodiments, fiberglass mats containing one
or more of the compositions disclosed herein can have an average
dry tensile strength of at least 20 lbs/3 inch; at least 25 lbs/3
inch, at least 30 lbs/3 inch, at least 35 lbs/3 inch, at least 40
lbs/3 inch, at least 45 lbs/3 inch, at least 50 lbs/3 inch, at
least 55 lbs/3 inch, at least 60 lbs/3 inch, at least 65 lbs/3
inch, at least 70 lbs/3 inch, at least 75 lbs/3 inch, at least 80
lbs/3 inch, at least 85 lbs/3 inch, at least 90, lbs/3 inch, at
least 95 lbs/3 inch, at least 100 lbs/3 inch, or at least 105 lbs/3
inch.
[0137] In one or more embodiments, fiberglass mats containing one
or more of the compositions disclosed herein can have an average
tear strength of about 250 grams force (gf), about 275 gf, about
300 gf, about 325 gf, about 350 gf, about 375 gf, about 400 gf,
about 425 gf, 450 gf, about 475 gf, about 500 gf, about 525 gf,
about 550 gf, about 575 gf, about 600 gf, about 625 gf, about 650
gf, about 675 gf, about 700 gf, about 725 gf, about 750 gf, about
775 gf, or about 800 gf. In one or more embodiments, fiberglass
mats containing one or more of the compositions disclosed herein
can have an average tear strength of at least 325 gf, at least 350
gf, at least 375 gf, at least 400 gf, at least 425 gf, at least 450
gf, or at least 475 gf. In one or more embodiments, fiberglass mats
containing one or more of the compositions disclosed herein can
have an average tear strength of at least 485 gf, at least 490 gf,
at least 495 gf, at least 500 gf, at least 505 gf, at least 510 gf,
at least 515 gf, at least 520 gf, at least 525 gf, at least 530 gf,
at least 535 gf, at least 540 gf, at least 545 gf, at least 550 gf,
at least 555 gf, at least 560 gf, at least 565 gf, at least 570 gf,
or at least 575 gf. In one or more embodiments, fiberglass mats
containing one or more of the compositions disclosed herein can
have an average tear strength ranging from a low of about 500 gf,
about 525 gf, about 550 gf, or about 575 gf to a high of about 590
gf, about 620 gf, about 650 gf, about 700 gf, about 750 gf, about
800 gf, about 850 gf, or about 900 gf.
[0138] In one or more embodiments, fiberglass mats containing one
or more of the compositions disclosed herein can have a basis
weight (BW) ranging from a low of about 0.5 lbs/100 ft.sup.2, about
0.7 lbs/100 ft.sup.2, about 0.9 lbs/100 ft.sup.2, about 1 lbs/100
ft.sup.2, about 1.2 lbs/100 ft.sup.2, about 1.4 lbs/100 ft.sup.2,
about 1.5 lbs/100 ft.sup.2, about 1.6 lbs/100 ft.sup.2, about 1.7
lbs/100 ft.sup.2, or about 1.8 lbs/100 ft.sup.2 to a high of about
2 lbs/100 ft.sup.2, about 2.1 lbs/100 ft.sup.2, about 2.2 lbs/100
ft.sup.2, about 2.3 lbs/100 ft.sup.2, about 2.4 lbs/100 ft.sup.2,
about 2.5 lbs/100 ft.sup.2, about 2.7 lbs/100 ft.sup.2, about 2.9
lbs/100 ft.sup.2, or about 3 lbs/100 ft.sup.2. For example, the
fiberglass mats can have a basis weight of about 1.65 lbs/100
ft.sup.2, about 1.75 lbs/100 ft.sup.2, about 1.85 lbs/100 ft.sup.2,
about 1.95 lbs/100 ft.sup.2, or about 2.1 lbs/100 ft.sup.2.
[0139] In one or more embodiments, fiberglass mats containing one
or more of the compositions disclosed herein can have a percent of
hot-wet retention (% HW) of greater than about 50%, about 55%,
about 60%, about 65%, about 70%, about 75%, about 80%, or about
85%. For example, the % HW can range from about 50% to about 80%,
about 55% to about 85%, or about 60% to about 80%.
[0140] In one or more embodiments, the composition can at least
partially dry to a film that a tack tester falls over in less than
about 120 seconds, less than about 110 seconds, less than about 100
seconds, less than about 90 seconds, less than about 80 seconds,
less than about 70 seconds, less than about 60 seconds, less than
about 45 seconds, less than about 30 seconds, less than about 15
seconds, less than about 5 seconds, or less than about 1, once a
300 gram weight is removed after being place for 5 seconds on the
base of the tack tester, according to ASTM 1640-03. In one or more
embodiments, the composition or dedusting composition can at dry to
a film that a tack tester falls over in less than about 120
seconds, less than about 110 seconds, less than about 100 seconds,
less than about 90 seconds, less than about 80 seconds, less than
about 70 seconds, less than about 60 seconds, less than about 45
seconds, less than about 30 seconds, less than about 15 seconds,
less than about 5 seconds, or less than about 1, once a 300 gram
weight is removed after being place for 5 seconds on the base of
the tack tester, according to ASTM 1640-03. In one or more
embodiments, the composition or dedusting composition can form an
at least partially dried film that is tack free according to ASTM
1640-03. In one or more embodiments, the composition or dedusting
composition can form a dried film that is tack free according to
ASTM 1640-03.
EXAMPLES
[0141] In order to provide a better understanding of the foregoing
discussion, the following non-limiting examples are offered.
Although the examples may be directed to specific embodiments, they
are not to be viewed as limiting the invention in any specific
respect. All parts, proportions, and percentages are by weight
unless otherwise indicated.
Example I
[0142] Two inventive compositions (Ex. 1 and 2) and three
comparative compositions (CE1-3) were prepared. For all examples
(CE1-3 and Ex. 1 and 2) a premix was prepared by mixing 1142.86
grams of a phenol-formaldehyde polymer and 800 grams of a 40% urea
solution. The premix was allowed to pre-react overnight at room
temperature. The premix had a non-volatiles content of about
41.2%.
[0143] Additional ingredients were then mixed with the premix in a
0.5 gallon jar. Every example included about 364 grams of the
premix, about 30 grams of a 20% ammonium sulfate solution, about 3
grams of ammonia, about 0.3 grams of Silane A1100, varying amounts
of different dedusting agents, and an appropriate amount of water
to produce a composition having about 10% solids.
[0144] The mixture of the premix and the additional ingredients was
used for the comparative example CE1, i.e. no dedusting agent was
added. For comparative example CE2 mineral oil was added as a
dedusting agent. The mineral oil was added in the form of an
emulsion that contained 50 grams mineral oil, 5 grams of
polyethylene glycol (PEG 400), and 45 grams of water. For
comparative example CE3, about 5 grams of PEG 400 was added as a
dedusting agent.
[0145] For inventive example Ex. 1 the dedusting agent added
contained a mixture of two components (A and B). Component A was an
emulsion of pitch prepared using distilled tall oil (DTO) as the
emulsifier. The component A pitch emulsion was manufactured using a
Ross bench-top mill (Charles Ross & Son Company). 1200 g of
water was heated to 60.degree. C. 16 g of a 50 wt % aqueous NaOH
caustic solution was added to the water. The water and caustic
mixture was loaded into a stainless steel beaker and the solution
was stirred using the Ross bench-top mill. A mixture of tall oil
pitch (GP XTOL.RTM. Tall Oil Pitch) and distilled tall oil (DTO)
(GP XTOL.RTM. 520) was separately prepared by mixing 600 g of the
tall oil pitch at 60.degree. C. with 200 g of the DTO, which was at
60.degree. C. The pitch and DTO mixture was then added to the
stirred water and caustic mixture over approximately 1 minute. No
additional heating was supplied during the addition of the pitch
and DTO mixture to the water and caustic mixture. The pitch was
emulsified upon contact with the aqueous phase, as evidenced by a
light tan homogeneous appearance of the product. The emulsion was
removed from the Ross bench-top mill after the completion of the
raw material addition and was allowed to cool to room
temperature.
[0146] Component B was a styrene-maleic anhydride solution. 41.2 g
of water, 0.04 grams of a defoamer (Taylor TA-103H Antifoam, a
commercial silicone defoarmer), 2.4 g of styrene-maleic anhydride
copolymer (ENTEL 2612 SMA, manufactured by Ineos ABS), 9.6 g of an
additional styrene-maleic anhydride copolymer (XIRAN SZ 26120 SMA,
manufactured by Polyscope), 4.4 g of a 28 wt % aqua ammonia
solution, and 1.1 g of a 50 wt % aqueous caustic solution were
added to a stainless steel reactor. The contents of the reactor
were heated to 90.degree. C. and an additional 40.0 grams of water
were added. The mixture was further heated to 105.degree. C. and
maintained at 105.degree. C. for 2.5 hours to solubilize the SMA.
The solution was then cooled to 40.degree. C. and additional
defoamer (0.004 g) was added and the solution was cooled to room
temperature. The styrene-maleic anhydride solution (component B)
contained about 13% by weight solids in water.
[0147] The pitch emulsion was made by mixing at room temperature
100 grams of component A and 30.8 grams of component B. The
dedusting agent used in EX. 1 was this mixture of Components A and
B.
[0148] For the inventive example (Ex. 2) the dedusting agent was an
aqueous solution that contained about 37.1 wt % tall oil pitch,
about 12.4 wt % distilled tall oil (DTO), about 49.5 wt % water,
and about 1 wt % of a 50% sodium hydroxide solution. The dedusting
agent used in Ex. 2 was prepared in similar manner as component A
discussed above. The composition of each example is shown in Table
1.
TABLE-US-00001 TABLE 1 Pitch Emulsion Pitch, 20% Min. PEG and DTO,
Silane Premix (NH.sub.4).sub.2SO.sub.4 NH.sub.3 Oil 400 SMA water,
A1100 Water (g) solution (g) (g) (g).sup.1 (g) (g) base (g) (g) (g)
CE1 364.29 30 3 0.3 1102.71 CE2 364.29 30 3 30 0.3 1072.71 CE3
364.29 30 3 15 0.3 1087.71 Ex. 1 364.29 30 3 46.9 0.3 1055.84 Ex. 2
364.29 30 3 37.5 0.3 1065.21
[0149] Handsheets for each example (CE1-3 and Ex. 1 and 2) were
prepared by making glass fiber sheets, soaking the sheets in the
compositions, vacuuming the excess binder off the sheets, and
curing the sheets in an oven at 205.degree. C. for 90 seconds. The
handsheets were cut into six pieces measuring 3 inches wide by 5
inches long. The thickness of the handsheets prior to curing, i.e.
while wet, were not measured. The thickness of the handsheets after
curing was about 35 mils. The glass fibers for all examples had an
average length of about 1.25 inches. Each set was tested for dry
and hot/wet tensile strength on a Thwing-Albert tensile tester
(0-200 kg load cell). The hot/wet tensile strengths were measured
by soaking the handsheets in water at 185.degree. F. for 10 minutes
immediately prior to breaking the handsheets in the tensile tester.
The results of the handsheet studies are shown in Table 2.
TABLE-US-00002 TABLE 2 Avg Dry Tensile, Avg Hot/Wet Tensile, lbs/3
inch lbs/3 inch CE1 76 60 CE2 75 62 CE3 85 62 Ex. 1 90 74 Ex. 2 82
64
[0150] The binder stability was determined by visual observation.
The binders were visually observed over a 24 hour period looking
for signs of precipitation and separation. The binders for CE1, Ex.
1, and Ex. 2 had good stability, were stable overnight, and did not
exhibit any signs of separation or precipitation. The binder for
CE2 (mineral oil) was not stable. The binder for CE3 became cloudy
when the PEG 400 was added.
[0151] As shown in Table 2, the inventive dedusting agents used in
examples 1 and 2 exhibited both dry and hot/wet tensile strengths
equal to or better than the comparative examples (CE1-3).
Example II
[0152] Seven inventive compositions (Ex. 3-9) and three comparative
compositions were prepared. For all examples, a premix was prepared
by mixing a phenol-formaldehyde polymer with a 50 wt % urea
solution. The premix had a 35 wt % concentration of the urea
solution. The premix was allowed to pre-react overnight for about
18 hours at room temperature Ammonium sulfate (7.6 wt %) was added
to the premix as a catalyst and ammonium hydroxide (0.8 wt %) was
added to adjust the pH to about 8.8. The premix was then diluted
with water to form a premix having a concentration of about 10 wt %
solids.
[0153] Mineral oil, a dedusting agent, styrene maleic anhydride, or
a combination thereof were added to the premixes. The mineral oil
was an emulsion containing 7.5 g polyethyleneglycol (PEG 400), 50 g
mineral oil, and 45 g of deionized water. The emulsion was mixed
for about five minutes prior to use. The dedusting agent was a 50%
emulsion containing 3 parts pitch and 1 part distilled tall oil.
The SMA was a 13% solution of styrene maleic anhydride in water.
The specific blends prepared for the comparative examples (CE4-6)
and the inventive examples (Ex. 3-9) are shown in Table 3
below.
TABLE-US-00003 TABLE 3 Premix, 10 Mineral Dedusting Order Ex. No.
wt % solids Oil Agent SMA of Tack CE4 10.00 9 CE5 9.00 1.00 1 CE6
9.50 0.50 2 Ex. 3 9.00 1.00 10 Ex. 4 9.00 1.00 1.0 4 Ex. 5 9.50
0.50 8 Ex. 6 9.50 0.50 0.5 3 Ex. 7 9.50 0.50 0.50 5 Ex. 8 9.75 0.25
0.25 7 Ex. 9 9.67 0.33 0.33 6
[0154] Draw down films were made with all the blends shown in Table
2 using an 8 mm draw down square and a 2.5 g sample. The films were
allowed to dry in an oven for about 10 minutes at 205.degree. C.
The level of tack was tested by contacting the film with a gloved
finger. According to the tackiness or level of adhesion between the
gloved finger and the film, the films were ranked in order of
tackiness, with 1 corresponding to the least tack and 10
corresponding to the most tack. The testing procedure according to
ASTM 1640-03, section 7.5 was followed.
[0155] The two compositions containing the premix and the mineral
oil (CE5 and CE6) had the lowest tack of all the samples evaluated
and were ranked 1 and 2, respectively. As the level of mineral oil
decreased the tack increased. The addition of the dedusting agent
to the premix produced a sample having the highest level of tack
(Ex. 3) Decreasing the amount of the dedusting agent reduced the
level of tack, as shown by Ex. 5.
[0156] The addition of the SMA to the binder having both the premix
and the dedusting agent produced samples having a reduced level of
tack (EX. 4 and 6). For example, EX. 3 contained the premix and the
dedusting agent and showed a higher tack than EX. 4, which
contained the same amount of premix and dedusting agent as EX. 3,
but further included SMA.
[0157] Embodiments of the present disclosure further relate to any
one or more of the following paragraphs:
[0158] 1. A composition, comprising: a binder; and a dedusting
agent comprising an emulsion comprising one or more pitches, one or
more fatty acids, one or more rosins, or any combination
thereof.
[0159] 2. A fiberglass product, comprising: a plurality of fibers;
and the composition according to paragraph 1, wherein the
composition is at least partially cured.
[0160] 3. A process for preparing a fiberglass product, comprising:
contacting a plurality of fibers with the composition according to
paragraph 1; collecting the contacted fibers to form a non-woven
mat; and heating the non-woven mat to at least partially cure the
composition.
[0161] 4. The composition according to any one paragraphs 1 to 3,
wherein the binder comprises an aldehyde containing polymer, a
mixture of Maillard reactants, a copolymer of one or more vinyl
aromatic derived units and at least one of maleic anhydride and
maleic acid, or any combination thereof.
[0162] 5. The composition according to paragraph 4, wherein the
mixture of Maillard reactants comprises at least one polycarboxylic
acid, at least one of ammonia and an amine, and at least one
carbohydrate source.
[0163] 6. The composition according to paragraph 4, wherein the
mixture of Maillard reactants comprises ammonia, citric acid, and
dextrose.
[0164] 7. The composition according to any one of paragraphs 1 to
3, wherein the binder comprises an aldehyde containing polymer, and
wherein the aldehyde containing polymer comprises a
urea-formaldehyde polymer, a phenol-formaldehyde polymer, a
melamine-formaldehyde polymer, or any combination thereof.
[0165] 8. The composition according to any one of paragraphs 1 to
7, wherein the binder is combined with an extender to from a
premix, and wherein the premix is combined with the dedusting
agent.
[0166] 9. The composition according to any one of paragraphs 1 to
8, wherein the emulsion comprises water, a pitch, and a distilled
tall oil.
[0167] 10. The composition according to any one of paragraphs 1 to
9, wherein the pitch comprises a tall oil pitch.
[0168] 11. The composition according to any one of paragraphs 1 to
10, wherein the emulsion has a concentration of water ranging from
about 30 wt % to about 75 wt %, a concentration of pitch ranging
from about 20 wt % to about 50 wt %, and a concentration of
distilled tall oil ranging from about 5 wt % to about 20 wt %,
based on the combined weight of the water, pitch, and distilled
tall oil.
[0169] 12. The composition according to any one of paragraphs 1 to
11, wherein the emulsion comprises water, a pitch, a distilled tall
oil, and a base compound, and wherein the emulsion has a
concentration of water ranging from about 30 wt % to about 75 wt %,
a concentration of pitch ranging from about 20 wt % to about 50 wt
%, a concentration of distilled tall oil ranging from about 5 wt %
to about 20 wt %, and a concentration of base compound ranging from
about 0.1 wt % to about 5 wt %, based on the combined weight of the
water, pitch, distilled tall oil, and base compound.
[0170] 13. The composition according to any one of paragraphs 1 to
12, wherein a source for at least a portion of the one or more
pitches, one or more fatty acids, and one or more rosins comprises
crude tall oil.
[0171] 14. The composition according to any one of paragraphs 1 to
13, wherein a source for at least a portion of the one or more
pitches, the one or more fatty acids, and the one or more rosins is
derived from crude tall oil.
[0172] 15. The composition according to any one of paragraphs 1 to
14, wherein the dedusting agent further comprises one or more
oils.
[0173] 16. The composition of according to any one of paragraphs 1
to 15, wherein the dedusting agent further comprises one or more
mineral oils.
[0174] 17. The composition according to any one of paragraphs 15 to
16, wherein the one or more oils is present in an amount ranging
from about 1 wt % to about 50 wt %, based on the combined weight of
the one or more oils and the emulsion.
[0175] 18. The composition according to any one of paragraphs 15 to
17, wherein the one or more oils has a flash point greater than
about 200.degree. C.
[0176] 19. The composition according to any one of paragraphs 1 to
18, wherein the dedusting agent further comprises one or more film
forming polymers.
[0177] 20. The composition according to any one of paragraphs 1 to
19, wherein the dedusting agent is present in an amount ranging
from about 0.1 wt % to about 20 wt %, based on the combined weight
of the binder and the dedusting agent.
[0178] 21. The composition according to any of paragraphs 1 to 20,
wherein the combined weight of the one or more pitches, one or more
fatty acids, and one or more rosins in the emulsion ranges from
about 10 wt % to about 60 wt %, based on the total weight of the
emulsion.
[0179] 22. The composition according to any one of paragraphs 1 to
21, wherein the emulsion further comprises a base compound.
[0180] 23. The fiberglass product according to paragraph 2, wherein
the fiberglass product is a non-woven mat.
[0181] 24. The fiberglass product according to paragraph 22,
wherein the non-woven mat has a thickness of from about 1 mm to
about 50 cm.
[0182] 25. The fiberglass product according to paragraph 2, wherein
the plurality of fibers have a length of from about 3 mm to about
50 mm and a diameter of from about 5 .mu.m to about 40 .mu.m.
[0183] 26. The process according to paragraph 3, wherein the
plurality of fibers have a length of from about 3 mm to about 50 mm
and a diameter of from about 5 .mu.m to about 40 .mu.m.
[0184] 27. The composition according to any one of paragraphs 1 to
26, wherein at least a portion of the one or more pitches, the one
or more fatty acids, and the one or more rosins are provided in the
form of crude tall oil, are derived from crude oil, or a
combination thereof.
[0185] Certain embodiments and features have been described using a
set of numerical upper limits and a set of numerical lower limits.
It should be appreciated that ranges from any lower limit to any
upper limit are contemplated unless otherwise indicated. Certain
lower limits, upper limits and ranges appear in one or more claims
below. All numerical values are "about" or "approximately" the
indicated value, and take into account experimental error and
variations that would be expected by a person having ordinary skill
in the art.
[0186] Various terms have been defined above. To the extent a term
used in a claim is not defined above, it should be given the
broadest definition persons in the pertinent art have given that
term as reflected in at least one printed publication or issued
patent. Furthermore, all patents, test procedures, and other
documents cited in this application are fully incorporated by
reference to the extent such disclosure is not inconsistent with
this application and for all jurisdictions in which such
incorporation is permitted.
[0187] While the foregoing is directed to embodiments of the
present invention, other and further embodiments of the invention
may be devised without departing from the basic scope thereof, and
the scope thereof is determined by the claims that follow.
* * * * *