Surfactant-containing insulation binder

Abstract

A fiberglass insulation binder composition made from a polycarboxy polymer, a polyhydroxy crosslinking agent, and a cationic surfactant, amphoteric surfactant, nonionic surfactant, or mixture thereof. Also, a process for manufacturing a fiberglass insulation product, which involves a step of applying the binder composition onto a fiberglass substrate and curing the fiberglass substrate so treated. Binders produced in accordance with the present invention are characterized by improved atomization, improved binder dispersion and fiber wetting properties, and improved protection of individual fibers during processing.

1 . A fiberglass insulation binder composition comprising a polycarboxy polymer, a polyhydroxy crosslinking agent, a surfactant and sufficient water to provide a mixture comprising up to 98 wt-% water based on the total weight of solids in the mixture, said surfactant being added in an amount sufficient to control the surface tension to less than the surface tension of an equivalent weight percent solids phenolic binder.  
     
     
         2 . (canceled)  
     
     
         3 . (canceled)  
     
     
         4 . The fiberglass insulation binder composition of  claim 1 , wherein the polycarboxy polymer is a polyacrylic acid polymer.  
     
     
         5 . A process for producing a fiberglass insulation binder comprising the steps of: 
 preparing a mixture of a polycarboxy polymer, a polyhydroxy crosslinking agent, a surfactant and sufficient water to provide a mixture comprising up to 98 wt-% water based on the total weight of solids in the mixture, said surfactant being added in an amount sufficient to control the surface tension of the binder to less than 66 dyne/cm, and blending the mixture to form a polymeric composition useful as a fiberglass insulation binder.    
     
     
         6 . The process of  claim 5 , wherein the amount of surfactant employed ranges from about 0.01 to about 10 weight percent based on the total weight of binder solids.  
     
     
         7 . The process of  claim 6 , wherein the amount of surfactant employed ranges from about 0.2 to about 5 weight percent based on the total weight of binder solids.  
     
     
         8 . The process of  claim 5 , wherein a pre-mixture containing the polymer and crosslinking agent comprises about 50 to 60 wt-% water.  
     
     
         9 . The process of  claim 5 , further comprising the step of adding a hydrolyzed silane coupling agent to the mixture.  
     
     
         10 . The process of  claim 9 , wherein the weight of hydrolyzed silane coupling agent added is from 0.01 to 10 wt-% based upon the weight of the mixture.  
     
     
         11 . The process of  claim 1 , wherein mineral oil dust suppressing agent is added in an amount up to 20 wt % based upon the weight of the mixture.  
     
     
         12 . The process of  claim 5 , wherein the polycarboxy polymer is a polyacrylic acid polymer.  
     
     
         13 . (canceled)  
     
     
         14 . (canceled)  
     
     
         15 . The process of  claim 5 , wherein curing is carried out in a curing oven at a temperature from 200° C. to 350° C. (392° F. to 617° F.) for 30 seconds to 3 minutes.  
     
     
         16 . (canceled)  
     
     
         17 . A process for manufacturing a fiberglass insulation product, which comprises the steps of: 
 (a) supplying melted glass to a fiber forming device;    (b) blowing said melted glass downwardly within a forming chamber of said forming device to attenuate glass fibers;    (c) applying a binder composition including a polycarboxy polymer, a polyhydroxy crosslinking agent, a surfactant, and sufficient water to provide a mixture having up to 98 wt % water based on the total weight of solids onto said glass fibers, said surfactant being added in an amount sufficient to control the surface tension to less than the surface tension of an equivalent weight percent solids phenolic binder.    (d) depositing said glass fibers onto a foraminous forming conveyor within said forming chamber;    (e) gathering and forming said glass fibers into a mat on said conveyor, wherein residual heat contained in said glass fibers and said vacuum volatilizes said water; and    (f) curing the mat.    
     
     
         18 . The process of  claim 17 , wherein curing is carried out in a curing oven at a temperature from 200° C. to 350° C. (392° F. to 617° F.) for 30 seconds to 3 minutes.  
     
     
         19 . (canceled)  
     
     
         20 . The binder composition of  claim 1 , wherein the surface tension of the binder is less than about 65.75 dyne/cm.  
     
     
         21 . The binder composition of  claim 20 , wherein the surface tension of the binder is less than about 62.87 dyne/cm.  
     
     
         22 . The binder composition of  claim 21 , wherein the surface tension of the binder is less than bout 60.54 dyne/cm.  
     
     
         23 . The process for producing a binder composition of  claim 5 , wherein the surface tension of the binder is less than about 67.75 dyne/cm.  
     
     
         24 . The process of  claim 23 , wherein the surface tension of the binder is less than about 62.87 dyne/cm.  
     
     
         25 . The process of  claim 24 , wherein the surface tension of the binder is less than about 60.54 dyne/cm.  
     
     
         26 . The process for manufacturing a fiberglass insulation product of  claim 17 , wherein the surface tension of the binder is less than about 65.75 dyne/cm.  
     
     
         27 . The process of  claim 26 , wherein the surface tension of the binder is less than about 62.87 dyne/cm.  
     
     
         28 . The process of  claim 27 , wherein the surface tension of the binder is less than about 60.54 dyne/cm.