Curable fiberglass binder

Abstract

A curable formaldehyde-free binding composition for use with fiberglass is provided. Such curable composition comprises an addition product of an amine and a reactant to form an amino-amide intermediate. To the amino-amide is added an aldehyde or ketone to form the curable binder composition. The composition when applied to fiberglass is cured to form a water-insoluble binder which exhibits good adhesion to glass. In a preferred embodiment the fiberglass is in the form of building insulation. In other embodiments the product is a microglass-based substrate for use in a printed circuit board, battery separator, filter stock, or reinforcement scrim.

What is claimed is: 
     
         1 . A formaldehyde-free fiberglass product, wherein the fiberglass product is made from:
 glass fibers; and   a binder composition comprising an aldehyde or ketone, and an amino-amide compound,   wherein the formaldehyde-free fiberglass product includes a cured binder comprising reaction products of the aldehyde or ketone and the amino-amide compound.   
     
     
         2 . The formaldehyde-free fiberglass product of  claim 1 , wherein the amino-amide compound is an addition product of an amine and a carbonyl-containing compound. 
     
     
         3 . The formaldehyde-free fiberglass product of  claim 2 , wherein the amine includes at least one of an aliphatic amine, a cycloaliphatic amine, or an aromatic amine. 
     
     
         4 . The formaldehyde-free fiberglass product of  claim 2 , wherein the amine includes at least one of 1,2-diethylamine, 1,3-propanediamine, 1,4-butanediamine, 1,5-pentanediamine, 1,6-hexanediamine, α,α′-diaminoxylene, diethylenetriamine, triethylenetetramine, or tetraethylenepentamine. 
     
     
         5 . The formaldehyde-free fiberglass product of  claim 2 , wherein the carbonyl-containing compound includes at least one of an organic acid or an organic anhydride. 
     
     
         6 . The formaldehyde-free fiberglass product of  claim 2 , wherein the carbonyl-containing compound includes at least one of maleic anhydride, succinic anhydride, glutaric anhydride, phthalic anhydride, or tetrahydro phthalic anhydride. 
     
     
         7 . The formaldehyde-free fiberglass product of  claim 2 , wherein the carbonyl-containing compound includes at least one of maleic acid, fumaric acid, glutaric acid, phthalic acid, or tetrahydro phthalic acid. 
     
     
         8 . The formaldehyde-tree fiberglass product of  claim 1 , wherein the aldehyde includes at least one of acetaldehyde, hydroxy acetaldehyde, butyraldehyde, acrolein, furfural, glyoxal, glyceraldehyde, glutaraldehyde, polyfurfural, or polyacrolein. 
     
     
         9 . The formaldehyde-tree fiberglass product of  claim 1 , wherein the aldehyde includes at least one of a monosaccharide, a disaccharide, or a polysaccharide. 
     
     
         10 . The formaldehyde-free fiberglass product of  claim 1 , wherein the aldehyde includes dextrose. 
     
     
         11 . The formaldehyde-free fiberglass product of  claim 1 , wherein the ketone includes at least one of acetone, acetyl acetone, 1,3-dihydroxy acetone, benzyl, benzoin, or fructose. 
     
     
         12 . The formaldehyde-free fiberglass product of  claim 1 , wherein the amino-amide compound is an amino-amide oligomer. 
     
     
         13 . The formaldehyde-free fiberglass product of  claim 12 , wherein the amino-amide oligomer includes at least one of an amino-amide dimer, an amino-amide trimer, or an amino-amide tetramer. 
     
     
         14 . The formaldehyde-free fiberglass product of  claim 1 , wherein the formaldehyde-free fiberglass product is building insulation. 
     
     
         15 . A formaldehyde-free fiberglass product comprising a combination of:
 glass fibers; and   a cured binder made from a binder composition that comprises and aldehyde or ketone and an amino-amide oligomer consisting of an addition product of an amine and a carbonyl-containing compound, wherein the cured binder includes reaction products of the aldehyde or ketone and the amino-amide oligomer.   
     
     
         16 . The formaldehyde-free fiberglass product of  claim 15 , wherein the aldehyde or ketone comprises a reducing sugar. 
     
     
         17 . The formaldehyde-free fiberglass product of  claim 16 , wherein the reducing sugar comprises dextrose. 
     
     
         18 . The formaldehyde-free fiberglass product of  claim 15 , wherein the amine includes a diamine having at least one primary amine group. 
     
     
         19 . The formaldehyde-free fiberglass product of  claim 15 , the amine comprises at least one amine selected from the group consisting of 1,2-diethylamine, 1,3-propanediamine, 1,4-butanediamine, 1,5-pentanediamine, 1,6-hexanediamine, α,α′-diaminoxylene, diethylenetriamine, triethylenetetramine, and tetraethylenepentamine. 
     
     
         20 . The formaldehyde-free fiberglass product of  claim 15 , wherein the carbonyl-containing compound is selected from the group consisting of a saturated or unsaturated anhydride, a carboxylic acid, an ester, and salts and mixtures thereof. 
     
     
         21 . The formaldehyde-free fiberglass product of  claim 15 , wherein the carbonyl-containing compound is selected from the group consisting of maleic acid, fumaric acid, maleic anhydride, mono- and di-esters of maleic acid, mono- and di-esters of fumaric acid, and phthalic anhydride, tetrahydro phthalic anhydride, succinic acid and anhydride, glutaric acid and anhydride, salts and mixtures thereof. 
     
     
         22 . The formaldehyde-free fiberglass product of  claim 15 , wherein the formaldehyde-free fiberglass product is building insulation. 
     
     
         23 . A formaldeyde-free fiberglass product comprising a combination of:
 glass fibers; and   a cured binder made from a binder composition that comprises and aldehyde or ketone and an amino-amide, wherein the amino-amide is a dimer, trimer, or tetramer, and wherein the amino-amide consists of an addition product of an aqueous solution of a diamine and a reactant comprising at least one of an unsaturated anhydride, a carboxylic acid, an ester or salts thereof.   
     
     
         24 . The formaldehyde-free fiberglass product of  claim 23 , wherein the aldehyde or ketone comprises a reducing sugar. 
     
     
         25 . The formaldehyde-free fiberglass product of  claim 24 , wherein the reducing sugar comprises dextrose. 
     
     
         26 . The formaldehyde-free fiberglass product of  claim 23 , wherein the diamine comprises 1,6-hexanediamine. 
     
     
         27 . The formaldehyde-free fiberglass product of  claim 23 , wherein the aqueous solution of the diamine and the reactant are reacted at a temperature ranging from 120° C. to 150° C. to form the addition product. 
     
     
         28 . The formaldehyde-free fiberglass product of  claim 23 , wherein the formaldehyde-free fiberglass product is building insulation.