Formaldehyde free binder compositions with urea-aldehyde reaction products

Abstract

Binder compositions are described that contain (1) a reducing sugar and (2) a reaction product of a urea compound and an aldehyde-containing compound. A specific example of the binder compositions include dextrose and an imidazolidine compound such as 4,5-dihydroxyimidazolidin-2-one. The binder compositions may be applied to collections of fibers and cured to form a fiber-containing composite, such as fiberglass insulation.

What is claimed is: 
     
         1 . A binder composition comprising:
 a reducing sugar;   a crosslinking agent comprising a reaction product of a urea compound and an aldehyde-containing compound, wherein the crosslinking agent and the reducing sugar have a molar ratio ranging from 1:2 to 1:50; and   an organosilane compound.   
     
     
         2 . The binder composition of  claim 1 , wherein the binder composition further comprises a crosslinking catalyst for catalyzing a crosslinking reaction between the reducing sugar and the crosslinking agent. 
     
     
         3 . The binder composition of  claim 2 , wherein the crosslinking catalyst comprises a sulfonic acid compound. 
     
     
         4 . The binder composition of  claim 3 , wherein the sulfonic acid compound comprises at least one of p-toluene sulfonic acid or methane sulfonic acid. 
     
     
         5 . The binder composition of  claim 1 , wherein the urea compound comprises H 2 N—CO—NH 2 . 
     
     
         6 . The binder composition of  claim 1 , wherein the aldehyde-containing compound comprises a dialdehyde. 
     
     
         7 . The binder composition of  claim 6 , wherein the dialdehyde comprises glyoxal. 
     
     
         8 . The binder composition of  claim 1 , wherein the crosslinking agent comprises 4,5-dihydroxyimidazolidin-2-one. 
     
     
         9 . The binder composition of  claim 1 , wherein the reducing sugar monosaccharide comprises dextrose. 
     
     
         10 . The binder composition of  claim 1 , wherein the crosslinking agent and the reducing sugar have a molar ratio ranging from 1:4 to 1:10. 
     
     
         11 . The binder composition of  claim 1 , wherein the binder composition includes one or more non-reducing carbohydrates comprising starch, modified starch, cellulose, modified cellulose, or dextrins. 
     
     
         12 . The binder composition of  claim 1 , wherein the binder composition includes one or more additional components comprising adhesion promoters, flame retardants, organic fillers, inorganic fillers, waxes, colorants, or release agents. 
     
     
         13 . The binder composition of  claim 1 , wherein the binder composition is an aqueous binder composition having a pH ranging from 6 to 8. 
     
     
         14 . A binder composition comprising:
 a reducing sugar;   a crosslinking agent comprising 4,5-dihydroxyimidazolidin-2-one;   a crosslinking catalyst for catalyzing a crosslinking reaction between the reducing sugar and the 4,5-dihydroxyimidazolidin-2-one; and   an organosilane compound.   
     
     
         15 . The binder composition of  claim 14 , wherein the reducing sugar comprises dextrose. 
     
     
         16 . The binder composition of  claim 14 , wherein the 4,5-dihydroxyimidazolidin-2-one and the reducing sugar have a molar ratio ranging from 1:2 to 1:50 
     
     
         17 . The binder composition of  claim 14 , wherein the crosslinking catalyst comprises p-toluene sulfonic acid or methane sulfonic acid. 
     
     
         18 . A binder composition comprising:
 dextrose;   4,5-dihydroxyimidazolidin-2-one, wherein a molar ratio of the 4,5-dihydroxyimidazolidin-2-one to the dextrose ranges from 1:2 to 1:50;   a sulfonic acid compound; and   an organosilane compound.   
     
     
         19 . The binder composition of  claim 18 , wherein the binder composition includes one or more non-reducing carbohydrates comprising starch, modified starch, cellulose, modified cellulose, or dextrins. 
     
     
         20 . The binder composition of  claim 18 , wherein the binder composition includes one or more additional components comprising adhesion promoters, flame retardants, organic fillers, inorganic fillers, waxes, colorants, or release agents.