Aromatic polyol-stabilized resol resin
The invention relates to a stabilized resol resin comprising water, a water-soluble amino phenol resin and a water-soluble aromatic polyol, as a solubilizer for the water-soluble amino phenol resin. The invention also relates to a diluted aqueous binder composition containing such a stabilized resol resin and additives, and to a method for producing a fibrous insulation product using such an aqueous binder composition.
1 . A stabilized resol resin, comprising
water,
from 80 to 97% by weight of a water-soluble amino phenol resin, and
from 3 to 20% by weight of a water-soluble aromatic polyol, as a solubilizer for the water-soluble amino phenol resin, these percentages being relative to the total dry weight of the stabilized resol resin,
said stabilized resol resin having a pH of between 1.0 and 6.5.
2 . The stabilized resol resin according to claim 1 , comprising:
from 85 to 95% by weight of the water-soluble amino phenol resin, and
from 5 to 15% by weight of the water-soluble aromatic polyol,
these percentages being relative to the total dry weight of the stabilized resol resin.
3 . The stabilized resol resin according to claim 1 , wherein the water-soluble aromatic polyol is a compound comprising a monocyclic or bicyclic aromatic ring, bearing at least two hydroxyl functions located directly on the aromatic ring.
4 . The stabilized resol resin according to claim 3 , wherein the water-soluble aromatic polyol is selected from the group consisting of resorcinol, phloroglucinol, pyrocatechol, gallic acid, 3,4-dihydroxybenzoic acid, 2,4-dihydroxybenzoic acid, 2,4-dihydroxybenzaldehyde, 2-hydroxy-3-methoxybenzaldehyde, 4-methoxybenzene-1,2-diol, 4-methoxybenzene-1,3-diol, and mixtures of these compounds.
5 . The stabilized resol resin according to claim 4 , wherein the water-soluble aromatic polyol is selected from the group consisting of resorcinol and phloroglucinol.
6 . The stabilized resol resin according to claim 1 , further comprising from 0.1 to 15% by weight of urea, relative to the total dry weight of the stabilized resol resin.
7 . The stabilized resol resin according to claim 1 , being free of urea.
8 . The stabilized resol resin according to claim 1 , wherein the water-soluble amino phenol resin consists essentially of phenol-formaldehyde condensates and phenol-formaldehyde-amine condensates.
9 . The stabilized resol resin according to claim 1 , having a pH of between 1.5 and 5.5.
10 . An aqueous binder composition comprising water, a stabilized resol resin according to claim 1 , and one or more additives selected from the group consisting of coupling agents, anti-dusting oils, emulsions, hydrophobizing agents and curing reaction accelerators.
11 . The aqueous binder composition according to claim 10 , comprising from 75 to 98% by weight of water.
12 . The aqueous binder composition according to claim 10 , being free of urea.
13 . A method for manufacturing an insulating product based on mineral or organic fibers, comprising
applying an aqueous binder composition according to claim 10 to mineral or organic fibers, and
heating the fibers bonded with the aqueous binder composition so as to evaporate the volatile phase of the aqueous binder composition and to bring about the thermal curing of the non-volatile residue, or packaging the mineral or organic fibers bonded with the uncured aqueous binder composition for the purpose of storage and/or transport.
14 . The method according to claim 13 , wherein the mineral fibers are mineral wool fibers.
15 . An insulating product based on mineral or organic fibers, obtained by the method according to claim 13 .