Aqueous formaldehyde-free composition and fiberglass insulation including the same
View Patent ↗An aqueous composition that includes a) aqueous hydroxy functional, carboxy functional polymer including the reaction product of at least 5% by weight α,β-ethylenically unsaturated hydroxy monomer, at least 30% by weight ethylenically unsaturated carboxylic acid monomer, from 0% by weight to less than 50% by weight α,β-ethylenically unsaturated nonhydroxy functional, noncarboxy functional monomer, and chain transfer agent, and b) condensation accelerator, and articles that include a nonwoven web including glass fibers, and cured aqueous binder composition.
1. An aqueous composition comprising
a) aqueous water soluble hydroxy functional, carboxy functional polymer comprising the reaction product of
i) at least 5% by weight α,β-ethylenically unsaturated hydroxy functional monomer,
ii) at least 30% by weight ethylenically unsaturated carboxylic acid monomer,
iii) 0% by weight to less than 50% by weight α,β-ethylenically unsaturated nonhydroxy functional, noncarboxy functional monomer, and
iv) chain transfer agent; and
b) condensation accelerator
wherein said aqueous composition has a pH less than 7.
2. The aqueous composition of claim 1 , wherein said aqueous hydroxy functional carboxy functional polymer has a number average molecular weight no greater than 10,000.
3. The aqueous composition of claim 1 , wherein said aqueous hydroxy functional carboxy functional polymer comprises from 20% by weight to 60% by weight solids.
4. The aqueous composition of claim 1 , wherein said aqueous composition has a pH from about 2 to about 4.
5. The aqueous composition of claim 1 , wherein said α,β-ethylenically unsaturated hydroxy functional monomer comprises 2-hydroxy ethyl acrylate.
6. The aqueous composition of claim 5 , wherein said ethylenically unsaturated carboxylic acid monomer comprises glacial acrylic acid.
7. The aqueous composition of claim 1 , wherein said ethylenically unsaturated carboxylic acid monomer comprises glacial acrylic acid.
8. The aqueous composition of claim 1 , wherein said aqueous hydroxy functional carboxy functional polymer is prepared from no greater than 40% by weight α,β-ethylenically unsaturated nonhydroxy functional, noncarboxy functional monomer.
9. The aqueous composition of claim 1 , wherein said aqueous hydroxy functional carboxy functional polymer has an acid number of at least 300 mg KOH/g dried polymer.
10. The aqueous composition of claim 1 , wherein said aqueous hydroxy functional, carboxy functional polymer comprises the reaction product of
i) from 10% by weight to 70% by weight α,β-ethylenically unsaturated hydroxy functional monomer,
ii) from 40% by weight to 90% by weight ethylenically unsaturated carboxylic acid monomer, and
iii) chain transfer agent.
11. The aqueous composition of claim 1 , wherein said aqueous hydroxy functional, carboxy functional polymer comprises the reaction product of
i) from 20% by weight to 60% by weight α,β-ethylenically unsaturated hydroxy functional monomer,
ii) from 50% by weight to 90% by weight ethylenically unsaturated carboxylic acid monomer, and
iii) chain transfer agent.
12. The aqueous composition of claim 1 , wherein said aqueous hydroxy functional, carboxy functional polymer comprises the reaction product of
i) from 20% by weight to 60% by weight α,β-ethylenically unsaturated hydroxy functional monomer,
ii) from 60% by weight to 80% by weight ethylenically unsaturated carboxylic acid monomer, and
iii) chain transfer agent.
13. The aqueous composition of claim 1 , wherein when said composition is employed in the Dry Tensile Strength Test Method, the cured treated paper exhibits a dry tensile strength of at least 5 pounds of force.
14. The aqueous composition of claim 1 , wherein when said composition is employed in the Wet Tensile Strength Test Method, the cured treated paper exhibits a wet tensile strength of at least 5 pounds of force.
15. The aqueous composition of claim 1 , wherein said composition is essentially free of polyol having an acid number less than 100 mg KOH/g dried material.
16. The aqueous composition of claim 1 , wherein said aqueous hydroxy functional, carboxy functional solution polymer is free of α,β-ethylenically unsaturated nonhydroxy functional, noncarboxy functional monomer.
17. Fiberglass insulation comprising
a) a nonwoven web comprising glass fibers; and
b) a binder composition comprising the reaction product of
i) aqueous water soluble hydroxy functional, carboxy functional polymer comprising the reaction product of
at least 5% by weight α,β-ethylenically unsaturated hydroxy functional monomer,
at least 30% by weight ethylenically unsaturated carboxylic acid monomer,
from 0% by weight to less than 50% by weight α,β-ethylenically unsaturated nonhydroxy functional, noncarboxy functional monomer, and
chain transfer agent; and
condensation accelerator
wherein said binder composition has a pH less than 7.
18. The fiberglass insulation of claim 17 , wherein said fiberglass insulation comprises from about 5% by weight to about 14% by weight dried binder composition based on the weight of the glass fibers.
19. A method of making fiberglass insulation comprising:
a) contacting glass fibers with a binder composition comprising
i) aqueous water soluble hydroxy functional carboxy functional polymer comprising the reaction product of
at least 5% by weight α,β-ethylenically unsaturated hydroxy functional monomer,
at least 30% by weight ethylenically unsaturated carboxylic acid monomer,
less than 50% by weight nonhydroxy functional, noncarboxy functional monomer,
chain transfer agent; and
ii) condensation accelerator
wherein said binder composition has a pH less than 7
b) curing said composition.
20. An aqueous fiberglass binder composition comprising
a) aqueous water soluble hydroxyl functional, carboxy functional solution polymer consisting essentially of the reaction product of
i) at least 5% by weight α,β-ethylenically unsaturated hydroxy functional monomer,
ii) at least 30% by weight ethylenically unsaturated carboxylic acid monomer,
iii) chain transfer agent; and
b) condensation accelerator
wherein said binder composition has a pH less than 7.