Granted Patent B2

US 7,323,534 · App. 11/248,105 · Granted Jan 29, 2008

Abstract

Claims (8)

1. A resin comprising the reaction product of a composition comprising:

a hydroxyaromatic compound;

about 0.025 to about 0.40 moles of alkaline catalyst per mole of hydroxyaromatic compound;

an aldehyde, wherein the initial molar ratio of hydroxyaromatic compound to aldehyde is about 2.0:1 to about 6.0:1; and

a urea-aldehyde condensate, wherein the urea-aldehyde condensate is previously formed from urea and an aldehyde at a temperature of about 50 to about 80° C. for a time effective to form a reaction product having a free aldehyde concentration of about 1 to about 35 weight %; and wherein the amount of urea present in the resulting resin is about 1 to about 40% by weight of the total solids.

2. A resin according to claim 1 wherein a binder composition comprising the resin demonstrates a resin efficiency of greater than or equal to 105% as determined by resin efficiency testing.

3. A resin according to claim 1 wherein the resin has an emission of hydroxyaromatic compound of at least 10% less than a resole which does not comprise the urea-aldehyde condensate, as determined using tube furnace emissions testing.

4. A resin according to claim 1 wherein the resin has an emission of aldehyde of at least 10% less than a resole which does not comprise the urea-aldehyde condensate, as determined using tube furnace emissions testing.

Assignments (29)