Composite maillard-resole binders

1. A composition comprising a binder and loosely assembled matter, the binder comprising a polymeric product of a curing reaction between phenol, formaldehyde, a carbohydrate, and an ammonium salt of a polycarboxylic acid, wherein the phenol, the formaldehyde, the carbohydrate, and the ammonium salt of the polycarboxylic acid are reactants that (i) are combined at ratios such that the polymeric product is infusible, water-resistant, and includes a mixture of cured resole resin and melanoidins, (ii) form a coating of high-solids liquid on the loosely assembled matter after being disposed thereon, and (iii) function as an uncured binder of the loosely assembled matter prior to the curing reaction thereon.

2. The composition of claim 1 , wherein a molar ratio of the phenol to the formaldehyde is in a range from about 1:1.1 to about 1:5 and a second molar ratio of the polycarboxylic acid to the carbohydrate reactant is in a second range from about 1:4 to about 1:15.

3. The composition of claim 1 , wherein the carbohydrate reactant is a monosaccharide in its aldose or ketose form.

4. The composition of claim 1 , wherein the carbohydrate reactant is selected from the group consisting of dextrose, xylose, fructose, dihydroxyacetone, and mixtures thereof.

5. The composition of claim 1 , wherein the polycarboxylic acid is selected from the group consisting of citric acid, maleic acid, tartaric acid, malic acid, succinic acid, and mixtures thereof.

6. The composition of claim 1 , wherein the loosely assembled matter includes fibers, the fibers selected from the group consisting of mineral fibers, aramid fibers, ceramic fibers, metal fibers, carbon fibers, polyimide fibers, polyester fibers, rayon fibers, mineral wool, glass fibers, and cellulosic fibers.

7. The composition of claim 6 , further comprising a silicon-containing compound.

8. The composition of claim 7 , wherein the silicon-containing compound is selected from the group consisting of gamma-aminopropyltriethoxysilane, gamma-glycidoxypropyltrimethoxysilane, aminoethylaminopropyltrimethoxysilane, n-propylamine silane, and mixtures thereof.

9. The composition of claim 1 , further comprising a non-carbohydrate polyhydroxy reactant.

10. The composition of claim 9 , wherein the non-carbohydrate polyhydroxy reactant is selected from the group consisting of trimethylolpropane, glycerol, pentaerythritol, sorbitol, 1,5-pentanediol, 1,6-hexanediol, polyTHF 650 , polyTHF 250 , textrion whey, polyvinyl alcohol, partially hydrolyzed polyvinyl acetate, fully hydrolyzed polyvinyl acetate, and mixtures thereof.

11. The composition of claim 1 , further comprising a component selected from the group consisting of dedusting oil, monoammonium phosphate, sodium metasilicate pentahydrate, melamine, tin (II) oxalate, and methylhydrogen silicone fluid emulsion.