Phenolic binders for mineral fiber thermal insulation

Claim 2

AN AQUEOUS PHEOLIC RESIN SYSTEM WHICH COMPRISES: A. A MODIFIED RESOLE COMPRISING A PHENOL-FORMALDEHYDE CONDENSATE AND A DICYANDIAMIDE-FORMALDEHYDE OR A MELAMINEFORMALDEHYDE CONDENSATE WHEREIN THE MOLE RATIO OF PHENOL TO DICYANDIAMIDE OR MELAMINE IS IN THE RANGE OF 1:0.2 TO 1:1.2, WHEREIN THERE ARE BETWEEN 1.5 AND 2.5 MOLES OF FORMALDEHYDE PER MOLE OF PHENOL, AND, ADDITIONALLY, BETWEEN 0.9 AND 2.0 MOLES FORMALDEHYDE PER MOLE OF DICYANDIAMIDE OR MELAMINE, B. AN ETHERIFIED METHYLOLAMINOTRIAZINE WHEREIN THE DEGREE OF METHYLOLATION IS AT LEAST 1.5, THE DEGREE OF ETHERIFICATION IS AT LEAST 0.5, AND THE ETHERIFICATION AGENT IS AN ALCOHOL CONTAINING FROM 1 TO 4 CARBON ATOMS, AND C. A PROTEINACEOUS COMPOUND SOLUBLE IN AQUEOUS MEDIA AT A PH OF 7 TO 10, WHEREIN THE WEIGHT RATIO OF THE MODIFIED RESOLE TO THE ETHERIFIED METHYLOLAMINOTRIAZINE IS IN THE RANGE OF 10:1 TO 1:2 AND WHEREIN THE WEIGHT RATIO OF THE PROTEINACEOUS COMPOUND TO THE MODIFIED RESOLE AND THE ETHERIFIED METHYLOLAMINOTRAZINE IS IN THE RANGE OF 1:1000 TO 1:20.

Claim 3

The aqueous phenolic resin system of claim 1 wherein the methylolaminotriazine is selected from the group consisting of methylolmelamines, methylolguanamines and methylolbenzoguanamines.

Claim 4

The aqueous phenolic resin system of claim 1 wherein the methylolaminotriazine is a methylolmelamine and the alcohol is methylalcohol.

Claim 5

The aqueous phenolic resin system of claim 1 wherein the proteinaceous compound is casein.

Claim 6

The aqueous phenolic resin of system claim 1 wherein the proteinaceous compound is soya protein.

Claim 7

The aqueous phenolic resin of system claim 1 which additionally comprises up to 0.7 mole urea per mole of phenol.

Claim 8

An aqueous phenolic resin system which comprises: A. a modified resole comprising a phenol-formaldehyde condensate and a dicyandiamide-formaldehyde condensate wherein the mole ratio of phenol to dicyandiamide is in the range of 1:0.2 to 1: 1.2, wherein there are between 1.5 and 2.5 moles of formaldehyde per mole of phenol, and, additionally, between 0.9 and 2.0 moles formaldehyde per mole of dicyandiamide, B. a methoxymethylmelamine wherein the degree of methylolation is at least 1.5 and the degree of methylation is at least 0.5, and C. a proteinaceous compound selected from the group consisting of casein and soya protein; wherein the weight ratio of the modified resole to the methoxymethylmelamine is in the range of 10:1 to 1:2 and wherein the weight ratio of the proteinaceous compound to the modified resole and the methoxymethylmelamine is in the range of 1:1000 to 1:20.

Claim 9

An aqueous phenolic resin system which comprises: A. a modified resole comprising a phenol-formaldehyde condensate and a dicyandiamide-formaldehyde condensate wherein the mole ratio of phenol to dicyandiamide is in the range of 1:0.2 to 1: 1.2, wherein there are between 1.5 and 2.5 moles of formaldehyde per mole of phenol, and, additionally, between 0.9 and 2.0 moles formaldehyde per mole of dicyandiamide, B. a methoxymethylmelamine wherein the degree of methylolation is at least 1.5 and the degree of methylation is at least 0.5, and C. a proteinaceous compound selected from the group consisting of casein and soya protein; wherein the weight ratio of the modified resole to the methoxymethylmelamine is in the range of 10:1 to 1:2 and wherein the weight ratio of the proteinaceous compound to the modified resole and the methoxymethylmelamine is in the range of 1:1000 to 1:20.

Claim 10

A process for preparing an aqueous phenolic resin system which comprises: A. reacting formaldehyde and phenol in a mole ratio of 1.5:1 to 2.5:1 in an aqueous alkaline medium to form a resole, B. reacting formaldehyde with dicyandiamide or melamine in a mole ratio of 0.9:1 to 2.0:1 in the presence of the aqueous alkaline resole at a temperature in the range of 20*-70*C., to form a modified resole, C. adjusting the pH of the modified resole to between 7 and 9, D. adding a methylolaminotriazine etherified with an alcohol containing from 1 to 4 carbon atoms, wherein the degree of methylolation is at least 1.5 and the degree of etherification is at least 0.5, and E. adding a proteinaceous compound soluble in aqueous media at a pH of 7 to 10; wherein the mole ratio of phenol to dicyandiamide or melamine is in the range of 1:0.2 to 1:1.2, wherein the weight ratio of the modified resole to the etherified methylolaminotriazine is in the range of 10:1 to 1:2 and wherein the weight ratio of the proteinaceous compound to the modified resole and the etherified methylolaminotriazine is in the range of 1:1000 to 1:20.

Claim 11

A process for preparing an aqueous phenolic resin system which comprises: A. reacting formaldehyde and phenol in a mole ratio of 1.5:1 to 2.5:1 in an aqueous alkaline medium to form a resole, B. reacting formaldehyde with dicyandiamide or melamine in a mole ratio of 0.9:1 to 2.0:1 in the presence of the aqueous alkaline resole at a temperature in the range of 20*-70*C., to form a modified resole, C. adjusting the pH of the modified resole to between 7 and 9, D. adding a methylolaminotriazine etherified with an alcohol containing from 1 to 4 carbon atoms, wherein the degree of methylolation is at least 1.5 and the degree of etherification is at least 0.5, and E. adding a proteinaceous compound soluble in aqueous media at a pH of 7 to 10; wherein the mole ratio of phenol to dicyandiamide or melamine is in the range of 1:0.2 to 1:1.2, wherein the weight ratio of the modified resole to the etherified methylolaminotriazine is in the range of 10:1 to 1:2 and wherein the weight ratio of the proteinaceous compound to the modified resole and the etherified methylolaminotriazine is in the range of 1:1000 to 1:20.

Claim 12

The process of claim 8 wherein the methylolaminotriazine is selected from the group consisting of methylolmelamines, methylolguanamines and methylolbenzoguanamines.

Claim 13

The process of claim 8 wherein the methylolaminotriazine is a methylolmelamine and the alcohol is methyl alcohol.

Claim 14

The process of claim 8 wherein the proteinaceous compound is casein.

Claim 15

The process of claim 8 wherein the proteinaceous compound is soya protein.

Claim 16

A process for preparing an aqueous phenolic resin system which comprises: A. reacting formaldehyde and phenol in a mole ratio of 1.5:1 to 2.5:1 in an aqueous alkaline medium to form a resole, B. reacting formaldehyde and dicyandiamide or melamine in a mole ratio of 0.9:1 to 2.0:1 in the presence of the aqueous alkaline resole at a temperature in the range of 40*-60*C. to form a modIfied resole, C. adjusting the pH of the modified resole to between 7 and 9, D. adding a methoxymethylmelamine wherein the degree of methylolation is at least 1.5 and the degree of methylation is at least 0.5, and E. adding a proteinaceous compound selected from the group consisting of casein and soya protein; wherein the mole ratio of phenol to dicyandiamide is in the range of 1:0.2 to 1:1.2, wherein the weight ratio of the modified resole to the methoxymethylmelamine is in the range of 10:1 to 1: 2 and wherein the weight ratio of the proteinaceous compound to the modified resole and the methoxymethylmelamine is in the range of 1:1000 to 1:20.

Claim 17

A process for preparing an aqueous phenolic resin system which comprises: A. reacting formaldehyde and phenol in a mole ratio of 1.5:1 to 2.5:1 in an aqueous alkaline medium to form a resole, B. reacting formaldehyde and dicyandiamide or melamine in a mole ratio of 0.9:1 to 2.0:1 in the presence of the aqueous alkaline resole at a temperature in the range of 40*-60*C. to form a modIfied resole, C. adjusting the pH of the modified resole to between 7 and 9, D. adding a methoxymethylmelamine wherein the degree of methylolation is at least 1.5 and the degree of methylation is at least 0.5, and E. adding a proteinaceous compound selected from the group consisting of casein and soya protein; wherein the mole ratio of phenol to dicyandiamide is in the range of 1:0.2 to 1:1.2, wherein the weight ratio of the modified resole to the methoxymethylmelamine is in the range of 10:1 to 1: 2 and wherein the weight ratio of the proteinaceous compound to the modified resole and the methoxymethylmelamine is in the range of 1:1000 to 1:20.

Claim 18

A thermoset resin comprising the condensation product of an phenolic resin system which comprises: A. a modified resole comprising a phenol-formaldehyde condensate and a dicyandiamide-formaldehyde or a melamineformaldehyde condensate wherein the mole ratio of phenol to dicyandiamide or melamine is in the range of 1:0.2 to 1:1.2, wherein there are between 1.5 and 2.5 moles of formaldehyde per mole of phenol, and, additionally, between 0.9 and 2.0 moles formaldehyde per mole of dicyandiamide or melamine, B. an etherified methylolaminotriazine wherein the degree of methylolation is at least 1.5, the degree of etherification is at least 0.5, and the etherification agent is an alcohol containing from 1 to 4 carbon atoms, and C. a proteinaceous compound soluble in aqueous media at a pH of 7 to 10; wherein the weight ratio of the modified resole to the etherified methylolaminotriazine is in the range of 10:1 to 1:2 and wherein the weight ratio of the proteinaceous compound to the modified resole and the etherified methylolaminotriazine is in the range of 1:1000 to 1:20.

Claim 19

A thermoset resin comprising the condensation product of an phenolic resin system which comprises: A. a modified resole comprising a phenol-formaldehyde condensate and a dicyandiamide-formaldehyde or a melamineformaldehyde condensate wherein the mole ratio of phenol to dicyandiamide or melamine is in the range of 1:0.2 to 1:1.2, wherein there are between 1.5 and 2.5 moles of formaldehyde per mole of phenol, and, additionally, between 0.9 and 2.0 moles formaldehyde per mole of dicyandiamide or melamine, B. an etherified methylolaminotriazine wherein the degree of methylolation is at least 1.5, the degree of etherification is at least 0.5, and the etherification agent is an alcohol containing from 1 to 4 carbon atoms, and C. a proteinaceous compound soluble in aqueous media at a pH of 7 to 10; wherein the weight ratio of the modified resole to the etherified methylolaminotriazine is in the range of 10:1 to 1:2 and wherein the weight ratio of the proteinaceous compound to the modified resole and the etherified methylolaminotriazine is in the range of 1:1000 to 1:20.

Claim 20

The thermoset resin of claim 14 wherein the methylolaminotriazine is selected from the group consisting of methylolmelamines, methylolguanamines and methylolbenzoguanamines.

Claim 21

The thermoset resin of claim 14 wherein the methylolaminotriazine is a methylolmelamine and the alcohol is methyl alcohol.

Claim 22

The thermoset resin of claim 14 wherein the proteinaceous compound is casein.

Claim 23

The thermoset resin of claim 14 wherein the proteinaceous compound is soya protein.

Claim 24

The thermoset resin of claim 14 wherein the admixture comprises additionally up to 0.7 mole urea per mole of phenol.

Claim 25

A thermoset resin comprising the condensation product of an phenolic resin system which comprises: A. a modified resole comprising a phenol-formaldehyde condensate and a dicyandiamide-formaldehyde condensate wherein the mole ratio of phenol to dicyandiamide is in the range of 1:0.2 to 1: 1.2, wherein there are between 1.5 and 2.5 moles of formaldehyde per mole of phenol, and, additionally, between 0.9 and 2.0 moles formaldehyde per mole of dicyandiamide, B. a methoxymethylmelamine wherein the degree of methylolation is at least 1.5 and the degree of methylation is 0.5, C. a proteinaceous compound selected from the group consisting of casein and soya protein; wherein the weight ratio of the modified resole to the methoxymethylmelamine is in the range of 10:1 to 1:2 and wherein the weight ratio of the proteinaceous compound to the modified resole and the methoxymethylmelamine is in the range of 1:1000 to 1:20.

Claim 26

A thermoset resin comprising the condensation product of an phenolic resin system which comprises: A. a modified resole comprising a phenol-formaldehyde condensate and a dicyandiamide-formaldehyde condensate wherein the mole ratio of phenol to dicyandiamide is in the range of 1:0.2 to 1: 1.2, wherein there are between 1.5 and 2.5 moles of formaldehyde per mole of phenol, and, additionally, between 0.9 and 2.0 moles formaldehyde per mole of dicyandiamide, B. a methoxymethylmelamine wherein the degree of methylolation is at least 1.5 and the degree of methylation is 0.5, C. a proteinaceous compound selected from the group consisting of casein and soya protein; wherein the weight ratio of the modified resole to the methoxymethylmelamine is in the range of 10:1 to 1:2 and wherein the weight ratio of the proteinaceous compound to the modified resole and the methoxymethylmelamine is in the range of 1:1000 to 1:20.