Water soluble binder compositions containing beta-hydroxy urethanes and polyfunctional carboxylic acids

Claim 2

A process for preparing fiberglass mat which comprises contacting glass fibers with a liquid binder composition, forming the glass fibers into a mat, and thereafter heat curing the binder composition retained on the glass fibers; wherein the improvement comprises: contacting the glass fibers with a binder composition comprising: (i) a beta-hydroxy urethane functional material, (ii) a polycarboxylic acid ingredient; wherein the weight ratio of (i) to (ii) is from about 4:1 to about 1:5.

Claim 3

The process of claim 1 wherein the binder composition comprises: (i) a beta-hydroxy urethane functional material, (ii) a polycarboxylic acid ingredient selected from the group consisting of (a) 1,2,3,4-butanetetracarboxylic acid (BTCA) (b) 1,2,3,4-butanetetracarboxylic acid anhydride (c) 1,2,3,4-cyclopentane-tetracarboxylic acid (d) 1,2,3,4-cyclopentane-tetracarboxylic acid anhydride (e) pyromellitic acid (f) pyromellitic dianhydride (g) maleic acid (h) maleic anhydride (i) polymaleic acid (j) polymaleic anhydride (k) 1,2,3,4-cyclopentanetetracarboxylic acid anhydride (l) 2,3,4,5-tetrahydrofuran carboxylic acid (m) 2,3,4,5-tetrahydrofuran carboxylic acid anhydride (n) and mixtures of (a), (b), (c), (d), (e), (f), (g), (h), (i), (j), (k), (l), and (m).

Claim 4

The process of claim 2 wherein the beta-hydroxy urethane functional material in the binder formulation is selected from: a. triazine compounds of the formula C.sub.3 N.sub.6 (CH.sub.2 OR).sub.6-x (CH.sub.2 NHCOOR.sub.1).sub.x b. benzoguanamine compounds of the formula C.sub.3 N.sub.5 (C.sub.6 H.sub.5)(CH.sub.2 OR).sub.4-y (CH.sub.2 NHCOOR.sub.1).sub.y c. glycoluril compounds of the formula C.sub.4 H.sub.2 N.sub.4 O.sub.2 (CH.sub.2 OR).sub.4-y (CH.sub.2 NHCOOR.sub.1).sub.y d. acetoguanamine compounds of the formula C.sub.3 N.sub.5 (CH.sub.3)(CH.sub.2 OR).sub.4-y (CH.sub.2 NHCOOR.sub.1).sub.y e. 4,5-dihydroxy-2-imidazolidone compounds of the formula C.sub.3 H.sub.4 N.sub.2 O.sub.3 (CH.sub.2 NHCOOR.sub.1).sub.2 f. an oligomer of (a), g. an oligomer of (b), h. an oligomer of (c), i. an oligomer of (d), j. an oligomer of (e); wherein the R groups are, independently, hydrogen or alkyl from 1 to 12 carbon atoms, and the R 1 groups are, independently, beta-hydroxyalkyl, of from 2 to 18 carbon atoms, alone, or combined with alkyl of from 1 to 18 carbon atoms, x is in the range of from about 2 to 6, and y is in the range of from about 2 to 4.

Claim 5

The process of claim 2 wherein the beta-hydroxy urethane functional material and the polycarboxylic acid ingredient of the binder composition constitute in combination from about 50 to 100 weight percent of the total weight of the binder formulation ingredients (exclusive of water).

Claim 6

The process of claim 2 wherein the glass fibers are contacted with the binder composition are cured at a temperature of from 177° C. to 288° C. for a period of from about one-half minute to about five minutes.

Claim 7

The process of claim 2 wherein the binder composition is contacted one or more times with the glass fiber so as to deposit from about 3 to about 10 weight percent of the binder solid ingredients based on the weight of treated fiberglass onto the glass fibers.

Claim 8

The process of claim 2 wherein the binder formulation is an aqueous formulation that is contacted with the glass fiber by spraying.