Fiberglass nonwoven binder

Abstract

The present invention relates to a nonwoven binder composition containing an aqueous solution of a copolymer binder having both an acid functionality and hydroxyl or amine functionality. The binder is especially useful as a binder for fiberglass fibers, to produce a fiberglass mat that is strongly bound, yet flexible.

1 . A method of bonding fibrous substances to form non-woven material, the method comprising the steps of: 
 preparing an aqueous binder composition comprising a copolymer having 
 at least one acid functional monomer in an amount of 50 to 95 mole percent, based on total mole percent of the copolymer, and  
 at least one hydroxyl or amine (alkyl)acrylate functional monomer in an amount of 1 to 20 mole percent, based on total mole percent of the copolymer; and  
   applying the binder composition to the fibrous substances thereby forming non-woven material.    
     
     
         2 . The method according to  claim 1  wherein the at least one acid functional monomer is selected from the group consisting of carboxylic acid monomers, phosphonic acid monomers, sulfonic acid monomers and mixtures thereof.  
     
     
         3 . The method according to  claim 2  wherein the at least one acid functional monomer is at least a carboxylic acid monomer and the carboxylic acid monomer further comprises acrylic acid, methacrylic acid, maleic acid or mixtures thereof.  
     
     
         4 . The method according to  claim 1  wherein the at least one acid functional monomer and the at least one hydroxyl or amine (alkyl)acrylate functional monomer are present in a mole ratio of from 100:1 to 1:1.  
     
     
         5 . The method according to  claim 1  wherein the copolymer further comprises up to 50 mole percent of at least one non-functional ethylenically unsaturated monomer.  
     
     
         6 . The method according to  claim 1  wherein the binder composition further comprises up to 25 weight percent, based on total weight of the binder composition, of at least one catalyst.  
     
     
         7 . The method according to  claim 1  wherein the fibrous substances are selected from heat-resistant non-woven fibers, mineral fibers and wood.  
     
     
         8 . The method according to  claim 7  wherein the fibrous substances are mineral fibers and the mineral fibers are glass fibers.  
     
     
         9 . The method according to  claim 1  wherein the fibrous substances are glass fibers, further comprising applying the binder composition to a mat of the glass fibers as the mat is being formed, and 
 removing water from the binder composition by use of residual heat from the glass fibers, and    heating the fiberglass mat thereby curing the binder composition.    
     
     
         10 . The method according to  claim 9  wherein the cured binder composition is in the form of a flexible film that permits the fiberglass mat, when compressed, to return to its vertical height when released from compression.