Water-Dilutable Urea-Formaldehyde Resin Binder for Fibrous Materials
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Solution Overview
Problem
Urea formaldehyde (UF) resins emit toxic formaldehyde during curing and lack water solubility, making them unsuitable as binders for composite materials like glass or polyester fiber products.
Innovation Solution
A water-dilutable resin composition is developed as a reaction product of an aldehyde, urea, and glycerol, with specific molar ratios and processing conditions that reduce formaldehyde emissions and achieve infinite water solubility, using formaldehyde and sugar alcohols like glycerol to prevent formaldehyde evaporation and maintain resin strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If UF resins incorporate diethylene glycol as plasticizer, then resin flexibility is improved, but formaldehyde emissions increase and water solubility is lost
Solution Approach 1:
The patent changes the chemical parameters by replacing diethylene glycol with glycerol as the plasticizer, and adjusts the molar ratios of formaldehyde to urea (1.0-3.0) and urea to glycerol (1:1.1 to 1:1100) to achieve reduced formaldehyde emissions while maintaining flexibility and water solubility
Solution Approach 2:
The patent uses glycerol, a cheaper and more environmentally benign alternative to diethylene glycol, achieving the plasticizing effect without the harmful formaldehyde emissions associated with conventional additives
2Stability of the object's composition
If UF resins incorporate glycerol as plasticizer, then resin flexibility is improved, but water solubility is lost
Solution Approach 1:
The patent optimizes the molar ratio parameters, specifically keeping formaldehyde to urea between 1.0-3.0 and urea to glycerol between 1:1.1 to 1:1100, which maintains the hydrophilic balance necessary for water solubility while incorporating sufficient glycerol for flexibility
Solution Approach 2:
The patent creates a composite resin system combining urea, formaldehyde, and glycerol in specific proportions, where the synergistic interaction of components maintains both flexibility and water solubility properties
3Strength
If aldehyde to urea molar ratio is increased, then resin strength is improved, but formaldehyde emissions increase
Solution Approach 1:
The patent optimizes the aldehyde to urea molar ratio within the range of 1.0-3.0, finding the optimal balance point where sufficient cross-linking for strength occurs without excessive free formaldehyde remaining to emit during curing
Solution Approach 2:
The patent converts the potentially harmful excess formaldehyde into beneficial cross-linking sites by controlling the molar ratio and curing conditions, where formaldehyde that would otherwise emit is instead utilized to form strong cross-links in the resin matrix
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resin composition significantly reduces formaldehyde emissions during curing while maintaining resin strength and achieving high water solubility, making it suitable for use as a binder in glass and polyester fiber mats and filters.
Implementation Method 1
U.S. Patent No. 1,633,337 describes a UF resin that incorporates glycerol as well
Implementation Method 2
the resin composition has a water solubility of greater than 50 parts water to one part resin composition
Implementation Method 3
during curing they tend to emit formaldehyde, a toxic irritant
Data Source
AI summary
The invention relates to water dilutable resin compositions that are reaction products of an aldehyde, an amino compound comprising 2-6 amino groups, and a sugar alcohol. The invention further relates to processes for the manufacture of the resin compositions. The invention further relates to the use of the resin compositions as a binder material for non-woven fibrous materials, in particular glass and polyester fiber mats and glass fiber filters.