Patent ID: 6441122
Filing Date: 2002-08-27
Classification: C08G

Abstract:
A method for manufacturing an aqueous binder solution suitable for applying to fiberglass as a binder, said binder having high binding efficiency, wherein said aqueous binder solution is prepared by the steps of:(A) first selecting an aqueous resole having a pH greater than 7, prepared by reacting phenol with excess formaldehyde under alkaline conditions; (B) subsequently adding to said aqueous resole (A) urea in an amount from about 20 to about 70 parts by weight based on 100 parts by weight of the phenol/formaldehyde resole solids in component A and reacting to form a urea-extending prereact; (C) thereafter dissolving into said prereact from about 1 to about 10 weight percent melamine based on the weight of the solids in the urea-extended phenol/formaldehyde prereact (B); wherein said alkaline resole contains sufficient excess formaldehyde to react with said urea and said melamine on a substantially equimolar basis.