Glass fiber binding composition containing latex elastomer and method of reducing fallout from glass fiber compositions

Described is an aqueous sprayable glass fiber binding composition comprising: a) an aqueous compatible formaldehyde thermosetting coating composition; and b) a compatible aqueous latex elastomeric composition. Also described are binder compositions that decrease fallout of glass fiber and binder from the coated glass fiber. Also disclosed is a glass fiber binder composition having low odor content.

TECHNICAL FIELD 
This invention relates to aqueous glass fiber binder compositions and 
reduced fallout from glass fiber compositions. By "fallout", it is meant 
glass fibers and/or binder that comprises the dust that results from the 
handling of glass fiber compositions during use. 
BACKGROUND ART 
Fiberglass comes in many shapes and sizes and can be used for a variety of 
applications. A general discussion of glass fiber technology is provided 
in "Fiberglass" by J. Gilbert Mohr and William P. Rowe, Van Nostrand 
Reinhold Co., New York, 1978, which is hereby incorporated by reference. 
Water soluble phenolformaldehyde resins such as resoles have been known 
for a number of years. See, for example, U.S. Pat. Nos. 4,060,504, 
4,757,108 and 4,960,826, hereby incorporated by reference. 
A number of references disclose mats that are comprised of short siliceous 
materials such as chopped glass fiber from a continuous filament glass 
fibers. These fibers are extremely short in length, namely one-half inch 
and less. The glass materials may also be obtained by chopping other glass 
fibers to obtain short length siliceous materials. U.S. Pat. No. 2,723,209 
describes such mats utilizing a binder formulation of 
acrylonitrile-butadiene copolymer. To this is added a phenolic resin 
solution which is then further diluted with water so that the solids 
content is approximately 2%. A small amount of this mixture is sprayed 
onto a glass fiber mat and an excessive amount is later poured onto a 
roller over which the wetted mat travels. The impregnated mat then passes 
over concentrated heat of direct fired or radiant burners and then into a 
baking oven at a temperature of 250.degree. to 400.degree. F. for 10 to 25 
minutes. The mat with the resin material thereon is fully cured. Mats 
comprised of a bed of glass fibers are to be treated as a sheet so that it 
can be impregnated. Utilization of resinous materials for such 
compositions are primarily for complete support of the overall structure. 
This technique is sharply contrasted with the present invention which is 
concerned with binders that are to be applied to glass fibers after the 
fiber is formed by different techniques. 
Another glass fiber mat reference is U.S. Pat. No. 4,006,272 which pertains 
to a process for preparing resin impregnated glass fiber mats in which the 
binder resin has a high rate of dissolution in vinyl monomers. The binder 
resin is a styrene resin or copolymer composed mainly of styrene. Blended 
with the styrene may also be unsaturated polyester resin having a melting 
point of 80.degree. to 130.degree. C. 
U.S. Pat. No. 4,258,098 pertains to a glass fiber mat which utilizes a urea 
formaldehyde resin together with styrene butadiene latex copolymer further 
containing 0.1 to 5% by weight acrylamide, methacrylamide, 
N-methylolacrylamide or N-methylolmethacrylamide. Another glass fiber mat 
document is U.S. Pat. No. 4,560,612 which has a binder composition of urea 
formaldehyde, styrene-butadiene latex copolymer and a fully methylated 
melamine-formaldehyde copolymer. 
Another glass fiber mat is disclosed in U.S. Pat. No. 4,849,281 where the 
mat has a particular unique blend of glass fibers such as wool fibers and 
textile glass fibers together with melamine cross-linked styrene butadiene 
resin. 
U.S. Pat. No. 4,892,695 discloses a fiber glass mat containing glass 
fibers, polyolefin fibers and polyamide fibers together with a latex 
binder such as styrene-butadiene latex. 
U.S. Pat. No. 3,914,192 discloses for use as reinforcement for elastomeric 
materials a plurality of glass fibers, a thin film coating on the surface 
of the glass fibers and an impregnant in the bundle, the impregnant 
comprising a blend of resorcinol aldehyde resin and an elastomer. 
It is an object of the present invention to have an improved glass fiber 
binding composition utilizing the combination of aqueous latex and a 
thermosetting composition. The binder coats the entire fiber as well as 
the juncture points. In the prior art, binders with a formaldehyde 
thermosetting composition are designed to coat and/or migrate to the glass 
fiber juncture points not to coat individual fibers. 
It is an object of the present invention to obtain glass fiber compositions 
of improved handleability and reduced fiber "fallout" in the use of the 
glass fiber compositions. Prior to the present invention, handlers of 
fibrous glass products vigorously complained about the handleability and 
skin irritation they receive. 
It is an object of the present invention to obtain glass fiber compositions 
in their fully cured state that have low odor associated with such cured 
glass fiber compositions.

SUMMARY OF THE INVENTION 
Described is an aqueous sprayable glass fiber binding composition 
comprising: 
a. an aqueous compatible formaldehyde thermosetting coating composition; 
and 
b. a compatible aqueous latex elastomeric composition. 
Another embodiment of the invention is the utilization of an acrylic latex 
composition used in conjunction with the elastomeric composition. 
Another embodiment of the invention pertains to a method of reducing fiber 
fallout and/or irritation by applying the aforementioned aqueous 
compatible binder composition to newly formed glass fibers and curing the 
binder composition. 
Another embodiment of the invention is to decrease the odor of cured glass 
fiber composition comprising the steps of: 
a. providing newly formed glass fibers; 
b. applying the aforementioned glass fiber binding composition; and 
c. curing the resin wherein the cured composition has an alkylamine content 
of less than 100 ppm. 
Also described is a curable, e.g. A-stage or B-stage, glass fiber 
composition containing glass fibers having the aforementioned binder 
composition applied thereto wherein the B-stage cured glass fiber 
composition has an alkylamine content of less than 100 ppm. 
Also described is a C-staged cured glass fiber composition containing glass 
fibers having the aforementioned binder composition applied thereto 
wherein the C-staged cured glass fiber composition has an alkylamine 
content of less than 100 ppm. 
DESCRIPTION OF PREFERRED EMBODIMENTS 
The binder compositions in the present invention utilizes elastomer aqueous 
emulsions compatible with thermosetting formaldehyde containing resins. 
Application of the binder compositions will be to newly formed glass 
fibers using known prior art fiber manufacturing methods. The binder will 
be applied to the newly formed glass fibers mid-air prior to their 
collection using normal known manufacturing techniques. Further note that 
during the application of the inventive binder the glass is collected on a 
permeable chain or webbing to form a blanket of fibrous glass with the wet 
or uncured inventive binder coating each fiber making up the blanket. No 
excess binder need be applied nor drawn off. The blanket has normal 
thickness of one (1) to twelve (12) inches but can be made to almost any 
thickness desired. In this state, the blanket is wet or A stage and the 
inventive binder is uncured. The blanket can now be distributed to 
customers as is or dimensionally sized by heated rollers and cured in an 
oven or the uncured blanket can be placed into molds to be formed into 
various configurations. An example of a blanket which has been sized by 
heated rollers and then cured out in an oven would be home insulation. The 
blanket fiber glass material thus should have the properties of being low 
density with a high thermal resistance or R value. 
The glass fiber which makes up this blanket has various fiber diameters and 
lengths dependent on the fiber forming equipment and process. For example, 
in a pot and marble process or flame attenuated process, the burner flame 
temperature will help determine fiber diameter and length of fiber. As 
another example, the diameter of the semi molten glass strand being pulled 
from a high temperature crucible during the manufacturing process will 
also effect the diameter and length of the newly formed glass fibers. The 
majority of glass fibers formed by this process will fall into the 
diameter range of 3 to 20 microns. 
A fiber glass mat utilizes glass fibers with identical fiber diameters cut 
to a predetermined length. The length of the fiber is important in the mat 
forming process because the fibers may not be much more than three (3) 
inches in length to be used successfully in the mat forming process. 
Fibers with lengths in excess of three (3) inches will fold over or become 
entangled with each other causing a bunching or lump in the mat. 
When forming a blanket, fiber length is also very important to the strength 
of the blanket. The mean fiber length is much longer than three (3) inches 
for the products manufactured from this blanket to have the desired 
strength. Fiber lengths up to twelve (12) inches can be expected in the 
blanket. 
The present invention is concerned with glass fiber binder compositions. 
Any technique for the manufacture of glass fibers is satisfactory. While 
not a complete listing of all glass fiber manufacturing techniques, some 
of the fiberization manufacturing techniques can be described as the pot 
and marble process or the flame attenuated process, and the rotary 
processes. In the rotary process, the glass melt is formed and the glass 
is passed through spinnerettes with calibrated perforations thereby 
forming the glass fiber. A flame attenuation process utilizes a technique 
whereby the fibers are formed from primary filaments being drawn through 
calibrated perforations from the bottoms of high temperature crucibles 
called pots. One process rolls molten glass into marbles so that the glass 
can be transferred or fed more readily into the manufacturing processes. 
This is called the Pot and Marble process. See the book "Glass Fibers" by 
J. Gilert Mohr and William P. Rowe, Van Nostrand, Reinhold Company, 
published in 1978. The book describes numerous fiberizing techniques at 
pp. 4-16, hereby incorporated by reference. 
In each of the fiberizing techniques, newly formed glass fibers are warm. 
The glass fibers then have an aqueous binder applied thereto to bind the 
junctions of the glass fibers. It is to be appreciated that the glass 
fibers to which this invention is directed can also include glass fibers 
other than recently formed glass fibers. 
Application of the binder compositions will be to newly formed glass fibers 
in mid-air prior to their collection using normal known manufacturing 
techniques. 
The binder compositions in the present invention utilize thermosettable 
aqueous compatible formaldehyde containing compositions. The formaldehyde 
containing compositions are well known, commercially available materials. 
Low phenol formaldehyde resins are commercially available such as from 
Borden Chemical of Columbus, Ohio identified as IB746B. A broad listing of 
phenol formaldehyde resins are described in U.S. Pat. Nos. 4,257,108 and 
4,960,826, hereby incorporated by reference. Other thermosetting 
compositions that may be utilized are urea formaldehyde compositions; 
resorcinolformaldehyde resins or other polyhydric phenol or cresol 
thermosetting compositions. It is to be appreciated that such resins may 
be modified with methylol groups which upon curing form methylene or ether 
linkages. Such methylols include N,N'-dimethylol, 
dihydroxymethlolethylene, N,N'-bis (methoxy methyl), 
N,N'dimethylolpropylene, 5,5-dimethyl-N,N'-dimethylol propylene, 
N,N'-dimethylol ethylene, and the like. 
The aqueous compatible latex composition that is utilized in the present 
case is an elastomeric containing material. Suitable elastomeric latex 
materials are olefin based elastomers such as olefin based rubbers, such 
as butadiene polymers, such as styrene butadiene and the like, EPM 
(ethylene propylene monomer as a copolymer), EPDM (ethylene 
propylene-diene terpolymer), ethylene-butene-1 copolymer rubber, 
carboxylated styrene-butadiene latex and the like. The most preferred 
material is a carboxylated styrene-butadiene latex having a glass 
transition temperature of -15.degree. C., a viscosity at ambient of 700 
centipoise available under the mark TYLAC-97834 (trademark of Reichhold of 
Dover, Del.). The 97834 has typical properties of 53% nonvolatiles with a 
pH of 8.5 with a Brookfield viscosity of (#3 spindle at 60 rpm) 700 with 
an emulsifier type that is anionic. 
To improve strength to the glass fibers matrix, it is desirable to add an 
additional component to the glass fiber binding composition, namely, an 
acrylic polymer. The acrylic material likewise adds water resistance. It 
preferably has a glass transition temperature that is greater than 0 to 
about 50, preferably about 350.degree. C. A wide variety of acrylic 
latexes are available such as those comprised of polymers or copolymers of 
acrylic acid, methacrylic acid, acrylic or methacrylic acid esters of from 
1 to 4 carbon atoms, acrylamide polymers or copolymers and esters thereof 
of from 1 to 4 carbon atoms. Suitable acrylic materials are available from 
Rohm & Haas under the mark RHOPLEX, preferably RHOPLEX-R GL-618 emulsion 
which has 46% to 48% acrylic copolymer by weight, formaldehyde of 0.05% 
with 52% to 54% water having a pH of 7.5 to 9.8 with a viscosity of 50 to 
200 centipoise. 
It has likewise been found desirable to add a formaldehyde scavenger. While 
a wide variety of scavengers are available, it is preferred that an 
aqueous compatible latex be employed preferably a vinyl containing 
material such as aromatic or aliphatic vinyl such as vinyl chloride 
polymeric compositions. Suitable vinyl chloride copolymers are available 
from the trade such as from B.F. Goodrich under the mark GEON. Most 
preferably, the GEON material is GEON TN801 which has a glass transition 
temperature of 65.degree. C. The PVC containing material is also useful 
for stiffening purposes. 
It is to be appreciated that thermosetting composition preferably employs a 
catalyst for the curing of the thermosetting composition. Any well known 
catalyst can be used such as melamine formaldehyde, CYMEL resins, 
preferably CYMEL-303 resin which is a modified melamine formaldehyde 
resin. Any of the commercially available amino resins for cross-linking 
purposes may be utilized. 
For utilization of additional phenol formaldehyde resins that have low free 
formaldehyde and formaldehyde scavengers, see the compositions described 
in applicant's assignee's co-pending application filed on May 19, 1992, 
Ser. No. 886,666. Formaldehyde scavengers that are utilized are nitrogen 
heterocyclic materials having a replaceable hydrogen attached to an amine 
of the compound such as amino triazines such as melamine, guanamine, 
benzol guanamine, and the like. Other formaldehyde scavengers may be 
utilized such as guanidine, dicyandiamide, and the like. 
The aqueous binder compositions of the present invention are preferably 
described below in Table I. 
TABLE I 
______________________________________ 
Composition Range Preferred Range 
% By Weight % By Weight 
% By weight 
______________________________________ 
Thermosetting 10-50% 40% 
Formaldehyde Resin 
(46% nonvolatiles) 
Latex Elastomer 
20-80% 37% 
(53% nonvolatiles) 
Acrylic Latex 0-30% 17% 
(46% nonvolatiles) 
preferably 
10-30% 
Formaldehyde 0-30% 5% 
Scavenger preferably 
(51% nonvolatiles) 
1-30% 
Cross-Linking 0-5% 1% 
Catalyst preferably 
1-5% 
100% 100% 
______________________________________ 
It is to be appreciated that the aforementioned compositions are to be 
blended with water where the water content ranges from about 50-98% by 
weight with the remainder being the aforementioned binder composition with 
the total being 100% by weight. 
Delivery of the binder to the formed glass fibers in such processes may be 
achieved via the use of standard spray systems, column expanders, or 
alternatively, conventional air assisted spray equipment. One type of air 
assisted spray equipment is described in U.S. Pat. No. 4,832,723, issued 
May 23, 1989 to Shisler et al., which is incorporated by reference. 
Most preferably, the newly formed glass fibers with a binder sprayed 
thereon are collected on a moving chain as a loose blanket. The blanket 
may be pulled into heated tools for molding, coiled up onto mandrels or 
pulled between heated rollers to achieve desired blanket thickness and 
density wherein the blanket is partially compressed before being fully 
cured or C stage. To provide the blanket with enough tensile strength to 
be pulled into or onto various manufacturing processes, the binder should 
provide enough strength to the uncured blanket. The uncured binder should 
be tacky enough to hold the glass fibers together. This is why present art 
concerns itself only with binders capable of coating fiber juncture points 
and not the entire fiber. To coat the entire fiber was deemed unnecessary 
and wasteful for prior art binder compositions. With the inventive binder, 
the juncture points should be coated for wet tensile strength via the 
tacky thermoset resins and the glass fibers should be coated for reducing 
fall out and irritation via the thermoplastic elastomer latex emulsions. 
The entire glass fiber should be coated to reduce fall out because the 
glass fibers are very brittle and when they break during handling, the 
"rubber" latex coating holds the fiber together and prevents fiber 
splintering. 
This explains in part why the inventive binder is a combination of tacky 
thermoset resins in combination with compatible latex emulsions. Thermoset 
resins should also be used to provide adequate strength to the fibrous 
glass products at elevated temperatures. Latex resins alone were much too 
weak to be used as a binder. There simply was no strength to the fiber 
glass parts, specifically, automotive hoodliners and headliners. Parts 
made from the inventive composition should be comparable to the strength 
of parts made from the standard binder compositions. Thus, these parts 
should have enough tensile, flexure and internal bond strength. The 
invention has solved this problem by its unique composition. 
After the application of the binder composition to the glass fibers, it may 
be sold as-is, i.e., in the uncured unit state, namely, A-stage. Also, 
there may be a partial curing of what is called the B-stage product. By 
this is meant that the glass fiber composition has much of the water 
removed from the blanket. The B-stage product facilitates handling and 
shipping of the glass fiber blanket, and the like. 
The final cured compositions or C-stage take on an innumerable number of 
forms as desired by the end user. Suitable C-stage configurations for 
glass fiber compositions of the present invention include vehicular 
interior trim including headliners, dash insulators, HVAC (heating 
ventilation air conditioning) insulators, hood insulators, duct wrap, duct 
board, duct liner, air filtration, and other desirable C-stage 
compositions. Generally, the desired shape occurs by a molding technique. 
The curing of the glass fiber composition with a binder applied thereto as 
described herein is generally very quick depending upon the temperature 
and time desired. Generally, the temperature ranges from about 500.degree. 
to about 550.degree. F. with a period of time of less than 5 minutes, 
preferably from 10 seconds to 2 minutes, and even more preferably 20 
seconds to 90 seconds such as for automotive headliners or hoodliners. 
Presently, automotive headliners and hoodliners require elevated molding 
temperatures to have cure cycle times competitive to non-fiber glass 
headliners and hoodliners. The inventive binder provides the same cure 
cycle process time with much lower molding temperatures. For example, a 
hoodliner containing the standard thermoset resins will have a cure cycle 
time of 20 seconds when mold temperatures are 650.degree. F. When using 
the inventive binder mold, temperatures can be reduced to 425.degree. F. 
Mold temperatures of 650.degree. F. are too hot for aluminum tools thus 
manufacturers are forced to use steel tools at a much greater expense. 
Manufacturers of automotive headliners and hoodliners may now use aluminum 
tools instead of steel tools. 
Another problem is encountered using temperatures in excess of 475.degree. 
F. when manufacturing headliners or hoodliners. Headliners and hoodliners 
are usually faced by a non-woven mat weighing between 0.5 ounces to 2 
ounces per square yard to encapsulate the automotive glass product and/or 
to make the product more attractive. The non-woven mat is made from rayon 
and polyester fibers. The mat degrades at elevated tool temperatures above 
475.degree. F. The inventive binder will resolve this problem. 
It has also been found desirable to add to the binding composition as 
desired, silicon containing materials which decrease the moisture 
absorption of the resin. A suitable material is a silane. It assists in 
the coupling of the polymer to the glass fiber. A preferred material is 
Union Carbide 1101 which is an amino functional silane. 
In order to detect the alkyl amine, suitable analytical testing is 
permissible. A technique is to subject the final cured product to high 
temperature of about 125.degree. F. and 95% relative humidity for a 
desired period of time such as 3 hours and thereby detect the presence of 
the alkyl amine. The composite density of the final product can range up 
to about 20 pounds per cubic foot (PCF), preferably 1 to about 15 PCF. The 
most undesirable alkyl amine that causes odor in the composition is 
trimethyl amine. 
It is to be appreciated that the amount of binder that is applied to the 
glass fiber is preferably of a nature to completely coat the glass fiber, 
as well as to give a binding at the junction of the glass fibers. The 
final cured product therefore can be characterized as having a binder on 
the glass composition as a maximum of 30% loss on ignition (LOI), 
preferably 16% LOI. 
Listed below are exemplifications of preferred embodiments of the invention 
wherein all parts are parts by weight and all temperatures are in degrees 
Centigrade, unless otherwise indicated. 
EXAMPLE 1 
The binder tested was labeled as "IMP" and had the following composition: 
a) 48% by weight 97834 latex manufactured by Reichhold Chemicals, Inc. 
The latex is a carboxylated butadiene-styrene which has the following 
properties: 
______________________________________ 
Nonvolatiles, % 53% 
pH 8.5 +/- 0.5 
Emulsifier type Anionic 
Glass Transition Temperature 
-15.degree. C. 
Appearance White 
Odor Slight ammonical 
______________________________________ 
b) 40% by weight phenol formaldehyde binder prepared from a resin mixture 
as follows: 
825 g phenol formaldehyde resin (46.5% by weight solids: Georgia Pacific GP 
2804) 
______________________________________ 
96 g urea 
9.6 g ammonium sulfate 
96 g ammonia 
(pH adjustment to neutral) 
0.96 g silane 
168 g distilled water 
______________________________________ 
c) 12% 911-138-018 latex binder manufactured by B.F. Goodrich. 
The B.F. Goodrich latex is a polyvinyl chloride copolymer and has the 
following properties: 
______________________________________ 
Nonvolatiles, % 53% 
pH 5.7 +/- 0.5 
Emulsifier type Anionic 
Glass Transition Temperature 
65.degree. C. 
Appearance White 
Odor Polymer 
______________________________________ 
Tensile Strength 
The first strength test performed was the ASTM D751 tensile strength test. 
The machine parameters for all samples were as follows: 
______________________________________ 
Sample rate (Pts/sec): 
9.10 
Crosshead Speed (in/min): 
12.0 
Humidity (%) 50 
Temperature .degree.F. 
73 
______________________________________ 
Ten samples of each material were prepared for testing. Five were tested in 
the machine direction ("MD") and five were tested in the cross machine 
direction ("CM"). The tensile strength mean of each group is shown in FIG. 
1. FIG. 1 shows the calculated tensile strengths of each material tested 
in machine direction ("MD") and cross machine direction ("CM") in pounds. 
Each sample studied had the following dimensions: 
______________________________________ 
Thickness (in): 0.25 
Width (in): 4.0 
Gauge Length (in): 3.0 
Specimen Gauge Length (in): 
3.0 
Weight per square foot (gr.) 
76 
______________________________________ 
Table II shows the results from tensile strength test ASTM D751 using 
standard glass fiber wool, machine direction. Out of five specimens, zero 
were excluded. 
TABLE II 
______________________________________ 
Specimen Number 
Load at Maximum Load (lbs.) 
______________________________________ 
1 212.5 
2 220.7 
3 219.9 
4 198.2 
5 232.8 
______________________________________ 
Mean: 216.8 
Standard Deviation: 12.7 
Minimum: 198.2 
Maximum: 232.8 
Table III shows the results from tensile strength test ASTM D751 using 
standard glass fiber wool, cross machine direction. Out of five specimens, 
zero were excluded. 
TABLE III 
______________________________________ 
Specimen Number 
Load at Maximum Load (lbs.) 
______________________________________ 
1 259.0 
2 284.5 
3 321.6 
4 244.5 
5 248.2 
______________________________________ 
Mean: 271.6 
Standard Deviation: 32.1 
Minimum: 244.5 
Maximum: 321.6 
Flexure Strength 
The second test conducted on the inventive product was a three point 
flexure strength test. The machine parameters for all samples were as 
follows: 
______________________________________ 
Sample rate (Pts/sec): 
9.10 
Crosshead Speed (in/min): 
1.0 
Humidity (%) 50 
Temperature .degree.F. 
73 
______________________________________ 
The flexural strength means of each group is shown in FIG. 2. FIG. 2 shows 
the calculated flexure strengths of material tested in machine direction 
and cross machine direction in newtons. The standard samples were very 
anisotropic which can be seen by reviewing FIGS. 3 and 4. The IMP binder 
provides a more uniform material. This was an unexpected result and 
provides the manufacturer greater flexibility when designing new parts. 
The flexure strength was determined adequate but another unexpected 
benefit when installing the automotive hoodliners was noted. The hoodliner 
parts flexed instead of breaking during installation. 
EXAMPLE 2 
Using the binder composition of Example 1, additional testing was 
performed. Table IV shows a dramatic improvement in fall out weight when 
the inventive glass composition is tested using a simulated handling test. 
These samples were initially produced in blanket form then compressed and 
cured to flat sheets 0.25 inch in thickness. Then cut into 3.times.3 inch 
squares and mounted into a special jig which scrapes the edge of each 
sample identically to simulate human handling. Glass fiber and binder fall 
out was collected and weighed. All samples had identical weights and 
densities. The data shown in Table IV are averages collected from 9 test 
samples of the material. 
TABLE IV 
______________________________________ 
Sample Weight Of All Fall Out Micrograms 
______________________________________ 
IMP 0.309 
______________________________________ 
It is an object of the present invention to obtain glass fiber compositions 
in their fully cured state that have low odor associated with such cured 
glass fiber compositions. Many thermosetting binders have high 
formaldehyde emissions when cured at elevated temperatures. The 
formaldehyde in itself is an irritant and a potential toxic agent but does 
combine with other free radicals into compounds having distinct and 
unfavorable odor to people. An example of such a compound is 
trimethylamine. The present invention eliminates much of the thermosetting 
binder and replaces it with aqueous latex emulsions. The latex emulsions 
release very little free formaldehyde. Thus, much of the odor otherwise 
caused by the free formaldehyde is reduced or eliminated. 
Table V shows the decreased formaldehyde content of the present invention. 
The values shown in the chart are averages of micrograms formaldehyde per 
dry gram of resin which is equivalent to parts per million. 
TABLE V 
______________________________________ 
Micrograms Formaldehyde 
Resin Per Dry Dram Of Resin 
______________________________________ 
IMP 167 
______________________________________ 
EXAMPLE 3 
The glass fiber composition described below was sprayed at 5% by weight 
solids in water onto newly formed glass fibers. The composition of the 
glass fibers was generally commercially available glass fibers having the 
approximate composition as follows: 
______________________________________ 
Oxide % By Weight 
______________________________________ 
SiO.sub.2 63.8 
Al.sub.2 O.sub.3 
4.6 
B.sub.2 O.sub.3 
6.0 
Na.sub.2 O 16.2 
K.sub.2 O 1.0 
CaO 4.6 
MgO 3.2 
Trace amounts 0.6 
______________________________________ 
The glass fibers had a softening point of 1264.degree. F., a density of 
about 2.5 g/cc with a liquidus temperature of 1300.degree. F. (maximum). 
The coated glass fibers were cured at approximately 500.degree. F. The 
fiberglass product was then subjected to various tests. The glass fiber 
binder composition that was sprayed onto the glass fibers is the most 
preferred composition in Table I. 
Mass/Unit 
Mass/Unit area for glass fibers (ASTM D751). Tolerance of +/- 15% (76 gram 
material). 
Samples: (1) 35 mm.times.305 mm or 12".times.12" 
Test Equipment: AND Electronic Digital Balance Model Number EP-12KB 
Results: 85 grams--112% (including facing) 
Conclusion: Pass 
Tensile Strength 
Tensile Strength (ASTM D751, Grab Method glass fiber blanket only). Minimum 
of 22N, machine and against machine direction, when using a 25.times.75 mm 
jaw front and back. 
Sample: Specimen 100 mm (4") in width and not less than 150 mm (6") in 
length. 
Test Equipment: Instron model 1130 Universal Testing Instrument with 100 
lb. load cell. 
Results as follows: 
Longitudinal: 5 samples all 444 Newton+ 
Transverse: 4 samples 444 Newtons+ 1 sample 422 Newtons 
Bond Strength 
Automotive headliners require a knap knit nylon cloth to be added to the 
top surface of the headliner. For this reason, a bond adhesion test is 
done to test the glass to foam adhesion. 
Bond strength facing to glass fiber (ASTM D751, 305 mm/minute). 0.5N 
minimum 
Sample: Molded fiberglass samples, faced, cut 50 mm.times.250 mm. 
Test Equipment: Instron model 1130 Universal Testing Instrument with 100 
lb. load cell. 
Results: 2.2N to 6.5N 
Conclusion: Pass 
Internal Bond Strength 
Automotive headliners and hoodliners should not internally delaminate. 
Thus, an Internal Bond Strength test should be passed. Internal Bond 
Strength of glass fiber (GM9193P, 300 mm/min.) 3N minimum. 
Internal Bond Strength of glass fiber (GM9193P, 300 mm/min.) 3N minimum 
Samples: (5) molded fiberglass samples, faced front and back, cut 125 
mm.times.125 mm. 
Test Equipment: Chatillon Pull Tester #IN-25 
Results: 
53.3 Newtons 
82.0 Newtons 
62.2 Newtons 
53.3 Newtons 
84.5 Newtons 
Immersion 
Automotive headliners and hoodliners should pass an immersion test. 
The material shall be immersed for 2 hours in water at 95.degree. 
C.+/-5.degree. C. (no rapid boiling) without any evidence of binder 
breakdown. Slight color bleed in the water is acceptable and not cause for 
rejection. 
Sample: 30 mm.times.30 mm cured black fiberglass 
Test Equipment: Hot plate, thermometer in Centigrade, beaker, and water. 
Results: No binder breakdown, slight color bleed 
Conclusion: Pass 
Trimethylamine 
50 parts per million were detected. 
The testing technique utilized to determine the trimethylamine was as 
follows: 
The equipment that was utilized, as well as the reagents, are as follows: 
Wide mouth glass quart jars with screw cap (Mason Jar); 
Crimp seal sample vials (approximately 4.0 ml); 
Convection oven capable of maintaining 38.degree. C..+-.2.degree. C.; 
Gas Chromatograph with Flame Ionization Detector; 
Stock TMA solution, 1000 ppm--Weight 0.163 g of Trimethylamine 
Hydrochloride into a 100 ml volumetric flask and dilute to 100 ml with 
distilled water; 
2 normal sodium hydroxide; and 
Acetone, chromatography grade. 
The test procedure is as follows: 
Weight 10.00.+-.0.02 grams boiled distilled water into a glass quart jar 
containing a 6.5 centimeter tall sample support (open ended 100 milliliter 
plastic tricornered polypropylene beaker with corners clipped and out to 
6.5 centimeter height). Place an 8.9 centimeter diameter disk (cut from 
non-absorbing plastic open mesh sink matting) on top of the sample 
support. Evenly distribute 12.00.+-.0.10 grams of well mixed cubed 
insulation into jar above the sample support. Cubes should be 
approximately 1".times.1". Screw the lid over a piece of clear 
polyethylene film to seal each jar. Place jars in a convection oven set at 
38.degree. C..+-.2.degree. C. over 16 hours. Remove jars from oven and 
cool to room temperatures. 
The sample analysis is as follows: 
Add 1.71 ml of water from mason jar to a crimp seal sample vial. Add 0.09 
ml of 2 Normal NaOH containing 0.02% v/v Acetone and seal sample vial. Use 
injection volume of 2 microliters. Make calibration curve from 1, 4, 10, 
20, 80 ppm TMA solutions prepared from 1000 ppm solution. 
______________________________________ 
G-C Conditions 
______________________________________ 
1. Machine: HP-5890 with FID 
2. Column: Wide bore capillary column 
30 meter DB Wax 
J&W Scientific 
Folsom, CA 
1 micron film, 0.53 mm diameter 
3. Carrier Gas: 
11 ml/min Helium 
4. Program: Injector temp. 180.degree. C. 
Detector temp. 240.degree. C. 
35.degree. C. for 5 min. 
15.degree. C./min. to 180.degree. C. 
180.degree. C. for 10 min. 
______________________________________ 
With respect to results, report trimethylamine as micrograms of TMA in 
water based on sample weight (microgram/gram) of fiber glass. 
While the forms of the invention herein disclosed constitute presently 
preferred embodiments, many others are possible. It is not intended herein 
to mention all of the possible equivalent forms or ramifications of the 
invention. it is understood that terms used herein are merely descriptive 
rather than limiting, and that various changes may be made without 
departing from the spirit or scope of the invention. 
An example could be the use of a standard commercially available phenol 
formaldehyde resin in conjunction with a latex elastomer in the % by 
weight shown in Table I without additional resinous components in the 
binder composition.