Patent Abstract:
A molding process includes the operation of placing insulation material comprising fibers and binder on the fibers in a mold cavity. The molding process further includes the operation of transferring heat to the insulation material to cause the binder to cure.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 61/779,732, filed Mar. 13, 2013, the disclosure of which is hereby incorporated herein by reference. 
       BACKGROUND 
       [0002]    The present disclosure relates to a process for making an insulation product, and particularly to a molding process. More particularly, the present disclosure relates to a molding process for making an insulation product where binder included in the insulation product is cured during the molding process. 
       SUMMARY 
       [0003]    A molding process for molding a cured product may include several operations. One of the operations may be providing an uncured blank including fibers and uncured binder. The molding process may include inserting the uncured blank in a mold cavity and closing the mold. The molding process may further include applying heat and pressure to the uncured blank to cause the uncured blank to adopt and retain a shape of the mold cavity. 
         [0004]    In some embodiments, the operation of applying heat and pressure to the uncured blank may be only sufficient to cure a portion of the binder included in the uncured part. As a result, the uncured blank may retain a molded shape after the removal from the mold and a shaped product may be established. The molding process may further include the operations of opening the mold to release the shaped product. 
         [0005]    In some embodiments, the molding process may further include the operation of inserting the shaped product in a heater. The molding process may further include the operation of transferring a curing heat to the shaped product to cause the remainder of the uncured binder to cure. As a result, the cured product may be established. 
         [0006]    In some embodiments, the uncured binder may be a phenol-formaldehyde binder. In some embodiments, the uncured binder may be a substantially formaldehyde free binder. 
         [0007]    In some embodiments, during the transferring the shaping heat operation, the shaping heat may be applied by the mold. During the transferring the curing heat operation, the curing heat may be applied by a heating unit in spaced-apart relation to the mold. 
         [0008]    In some embodiments, the uncured part may be exposed to a temperature of about 200 degrees Fahrenheit to about 500 degrees Fahrenheit. The transferring the shaping heat operation may occur during a first cycle time. The transferring the curing heat operation may occur during a second cycle time. The second cycle time may be larger than the first cycle time. 
         [0009]    A molding process may comprise several operations. The molding process may include the operation of providing an uncured blank including fibers and uncured binder. 
         [0010]    In some embodiments, the molding process may further include the operation of molding the uncured blank to establish a shaped product having a molded shape that does not change after removal from a mold cavity. The shaped product may include the fibers, a first portion of cured binder, and a remainder of the uncured binder. 
         [0011]    In some embodiments, the uncured binder may be a phenol-formaldehyde binder. The uncured binder may be a substantially formaldehyde free binder. 
         [0012]    Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived. 
     
    
     
       BRIEF DESCRIPTIONS OF THE DRAWINGS 
         [0013]    The detailed description particularly refers to the accompanying figures in which: 
           [0014]      FIG. 1  is a diagrammatic and perspective view of a first embodiment of a molding process in accordance with the present disclosure showing that the molding process includes the operations of inserting an uncured blank into a mold cavity, shaping and applying heat to the uncured blank, removing a shaped product from the mold cavity, applying heat to the shaped product to establish a cured product, cutting the cured product from a carrier sheet, and storing the cured product; 
           [0015]      FIG. 2  is a diagrammatic view of the molding process of  FIG. 1  showing that the molding process includes the operations of inserting the uncured blank, closing the mold, applying a shaping heat, establishing the shaped product, opening the mold, removing the shaped product, inserting the shaped product into a heating unit, applying a curing heat from the heating unit, establishing the cured product, removing the cured product, optionally cutting the carrier sheet, and storing the cured product; 
           [0016]      FIG. 3  is a diagrammatic and perspective view of another embodiment of a molding process in accordance with the present disclosure showing that the molding process includes the operations of inserting an uncured blank into a mold cavity, shaping and applying heat to the uncured blank, removing a shaped product from the mold cavity, optionally cutting the carrier sheet to free the shaped product, accumulating the shaped products to establish a shaped-products batch, applying heat to the shaped product to establish a cured-products batch, and storing the cured-products batch; and 
           [0017]      FIG. 4  is a diagrammatic view of the molding process of  FIG. 3  showing that the molding process includes the operations of inserting the uncured blank, closing the mold, applying a shaping heat, establishing the shaped product, opening the mold, removing the shaped product, optionally cutting the carrier sheet, accumulating the shaped products, inserting the shaped-products batch, applying a curing heat, establishing the cured-products batch, removing the cured-products batch, and storing the cured-products batch. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    A first embodiment of a molding process  10  is shown, for example, in  FIGS. 1 and 2 . The molding processes  10  and  110  are used to establish a cured product  12  while minimizing a cycle time of a molding machine  14 . The cycle time is minimized by first establishing a shaped product  16  and second curing the shaped product  16  to establish the cured product  12 . The shaped product  16  includes fibers, a cured-binder portion  16 C along an outer surface  16 S of the shaped product  16 , and an uncured-binder portion  16 U in an interior region  161  defined by the outer surface  16 S of the shaped product  16 . The cured product  12  is established when the uncured-binder portion  16 U of the shaped product is transformed into cured binder so that only cured binder exists in the cured product  12 . The molding process  10 , as shown in  FIG. 1 , is an illustrative example of a continuous process. The molding process  110 , as shown in  FIG. 3 , is an illustrative example of a batch process. 
         [0019]    The molding process  10  includes a series of operations as shown in  FIGS. 1 and 2 . The molding process  10  includes an operation  20  in which an uncured blank  22  is inserted into the molding machine  14  as shown in  FIG. 1 . The uncured blank  22  is carried by a carrier sheet  24  into the molding machine  14  as part of a continuous process. In the example shown in  FIG. 1 , the uncured blank  22  includes an outer trim layer  22 A, a first blanket  22 B, and a second blanket  22 C. Each blanket  22 B,  22 C is made of a substrate and an uncured binder. In one example, the substrate is a fiber. For example, the fiber is glass, cellulose, or mineral wool. In still yet another example, the substrate may be a laminate or a veneer. For example, the laminate or veneer is a wood chip or wood particle. In addition, the uncured blank may have any number of blankets and trim layers. In addition, the uncured blank may include a thermoplastic layer, also called an interleaf, located between each neighboring pair of blankets to interconnect the neighboring pairs of blankets. The interleaf may be located between the trim layer and the blanket. 
         [0020]    The molding process  10  then proceeds to an operation  26  in which a mold system  28  included in the molding machine  14  is moved from an opened position shown in  FIG. 1  to a closed position. The mold system  28  includes, for example, a first mold tool  28 A and a second mold tool  28 B. In the illustrative example, the first mold tool  28 A is a female mold tool and the second mold tool  28 B is a male mold tool. The uncured blank  22  is trapped in a mold cavity formed in the mold system  28  when the mold system  28  is in the closed position. 
         [0021]    However, it is within the scope of the present disclosure for the mold system to include a first platen and a second platen for forming relatively flat panels from the uncured blank  22 . It is further within the scope of the present disclosure for the mold system to include a first mold tool, a first platen, a second mold tool, and a second platen. 
         [0022]    The molding process  10  then proceeds to an operation  30  in which heat and pressure are applied to the uncured blank  22  as shown in  FIG. 2 . While the mold system  28  is in the closed position, heat and pressure are applied to the uncured blank  22  to cause a shape of the mold cavity to be taken on by the uncured blank  22 . In addition, the heat applied by the mold system  28  causes a first portion of the binder included in the uncured blank  22  to be cured. In another example, hot gas may be directed through the mold cavity while the uncured product is located in the mold cavity. As a result, cycle time of the molding machine may be further minimized due to increased convective heat transfer from the hot gas to the uncured product. 
         [0023]    This type of molding operation may be called shape molding. Shape molding is a process by which the uncured blank is intentionally only partly cured. The degree of cure is generally chosen to ensure that the uncured blank retains its shape from the molding system  10  and satisfies all dimensional requirements when the shaped product is removed from a mold cavity formed in the molding machine  14 . Some portions of a shaped product, typically portions in the core, are not fully cured. The shape-molded product is subjected to a subsequent secondary curing process to ensure full cure as described below in an operation  44 . 
         [0024]    Once the first portion of binder is cured, the molding process  10  proceeds to an operation  32  in which a molded shape is retained and the shaped product  16  is established. The shaped product  16  includes fibers, the first cured portion of binder, and a second uncured portion located in an interior region of the shaped product  16 . The molding machine  14  has a cycle time which is measured from the closure of the mold system  28  to the opening of the mold system  28 . In one example, the cycle time is between about 30 seconds and about 10 minutes. However, cycle time is dependent on part thickness, binder type used, and density of the uncured blank  22 . 
         [0025]    As an example, the first portion of cured binder is located along a surface of the shaped product  16  that interfaces and engages an inner surface of the mold system  28 . The first portion of cured binder is sufficient to retain the molded shape of the shaped product  16  once the shaped product  16  is removed from the mold system  28 . 
         [0026]    The molding process  10  then proceeds to an operation  34  in which the mold system  28  is moved from the closed position to the opened position. As a result, the shaped product  16  is freed for removal as suggested in  FIG. 2 . 
         [0027]    The molding process  10  then proceeds to an operation  36  in which the shaped product  16  is removed from the mold system  28  as shown in  FIGS. 1 and 2 . As shown, for example, in  FIG. 1 , the shaped product  16  is still coupled to the carrier sheet  24 . However, it is within the scope of the present disclosure for the molding machine  14  to also separate the shaped product  16  from the carrier sheet  24  as part of the operation  30 . 
         [0028]    The molding process  10  then proceeds to an operation  38  in which the shaped product  16  is inserted into a heating unit  40  as shown in  FIG. 1 . The heating unit  40  is, for example, a heat tunnel using infrared lamps to provide a curing heat  42  that is applied to the shaped product  16 . The curing heat  42 , for example, causes an air temperature in the heat tunnel to be about 200 degrees Fahrenheit to about 500 degrees Fahrenheit. These temperatures may be similar to or equal to temperatures achieved during the operation  30 . 
         [0029]    Once the shaped product  16  is in the heating unit  40 , curing heat  42  is applied to the shaped product  16  in an operation  44  as shown in  FIGS. 1 and 2 . Curing heat  42  is applied to the shaped product  16  to cause the second portion of uncured binder to cure. As a result, substantially all binder in the shaped product  16  is now cured. The heating unit  40  also includes a cycle time measured from when one part enters the heating unit  40  to when a different part exits the heating unit  40 . As a result, the cycle time of the heating unit is substantially the same as the molding machine  14 . However, the amount of time any given shaped product  16  remains in the heating unit  40  may vary and be a multiple of the cycle time of the molding machine  14 . 
         [0030]    The molding process  10  proceeds to an operation  46  in which all the second portion of binder has cured in the shaped product  16  so that all the binder has been cured. As a result, the cured product  12  is established in the operation  46  as shown in  FIGS. 1 and 2 . 
         [0031]    The molding process  10  then proceeds to an operation  48  in which the cured product  12  is removed from the heating unit  40  as shown in  FIGS. 1 and 2 . The cured product  12  is, for example, still carried by the carrier sheet  24 . However, substantially all the binder has now been cured. 
         [0032]    The molding process  10  then proceeds to an optional operation  50  in which the cured product  12  is separated from the carrier sheet  24 . As discussed previously, the shaped product  16  may have been separated from the carrier sheet in the operation  30 . However, the shaped product  16  may have remained coupled to the carrier sheet  24  to simplify transportation of the carrier sheet  24  and shaped product  16  through subsequent operations. As a result, the molding process  10  may separate the cured product  12  from the carrier sheet  24  in the operation  50 . As an example, the operation  50  uses a cutter  52 , which in the illustrative example is a water cutter, cuts the carrier sheet  24  to free the cured product  12  as shown in  FIG. 1 . However, the cutter  52  may be another suitable alternative. 
         [0033]    The molding process  10  then proceeds to an operation  54  as shown in  FIGS. 1 and 2 . The operation  54  causes the cured product  12  to be stored for transportation or storage. 
         [0034]    The molding process  110  includes a series of operations as shown in  FIGS. 2 and 3 . The molding process  110  includes an operation  120  in which an uncured blank  122  is removed from an uncured-blank stack  166  and inserted into the molding machine  114  as shown in  FIG. 3 . The uncured blank  122  is carried by a carrier sheet  124  into the molding machine  114  as part of a batch process. In the example shown in  FIG. 3 , the uncured blank  122  includes a series of layers that include, for example, an outer trim layer  122 A and a blanket  122 B. However, it is within the scope of the present disclosure for uncured blank  122  to have any number of blankets, trim layers, or polymeric binding layers. The blanket  122 B is made of fibers and uncured binder. 
         [0035]    The molding process  110  then proceeds to an operation  126  in which a mold system  128  included in the molding machine  114  is moved from and opened position shown in  FIG. 3  to a closed position. The mold system  128  includes, for example, a first mold tool  128 A and a second mold tool  128 B. The uncured blank  122  is trapped in a mold cavity formed in the mold system  128  when the mold system  128  is in the closed position. 
         [0036]    The molding process  110  then proceeds to an operation  130  in which heat and pressure are applied to the uncured blank  122  as shown in  FIG. 4 . While the mold system  128  is in the closed position, heat and pressure are applied to the uncured blank  122  to cause a shape of the mold cavity to be taken on by the uncured blank  122 . In addition, the heat applied by the mold system  128  causes a first portion of the binder included in the uncured blank  122  to be cured. 
         [0037]    Once the first portion of binder is cured, the molding process  110  proceeds to an operation  132  in which a molded shape is retained and the shaped product  16  is established. The shaped product  116  includes fibers, the first cured portion of binder, and a second uncured portion located an interior region of the shaped product  116 . The molding machine  114  has a cycle time that is measured from the closure of the mold system  128  to the opening of the mold system  128 . In one example, the cycle time is between about 30 seconds and about 10 minutes. However, cycle time is dependent on part thickness, binder type used, and density of the uncured blank  122 . 
         [0038]    As an example, the first portion of cured binder is located along a surface of the shaped product  116  that interfaces and engages an inner surface of the mold system  128 . The first portion of cured binder is sufficient to retain the molded shape of the shaped product  16  once the shaped product  16  is removed from the mold system  128 . 
         [0039]    The molding process  110  then proceeds to an operation  134  in which the mold system  128  is moved from the closed position to the opened position. As a result, the shaped product  116  is freed for removal as suggested in  FIG. 4 . 
         [0040]    The molding process  110  then proceeds to an operation  136  in which the shaped product  116  is removed from the mold system  28  as shown in  FIGS. 3 and 4 . As shown, for example, in  FIG. 3 , the shaped product  116  is still coupled to the carrier sheet  124 . However, it is within the scope of the present disclosure for the molding machine  114  to also separate the shaped product  116  from the carrier sheet  124  as part of the operation  130 . 
         [0041]    The molding process  10  then proceeds to an optional operation  150  in which the shaped product  116  is separated from the carrier sheet  124 . As discussed previously, the shaped product  116  may have been separated from the carrier sheet in the operation  130 . However, the shaped product  116  may have remained coupled to the carrier sheet  124  to simplify transportation of the carrier sheet  124  and shaped product  116  through subsequent operations. As a result, the molding process  110  may separate the shaped product  116  from the carrier sheet  124  in the operation  150 . As an example, the operation  150  uses a cutter  152 , which in the illustrative example is a water cutter, cuts the carrier sheet  124  to free the shaped product  116  as shown in  FIG. 3 . However, the cutter  52  may be another suitable alternative. 
         [0042]    The molding process  110  then proceeds to an operation  156  in which the shaped products  116  are accumulated to establish a shaped-products batch  158  as shown in  FIGS. 3 and 4 . The shaped-products batch  156  may be several shaped products  116  stacked on one another and located in a bin. However, the shaped-products batch  156  may be several shaped products  116  located on trays in a rack spaced apart from one another to facilitate movement of air and relatively faster curing. 
         [0043]    Once the shaped-products batch  156  is established, the molding process  110  proceeds to an operation  160  in which the shaped-products batch  156  is inserted into an oven  162  for batch curing of the shaped products  116  as shown in  FIG. 3 . As an example, the oven  162  is configured to apply the curing heat to the shaped products  116  to cause the second portion of uncured binder to cure. The oven  162  may apply the curing heat using infrared heaters, an open flame to heat the air in the oven, or any other suitable alternative. The curing heat  42 , for example, causes an air temperature in the heat tunnel to be about 200 degrees Fahrenheit to about 500 degrees Fahrenheit. These temperatures may be similar to or equal to temperatures achieved during the operation  130 . 
         [0044]    Once the shaped-products batch  158  is in the oven  162 , curing heat is applied to the shaped-products batch  158  in an operation  144  as shown in  FIGS. 3 and 4 . Curing heat is applied to the shaped-products  158  to cause the second portion of uncured binder to cure. As a result, substantially all binder in each shaped product  116  is now cured. The oven also includes a cycle time measured from when the shaped-products batch  158  enters the oven  162  to when the shaped-products batch  158  exits the oven  162 . As a result, the cycle time of the heating unit may be substantially different due to the number of shaped products  116  included in the shaped-products batch  158 . 
         [0045]    The molding process  110  proceeds to an operation  146  in which all the second portion of the binder has been cured to cause all the binder to be cured. As a result, a cured-products batch  164  is established in the operation  146  as shown in  FIGS. 3 and 4 . 
         [0046]    The molding process  110  then proceeds to an operation  148  in which the cured-products batch  164  of cured products  112  are removed from the oven  162  as shown in  FIGS. 3 and 4 . 
         [0047]    The molding process  110  then proceeds to an operation  154  as shown in  FIGS. 3 and 4 . The operation  154  causes the cured products  112  to be stored for transportation or storage. 
         [0048]    The molding processes  10 ,  110  fully cure the thermosetting binder of partly mold-pressed parts (shaped products). In the first operation of the process, a part, also called a blanket, (i.e. a collection of fiberglass) impregnated with a thermosetting binder is shape-molded using a heated mold press. The shaped product includes portions of the thermosetting binder that are cured and uncured while the molded shape is retained. This is referred as shape molding and is a molding process that provides a molded part having sufficient integrity to keep its intended shape. 
         [0049]    As an example, the thermosetting binder, after shape-molding, is not fully cured. In particular, the binder in a core of the shaped product is not fully cured. The shape-molded part is subsequently subjected to a secondary curing operation to fully cure the part. This secondary curing can be arranged to be in-line with the mold press in such a fashion that the shape-molded part directly is subjected to the secondary curing operation without any or significant heat loss. 
         [0050]    The heat for the secondary curing may be provided by radiant heaters (i.e. IR heaters) arranged on top and or below the part when exiting the mold press or oven zones adjacent or attached to the mold press. The shape molded parts pass through the heating zones, supported by a conveying system, and are fully cured when exiting the secondary heating zones. The fully cured parts are then finished (i.e. die-cut, water jet cut, etc.) and packaged. 
         [0051]    In another example, the shape molded parts can be fully cured in a batch process. In a batch process, the shape molded parts are collected after molding. A collection of shape molded parts are then placed into an oven for a predetermined time sufficient to fully cure the parts. The fully cured parts are then taken out of the oven. The batch process is flexible and allows the confection of the finished parts (i.e. cutting out of the desired shape) before or after the secondary curing operation. Other sources of heat for the secondary curing operation may be radiant heating, convection heating, microwave heating, a combination of sources, or any other suitable alternative heat or energy sources. 
         [0052]    The molding processes  10 ,  110  provide several surprising findings. Some parts with various thicknesses ranging from highly compressed, thin areas to low density, thick, high loft areas (i.e. automotive hood liners) are difficult to cure while in the molding machine  14 . This is applicable to parts impregnated with thermosetting binders that require elevated cure temperatures and high cure energies. These parts sometimes use double or triple typical cycle times to cure the part when compared to a phenol-formaldehyde (PF) binder. It was found surprisingly that shape molding followed by secondary curing operation is possible, and that those parts will keep their designed shape despite the core in high loft areas not being fully cured. 
         [0053]    The molding processes  10 ,  110  also provide a process that improves the cycle time of the molding machine regardless of the nature of the binder chemistry and temperature sensitivity of components molded in the molding machine. Cycle times of molding machines are typically adjusted through increasing or decreasing temperatures during molding. However, minimizing cycle time through increasing temperatures is limited by the nature of the binder and components of the molded parts so that decomposition or damage to the molded parts is minimized. 
         [0054]    In addition, the molding processes  10 ,  110  may be used with existing molding equipment. As a result, molding machine cycle times may be improved without obtaining new molding equipment thus minimizing capital costs. 
         [0055]    Shape molding followed by secondary curing increases robustness. In particular, the molding processes  10 ,  110  can achieve fully cured products with high reliability despite product quality variations (density, moisture distribution and content, wet spots of the uncured blanks.) 
         [0056]    The molding processes  10 ,  110  provide consistently fully cured parts regardless of product quality variations in the uncured blank. The uncured blank may be sold by a supplier to the manufacturer operating the molding processes  10 ,  110  as Shipout Uncured (SOUC). Variations in quality include density, density distribution, moisture, moisture distribution, binder concentration, and binder concentration distribution. These variations impact cure cycle time in a molding process that does not include a post-cure operation. In this example, cure cycle time is the minimum time needed to fully cure the binder within the entire molded part. 
         [0057]    The molding processes  10 ,  110  may be used with various binder types. In one example, the binder is a Phenol-Formaldehyde (PF) thermosetting binder. PF binder cures relatively quickly at relatively low temperatures and requires relatively less heat energy to cure. However, PF binder is associated with various emission and toxicity concerns. In another example, the binder may be a formaldehyde-free binder. Formaldehyde-free binders may require relatively greater heat energy to cure the binder. As a result, molding-machine cycle times may be relatively large to completely cure an uncured blank using a formaldehyde-free binder. 
         [0058]    Examples of formaldehyde-free binders are described in U.S. Pat. Nos. 7,854,980 B2, 5,977,232, 7,803,879, 6,699,945, 5,318,990, 6,194,512, PCT publication PCT/US2006/028929, U.S. application Ser. Nos. 11/675413, 12/599858, WO2011/138459 A1, WO2011/138458 A1, WO2011/123593 A1, WO2012/152731 A1 and WO2011/022668, EP1732968, Patent Applications EP2386394 and EP2199332A1, Patent Applications US2009/0275699, and 2007/0292619 (each of which is incorporated by reference herein). 
         [0059]    The uncured binder may comprises a carbohydrate reactant and/or a nitrogen-containing reactant. The nitrogen-containing reactant and the carbohydrate reactant may be Maillard reactants that react during curing to form Maillard reaction products, notably a melanoidin product. Curing of the binder may comprise or consists essentially of a Maillard reaction. The cured binder may comprises a melanoidin-containing and/or nitrogenous-containing polymer binder; this may be substantially water insoluble and/or substantially formaldehyde free. 
         [0060]    The carbohydrate reactant may comprise: a monosaccharide, a disaccharide, a polysaccharide, a reducing sugar, molasses, starch, starch hydrolysate, cellulose hydrolysates, reaction product(s) thereof or mixtures thereof. While non-reducing sugars, for instance sucrose, may not be preferable, they may none-the-less be useful by  in - situ  conversion to a reducing sugar. The carbohydrate reactant may comprise a monosaccharide in its aldose or ketose form; it may comprise a triose, a tetrose, a pentose, xylose, a hexose, dextrose, fructose, a heptose, a polysaccharide, or combinations thereof. The carbohydrate reactant may comprise high fructose corn syrup or invert sugar. The carbohydrate reactant may have a dextrose equivalent of at least about 50, at least about 60, at least about 70, at least about 80 or at least about 90. 
         [0061]    The nitrogen-containing reactant may comprise NH3, inorganic amine(s), organic amine(s) comprising at least one primary amine group, salts thereof and combinations thereof. For example, the nitrogen-containing reactant may comprise NH3 (e.g. in the form of an aqueous solution), any type of inorganic and organic ammonium salts, ammonium sulfate, ammonium phosphate, ammonium chloride, ammonium nitrate and combinations thereof. The nitrogen-containing reactant may comprise a polyamine; it may comprise a primary polyamine. Herein, the term “polyamine” includes any organic compound having two or more amine groups, which may independently be substituted. As used herein, a “primary polyamine” is an organic compound having two or more primary amine groups (—NH2). Within the scope of the term primary polyamine are those compounds which can be modified  in situ  or isomerize to generate a compound having two or more primary amine groups (—NH2). The primary polyamine may be a diamine, for example a di-primary diamine, triamine, tetraamine, or pentamine. The polyamine may comprise a diamine selected from 1,2-diaminoethane, 1,4-diaminobutane, 1,5-diaminopentane, 1,6-diaminohexane (hexamethylenediamine, HMDA), 1,12-diaminododecane, 1,4-diaminocyclohexane, 1,4-diaminobenzene, 1,5-diamino-2-methylpentane (2-methyl-pentamethylenediamine), 1,3-pentanediamine, and 1,8-diaminooctane. The nitrogen-containing reactant may comprise a primary polyamine polyether-polyamine; said polyether-polyamine may be a diamine or a triamine In one embodiment, the polyether-polyamine is a trifunctional primary amine having an average molecular weight of 440 known as Jeffamine T-403 Polyetheramine (Huntsman Corporation). EDR-104 and EDR-148 (Huntsman) may also be used. The nitrogen-containing reactant may comprise a polymeric polyamine, for example chitosan, polylysine, polyethylenimine, poly(N-vinyl-N-methyl amine), polyaminostyrene, polyvinylamines, a polyvinyl amine (which may be a homopolymer or a copolymer). 
         [0062]    The binder may comprising a silicon-containing compound, notably selected from the group consisting of gamma-aminopropyl-triethoxysilane, gamma-glycidoxypropyltrimethoxysilane, aminoethylaminopropyl-trimethoxysilane, an aminofunctional oligomeric silane, and mixtures thereof. 
         [0063]    The binder may comprising a non-aqueous moisturizer, for example a polyoxyalkylene glycol or a polypropylene glycol. 
         [0064]    The binders may include ester and/or polyester compounds, for example in combination with a vegetable oil, such as soybean oil. 
         [0065]    The carbohydrate reactant, may make up: at least 30%, preferably at least 40%, preferably at least 50%, more preferably at least 60%, more preferably at least 70%, even more preferably at least 80% by dry weight of the uncured binder; and/or less than 99%, preferably less than 97%, more preferably less than 95% by dry weight of the uncured binder. 
         [0066]    The nitrogen-containing component, may make up less than 70%, preferably less than 50%, more preferably less than 30%, even more preferably less than 20% by dry weight of the uncured binder; and/or at least 2.5%, preferably at least 5%, more preferably at least 10% by dry weight of the uncured binder. 
         [0067]    The molding processes  10 ,  110  also minimize the presence of acidic byproducts of uncured or partly cured products. SOUC parts based on polyester and polyamide chemistries (i.e. polyacrylic acid or styrene-maleic-anhydride based binders) may have an acidic to neutral pH which will become neutral to alkaline upon full cure. The corrosivity of the uncured or partly cured binder decreases with fully curing the binder. As a result, the pH of the binder increases. As a result, the molding processes  10 ,  110  minimize the corrosiveness of parts including binders based on polyester and polyamide chemistries. 
         [0068]    A cured product in accordance with the present disclosure may be used for sound absorption or a thermal shield. Sound absorption may be desired in flat architectural applications (i.e. wall system for office spaces and theaters) and contoured parts in automotive applications (i.e. hood liners). Some molded parts are used in Original Equipment Manufacturers (OEM) equipment for sound absorption (HVAC equipment, clothes washers, clothes dryers, dishwashers, etc.). 
         [0069]    A cured product may have a width of about one inch to about six feet. A cured product may have a length of about of about two inches to about twelve feet. The cured product may have a thickness of about ⅛ of an inch to about two inches in one example. In another example, the cured product may have a thickness less than ⅛ of an inch and greater than two inches. The cured product may have a density of about one pound per cubic foot to about 50 pounds per cubic foot. In addition, the density and dimensions of the cured product may vary throughout the cured product. 
         [0000]    
       
         
               
             
               
               
             
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Comparison of cycle times to full cure of an uncured product 
               
               
                 for two different binders types with and without convection heating in the mold cavity 
               
             
          
           
               
                   
                 Cycle time (min) 
               
             
          
           
               
                   
                   
                   
                 Shape 
                   
                   
               
               
                   
                   
                 Shape 
                 Molding 
                 Full Cure 
                 Full Cure 
               
               
                   
                   
                 Molding No 
                 with 
                 No 
                 with 
               
               
                   
                   
                 Convection 
                 Convection 
                 Convection 
                 Convection 
               
               
                 Sample 
                   
                 Heating 
                 Heating 
                 Heating 
                 Heating 
               
               
                   
               
             
          
           
               
                 1 
                 Formaldehyde-Free 
                 5.50 
                 1.00 
                 7.10 
                 2.00 
               
               
                   
                 Binder, 4 lb/cubic foot 
               
               
                   
                 density, 15% LOI, 1 inch 
               
               
                   
                 Loft, 380 degrees 
               
               
                   
                 Fahrenheit 
               
               
                 2 
                 PF Binder, 4 lb/cubic foot 
                 3.00 
                 1.00 
                 &gt;3.00 
                 1.50 
               
               
                   
                 density, 15% LOI, 1 inch 
               
               
                   
                 Loft, 380 degrees 
               
               
                   
                 Fahrenheit

Technology Classification (CPC): 3