Georgia-Pacific Resins, Inc.

David J Bir

Kurt D Gabrielson

David A Hutchings

Rajan Hariharan

Kim K Tutin

Carl R White

Edward Lucas, Jr

Syed A Elahi

A phenol-formaldehyde resole resin is combined with an ammonia-based formaldehyde scavenger to produce a product useful, for example, as a binder used in the production of glass fiber insulation products. The starting resin may have a free formaldehyde content of 1.5 to 14 wt. %, based on a total weight of the resin, and the resin and scavenger may be combined at a molar ratio in the range of 0.1 to 5. The resulting binder may have a free formaldehyde content of 1 wt. % or less, based on a total weight of the reaction product. This binder may then be applied to a glass fiber base material in a conventional manner.

Ammonium hydroxide scavenged binder for low TMA fiberglass insulation products

Phenol aralkyistion polymers can be prepared by reaction among a phenolic monomer, at least one styrenic monomer and an aryl diolefin. A phenolic monomer can be initially aralkylated in the presence of an acid catalyst with a first portion of at least one styrenic monomer to obtain an aralkylated phenol. The aralkylated phenol thereafter can be reacted with an aryl diolefin to obtain a phenol aralkylation polymer. Optionally, (though preferably) the phenol aralkylation polymer is further aralkylated with a second portion of at least one styrenic monomer. By employing specific catalyst concentrations, reactant concentrations, reaction temperatures, and reaction times, the formation of mono-functional and non-functional by-products is substantially reduced.

Process for reducing mono-functional and non-functional by-products during aralkylation of phenolics

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Conyers, GA, United States of America

David J Bir