Abstract: Aqueous binder compositions with reduced rates of salt precipitation are described. The compositions may include a carbohydrate and a sequestrant for sequestering one or more multivalent ions (e.g., Ca2+, Mg2+, Ba2+, Al3+, Fe2+, Fe3+, etc.). The sequestrant reduces a precipitation rate for the multivalent ions from the aqueous binder composition. Methods of reducing salt precipitation from a binder composition are also described. The methods may include the steps of providing an aqueous binder solution having one or more carbohydrates. They may also include adding a sequestrant for one or more multivalent ions to the aqueous binder solution. The sequestrant reduces a precipitation rate for the multivalent ions from the binder composition.

Abstract: Sizing compositions to size fibers or particles used in plastic composites are described. The compositions may include a solution with a polymerization compound selected from: (a) at least one non-isocyanate-containing polymerization initiator (PI) for initiating the polymerization of caprolactam monomers; or (b) at least one precursor for a non-isocyanate-containing PI for initiating the polymerization of caprolactam monomers. Methods of making the sizing the composition, as well as methods of making reinforced thermoplastic composites from sized fibers or particles, are also described.

Abstract: Provided are nonwoven polymeric fiber webs using an improved curable composition. Such curable composition comprises an aldehyde or ketone and an amine salt of an inorganic acid. The composition when applied to polymeric fibers is cured to form a water-insoluble polymer binder which exhibits good adhesion and thermodimensional stability.

Abstract: Compositions for binding organic or inorganic fibers is described. The compositions may include an aqueous solution having a pH of about 4.5 or more. The aqueous solution may include a polycarboxy polymer that is about 10%, by wt., to 100%, by wt., of a butenedioic acid or butenedioic anhydride; and a polyol. The compositions can maintain a pH of about 5 or more after being cured into a thermoset plastic with the fibers. Processes for preparing a binder composition for organic or inorganic fibers are also described. The processes may include providing an aqueous solution of polycarboxylic acid polymers, where the polymers comprise about 10%, by wt., to 100%, by wt., of a butenedioic acid or butenedioic anhydride; adding a polyol to the aqueous solution; and maintaining the pH of the aqueous solution at about 5 or more.

Abstract: Viscosity-modified carbohydrate binder compositions are described. The binder compositions may include a carbohydrate, a nitrogen-containing compound, and a thickening agent. The binder compositions may have a Brookfield viscosity of 7 to 50 centipoise at 20° C. The thickening agents may include modified celluloses such as hydroxyethyl cellulose (HEC) and carboxymethyl cellulose (CMC), and polysaccharides such as xanthan gum, guar gum, and starches.

Abstract: Soy protein and carbohydrate containing binder compositions are described. The binder compositions may include a carbohydrate, a nitrogen-containing compound, and a soy protein. The binder compositions may also optionally include thickening agents such as modified celluloses and polysaccharides.

Abstract: Provided are nonwoven polymeric fiber webs using an improved curable composition. Such curable composition comprises an aldehyde or ketone and an amine salt of an inorganic acid. The composition when applied to polymeric fibers is cured to form a water-insoluble polymer binder which exhibits good adhesion and thermodimensional stability.

Abstract: Provided are spunbond polyester mats using an improved curable composition. The curable composition comprises a reaction product of an amine and a reactant in the form of an amino-amide intermediate. To the amino-amide is added an aldehyde or ketone to form the curable binder composition. The composition when used as a binder in the mat is cured to form a water-insoluble binder which exhibits good adhesion and thermodimensional stability.

Abstract: One-part binder compositions are described that may include a protein and a crosslinking combination. The crosslinking combination may include at least a first crosslinking compound and a second crosslinking compound. The first and second crosslinking compounds are individually crosslinkable with each other and with the protein. Examples of the protein include soy protein. Fiber products and methods of making the fiber products are also described. The fiber products may include organic fibers, inorganic fibers, or both, in a cured thermoset binder based on solutions of the one-part binder compositions.

Abstract: Processes are described for binding a fibrous material. The processes may include applying to a surface of the fibrous material an aqueous binding composition to form a coated fibrous material. The binding composition may include: (a) a water-soluble polyamic acid, and (b) an organic crosslinking agent capable of undergoing a covalent crosslinking reaction with the water-soluble polyamic acid when heated. The water-soluble polyamic acid may be formed by the reaction of: a (i) a polycarboxylic acid or polyanhydride having a molecular weight of at least 150 g/mol, and (ii) ammonia or an amine compound. The processes may further include heating the coated fibrous material to crosslink the water-soluble polyamic acid with the organic crosslinking agent to form a cured binder. One or more adjoining fibers of the fibrous material may be bound to each other at cross over points by the cured binder.

Abstract: Provided are nonwoven polymeric fiber webs using an improved curable composition. Such curable composition comprises a reaction product of an amine and a reactant in the form of an amino-amide intermediate. To the amino-amide is added an aldehyde or ketone to form the curable binder composition. The composition when applied to the polymeric fibers is cured to form a water-insoluble polymer binder which exhibits good adhesion and thermo-dimensional stability.

Abstract: Provided are spunbond polyester mats using an improved curable composition. Such curable composition comprises the reaction product of an aldehyde or ketone and an amine salt of an inorganic acid. The composition when applied to spunbond polyester continuous filaments is cured to form a water-insoluble polymer binder which exhibits good adhesion and thermodimensional stability.

Abstract: Formaldehyde-free binder compositions are described that include an aldehyde or ketone, an organic anhydride, an alkanol amine, and a nitrogen-containing salt of an inorganic acid. The binder compositions may be applied to fibers, such as glass fibers, to make formaldehyde-free, fiber-reinforced composites. Methods of making fiber-reinforced composites are also described, where such methods may include mixing an alkanol amine with an organic anhydride to make a first mixture, and adding a reducing sugar to the first mixture to make a second mixture. A nitrogen-containing salt may be added to the second mixture to make a binder composition, which may be applied to fibers to form a binder-fiber amalgam. The amalgam may be heated to cure the binder composition and form the fiber-reinforced composite.

Abstract: Binder compositions are described that contain (1) a reducing sugar and (2) a reaction product of a urea compound and an aldehyde-containing compound. A specific example of the binder compositions include dextrose and an imidazolidine compound such as 4,5-dihydroxyimidazolidin-2-one. The binder compositions may be applied to collections of fibers and cured to form a fiber-containing composite, such as fiberglass insulation.

Abstract: Methods are described for activating a glass fiber or flake to participate in polymerizing a resin. The methods may include sizing the glass fiber or flake with a sizing composition that includes a solution containing a polymerization initiator, and activating the polymerization initiator by forming a free radical moiety on the polymerization initiator that can initiate the polymerization of the resin. Additional methods of making a glass reinforced composite are described. The methods may include sizing glass fibers or flakes with a sizing composition that includes a solution containing a polymerization initiator, forming a free radical moiety on the polymerization initiator to make activated glass fibers or flakes, and contacting the activated glass fibers or flakes with a polymer resin. The activated glass fibers or flakes initiate the polymerization of the resin around the glass fibers or flakes to form the glass reinforced composite.

Abstract: Prepreg compositions and methods of making them from particles and a binder composition are disclosed. The methods may include placing the particles on a moving conveying belt and applying the binder composition to the particles on the moving conveying belt to form a moving mass. Alternate methods may include first placing the binder composition on the moving conveying belt and then applying the particles to the binding composition to form the moving mass. The methods may further include passing the moving mass through one or more pairs of opposed, compacting rolls, where the particles and the binder composition are pressed into further contact while passing through the compacting rolls to form the prepreg. The binder composition in the prepreg may include monomers and/or oligomers of a polymer that are capable of polymerizing into the polymer under polymerization conditions.

Abstract: Methods of forming multi-component reinforced composites are described. The methods may include forming a particle-reinforced component and a polymer-containing component where the particle-reinforced component and the polymer-containing component are in contact with one another. The particle reinforced component may be formed by a process that includes providing reactive particles that have a reactive polymerization promoter chemically bonded or coated on the surface of the reactive particles and contacting the reactive particles with a resin solution that includes monomers of a polymer. The polymerization promoter chemically bonded or coated on the surface of the reactive particles may promote the polymerization of the monomers. The resin solution may subsequently be polymerized forming a polymer matrix around the reactive particles.

Abstract: Sizing compositions to size fibers or particles used in plastic composites are described. The compositions may include a solution with a polymerization compound selected from: (a) at least one non-isocyanate-containing polymerization initiator (PI) for initiating the polymerization of caprolactam monomers; or (b) at least one precursor for a non-isocyanate-containing PI for initiating the polymerization of caprolactam monomers. Methods of making the sizing the composition, as well as methods of making reinforced thermoplastic composites from sized fibers or particles, are also described.

Abstract: Formaldehyde-free binder compositions are described that include an aldehyde or ketone, a nitrogen-containing salt of an inorganic acid, and an acidic compound. The acidic compound may be an organic acid, such as maleic acid or citric acid among others. The acidic compound is supplied in quantities that lower the pH of the binder composition to about 5 or less. The binder compositions may be used in methods of binding fiberglass and the resulting fiberglass products have an improved tensile strength due to the addition of the acidic compound.

Abstract: Formaldehyde-free binder compositions are described that include an aldehyde or ketone, a reaction product between a polyamine and an organic anhydride, and an acidic compound. The acidic compound may be an organic acid, an acidic catalyst, or both. The acidic compound is supplied in quantities that lower the pH of the binder composition to about 5 or less. The binder compositions may be used in methods of binding fiberglass and the resulting fiberglass products have an improved tensile strength due to the addition of the acidic compound.