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.

Abstract: A method of using a self-stick insulation. The method includes providing a piece of insulation product with an adhesive coating. The adhesive coating includes polystyrene-maleic anhydride (SMA) and/or polyacrylic acid (PAA); an alcohol amine; and at least one of a polyvinyl alcohol and a starch. The adhesive coating is then activated with liquid water. Once the adhesive coating is active, the insulation product is attached to a surface with the adhesive coating.

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.

Abstract: A roofing membrane includes a thermoplastic polyolefin (TPO) layer and a polyvinyl chloride (PVC) layer. The TPO layer forms a bottom layer of the roofing membrane, and the PVC layer is positioned atop the TPO layer so that the PVC layer forms a top layer of the roofing membrane. The TPO layer and the PVC layer are configured to be chemically compatible so that the TPO layer and the PVC layer are chemically bonded and function as a single roofing membrane. Compatibilizing includes at least one of (i) adding a compatibilizing agent to at least one of the TPO material and the PVC material prior to extrusion and (ii) positioning at least one compatibilizing film, prior to bonding, between the TPO material and the PVC material.

Abstract: Provided is a polymer blend composition comprising linear low density polyethylene, a polypropylene polymer, generally comprising a random polypropylene copolymer, and a compatibilizer. In one embodiment, there is provided a polymer blend composition comprising 15 to 35 wt % of a polypropylene polymer, 30-60 wt % of a linear low density polyethylene, and a compatibilizer polymer composition comprising 21-50 wt % of the polymer blend. The polymer blend is quite useful in a roofing membrane.

Abstract: A fibrous insulation product, such as a fibrous insulation blanket or board product, includes a plurality of fibers that are entangled together and a crosslinked aromatic polymeric binder that bonds the plurality of fibers together. The fibrous insulation product includes between 80 and 99 weight percent of the fibers and between 1% by weight and 20% by weight of the crosslinked aromatic binder. The fibrous insulation product has a density of between 0.4 and 6.0 pounds per cubic foot (pcf) and an R-value of between 4 and 50. The crosslinked aromatic polymeric binder has an aromaticity of greater than 10%.

Abstract: A method of using a self-stick insulation. The method includes providing a piece of insulation product with an adhesive coating. The adhesive coating includes polystyrene-maleic anhydride (SMA) and/or polyacrylic acid (PAA); an alcohol amine; and at least one of a polyvinyl alcohol and a starch. The adhesive coating is then activated with liquid water. Once the adhesive coating is active, the insulation product is attached to a surface with the adhesive coating.

Abstract: Provided is a roofing membrane composition comprising from 20 to 30 wt % of a thermoplastic polypropylene polymer, from 30 to 40 wt % of a linear low density polyethylene, and about 1 to 5 wt % of a compatibilizer polymer composition, which has been found to provide an economical roofing membrane which meets the elevated temperature requirements and mechanical properties now demanded in the industry.

Abstract: Provided is a roofing membrane composition comprising from 3 to 6 wt % of a thermoplastic polypropylene polymer, from 32 to 57 wt % of a linear low density polyethylene, and from 5 to 25 wt % of a performance modifier polymer. The roofing membrane composition has been found to provide an economical roofing membrane which meets the elevated temperature requirements now demanded in the industry. The roofing membrane composition further comprises a flame retardant, an ultraviolet stabilizer, and a pigment.

Abstract: Provided is a roofing membrane composition comprising metallocene-catalyzed alpha-olefin polyethylene and a random polypropylene copolymer. The polymer blend is quite useful in a roofing membrane which exhibits excellent performance. The excellent performance is particularly evident in the mechanical properties and thermal properties of the roofing membrane.

Abstract: A fibrous insulation product, such as a fibrous insulation blanket or board product, includes a plurality of fibers that are entangled together and a crosslinked aromatic polymeric binder that bonds the plurality of fibers together. The fibrous insulation product includes between 80 and 99 weight percent of the fibers and between 1% by weight and 20% by weight of the crosslinked aromatic binder. The fibrous insulation product has a density of between 0.4 and 6.0 pounds per cubic foot (pcf) and an R-value of between 4 and 50. The crosslinked aromatic polymeric binder has an aromaticity of greater than 10%.

Abstract: Dedusting oil compositions and binder compositions including such dedusting oil compositions for use with fiberglass insulation are provided. Dedusting oil compositions are formed from an epoxidized plant oil and a high activity amine. Binders may include a polycarboxylic acid based binder, a formaldehyde-based binder, or a formaldehyde-free binder and include a dedusting oil composition. Methods of making the binders and fiber-containing composites made with the binders are also provided.

Abstract: Dedusting oil compositions and binder compositions including such dedusting oil compositions for fiberglass are provided. Dedusting oil compositions are formed from a plant oil and a high activity aromatic amine. Binders may include polyacrylic acid polymers crosslinked with a polyol crosslinking agent and include a dedusting oil composition. Methods of making the binders and fiber-containing composites made with the binders are also provided.

Abstract: A polyisocyanurate foam insulation product is produced from an isocyanate component and a first component. The first component includes one or more polyester polyols, a fire retardant, and a multi-functional alcohol. The multi-functional alcohol is present in an amount of greater than 20 parts per 100 parts of polyester polyol The polyisocyanurate foam insulation product may have an R-value per inch of at least 6.5 when measured at 40° F. and may have an R-value per inch of at least 6.2 when measured at 25° F.

Abstract: A system for manufacturing a thermoplastic prepreg includes a double belt mechanism that is configured to compress a fiber mat, web, or mesh that is passed through the double belt mechanism, a resin applicator that is configured to apply monomers or oligomers to the fiber mat, web, or mesh, and a curing oven that is configured to effect polymerization of the monomers or oligomers and thereby form the thermoplastic polymer as the fiber mat, web, or mesh is moved through the curing oven. The double belt mechanism compresses the fiber mat, web, or mesh and the applied monomers or oligomers as the fiber mat, web, or mesh is passed through the curing oven so that the monomers or oligomers fully saturate the fiber mat, web, or mesh. Upon polymerization of the monomers or oligomers, the fiber mat, web, or mesh is fully impregnated with the thermoplastic polymer.

Abstract: A method of forming a binder composition includes providing a urea-formaldehyde resin and combining one or more starch compounds with the urea-formaldehyde resin to form a starch modified urea-formaldehyde resin. The one or more starch compounds may be combined with the urea-formaldehyde resin so that the starch modified urea-formaldehyde resin includes about 1 wt. % to about 10 wt. % of the one or more starch compounds.

Abstract: A lightweight polymer-based composite product may include a polymer material body and a lightweight filler material that is embedded in the polymer. The polymer material body may be an in-situ polymerized polymer formed via casting of a reactive resin in a mold. The polymer may have a density of at least 1.0 g/cm3. The lightweight filler material may be concentrated on at least a portion of a first surface of the polymer material body. The lightweight filler material may have a density of between 0.1 and 1.0 g/cm3. The lightweight polymer-based composite product may have a density that is less than a comparable product that consists mainly of the polymer.

Abstract: A method of forming a binder composition includes providing a urea-formaldehyde resin and combining one or more starch compounds with the urea-formaldehyde resin to form a starch modified urea-formaldehyde resin. The one or more starch compounds may be combined with the urea-formaldehyde resin so that the starch modified urea-formaldehyde resin includes about 1 wt. % to about 10 wt. % of the one or more starch compounds.

Abstract: Provided is a roofing membrane composition comprising metallocene-catalyzed alpha-olefin polyethylene and a random polypropylene copolymer. The polymer blend is quite useful in a roofing membrane which exhibits excellent performance. The excellent performance is particularly evident in the mechanical properties and thermal properties of the roofing membrane.

Abstract: A chopped roving thermoplastic composite sheet includes a web or mesh of chopped rovings and a thermoplastic resin that fully saturates the web or mesh of chopped rovings. The web or mesh of chopped rovings is not mechanically bonded and does not include a binder that bonds or adheres the chopped rovings together other than thermoplastic resin. As such, the thermoplastic resin and the web or mesh of chopped rovings are able to flow and conform to a mold or cavity when the chopped roving thermoplastic composite sheet is pressed within the mold or cavity and when the chopped roving thermoplastic composite sheet is heated to above the melting temperature of the thermoplastic resin.