Abstract: Using urea extended phenolic binders with a resin to urea solids ratio below 60/40 can significantly reduce production costs in the manufacture of fiber glass products without adversely affecting product performance or producing formaldehyde or ammonia emissions at unacceptable levels. The phenolic binders are produced by reacting urea with phenolic resins that are prepared in a reaction in which the formaldehyde and phenol are initially present in mole ratios of greater than 3.75:1. In preparing the phenol/formaldehyde based binder, the molar ratio of free formaldehyde to urea must be carefully controlled in order to minimize emissions of ammonia and formaldehyde. Typically this molar ratio is kept between 0.8 and 1.0, therefore, higher free formaldehyde resins may be reacted with a higher percentage of urea to maintain the target formaldehyde to urea molar ratio. No ammonia is needed in the making the phenolic binder.

Abstract: A process for preparing binder-coated fiber-glass products employs as a binder aqueous polymer systems comprising a nitrogenous formaldehyde resin such as a urea-extended alkaline phenol/formaldehyde resole together with an acidic polyacrylate which cocure to form a thermoset polymer while synergistically reducing ammonia emissions which normally occur during cure of the nitrogenous formaldehyde resin. The polymer system may be used in applications other than fiberglass where reduced emissions are desired.

Abstract: The present invention relates to a glass fiber binding composition comprising an effective binding amount of an aqueous soluble furan resin, 15 to 99 percent by weight water, and an effective amount of a catalyst for curing the furan resin. The invention further pertains to a process of binding glass fibers at junctions of the fibers comprising the steps of providing newly formed glass fibers, applying an effect binding amount of an aqueous soluble furan resin to the junctions of the glass fibers, and curing the resin at the junctions of the glass fibers. Finally, the invention also discloses a glass fiber composition comprising a plurality of glass fibers having a plurality of junctions where two or more fibers meet, and an effective binding amount of an aqueous soluble furan resin comprising 15 to 99% water applied to the junctions of the glass fibers.

Abstract: Fiberglass binder solutions based on phenol/formaldehyde resins emit lower formaldehyde emissions when a water soluble bisulfite formaldehyde scavenger is added to the binder prior to spraying onto fiberglass. Sodium bisulfite and ammonium bisulfite in amounts of from 4 to 6 percent based on binder solids can reduce formaldehyde emissions by c.a. 50 percent. The fiberglass products prepared from the binders exhibit no significant loss of physical properties as compared to conventional binders.

Abstract: The present invention relates to furan resins having low levels of VOCs. The claimed furan resins are the reaction product of a source of ammonia and a first reaction product, said first reaction product being derived from the reaction between a source of reactable formaldehyde, a formaldehyde scavenger, and an acidic furan resin resulting from the polymerization reaction wherein at least one reagent is selected from the group consisting of the furan containing molecule having the general formula ##STR1## and its saturated analogs thereof having zero to one carbon-carbon double bonnets, wherein X and Y are independently comprised of organic molecular groups.

Abstract: Emissions of formaldehyde and ammonia from urea-extended alkaline phenol/formaldehyde resole fiberglass binders are sharply reduced by using as a catalyst an emission-reducing effective amount of an acidifying agent which is a hydrolyzable inorganic salt, mineral acid, monomeric carboxylic acid or partial ester of a polycarboxylic acid such that the instantaneous pH of the binder solution is lower than 5.5. Use of the catalysts of the subject process also allow for additional urea-extension without degradation of fiberglass product physical properties. The preferred catalyst is aluminum sulfate in an amount of from 2.0 weight percent to about 4.0 weight percent based on the resin solids.

Abstract: The present invention relates to a glass fiber binding composition having an effective binding amount of an aqueous compatible furan resin mixed with sufficient water to result in a binding composition having from 0.5 to 80% nonvolatile. The aqueous compatible furan resin is the reaction product of a source of ammonia and a first reaction product, the first reaction product being derived from the reaction of an acidic furan resin, a source of reactable formaldehyde, and a formaldehyde scavenger. The invention further pertains to a process of binding glass fibers at junctions of the fibers comprising the steps of providing glass fibers, applying an effect binding amount of the binding composition of the invention to the glass fibers such that the binder is present at a portion of the junctions, and curing the resin at the junctions of the glass fibers.

Abstract: The present invention relates to furan resins having low levels of VOCs. The claimed furan resins are the reaction product of a source of ammonia and a first reaction product, said first reaction product being derived from the reaction between a source of reactable formaldehyde, a formaldehyde scavenger, and an acidic furan resin resulting from the polymerization reaction wherein at least one reagent is selected from the group consisting of the furan containing molecule having the general formula ##STR1## and its saturated analogs thereof having zero to one carbon-carbon double bonnets, wherein X and Y are independently comprised of organic molecular groups.

Abstract: Several flat cable embodiments (10, 10', 10", 10'", 10"") are disclosed, as are methods and apparatus (30) for the selective manufacture and connectorization of same. In accordance with one preferred flat cable embodiment (10), adapted for telephone under carpet applications, two precisely offset arrays of rectangularly shaped conductors (13, 14) are separated by a center film (16), with each array being adhesively bonded through an associated adhesive coating (21 or 22) to only the respectively adjacent one of two outer films (18 or 19).

Abstract: Several flat cable embodiments (10, 10', 10", 10'", 10"") are disclosed, as are methods and apparatus (30) for the selective manufacture and connectorization of same. In accordance with one preferred flat cable embodiment (10), adapted for telephone under carpet applications, two precisely offset arrays of rectangularly shaped conductors (13, 14) are separated by a center film (16), with each array being adhesively bonded through an associated adhesive coating (21 or 22) to only the respectively adjacent one of two outer films (18 or 19).

Abstract: Several flat cable embodiments (10, 10', 10", 10'", 10"") are disclosed, as are methods and apparatus (30) for the selective manufacture and connectorization of same. In accordance with one preferred flat cable embodiment (10), adapted for telephone under carpet applications, two precisely offset arrays of rectangularly shaped conductors (13, 14) are separated by a center film (16), with each array being adhesively bonded through an associated adhesive coating (21 or 22) to only the respectively adjacent one of two outer films (18 or 19).

Abstract: Several flat cable assembly embodiments (10, 30, 60) are disclosed, as are methods for terminating and connectorizing the terminating ends of ribbon-shaped conductors (13, 33, 34, 63) arranged in at least one laterally disposed array in a flat cable (12, 32, 62). In accordance with all of the flat cable assembly embodiments, terminated insulation-stripped conductor end portions (13a', 33a', 34a', 63a') are twisted angularly a predetermined number of degrees from their initial orientation, as originally confined within the cable, prior to being secured to respectively associated connector mating elements of either the solder type (19, 44), or solderless type (64).

Abstract: Several flat cable embodiments (10, 10',10",10"',10"") are disclosed, as are methods and apparatus (30) for the selective manufacture and connectorization of same. In accordance with one preferred flat cable embodiment (10), adapted for telephone under carpet applications, two precisely offset arrays of rectangularly shaped conductors (13, 14) are separated by a center film (16), with each array being adhesively bonded through an associated adhesive coating (21 or 22) to only the respectively adjacent one of two outer films (18 or 19).

Abstract: A flat cable assembly embodiment (10) is disclosed, as are two terminated cable embodiments (12,12') and methods for terminating and connectorizing same, when the cable is of the type wherein two overlying/underlying arrays of laterally disposed conductors (13, 14, 13', 14') are respectively laminated between a common insulative center film (16, 16'), and an associated one of two opposite side outer insulative films (18, 19, 18', 19'), with a plurality of isolating strips (23, 24, 23', 24') interposed between, and adapted to adhere selectively to, the center film and an associated one of the two arrays of conductors. The isolating strips are positioned transversely across the center film in aligned pairs at each of a succession of predetermined terminating sites (e.g., at 5, 10 or 15 ft. intervals) along the cable, as fabricated.