Infinitely water soluble, storage stable, low molecular weight,
amine-modified resins/binders (e.g., phenol-formaldehyde resole resins and
binders made therefrom) are used to produce low odor fiberglass products,
such as fiberglass insulation for automobile headliners and room dividers.
The cured, bonded fiberglass products have low TMA (trimethylamine)
emission because the free formaldehyde in the resin has been scavenged
with melamine, which resists thermal decomposition, and because the binder
contains a relatively low urea content, which is a TMA contributor. The
resole resin production process includes adding two different formaldehyde
scavengers (e.g., melamine and urea) to produce a modified
phenol-formaldehyde resole resin. This resole resin is produced into a
binder by mixing with water, optionally in the presence of a latent acid
catalyst (e.g., an ammonium salt of a strong acid). The binder can be
applied to a fiberglass base material, dried, stored for an extended time
period, and then cured and shaped into a final desired shape.
