Abstract
Safety and health concerns about the use of formaldehyde based thermosets has sparked investigation into alternative, safe thermoset binders. Predicting the performance of thermosetting binders in industrial nonwoven applications, such as the manufacturing of fiberglass building insulation, is key to the development of new, safe binder technology. Reliably predictive laboratory scale experiments facilitate rapid testing of small quantities of experimental binder formulations without the cost and inconvenience associated with full-scale plant trials. The challenge is to mimic key aspects of the industrial process on the laboratory scale. The gap between laboratory and manufacturing environment is exacerbated when making large changes in resin chemistry or formulation, for example, using acrylic thermoset resins such as TSET#1™, in place of phenol-formaldehyde resins. We have developed a battery of laboratory scale tests to assess acrylic thermosetting binders in a fiberglass insulation process. These methods focus on binder cure properties, binder-substrate interactions, or other processing aspects. Aspects of testing such as surrogate substrate materials, time-temperature history, and humid aging are discussed. Each method provides an insight to one aspect of binder performance, and, taken in aggregate, the data from these techniques can be used as a tool to predict binder performance on the plant scale.