# US 10,307,955 B2 · Molding process for insulation product > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,307,955 B2 - Document ID: US10307955B2 - Status: Granted - Kind: B2 - Application number: 14/775,955 - Filed: 2014-03-12 - Published: 2016-02-04 - Granted: 2019-06-04 - Earliest claimed: 2013-03-13 - Assignees: Knauf Insulation, Inc. - Applicants: Knauf Insulation, Inc. - Inventors: Gert R. Mueller; Robert W. Zembrodt; Charles F. Appley; Walter A. Johnson; Steven L. Collings - Web page: https://patentgrep.com/patent/US10307955B2 ## CPC - B29C 51/421: {of preforms, specially adapted for thermoforming (preheating sheets in general B29B13/023; B29C51/427 takes precedence)} - B29C 35/06: for articles of indefinite length - B29C 35/10: for articles of indefinite length - B29C 43/203: {Making multilayered articles} - B29C 71/02: Thermal after-treatment {(B29C71/0063 and B29C71/0072 take precedence)} - B29C 43/36: Moulds for making articles of definite length, i.e. discrete articles - B29C 2035/0822: {using IR radiation} - B29C 2035/0855: {using microwave} - B29C 2035/1658: {using gas} - B29K 2103/00: Use of resin-bonded materials as moulding material - B29K 2105/12: of short lengths, e.g. chopped filaments, staple fibres or bristles - B29K 2105/128: {in the form of a mat} - B29K 2105/253: {Preform} - B29K 2509/08: Glass - B29K 2511/00: Use of natural products or their composites, not provided for in groups {B29K2401/00 - B29K2509/00,} as filler - B29K 2995/0002: insulating - B29K 2995/0015: Insulating - B29L 2031/776: {Walls, e.g. building panels} - D04H 1/587: characterised by the bonding agents used - D04H 1/655: characterised by the apparatus for applying bonding agents - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B) ## Abstract A molding process includes the operation of placing insulation material comprising fibers and binder on the fibers in a mold cavity. The molding process further includes the operation of transferring heat to the insulation material to cause the binder to cure. ## Claims ### Claim 1 A molding process comprising providing an uncured blank including fibers and uncured binder, molding the uncured blank to establish a shaped product having a molded shape that does not change after removal from a mold cavity formed in a mold, the shaped product including the fibers, a first portion of cured binder, and a remainder of the uncured binder, wherein the uncured binder comprises: at least 50% by dry weight of a carbohydrate reactant selected from one or more reducing sugars, one or more carbohydrate reactants that yield one or more reducing sugars in situ under thermal curing conditions and combinations thereof; and at least 10% by dry weight of a nitrogen-containing reactant selected from ammonia, ammonium salts, inorganic amines, inorganic amine salts, organic amines comprising at least one primary amine group, salts of organic amines comprising at least one primary amine group, and combinations thereof. ### Claim 2 (depends on 1) The molding process of claim 1, wherein the uncured binder is a substantially formaldehyde-free binder. ### Claim 3 (depends on 1) The molding process of claim 1, wherein the uncured blank is exposed to a temperature of about 200 degrees Fahrenheit to about 500 degrees Fahrenheit. ### Claim 4 (depends on 1) The molding process of claim 1, wherein the fibers are glass fibers. ### Claim 5 (depends on 1) The molding process of claim 1 wherein the carbohydrate reactant comprises high-fructose corn syrup. ### Claim 6 (depends on 1) The molding process of claim 1 wherein the nitrogen-containing reactant comprises ammonium sulfate, ammonium phosphate or combinations thereof. ### Claim 7 A molding process comprising providing an uncured blank including fibers and uncured binder, molding the uncured blank to establish a shaped product having a molded shape that does not change after removal from a mold cavity formed in a mold, the shaped product including the fibers, a first portion of cured binder, and a remainder of the uncured binder, wherein curing of the binder consists essentially of a Maillard reaction. ### Claim 8 (depends on 7) The molding process of claim 7, wherein the uncured binder is a substantially formaldehyde-free binder. ### Claim 9 (depends on 7) The molding process of claim 7, wherein the uncured blank is exposed to a temperature of about 200 degrees Fahrenheit to about 500 degrees Fahrenheit. ### Claim 10 (depends on 7) The molding process of claim 7, wherein the fibers are glass fibers. ### Claim 11 A molding process comprising providing an uncured blank including fibers and uncured binder, molding the uncured blank to establish a shaped product having a molded shape that does not change after removal from a mold cavity formed in a mold, the shaped product including the fibers, a first portion of cured binder, and a remainder of the uncured binder, wherein the cured binder comprises a substantially water insoluble nitrogen containing polymer. ### Claim 12 (depends on 11) The molding process of claim 11, wherein the uncured binder is a substantially formaldehyde-free binder. ### Claim 13 (depends on 11) The molding process of claim 11, wherein the uncured blank is exposed to a temperature of about 200 degrees Fahrenheit to about 500 degrees Fahrenheit. ### Claim 14 (depends on 11) The molding process of claim 11, wherein the fibers are glass fibers.