# US 10,767,050 B2 · Liquid high solids binder composition > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,767,050 B2 - Document ID: US10767050B2 - Status: Granted - Kind: B2 - Application number: 15/822,102 - Filed: 2017-11-24 - Published: 2018-05-24 - Granted: 2020-09-08 - Earliest claimed: 2011-05-07 - Assignees: Knauf Insulation, Inc.; Knauf Insulation SPRL - Applicants: Knauf Insulation SPRL; Knauf Insulation, Inc. - Inventors: Gert Mueller - Web page: https://patentgrep.com/patent/US10767050B2 ## CPC - C08L 79/02: Polyamines - B29C 70/06: Fibrous reinforcements only - C03C 25/32: obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds - C08G 12/00: Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen (aminophenols C08G8/16) - C08G 14/00: Condensation polymers of aldehydes or ketones with two or more other monomers covered by at least two of the groups C08G8/00 - C08G12/00 - C08G 16/00: Condensation polymers of aldehydes or ketones with monomers not provided for in the groups C08G4/00 - C08G14/00 (with polynitriles C08G69/38) - C08J 5/043: {with glass fibres} - C08L 61/00: Compositions of condensation polymers of aldehydes or ketones (with polyalcohols C08L59/00; with polynitriles C08L77/00); Compositions of derivatives of such polymers - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) - 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) - C03C: CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS - C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) ## Abstract The invention described herein pertains to formaldehyde free, thermosetting liquid high solids binder compositions having rapid cure times on thermal curing and slow cure times at ambient temperatures so that the uncured binder compositions and products which comprise the uncured binder compositions have improved shelf lives. ## Claims ### Claim 1 A method of fabricating a fiberglass or stone wool product, comprising spraying a liquid, curable, thermosetting, aqueous, substantially formaldehyde free, binder composition, which is free of solid particles, which comprises a primary or secondary polyetheramine and a carbohydrate and which has a concentration of at least 35% solids on a collection of glass or stone wool fibers; dehydrating the aqueous binder composition disposed on the collection of glass or stone wool fibers to form an uncured fiberglass or stone wool product; and subjecting the uncured fiberglass or stone wool product to heat to cure the binder composition. ### Claim 2 (depends on 1) The method of claim 1 comprising spraying the aqueous binder composition on a collection of glass or stone wool fibers; dehydrating the aqueous binder composition disposed on the collection of glass or stone wool fibers to form an uncured fiberglass or stone wool product; storing the uncured fiberglass or stone wool product, and curing the uncured fiberglass or stone wool product by subjecting it to heat. ### Claim 3 (depends on 2) The method of claim 2 wherein the uncured fiberglass or stone wool product is stored as a roll. ### Claim 4 (depends on 1) The method of claim 1 wherein the uncured product is molded into the shape of a final product prior to curing. ### Claim 5 (depends on 1) The method of claim 1 wherein the uncured product is stored at or below about 90° F. (32° C.) prior to curing. ### Claim 6 (depends on 1) The method of claim 1 wherein the uncured product is stored at or below about 70° F. (21° C.) prior to curing. ### Claim 7 (depends on 1) The method of claim 1 wherein the uncured product is stored at or below about 50° F. (10° C.) prior to curing. ### Claim 8 (depends on 1) The method of claim 1 wherein the approximate molecular weight of the polyetheramine does not exceed 1000. ### Claim 9 (depends on 1) The method of claim 1 wherein the polyetheramine comprises a primary amine. ### Claim 10 (depends on 1) The method of claim 1 wherein the polyetheramine has an amine hydrogen equivalent weight (AHEW) of less than about 200 g/eq. ### Claim 11 (depends on 1) The method of claim 1 wherein the polyetheramine has an amine hydrogen equivalent weight (AHEW) of less than about 125 g/eq. ### Claim 12 (depends on 1) The method of claim 1 wherein the polyetheramine has an amine hydrogen equivalent weight (AHEW) of less than about 85 g/eq. ### Claim 13 (depends on 1) The method of claim 1 wherein the polyetheramine has an amine hydrogen equivalent weight (AHEW) of less than about 60 g/eq. ### Claim 14 (depends on 1) The method of claim 1 wherein the polyetheramine comprises a primary triamine. ### Claim 15 (depends on 14) The method of claim 14 wherein the polyetheramine has the following structural formula: ### Claim 16 (depends on 1) The method of claim 1 wherein the polyetheramine comprises a primary diamine. ### Claim 17 (depends on 16) The method of claim 16 wherein the polyetheramine has one of the following structural formulas: ### Claim 18 (depends on 16) The method of claim 16 wherein the polyetheramine has the following structural formula: ### Claim 19 (depends on 1) The method of claim 1 wherein the carbohydrate comprises a reducing carbohydrate or a combination of a reducing carbohydrate and a non-reducing carbohydrate. ### Claim 20 (depends on 1) The method of claim 1 wherein the carbohydrate comprises a monosaccharide or a disaccharide or a combination thereof. ### Claim 21 (depends on 1) The method of claim 1 wherein the carbohydrate comprises one or more monosaccharides. ### Claim 22 (depends on 21) The method of claim 21 wherein the carbohydrate comprises dextrose, fructose or xylose, or a mixture thereof. ### Claim 23 (depends on 22) The method of claim 22 wherein the carbohydrate comprises a mixture of dextrose and fructose. ### Claim 24 (depends on 23) The method of claim 23 wherein the dextrose to fructose ratio is about 80:20 to about 20:80. ### Claim 25 (depends on 1) The method of claim 1 wherein the ratio of carbohydrate carbonyl-group to polyetheramine amino-group is in the range of about 0.15:1 to about 6:1. ### Claim 26 (depends on 1) The method of claim 1 wherein the ratio of carbohydrate carbonyl-group to polyetheramine amino-group is in the range of about 0.5:1 to about 2:1. ### Claim 27 (depends on 1) The method of claim 1 wherein the ratio of carbohydrate carbonyl-group to polyetheramine amino-group is in the range of about 0.75:1 to about 1.33:1. ### Claim 28 (depends on 1) The method of claim 1 further comprising a silicon-containing compound. ### Claim 29 (depends on 28) The method of claim 28 wherein the silicon-containing compound is selected from the group consisting of gamma-aminopropyltriethoxysilane, gamma-glycidoxypropyltrimethoxysilane, aminoethylaminopropyltrimethoxysilane, an aminofunctional oligomeric silane, and mixtures thereof. ### Claim 30 (depends on 29) The method of claim 29 wherein the silicon-containing compound is gamma-aminopropyltriethoxysilane. ### Claim 31 (depends on 1) The method of claim 1 further comprising a corrosion inhibitor selected from the group consisting of dedusting oil, ammonium phosphates, sodium metasilicate pentahydrate, melamine, tin (II) oxalate, and a methylhydrogen silicone fluid emulsion. ### Claim 32 (depends on 1) The method of claim 1 wherein the binder concentration is at least 50% solids. ### Claim 33 (depends on 1) The method of claim 1 wherein the binder concentration is at least 70% solids. ### Claim 34 (depends on 1) The method of claim 1 wherein the binder concentration is at least 85% solids. ### Claim 35 (depends on 1) The method of claim 1 wherein the binder concentration is at least 90% solids. ### Claim 36 (depends on 1) The method of claim 1 wherein the viscosity is less than about 5 Pa·s. ### Claim 37 (depends on 1) The method of claim 1 wherein the viscosity is less than about 2 Pa·s. ### Claim 38 (depends on 1) The method of claim 1 wherein the viscosity is less than about 1 Pa·s. ### Claim 39 (depends on 1) The method of claim 1 wherein the increase in viscosity on standing for 1 week at a temperature not exceeding about 25° C. does not exceed 1 Pa·s. ### Claim 40 (depends on 1) The method of claim 1 wherein the increase in viscosity on standing for 2 weeks at a temperature not exceeding about 25° C. does not exceed 1 Pa·s. ### Claim 41 (depends on 1) The method of claim 1 wherein the increase in viscosity on standing for 3 weeks at a temperature not exceeding about 25° C. does not exceed 1 Pa·s. ### Claim 42 (depends on 1) The method of claim 1 wherein the increase in viscosity on standing for 4 weeks at a temperature not exceeding about 25° C. does not exceed 1 Pa·s. ### Claim 43 (depends on 1) The method of claim 1 wherein the composition is free or substantially free of an acid component. ### Claim 44 (depends on 1) The method of claim 1 wherein curing the binder composition turns the fiberglass or stone wool product brown.