# US 11,111,372 B2 · Aqueous binder compositions

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- Number: US 11,111,372 B2
- Document ID: US11111372B2
- Status: Granted
- Kind: B2
- Application number: 16/154,782
- Filed: 2018-10-09
- Published: 2019-04-11
- Granted: 2021-09-07
- Earliest claimed: 2017-10-09
- Assignees: Owens Corning Intellectual Capital, LLC
- Applicants: Owens Corning Intellectual Capital, LLC
- Inventors: Xiujuan Zhang; Gert Mueller; Kendel Smith
- Web page: https://patentgrep.com/patent/US11111372B2

## CPC

- C08L 31/04: Homopolymers or copolymers of vinyl acetate
- C08K 5/053: Polyhydroxylic alcohols
- C08K 5/092: Polycarboxylic acids
- C08K 5/17: Amines; Quaternary ammonium compounds
- C08L 29/04: Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
- D04H 1/4218: Glass fibres
- D04H 1/587: characterised by the bonding agents used
- D04H 1/64: the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
- C09D 133/02: Homopolymers or copolymers of acids; Metal or ammonium salts thereof
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- 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)
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)

## Abstract

An aqueous binder composition is disclosed that comprises at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons; a primary cross-linking agent comprising at least two carboxylic acid groups; and a secondary cross-linking agent comprising a short-chain polyol having at least two hydroxyl groups and a number average molecular weight less than 2,000 Daltons.

## Claims

### Claim 1

An aqueous binder composition comprising:
at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons;
at least 63 wt. % of a cross-linking agent comprising at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition; and
a short-chain polyol having at least two hydroxyl groups and a number average molecular weight less than 2,000 Daltons; and
a catalyst,
wherein said binder composition has a pH after cure between 5 and 9 and achieves a b* color value, using L*a*b* coordinates, of less than 45.

### Claim 2 (depends on 1)

The aqueous binder composition of claim 1, wherein said cross-linking agent is a polymeric polycarboxylic acid.

### Claim 3 (depends on 1)

The aqueous binder composition of claim 1, wherein said cross-linking agent is present in the binder composition in an amount from 65 wt. % to 85 wt. %, based on the total solids content of the aqueous binder composition.

### Claim 4 (depends on 1)

The aqueous binder composition of claim 1, wherein said cross-linking agent is present in the binder composition in an amount from 70 wt. % to 80 wt. %, based on the total solids content of the aqueous binder composition.

### Claim 5 (depends on 1)

The aqueous binder composition of claim 1, wherein said long-chain polyol is selected from the group consisting of polyvinyl alcohol and polyvinyl acetate.

### Claim 6 (depends on 1)

The aqueous binder composition of claim 1, wherein said long-chain polyol is present in the binder composition in an amount from 5 wt. % to 30 wt. %, based on the total solids content of the aqueous binder composition.

### Claim 7 (depends on 1)

The aqueous binder composition of claim 1, wherein said short-chain polyol comprises one or more of a sugar alcohol, 2,2-bis(methylol)propionic acid, tri(methylol)propane, and a short-chain alkanolamine.

### Claim 8 (depends on 7)

The aqueous binder composition of claim 7, wherein said short-chain polyol comprises a sugar alcohol selected from the group consisting of glycerol, erythritol, arabitol, xylitol, sorbitol, maltitol, mannitol, iditol, isomaltitol, lactitol, cellobitol, palatinitol, maltotritol, syrups thereof, and mixtures thereof.

### Claim 9 (depends on 1)

The aqueous binder composition of claim 1, wherein said short-chain polyol is present in the binder composition in an amount from 3 wt. % to 30 wt. %, based on the total solids content of the aqueous binder composition.

### Claim 10

An insulation product comprising:
a plurality of randomly oriented fibers; and
an aqueous binder composition at least partially coating said fibers, said binder composition comprising:
at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons;
at least 63 wt. % of a cross-linking agent comprising at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition; and
a short-chain polyol having at least two hydroxyl groups and a number average molecular weight less than 2,000 Daltons; and
a catalyst,
wherein said binder composition has a pH after cure between 5 and 9 and achieves a b* color value, using L*a*b* coordinates, of less than 45.

### Claim 11 (depends on 10)

The insulation product of claim 10, wherein the fibers comprise one or more of mineral fibers, natural fibers, and synthetic fibers.

### Claim 12 (depends on 10)

The insulation product of claim 10, wherein the fibers comprise glass fibers, mineral wool fibers, or a mixture thereof.

### Claim 13 (depends on 10)

The insulation product of claim 10, wherein when said insulation product after cure has a thickness of 1 inch and a density of 6 lbs/ft3, said insulation product has a flexural elastic modulus of at least 40 psi.

### Claim 14 (depends on 10)

The insulation product of claim 10, wherein when said insulation product after cure has a thickness of 1 inch and a density of 6 lbs/ft3, said insulation product has a compressive strength at 10% deformation of at least 200 lbs/ft2.

### Claim 15 (depends on 10)

The insulation product of claim 10, wherein a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups in the binder composition is from 1/0.05 to 1.0/5.0.

### Claim 16

A method for controlling color in insulation products formed using a formaldehyde-free binder composition, the method comprising:
preparing a formaldehyde-free binder composition comprising:
at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons;
at least 63 wt. % of a cross-linking agent comprising at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition; and
a short-chain polyol having at least two hydroxyl groups and a number average molecular weight less than 2,000 Daltons; and
a catalyst, and
curing said binder composition to achieve a b* color value, using L*a*b* coordinates, of less than 45 and a cured binder pH of between 5 and 9.

### Claim 17 (depends on 16)

The method of claim 16, wherein said cross-linking agent is a polymeric polycarboxylic acid.

### Claim 18 (depends on 16)

The method of claim 16, wherein a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is from 1/0.05 to 1.0/5.0.

### Claim 19 (depends on 16)

The method of claim 16, wherein said long-chain polyol is selected from the group consisting of polyvinyl alcohol and polyvinyl acetate.

### Claim 20 (depends on 16)

The method of claim 16, wherein said long-chain polyol is present in the binder composition in an amount from 5 wt. % to 30 wt. %, based on the total solids content of the aqueous binder composition.

### Claim 21 (depends on 16)

The method of claim 16, wherein said short-chain polyol comprises one or more of a sugar alcohol, 2,2-bis(methylol)propionic acid, tri(methylol)propane, and a short-chain alkanolamine.

### Claim 22 (depends on 16)

The method of claim 16, wherein said short-chain polyol is present in the binder composition in an amount from 3 wt. % to 30 wt. %, based on the total solids content of the aqueous binder composition.

### Claim 23 (depends on 16)

The method of claim 16, wherein said binder composition includes a ratio of long-chain polyol to short-chain polyol is from 0.1/0.9 to 0.9/0.1.

### Claim 24 (depends on 16)

The method of claim 16, wherein prior to curing, the pH of the binder composition is adjusted by 0.25 to 1.5 pH units.

### Claim 25 (depends on 24)

The method of claim 24, wherein said pH is adjusted by the addition of one or more of a non-volatile base and alkaline water.

### Claim 26 (depends on 16)

The method of claim 16, wherein said binder composition achieves a b* color value, using L*a*b* coordinates, of less than 40.

### Claim 27 (depends on 16)

The method of claim 16, wherein said binder composition has an un-cured pH of 2 to 5.

### Claim 28 (depends on 16)

The method of claim 16, wherein said binder composition has a cured pH of between 6.0 and 8.0.

### Claim 29 (depends on 16)

The method of claim 16, wherein when said insulation product after cure has a thickness of 1 inch and a density of 6 lbs/ft3, said insulation product has a flexural elastic modulus of at least 40 psi.

### Claim 30 (depends on 16)

The method of claim 16, wherein when said insulation product after cure has a thickness of 1 inch and a density of 6 lbs/ft3, said insulation product has a compressive strength at 10% deformation of at least 200 lbs/ft2.

### Claim 31 (depends on 16)

The method of claim 16, wherein when said insulation product after cure has a thickness of 1 inch and a density of 6 lbs/ft3, said insulation product has a bond strength at break of at least 7.5 lbs/ft2/LOI.