Formaldehyde free composites made with carbohydrate and alpha-carbon nucleophile binder compositions
AssigneeJohns Manville
InventorKiarash Alavi
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Abstract
Fiber-containing composites are described that contain woven or non-woven fibers, and a cured binder formed from a binder composition that includes (1) a reducing sugar and (2) a crosslinking agent that includes a first carbon moiety selected from an aldehyde, a ketone, a nitrile, and a nitro group, wherein an α-carbon atom having at least one acidic hydrogen is directly bonded to the first carbon moiety. Exemplary reducing sugars include dextrose and exemplary crosslinking agents include glyoxal. Exemplary fiber-containing composites may include fiberglass insulation.
Claims22
A fiber-containing composite comprising:
- woven or non-woven fibers;
- and
- a cured binder formed from a binder composition consisting of:
- one or more reducing sugars, or a polysaccharide capable of generating at least one reducing sugar in situ when the binder composition is cured;
- 5 wt. % to 25 wt. % by dry weight of the binder composition of a crosslinking agent that is an organic compound comprising:
- a first carbon moiety selected from an aldehyde and a ketone;
- and
- an α-carbon atom directly bonded to the first carbon moiety, wherein the α-carbon atom has at least one acidic hydrogen atom, and
- one or more additional binder components selected from the group consisting of polymerization catalysts, dedusting oils, waxes, biocides, pigments, inorganic fillers, and colorants;
- wherein the α-carbon atom forms a nucleophile that reacts with a carbonyl carbon on the carbohydrate during polymerization of the binder composition to form the cured binder,
- wherein the crosslinking agent lacks a nitrogen-containing group, and
- wherein the binder composition lacks an inorganic ammonium salt.
A fiber-containing composite comprising:
- woven or non-woven fibers;
- and
- a cured binder formed from a binder composition consisting of:
- one or more reducing sugars, or a polysaccharide capable of generating at least one reducing sugar in situ when the binder composition is cured;
- 5 wt. % to 25 wt. % by dry weight of the binder composition of a crosslinking agent comprising an α-carbon atom bonded to a carbonyl carbon and an aldehyde or ketone group, wherein the α-carbon atom has at least one acidic hydrogen atom, and
- one or more additional binder components selected from the group consisting of polymerization catalysts, dedusting oils, waxes, biocides, pigments, inorganic fillers, and colorants;
- wherein the cured binder includes a bond between a carbon atom of the carbohydrate and the α-carbon atom of the crosslinking agent,
- wherein the crosslinking agent lacks a nitrogen-containing group, and
- wherein the cured binder lacks an inorganic ammonium salt.
A fiber-containing composite comprising:
- woven or non-woven fibers;
- and
- a cured binder formed from a binder composition consisting of:
- 50% to 99% by dry weight of the binder composition of dextrose;
- 1% to 50% by dry weight of the binder composition of glyoxal, and, one or more additional binder components selected from the group consisting of polymerization catalysts, dedusting oils, waxes, biocides, pigments, inorganic fillers, and colorants;
- wherein the cured binder includes a bond between a carbon atom of the reducing sugar and the α-carbon atom of the crosslinking agent;
- wherein the crosslinking agent lacks a nitrogen-containing group;
- and
- wherein the cured binder lacks an inorganic ammonium salt;
- wherein the α-carbon atom forms a nucleophile that reacts with a carbonyl carbon on the carbohydrate during polymerization of the binder composition to form the cured binder.
Dependencies are inferred from the claim text.