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US 12,638,124 B2Granted
Formaldehyde free composites made with carbohydrate and alpha-carbon nucleophile binder compositions
AssigneeJohns Manville
InventorsKiarash Alavi, Ameya Natu
Life of this patent
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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.
Claims23
A fiber-containing composite comprising:
- woven or non-woven fibers;
- and
- a cured binder formed from a binder composition comprising:
- a carbohydrate;
- a crosslinking agent that is an organic compound comprising:
- a first carbon moiety comprising an electron withdrawing group;
- 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, 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;
- and wherein the molar ratio of crosslinking agent to carbohydrate is from 1:4 to 1:10.
9 more elements
Dependencies are inferred from the claim text.