# US 2014/0197349 A1 · Binder compositions and associated methods

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- Number: US 2014/0197349 A1
- Document ID: US20140197349A1
- Status: Published application
- Kind: A1
- Application number: 14/217,604
- Filed: 2014-03-18
- Published: 2014-07-17
- Earliest claimed: 2004-03-11
- Assignees: Knauf Insulation, Inc.
- Applicants: Knauf Insulation GmbH
- Inventors: Clarence H. HELBING
- Web page: https://patentgrep.com/patent/US20140197349A1

## CPC

- C08G 63/12: derived from polycarboxylic acids and polyhydroxy compounds
- C09D 129/04: Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
- 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
- F16L 59/028: {Compositions for or methods of fixing a thermally insulating material}
- C08K 5/092: Polycarboxylic acids
- Y10T 428/249924: Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T 428/24994: Fiber embedded in or on the surface of a polymeric matrix
- Y10T 428/249944: Fiber is precoated
- Y10T 428/249946: Glass fiber
- Y10T 428/249948: Fiber is precoated
- Y10T 428/2933: Coated or with bond, impregnation or core
- Y10T 428/2964: Artificial fiber or filament
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- 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)
- 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)
- F16L: PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Disclosed are formaldehyde-free, thermally-curable, alkaline, aqueous binder compositions, curable to formaldehyde-free, water-insoluble thermoset polyester resins, and uses thereof as binders for non-woven fibers and fiber material.

## Claims

### Claim at position 1

-25. (canceled)

### Claim 26

A binder comprising
a polyester polymer, the polyester polymer comprising a reaction product of a polycarboxylic acid component and a polymeric polyhydroxyl component in the presence of a catalyst, wherein a solution of the polycarboxylic acid component, the polymeric polyhydroxyl component, and the catalyst has an alkaline pH and the polycarboxylic acid component is a dicarboxylic acid, tricarboxylic acid, tetracarboxylic acid, or pentacarboxylic acid, or salts or anhydride derivatives thereof, or combinations thereof.

### Claim 27 (depends on 26)

The binder of claim 26, wherein the alkaline pH is in the range from about 7 to about 10.

### Claim 28 (depends on 26)

The binder of claim 26, wherein the solution has the alkaline pH due to inclusion of a base in the solution.

### Claim 29 (depends on 28)

The binder of claim 28, wherein the base is sodium hydroxide.

### Claim 30 (depends on 29)

The binder of claim 29, wherein the polyester polymer is colorless.

### Claim 31 (depends on 28)

The binder of claim 28, wherein the base is ammonium hydroxide.

### Claim 32 (depends on 29)

The binder of claim 29, wherein the polyester polymer is light tan.

### Claim 33 (depends on 26)

The binder of claim 26, wherein the polycarboxylic acid component is citric acid.

### Claim 34 (depends on 26)

The binder of claim 26, wherein the catalyst is sodium hypophosphite.

### Claim 35

An insulation product comprising
a formaldehyde-free polymeric binder composition in contact with mineral fibers, the formaldehyde-free polymeric binder comprising a product of a dried and cured alkaline aqueous solution, the solution comprising a polymeric polyhydroxyl component, a polycarboxylic acid component selected from a dicarboxylic acid, tricarboxylic acid, tetracarboxylic acid, or pentacarboxylic acid, and a catalyst.

### Claim 36 (depends on 35)

The insulation product of claim 35, wherein the polycarboxylic acid component is a dicarboxylic acid or a tricarboxylic acid.

### Claim 37 (depends on 35)

The insulation product of claim 35, wherein the polycarboxylic acid component is citric acid and the catalyst is sodium hypophosphite.

### Claim 38 (depends on 35)

The insulation product of claim 35, the solution further comprising a base.

### Claim 39 (depends on 38)

The insulation product of claim 38, wherein the base is sodium hydroxide.

### Claim 40 (depends on 35)

The insulation product of claim 35, wherein the solution further comprises a silicon-containing coupling agent.