B-stageable aqueous binder compositions
AssigneeOwens Corning Intellectual Capital, LLC
InventorsGert Mueller, Andrew Broderick, Xiujuan Zhang, Liang Chen
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Abstract
An aqueous binder composition is disclosed that includes 5.0% by weight to 50.0% by weight of a monomeric polyol having at least four hydroxyl groups, based on the total solids content of the aqueous binder composition; and at least 50.0% by weight of a cross-linking agent comprising a polymeric polycarboxylic acid having at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition. The aqueous binder composition includes a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.15/1.0 and 2.23/1 and has a pH of 2.2 to 4.0 and a viscosity at 40% solids and 25° C. of 10 cP to 60 cP.
Claims23
An aqueous binder composition comprising:
- 5.0% by weight to 50.0% by weight of a monomeric polyol having at least four hydroxyl groups, based on the total solids content of the aqueous binder composition;
- and
- at least 50.0% by weight of a cross-linking agent comprising a polymeric polycarboxylic acid having at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition,
- wherein a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.15/1.0 and 2.23/1, and wherein the aqueous binder composition has a pH of 2.2 to 4.0 and a viscosity at 40% solids and 25° C. of 10 cP to 60 cP.
A B-stageable fibrous insulation product comprising:
- a plurality of randomly oriented fibers;
- and
- an uncured aqueous binder composition at least partially coating said fibers, the aqueous binder composition comprising:
- 5.0% by weight to 50.0% by weight of at least one monomeric polyol having at least four hydroxyl groups, based on the total solids content of the aqueous binder composition;
- and
- at least 50.0% by weight of a cross-linking agent comprising a polymeric polycarboxylic acid having at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition, wherein the uncured aqueous binder composition has a viscosity at 40% solids and 25° C. of 10 cP to 60 cP, and
- wherein the B-stageable fibrous insulation product has a drying time, as measured by a CEM Smart 6 moisture analyzer, of at least 500 seconds.
A method for producing a fibrous insulation product having a low level of water soluble material, comprising:
- applying a formaldehyde-free aqueous binder composition to a plurality of fibers, the formaldehyde-free aqueous binder composition comprising:
- 5.0% by weight to 50.0% by weight of at least one monomeric polyol having at least four hydroxyl groups, based on the total solids content of the aqueous binder composition;
- and
- at least 50.0% by weight of a cross-linking agent comprising a polymeric polycarboxylic acid having at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition,
- gathering the fibers onto a substrate, forming a binder-infused fibrous pack;
- and
- curing the binder-infused fibrous pack, wherein the fibrous insulation product contains less than 5.5% by weight of water soluble material.
An aqueous formaldehyde-free binder composition comprising:
- 5.0% by weight to 37.0% by weight of at least one monomeric polyol having at least four hydroxyl groups;
- 50.0% by weight to 62% by weight of a polyacrylic acid crosslinking agent;
- 0.5% to 5.0% by weight a catalyst;
- 2.0% to 15.0% by weight of a processing aid;
- 0 to 5.0% by weight of a surfactant;
- 0 to 2.0% by weight of a pigment;
- and
- 0 to 15% by weight of silicone, each percentage being based on a total solids content of the aqueous binder composition, wherein a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.26/1 and 0.75/1, wherein the aqueous binder composition has a pH of 2.2 to 4.0 and a viscosity at 40% solids and 25° C. of 30 cP to 55 cP.
Dependencies are inferred from the claim text.