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US 7,842,382 B2Granted
Binder compositions and associated methods
AssigneeKnauf Insulation, Inc.
InventorClarence H. Helbing
Life of this patent
Estimating the term…
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 materials.
Claims15
A formaldehyde free binder composition, comprising:
- a reaction product of a polycarboxylic acid component with a polymeric polyhydroxyl component, wherein
- i) the polycarboxylic acid component and polyhydroxyl component have an alkaline pH,
- ii) the ratio of the number of molar equivalents of acid groups of the polycarboxylic acid to the number of molar equivalents of hydroxyl groups of the polymeric polyhydroxyl component is in the range from about 0.6:1 to about 1.2:1,
- iii) the polycarboxylic acid component is selected from a dicarboxylic acid, tricarboxylic acid, tetra carboxylic acid, or penta carboxylic acid, and salts and anhydride derivatives thereof, and combinations thereof, and
- iv) the reaction product consists of a maximum of 5 ester linkages between a given molecule of the polycarboxylic acid component and one or more molecule of the polymeric polyhydroxyl components.
2 more elements
An insulation product, comprising:
- glass fibers in contact with an alkaline formaldehyde-free binder composition, wherein:
- (i) the binder composition includes a reaction product of a polycarboxylic acid component with a polymeric polyhydroxyl component,
- (ii) the polymeric polyhydroxy component includes a partially hydrolyzed polyvinyl acetate,
- (iii) the polycarboxylic acid component is selected from a dicarboxylic acid, tricarboxylic acid, tetra carboxylic acid, or penta carboxylic acid, and salts and anhydride derivatives thereof, and combinations thereof, and
- (iv) the reaction product consists of a maximum of 5 ester linkages between a given molecule of the polycarboxylic acid component and one or more molecule of the polymeric polyhydroxyl components.
2 more elements
An insulation product comprising:
- glass fibers in contact with a formaldehyde-free binder composition wherein the binder composition includes an ester-linked reaction product of a dicarboxylic acid, tricarboxylic acid, tetra carboxylic acid, or penta carboxylic acid, or salts or anhydride derivatives thereof, or combinations thereof with a polymeric polyhydroxyl component characterized by the dicarboxylic acid or salts or anhydride derivatives thereof forming a maximum of two ester bonds with the polymeric polyhydroxyl component, the tricarboxylic acid or salts or anhydride derivatives thereof forming a maximum of three ester bonds with the polymeric polyhydroxyl component, the tetra carboxylic acid or salts or anhydride derivatives thereof forming a maximum of four ester bonds with the polymeric polyhydroxyl component, the penta carboxylic acid forming or salts or anhydride derivatives thereof a maximum of five ester bonds with the polymeric polyhydroxyl component and the binder composition has a pH of about 7 to about 10.
A method of making a formaldehyde-free insulation product comprising;
- disposing an aqueous solution that includes a substantially unreacted dicarboxylic acid, tricarboxylic acid, tetra carboxylic acid, or penta carboxylic acid, or salts or anhydride derivatives thereof, or combinations thereof and a polymeric polyhydroxyl component onto glass fibers and curing the glass fiber aqueous solution composition to produce a formaldehyde-free water insoluble thermoset polyester resin disposed on the glass fibers.
A composition comprising a polyester binder disposed on a collection of fibers, the polyester binder being a reaction product of:
- (i) dehydrating an alkaline solution consisting of a hydrolyzed polyvinyl acetate component, a polycarboxylic acid component and a silicon-containing compound and
- (ii) curing in contact with the collection of fibers.
Dependencies are inferred from the claim text.