Binders and materials made therewith

• US 20070123680A1
• Filed: 01/25/2007
• Published: 05/31/2007
• Est. Priority Date: 07/26/2005
• Status: Active Grant

• Current Assignee: Knauf Insulation, Inc. (GEBR Knauf Verwaltungsgesellschaft KG)
• Original Assignee: Brian Swift, Ronald Kissell, Ruijian Xu
• Inventors: Xu, Ruijian, Swift, Brian, Kissell, Ronald
• Granted Patent: US 7,772,347 B2
• Time in Patent Office: Days
• US Class Current: 527/312
• CPC Class Codes: B29C 70/68 by incorporating or moulding on preformed parts, e.g. inserts or layers , e.g. foam blocks mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70
• CPC Class Codes: C03C 17/28 with organic material C03C17/34, C03C17/44 take precedence
• CPC Class Codes: C03C 25/14 Spraying
• CPC Class Codes: C03C 25/321 Starch; Starch derivatives
• CPC Class Codes: C07H 5/04 to nitrogen
• CPC Class Codes: C08F 251/02 on to cellulose or derivatives thereof
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 51/02 grafted on to polysaccharides
• CPC Class Codes: C09D 105/00 Coating compositions based on polysaccharides or on their derivatives, not provided for in groups C09D101/00 or C09D103/00
• CPC Class Codes: C09D 167/04 Polyesters derived from hydroxycarboxylic acids, e.g. lactones C09D167/06 takes precedence
• CPC Class Codes: C09D 5/08 Anti-corrosive paints
• CPC Class Codes: E04B 1/78 Heat insulating elements E04B1/7662 takes precedence
• CPC Class Codes: E04B 1/84 Sound-absorbing elements
• CPC Class Codes: E04B 1/88 Insulating elements for both heat and sound
• CPC Class Codes: F16L 59/026 Mattresses, mats, blankets or the like
• CPC Class Codes: F16L 59/14 Arrangements for the insulation of pipes or pipe systems F16L59/02 - F16L59/12 take precedence
• CPC Class Codes: H05K 999/99 dummy group
• CPC Class Codes: Y10T 428/31971 Of carbohydrate
• CPC Class Codes: Y10T 442/60 Nonwoven fabric [i.e., nonwoven strand or fiber material]
• CPC Class Codes: Y10T 442/691 Inorganic strand or fiber material only

Abstract

Binders to produce or promote cohesion in non or loosely assembled matter.

Claims

1. A composition, comprising:

Maillard reactants disposed as a binder on a collection of matter, wherein said Maillard reactants comprise a mixture of

(a) a monosaccharide; and

(b) an ammonium salt of a polycarboxylic acid.

2. The composition of claim 1, wherein the composition is free of melanoidins.

3. The composition of claim 1, wherein the collection of matter includes fibers selected from the group consisting of mineral fibers, aramid fibers, ceramic fibers, metal fibers, carbon fibers, polyimide fibers, polyester fibers, rayon fibers, glass fibers, and cellulosic fibers.

4. The composition of claim 1, wherein the collection of matter includes glass fibers.

5. The composition of claim 4, wherein the composition is uncured fiberglass insulation.

6. The composition of claim 1, wherein the collection of matter includes cellulosic fibers.

7. The composition of claim 6, wherein the cellulosic fibers are present in a cellulosic substrate selected from the group consisting of wood shavings, sawdust, wood pulp, and ground wood.

8. The composition of claim 6, wherein the composition is uncured wood fiber board.

9. The composition of claim 1 wherein the monosaccharide is selected from the group consisting of dextrose, xylose, fructose, dihydroxyacetone, and mixtures thereof.

10. The composition of claim 1, wherein the monosaccharide is dextrose.

11. The composition of claim 1, wherein the polycarboxylic acid is a monomeric polycarboxylic acid.

12. The composition of claim 1, wherein the polycarboxylic acid is a polymeric polycarboxylic acid.

13. The composition of claim 11, wherein the monomeric polycarboxylic acid is selected from the group consisting of an unsaturated aliphatic polycarboxylic acid, a saturated aliphatic polycarboxylic acid, an aromatic polycarboxylic acid, an unsaturated cyclic polycarboxylic acid, a saturated cyclic polycarboxylic acid, hydroxy-substituted derivatives thereof, anhydrides thereof, and mixtures thereof.

14. The composition of claim 12, wherein the polymeric polycarboxylic acid is selected from the group consisting of polyacrylic acid, polymethacrylic acid, and polymaleic acid, copolymers thereof, and mixtures thereof.

15. The composition of claim 10, wherein the polycarboxylic acid is selected from the group consisting of citric acid, maleic acid, tartaric acid, malic acid, succinic acid, and mixtures thereof.

16. The composition of claim 10, wherein the polycarboxylic acid is citric acid.

17. The composition of claim 16, wherein a dried sample of the Maillard reactants displays the infra-red absorption spectrum shown in FIG. 3.

18. The composition of claim 1, wherein the composition further comprises a silicon-containing compound.

19. The composition of claim 18, wherein the silicon-containing compound is amino-substituted.

20. The composition of claim 18, wherein the silicon-containing compound is a silylether.

21. The composition of claim 18, wherein the silicon-containing compound is selected from the group consisting of gamma-aminopropyltriethoxysilane, gamma-glycidoxypropyltrimethoxysilane, aminoethylaminopropyltrimethoxysilane, n-propylamine silane, and mixtures thereof.

22. The composition of claim 18, wherein the silicon-containing compound is gamma-aminopropyltriethoxysilane.

23. The composition of claim 1, wherein the composition further comprises a non-carbohydrate polyhydroxy reactant.

24. The composition of claim 23, wherein the non-carbohydrate polyhydroxy reactant is selected from the group consisting of trimethylolpropane, glycerol, pentaerythritol, polyvinyl alcohol, partially hydrolyzed polyvinyl acetate, fully hydrolyzed polyvinyl acetate, and mixtures thereof.

25. The composition of claim 1, wherein the composition further comprises a corrosion inhibitor, said inhibitor capable of decreasing the corrosivity of glass fibers.

26. The composition of claim 25, wherein the corrosion inhibitor is selected from the group consisting of dedusting oil, monoammonium phosphate, sodium metasilicate pentahydrate, melamine, tin (II)oxalate, and a methylhydrogen silicone fluid emulsion.

27. A composition, comprising:

water-insoluble melanoidins disposed as a binder on a collection of matter, wherein said binder displays the elemental analysis results shown in Table 2.

28. The composition of claim 27, wherein the binder displays the infra-red absorption spectrum shown in FIG. 4.

29. The composition of claim 27, wherein the composition is free of melanoidin reactant compounds.

30. The composition of claim 27, wherein the collection of matter includes fibers selected from the group consisting of mineral fibers, aramid fibers, ceramic fibers, metal fibers, carbon fibers, polyimide fibers, polyester fibers, rayon fibers, glass fibers, and cellulosic fibers.

31. The composition of claim 27, wherein the collection of matter includes glass fibers.

32. The composition of claim 31, wherein the composition is cured fiberglass insulation.

33. The composition of claim 32, wherein the cured fiberglass insulation is selected from the group consisting of cured blanket, air duct board, residential blanket insulation, and pipe insulation.

34. The composition of claim 32, wherein the cured fiberglass insulation has an average smoke development on ignition in the range from about 2,500 m²/kg at 35 kW/m² external heat flux to about 2,300 m²/kg at 50 kW/m² external heat flux.

35. The composition of claim 27, wherein the collection of matter includes cellulosic fibers.

36. The composition of claim 35, wherein the composition is cured wood fiber board.

37. The composition of claim 27, wherein the binder is a water-resistant thermoset binder.

38. The composition of claim 27, wherein the melanoidins are produced from Maillard reactants upon thermal curing thereof, said Maillard reactants comprising a mixture of:

(a) dextrose; and

(b) triammonium citrate,

where the ratio of the number of moles of said triammonium citrate to the number of moles of said dextrose is about 1;

6.

39. The composition of claim 38, wherein the Maillard reactants further comprise a silicon-containing compound.

40. The composition of claim 39, wherein the silicon-containing compound is amino-substituted.

41. The composition of claim 39, wherein the silicon-containing compound is a silylether.

42. The composition of claim 39, wherein the silicon-containing compound is selected from the group consisting of gamma-aminopropyltriethoxysilane, gamma-glycidoxypropyltrimethoxysilane, aminoethylaminopropyltrimethoxysilane, n-propylamine silane, and mixtures thereof.

43. The composition of claim 39, wherein the silicon-containing compound is gamma-aminopropyltriethoxysilane.

44. The composition of claim 38, wherein the Maillard reactants further comprise a non-carbohydrate polyhydroxy reactant.

45. The composition of claim 44, wherein the non-carbohydrate polyhydroxy reactant is selected from the group consisting of trimethylolpropane, glycerol, pentaerythritol, polyvinyl alcohol, partially hydrolyzed polyvinyl acetate, fully hydrolyzed polyvinyl acetate, and mixtures thereof.

46. The composition of claim 38, wherein the Maillard reactants further comprise a corrosion inhibitor, said inhibitor capable of decreasing the corrosivity of glass fibers.

47. The composition of claim 46, wherein the corrosion inhibitor is selected from the group consisting of dedusting oil, monoammonium phosphate, sodium metasilicate pentahydrate, melamine, tin (II) oxalate, and methylhydrogen silicone fluid emulsion.

48. The composition of claim 38, wherein the composition further comprises an ester or polyester compound.