Binders and materials made therewith

• US 20070142596A1
• Filed: 01/25/2007
• Published: 06/21/2007
• 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 7,655,711 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: 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 binder, comprising:

a mixture of Maillard reactants, wherein said Maillard reactants comprise

(a) a monosaccharide; and

(b) an ammonium salt of a polycarboxylic acid,

wherein said binder is an aqueous solution and wherein the ratio of the number of moles of said ammonium salt to the number of moles of said monosaccharide is in the range from about 1;

4 to about 1;

15.

2. The binder of claim 1, wherein the ratio of the number of moles of the ammonium salt to the number of moles of the monosaccharide is in the range from about 1:

5 to about 1;

7.

3. The binder of claim 2, wherein the ratio of the number of moles of the ammonium salt to the number of moles of the monosaccharide is about 1:

6.

4. The binder of claim 1, wherein the binder is free of melanoidins.

5. The binder of claim 1, wherein the pH of the binder is in the range from greater than about 7 to less than or equal to about 10.

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

7. The binder of claim 1, wherein the monosaccharide is dextrose.

8. The binder of claim 1, wherein the polycarboxylic acid is a monomeric polycarboxylic acid.

9. The binder of claim 8, 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.

10. The binder of claim 1, wherein the polycarboxylic acid is a polymeric polycarboxylic acid.

11. The binder of claim 10, wherein the polymeric polycarboxylic acid is selected from the group consisting of polyacrylic acid, polymethacrylic acid, and polymaleic acid, copolymers thereof, anhydrides thereof, and mixtures thereof.

12. The binder of claim 7, wherein the polycarboxylic acid is selected from the group consisting of citric acid, maleic acid, tartaric acid, malic acid, succinic acid, and mixtures thereof.

13. The binder of claim 7, wherein the polycarboxylic acid is citric acid.

14. The binder of claim 13, wherein a dried sample of the Maillard reactants displays the infra-red absorption spectrum shown in FIG. 3.

15. The binder of claim 13, wherein a cured sample of the binder displays the infra-red absorption spectrum shown in FIG. 4.

16. The binder of claim 1, wherein the binder further comprises a silicon-containing compound.

17. The binder of claim 16, wherein the silicon-containing compound is amino-substituted.

18. The binder of claim 16, wherein the silicon-containing compound is a silylether.

19. The binder of claim 16, wherein the silicon-containing compound is selected from the group consisting of gamma-aminopropyltriethoxysilane, gamma-glycidoxypropyltrimethoxysilane, aminoethylaminopropyltrimethoxysilane, n-propylamine silane, and mixtures thereof.

20. The binder of claim 16, wherein the silicon-containing compound is gamma-aminopropyltriethoxysilane.

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

22. The binder of claim 21, 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.

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

24. The binder of claim 23, 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.

26. The method of claim 25, wherein the contacting step includes the binder of claim 1.

28. The method of claim 27, wherein the contacting step includes the binder of claim 1.

30. A composition, comprising fibers bound by the method of, claim 26.

32. A composition, comprising fibers bound by the method of claim 28.

25. A method for binding fibers, comprising the steps of:

(a) contacting said fibers with a binder comprising a mixture of Maillard reactants; and

(b) removing water from said binder in contact with said fibers to dehydrate said binder.

27. The method of claim 25, further comprising the step of:

(c) heating the dehydrated binder in contact with the fibers at a temperature sufficient to cure the dehydrated binder and produce a water-resistant thermoset binder.

29. A composition, comprising fibers bound by the method of claim 25.

31. A composition, comprising fibers bound by the method of claim 27.