Hydraulic binder composition and its uses

• US 5,459,181 A
• Filed: 07/23/1993
• Issued: 10/17/1995
• Est. Priority Date: 07/23/1993
• Status: Expired due to Term

• Current Assignee: Mat Incorporated
• Original Assignee: Weyerhaeuser Company (Weyerhauser)
• Inventors: West, Hugh, Delgado-Fornue, Ezequeil
• Primary Examiner(s): SANDERS, KRIELLION ANTIONETTE
• Application Number:
  US08/096,082
• Time in Patent Office: 816 Days
• Field of Search: 524/35, 524/55, 524/56, 524/598, 523/132
• US Class Current: 524/35
• CPC Class Codes: B09B 3/21 using organic binders or matrix
• CPC Class Codes: C09K 17/48 Organic compounds mixed with inorganic active ingredients, e.g. polymerisation catalysts
• CPC Class Codes: C09K 17/50 the organic compound being of natural origin, e.g. cellulose derivatives
• CPC Class Codes: Y02W 30/78 Recycling of wood or furniture waste

Abstract

A three-part dry blended soluble mixture which includes a water soluble hydroxyl group bearing polymer, a covalent crosslinking agent, and a catalyst is made into an aqueous solution which is then applied to any underlying material of choice. After drying, the crosslinked polymer forms a material that is completely insoluble in water, thereby serving as a binder or tackifier. One additive that may be included with the dry blend is wood fiber in an approximate weight ratio of nine to one and thereafter this dry blend is combined with water where the three-part dry blend goes into solution while the fibers remain in suspension. This composition is then spray applied to any underlying material and upon drying, there is formed a bonded fiber matrix which is relatively strong and which has many applications such as for use as an erosion control/seeding material, a covering for landfills, or a covering for other particulate materials stored in an outside location. The insoluble polymer with or without the fiber will biodegrade over time in an outdoor environment.

Claims

1. A dry blend composition that is initially a mixture that is soluble in water, but, after being admixed with water and allowed to dry, said composition becomes a water insoluble, cross-linked polymer, said dry blend composition comprising:

about ten parts by weight of a water soluble hydroxyl group bearing polymer,

0.01 to 5 parts by weight of an amine/formaldehyde condensate pre-polymer bearing two or more methylol groups as a cross-linking agent for said hydroxyl group bearing polymer, and

an effective amount of an acid or base catalyst to enhance the reaction between the amine/formaldehyde condensate pre-polymer and said cross-linking agent.

2. The composition of claim 1 further including a formaldehyde scavenging compound present in an amount of from 0 to 5 parts by weight.

3. The composition of claim 1 further including fibers as an additive to the water soluble mixture.

4. The composition of claim 3 wherein the fibers are wood fibers.

8. The composition of claim 1 wherein said catalyst is present in an amount from 0.01 to about 5 parts by weight.

5. A water insoluble, cross-linked polymer material useful as a binder which is formed by dissolving in water, and thereafter being allowed to dry, a three-part dry blend comprising:

water soluble hydroxyl group bearing polymer, present in about ten parts by weight,

an amine/formaldehyde condensate pre-polymer bearing two or more methylol groups as a cross-linking agent for said hydroxyl group bearing polymer, in an amount of from 0.01 to 5 parts by weight, and

an acid or base catalyst in an amount effective to enhance the reaction between the hydroxyl group bearing polymer and crosslinking agent.

6. The insoluble polymer of claim 5 further including fibers which are suspended in the aqueous solution and after drying are part of a fiber-polymer matrix.

7. The polymer of claim 6 wherein the fibers are wood fibers.

9. The composition of claim 5 wherein said catalyst is present in an amount from 0.01 to about 5 parts by weight.