Binders and Materials Made Therewith

• US 20130237113A1
• Filed: 04/23/2013
• Published: 09/12/2013
• Est. Priority Date: 07/26/2005
• Status: Active Grant

• Current Assignee: Knauf Insulation, Inc. (GEBR Knauf Verwaltungsgesellschaft KG)
• Original Assignee: Knauf Insulation GmbH (GEBR Knauf Verwaltungsgesellschaft KG)
• Inventors: SWIFT, Brian Lee, XU, Ruijian, KISSELL, Ronald E.
• Granted Patent: US 9,464,207 B2
• Time in Patent Office: Days
• US Class Current: 442/410
• 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

A curable aqueous composition is disclosed comprising a carbohydrate, a crosslinking agent, and an amine base, wherein the curable aqueous composition has a pH adjusted by the amine base. Further disclosed is a method of forming a curable aqueous solution.

Claims

1-22. -22. (canceled)

23. A method of making a thermal or acoustical fiberglass insulation product, comprising the steps of:

spraying an aqueous binder onto a mat of fibers, the aqueous binder comprising;

Maillard reactants including (i) an amine reactant and (ii) a carbohydrate reactant, wherein the binder is uncured;

transferring the binder coated mat to a curing oven; and

heating the mat in the curing oven and curing the binder so as to produce the thermal or acoustical fiberglass insulation product, wherein curing of the binder consists essentially of a Maillard reaction.

24. The method of claim 23, wherein the amine reactant is selected from the group consisting of proteins, peptides, amino acids, a compound possessing a primary amino group, a compound possessing a secondary amino group, an ammonium salt of one or more monomeric polycarboxylic acids, and an ammonium salt of one or more polymeric polycarboxylic acids.

25. The method of claim 23, wherein the carbohydrate reactant is selected from one or more carbohydrate reactants having one or more reducing sugars, one or more carbohydrate reactants which yield one or more reducing sugars in situ under thermal curing conditions, and combinations thereof.

26. The method of claim 23, wherein the carbohydrate reactant includes a monosaccharide reducing sugar.

27. The method of claim 26, wherein the monosaccharide reducing sugar is selected from the group consisting of erythrose, threose, erythrulose, ribose, arabinose, lyxose, ribulose, arabulose, xylulose, lyxulose, mannose, galactose, allose, altrose, talose, gulose, psicose, sorbose, tagatose, and sedoheptulose.

28. The method of claim 26, wherein the monosaccharide reducing sugar is selected from the group consisting of dextrose, xylose, fructose, and dihydroxyacetone.

29. The method of claim 26, wherein the monosaccharide reducing sugar comprises dextrose.

30. The method of claim 25, wherein the carbohydrate reactant comprises one or more carbohydrate reactants which yield one or more reducing sugars in situ under thermal curing conditions selected from the group consisting of sucrose, lactose, maltose, starch, and cellulose.

31. The method of claim 23, wherein the binder further comprises one or more acids or salts thereof.

32. The method of claim 31, wherein the one or more acids or salts thereof comprise an inorganic acid.

33. The method of claim 32, wherein the inorganic acid salts comprise a sodium salt or a potassium salt.

34. The method of claim 31, wherein the one or more acids or salts thereof comprise an organic acid.

35. The method of claim 34, wherein the organic acid comprises a monomeric polycarboxylic acid.

36. The method of claim 35, wherein the monomeric polycarboxylic acid comprises citric acid.

37. The method of claim 34, wherein the organic acid comprises a polymeric polycarboxylic acid.

38. The method of claim 23, wherein the binder further comprises a silicon-containing coupling agent.

39. The method of claim 38, wherein the silicon-containing coupling agent is amino-substituted.

40. The method of claim 38, wherein the silicon-containing coupling agent is a silyl ether.

41. The method of claim 38, wherein the silicon-containing coupling agent includes at least one of gamma-aminopropyltriethoxysilane, gamma-glycidoxypropyltrimethoxysilane, aminoethylaminopropyltrimethoxysilane, and n-propylamine silane.

42. The method of claim 23, wherein the binder further comprises a corrosion inhibitor.

43. The method of claim 42, wherein the corrosion inhibitor is selected from at least one of the group consisting of dedusting oil, monoammonium phosphate, sodium metasilicate pentahydrate, melamine, tin(II)oxalate, and a methylhydrogen silicone fluid emulsion.

44. The method of claim 23, wherein the aqueous binder applied to the mat of fibers has an alkaline pH.

45. The method of claim 23, wherein binder in contact with the fibers is dehydrated and subsequently cured.

46. The method of claim 23, wherein the aqueous binder applied to the mat of fibers is formaldehyde free.

47. The method of claim 23, wherein the fiberglass insulation product comprises fibers selected from mineral fibers and glass fibers.

48. The method of claim 23, wherein curing of the binder generates water-insoluble melanoidins.

49. The method of claim 23, wherein the binder comprises polymers and/or oligomers and wherein curing of the binder comprises chemically cross-linking the polymers and/or oligomers.

50. The method of claim 23, wherein curing of the binder includes concurrent, contemporaneous, or sequential production and cross-linking of melanoidins.

51. A thermal or acoustical fiberglass insulation product made by a process comprising the steps of:

spraying an aqueous binder onto a mat of fibers, the aqueous binder consisting essentially of;

(i) at least one amine reactant, (ii) at least one carbohydrate reactant selected from one or more carbohydrate reactants having one or more reducing sugars, one or more carbohydrate reactants which yield one or more reducing sugars in situ under thermal curing conditions, and combinations thereof, and (iii) optionally one or more acids or salts thereof, wherein the binder is uncured;

transferring the binder coated mat to a curing oven; and

heating the mat in the curing oven and curing the binder so as to produce the thermal or acoustical fiberglass insulation product.

52. The fiberglass insulation product of claim 51, wherein the one or more acids or salts thereof comprise an inorganic acid.

53. The fiberglass insulation product of claim 52, wherein the inorganic acid salts comprise a sodium salt or a potassium salt.

54. The fiberglass insulation product of claim 51, wherein the one or more acids or salts thereof comprise an organic acid.

55. The fiberglass insulation product of claim 54, wherein the organic acid comprises a monomeric polycarboxylic acid.

56. The fiberglass insulation product of claim 55, wherein the monomeric polycarboxylic acid comprises citric acid.

57. The fiberglass insulation product of claim 54, wherein the organic acid comprises a polymeric polycarboxylic acid.

58. The fiberglass insulation product of claim 51, wherein the at least one amine reactant is selected from the group consisting of proteins, peptides, amino acids, a compound possessing a primary amino group, a compound possessing a secondary amino group, ammonium salts of polymeric polycarboxylic acids, and ammonium salts of monomeric polycarboxylic acids.

59. The fiberglass insulation product of claim 51, wherein the at least one carbohydrate reactant includes a monosaccharide reducing sugar.

60. The fiberglass insulation product of claim 59, wherein the monosaccharide reducing sugar is selected from the group consisting of erythrose, threose, erythrulose, ribose, arabinose, lyxose, ribulose, arabulose, xylulose, lyxulose, mannose, galactose, allose, altrose, talose, gulose, psicose, sorbose, tagatose, and sedoheptulose.

61. The fiberglass insulation product of claim 59, wherein the monosaccharide reducing sugar is selected from the group consisting of dextrose, xylose, fructose, and dihydroxyacetone.

62. The fiberglass insulation product of claim 59, wherein the monosaccharide reducing sugar comprises dextrose.

63. The fiberglass insulation product of claim 51, wherein the at least one carbohydrate reactant comprises one or more carbohydrate reactants which yield one or more reducing sugars in situ under thermal curing conditions selected from the group consisting of sucrose, lactose, maltose, starch, and cellulose.

64. The fiberglass insulation product of claim 51, wherein the binder includes a silicon-containing coupling agent.

65. The fiberglass insulation product of claim 64, wherein the silicon-containing coupling agent is amino-substituted.

66. The fiberglass insulation product of claim 64, wherein the silicon-containing coupling agent is a silyl ether.

67. The fiberglass insulation product of claim 64, wherein the silicon-containing coupling agent includes at least one of gamma-aminopropyltriethoxysilane, gamma-glycidoxypropyltrimethoxysilane, aminoethylaminopropyltrimethoxysilane, and n-propylamine silane.

68. The fiberglass insulation product of claim 51, wherein the binder includes a corrosion inhibitor.

69. The fiberglass insulation product of claim 68, wherein the corrosion inhibitor is selected from at least one of the group consisting of dedusting oil, monoammonium phosphate, sodium metasilicate pentahydrate, melamine, tin(II)oxalate, and a methylhydrogen silicone fluid emulsion.

70. The fiberglass insulation product of claim 51, wherein the aqueous binder applied to the mat of fibers has an alkaline pH.

71. The fiberglass insulation product of claim 51, wherein binder in contact with the fibers is dehydrated and subsequently cured.

72. The fiberglass insulation product of claim 51, wherein the aqueous binder applied to the mat of fibers is formaldehyde free.

73. The fiberglass insulation product of claim 51, wherein the fiberglass insulation product comprises fibers selected from mineral fibers and glass fibers.

74. The fiberglass insulation product of claim 51, wherein the cured binder comprises water-insoluble melanoidins.

75. The fiberglass insulation product of claim 51, wherein curing of the binder consists essentially of a Maillard reaction.

76. The fiberglass insulation product of claim 51, wherein the aqueous binder consists of (i) the amine reactant(s), (ii) the carbohydrate reactant(s), (iii) optionally one or more acids, and (iv) optionally one or more additives.

77. The fiberglass insulation product of claim 51, wherein the aqueous binder consists of (i) the amine reactant(s), (ii) one or more reducing sugar carbohydrate reactant(s), (iii) optionally one or more acids, and (iv) optionally one or more additives.

78. The fiberglass insulation product of claim 51, wherein the amine reactant is ammonium citrate and the carbohydrate reactant is dextrose.