Binders

• US 8,114,210 B2
• Filed: 08/01/2008
• Issued: 02/14/2012
• Est. Priority Date: 08/03/2007
• Status: Active Grant

• Current Assignee: Knauf Insulation, Inc. (GEBR Knauf Verwaltungsgesellschaft KG)
• Original Assignee: Knauf Insulation Sprl (GEBR Knauf Verwaltungsgesellschaft KG)
• Inventors: Mueller, Gert, Hampson, Carl, Appley, Charles
• Primary Examiner(s): Brunsman, David M
• Application Number:
  US12/599,858
• Publication Number:
  US 20100301256A1
• Time in Patent Office: 1,292 Days
• Field of Search: 106/217.6, 106/217.9
• US Class Current: 106/217.6
• CPC Class Codes: C03C 13/06 Mineral fibres, e.g. slag wool, mineral wool, rock wool
• CPC Class Codes: C03C 25/32 obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds
• CPC Class Codes: C03C 25/321 Starch; Starch derivatives
• CPC Class Codes: C03C 25/34 Condensation polymers of aldehydes, e.g. with phenols, ureas, melamines, amides or amines
• CPC Class Codes: C08H 8/00 Macromolecular compounds derived from lignocellulosic materials pretreatment thereof B27N
• CPC Class Codes: C08K 5/175 containing COOH-groups; Esters or salts thereof
• CPC Class Codes: C08K 7/14 Glass
• CPC Class Codes: C08L 101/025 containing nitrogen atoms
• CPC Class Codes: C08L 101/06 containing oxygen atoms C08L101/025 takes precedence
• CPC Class Codes: C08L 97/02 Lignocellulosic material, e.g. wood, straw or bagasse manufacture of articles made from lignocellulosic material by dry processes B27N
• CPC Class Codes: C08L 99/00 Compositions of natural macromolecular compounds or of derivatives thereof not provided for in groups C08L89/00 - C08L97/00
• CPC Class Codes: C09D 197/02 Lignocellulosic material, e.g. wood, straw or bagasse
• CPC Class Codes: C09D 199/00 Coating compositions based on natural macromolecular compounds or on derivatives thereof, not provided for in groups C09D101/00 - C09D107/00 or C09D189/00 - C09D197/00
• CPC Class Codes: C09D 201/025 containing nitrogen atoms
• CPC Class Codes: C09D 201/06 containing oxygen atoms C09D201/025 takes precedence
• CPC Class Codes: C09K 3/00 Materials not provided for elsewhere
• CPC Class Codes: D04H 1/4209 Inorganic fibres
• CPC Class Codes: D04H 1/4218 Glass fibres
• CPC Class Codes: D04H 1/64 the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• CPC Class Codes: E04B 1/7658 comprising fiber insulation, e.g. as panels or loose filled fibres
• CPC Class Codes: E04B 1/7662 : comprising fiber blankets or batts
• CPC Class Codes: F16L 59/028 : Composition or method of fixing a thermally insulating material

Abstract

An un-reacted substantially formaldehyde free curable binder solution for binding loose matter consists essentially of a solution obtainable by dissolving a reducing sugar, an ammonium salt acid precursor optionally a carboxylic acid or a precursor thereof and optionally ammonia in water.

Claims

1. A substantially formaldehyde free binder solution consisting essentially of a solution obtainable by dissolving

a reducing sugar, and

at least 2.5% by dry weight with respect to the reducing sugar of a material selected from the group consisting of ammonium sulphate salts, ammonium phosphate salts, ammonium nitrate salts, ammonium carbonate salts, and combinations thereof

in water.

2. The substantially formaldehyde free binder solution of claim 1, in which the reducing sugar consists essentially of dextrose and there is at least 7% by dry weight of the salt material with respect to dextrose.

3. The substantially formaldehyde free binder solution in accordance with claim 1, in which a carboxylic acid is included or provided in the form of an ammonium salt.

4. The substantially formaldehyde free binder solution in accordance with claim 1, in which the pH of the solution is greater than 7.

5. The substantially formaldehyde free binder solution in accordance with claim 1, in which the binder solution has a pH which, in its conditions of use, prevents precipitation of sulphates, phosphates, nitrates or carbonates.

6. The substantially formaldehyde free binder solution in accordance with claim 1, in which material selected from the group consisting of ammonium sulphate salts, ammonium phosphate salts, ammonium nitrate salts, ammonium carbonate salts, and combinations thereof makes up between 5% and 25% by dry weight of the binder solution.

7. The substantially formaldehyde free binder solution in accordance with claim 1, in which the binder solution contains at least 5% solids and less than 50% solids.

8. The substantially formaldehyde free binder solution in accordance with claim 1, in which the ratio by dry weight of reducing sugar to material selected from the group consisting of ammonium sulphate salts, ammonium phosphate salts, ammonium nitrate salts, ammonium carbonate salts, and combinations thereof (expressed as dry weight of reducing sugar/dry weight of ammonium salt) is in the range 2.5 to 13.

9. The substantially formaldehyde free binder solution in accordance with claim 1, in which the binder solution contains between 0.1% and 1% of a silane or silicon-containing coupling agent calculated as dissolved binder solids.

10. A method of manufacturing a product comprising the steps of:

providing a collection of loose matter;

treating the collection of loose matter with the substantially formaldehyde free binder solution of claim 1;

arranging the collection of loose matter treated with the binder solution into the shape of the product; and

curing the binder by applying a source of energy.

11. The method of claim 10, in which the curing of the binder is carried out by passing the arranged collection of loose matter treated with the binder solution through at least one zone of a curing oven at a temperature within the range 230°

C.-300°

C. with an oven residence time in the range 30 seconds to 20 minutes.

12. The method of claim 10, in which the curing of the binder is carried out by between platens of a press.

13. A material comprising a collection of loose matter and uncured or partially cured substantially formaldehyde free binder characterised in that the binder has a pH of greater than 6 when dissolved in water and comprises

a reducing sugar, and

at least 2.5% by dry weight with respect to the reducing sugar of an ammonium salt selected from the group consisting of ammonium sulphate salts, ammonium phosphate salts, ammonium nitrate salts, ammonium carbonate salts, and combinations thereof.

14. The material of claim 13 in which the loose matter comprises mineral fibres.

15. The material of claim 13, having more than 500 mg/kg of species selected from the group consisting of sulphates, phosphates, nitrates, carbonates, and combinations thereof.

16. The material of claim 15, in which the species selected from the group consisting of sulphates, phosphates, nitrates, carbonates, and combinations thereof is derived from the ammonium salt.

17. The material of claim 15, in which the binder is partially cured and comprises melanoidins.