Binders and materials made therewith

  • US 9,464,207 B2
  • Filed: 04/23/2013
  • Issued: 10/11/2016
  • Est. Priority Date: 07/26/2005
  • Status: Active Grant
First Claim
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1. A method of making a thermal or acoustical fiberglass insulation product, wherein the thermal or acoustical fiberglass insulation product comprises glass fibers, said glass fibers being present in the fiberglass insulation product in the range from about 80% to about 99% by weight, wherein the method comprises:

  • spraying an uncured aqueous binder solution onto a mat of glass fibers during production of the fiberglass insulation product such that, once the aqueous binder solution is in contact with the glass fibers, residual heat from the glass fibers and flow of air through the mat evaporates water from the aqueous binder solution, the aqueous binder solution comprising;

    Maillard reactants including (i) an amine reactant and (ii) a carbohydrate reactant, 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, wherein the percent by dry weight of the reducing sugar from the carbohydrate reactant with respect to the total weight of reactants in the aqueous binder solution ranges from about 73% to about 96%;

    transferring the binder coated mat to and through a curing oven;

    heating the binder coated mat in the curing oven and curing the binder so as to produce the thermal or acoustical fiberglass insulation product, wherein i) heated air is passed through the mat to cure the binder in contact with the glass fibers, ii) flights above and below the mat slightly compress the mat to give the fiberglass insulation product a predetermined thickness and surface finish, and iii) fibrous glass having a cured, rigid binder matrix emerges from the curing oven so as to produce the fiberglass insulation product in the form of a batt; and

    compressing the batt for packaging and shipping to a thickness of less than about 90% of its end of line thickness,wherein curing of the binder consists essentially of a Maillard reaction, and wherein the cured binder is a formaldehyde-free, water resistant, thermoset binder comprising nitrogen-containing polymers that attach the glass fibers of the mat together.

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