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    • 专利摘要:
    aqueous binder composition for use in forming nonwoven veils and fiberglass insulators, fibrous insulating product, nonwoven veil, insulating product formed by the process and method of producing a fibrous insulating product. An aqueous binder composition comprising a carbohydrate and a crosslinking agent is provided. in exemplary embodiments, the carbohydrate-based optimum composition may also include a catalyst, a coupling agent, a process aid, a crosslinked density enhancer, an extender, a moisture resistant agent, a non-dusty oil, a dye, a corrosion inhibitor, a surfactantwith a ph adjuster and combinations thereof. Carbohydrate can be nartural in origin and derived from renewable sources. In addition, the carbohydrate polymer has a dextrose equivalent number of from 2 to 20. In at least one exemplary embodiment the carbohydrate is a water soluble polysaccharide such as dextrin or maltodextrin and the crosslinking agent is citric acid. Advantageously, carbohydrates have a low viscosity and cure at moderate temperatures. The environmentally sustainable formaldehyde free binder can be used in forming insulating materials and nonwoven shredded webs. A method of manufacturing fibrous insulating products is also provided.
    公开号:BR112012007961B1
    申请号:R112012007961-1
    申请日:2010-10-08
    公开日:2019-11-19
    发明作者:Christopher Hawkins；Jesus Hernandez-Torres；Liang Chen
    申请人:Owens Corning Intellectual Capital, Llc；
    IPC主号:
    专利说明:

    “COMPOSITION OF WATER BINDER FOR USE IN FORMING NON-WOVEN CARPETS AND FIBERGLASS INSULATORS, FIBROUS INSULATING PRODUCTS, NON-WOVEN CARPETS AND PROCESS FOR FORMING FIBROUS INSULATING PRODUCTS”
    CROSS REFERENCE TO RELATED APPLICATIONS [001] This application refers to and claims priority benefits from United States Provisional Patent Application Serial No. 61 / 250,187 entitled “Binders based on biological matter for insulating and non-woven veils” filed on 9 October 2009, the entire content of which is expressly incorporated herein by reference.
    TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION [002] The present invention relates in general to rotating and non-woven fiber insulating veils and, more particularly, to a binder based on biological material for use in the manufacture of both insulating veils of glass and non-woven fibers that are based on biological material, do not contain added formaldehyde, are cross-linked through an esterification reaction and are environmentally friendly.
    BACKGROUND OF THE INVENTION [003] Conventional fibers are useful in a variety of applications including reinforcement materials, textiles and acoustic and thermal insulation. Although mineral fibers (eg, glass fibers) are normally used in insulating products and non-woven veils, depending on the particular application, organic fibers such as polypropylene, polyester and multi-component fibers can be used alone or in combination with fibers minerals in the formation of the insulating product or non-woven veil.
    [004] Fibrous insulation is usually manufactured by breaking fibers into a melted composition of polymer, glass or other material and spinning fine fibers
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    2/55 from a fiber breaker, such as a spinner. To form an insulating product, fibers produced by the spinning guarantor are dragged downward from the guarantor towards a transmitter by a fan. As the fibers move downward, a binder material is sprayed onto the fibers and the fibers are collected on a continuous high mat blanket at the transmitter. The binder material gives the insulating product resilience for recovery after packaging and provides rigidity and malleability so that the insulating product can be handled and applied when necessary in the insulating cavities of buildings. The binder composition also provides fiber protection from inter-filament abrasion and promotes compatibility between individual fibers.
    [005] The mat containing the binder-coated fibers is then passed through a curing oven and the binder is cured to adjust the mat to a desired thickness. After the binder has cured, the fiber insulation can be cut into pieces to form individual insulating products, and the insulating products can be packaged for transportation to customer locations. A typical insulating product produced is a covering or blanket, which is suitable for use as a wall insulator in residential homes or as an insulator in the attic and floor insulation cavities in buildings. Another common insulating product is air-blown insulating (via air blowing) or insulating with filling which is suitable for use as side wall and attic insulators in residential and commercial buildings as well as in any difficult to reach locations. Insulation with filling is formed of small cubes that are cut from insulating blankets, compressed and packed in bags.
    [006] Non-woven veils can be formed by wet-laid processes. For example, wet chopped fibers are dispersed in water sludge containing surfactants, viscosity modifiers, defoaming agents and / or other
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    3/55 chemical agents. The sludge containing the chopped fibers is then agitated so that the fibers become dispersed throughout the sludge. The sludge containing the fibers is deposited on a moving canvas where a substantial portion of the water is removed to form a blanket. A binder is then applied and the resulting veil is dried to remove any remaining water and cure the binder. The formed non-woven veil is a set of individual, scattered glass filaments.
    [007] Several attempts have been made to reduce undesirable formaldehyde emissions from formaldehyde based resins. For example, several formaldehyde scavengers such as ammonia and urea have been added to the formaldehyde-based resin in an attempt to reduce formaldehyde emissions from the insulating product. Due to its low cost, urea is added directly to the uncured resin system to act as a formaldehyde sweeper. The addition of urea to the resin system produces resins of extended urea phenol-formaldehyde. These resins resins can be further treated or applied as a coating or binder and then cured. Unfortunately, the urea extended soles are unstable and, due to their instability, the urea extended soles must be prepared on the spot. In addition, the binder of the invention must be monitored carefully to avoid processing problems caused by crystalline precipitates of dimer species that may form during storage. Ammonia is not a particularly desirable alternative to urea as a formaldehyde sweeper because ammonia generates an unpleasant odor and can irritate workers' throat and nose. In addition, the use of a formaldehyde sweeper in general is undesirable due to its potential adverse effects on the properties of the insulating product, such as poor recovery and lower stiffness.
    [008] In addition, prior art has focused on the use of polyacrylic acid with a polyhydroxy cross-linking agent or carbohydrate-based chemical that
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    4/55 is linked to the Maillard reaction. Polyacrylic acid binders, however, have numerous disadvantages. For example, polyacrylic acid binders use petroleum-based materials and typically cost at least twice the cost of today's phenolic binder systems. In addition, the high viscosity and different curing characteristics present process difficulties. Also, products based on the Maillard reaction have an undesirable dark brown color after curing. In addition, the use of large amounts of ammonia required to make the binder poses a safe risk and possible emission problems.
    [009] In view of the existing problems with current binders, there remains a need in the art for a binder system that is not dependent on oil, has no added formaldehyde, is based on biological and environmentally friendly material and is competitive in cost.
    SUMMARY OF THE INVENTION [010] It is an object of the invention, to provide a binder composition for use in the formation of fiberglass insulator and nonwoven chopped filament veils that include at least one carbohydrate that is natural in origin and at least one crosslinking agent. The carbohydrate and cross-linking agent form a thermo-adjustable polyester resin. The carbohydrate can have a dextrose equivalent (DE) of 2 to 20. Additionally, the carbohydrate can be a water-soluble polysaccharide selected from pectin, dextrin, maltodextrin, starch, modified starch, starch derivatives and combinations thereof. The crosslinking agent can be selected from polycarboxylic acids, polycarboxylic acid salts, anhydrides, monomeric and polymeric polycarboxylic acid with anhydride, citric acid, citric acid salts, adipic acid, adipic acid salts, polyacrylic acid, polyacrylic acid salts , resins based on polyacrylic acid and the combination of these. In one or more embodiments, the cross-linking agent can be citric acid or monomeric or polymeric polycarboxylic acid and its corresponding salts. In some
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    5/55 exemplary embodiments, the binder composition may include a moisture resistant agent and a pH adjuster. The binding composition is free of added formaldehyde and is environmentally friendly.
    [011] It is another object of the present invention to provide a fibrous insulating product that includes a plurality of randomly oriented fibers and a binder composition applied to at least a portion of the fibers and interconnecting the fibers. The binder includes at least one carbohydrate that is natural in origin and at least one cross-linking agent. The carbohydrate can have a dextrose equivalent (DE) of 2 to 20. In exemplary embodiments, the carbohydrate is a water-soluble polysaccharide selected from pectin, dextrin, maltodextrin, starch, modified starch, starch derivatives and combinations thereof. The binder composition can also include one or more members selected from a catalyst, a coupling agent, a process aid, a crosslink density intensifier, an extender, a moisture resistant agent, a dust removing oil, a dye, a corrosion inhibitor, a surfactant and a pH adjuster. The process aid agent includes a polyol such as glycerol, triethanolamine, polyethylene glycol and pentaerythritol. In one or more embodiments, the cross-linking agent can be citric acid or any monomeric and polymeric polycarboxylic acid and its corresponding salts. Additionally, in low density products (for example, residential insulation products), the binder has a light color (for example, white or brown) after it has been cured.
    [012] It is yet another object of the present invention to provide a chopped nonwoven filament veil formed of a plurality of randomly oriented glass fibers having a discrete size entangled in the form of a veil having a first main surface and a second main surface and a binder composition covering at least partially the first main surface of the web. The binder includes (1) at least one carbohydrate that is natural in origin and has a
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    6/55 dextrose equivalent of 2 to 20 and (2) at least one cross-linking agent. The binder composition can also include one or more members selected from a catalyst, a moisture resistant agent and a pH adjuster. In at least one exemplary embodiment, carbohydrate is a water-soluble polysaccharide selected from pectin, dextrin, maltodextrin, starch, modified starch, starch derivatives and combinations thereof. In addition, the crosslinking agent can be selected from polycarboxylic acids, polycarboxylic acid salts, anhydrides, monomeric and polymeric polycarboxylic acid with anhydride, citric acid, citric acid salts, adipic acid, adipic acid salts, polyacrylic acid, salts of polyacrylic acid, resins based on polyacrylic acid, amino-alcohols, sodium metaborate, polyalkyl-amines, polyamines, polyols and combinations thereof. The binder has a light color after curing, is environmentally friendly and is free of added formaldehyde.
    [013] It is an advantage of the present invention that the carbohydrate is natural in origin and derived from renewable sources.
    [014] It is yet another advantage of the present invention that maltodextrin is readily available and of low cost.
    [015] It is an additional advantage of the present invention that insulating products and non-woven veils using the inventive binder composition can be manufactured using current production lines, saving time and money.
    [016] It is another advantage of the present invention that the binder composition has no formaldehyde added.
    [017] It is also an advantage of the present invention that in low density products (for example, residential insulating products), the final product has a light color that allows the use of paints, pigments and other dyes to render a variety of colors for the insulating product.
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    7/55 [018] It is still an advantage of the present invention that the binder composition has a reduction in particulate emission compared to the conventional phenol / urea / formaldehyde binder composition.
    [019] It is a feature of the present invention that the carbohydrate polymer can have an equivalent number of dextrose (DE) from 2 to 20.
    [020] It is a feature of the present invention that maltodextrin can form an aqueous mixture that can be applied by conventional binder applicators, including spray applicators.
    [021] It is an additional feature of the present invention that the binder can be acidic, neutral or basic.
    [022] It is another feature of the present invention that the inventive insulating products and non-woven veils have no added formaldehyde.
    [023] It is also a feature of the invention that the inventive binder composition can be useful for reinforcing compositions, such as chopped filaments, for use in thermoplastic, heat-adjustable and roofing applications. In addition, the inventive binders can be used in both single and multiple ends.
    [024] The aforementioned and other objectives, characteristics and advantages of the invention will appear more fully below from consideration of the detailed description that follows. It is to be expressly understood, however, that the figures are for illustrative purposes and not to be interpreted as defining the limits of the invention.
    BRIEF DESCRIPTION OF THE FIGURES [025] The advantages of this invention will become evident after considering the following detailed report of the invention, especially when taken in conjunction with the accompanying figures, in which:
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    8/55
    FIG. 1 is a schematic illustration of the formation of an insulating product coated with the inventive binder composition according to an exemplary embodiment;
    FIG.2 is a top view of a manufacturing line for producing a fiberglass insulating product with the inventive binder composition where the insulating product does not contain a coating material according to another exemplary embodiment of the present invention; and
    FIG 3 is a schematic illustration of a nonwoven processing line for forming a shredded filament web using the inventive binder composition according to an additional exemplary embodiment of the present invention.
    DETAILED DESCRIPTION AND PREFERENTIAL MODALITIES OF THE INVENTION [026] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by someone ordinarily skilled in the technique to which the invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are described here. All references cited here, including published or corresponding US or foreign patent applications, US or foreign published patents, and any other references, are each incorporated by reference in their entirety, including all data, tables, figures and texts presented in the cited references.
    [027] In the figures, the thickness of lines, layers and regions can be exaggerated for clarity. It will be understood that when an element such as a layer, region, substrate or panel is referred to as "over" another element, it may be directly over the other element or intervening elements may be present. In addition, when an element is referred to as being
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    9/55 “adjacent” to another element, the element may be directly adjacent to the other element or intervening elements may be present. The terms "top", "bottom", "side" and others are used here for explanation purposes only. Equal numbers found in the figures denote equal elements. It should be noted that the phrases; "Binder", "biological material based binder", "binder composition" and "binder formulation" can be used interchangeably here.
    [028] The present invention relates to aqueous polyester binder compositions, environmentally friendly, which contain at least one component based on biological material. In an exemplary embodiment, the component based on biological material is a carbohydrate and the binder and includes a carbohydrate and a cross-linking agent. In some exemplary embodiments, the carbohydrate-based binder composition also includes a coupling agent, a process aid agent, an extender, a pH adjuster, a catalyst, a cross-linked density enhancer, a deodorant, an antioxidant , a dust suppressant, a biocide, a moisture resistant agent or a combination thereof. The binder can be used in the formation of insulating materials and veils of chopped nonwoven filaments. In addition, the binder is free or added formaldehyde. In addition, the binder composition has a reduction in particulate emissions compared to conventional phenol / urea / formaldehyde binder compositions. The inventive binder can also be useful in the formation of particleboard, plywood and / or rigid agglomerates.
    [029] In one or more exemplary modalities, the binder includes at least one carbohydrate that is natural in origin and derived from renewable sources. For example, carbohydrate can be derived from plant sources such as vegetables, yellow corn, white corn, waxy corn, sugar cane, sorghum (milo), white sorghum, potatoes, sweet potatoes, tapioca, rice, peas, sago, oats, wheat, barley, rye, amaranth and / or manioc, as well as other plants that have a high starch content. O
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    10/55 carbohydrate polymer can also be derived from products containing raw starch derived from plants that contain protein residues, polypeptides, lipids and low molecular weight carbohydrates. Carbohydrates can be selected from monosaccharides (eg, xylose, glucose and fructose), disaccharides (eg, sucrose, maltose and lactose), oligosaccharides (eg, glucose syrup and fructose syrup) and water-soluble polysaccharides and polysaccharides (for example, pectin, dextrin, maltodextrin, starch, modified starch and starch derivatives).
    [030] The carbohydrate polymer can have an average molecular weight number of about 1,000 to about 8,000. In addition, the carbohydrate polymer can have a dextrose equivalent number (DE) of 2 to 20, 7 to 11 or 9 to 14. Carbohydrates have a beneficial low viscosity and cure at moderate temperatures (eg 80- 250 ° C) alone or with additives. The low viscosity allows the carbohydrate to be used in a binder composition. In exemplary modalities, the viscosity of the carbohydrate can be less than 500cps at 50% concentration and between 20 and 30 ° C. The use of a carbohydrate in the inventive binding composition is advantageous in that carbohydrates are readily available or readily available and are low in cost.
    [031] In at least one exemplary embodiment, carbohydrate is a water-soluble polysaccharide such as dextrin or maltodextrin. The carbohydrate polymer can be present in the binder composition in an amount of about 40% to about 95% by weight of the total solids in the binder composition, from about 50% to about 95% by weight of the total solids in the binder composition, from about 60% to about 90% or from about 70% to about 85%. As used herein,% by weight indicates% by weight of the total solids in the binder composition.
    [032] In addition, the binder composition contains a cross-linking agent. The cross-linking agent can be any compound suitable for
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    11/55 cross-connect the carbohydrate. In exemplary embodiments, the crosslinker has an average molecular weight number greater than 90, from about 90 to about 10,000, or from about 190 to about 4,000. In some exemplary embodiments, the crosslinker has an average molecular weight number less than about 1000. Non-limiting examples of suitable crosslinkers include polycarboxylic acids (and their salts), anhydrides, monomeric and polymeric polycarboxylic acid with anhydride (ie mixed anhydrides), citric acid (and its salts, such as ammonia citrate), 1,2,3,4-butane tetracarboxylic acid, adipic acid (and its salts), polyacrylic acid (and its salts) and polyacrylic acid based resins such as QXRP 1734 and Acumer 9932, both commercially available from The Dow Chemical Company. In exemplary embodiments, the cross-linking agent can be any monomeric or polymeric polycarboxylic acid, citric acid and its corresponding salts. The cross-linking agent can be present in the binder composition in an amount of up to 50% by weight of the binder composition. In exemplary embodiments, the crosslinking agent can be present in the binder composition in an amount of about 5.0% to about 40% by weight of the total solids in the binder composition or from about 10% to about 30% % by weight.
    [033] Optionally, the binder composition can include a catalyst to assist in cross-linking. The catalyst may include inorganic salts, Lewis acids (for example, aluminum chloride or boron trifluoride), Bronsted acids (ie, sulfuric acid, p-toluenesulfonic acid and boric acid), organometallic complexes (ie, carboxylates of lithium, sodium carboxylates) and / or Lewis bases (i.e., polyethyleneimine, diethylamine or triethylamine). In addition, the catalyst may include an alkali metal salt of an organic acid containing phosphorus; in particular, alkali metal salts of phosphorous acid, hypophosphorous acid or polyphosphoric acids. Examples of such phosphorous catalysts include, but are not
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    12/55 limited to, sodium hypophosphite, sodium phosphate, potassium phosphate, disodium pyrophosphate, tetrasodium pyrophosphate, sodium tripolyphosphate, sodium hexaheta-phosphate, potassium phosphate, potassium tripolyphosphate, sodium trimetaphosphate, sodium tetrametaphosphate, and mixtures thereof. In addition, the curing catalyst or accelerator may be a fluoroborate compound such as a fluoroboric acid, sodium tetrafluoroborate, potassium tetrafluoroborate, calcium tetrafluoroborate, magnesium tetrafluoroborate, zinc tetrafluoroborate, its tetrafluoride and tetrafluoride. In addition, the catalyst can be a mixture of phosphorus and fluoroborate compounds. Other sodium salts such as sodium sulfate, sodium nitrate, sodium carbonate can also or alternatively be used as the catalyst / accelerator. The curing catalyst or accelerator can be present in the binder composition in an amount of about 0% to about 10% by weight of the total solids in the binder composition, or about 1.0% to about 5.0 % by weight, or about 3.0% to about 5.0% by weight.
    [034] The binder composition may optionally contain at least one coupling agent. In at least one exemplary embodiment, the coupling agent is a silane coupling agent. The coupling agent (s) can be present in the binder composition in an amount of about 0.01% to about 5.0% by weight of the total solids in the binder composition, from about 0.01% to about from 2.5% by weight, or from about 0.1% to about 0.5% by weight.
    [035] Non-limiting examples of silane coupling agents that can be used in the binder composition can be characterized by the functional groups alkyl, aryl, amino, epoxy, vinyl, methacryloxy, ureido, isocyanate and mercapto. In exemplary embodiments, the silane coupling agent (s) includes silanes containing one or more nitrogen atoms that have one or more functional groups such as amine (primary, secondary, tertiary and quaternary), amino, imino, starch, imido, ureido or isocyanate. Specific non-limiting examples of
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    Suitable silane coupling agents include, but are not limited to, aminosilanes (for example, 3-aminopropyl-triethoxysilane and 3-aminopropyl-trihydroxysilane), trialoxy-oxisilanes epoxy (for example, 3-glycidooxypropyltrimethoxysilane and
    3-glycidoxypropyltriethoxysilane), methacryl trialkoxysilanes (for example, 3methacryloxypropyltrimethoxysilane and 3-methacryloxypropyltriethoxysilane), trialkoxysilanes hydrocarbon, trihydroxysilanes, hydroxy hydroxylsilanes and trihydroxylsilanes, methiloxy hydroxylsilanes, In one or more exemplary embodiments, silane is an aminosilane, such as y-aminopropyltriethoxysilane.
    [036] Additional exemplary coupling agents (including silane coupling agents) suitable for use in the binder composition are shown below:
    - Acryl: 3-acryloxypropyltrimethoxysilane; 3-acryloxypropyltriethoxysilane; 3acryloxypropylmethyldimethoxysilane; 3-acryloxypropylmethyldietoxysilane; 3 methacryloxypropyltrimethoxysilane; 3-methacryloxypropyltriethoxysilane
    - Amino: aminopropylmethyldimethoxysilane; aminopropyltriethoxysilane; aminopropyltrimethoxysilane / EtOH; aminopropyltrimethoxysilane; N- (2-aminoethyl) -3aminopropyltrimethoxysilane; N- (2-aminoethyl) -3-aminopropylmethyldimethoxysilane; (2-
    aminoethyl) - (2-aminoethyl) 3-aminopropyltrimethoxysilane; N- phenylaminopropyltrimethoxysilane - Epoxy: 3-Glycidooxypropylmethyldietoxysilane; 3- glycidoxypropylmethyldimethoxysilane; 3-glycidoxypropyltriethoxysilane; 2- (3,4-
    eoxycyclohexyl) ethylmethyldimethoxysilane; 2- (3,4-epoxycyclohexyl) ethylmethyldietoxysilane; 2 (3,4-epoxycyclohexyl) ethyltrimethoxysilane; 2- (3,4-Epoxycyclohexyl) ethyltriethoxysilane;
    - Mercapto: 3-mercaptopropyltrimethoxysilane; 3-Mercaptopropyltriethoxysilane;
    3-mercaptopropylmethyldimethoxysilane; 3-
    Mercaptopropylmethyldietoxysilane
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    - Sulfide: bis [3- (triethoxysilyl) propyl] -tetrasulfide; bis [3- (triethoxysilyl) propyl] disulfide
    - Vinyl: vinyltrimethoxysilane; vinyltriethoxysilane; vinyl tris (2-methoxyethoxy) silane; vinyltrichlorosilane; trimethylvinylsilane
    - Alkyl: methyltrimethoxysilane; methyltriethoxysilane; dimethyldimethoxysilane;
    dimethyldietoxysilane; tetramethoxysilane; tetraethoxysilane; ethyltriethoxysilane; npropyltrimethoxysilane; n-propyltriethoxysilane; isobutyltrimethoxysilane;
    hexyltrimethoxysilane; hexyltriethoxysilane; octyltrimethoxysilane; decyltrimethoxysilane; decyltriethoxysilane; octyltriethoxysilane; tert-butyldimethylchlorosilane;
    cyclohexylmethyldimethoxysilane; dicylhexyldimethoxysilane; cyclohexylethyldimethoxysilane; tbutilmethyldimethoxysilane
    - Chloroalkyl: 3-chloropropyltriethoxysilane; 3-chloropropyltrimethoxysilane; 3chloropropylmethyldimethoxysilane
    - Perfluoro: decafluoro- 1,1,2,2 -tetrahydrodecyl) trimethoxysilane; ((heptadecafluoro-1,1,2,2-tetrahydrodecyl) trimethoxysilane
    - Phenyl: phenyltrimethoxysilane; phenyltriethoxysilane; diphenyldietoxysilane; diphenyldimethoxysilane; diphenyldichlorosilane
    - Hydrolysates of the silanes listed above
    - Zirconates: zirconium acetylacetonate; zirconium methacrylate
    - Titanates: tetra-methyl titanate; tetraethyl titanate; tetra-n-propyl titanate; tetraisopropyl titanate; tetraisobutyl titanate; tetra-sec-butyl titanate; tetra-tert-butyl titanate; mono n-butyl, trimethyl titanate; mono ethyl tricyclohexyl titanate; tetra-n-amyl titanate; tetra-n-hexyl titanate; tetra-cyclopentyl titanate; tetra-cyclohexyl titanate; tetran-decyl titanate; n-dodecyl titanate tetra; tetra (2-ethyl hexyl) titanate; tetra octylene glycol titanate ester; tetrapropylene glycol titanate ester; benzyl tetra titanate; tetra-p-chloro benzyl titanate; 2-chloroethyl titanate tetra; 2-bromoethyl titanate tetra; 2-methoxyethyl titanate tetra; tetra 2-ethoxyethyl titanate.
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    15/55 [037] Especially suitable titanate ester stabilizers of the invention are proprietary titanate ester compositions manufactured under the Tyzer® trade name from Dupont de Nemours & Co., Inc. Non-limiting examples include Tyzor® titanate esters sold at forms 100% instead of as solutions, for example, in a lower aliphatic alcohol, such as Tyzor® TBT (tetrabutyl titanate), Tyzor® TPT (tetraisopropyl titanate) and Tyzor® OG (tetraoctylene glycol titanate ester).
    [038] In addition, the binder composition may include a process aid (eg, polyol) in addition to the carbohydrates described above. Process aid is not particularly limiting as long as the process aid functions facilitate the processing of fiber formation and orientation. The process aid can be used to reinforce the uniformity of distribution of binder application, to reduce the viscosity of the binder, to increase ramp height after formation, to reinforce the uniformity of vertical weight distribution and / or to accelerate the rinsing both in the formation process and in the oven curing process. The process aid can be present in the binder composition in an amount of about 0% to about 25% by weight, from about 1.0% to about 20.0% by weight or about 5.0 % to about 15.0% by weight.
    [039] Examples of processing aids include viscosity modifiers (eg, glycerol, 1,2,4-butanotriol, 1,4-butanediol, 1,2-propanediol,
    1,3-propanediol, poly (ethylene glycol) and antifoam agents (for example, emulsions and / or dispersions of mineral, paraffin or vegetable oils, dispersions of polydimethylsiloxane fluids (PDMS) and silica that have been hydrophobized with polydimethylsiloxane or others materials, and particles made of starch waxes such as ethylenebisstearamide silica (EBS) or hydrophobized silica). An auxiliary to the additional process that can be used in the binder composition is a surfactant. One or more
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    16/55 surfactants can be included in the binder composition to aid in atomization of binder, rinse, and interfacial adhesion.
    [040] The surfactant is not particularly limited and includes surfactants such as, but not limited to, ionic surfactants (for example, sulfate, sulfonate, phosphate and carboxylate); sulfates (for example, alkyl sulfates, ammonium lauryl sulfate, sodium lauryl sulfate (SDS), alkyl ether sulfates, sodium lauryl sulfate and sodium mireth sulfate); amphoteric surfactants (for example, alkyl betaines such as lauryl betaine); sulfonates (for example, sodium dioctyl sufosuccinate, perfluorooctanosulfonate, perfluorobutanesulfonate and alkyl benzene sulfonates); phosphates (for example, alkyl aryl ether phosphate and alkyl ether phosphate), carboxylates (for example, alkyl carboxylates, fatty acid salts (soaps), sodium stearate, sodium lauryl sarcosinate, fluorosurfactant carboxylate, perfluoronanoate and perfluorooctanoate); cationic (alkylamine salts such as laurylamine acetate); pH-dependent surfactants (primary, secondary or tertiary amines); permanently charged quaternary ammonium cations (for example, alkitrimethylammonium salts, cetyl trimethylammonium bromide, cetyl trimethylammonium chloride, cetylpyridinium chloride and benzethonium chloride); and zwitterionic surfactants, quaternary ammonium salts (for example, lauryl trimethyl ammonium chloride and alkyl benzyl dimethylammonium chloride) and polyoxyethylenealkylamines.
    [041] Suitable non-ionic surfactants that can be used in conjunction with this invention include polyethers (for example, condensates of ethylene oxide and propylene oxide, which include straight and branched alkyl and alkaryl polyethylene glycol and polypropylene glycol ethers and thioethers) ; alkylphenoxypoly (ethyleneoxy) ethanols having alkyl groups containing from about 7 to about 18 carbon atoms and having from about 4 to about 240 ethyleneoxy unit (e.g., heptylphenoxypoly (ethyleneoxy) ethanols and nonylphenoxypoly (ethyleneoxy) ethanols); polyoxyalkylene derivatives of hexitol including
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    17/55 sorbitans, it-sorbides, mannitans and mannides; esters of partially long chain fatty acids (for example, polyoxyalkylene derivatives of sorbitan monolaurate, sorbitan monopalmitate, sorbitan monostearate, sorbitan tristearate, sorbitan monooleate and sorbitan trioleate); condensates of ethylene oxide with a hydrophobic base, the base being formed by condensation of propylene oxide with propylene glycol; sulfur containing condensates (for example, condensates prepared by condensing ethylene oxide with higher alkyl mercaptans, such as nonyl, dodecyl or tetradecyl mercaptan, or with alkylthiophenols where the alkyl group contains about 6 to about 15 carbon atoms ); ethylene oxide derivatives of long-chain carboxylic acids (for example, lauric, myristic, palmitic and oleic acids, such as high oil fatty acids); ethylene oxide derivatives of long chain alcohols (for example, octyl, decyl, lauryl or cetyl alcohols); and ethylene oxide / propylene oxide copolymers.
    [042] In at least one exemplary mode, the surfactants are SURFONYL® 420, SURFONYL® 440 and SURFONYL® 465, which are surfactants
    2,4,7,9-tetramethyl-5-decin-4,7-diol ethoxylates (commercially available from Air Products and Chemicals, Inc. (Allentown, PA)), Stanfax (a sodium lauryl sulfate), Surfynol 465 ( a 2,4,7,9-tetramethyl 5 decin-4,7-diol ethoxylated), Triton TM GR-PG70 (1,4-bis (2-ethylhexyl) sulfoccinate) and Triton TM CF-10 (poly ( oxy-1,2-ethanediyl), alpha- (phenylmethyl) -mega- (1,1,3,3-tetramethylbutyl) phenoxy). The surfactant can be present in the binder composition in an amount of about 0.0% to about 10% by weight of the total solids in the binder composition, from about 0.01% to about 10% by weight, or from about 0.2% to about 5.0% by weight.
    [043] The binder composition can optionally include a corrosion inhibitor to reduce or eliminate any potential corrosion to the process equipment. The corrosion inhibitor can be chosen from a variety of
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    18/55 agents, such as, for example, hexamine, benzotriazole, phenylenediamine, dimethylethanolamine, polyaniline, sodium nitrite, benzotriazole, dimethylethanolamine, polyaniline, sodium nitrite, cinnamaldehyde, condensation products of aldehydes and amines (imines), chromates, nitrites, phosphates, hydrazine, ascorbic acid, tin oxalate, tin chloride, tin sulfate, thiourea, zinc oxide and nitrile. Alternatively, corrosion can be reduced or eliminated by reducing process control, such as neutralizing process water, removing corrosive ingredients and treating process water to minimize corrosivity. The corrosion inhibitor can be present in the binder composition in an amount of about 0% to about 15.0% by weight, about 1.0% to about 5.0% by weight or from about 0, 2% to about 1.0% by weight.
    [044] In addition, the binder composition may also contain one or more biocides such as 3-iodo-2propyl-n-butylcarbamate, carbamic acid, butyl-, 3-iodine-
    2-propynyl ester (IPBC), 2-bromo-2-nitropropane-1,3-diol, magnesium nitrate, 5chloro-2-methyl-4-isothiazolin-3-one, magnesium chloride, sulfamic acid, N-bromine , sodium salt, diiodomethyl-p-tolisulfone, dibromoacetonitrile and 2,2-dibromo-3nitrilepropionamide to reduce or eliminate mold and mold growth in the fiberglass product. The biocide can be present in the binder composition in an amount of about 0% to about 10.0% by weight, from about 0.05% to about 1.0% by weight, or 0.1% to about 0.5% by weight.
    [045] Additionally, the binder composition may optionally include at least one crosslink density enhancer to enhance the degree of crosslinking of the carbohydrate based on a polyester binder. Intensification of cross-link density can be achieved by increasing esterification between the hydroxyl and carboxylic acid groups and / or by introducing free radical bonds to reinforce the strength of the thermo-adjustable resin. The esterification crosslink density can be adjusted by changing the ratio between hydroxyl and carboxylic acid
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    19/55 and / or adding additional esterification functional groups such as triethanolamine, diethanolamine, mono ethanolamine, 1-amino-2-propanol, 1,1'aminobis, -2-propanol, 1,1nitrilotri-2-propanol, 2- methylaminoethanol, 2dimethylaminoethanol, 2- (2-aminoethoxy) ethanol, 2 {(2aminoethyl) amino} ethanol, 2diethylaminoethanol, 2-butylaminoethanol, 2dibutylaminoethanol, 2cyclohexylamincethanol, 2,2 '- (methylamino) bis-ethanol, 2,2' butylamino) bis-ethanol, 1-methylamino-2propanol, 1-dimethylamino-2-propanol, 1- (2-aminoethylamino) -2-propanol, 1,1 '- (methylimino) bis-2propanol, 3-amino-1-propanol, 3-dimethylamino-Ipropanol, 2-amino-1-butanol, 1-ethylamino-2-butanol, 4-diethylamino-1-butanol, 1-diethylamino-2-butanol, 3-amino -2,2dimethyl-l-propanol, 2, 2-dimethyl-3-dimethylamino-1-propanol, 4-diethylamino-2-butin-1-ol,
    5- diethylamino-3-pentine-2-ol, bis (2-hydroxypropyl) amine, as well as other alkanolamines, their mixtures and their polymers. Another method for achieving cross-link density reinforcement is to use both esterification and free radical reactions for cross-link reactions. Chemicals that can be used for both reactions include maleic anhydride, maleic acid or itaconic acid. The crosslink density intensifier can be present in the binder composition in an amount of about 0% to about 25.0% by weight, from about 1.0.0% to about 20.0% by weight, or from about 5.0% to about 15.0% by weight.
    [046] The binder can also include organic and / or inorganic acids and bases in an amount sufficient to adjust the pH to a desired level. The pH can be adjusted depending on the intended application, or to facilitate compatibility of the ingredients of the binder composition. In exemplary embodiments, the pH adjuster is used to adjust the pH of the binder composition to an acidic pH. Examples of suitable acid pH adjusters include inorganic acids such as, but not limited to, sulfuric acid, phosphoric acid and boric acid and also organic acids such as p-toluenesulfonic acid, mono- or
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    20/55 polycarboxylics, such as, but not limited to, citric acid, acetic acid and its anhydrides, adipic acid, oxalic acid and their corresponding salts. In addition, inorganic salts that can be acid precursors. The acid adjusts the pH and, in some cases, as discussed above, acts as a cross-linking agent. Optionally, organic and / or inorganic bases, such as sodium hydroxide, ammonium hydroxide and diethylamine and any type of primary, secondary or tertiary amine (including alkanol amine), can be used for pH adjustment. The pH of the binder composition, when in an acidic state, can vary from about 1 to about 6, and in some exemplary embodiments from about 2 to about 5, including all amounts and intervals between them. In at least one exemplary embodiment, the pH of the binder composition is about 2.5. The pH adjuster in an acidic binder composition may be present in the binder composition in an amount sufficient to obtain the desired pH.
    [047] The binder composition may also contain a moisture resistant agent, such as an alum, aluminum sulfate, latex, a silicon emulsion, a hydrophobic polymer emulsion (for example, polyethylene emulsion or polyester emulsion) and mixtures of these. In at least one exemplary embodiment, the latex system is an aqueous latex emulsion. The latex emulsion includes latex particles that are normally produced by emulsion polymerization. In addition to latex particles, the latex emulsion may include water, a stabilizer such as ammonia and a surfactant. The moisture resistant agent can be present in the binder composition in an amount of about 0% to about 20% by weight of the total solids in the binder composition, from about 5.0% to about 10% by weight or from about 5.0% to about 7.0% by weight.
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    21/55 [048] Additionally, the binder may contain a dust suppression agent to reduce or eliminate the presence of inorganic and / or organic particles that can have adverse impacts on the subsequent manufacture and installation of insulating materials. The dust suppression agent can be any conventional mineral oil, mineral oil emulsion, natural or synthetic oil, oil based on biological material or lubricant, such as, but not limited to, silicone and silicone emulsions, polyethylene glycol, as well as any petroleum or non-petroleum oil with a high flash point to minimize evaporation of the oil inside the oven.
    [049] In addition, the binder can optionally include at least one extender to improve the appearance of the binders and / or decrease the total cost of manufacture. The extender can be an inorganic filler, such as tin oxide or calcium carbonate or organic materials such as lignin, lignin sulfonate or a protein-based biomass. In exemplary modalities, the extender is a biomass containing protein. Like carbohydrate, protein-containing biomass is natural in origin and derived from renewable sources. For example, protein can be derived from plant sources such as soy (for example, soy flour), peanuts, sunflowers, beans, nuts, or from other plants that have a high protein content. Alternatively, the protein can come from animal sources such as, but not limited to, eggs, blood and animal tissue (for example, beef, pork or chicken as well as fish). Protein-containing biomass can contain up to about 95% protein, and in exemplary modalities, up to 90%, 75% or 50% protein. As used here, the term protein can be defined as a macromolecule composed of one or more polypeptides and includes any combination of polypeptides in relation to their amino acid sequence. In addition, the term protein is intended to include all possible structures in which a protein can be obtained naturally or a protein that has been
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    22/55 modified to improve its reactivity. It should be appreciated that derivatives of natural proteins and synthetic proteins are also included within the scope of the term protein. In one or more exemplary modalities, the biomass containing protein is soy flour. The extender can be present in the binder composition in an amount of about 0% to about 70.0% by weight of the total solids in the binder composition, from about 5.0% to about 50.0% by weight , or from about 10.0% to about 40.0% by weight.
    [050] The binder may optionally contain conventional additives such as, but not limited to, paints, pigments, fillers, dyes, UV stabilizers, thermal stabilizers, anti-foaming agents, antioxidants, emulsifiers, preservatives (eg sodium benzoate) , corrosion inhibitors and mixtures thereof. Other additives can be added to the binder composition to improve product performance and process. Such additives include lubricants, rinsing agents, surfactants, anti-static agents and / or water-repellent agents. Additives can be present in the binder composition from amounts of trace (such as <about 0.1% by weight of the binder composition) to about 10.0% by weight of the total solids in the binder composition. In some exemplary embodiments, the additives are present in an amount of about 0.1% to about 5.0% by weight of the total solids in the binder composition of about 1.0% to about 4.0% in weight, or from about 1.5% to about 3.0% by weight.
    [051] The binder also includes water to dissolve or disperse the active solids for application on the reinforcing fibers. Water can be added in an amount sufficient to dilute the aqueous binder composition to a viscosity that is suitable for its application to the reinforcement fibers and to achieve a desired solids content on the fibers. In particular, the binder composition may contain
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    23/55 water in an amount of about 50% to about 98.0% by weight of the total solids in the binder composition.
    [052] The binder composition can be made by dissolving or dispersing the crosslinking agent in water to form a mixture. Then, the carbohydrate can be mixed with the cross-linking agent in the mixture to form the binder composition. If desired, a curing accelerator (i.e., catalyst) can be added to the binder composition. The binder composition can be further diluted with water to obtain a desired amount of solids. If necessary, the pH of the mixture can be adjusted to the desired pH level with organic and inorganic acids and bases.
    [053] In the broadest aspect of the invention, the carbohydrate-based binder composition is formed of a carbohydrate (for example, maltodextrin) and a cross-linking agent (for example, polyacrylic acid or citric acid). The range of components used in the inventive binder composition according to the modalities of the invention is shown in Table 1.
    TABLE 1
    Component % By weight of Total Solids Carbohydrate 60.0- 95.0 Cross-linking agent 5.0- 40.0
    [054] Compositions of aqueous binders according to other exemplary embodiments of the present invention that include a process aid agent (e.g., glycerol) or low molecular weight carbohydrate are shown in Table 2.
    TABLE 2
    Component % By weight of Total Solids Carbohydrate 5.0- 90.0 Process aid agent 1.0- 40.0
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    Cross-linking agent 5.0- 40.0
    [055] Aqueous binder compositions according to additional exemplary embodiments of the present invention that include a process aid agent and a curing catalyst / accelerator are shown in Table 3.
    TABLE 3
    Component % By weight of total solids Carbohydrate 5.0 - 90.0 Process aid agent 1.0 - 40.0 Cross-linking agent 5.0 - 40.0 Healing Catalyst / Accelerator 1.0 -5.0
    [056] In an exemplary embodiment, the binder composition is used to form an insulating product. Fibrous insulating products are generally formed from interlaced inorganic fibers joined by a cured, thermo-adjustable polymeric material. Examples of suitable inorganic fibers include glass fibers, glass wool fibers and ceramic fibers. Optionally, other reinforcement fibers, such as natural fibers and / or synthetic fibers such as polyester, polyethylene, polyethylene terephthalate, polypropylene, polyamide, aramid and / or polyamide fibers can be present in the insulating product in addition to the glass fibers. The term natural fiber as used in conjunction with the present invention refers to plant fibers extracted from any part of a plant, including, but not limited to, stem, seeds, leaves, roots or phloem. Examples of natural fibers suitable for use as reinforcement fiber material include basalt, cotton, jute, bamboo, ramie, bagasse, hemp, coconut fiber, linen, kenaf, sisal, linen, henequem and combinations thereof. Insulating products can be formed entirely from one type of fiber, or they can be formed from a combination of fiber types. For example, the insulating product can be formed from combinations of various types of glass fibers or various combinations of different inorganic fibers and / or natural fibers
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    25/55 depending on the desired application for insulation. The modalities described here are with reference to insulating products formed entirely of glass fibers.
    [057] The manufacture of fiberglass insulator can be carried out in a continuous process by breaking into molten glass fibers, immediately forming a fibrous glass cover on a moving transmitter, and curing the binder on the fibrous glass insulating cover. to form an insulating blanket as shown in FIGS. 1 and 2. Glass can be melted in a tank (not shown) and supplied to a fiber forming device such as a fiber breaker. The spinners 15 are spun at high speeds. Centrifugal force causes the molten glass to pass through the holes in the circumferential side walls of the fiber breakers 15 to form glass fibers. Glass fibers 30 of random sizes can be attenuated from fiber break spinners 15 and blown generally downwardly, that is, generally perpendicular to the plane of the spinners 15, by blowers 20 positioned within a forming chamber 25. It should be appreciated that the glass fibers 30 can be of the same type of glass or they can be formed of different types of glass. It is also within the limit of the present invention that at least one of the fibers 30 formed from the fiber break spinners 15 is double glass fiber where each individual fiber is formed from two different compositions.
    [058] The blowers 20 turn the fibers 30 downwardly to form a fibrous covering 40. The glass fibers 30 can have a diameter of about 2 to about 9 microns, or about 3 to about 6 microns. The small diameter of the glass fibers 30 helps to give the final insulating product a smooth appearance and flexibility.
    [059] The glass fibers, while in transit in the formation chamber 25 and while still hot from the extraction operation, are sprayed with the
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    26/55 inventive aqueous binder composition by an annular spray ring 35 so as to result in a distribution of the binder composition throughout the formed insulating package 40 of fiberglass. Water can also be applied to the glass fibers 30 in the forming chamber 25, such as by spraying, before applying the aqueous binder composition to cool the glass fibers 30 at least partially. The binder can be present in an amount of less than or equal to 30% by weight of the total product.
    [060] The glass fibers 30 having an uncured resin binder adhered to them can be harvested and formed in an uncured insulating package 40 on an endless forming transmitter 45 inside the forming chamber 25 with the aid of a drag vacuum (not shown) through the fibrous pack 40 below the forming transmitter 45. The residual heat from the glass fibers 30 and the air flow through the fibrous pack 40 during the forming operation are generally sufficient to volatilize a majority of the water of the binder before the glass fibers 30 leave the forming chamber 25, thus leaving the remaining components of the fiber binder 30 as a liquid of highly viscous or semi-viscous solids.
    [061] The coated fibrous package 40, which is in a compressed state due to the air flow through the package 40 in the forming chamber 25, is then transferred out of the forming chamber 25 under the outlet roller 50 to a zone transfer 55 where the package 40 expands vertically due to the resilience of the glass fibers. The expanded insulating package 40 is then heated in order to transmit the package 40 through a curing oven 60 where heated air is blown through the insulating package 40 to evaporate any water remaining in the binder, cure the binder and rigidly join the fibers. Heated air is forced through a fan 75 through the lower oven transmitter 70, the insulating package 40, the oven transmitter 65, and out of the curing oven 60
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    27/55 through an exhaust device 80. The cured binder gives strength and resilience to the insulating mat 10. It must be appreciated that the drying and curing of the binder can be performed either in one or two different steps. The two-stage (two-stage) process is commonly known as a double-stage (B / B-staging) process.
    [062] Also, in the curing oven 60, the insulating package 40 can be compressed by upper and lower porous oven transmitters 65, 70 to form a fibrous insulating mat 10. It should be appreciated that the insulating mat 10 has an upper surface and a bottom surface. In particular, the insulating mat 10 has two main surfaces, usually an upper and a lower surface, and two smaller and side surfaces with fiber mat 10 oriented so that the main surfaces have a substantially horizontal orientation. The transmitters, upper and lower 65, 70, can be used to compress the insulating package 40 to give the insulating mat 10 a predetermined thickness. It should be appreciated that although FIG. 1 display transmitters 65, 70 as being in a substantially parallel orientation, they can alternatively be positioned at an angle relative to each other (not shown).
    [063] The curing oven 60 can be operated at a temperature of about 100 ° C to about 325 ° C, or from about 250 ° C to about 300 ° C. The insulating package 40 can remain in the oven for a period of time sufficient to cross-link (cure) the binder and form the insulating mat 10. The inventive binder composition cures at a temperature that is less than the curing temperature conventional formaldehyde binders. This lower curing temperature requires less energy to heat the insulating package, and a non-woven chopped filament veil described in detail below, which results in lower manufacturing costs.
    [064] A coating material 93 can then be placed on the insulating mat 10 to form a coating layer 95. Non-limiting examples
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    28/55 of suitable coating materials 93 include Kraft paper, a laminate of scrim-Kraft paper, recycled paper and calendered paper. The coating material 93 can be adhered to the surface of the insulating mat 10 by a bonding agent (not shown) to form a coated insulating product 97. Suitable bonding agents include adhesives, polymeric resins, asphalt and bituminous materials that can be coated or otherwise applied to the coating material 93. The coated fibrous insulator 97 can be rolled subsequently for storage and / or transportation or cutting to predetermined sizes by a cutting device (not shown). Such coated insulating products can be used, for example, as panels in basic finishing systems such as ductwrap (duct wrap), ductboard (duct board), as coated residential insulator, and as pipe insulator. It should be appreciated that, in some exemplary embodiments, the insulating mat 10 that appears from the oven 60 is rolled on a receiving roller or cut into sections having a desired length and is not coated with a coating material 93. Optionally, the insulating mat 10 can be cut in layers and by a cutter then cut to a desired size (not shown).
    [065] A significant portion of the insulation placed in the insulating cavities of the buildings is in the form of insulating blankets rolled from the insulating products as described above. Coated insulating products are installed with the plane placed covering over the edge of the insulating cavity, usually on the inner side of the insulating cavity. Insulating products where the coating is a vapor retardant are commonly used to insulate cavities in the wall, floor or ceiling that separate a warm internal space from a cold external space. The vapor retarder is placed on one side of the insulating product to delay or prohibit the movement of water vapor through the insulating product.
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    29/55 [066] The presence of water, dust and / or other microbial nutrients in the insulating product 10 can support the growth and proliferation of microbial organisms. Bacterial growth and / or mold in the insulating product can cause odor, fading and deterioration of the insulating product 10, such as, for example, deterioration of the vapor barrier properties of the coating Kraft paper. To inhibit the growth of undesirable microorganisms such as bacteria, fungus and / or mold in the insulating product 10, the insulating package 40 can be treated with one or more antimicrobial, fungicidal and / or biocidal agents. Antimicrobial, fungicidal and / or biocidal agents can be added during manufacturing or in the post-manufacturing process of the insulating product 10. It should be appreciated that the insulating product using the inventive binder composition can be a fiberglass cover as shown, or as insulation with duct board filler, or tubular wrap (not shown in the figures).
    [067] In a second embodiment of the present invention, the binder composition can be used to form a chopped nonwoven filament veil. In particular, the binder is added during the formation of the chopped filament web in a web processing line which is made to moisten. An exemplary process of separately adding the coupling agent to the chopped filament web is shown in FIG. 3. It should be appreciated that reference is made here to glass fibers, although the chopped filament veil could be formed of, or include, non-glass fibers. Chopped glass fibers 110 can be provided for a transmission apparatus such as a transmitter 112 by a storage container 114 for transmission to a mixing tank 116 containing various surfactants, viscosity modifiers, defoaming agents and / or other agents Agitated chemicals to disperse the fibers and form a chopped glass fiber sludge (not shown). The fiberglass sludge can be transferred to a head box 118 where the sludge is deposited on a transmission device such as
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    30/55 a moving screen or porous transmitter 120 and a substantial portion of water from the mud is removed to form a blanket (veil) 122 of interlaced fibers. Water can be removed from the blanket 122 by a conventional vacuum or air suction system (not shown).
    [068] The inventive binder 124 is applied to the mat 122 by a suitable binder applicator, such as spray applicator 126 or a curtain liner (not shown). Once the binder 124 has been applied to the web 122, the web covered with binder 128 is passed through at least one drying oven 130 to remove any remaining water and cure the binder composition 124. The chopped filament web of no formed fabric 132 appearing from oven 130 is a set of individual glass fibers, dispersed, randomly oriented. The chopped filament veil 132 can be rolled on a receiving roll 134 for storage for later use as illustrated. The non-woven veil can be used in lining, floor, ceiling and wall applications, as filters, in vehicles with a round base and in an airplane.
    [069] There are numerous advantages provided by inventive binder formulations. For example, unlike conventional urea-formaldehyde binders, inventive binders have a light color after curing (in low density products). In addition, the carbohydrate is natural in origin and derived from renewable sources. By decreasing or eliminating formaldehyde emissions, the total volatile organic compounds (VOCs) emitted in the workplace are reduced. Additionally, because carbohydrates are relatively inexpensive, the insulating product or chopped fiber veil can be manufactured at a lower cost. Additionally, the binder has low to almost no odor, making it more desirable to work with.
    [070] Having generally described this invention, an additional understanding can be obtained by reference to certain specific examples illustrated
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    31/55 below that are provided for purposes of illustration only and are not intended to be all inclusive or limiting unless otherwise specified.
    EXAMPLES
    Example 1:
    [071] The binder formulations shown in Table 4 were used to form experimental sheets in the manner described in detail below. The experimental non-woven fiberglass sheets were dried and cured for three minutes at 204 ° C (400 ° F). The stress strength, Ignition Loss (LOT), and stress strength divided by LOI (stress strength / LOT) for each sample was determined under ambient and vapor conditions. The tensile strength was measured using an Instron. The loss on ignition (LOI) of the reinforcement fibers is the reduction in weight experienced by the fibers after heating them to a temperature sufficient to burn or pyrolyze the organic size of the fibers. The ignition loss was measured according to the procedure shown in TAPPI T-1013 OM06, Loss on Fiberglass Veil Ignition (2006). To place the experimental sheet in a steam environment, the experimental sheets were placed in an autoclave at 116 ° C (240 ° F) at a pressure between 400 and 500 psi for 30 minutes.
    [072] The experimental sheets were made according to the following procedure. First, water is added to a container (approximately 5 liters). To this water, 8 drops of NALCO 01NM 159 dispersant were added. A pneumatic stirrer was lowered into the vessel and adjusted at a low speed in order to stir, but not produce foam. Wet chopped glass fibers (8 grams) were added to this stirring mixture and allowed to stir for 5 minutes. A screen fragment was placed on a 40-liter 30 x 30 X 30 cm (12 X 12 X 12 inch) Williams pulp tester (also known as a deckle box) and the box was closed . The screen frame was then filled with water up to mark 3 and a
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    32/55 plate shaker was placed in the screen frame. A 0.5% by weight polyacrylamide solution, NALCO 7768, (80 grams) was added to the water in the screen frame and mixed until dissolved using the plate shaker. After the fiberglass water was stirred for 5 minutes, a 0.5 wt.% Polyacrylamide solution, NALCO 7768 (80 grams) was added and stirred at low speed for one minute, after which the stirring speed was set to the highest setting and allowed to stir for another 2 minutes. The fiberglass solution is then immediately sunk into the screen frame, and agitated with the plate shaker for 10 rapid strokes. At this point, the valve on the screen frame was depressed until the screen frame was cleaned. After the screen frame was drained, the frame was opened and the screen with the experimental sheet was removed from the base holding the opposite ends of the screen. The screen was then placed in a wooden frame and the binder based on biological material was applied to the experimental sheet using a roller coater. The excess binder was then evacuated out. The binder-coated experimental sheet was placed in an oven for curing and cut into 3 cm (1 inch) strips. These strips were placed in a desiccator overnight.
    [073] The results of this experiment are shown in Table 5. It should be noted that the weights in Table 4 are expressed in grams (g).
    TABLE 4
    Component Sample 1 (10% Acumer Sample 2 (Control) Sample3 (20% Acumer Sample 4(20% Acumer Sample 5(20% Acumer Sample 6 (15% Acumer9932)9932) 9932) 9932) 9932) Maltodextrin(FROM 11.0) 79.9Maltodextrin(FROM 18.0) 79.9
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    Maltodextrin(FROM 7.5) 89.879.9 84.9 gamaaminopropiltrihidróxi-silane (1.24% solution) 13.7 9.1 13.7 13.7 13.7 13.7 Acumer 9932 / Cross-linking agent ( ') 20.841.7 41.7 41.7 31.2 Acrylic Binder QRXP 1734 (2) 127.8 Water 675.7 663.1 664.8 664.8 664.8 670.2 Total (g) 800 800 800 800 800 800
    (1) Acumer 9932: a polyacrylic acid resin (46% solids) commercially available from The Dow Chemical Company.
    (2) QXRP 1734: a commercially available polyacrylic acid resin from The Dow Chemical Company.
    TABLE 5
    Sample 1 Sample 2 Sample3 Sample 4 Sample5 Sample 6 Tension Force (Ibf) 20.7 30.4 20.9 20.6 29.3 26.1 LOI (%) 9.7 8.4 9.3 9.5 11.0 11.3 Voltage / LO1 2.1 3.6 2.3 2.2 2.7 2.3 Tensile strength after aging by steam (lbf) 18.9 16.2 19.9 16.2 22.6 26.1 LOI after steam aging (%) 9.9 9.5 9.8 9.4 10.5 11.3 Tension / LOI after steam aging 1.9 1.7 2.0 1.7 2.2 2.3
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    34/55 [074] From the data shown in Tables 4 and 5, it was concluded that the binder formulations demonstrated tension forces equal to or better compared to the tension forces of the current commercially available products.
    Example 2:
    [075] The binder formulations shown in Table 6 were used to form experimental sheets according to the procedure shown in Example
    1. The experimental non-woven fiberglass sheets were dried and cured for three minutes at 204 ° C (400 ° F). The stress strength, loss on ignition (LOI) and stress strength divided by LOI (Stress Strength / LOI) for each sample were determined under ambient and vapor conditions. The vapor conditions were identical to those shown in Example 1. In addition, the loss on ignition and stress strength of each of the samples were measured according to the procedures described in Example 1. The results are shown in Table 7. noted that the weights in Table 6 are expressed in grams (g).
    OK BELA 6 Component Sample1 10% Citric Acid 5% SHP Sample 2 Control Sample 3 20% Citric Acid 5% SHP Sample 4 20% Citric Acid 5% SHP Maltodextrin(FROM 11.0) 79.9 Maltodextrin(FROM 18.0) 79.9Maltodextrin (DE 7.5) 89 8 gamaaminopropiltrihidróxi-silane (1.24% solution) 13.7 13.7 13.7 13.7 Citric Acid / Cross-linking Agent 9.619.2 19.2
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    Acrylic Binder QRXP 1734 (') 191.7 Sodium hypophosphite (SHP) 4.8 4.8 4.8 4.8 Water 682.1 589.9 682.5 682.5 Total (g) 800 800 800 800
    (1) QXRP1734: a commercially available polyacrylic acid resin from The
    Dow Chemical Company
    OK BELA 7Sample 1 Sample 2 Control Sample3 Sample 4 Tension Force (Ibf) 16.56 23.31 20.40 20.76 LOI (%) 9.12 7.20 7.99 8.69 Voltage / LO1 1.82 3.24 2.55 2.39 Tensile strength after steam aging (lbf) 15.67 13.01 13.03 14.86 LOI after steam aging (%) 9.73 7.54 8.78 9.11 Stress / LOI after steam aging 1.61 1.73 1.48 1.63
    [076] From the data presented in Tables 6 and 7, it was concluded that binder formulations containing maltodextrin having different Dextrose Equivalent (DE), LOIs, and LOIs after steam aging that were better than or comparable to products commercially available.
    Example 3:
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    36/55 [077] The binder formulations shown in Table 8 were used to form experimental sheets according to the procedure shown in Example 1. The non-woven fiberglass experimental sheets were dried and cured for three minutes at 204 ° C (400 ° F). The tensile strength, LOI, and tensile strength / LOI for each sample were determined under ambient and vapor conditions. The steam conditions were identical to those shown in example 1. In addition, the ignition loss and tension strength of each of the samples were measured according to the procedures described in Example 1. The results are shown in Table 9. noted that the weights in Table 8 are expressed in grams (g).
    TAB SHE 8 Component Sample 1 70:30 MD-CA w / 5% SHP Sample 2 70:30 MD-CA w / 5% SHP and 10% H3PO4 Sample 3 70:30 MD-CA w / 4% H3PO2 Sample 4 70:30 MD-CA w / 5% A1C13 Sample 5 70:30 MD-CA w / 3% LiCarboxIiato Maltodextrin(FROM 11.0) 45.1 42.6 46.0 45.1 52.0 Citric acid 19.3 14.2 19.2 19.3 23.3 gamaaminopropyltrihidroxisilane (solution1.24%) 10.2 11.2 10.3 10.2 11.5 Catalyst (Sodium hypophosphite) 4.1 4.5 Catalyst(85%H3PO4)8.5 Catalyst (50%H3PO2) 5.2 Catalyst (55.2% AlC13) 6.1
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    Lithium Carboxylate (50% conc.) 4.1 Water (g) 721.3 719.0 719.3 719.3 710.1
    ** MD = maltodextrin, CA = citric acid, SHP = sodium hypophosphite
    TABLE 9
    Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Tension Force (Ibf) 14.40 11.87 11.08 6.54 15.94 LOI (%) 6.27 6.28 6.42 5.31 4.87 Voltage / LO1 2.30 1.89 1.73 1.23 3.28 Tensile strength after steam aging (lbf) 7 81 5.98 7.84 2.93 10.63 LOI after steam aging (%) 6.95 6.27 6.80 5.44 5.33 Stress / LOI after steam aging 1.12 0.95 1.15 0.54 1.99
    [078] From the data shown in Tables 8 and 9, it was concluded that binder formulations based on biological material containing different catalysts reached stress forces comparable to that of current commercially available products.
    Example 4:
    [079] The binder formulations shown in Table 10 were used to form insulating covers of R-19 fiberglass in a manner known to those skilled in the art. The insulating covers of R-19 glass fibers have a target LOI of 6% and have been cured at 266 ° C (510 ° F). The mechanical properties of the blankets at the end of the line were determined under ambient conditions. The results are shown in Table 11.
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    TABLE 10
    Component Sample 1 90:10 MD-CA w / 5% SHP Sample 2 80:20 MD-CA w / 5% SHP Sample 3 80:20 MDPA Sample 4 70:30 MD-CA w / 5% SHP Maltodextrin 76lbs 37lbs 66lbs 32lbs gammaaminopropyl trihydroxy silane (24.8% solution) 0.6lbs 0.3 lbs 0.6 lbs 0.3 lbs Citric acid 8.5 lbs 9 lbs14 lbs Acrylic Binder (Acumer 9932) 1) 36 lbsSodium hypophosphite 4.2 lbs 2.3 lbs2.3 lbs Oil emulsion (50%) 31.5 lbs 17 lbs 31 lbs 17 lbs Water lOlbs'2 583.4lbs 1040.4lbs 586.4lbs Total 1201lbs 649lbs 1174lbs 652lbs
    (1) Acumer 9932: a polyacrylic acid resin (46% solids) commercially available from The Dow Chemical Company.
    ** MD = maltodextrin, CA = citric acid, PA = polyacrylic acid, SHP = sodium hypophosphite
    TABLE 11
    Sample 1 Sample 2 Sample 3 Sample 4 Phenol / Urea / Formaldehyde (Control) Thickness Recovery (in) 6.4 6.3 6.3 6.2 6.2 Rigidity / Sag (degree) 23 19 35 15 18
    [080] From the data presented in Tables 10 and 11, it was concluded that binder formulations containing maltodextrin with polyacrylic acid or ratios
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    39/55 different from citric acid and maltodextrin could be cured under normal conditions of manufacture and achieved product performance comparable to that of current commercially available products.
    Example 5:
    [081] The binder formulations shown in Table 12 were used to form insulating covers of R-19 glass fibers in a conventional manner known to those skilled in the art. The insulating covers of R19 glass fibers have a loss on ignition (LOI) of 6%. The mechanical properties of the covers were determined under ambient conditions. The results are shown in Table 13.
    TABLE 1 2 Component Sample 170:20:10MD-CA-Gw / 5% SHP Sample 260:20:20MD-CA-G w / 5% SHP Sample 360:30:10MD-CA-Gw / 5% SHP Sample 450:30:20MD-CA-G w / 5% SHP Maltodextrin(50% Solid) 65.8 lbs 56.4 lbs 56.4 lbs 47.0 lbs Citric acid (50% solids) 18.8 lbs 18.8 lbs 28.2 lbs 28.2 lbs Sodium hypophosphite (41.5% solids) 5.66 lbs 5.66 lbs 5.66 lbs 5.66 lbs Glycerol 4.70 lbs 9.40 lbs 4.70 lbs 9.40 lbs Oil emulsion (50% solids) 4.24 lbs 4.24 lbs 4.24 lbs 4.24 lbs gamaaminopropiltrihidroxisilane (24.8% solution) 0.37 lbs 0.37 lbs 0.37 lbs 0.37 lbs Water 545.6 lbs 550.3 lbs 545.6 lbs 550.3 lbs
    ** MD = maltodextrin, G = glycerol, CA = citric acid, SHP = sodium hypophosphite
    TABLE 13
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    80:20 Sample 1 Sample 2 Sample 3 Sample 4MDCA for 5% SHP 70:10:20 MD-G-CA for 5% SHP 60:20:20 MD-G-CA for 5% SHP 60:10:30 MD-G-CAfor 5% SHP 50:20:30 MD-G-CA for 5% SHP Thickness Recovery(inches) 5.86 6.05 5.82 5.56 5.55 Rigidity / Sag(degree) 40 43 43 33 34
    ** MD = maltodextrin, CA = citric acid, G = glycerol, SHP = sodium hypophosphite [082] It was concluded from the data shown in Tables 12 and 13 that binder formulations containing process aid agents (for example, levels of variation reached product performance comparable to that of commercially available products. It was also observed that the ramp height of the uncured mat before entering the oven was improved in proportion to the percentage of glycerin present in the binder composition. For example, the height of the ramp increased from 15% to 50% as the percentage of glycerin present in the composition was increased from 5% to 15%.
    Example 6:
    [083] The binder formulations shown in Tables 14 and 16 were used to form experimental sheets according to the procedure shown in the example
    1. The experimental non-woven fiberglass sheets were dried and cured for three minutes at 204 ° C (400 ° F). The tensile strength, the LOI, and the tensile strength / LOI for each sample were determined under ambient and vapor conditions. The vapor conditions were identical to those shown in Example 1. In addition, the ignition loss and tension strength of each of the samples were measured
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    41/55 according to procedures described in Example 1. The results were shown in Tables 15 and 17. It should be noted that the weights in Tables 15 and 17 are expressed in grams (g).
    TABLE 14 Component Sample 1 80:20 MD-CA w / 5% SHP Sample 270:20:10 MD-CATEOA w / 5% SHP Sample 3 75: 20: 5 MDCA-TEOA w / 5% SHP Sample 4 70:20:10 MDCA-DEOA w / 5% SHP Maltodextrin(50% Solid) 116.14 101.62 108.88 101.62 Citric Acid (100% Solids) 14.52 14.52 14.52 14.52 Sodium hypophosphite (41.5% solids) 8.75 8.75 8.75 8.75 Triethanolamine(100% Solid)7.26 3.63Diethanolamine(100% Solid) 7.26 gamaaminopropiltrihidróxi-silane (1.24% solution) 11.47 11.47 11.47 11.47 Water 749.13 756.39 752.76 756.39 Total (g) 900 900 900 900
    ** MD = maltodextrin, CA = citric acid, TEOA = Triethanolamine, DEOA = Diethanolamine, SHP = sodium hypophosphite
    TABLE 15
    Sample 1 Sample 2 Sample 3 Sample 4 Tensile Force (lb1) 15.7 16.5 15.9 14.6 LOI(%) 5.74 5.52 5.27 4.79
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    Tensile / LOI 2 74 3.00 3.03 3.06
    TABLE 16
    Component Sample 6 70:30 MD-CA for 5% SHP Sample 7 60:30:10 MD-CATEOA for 5% SHP Sample 8 65: 30: 5 MD-CATEOA for 5% SHP Sample 9 60:30:10 MD-CATEOA Sample 10 65: 30: 5 MD-CATEOA Maltodextrin (50% Solids) 101.62 87.10 94.36 91.46 99.08 Citric Acid (100% Solids) 21.78 21.78 21.78 22.86 22.86 Sodium hypophosphite (41.5% solids) 8.75 8.75 8.75 Triethanolamine (100% Solids)7.26 3.63 7.62 3.81 Diethanolamine (100% Solids)gamaaminopropil trihydroxy silane (1.24% solution) 11.47 11.47 11.47 11.47 11.47 Water 756.39 763.64 760.01 766.58 762.77 Total (g) 900 900 900 900 900
    ** MD = maltodextrin, CA = citric acid, TEOA = Triethanolamine, DEOA = Diethanolamine, SHP = sodium hypophosphite
    TABLE 17
    Sample 6 Sample 7 Sample 8 Sample 9 Sample 10 Tension force (lbf) 15.5 19.1 18.9 16.3 18.2 LOI(%) 5.20 5.11 4.95 6.00 6.55 Voltage / LOI 2.99 3.74 3.83 3.27 2.78
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    43/55 [084] From the data shown in Tables 14-17, it was concluded that formulations containing alkanol amine added as a crosslink intensifier reached stress forces and LOIs comparable to or better than the current commercially available products.
    Example 7:
    [085] The binder formulations shown in Table 18 and Table 20 were used to form insulating covers of R-21 glass fiber in a conventional manner known to those skilled in the art. The insulating covers of R-21 fiberglass have a target ignition loss (LOI) of 5.5%. The mechanical properties of the covers at the end of the line were determined under ambient conditions. The results were shown in Tables 19 and 20.
    TABLE 8 Component Sample 1 80:20 MD-CA80:20 Sample 270:30 MD-CA for 5% SHP Sample 360:40 MD-CA for 5% SHP Sample 460:30:10 MD-CA-G for 5% SHP Sample 560: 30: 5: 5 MD-CA-GTEOA for 5% SHP Maltodextrin 258.7 lbs 226.4 lbs 194.0 lbs 194.0 lbs 194.0 lbs (68% Solid)Citric Acid (50% Solids) 88.The lbs 131.9 lbs 175.9 lbs 131.9 lbs 131.9 lbs Sodium hypophosphite (41.5% solids) 26.5 lbs 26.5 lbs 26.5 lbs 26.5 lbs 26.5 lbs Glycerol(100% Solid) 22.0 lbs 11.0 lbs Triethanolamine(100% Solid) 11 .Obs Diethanolamine(85% Solid)Oil emulsion (50% solids) 68.4 lbs 68.4 lbs 68.4 lbs 68.4 lbs 68.4 lbs
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    gamaaminopropiltrihidroxisilane (1.24% solution) 34.6 lbs 34.6 lbs 34.6 lbs 34.6 lbs 34.6 lbs Water 2228.5 lbs 2218.9 lbs 2209.3 lbs 2227.4 lbs 2227.4 lbs
    ** MD = maltodextrin, CA = citric acid, G = glycerol, TEOA = Triethanolamine,
    DEOA = Diethanolamine, SHP = sodium hypophosphite
    TABLE 19
    Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Rigidity / Sag (degree) 13.60 9.63 9.65 10.68 11.23
    TABLE 20
    Component Sample 660:30:10MD-CATEOA for 5% SHP Sample 760:30:10MD-CATEOA Sample 860:30:10MD-CHAIN for 5% SHP Sample 965: 30: 5MD-CHAIN for 5% SHP Sample 1067:33MD-CA Maltodextrin (68% Solids) 194.0 lbs 203.7 lbs 194.0 lbs 210.2 lbs 226.4 lbs Citric Acid (50% Solids) 131.9 lbs 138.5 lbs 131.9 lbs 131.9 lbs 153.9 lbs Sodium hypophosphite (41.5% solids) 26.5 lbs26.5 lbs 26.5 lbsGlycerol (100% Solids)Triethanolamine (100% Solids) 22.0 lbs 23.1 lbs Diethanolamine (85% Solids) 25.9 lbs 12.9 lbsOil Emulsion (50% Solid) 68.4 lbs 68.4 lbs 68.4 lbs 68.4 lbs 68.4 lbs gamaaminopropiltrihidróxi-silane (1.24% solution) 34.6 lbs 34.6 lbs 34.6 lbs 34.6 lbs 34.6 lbs Water 2227.4 lbs 2234.9 lbs 2224.2 lbs 2221.6 lbs 2224.9 lbs
    ** MD = maltodextrin, CA = citric acid, G = glycerol, TEOA = 5
    Triethanolamine, DEOA = Diethanolamine, SHP = sodium hypophosphite
    TABLE 21
    Sample 6 Sample 7 Sample 8 Sample 9 Sample 10
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    Rigidity / Sag(degree) 11.85 12.28 9.82 9.85 12.11
    [086] As shown in Tables 18-21, the addition of glycerol, diethanolamine and / or triethanamine to the binder based on biological material yielded insulating fiberglass products having good performance properties, such as rigidity / sag. In addition, binder formulations containing a mixture of maltodextrin and citric acid without the presence of a cured catalyst under typical manufacturing conditions and produced acceptable stiffness / sag performance.
    Example 8:
    [087] The binder formulations shown in Table 22 were used to form 1 inch thick 5 pcf fiberglass lining plates in a conventional manner known to those skilled in the art. Lining plates have a target ignition loss (LOI) of 13%. The mechanical properties of the lining plates were determined under ambient conditions. The results were shown in Table 23. Comparative samples 1-3 are shown in Table 22 and Sample 4, the Control in this experiment, although not specifically identified in Table 22, is a 1 inch thick liner plate of 5 pounds per foot cubic meters (pcf), a commercially available product.
    TABLE 22
    Binder formulation based on biological material for 5 inch thick liner plates of 5 pounds per cubic feet (pcf).
    Component Sample 170:30 MD-CA for 5% SHP Sample 250:35:15 MD-CA-G for 5% SHP Sample 3 60:30:10 MD-CA-TEOA w /5% SHP Maltodextrin (50% Solid) 709.1 lbs 506.5 lbs 607.8 lbs Citric Acid (50% Solids) 303.9 lbs 354.5 lbs 303.9 lbs
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    Sodium hypophosphite (41.5% solids) 61.0 lbs 61.0 lbs 61.0 lbs Glycerol(100% Solid)76.0 lbsTriethanolamine (100% Solids) 50.6 lbs Surfinol 465 (100% Solid) 1.1 lbs 1.1 lbs 1.1 lbs Oil Emulsion (50% Solid) 56.4 lbs 56.4 lbs 56.4 lbs gamaaminopropiltrihidroxisilane (24.8% solution) 4.0 lbs 4.0 lbs 4.0 lbs Water 1384.3 lbs 1447.1 lbs 1426.2 lbs
    ** MD = maltodextrin, CA = citric acid, G = glycerol, TEOA =
    Triethanolamine, SHP = sodium hypophosphite
    TABLE 23
    Product performance for 5 pcf 1 inch thick liner boards.
    Sample 170:30 MD-CA w / 5% SHP Sample 250:35:15MD-CA-G w / 5% SHP Sample 360:30:10MD-CATEOA w / 5% SHP Sample 4PhenolUrea / Formaldehyde (Control / ' Flex Module (ksi) 1931 2080 2000 1946 Compressive Load @ 10% Deformation (lbs) 37.1 32.5 37.1 31.1
    (1) Owens Corning 5 pound-per-cubic-feet (pcf) 1-inch thick lining plate, a commercially available product.
    [088] As shown in Tables 22 and 23, the binder based on biological material produced liner plates having good performance properties, such as
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    47/55 as improved flexible (or equivalent) modules and improved compressive load deformation.
    Example 9:
    [089] The binder formulations shown in Table 24 were used to form flexible fiberglass duct medium R-6 (FDM) in a conventional manner by those skilled in the art. The flexible duct medium has a target LOI of 6%. The mechanical properties of the flexible duct medium were determined under ambient conditions. The results are shown in Table 25.
    TABLE 24
    Binder formulation based on biological material for Flexible Duct Medium
    Component Sample 170:30 MD-CA for 5% SHP Maltodextrin(50% Solid) 529.9lbs Citric Acid (50% Solids) 227.1 lbs Sodium hypophosphite (41.5% solids) 45.6lbs Red Ink (35% Solid) 9.2 lbs Oil Emulsion (50% Solid) 106.9 lbs gamaaminopropiltrihidroxisilane (24.8% solution) 59.6lbs Water 3567.2 lbs
    ** MD = maltodextrin, CA = citric acid, SHP = sodium hypophosphite
    TABLE 25
    Product Performance for R-6 Flexible Duct Insulation
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    Sample 170:30 MD-CA for 5% SHP Owens Corning R-6 Phenol / Urea / Formaldehyde Flexible Duct Insulation (Control) Tension Force (lbf) 17 20
    [090] As shown in Tables 24 and 25, the R-6 flexible duct medium insulation produced based on biological material that processed a tensile strength comparable to that of an existing commercial R-6 flexible duct insulator product.
    Example 10:
    [091] The binder formulations shown in Table 26 were used to form R-13 fiberglass metal construction insulator (MBI) in a conventional manner known to those skilled in the art. Lining boards have a target LOI of 6.5%. The mechanical properties of the metal construction insulator were determined under ambient conditions. The results are shown in Table 27.
    TABLE 26
    Binder Formulation Based on Biological Material for Metal Construction Insulation
    Component Sample 170:30 MD-CA for 5% SHP Maltodextrin (50% Solids) 463.9 lbs Citric Acid (50% Solids) 198.8 lbs Sodium hypophosphite (41.5% solids) 39.9 lbs
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    Red Ink (35% Solid) 7.3 lbs Oil Emulsion (50% Solid) 84.9 lbs gamaaminopropiltrihidroxisilane (24.8% solution) 52.2lbs Water 1806 lbs
    ** MD = maltodextrin, CA = citric acid, SHP = sodium hypophosphite
    TABLE 27
    Product Performance for R-13 Metal Construction Insulation
    Sample 170:30 MD-CA for 5% SHP Owens Corning R-13Metal Phenol / Urea / Formaldehyde Construction Insulation(Control) Thickness (inch) 4.64 4.66
    [092] As shown in Tables 26 and 27, the binder based on biological material produced insulator of construction R-13 that had a thickness comparable to that of the commercially available metal construction insulator R-13.
    Example 11:
    [093] Surface stresses of biological matter-based binders containing surfactants to decrease binder surface tension, to improve binder spray atomization, to improve binder distribution uniformity and to improve binder rinse and binder movement for fiber-to-fiber joints, have been compared with a binder standard
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    50/55 phenol / urea / formaldehyde. Surface stresses of binder compositions based on inventive biological material were measured using a Surface Tensiometer 6000 (manufactured by SensaDyne Instrument Division of the ChemDyne Research Group). The instrument was calibrated with deionized water. Data was recorded every 5 seconds. After the system was stabilized and the test started, the average value over a one minute test period was obtained for each sample. The results are shown in Table 28.
    TABLE 28
    Surface tension of the binder based on biological material and addition of surfactant
    Binder Mixture (10% of total solids) Surfactant % on binder solids Surface Tension(dyne / cm) phenol / urea / formaldehyde (Control) none none 72.0 80:20 MD-CA for 5% SHP None none 77.7 80:20 MD-CA for 5% SHP Stanfax (i) 0.1 46.0 0.3 41.3 0.5 41.9 80:20 MD-CA for 5% SHP Surfinol 465 (2) 0.1 51.0 0.3 49.4 0.5 46.2 80:20 MD-CA for 5% SHP Triton ™ GR PG70 (3) 0.1 35.6 0.3 31.3 0.5 30.1 80:20 MD-CA w / 5% SHP Dodecyl Sodium Sulfate 0.1 60 0.3 51.9 0.5 50.8 80:20 MD-CA for 5% SHP Triton ™ CF-10 0.1 39.1 0.3 39.3 0.5 40
    (1) Stanfax - sodium lauryl sulfate (2) Surfinol 465 - ethoxylated 2,4,7,9-tetramethyl 5 decin-4,7-diol (3) Triton TM GR-PG70 - 1,4-bis (2- ethylhexyl) sodium sulfosuccinate (4) Triton TM CF-10 - poly (oxy-1,2-ethanediyl), alpha- (phenylmethyl) -omega-
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    51/55 (1,1,3,3-tetramethylbutyl) phenoxy ** MD = maltodextrin, CA = citric acid, SHP = sodium hypophosphite [094] It was concluded from the observation of the results shown in Table 28 that the surface tension of the binder based on biological material was reduced by adding surfactants.
    TABLE 29
    Coupling agents for binder formulations based on biological material - Experimental Fiberglass Sheets
    Component Sample 1 70:30MD-CA for 5% SHP Sample 270:30 MD-CA for 5% SHP and 0.19% Tyzor® TE Sample 3 70:30 MD-CA for 5% SHP and 0.38% Tyzor ® TE Sample 4 70:30 MD-CA for 5% SHP and 0.19% Tyzor ® AA-75 Sample 5 70:30 MD-CA for 5% SHP and 0.38% Tyzor ® AA-75 Sample 6 70:30 MD-CA for 5% SHP and 0.19% Tyzor ® TPT Maltodextrin (50% conc.) (DE 11.0) 90.3g 90.3g 90.0g 90.3g 90.0g 90.3g Citric acid 19.4g 19.4g 19.3g 19.4g 19.3g 19.4g gamaaminopropiltrihidróxi-silane (solution1.24%) 10.2gSodium hypophosphite(41.5% conc.) 3.9g 3.9g 3.9g 3.9g 3.9g 3.9g Tyzor® TE (80% Conc.)0.16g 0.32g Tyzor® AA-75(75% Conc.) 0.17g 0.34gTyzor® TPT (100% Conc.)0.13g Water 676.2 686.3 686.5 686.3 686.5 686.3 Total 800g 800g 800g 800g 800g 800g
    ** MD = maltodextrin, CA = citric acid, SHP = sodium hypophosphite
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    TABLE 30
    Mechanical properties for experimental sheets with binder formulations based on biological material containing different coupling agents
    Sample 170:30MD-CA Sample 2 70:30MD-CA Sample 3 70:30MD-CA Sample 4 70:30MD-CA Sample 5 70:30MD-CA Sample 6 70:30MD-CAfor 5% SHP for 5% SHP and 0.19% Tyzor® TE for 5% SHP and 0.38% Tyzor® TE for 5% SHP and 0.19% Tyzor® AA -75 for 5% SHP and 0.38% Tyzor® AA -75 for 5% SHP and 0.19% Tyzor® TPT Tension Force (lbf) 16.13 16.43 15.79 15.2 15.05 20.17 L0I (%) 5.85 6.27 6.34 6.33 6.17 6.73 Voltage / LOI 2.76 2.62 2.49 2.4 2.44 3.00 Strength ofAging stress after steam (lbf) 10.66 6.51 6.64 7.30 10.25 10.29 LOI after Steam aging (%) 5.03 6.06 6.36 6.58 6.46 8.44 Stress after Vapor / LOI aging 2.12 1.08 1.04 1.11 1.59 1.22
    ** MD = maltodextrin, CA = citric acid, SHP = sodium hypophosphite [095] From the data shown in Tables 29 and 30, it was concluded that formulations based on biological matter containing different coupling agents reached stress forces comparable to those current commercially available products.
    Example 12:
    [096] The binder based on biological material gives off an aroma depending on the product and curing conditions. To minimize the emission of
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    53/55 unwanted flavors, various amine alkanols were added to the binder composition and R-20 products were produced under typical (conventional) manufacturing conditions. The materials produced were cut in 8X8 ( 2 inches), placed in zip closure bags and sealed. Ten panelists were provided with a fresh sample bag and the panelists individually classified each of the samples with the strongest aroma (highest number) to the weakest aroma (lowest number). The results are shown in Table 31.
    TABLE 31
    Aroma decreases in the insulator made with the binder based on biological material
    Sample description Aroma Classification(descending order of intensity) Sample 1 70:30 MD-CA w / 5% SHP 4 Sample 2 60:30:10 MD-CA-TEOA 3 Sample 3 65: 30: 5 MD-CA-TEOA 2for 5% SHPSample 4 65: 30: 5 MD-CA-DEOAfor 5% SHP 1
    ** MD = maltodextrin, CA = citric acid, TEOA = Triethanolamine,
    DEOA = diethanolamine, SHP = sodium hypophosphite [097] Based on the data shown in Table 31, it is concluded that the aroma generated by the cured insulating product was reduced using a binder based on biological material containing an alkanol amine.
    Example 13:
    [098] Sample 1 and Sample 2 binder formulations exhibited in the
    Table 18 combined with the moisture resistant additives listed in Table 32 were used to form R-13 insulating fiberglass products in a conventional manner known to those skilled in the art. R-13 products have a target LOI of 6.5%. The mechanical properties of the matter binder
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    54/55 biological added to the moisture resistant additive were determined under ambient conditions. The results are shown in Table 32.
    TABLE 32
    Additives added to improve water resistance of glass fiber insulator made with binder blankets based on biological material - R-13
    description Added additive Amount added (% on Binder Solids) Rigidity / Sag (degree) 80:20 MD-CA for 5% SHP 39 70:30 MD-CA for 5% SHP 28 70:30 MD-CA for 5% SHP Polon MF56 0.3 32 70:30 MD-CA for 5% SHP SVE-148 0.3 30 70:30 MD-CA for 5% SHP LE-743 0.3 31 70:30 MD-CA for 5% SHP Silres BS-1042 0.3 37 70:30 MD-CA for 5% SHP ICM-2153 0.3 35 70:30 MD-CA for 5% SHP Silquest Y-9669 0.3 40
    ** MD = maltodextrin, CA = citric acid, SHP = sodium hypophosphite [099] Based on the data shown in Table 32, it was concluded that binder formulations based on biological material containing different moisture resistant additives obtained an insulating product from fiberglass with performance capabilities comparable to those of commercially available fiberglass insulating products.
    [100] An environmental emission test was to use the basic formulation shown as Sample 1 in Table 18 in conjunction with either alone or with an existing emulsified mineral non-dusty oil. The test was conducted over a period of at least 5 hours using a conventional production line to make an R-19 insulating product for each formulation including a control. A typical emission analytical sampling procedure was followed and the filtered particulate emission and formaldehyde emission were listed in Table 33.
    TABLE 33
    Result of Training Emission Tests
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    Sample Compound / Training Binder Type MDCA lbs / hour Binder Type MDCA -Oléo Veg.lbs / hour Binder Type Phenol / Urea / Formaldehyde (Control) lbs / hour Filtered Particles, M5 / 202 5,499 5,064 6,737 Formaldehyde M316 0.028 0.023 0.414
    [101] From the data shown in Table 33, it was concluded that the binder based on biological material, when applied in a conventional fiberglass insulating manufacturing process, particulate emission reduced by 18% or more and emission of formaldehyde almost eliminated during the formation of the insulator. It is noted that the small amount of formaldehyde detected may have been derived from the formaldehyde binder residue or some other contamination.
    [102] The invention of this application has been described above both generically and in relation to specific modalities. Although the invention has been shown to be believed to be the preferred embodiment, a wide variety of alternatives known to those skilled in the art can be selected within the generic disclosure. The invention is not limited in any other way, except as stated in the claims shown below.
    权利要求:
    Claims (18)
    [1]
    1. Aqueous binder composition for use in the formation of nonwoven carpets and fiberglass insulators, FEATURED by the fact that it comprises:
    maltodextrin having an equivalent dextrose number of 9 to 14, said maltodextrin comprising from 40% to 95% by weight of the total solids of said binder composition; and at least one crosslinking agent selected from monomeric polycarboxylic acid, citric acid, or its corresponding salts, said at least one crosslinking agent comprising from 5% to 40% by weight of the total solids of said binder composition, said at least one cross-linking agent having a molecular weight of 90 to 10,000.
    [2]
    2. Binder composition according to claim 1, CHARACTERIZED by the fact that said maltodextrin has an average molecular weight number of 1,000 to 8,000.
    [3]
    Binder composition according to claim 1, CHARACTERIZED by the fact that said cross-linking agent is citric acid or salt thereof.
    [4]
    Binder composition according to claim 1, CHARACTERIZED by the fact that said at least one cross-linking agent has a molecular weight of 190 to 4,000.
    [5]
    Binder composition according to claim 1, CHARACTERIZED by the fact that said binder composition further comprises at least one member selected from the group consisting of a coupling agent, a process aid, an extender, an adjuster of pH, a catalyst, a cross-linked density intensifier, a deodorant, an antioxidant, a dust suppressant, a biocide, a corrosion inhibitor, a moisture resistant agent and combinations thereof.
    Petition 870190103420, of 10/14/2019, p. 65/72
    2/4
    [6]
    Binder composition according to claim 5, CHARACTERIZED by the fact that said catalyst comprises a sodium hypophosphite catalyst.
    [7]
    7. Binder composition, according to claim 5, CHARACTERIZED by the fact that said process aid comprises one or more of a nonionic surfactant and vegetable oils.
    [8]
    Binder composition according to claim 5, CHARACTERIZED by the fact that said coupling agent comprises a silane coupling agent.
    [9]
    Binder composition according to claim 5, CHARACTERIZED by the fact that said binder comprises a biocide amount of up to 10% by weight.
    [10]
    Binder composition according to claim 1, CHARACTERIZED by the fact that said binder composition further comprises a coloring additive.
    [11]
    11. Binder composition according to claim 1, CHARACTERIZED by the fact that said binder composition further comprises a process aid selected from the group consisting of glycerol, 1,2,4-butanotriol, 1,4-butanediol, 1,2 -propanediol, 1,3-propanediol, poly (ethylene glycol), and mixtures thereof.
    [12]
    12. Fibrous insulating product CHARACTERIZED by the fact that it comprises:
    a plurality of randomly oriented fibers; and a binder composition applied to at least a portion of said fibers, said binder composition comprising the reaction product of:
    maltodextrin having an equivalent dextrose number of 9 to 14, said maltodextrin comprising from 40% to 95% by weight of the total solids of said binder composition; and
    Petition 870190103420, of 10/14/2019, p. 66/72
    3/4 at least one crosslinking agent selected from monomeric polycarboxylic acid, citric acid, or their corresponding salts, said at least one crosslinking agent comprising from 5% to 40% by weight of the total solids of said composition binder, said at least one cross-linking agent having a molecular weight of 90 to 10,000.
    [13]
    Fibrous insulating product according to claim 12, CHARACTERIZED by the fact that said binder composition in a cured state comprises at least one polyester.
    [14]
    14. Fibrous insulating product, according to claim 12, CHARACTERIZED by the fact that said insulating product is free of formaldehyde.
    [15]
    15. Non-woven rug FEATURED by the fact that it comprises:
    a plurality of glass fibers randomly oriented in the form of a carpet having a first main surface and a second main surface; and a binder composition at least partially coating said first main surface of said carpet, said binder composition comprising the reaction product of:
    maltodextrin having an equivalent dextrose number of 9 to 14, said maltodextrin comprising from 40% to 95% by weight of the total solids of said binder composition; and at least one crosslinking agent selected from monomeric polycarboxylic acid, citric acid, or its corresponding salts, said at least one crosslinking agent comprising from 5% to 40% by weight of the total solids of said binder composition, said at least one cross-linking agent having a molecular weight of 90 to 10,000.
    [16]
    16. Non-woven mat according to claim 15, CHARACTERIZED by the fact that said binder composition in a cured state comprises at least one polyester.
    Petition 870190103420, of 10/14/2019, p. 67/72
    4/4
    [17]
    17. Process for forming the fibrous insulating product, as defined in claim 12, CHARACTERIZED by the fact that the process comprises the following steps:
    forming a plurality of randomly oriented glass fibers;
    applying the binder composition to said glass fibers to form a fibrous insulating mat; and curing said binder of said fibrous insulating mat to form an insulating product, wherein said binder cured in said fibrous insulating product comprises at least one polyester.
    [18]
    18. Process, according to claim 17, CHARACTERIZED by the fact that said curing step comprises: passing said insulating mat through an oven.
    类似技术:
    公开号 | 公开日 | 专利标题
    BR112012007961B1|2019-11-19|aqueous binder composition for use in forming nonwoven mats and fiberglass insulators, fibrous insulating material, nonwoven carpet and process for forming the fibrous insulating product
    US10550294B2|2020-02-04|Bio-based binder systems
    US10000666B2|2018-06-19|Insulative products having bio-based binders
    EP2694717B1|2017-06-28|Bio-based binders including carbohydrates and a pre-reacted product of an alcohol or polyol and a monomeric or polymeric polycarboxylic acid
    JP2014515793A5|2016-02-12|
    WO2013188015A1|2013-12-19|Use of surfactants to improve aged properties of fiberglass insulation products
    CA3097841A1|2019-11-21|Nonwoven with two-part binder system
    NZ615164B2|2015-07-28|Insulative products having bio-based binders
    同族专利:
    公开号 | 公开日
    US20150017858A1|2015-01-15|
    CA2777078A1|2011-04-14|
    US9546263B2|2017-01-17|
    EP2899227A1|2015-07-29|
    AU2010303254B2|2015-10-01|
    CN102695684B|2016-06-15|
    US9290640B2|2016-03-22|
    EP3578528A1|2019-12-11|
    US20150033981A1|2015-02-05|
    US8864893B2|2014-10-21|
    CA2954722C|2020-03-10|
    CA2777078C|2017-11-21|
    AU2010303254A1|2012-04-26|
    CN102695684A|2012-09-26|
    CA2954722A1|2011-04-14|
    US20110086567A1|2011-04-14|
    WO2011044490A1|2011-04-14|
    BR112012007961A2|2016-03-29|
    EP2485989A1|2012-08-15|
    EP2485989B1|2019-07-10|
    US20160340499A1|2016-11-24|
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    法律状态:
    2018-04-10| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2018-11-27| B06T| Formal requirements before examination [chapter 6.20 patent gazette]|Free format text: O DEPOSITANTE DEVE RESPONDER A EXIGENCIA FORMULADA NESTE PARECER POR MEIO DO SERVICO DE CODIGO 206 EM ATE 60 (SESSENTA) DIAS, A PARTIR DA DATA DE PUBLICACAO NA RPI, SOB PENA DO ARQUIVAMENTO DO PEDIDO, DE ACORDO COM O ART. 34 DA LPI.PUBLIQUE-SE A EXIGENCIA (6.20). |
    2019-07-16| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|
    2019-10-22| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2019-11-19| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 08/10/2010, OBSERVADAS AS CONDICOES LEGAIS. (CO) 20 (VINTE) ANOS CONTADOS A PARTIR DE 08/10/2010, OBSERVADAS AS CONDICOES LEGAIS |
    2021-08-10| B21F| Lapse acc. art. 78, item iv - on non-payment of the annual fees in time|Free format text: REFERENTE A 11A ANUIDADE. |
    2021-11-30| B24J| Lapse because of non-payment of annual fees (definitively: art 78 iv lpi, resolution 113/2013 art. 12)|Free format text: EM VIRTUDE DA EXTINCAO PUBLICADA NA RPI 2640 DE 10-08-2021 E CONSIDERANDO AUSENCIA DE MANIFESTACAO DENTRO DOS PRAZOS LEGAIS, INFORMO QUE CABE SER MANTIDA A EXTINCAO DA PATENTE E SEUS CERTIFICADOS, CONFORME O DISPOSTO NO ARTIGO 12, DA RESOLUCAO 113/2013. |
    优先权:
    申请号 | 申请日 | 专利标题
    US25018709P| true| 2009-10-09|2009-10-09|
    PCT/US2010/052028|WO2011044490A1|2009-10-09|2010-10-08|Bio-based binders for insulation and non-woven mats|
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