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Surfactant-containing insulation binder

a fiberglass and polymer technology, applied in the field of fiberglass insulation, can solve the problems of poor interfacing/wetting between glass and polyacrylic, high surface tension, undesirable droplet size and binder distribution, etc., and achieve the effects of improving fiber protection, reducing surface tension of polycarboxy polymer binder composition, and improving wetting and distribution of binder into fiberglass matrix

Inactive Publication Date: 2005-09-01
DOBROWOLSKI RICHARD +3
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention provides a better fiber protection, less fiber damage, better product performance, and a more environmentally friendly manufacturing operation for fiberglass insulation. This is achieved by adding a surfactant to the polycarboxy polymer binder composition, which reduces the surface tension of the binder and improves its wetting and distribution in the fiberglass matrix. The invention includes a fiberglass insulation binder composition comprising a polycarboxy polymer, a polyhydroxy crosslinking agent, and a surfactant, as well as a process for preparing and applying the binder composition onto a fiberglass substrate. The technical effects of the invention include improved fiber protection, reduced fiber damage, better product performance, and a more environmentally friendly manufacturing operation.

Problems solved by technology

This poor interfacing / wetting between glass and the polyacrylic acid binder is believed to result from high surface tension due to the strong hydrogen bond of the acid and the acidity of the binder versus the alkalinity of the glass surface.
Such high surface tension binders prevent efficient atomization when the binder is applied by spraying it onto glass fibers e.g. in a forming hood, resulting in undesirable droplet size and binder distribution.
Once the binder is on the glass fiber, its acidity and high surface tension result in poor wetting and reduced binder flow to fiber-fiber junctions.
The poor wetting and reduced bonding efficiency decreases protection of individual glass fibers and results in increased fiber damage during processing.
As a result, product properties, including pack integrity and dusting, are adversely impacted.
The Seydel Research patent does not purport to address the above-noted problems.

Method used

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  • Surfactant-containing insulation binder
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  • Surfactant-containing insulation binder

Examples

Experimental program
Comparison scheme
Effect test

example 1

Surface Tension

[0029] A polyacrylic acid based binder having a solids content of 2.8 weight-% was prepared by diluting QRXP 1564 with water, followed by the addition of amino silane and oil emulsion. To make binder products of the present invention, small amounts (0.1 weight-% and 0.2 weight-%) of Surfynol 465 were blended into the binder composition.

[0030] Surface tensions of the polyacrylic acid based binder compositions of this invention and of two reference binder compositions were measured using a Surface Tensionmeter 6000, produced by the SensaDyne Instrument Division of the Chem-Dyne Research Group. The instrument was calibrated with deionized water. The data were taken every 5 seconds. After the testing started and the system stabilized, the average value over a one-minute testing period was obtained for each sample. The results are reported in Table 1.

TABLE 1SurfaceTensionBinder Description(dyne / cm)QRXP 1564 2.8% solid70.94QRXP 1564 2.8% + 0.1% S-46562.87QRXP 1564 2.8% ...

example 2

Binding Strength

[0032] A polyacrylic acid binder premix was prepared composed on 74.25 parts by weight (pbw) of Acumer 9932 (a 46% solids polyacrylic acid from Rohm & Haas), 10.40 pbw glycerol, 0.45 pbw corrosion inhibitor, and 14.90 pbw water, to provide a 45% solids premix. The premix was added along with silane and oil emulsion to water to provide a 3.5% solids polyacrylic acid glycerol binder (PAG+).

[0033] Surfynol 465 surfactant was added to this polyacrylic acid glycerol binder at various % levels based on the binder solids. These binder compositions were sprayed onto fiberglass as in a typical fiberglass insulation binder application to obtain a Loss On Ignition (LOI) of 1.9%. The binder fiberglass was formed into insulation blankets, conveyed to an oven, and cured therein at temperatures ranging from 350 to 590° F. The bond strength, a measure of mechanical strength, of the cured bindered insulation products was measured and is reported in Table 2.

TABLE 2BondStrengthBind...

example 3

SEM Examination

[0035] Scanning Electron Microscope imaging reveals structural details relating to the manner in which binder is distributed in a fiberglass matrix. SEM provides insight into such details as droplet size, wetting performance, and fiber-fiber junctions. FIG. 1 shows fiberglass insulation produced with no surfactant added to the polyacrylic acid binder. This sample shows poor binder dispersion and poor atomization. This “prior art” binder is poorly distributed throughout the pack and even forms some binder “nests”. FIGS. 2 and 3 show fiberglass insulation produced with surfactant added in accordance with this invention. In these products, the binder was much more uniformly distributed throughout the matrix, the binder showed much better wetting on the glass fiber surface, and more and better fiber-fiber junctions were observed. Thus the present invention significantly improves binder atomization, binder distribution, and binder wetting.

[0036] Fiberglass insulation pro...

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Abstract

A fiberglass insulation binder composition made from a polycarboxy polymer, a polyhydroxy crosslinking agent, and a cationic surfactant, amphoteric surfactant, nonionic surfactant, or mixture thereof. Also, a process for manufacturing a fiberglass insulation product, which involves a step of applying the binder composition onto a fiberglass substrate and curing the fiberglass substrate so treated. Binders produced in accordance with the present invention are characterized by improved atomization, improved binder dispersion and fiber wetting properties, and improved protection of individual fibers during processing.

Description

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION [0001] The present invention relates to fiberglass insulation. More specifically, the present invention provides a means for obtaining improved performance of polyacrylic acid and similar fiberglass insulation binders. BACKGROUND OF THE INVENTION [0002] Polyacrylic acid-based fiberglass insulation binders are typically manufactured with a low molecular weight polyacrylic acid, a polyhydroxy crosslinking agent, and a cure accelerator, such as sodium hypophosphite. Typical embodiments include QRXP-1564 and QRXP-1513, produced by Rohm & Haas. QRXP-1564 is a blend of Acumer 1020 (71.6 wt-%), glycerol (21.8 wt-%), sodium hypophosphite (5.6 wt-%), and a small amount of corrosion inhibitor. Water is added as a diluent. QRXP-1513 is a blend of Acumer 1020, triethanolamine, and sodium hypophosphite. Water is added as a diluent. Acumer 1020 is a polyacrylic acid produced from acrylic acid monomer and a sodium bisulfite reactant. Ac...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): C03C25/28C08K5/06
CPCC03C25/285C08K5/06C08L33/02
Inventor DOBROWOLSKI, RICHARDCHEN, LIANGHINZE, JAY WILLIAMHAGER, WILLIAM GERARD
Owner DOBROWOLSKI RICHARD
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