Curable biopolymer nanoparticle latex binder for mineral, natural organic, or synthetic fiber products and non-woven mats

Abstract

A curable aqueous binder composition includes a dispersion of biopolymer particles, optionally with and an inter-particle crosslinking agent, for use in the formation of composite materials such as mineral, natural organic, or synthetic fiber products, including mineral fiber insulation, non-woven mats, fiberglass insulation and related glass fiber products, and wood based products, and construction materials. In an application of the curable aqueous composition to making fiberglass insulation, the composition may be blended with a second resin which may be a non-formaldehyde resin. In an application of the composition to making fiberglass roofing shingles, the biopolymer particles may be mixed into a formaldehyde based resin during or after the polymerization of the resin.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS[0001]This patent claims the benefit of U.S. provisional patent application No. 61 / 493,266 filed on Jun. 3, 2011 which is incorporated herein by this reference to it.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH[0002]Not Applicable.BACKGROUND OF THE INVENTION[0003]1. Field of the Invention[0004]This invention relates to a curable composition, for example a composition useful for forming a composite material comprising biopolymer particles, and to composite materials, for example mineral fiber insulation and roofing shingles.[0005]2. Description of the Related Art[0006]The following discussion is not an admission that anything described below is common knowledge of persons skilled in the art, or citable as prior art.[0007]Mineral fibers used in insulation products and non-woven mats are usually bonded together with a crosslinked binder resin. The binder has to provide the resilience for recovery after packaging (in the case of insulation pro...

AI Technical Summary

Benefits of technology

"The patent describes a new way to make various fiber products using a combination of biopolymer nanoparticles and a curable binder. The use of biopolymer nanoparticles allows for improved bonding with the fibers, resulting in stronger and more durable products. The curable binder composition includes a multifunctional crosslinking agent that can react with the nanoparticles and the fibers to form a network of bonds. This crosslinking agent can trigger in the curing stage to lock in the desired fiber mat dimensions. The patent also describes a method for making non-woven materials and binding together glass fibers using the new binder composition. The technical effects of this invention include improved bonding strength, durability, and flexibility in the production of various fiber products."

Problems solved by technology

A serious disadvantage of formaldehyde-based resins is the release of free formaldehyde to the environment during manufacturing and use, contaminating the air that we breathe which is undesirable for health and ecological reasons.

In addition to the health and environmental problems, further compounding the problem is that the lowest cost formaldehyde based binders are based on UF resins.

These resins are typically used in outdoor applications, and therefore their main challenge is worker exposure during manufacturing, while in-use release of formaldehyde is less of a concern, especially in outdoor applications.

However, traditional biobased industrial materials derived from agricultural crops are generally viewed by manufacturing and packaging industries as less consistent and inferior to the dominant petrochemical-based synthetic products.

However, these have serious shortcomings such as high cost, high corrosivity, high viscosity, dark color, lack of rigidity, water sensitivity, poor bond strength, etc.

This technology has been found to result in major corrosion problems with the equipment used to manufacture fiberglass insulation products, as well as in-use applications where metal wall studs and other metal components are being used in combination with the fiber glass insulation product.

The problem is the much higher cost of PVOH relative to conventional formaldehyde binder systems.

In addition, since it is petroleum based it is a carbon positive material which is not environmentally preferred.

Without any additional enhancer, this binder does not provide sufficient wet strength and water resistance.

The major disadvantage of this binder is high cost and low pH which causes corrosion of fiber glass mat production equipment and during in-use applications.

Disadvantages of this system are low pH and high viscosity at relatively low solids content.

The problems as mentioned above include the much higher cost of PVOH relative to conventional formaldehyde binder systems, and since it is petroleum based it is a carbon positive material which is not environmentally preferred.

This binder is also corrosive due to relatively low pH (about 4) and does not provide the required water resistance.

However, a practical use of such a composition for insulation production is limited because the high acidity of these binder compositions will cause corrosion of production lines and during the in-use applications.

Moreover, whilst the strength of this binder is acceptable for some applications it is not as good as the commonly used formaldehyde based binders.

In addition, since it is petroleum based it is a carbon positive material which is not environmentally preferred.

), which a serious disadvantage.

Such a system has relatively low water resistance, is dark in color and generates ammonia emissions upon cure.

In addition, since it is petroleum based it is a carbon positive material which is not environmentally preferred.

These binders turn dark brown on curing and have poor water and biological resistance.

While these references and other prior art systems disclose various formaldehyde-free systems for insulation and non-woven mats, they all have limitations with respect to developing binders that are effective as well as environmentally friendly.

These binders have limited application due to high cost.

In addition, they are petroleum based carbon positive materials which are not environmentally preferred.

A major problem in the manufacturing process and use of some known fiber mats is inadequate wet web strength.

But higher vacuum draw will lead to undesired mat properties, such as a high mat tensile ratio (i.e. the ratio of dry to wet tensile strengths).

Inadequate dry mat tensile strengths also can reduce the ability of the finished roofing product to resist stresses during its service lifetime on the roof.

A major problem in the manufacturing process and use of fiber mats is inadequate wet web strength, which cannot be provided by a urea formaldehyde resin without an additive, as illustrated by the related art described in this paragraph.

In addition, since these binders are all petroleum based they are carbon positive materials and therefore not environmentally preferred.

The main disadvantage of these binders is a necessity of preparing the binder before applying it on the glass fiber mat due to a limited stability of a resin / latex mixture.

In addition, since these binders are petroleum based they are carbon positive materials which are not environmentally preferred.

However, all of these to date have serious shortcomings such as high cost, high corrosivity, high viscosity, dark color, lack of rigidity, water sensitivity, poor bond strength, etc.

No inter-particle crosslinks exist, as this would result in poor rheology and reduced binding power (reduced surface area).

Currently, the industry consumes over 4 billion pounds of SB and SA latex per annum.

As the price of oil continues to escalate, and as the price of synthetic binders has increased by more than 100% over the past few years, paper producers have faced increased production costs forcing them to find efficiencies, pass increases on to the consumer, or cease production.

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