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Bio-based binders including carbohydrates and a pre-reacted product of an alcohol or polyol and a monomeric or polymeric polycarboxylic acid

a bio-based, binder technology, applied in the field of binders, can solve the problems of unstable urea-extended resoles, ammonia is not a particularly desirable alternative, and irritation of workers' throats and noses, so as to reduce the viscosity of the binder, speed up the crosslinking reaction, and induce faster water evaporation

Inactive Publication Date: 2014-02-06
OWENS CORNING INTELLECTUAL CAPITAL LLC +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention provides an improved binder composition for insulation products that uses natural and renewable sources, such as carBOhydrates, which helps to speed the crosslinking reaction, decrease viscosity, reduce water requirements, decrease tackiness, and achieve a maximum vertical expansion of the insulation pack in the transfer zone. Additionally, the use of pre-reacted products form an alcohol or polyol with a monomeric or polymeric carboxylic acid helps to induce faster water evaporation, resulting in a lower cost for the binder composition. The inventive binder composition does not require added formaldehyde and allows for the use of a variety of colors and pigments for the insulation product. The final insulation product has a light color at low LOIs.

Problems solved by technology

Unfortunately, the urea-extended resoles are unstable, and because of this instability, the urea-extended resoles must be prepared on site.
Ammonia is not a particularly desirable alternative to urea as a formaldehyde scavenger because ammonia generates an unpleasant odor and may cause throat and nose irritation to workers.
Further, the use of a formaldehyde scavenger in general is undesirable due to its potential adverse affects to the properties of the insulation product, such as lower recovery and lower stiffness.
A binder that is formed mostly of polyacrylic acid inherently has problems due to its acidity and associated corrosion of machine parts.
In addition, polyacrylic acid binders have a high viscosity, high curing temperatures, and high associated curing costs.
Further, the Maillard-based products have an undesirable dark brown color after curing.
Also, the use of large amounts of ammonia needed to make the binder presents a safety risk and possible emission problems.
However, these alternative binder systems remain problematic.
For example, low molecular weight, low viscosity binders which allow maximum vertical expansion of the insulation pack in the transfer zone generally cure to form a non-rigid plastic matrix in the finished product, thereby reducing the attainable vertical height recovery of the finished insulation product when installed.
Conversely, high viscosity binders, which generally cure to form a rigid matrix in the finished product, do not allow the desired maximum vertical expansion of the coated, uncured pack.

Method used

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  • Bio-based binders including carbohydrates and a pre-reacted product of an alcohol or polyol and a monomeric or polymeric polycarboxylic acid
  • Bio-based binders including carbohydrates and a pre-reacted product of an alcohol or polyol and a monomeric or polymeric polycarboxylic acid
  • Bio-based binders including carbohydrates and a pre-reacted product of an alcohol or polyol and a monomeric or polymeric polycarboxylic acid

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0089]The effect on the ramp height of adding a pre-reacted glycerol-citric acid (GlyCA) to the binder mix is depicted in Table 3. As can be seen in Table 3, the addition of GlyCA improved ramp quality and ramp height when varying the ratios of the components without the need of additional water, which could require more water evaporation during curing (and longer curing times). It was noted that the results can vary depending on how long the glycerol-citric acid were pre-reacted (e.g., 1 h, 2 h or 3 h).

TABLE 3Ramp Height Measured While Making R-20Fiberglass Insulation Using Polyester Bio-Based BindersRampFormulationHeight (in)70:10:20 MD-CA-lyCA w / 5% SHP12.2060:10:30 MD-CA-GlyCA w / 5% SHP12.9950:20:30 MD-CA-GlyCA w / 5% SHP17.32**MD = maltodextrin, CA = citric acid, GlyCA = pre-reacted glycerol / citric acid, SHP = sodium hypophosphite

example 2

Pre-Reacted Product of Glycerol and Citric Acid

[0090]General procedure. Glycerol (USP grade) is added to a reaction vessel fitted with a temperature probe and agitator. The amount of glycerol is selected to provide a molar ratio of glycerol to citric acid of about 1.5-3:1. The glycerol is heated to a reaction temperature of about 115° C. to about 145° C. As the glycerol reaches a temperature of about 80° C., citric acid is added to the reaction vessel in small portions. The reaction is allowed to proceed for about 1.5 hours to about 24 hours. The reaction may be quenched with water or an aqueous sodium hydroxide solution if desired.

[0091]Using the general conditions above, 13 samples were prepared. The properties of these samples are provided in Table 4.

TABLE 4Glycerol:totalcitric / citrateTempRelative % ConversionGlycerol remainingExp #(molar ratio)(° C.)Other conditions(reduction of glycerol)(g gly / g product)1007-0062:113075% @ 8 hrs0.131007-0112:114075% @ 3 hrs0.131008-0022:112070%...

example 3

[0092]A pre-reacted product of glycerol and citric acid was made by heating 10 kg of glycerol combined with 10.4 kg of anhydrous citric acid in a chemical reactor at 130° C. for 1, 2, or 3 hours under ambient conditions. For most of the binder compositions, the GlyCA was dissolved in water to a 50% concentration prior to be used. FIG. 4 illustrates the rheology data obtained from the polyester bio-based binders containing a pre-reacted product of glycerol and citric acid where the glycerol and citric acid were pre-reacted for 1 h, 2 h, and 3 h, respectively, before adding the pre-reacted product to the binder composition. Additionally, a binder composition with added polyglycerol was included in FIG. 4 for comparison purposes.

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Abstract

An environmentally friendly, formaldehyde-free, aqueous binder composition that includes a carbohydrate, a crosslinking agent, and a pre-reacted product of an alcohol or polyol and monomeric or polymeric polycarboxylic acid or polyglycerol is provided. The pre-reacted product may include glycerol and esters of citric acid such a monoglyceryl citrate, diglyceryl citrate, and triglyceryl citrate as well as other higher molecular weight citric acid-based esters. The inclusion of the pre-reacted product in the binder composition helps to speed the crosslinking reaction, induces faster water evaporation, decreases the viscosity of the binder, helps to reduce the amount of water needed for application of the binder, decreases tackiness, and helps to achieve a maximum vertical expansion of the insulation pack in the transfer zone. The binder composition may be used in the formation of insulation materials and non-woven chopped strand mats.

Description

CROSS REFERENCE TO RELATED APPLICATION[0001]This application claims the benefit of the U.S. Provisional Patent Application Ser. No. 61 / 473,043, filed Apr. 7, 2011, entitled BIO-BASED BINDERS INCLUDING CARBOHYDRATES AND A PRE-REACTED PRODUCT OF AN ALCOHOL OR POLYOL AND A MONOMERIC OR POLYMERIC POLYCARBOXYLIC ACID, which is hereby incorporated by reference in its entirety.TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION[0002]The present invention relates generally to rotary fiber insulation and non-woven mats, and more particularly, to a binder for use in manufacturing both fiberglass insulation and non-woven mats that is bio-based, preferably containing no added formaldehyde, and is environmentally friendly.BACKGROUND OF THE INVENTION[0003]Conventional fibers are useful in a variety of applications including reinforcements, textiles, and acoustical and thermal insulation materials. Although mineral fibers (e.g., glass fibers) are typically used in insulation products and...

Claims

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Application Information

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IPC IPC(8): E04B1/78D06M15/327
CPCD06M15/327E04B1/78D04H1/587C09J103/02C09J103/04C09J105/06C08K5/0025C08K5/092C08L67/02Y10T442/2992C08K5/11C08K9/04D06M15/11
Inventor ANDERSON, KEVIN R.HEMANDEZ-TORRES, JESUS
Owner OWENS CORNING INTELLECTUAL CAPITAL LLC
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