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Bio-based binder systems

a technology of bio-based binder and binder plate, which is applied in the direction of pectin adhesives, adhesive types, coatings, etc., can solve the problems of unstable urea-extended resoles, ammonia is not a particularly desirable alternative, and throat and nose irritation of workers, so as to save time and money, low cost, and low loss of ignition

Inactive Publication Date: 2014-03-27
CARGILL INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

This patent describes a new binder system for insulation products that uses carbohydrates, such as maltodextrin, which are readily available and low-cost. The binder system can be used with existing manufacturing lines, saving time and money. Additionally, the binder system does not require added formaldehyde, and the final insulation product has a light color that allows for the use of dyes or pigments to achieve different colors. The binder composition can be provided in an aqueous formulation that can be applied using conventional applicators, such as spray applicators.

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.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

Blowing Corn Stillage Oil

[0112]Into a 6000 gallon steel tank equipped with an air sparge distributor, positive displacement blower, regenerative thermal oxidizer(RTO) system, controlled heat source(whether it be external steam or hot oil jacket), and cooling coils, 45,000 pounds of corn stillage oil, similar to the corn stillage oil described in PCT Publication WO 2010 / 135637, published Nov. 25, 2010 (entitled “Blown Corn Stillage Oil”) is charged. Air is sparged through the oil as it is heated. The air is sparged through the oil at a rate that maximizes the rate while at the same time causes a relatively even distribution of air bubbles within the oil. The rate of sparging is set so the reactor remains under a slight vacuum which indicates the RTO system can remove VOCs adequately and safely as they are produced from the reaction. The speed with which viscosity increases is directly proportional to the rate at which air is being blown into the corn stillage oil, and indirectly prop...

example 1a

Blowing Corn Stillage Oil and Soybean Oil Blends

[0113]Into a 6000 gallon steel tank equipped with an air sparge distributor, positive displacement blower, regenerative thermal oxidizer(RTO) system, controlled heat source(whether it be external steam or hot oil jacket), and cooling coils, 45,000 pounds of corn stillage oil and soybean oil blend, as indicated in Table 4 is charged. The corn stillage oil is similar to the corn stillage oil described in PCT Publication WO 2010 / 135637, published Nov. 25, 2010. The soybean oil is refined, bleached, and deodorized (RBD) soybean oil having an acid value of less than 0.5 mg KOH / gram. Air is sparged through the oil blend as it is heated to the temperature indicated in Table 4. The air is sparged through the oil blend at a rate that maximizes the rate while at the same time causes a relatively even distribution of air bubbles within the oil. The rate of sparging is set so the reactor remains under a slight vacuum which indicates the RTO system...

example 2

Stripping Blown Corn Stillage Oil

[0116]Into a 6000 gallon stainless steel reactor equipped with a mechanical agitator, a nitrogen sparge distributor, vacuum pump, regenerative thermal oxidizer(RTO) system, controlled heat source(hot oil jacket), and cooling coils, 45,000 pounds of blown corn stillage oil from Example 1, as indicated in Table 5, is charged. Nitrogen is sparged at about 5-10 CFM through the oil as it is heated to about 235° C. to 245° C. Once the oil reaches the desired temperature, shut off nitrogen sparge and apply full vacuum to the reactor (preferred pressure of 20 torr or less). The oil within the reactor is tested periodically to determine the viscosity at 40° C., flash point, and the acid value of the oil. When the oil reaches acid value of from 7-9 mg KOH / gram, break the vacuum to atmospheric pressure. Add desired amount of USP grade glycerol (which has lower than 0.3 weight percent impurities and less than or equal to 10 PPM Chloride ion (Cl−)) to the oil in ...

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Abstract

An environmentally friendly, bio-based binder system that is useful for the formation of fiberglass insulation, the system includes: A) an aqueous curable binder composition, which includes a carbohydrate and a crosslinking agent; and B) a dedust composition, which includes a blown, stripped plant-based oil and optionally at least one emulsifying agent. The bio-based binder system is typically heated to form a cured binder system.

Description

CROSS REFERENCE TO RELATED APPLICATION[0001]This application claims the benefit of the U.S. Provisional Patent Application, Ser. No. 61 / 490,695 filed 27 May 2011, entitled BIO-BASED BINDER SYSTEMS, 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 more particularly, to a bio-based binder system for use in manufacturing mineral fiber insulation (such as fiberglass insulation and stone wool insulation) that preferably contain no added formaldehyde, and are 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 and fibers made from stone) are typically used in insulation products, depending on the particular application, organic fibers such as polypropyl...

Claims

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Application Information

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IPC IPC(8): C03C25/32
CPCC03C25/321C09J103/04C09J105/06C09J191/00E04B1/7662C08K9/04D04H1/64D04H3/004D04H3/12C08K5/092C08K5/103C08K5/0025C08L3/02C08L91/00C09J103/02
Inventor LOCHEL, JR., FRANK P.TOLFA, JOHN CARL
Owner CARGILL INC
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