MANTA DE ISOLAMENTO FIBROSA E ARMAÇÃO DE CONSTRUÇÃO

Abstract

GLASS FIBER INSULATION PRODUCT. A fibrous insulation product is disclosed, consisting of a plurality of randomly oriented glass fibers and a binder composition that holds the glass fibers together. The fibrous insulation product has an R-value in the range of 10 to 54 and, after curing, has a density, when uncompressed, in the range of 0.30 pcf to 2.7 pcf. Furthermore, the fibrous insulation product includes glass fibers that, before the application of the binder composition, have an average fiber diameter of less than 15 HT and a binder quantity that is in the range of 2% to 10% by weight of the fibrous insulation product.

Description

"FIBROUS INSULATION BLANKET AND CONSTRUCTION REINFORCEMENT" CROSS-REFERENCE TO RELATED ORDERS

[001] This application claims priority and benefit of U.S. Provisional Application No. 62 / 945,328, filed December 9, 2019, the full contents of which are incorporated herein by reference. FIELD

[002] This application generally relates to fiberglass insulation products (“glass fiber reinforced plastic”) and, more particularly, to fiberglass insulation products made from small diameter fibers. FUNDAMENTALS

[003] The term “fibrous insulation product” is general and encompasses a variety of compositions, articles of manufacture, and manufacturing processes. Mineral fibers (e.g., glass fibers) are commonly used in insulation products and nonwoven mats. Fibrous insulation is typically manufactured by fibering a molten composition of polymer, glass, or other mineral and spinning fibers from a spinning apparatus, such as a rotary spinner. To form an insulation product, the fibers produced by the rotary spinner are pulled down from the spinner toward a conveyor by a blower. As the fibers move down, a binding material is sprayed onto the fibers, and the fibers are collected into a continuous, tall mat on the conveyor.The binder material gives the insulation product resilience for recovery after packaging and provides rigidity and handling so that the insulation product can be handled and applied as needed in building insulation cavities. The binder composition also provides protection to the fibers from interfilament abrasion and promotes compatibility between individual fibers.

[004] The mat containing the binder-coated fibers is then passed through a curing oven and the binder is cured to adjust the mat to the Petition 870240031999, dated 12 / 04 / 2024, page 12 / 60 2 / 43 desired thickness. After the binder has cured, the fiber insulation can be cut into pieces to form individual insulation products, and the insulation products can be packaged for shipment to customer locations. A typical insulation product produced is an insulation blanket or mat, which is suitable for use as wall insulation in homes or as insulation in attics and floor cavities in buildings. Another common insulation product is blown or loose-fill insulation, which is suitable for use as insulation for side walls and attics in residential and commercial buildings, as well as in hard-to-reach locations. Loose-fill insulation can be formed from small cubes that are cut from insulation blankets, compressed, and packaged in bags.

[005] Fibrous insulation products can be characterized by many different properties, such as density. Low-density flexible insulation blankets and mats typically have densities between 0.4 pounds per cubic foot (“cff”) and 2.0 cff and are frequently used for residential insulation in walls, attics, and basements. Fibrous insulation products also include higher-density products with densities of 7 cff to 10 cff, such as boards and panels or molded products. Higher-density insulation products are frequently used in industrial and / or commercial applications, including but not limited to insulation of walls and ceilings of metal buildings, insulation of pipes or tanks, ceiling and wall insulation panels, duct panels, etc. SUMMARY

[006] One aspect of the present disclosure relates to a fibrous insulation product with a plurality of randomly oriented glass fibers and a binding composition that holds the glass fibers together. The fibrous insulation product has an R-value in the range of 10 to 54 and, after curing, has a Petition 870240031999, dated April 12, 2024, page 13 / 60 3 / 43 density, when uncompressed, in the range of 0.30 pcf to 2.7 pcf. In addition, the fibrous insulation product includes glass fibers which, before the application of the binder composition, have an average fiber diameter in the range of 12 hundredths of a thousandth of an inch (HT) to 15 HT and a binder quantity that is in the range of 2% to 10% by weight of the fibrous insulation product.

[007] Another aspect of the present disclosure is directed to a construction frame with a plurality of parallel and spaced framing elements and a fiberglass insulation blanket received between two of the plurality of framing elements. The fiberglass blanket has a plurality of randomly oriented glass fibers and a binder composition that holds the glass fibers together. The fibrous insulation blanket has an R-value in the range of 10 to 54 and, after curing, has a density, when not compressed, in the range of 0.30 pcf to 2.7 pcf. Furthermore, the fibrous insulation blanket includes glass fibers that, before the application of the binder composition, have an average fiber diameter of 12 HT to 15 HT and a binder quantity that is in the range of 2% to 10% by weight of the fibrous insulation product. BRIEF DESCRIPTION OF THE DRAWINGS

[008] The features and advantages of the present invention will become apparent to those skilled in the art to which the invention pertains from reading the following description together with the accompanying drawings, in which:

[009] FIG. 1 is a perspective view of an exemplary embodiment of a fibrous insulation product;

[010] FIG. 2 is an elevation view of an exemplary embodiment of a manufacturing line for producing the fibrous insulation product of FIG. 1; and

[011] FIG. 3 is a graph of the comfort factor vs. average fiber diameter / density for samples of fibrous insulation. DETAILED DESCRIPTION Petition 870240031999, dated April 12, 2024, page 14 / 60 4 / 43

[012] Unless defined otherwise, all technical and scientific terms used in this document have the same meaning commonly understood by a person skilled in the art to which the invention pertains. Although any methods and materials similar or equivalent to those described in this document may be used in the practice or testing of the present invention, preferred methods and materials are described in this document. All numerical ranges are understood as including all possible incremental subranges within the outer limits of the range. Thus, for example, a density range of 0.3 pcf to 2.0 pcf discloses, for example, 0.5 pcf to 1.2 pcf, 0.7 pcf to 1.0 pcf, etc.

[013] FIG. 1 illustrates an exemplary embodiment of a fibrous insulation product 100. The fibrous insulation product 100 can be configured in various ways. Fibrous insulation products are generally formed from entangled inorganic fibers bonded together by a binding composition. Examples of suitable inorganic fibers include glass fibers, wool glass fibers, ceramic fibers, stone, slag, and basalt. Optionally, other reinforcing fibers, such as natural fibers and / or synthetic fibers, such as polyester, polyethylene, polyethylene terephthalate, polypropylene, polyamide, aramid, and / or polyaramid fibers, may be present in the insulation product in addition to glass fibers. The term “natural fiber,” as used in conjunction with the present invention, refers to vegetable fibers extracted from any part of a plant, including but not limited to stems, seeds, leaves, roots, or phloem.Examples of natural fibers suitable for use as reinforcing fiber material include cotton, jute, bamboo, ramie, bagasse, hemp, coconut, flax, kenaf, sisal, linen, henequen, and combinations thereof. Fibrous insulation products may be formed entirely from one type of fiber or from a combination of different types of fibers. For example, the fibrous insulation product may be formed from combinations of various types of glass fibers or various combinations of different inorganic fibers and / or fibers. Petition 870240031999, dated April 12, 2024, page 15 / 60 5 / 43 natural, depending on the desired application for insulation. The types described in this document refer to insulation products made entirely of glass fibers.

[014] In the embodiment illustrated, the 100 fibrous insulation product is a fiberglass insulation blanket, usually in box form. In other embodiments, however, the insulation product may have any suitable shape or size, such as, for example, a laminated product or a blanket. As an insulation blanket or mat, the 100 fibrous insulation product can be placed in the insulation cavities of buildings. For example, the 100 fibrous insulation product can be placed in the space or cavity between two parallel and spaced framing elements in a wall, roof, or floor framing of a building.

[015] The fibrous insulation product 100 includes an insulation layer 102 comprising non-woven glass fibers and a binder for bonding the glass fibers. Optionally, the fibrous insulation product 100 may also include a coating 104 fixed or otherwise adhered to the insulation layer 102. The fibrous insulation product 100 includes a first lateral surface 106, a second lateral surface 108 spaced and opposite the first lateral surface 106, a third lateral surface 110 extending between the first lateral surface 106 and the second lateral surface 108, and a fourth lateral surface 112 spaced and opposite the third lateral surface 110 and extending between the first lateral surface 106 and the second lateral surface 108.The fibrous insulation product 100 also includes a first face 114 connecting the side surfaces 106, 108, 110, 112 and a second face 116 parallel or generally parallel and opposite to the first face 114 and connecting the side surfaces 106, 108, 110, 112. The fibrous insulation product 100, when uncompressed, has a length Li, a width Wi and a thickness Ti. In some embodiments, the length Li is greater than the width Wi. Petition 870240031999, dated April 12, 2024, page 16 / 60 6 / 43, which is greater than the Ti thickness.

[016] The sheath 104 can be arranged on the insulation layer 102 to form all or part of the first face 114, the second face 116, or both faces of the fibrous insulation product 100. The sheath 104 can take a wide variety of different forms. The sheath 104 can be a single piece or several different pieces or sheets of material and can include a single layer or several layers of material. In the exemplary embodiment of FIG. 1, the sheath 104 is a single piece of material connecting the side surfaces 106, 108, 110, 112.

[017] Coating 104 can be made from a variety of different materials. Any material suitable for use with a fibrous insulation product can be used. For example, coating 104 may comprise nonwoven fiberglass and polymeric media; woven fiberglass and polymeric media; coating materials such as coating films made of polymeric materials; scrim; cloth; fabric; fiberglass reinforced kraft paper (FRK); a laminated kraft paper; recycled paper; and calendar paper.

[018] A significant amount of insulation placed in building insulation cavities is in the form of rolled insulation blankets made from insulation products such as those described in this document. Coated insulation products are installed with the coating 104 laid flat on the edge of the insulation cavity, typically on the inside side of the insulation cavity. Insulation products where the coating is a vapor retarder are commonly used to insulate wall, floor, or ceiling cavities that separate a warm interior space from a cold exterior space. The vapor retarder is placed on one side of the insulation product to retard or prevent the movement of water vapor through the insulation product.

[019] FIG. 2 illustrates an exemplary embodiment of an apparatus 118 Petition 870240031999, dated 12 / 04 / 2024, page 17 / 60 7 / 43 to manufacture the fibrous insulation product 100. The manufacture of the fibrous insulation product 100 can be carried out in a continuous process by melting glass fibers, coating the melted glass fibers with a binder, forming a fibrous glass bundle on a moving conveyor, and curing the binder to form an insulation blanket as represented in FIG. 2. The glass can be melted in a tank (not shown) and fed to a fiber forming device, such as one or more fiber spinners 119. Although the spinners 119 are shown as the fiber forming device in the exemplary embodiment, it will be understood that other types of fiber forming units can be used to form the fibrous insulation product 100. The spinners 119 are rotated at high speeds.Centrifugal force causes molten glass to pass through small holes in the circumferential side walls of the fiber spinners 119 to form glass fibers. Glass fibers 130 of random lengths can be drawn from the fiber spinners 119 and blown generally downwards (i.e., generally perpendicular to the plane of the spinners 119) by blowers 120 positioned within a forming chamber 125.

[020] Blowers 120 rotate the glass fibers 130 downwards. The glass fibers 130, while in transit downwards in the forming chamber 125 and while still hot from the drawing operation, are sprayed with an aqueous binder composition by an annular spray ring 135 so as to result in a relatively uniform distribution of the binder composition along the glass fibers 130. Water may also be applied to the glass fibers 130 in the forming chamber 125, such as by spraying, before the application of the binder composition to at least partially cool the glass fibers 130.

[021] Glass fibers 130 having the uncured resinous binder composition adhered to them can be gathered and formed into a fibrous bundle 140 on an endless forming conveyor 145 inside the forming chamber 125 Petition 870240031999, dated 12 / 04 / 2024, page 18 / 60 8 / 43 with the aid of a vacuum (not shown) pulled through the fibrous bundle 140 from below the forming conveyor 145. The residual heat of the glass fibers 130 and the airflow through the fibrous bundle 140 during the forming operation are generally sufficient to volatilize most of the water from the binder before the glass fibers 130 exit the forming chamber 125, thus leaving the remaining components of the binder composition in the glass fibers 130 as a viscous or semi-viscous high-solids liquid.

[022] The resin-coated fibrous bundle 140, which is in a compressed state due to airflow through the fibrous bundle 140 in the forming chamber 125, is then transferred out of the forming chamber 125 under the exit roll 150 to a transfer zone 155 where the fibrous bundle 140 expands vertically due to the resilience of the glass fibers 130. The expanded fibrous bundle 140 is then heated, such as by conveying the fibrous bundle 140 through a curing oven 160 where heated air is blown through the fibrous bundle 140 to evaporate any remaining water in the binder composition, cure the binder composition, and rigidly bond the glass fibers 130. The curing oven 160 includes an upper foraminous furnace conveyor 165 and a lower foraminous furnace conveyor 170, between which the fibrous bundle 140 is pulled.Heated air is forced through the lower oven conveyor 170, the fibrous bundle 140 and the upper oven conveyor 165 by a fan 175. The heated air exits the curing oven 160 through an exhaust device 180.

[023] Furthermore, in the curing oven 160, the fibrous bundle 140 can be compressed by the upper and lower forminous oven conveyors 165, 170 to form the insulation layer 102 of the fibrous insulation product 100. The upper and lower oven conveyors 165, 170 can be used to compress the fibrous bundle 140 to give the insulation layer 102 its predetermined thickness Ti. It should be appreciated that, although FIG. 2 represents the Petition 870240031999, dated April 12, 2024, page 19 / 60 9 / 43 conveyors 165, 170 as being in a substantially parallel orientation, they may alternatively be positioned at an angle to each other (not illustrated).

[024] The cured binder composition imparts strength and resilience to the insulation layer 102. It should be noted that the drying and curing of the binder composition can be carried out in one or two different stages. The two-stage (two-step) process is commonly known as preparation B. The curing oven 160 can be operated at a temperature of 100 °C to 325 °C, or 250 °C to 300 °C. The fibrous bundle 140 can remain inside the curing oven 160 for a period of time sufficient to crosslink (cure) the binder composition and form the insulation layer 102.

[025] Once the insulation layer 102 exits the curing oven 160, a coating material 193 can be placed on the insulation layer 102 to form the coating layer 104. The coating material 193 can be bonded to the first face 114, the second face 116, or both faces of the insulation layer 102 by a bonding agent (not shown) or some other means (e.g., stitching, mechanical entanglement) to form the fibrous insulation product 100. Suitable bonding agents include adhesives, polymer resins, asphalt, and bituminous materials that can be coated or otherwise applied to the coating material 193. The fibrous insulation product 100 can subsequently be rolled for storage and / or shipping or cut to predetermined lengths by a cutting device (not illustrated).It should be noted that, in some exemplary embodiments, the insulation layer 102 emerging from the curing oven 160 is rolled onto a collection roll or cut into sections of a desired length and is not coated with a coating material 193.

[026] In the context of the fibrous insulation product 100, a “composition Petition 870240031999, dated April 12, 2024, p. 20 / 60 10 / 43 “binder” refers to organic agents or chemicals, often polymeric resins, used to bond glass fibers 130 to one another in a three-dimensional structure. The binder composition may be in any form, such as a solution, an emulsion, or a dispersion. “Binder dispersions” or “binder emulsions” refer to mixtures of binder chemicals in a medium or vehicle. As used in this document, the terms “binder composition,” “aqueous binder composition,” “binder formulation,” “binder,” and “binder system” may be used interchangeably and are synonymous. Additionally, as used in this document, the terms “formaldehyde-free” or “no added formaldehyde” may be used interchangeably and are synonymous.

[027] A wide variety of binder compositions can be used with the glass fibers of the present invention. For example, binder compositions fall into two broad and mutually exclusive classes: thermoplastics and thermosets. Both thermoplastic and thermoset binder compositions can be used with the invention. A thermoplastic material can be repeatedly heated to a softened or molten state and will return to its previous state upon cooling. In other words, heating can cause a reversible change in the physical state of a thermoplastic material (e.g., from solid to liquid), but does not undergo any irreversible chemical reaction.Suitable examples of thermoplastic polymers for use in fibrous insulation product 100 include, but are not limited to, polyvinyls, polyethylene terephthalate (PET), polypropylene or polyphenylene sulfide (PPS), nylon, polycarbonates, polystyrene, polyamides, polyolefins, and certain polyacrylate copolymers.

[028] In contrast, the term thermosetting polymer refers to a range of systems that initially exist as liquids, but which, when heated, undergo a reaction to form a solid, highly cross-linked matrix. Thus, the Petition 870240031999, dated April 12, 2024, page 21 / 60 11 / 43 Thermosetting compounds comprise reactant systems—often pairs of reactants—that irreversibly crosslink upon heating. When cooled, they do not recover their previous liquid state but remain irreversibly crosslinked.

[029] Useful reagents such as thermosetting compounds generally have one or more of several reactive functional groups: for example, amine, amide, carboxyl, or hydroxyl. As used in this document, “thermosetting compound” (and its derived clauses such as “thermosetting compound”, “thermosetting binder”, or “thermoset binder”) refers to at least one of these reagents, it being understood that two or more may be required to form the crosslinking system characteristic of thermosetting compounds. In addition to the main reagents of thermosetting compounds, catalysts, processing aids, and other additives may exist.

[030] Phenolic / formaldehyde binder compositions are a known thermosetting binder system. The present invention encompasses both traditional phenolic-formaldehyde binder compositions as well as more recent formaldehyde-free binder compositions. Formaldehyde-free thermosetting binder systems may include carboxylic acid (such as, for example, polyacrylic acid) and polyol polymers. An example is the polyacrylic acid / polyol / polyacid binder system described in Patents Nos. 6,884,849 and 6,699,945 to Chen et al., the complete contents of which are each expressly incorporated herein by reference. A second category of formaldehyde-free thermosetting binder compositions are referred to as “bio-based” or “natural” binders.“Bio-based binder” and “natural binder” are used interchangeably in this document to refer to binding compositions made from nutrient compounds, such as carbohydrates, proteins, or fats, that have a high degree of reactive functionality. Because they are made of... Petition 870240031999, dated April 12, 2024, p. 22 / 60 12 / 43 nutritive compounds, they are environmentally friendly. The bio-based binder compositions are described in more detail in U.S. Patent Publication No. 2011 / 0086567 by Hawkins et al., filed October 8, 2010, the full contents of which are expressly incorporated herein by reference. In some exemplary embodiments, the binder includes Owens-Corning's EcoTouch™ binder or EcoPure™ binder, Owens Corning's Sustaina™ binder or Knauf's ECOSE® binder.

[031] Useful alternative reagents as thermosetting compounds are triammonium citrate-dextrose systems derived from the mixture of dextrose monohydrate, anhydrous citric acid, water and aqueous ammonia. Additionally, carbohydrate reagents and polyamine reagents are useful thermosetting compounds, wherein such thermosetting compounds are described in more detail in U.S. Patents Nos. 8,114,210, 9,505,883 and 9,926,464, disclosures of which are incorporated herein by reference.

[032] In one exemplary embodiment, the fibrous insulation product 100 includes a binder composition comprising maltodextrin, citric acid, sodium hypophosphite, and vegetable oil. For example, two exemplary embodiments of a binder composition with maltodextrin, citric acid, sodium hypophosphite, and vegetable oil are listed in Table 1 below: Table 1: Example of Binder Composition 1 Component Formulation Method A (% by weight of solids) Maltodextrin 50 to 80% Citric Acid 20 to 50% Sodium Hypophosphite 0.5 to 10% Non-ionic Surfactant 0 to 2% Vegetable Oil Mixture 1 to 20% Aminosilane 0.05 to 0.18% Pink Dye 0 to 5% Petition 870240031999, dated April 12, 2024, p. 23 / 60 13 / 43

[033] In another exemplary embodiment, the fibrous insulation product 100 includes a formaldehyde-free aqueous binder composition comprising at least one long-chain polyol and at least one primary crosslinking agent and at least one secondary crosslinking agent comprising at least one short-chain polyol.

[034] The long-chain polyol may comprise a polyol with at least two hydroxyl groups having a number average molecular weight of at least 2,000 Daltons, such as a molecular weight between 3,000 Daltons and 4,000 Daltons. In some exemplary embodiments, the long-chain polyol comprises one or more of a polyhydroxy polymeric compound, such as a polyvinyl alcohol, polyvinyl acetate, which may be partially or fully hydrolyzed, or mixtures thereof. For example, when a partially hydrolyzed polyvinyl acetate serves as the polyhydroxy component, an 80% to 89% hydrolyzed polyvinyl acetate can be used, such as Poval® 385 (Kuraray America, Inc.) and Sevol™ 502 (Sekisui Specialty Chemicals America, LLC), both with approximately 85% (Poval® 385) and 88% (Selvol™ 502) hydrolyzed content.

[035] The long-chain polyol may be present in the aqueous binder composition in an amount of up to about 30% by weight of total solids, including, without limitation, up to about 28%, 25%, 20%, 18%, 15% and 13% by weight of total solids. In any of the exemplary embodiments, the long-chain polyol may be present in the aqueous binder composition in an amount of 2.5% to 30% by weight of total solids, including, without limitation, 5% to 25%, 8% to 20%, 9% to 18% and 10% to 16% by weight of total solids.

[036] The primary crosslinking agent may be any compound suitable for crosslinking a polyol. In any of the exemplary embodiments, the primary crosslinking agent may have a number average molecular weight greater than 90 Daltons, from about 90 Daltons to about 10,000 Daltons, or from about 190 Petition 870240031999, dated April 12, 2024, p. 24 / 60 14 / 43 Daltons to about 5,000 Daltons. In any of the exemplary embodiments, the crosslinking agent may have a number average molecular weight of about 2,000 Daltons to 5,000 Daltons, or about 4,000 Daltons. Non-limiting examples of suitable crosslinking agents include materials with one or more carboxylic acid (-COOH) groups, such as polycarboxylic acids (and their salts), anhydrides, monomeric and polymeric polycarboxylic acid with anhydride (i.e., mixed anhydrides), and acrylic acid homopolymer or copolymer, such as polyacrylic acid (and its salts) and polyacrylic acid-based resins, such as QR-1629S and Acumer 9932, both commercially available from The Dow Chemical Company. Acumer 9932 is a polyacrylic acid / sodium hypophosphite resin with a molecular weight of approximately 4000 and a sodium hypophosphite content of 6 to 7% by weight. QR-1629S is a polyacrylic acid / glycerin mixture.

[037] The primary crosslinking agent may, in some cases, be pre-neutralized with a neutralizing agent. Such neutralizing agents may include organic and / or inorganic bases, such as sodium hydroxide, ammonium hydroxide and diethylamine, and any type of primary, secondary or tertiary amine (including alkanolamine). In several exemplary embodiments, the neutralizing agents may include at least one of sodium hydroxide and triethanolamine.

[038] In some exemplary embodiments, the primary crosslinking agent is present in the aqueous binder composition at least 50% by weight, based on the total solids content of the aqueous binder composition, including, without limitation, at least 55% by weight, at least 60% by weight, at least 63% by weight, at least 65% by weight, at least 70% by weight, at least 73% by weight, at least 75% by weight, at least 78% by weight and at least 80% by weight. In some exemplary embodiments, the primary crosslinking agent is present in the aqueous binder composition in an amount of 50% to 85% by weight, based on the total solids content of the aqueous binder composition, Petition 870240031999, dated April 12, 2024, page 25 / 60 15 / 43 including, without limitation, 60% to 80% by weight, 62% to 78% by weight and 65% to 75% by weight.

[039] The aqueous binder composition may further include a short-chain polyol. The short-chain polyol may comprise a water-soluble compound having a molecular weight of less than 2,000 Daltons, including less than 750 Daltons, less than 500 Daltons, and having a plurality of hydroxyl groups (-OH). Suitable short-chain polyol components include sugar alcohols, pentaerythritol, primary alcohols, 2,2-bis(methylol)propionic acid, tri(methylol)propane (TMP), 1,2,4-butanetriol, trimethylolpropane, and short-chain alkanolamines, such as triethanolamine, comprising at least three hydroxyl groups. In any of the embodiments disclosed in this document, the polyol may comprise at least four hydroxyl groups or at least five hydroxyl groups.

[040] In some exemplary embodiments, the short-chain polyol serves as a viscosity-reducing agent, which breaks the intra- and intermolecular hydrogen bonds between long-chain polyol molecules (e.g., polyvinyl alcohol) and thus reduces the viscosity of the composition. However, since these short-chain polyol molecules have structures similar to long-chain polyols, they can react similarly with crosslinking agents, therefore not negatively affecting the binder and product performance.

[041] Sugar alcohols are compounds obtained when the aldo or keto groups of a sugar are reduced (for example, by hydrogenation) to the corresponding hydroxyl groups. The starting sugar can be chosen from monosaccharides, oligosaccharides, and polysaccharides, and mixtures of these products, such as syrups, molasses, and starch hydrolysates. The starting sugar can also be a dehydrated form of a sugar. Although sugar alcohols resemble the corresponding starting sugars, they are not sugars. Thus, for example, Petition 870240031999, dated April 12, 2024, page 26 / 60 16 / 43 Sugar alcohols do not have reducing capacity and cannot participate in the Maillard reaction typical of reducing sugars. In some exemplary embodiments, the sugar alcohol includes glycerol, erythritol, arabitol, xylitol, sorbitol, maltitol, mannitol, iditol, isomaltitol, lactitol, cellobitol, palatinitol, maltotritol, syrups thereof, and mixtures thereof. In several exemplary embodiments, the sugar alcohol is selected from glycerol, sorbitol, xylitol, and mixtures thereof. In some exemplary embodiments, the secondary crosslinking agent is a dimeric or oligomeric condensation product of a sugar alcohol. In several exemplary embodiments, the condensation product of a sugar alcohol is isosorbide. In some illustrative embodiments, the sugar alcohol is a diol or glycol.

[042] In some exemplary embodiments, the short-chain polyol is present in the aqueous binder composition in an amount of up to about 30% by weight of total solids, including, without limitation, up to about 25%, 20%, 18%, 15%, 13%, 11% and 10% by weight of total solids. In some exemplary embodiments, the short-chain polyol is present in the aqueous binder composition in an amount of 0 to 30% by weight of total solids, including, without limitation, 2% to 30%, 3% to 25%, 5% to 20%, 8% to 18% and 9% to 15% by weight of total solids.

[043] In several exemplary embodiments, the long-chain polyol, crosslinking agent, and short-chain polyol are present in amounts such that the ratio of the number of molar equivalents of carboxylic acid groups, anhydride groups, or salts thereof to the number of molar equivalents of hydroxyl groups is from about 1 / 0.05 to about 1 / 5, such as from about 1 / 0.08 to about 1 / 2.0, from about 1 / 0.1 to about 1 / 1.5, and from about 1 / 0.3 to about 1 / 0.66. It has been surprisingly discovered, however, that within this ratio, the ratio of long-chain polyol to short-chain polyol affects the performance of the binder composition, as well as the tensile strength and water solubility of the binder. Petition 870240031999, dated April 12, 2024, p. 27 / 60 17 / 43 after curing. For example, a long-chain polyol to short-chain polyol ratio of about 0.1 / 0.9 to about 0.9 / 0.1, such as between about 0.3 / 0.7 and 0.7 / 0.3, or between about 0.4 / 0.6 and 0.6 / 0.4, provides a balance of desirable mechanical properties and physical color properties. In several exemplary embodiments, the long-chain polyol to short-chain polyol ratio is approximately 0.5 / 0.5. The long-chain polyol to short-chain polyol ratio can be optimized so that particular properties are optimized depending on the needs of an end-use application.

[044] In some exemplary embodiments, polyacrylic acid, polyvinyl alcohol, sorbitol and sodium hypophosphite. For example, an exemplary embodiment of a binder composition including polyacrylic acid, polyvinyl alcohol, sorbitol and sodium hypophosphite is listed in Table 2 below: Table 2: Example of Binder Composition 2 Component Formulation Method B (% by weight of solids) Polyacrylic Acid 60 to 80% Polyvinyl Alcohol “PVOH” 2.5 to 30% Sorbitol 8 to 30% Sodium Hypophosphite 2 to 10% Silane Coupling Agent 0.1 to 3% Surfactant (Surfinol, Non-ionic Surfactant, Antifoaming Agent, Acetylenic Aiol) 0.1 to 1.0%

[045] In another exemplary embodiment, the fibrous insulation product 100 includes a formaldehyde-free aqueous binder composition comprising at least one primary crosslinking agent and at least one short-chain polyol, as described above, but not yet comprising a long-chain polyol.

[046] In such aqueous binder compositions, the crosslinking agent is present in the aqueous binder composition at least 30.0% by weight, based on the total solids content of the aqueous binder composition, including, but not including, the aqueous binder composition. Petition 870240031999, dated April 12, 2024, page 28 / 60 18 / 43 limitation, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 52.0% by weight, at least 54.0% by weight, at least 56.0% by weight, at least 58.0% by weight and at least 60.0% by weight. In any of the embodiments disclosed in this document, the crosslinking agent may be present in the aqueous binder composition in an amount of 30% to 85% by weight, based on the total solids content of the aqueous binder composition, including, without limitation, 50.0% to 70.0% by weight, more than 50% to 65% by weight, 52.0% to 62.0% by weight, 54.0% to 60.0% by weight and 55.0% to 59.0% by weight.

[047] The polyol is present in the aqueous binder composition in an amount of up to about 70% by weight of total solids, including, without limitation, up to about 60%, 55%, 50%, 40%, 35%, 33%, 30%, 27%, 25% and 20% by weight of total solids. In some exemplary embodiments, the polyol is present in the aqueous binder composition in an amount of 2.0% to 65.0% by weight of total solids, including, without limitation, 5.0% to 40.0%, 8.0% to 37.0%, 10.0% to 34.0%, 12.0% to 32.0%, 15.0% to 30.0% and 20.0% to 28.0% by weight of total solids.

[048] In several exemplary embodiments, the crosslinking agent and the polyol are present in amounts such that the ratio of the number of molar equivalents of carboxylic acid groups, anhydride groups or salts thereof to the number of molar equivalents of hydroxyl groups is from about 0.6 / 1 to about 1 / 0.6, as well as from about 0.8 / 1 to about 1 / 0.8, or from about 0.9 / 1 to about 1 / 0.9.

[049] In any of the embodiments disclosed in this document, the aqueous binder composition may be free or substantially free of polyols comprising less than 3 hydroxyl groups, or free or substantially free of polyols comprising less than 4 hydroxyl groups. In any of the embodiments disclosed in this document, the aqueous binder composition is free Petition 870240031999, dated April 12, 2024, p. 29 / 60 19 / 43 or substantially free of polyols with a number average molecular weight of 2,000 Daltons or above, such as a molecular weight between 3,000 Daltons and 4,000 Daltons. Consequently, in any of the embodiments disclosed in this document, the aqueous binder composition is free or substantially free of diols, such as glycols; triols, such as, for example, glycerol and triethanolamine; and / or polyhydroxylated polymeric compounds, such as polyvinyl alcohol, polyvinyl acetate, which may be partially or totally hydrolyzed, or mixtures thereof. Polyvinyl alcohol is a known film former, which causes moisture to be released rapidly, leading to the formation of a film.

[050] In any of the embodiments disclosed in this document, the aqueous binder compositions may comprise or consist of a polymeric polycarboxylic acid-based crosslinking agent and a monomeric polyol with at least four hydroxyl groups with a ratio of carboxylic acid groups to hydroxyl groups OH groups between 0.60 / 1 and 1 / 0.6. Table 3: Example of Binder Composition 3 Component | Example Range 1 (% by Weight of Total Solids) | Example Range 2 (% by Weight of Total Solids) | Polycarboxylic Acid | 30 to 85 | 55 to 65 | Polyol | 15 to 70 | 20 to 35 | Catalyst | 0.5 to 5.0 | 2.0 to 3.5 | Coupling Agent | 0 to 2.0 | 0.12 to 0.5 | Oil Emulsion | 2 to 15 | 8 to 13 | Surfactant | 0 to 5.0 | 0.1 to 1.0 | Pigment | 0 to 2 | 0.1 to 1.0 | Silicone | 0 to 15 | 0.5 to 10.0

[051] In any of the aqueous binder compositions disclosed in this document, all or a percentage of the acid functionality in the polycarboxylic acid can be temporarily blocked by the use of an agent. Petition 870240031999, dated April 12, 2024, pp. 30-60 20 / 43 protective agent, which temporarily blocks the acidic functionality from complexing with the mineral wool fibers, and is subsequently removed by heating the binder composition to a temperature of at least 150 °C, releasing the acidic functionalities to crosslink with the polyol component and complete the esterification process during the curing process. In any of the exemplary embodiments, 10% to 100% of the carboxylic acid functional groups can be temporarily blocked by the protective agent, including between about 25% and about 99%, about 30% and about 90%, and about 40% and 85%, including all subranges and combinations of ranges therebetween. In any of the exemplary embodiments, a minimum of 40% of the acidic functional groups can be temporarily blocked by the protective agent.

[052] The protecting agent may be capable of reversibly binding to the carboxylic acid groups of the crosslinking agent. In any of the exemplary embodiments, the protecting agent comprises any compound comprising molecules capable of forming at least one reversible ionic bond with a single acidic functional group. In any of the exemplary embodiments disclosed in this document, the protecting agent may comprise a nitrogen-based protecting agent, such as an ammonium-based protecting agent; an amine-based protecting agent; or mixtures thereof. An exemplary ammonium-based protecting agent includes ammonium hydroxide.Examples of amine-based protective agents include alkylamines and diamines, such as, for example, ethyleneimine, ethylenediamine, hexamethylenediamine; alkanolamines, such as: ethanolamine, diethanolamine, triethanolamine; ethylenediamine-N,N'-disuccinic acid (EDDS), ethylenediaminetetraacetic acid (EDTA) and the like, or mixtures thereof. Furthermore, alkanolamine can be used both as a protective agent and as a participant in the crosslinking reaction to form an ester in the cured binder. Thus, alkanolamine has a dual functionality as a protective agent and a polyol for crosslinking with the acid. Petition 870240031999, dated April 12, 2024, page 31 / 60 21 / 43 polycarboxylic acid via esterification.

[053] The protective agent functions differently from a conventional pH adjuster. A protective agent, as defined in this document, only temporarily and reversibly blocks the acidic functional groups in the polycarboxylic acid polymer component. In contrast, conventional pH adjusters, such as sodium hydroxide, permanently terminate an acidic functional group, which prevents crosslinking between the acid and hydroxyl groups due to the blocked acidic functional groups. Thus, the inclusion of traditional pH adjusters, such as sodium hydroxide, does not provide the desired effect of temporarily blocking the acidic functional groups while releasing these functional groups during curing to allow crosslinking through esterification.Therefore, in any of the exemplary embodiments disclosed in this document, the binding composition may be free or substantially free of conventional pH adjusters, such as sodium hydroxide and potassium hydroxide. These conventional pH adjusters for high-temperature applications will permanently bind to the carboxylic acid groups and will not release the carboxylic acid functionality to allow crosslinking esterification.

[054] Any of the aqueous binder compositions disclosed in this document may further include an additive mixture comprising one or more processing additives that improve the processability of the binder composition by reducing the stickiness of the binder, resulting in a more uniform insulation product with greater tensile strength and hydrophobicity. Although several additives may exist that can reduce the stickiness of a binder composition, conventional additives are hydrophilic in nature, so the inclusion of such additives increases the overall water absorption of the binder composition. The additive mixture may comprise one or more additives of Petition 870240031999, dated April 12, 2024, page 32 / 60 22 / 43 Processing. Examples of processing additives include surfactants, glycerol, 1,2,4-butanetriol, 1,4-butanediol, 1,2-propanediol, 1,3-propanediol, poly(ethylene glycol) (e.g., Carbowax™), polyethylene glycol monooleate (MOPEG), silicone, polydimethylsiloxane dispersions (PDMS), emulsions and / or dispersions of mineral, paraffin or vegetable oils, waxes such as amide waxes (e.g., ethylene bis-stearamide (EBS)) and carnauba wax (e.g., ML-155), hydrophobized silica, ammonium phosphates or combinations thereof. Surfactants may include nonionic surfactants, including nonionic surfactants with alcohol functional groups. Examples of surfactants include Surfinol®, alkyl polyglycosides (e.g., Glucopon®) and alcohol ethoxylates (e.g., Lutensol®).

[055] The additive mixture may include a single processing additive, a mixture of at least two processing additives, a mixture of at least three processing additives, or a mixture of at least four processing additives. In any of the embodiments disclosed in this document, the additive mixture may comprise a mixture of glycerol and polydimethylsiloxane.

[056] The additive mixture may be present in the binder composition in an amount of 1.0% to 20% by weight, 1.25% to 17.0% by weight, or 1.5% to 15.0% by weight, or about 3.0% to 12.0% by weight, or 5.0% to 10.0% by weight based on the total solids content in the binder composition. In any of the exemplary embodiments, the binder composition may comprise at least 7.0% by weight of the additive mixture, including at least 8.0% by weight and at least 9% by weight, based on the total solids content in the binder composition. Consequently, in any of the exemplary embodiments, the aqueous binder composition may comprise 7.0% to 15% by weight of the additive mixture, including 8.0% to 13.5% by weight, 9.0% to 12.5% ​​by weight, based on the total solids content in the binder composition. Petition 870240031999, dated April 12, 2024, p. 33 / 60 23 / 43

[057] In embodiments where the additive mixture comprises glycerol, the glycerol may be present in an amount of at least 5.0% by weight, or at least 6.0% by weight, or at least 7.0% by weight, or at least 7.5% by weight, based on the total solids content of the binder composition. In any of the exemplary embodiments, the binder composition may comprise 5.0 to 15% by weight of glycerol, including 6.5 to 13.0% by weight, 7.0 to 12.0% by weight and 7.5 to 11.0% by weight of glycerol, based on the total solids content of the binder composition.

[058] In embodiments where the additive mixture comprises polydimethylsiloxane, the polydimethylsiloxane may be present in an amount of at least 0.2% by weight, or at least 0.5% by weight, or at least 0.8% by weight, or at least 1.0% by weight, or at least 1.5% by weight, or at least 2.0% by weight, based on the total solids content of the binder composition. In any of the exemplary embodiments, the binder composition may comprise 0.5 to 5.0% by weight of polydimethylsiloxane, including 1.0 to 4.0% by weight, 1.2 to 3.5% by weight, 1.5 to 3.0% by weight and 1.6 to 2.3% by weight of polydimethylsiloxane, based on the total solids content of the binder composition.

[059] In any of the embodiments disclosed in this document, the additive mixture may comprise a mixture of glycerol and polydimethylsiloxane, wherein the glycerol comprises 5.0 to 15% by weight of the binder composition and the polydimethylsiloxane comprises 0.5 to 5.0% by weight of the binder composition, based on the total solids content of the binder composition. In any of the embodiments disclosed in this document, the additive mixture may comprise a mixture of glycerol and polydimethylsiloxane, wherein the glycerol comprises 7.0 to 12% by weight of the binder composition and the polydimethylsiloxane comprises 1.2 to 3.5% by weight of the binder composition, based on the total solids content of the binder composition. Petition 870240031999, dated April 12, 2024, page 34 / 60 24 / 43

[060] In any of the embodiments disclosed in this document, the additive mixture may comprise an increased concentration of a silane coupling agent. Conventional binder compositions generally comprise less than 0.5% by weight of silane and more commonly about 0.2% by weight or less, based on the total solids content of the binder composition. Consequently, in any of the embodiments disclosed in this document, the silane coupling agent(s) may be present in the binder composition in an amount of 0.5% to 5.0% by weight of the total solids in the binder composition, including about 0.7% to 2.5% by weight, 0.85% to 2.0% by weight, or 0.95% to 1.5% by weight. In any of the embodiments disclosed in this document, the silane coupling agent(s) may be present in the binding composition in an amount of up to 1.0% by weight.

[061] The concentration of silane can also be characterized by the amount of silane in the fibers in a fibrous insulation product. Typically, fiberglass insulation products comprise between 0.001% by weight and 0.03% by weight of the silane coupling agent in the glass fibers. However, by increasing the amount of silane coupling agent that is included applied to the fibers, the amount of silane in the glass fibers increases to at least 0.10% by weight.

[062] Alternatively, the binder composition may comprise a conventional amount of silane coupling agent, if any. In such embodiments, the silane coupling agent(s) may be present in the binder composition in an amount of 0 to less than 0.5% by weight of the total solids in the binder composition, including 0.05% to 0.4% by weight, 0.1% to 0.35% by weight or 0.15% to 0.3% by weight.

[063] Non-limiting examples of silane coupling agents that can be used in the binding composition can be characterized by the alkyl, aryl, amino, epoxy, vinyl, methacryloxy, ureido, isocyanate and mercapto functional groups. Petition 870240031999, dated April 12, 2024, pp. 35-60 25 / 43 In exemplary embodiments, the silane coupling agent(s) include silanes containing one or more nitrogen atoms that possess one or more functional groups, such as amine (primary, secondary, tertiary and quaternary), amino, imino, amido, imido, ureido or isocyanate. Specific and non-limiting examples of suitable silane coupling agents include, but are not limited to, aminosilanes (e.g., triethoxyaminopropylsilane; 3-aminopropyl-triethoxysilane and 3-aminopropyl-trihydroxysilane), epoxy trialkoxysilanes (e.g., 3-glycidoxypropyltrimethoxysilane and 3-glycidoxypropyltriethoxysilane), methyl acrylate trialkoxysilanes (e.g., 3-methacryloxypropyltrimethoxysilane and 3-methacryloxypropyltriethoxysilane), hydrocarbon trialkoxysilanes, amino trihydroxysilanes, epoxy trihydroxysilanes, methacrylate trihydroxysilanes and / or hydrocarbon trihydroxysilanes.In one or more exemplary embodiments, the silane is an aminosilane, such as γ-aminopropyltriethoxysilane.

[064] Any of the aqueous binder compositions disclosed in this document may also include an esterification catalyst, also known as a curing accelerator. The catalyst may include inorganic salts, Lewis acids (i.e., aluminum chloride or boron trifluoride), Bronsted acids (i.e., sulfuric acid, p-toluenesulfonic acid and boric acid), organometallic complexes (i.e., lithium carboxylates, sodium carboxylates) and / or Lewis bases (i.e., polyethyleneimine, diethylamine or triethylamine). Additionally, the catalyst may include an alkali metal salt of a phosphorus-containing organic acid; in particular, alkali metal salts of phosphorus acid, hypophosphorous acid or polyphosphoric acid.Examples of such phosphorus catalysts include, but are not limited to, sodium hypophosphite, sodium phosphate, potassium phosphate, disodium pyrophosphate, tetrasodium pyrophosphate, sodium tripolyphosphate, sodium hexametaphosphate, potassium phosphate, potassium tripolyphosphate, sodium trimetaphosphate, sodium tetrametaphosphate, and mixtures thereof. In addition, the catalyst or curing accelerator may be a compound of... Petition 870240031999, dated April 12, 2024, page 36 / 60 26 / 43 Fluoroborate, such as fluoroboric acid, sodium tetrafluoroborate, potassium tetrafluoroborate, calcium tetrafluoroborate, magnesium tetrafluoroborate, zinc tetrafluoroborate, ammonium tetrafluoroborate and mixtures thereof. In addition, the catalyst may be a mixture of phosphorus and fluoroborate compounds. Other sodium salts such as sodium sulfate, sodium nitrate, sodium carbonate may also be used as catalysts.

[065] The catalyst may be present in the aqueous binder composition in an amount of about 0% to about 10% by weight of the total solids in the binder composition, including, without limitation, amounts of about 1% to about 5% by weight, or about 2% to about 4.5% by weight, or about 2.8% to about 4.0% by weight, or about 3.0% to about 3.8% by weight.

[066] Optionally, the aqueous binder composition may contain at least one coupling agent. In at least one exemplary embodiment, the coupling agent is a silane coupling agent. The coupling agent(s) may be present in the binder composition in an amount of about 0.01% to about 5% by weight of the total solids in the binder composition, from about 0.01% to about 2.5% by weight, from about 0.05% to about 1.5% by weight, or from about 0.1% to about 1.0% by weight.

[067] Non-limiting examples of silane coupling agents that may be used in the binding composition may be characterized by the functional groups alkyl, aryl, amino, epoxy, vinyl, methacryloxy, ureido, isocyanate and mercapto. In any embodiment, the silane coupling agent(s) may include silanes containing one or more nitrogen atoms possessing one or more functional groups, such as amine (primary, secondary, tertiary and quaternary), amino, imino, amido, imido, ureido or isocyanate. Specific and non-limiting examples of suitable silane coupling agents include, but are not limited to, aminosilanes (e.g., triethoxyaminopropylsilane; 3-aminopropyl Petition 870240031999, dated April 12, 2024, page 37 / 60 27 / 43 triethoxysilane and 3-aminopropyl-trihydroxysilane), epoxy trialkoxysilanes (e.g., 3-glycidoxypropyltrimethoxysilane and 3-glycidoxypropyltriethoxysilane), methyl acrylate trialkoxysilanes (e.g., 3-methacryloxypropyltrimethoxysilane and 3-methacryloxypropyltriethoxysilane), hydrocarbon trialkoxysilanes, amino trihydroxysilanes, epoxy trihydroxysilanes, methacrylate trihydroxysilanes and / or hydrocarbon trihydroxysilanes. In any of the embodiments disclosed in this document, the silane may comprise an aminosilane, such as γ-aminopropyltriethoxysilane.

[068] The aqueous binder composition may also include a processing aid. The processing aid is not particularly limiting provided that the processing aid functions to facilitate the processing of fiber formation and orientation. The processing aid may be used to improve the uniformity of binder application distribution, to reduce binder viscosity, to increase ramp height after formation, to improve vertical weight distribution uniformity and / or to accelerate binder dehydration in both the formation and oven curing processes. The processing aid may be present in the binder composition in an amount of 0 to about 10.0% by weight, about 0.1% to about 5.0% by weight, or about 0.3% to about 2.0% by weight or about 0.5% to 1.0% by weight, based on the total solids content in the binder composition.In some exemplary embodiments, the aqueous binder composition is substantially or completely free of any processing aids.

[069] Examples of process aids include antifoaming agents, such as emulsions and / or dispersions of mineral, paraffin or vegetable oils; dispersions of polydimethylsiloxane (PDMS) fluids and silica that has been hydrophobized with polydimethylsiloxane or other materials. Other process aids may include particles made of amide waxes, such as ethylene bis-stearamide (EBS) or silica. Petition 870240031999, dated April 12, 2024, pp. 38-60 28 / 43 hydrophobized. Another processing aid that can be used in the binder composition is a surfactant. One or more surfactants may be included in the binder composition to aid in atomization, wetting, and interfacial adhesion of the binder.

[070] The surfactant is not particularly limited and includes surfactants such as, but not limited to, ionic surfactants (e.g., sulfate, sulfonate, phosphate and carboxylate); sulfates (e.g., alkyl sulfates, ammonium lauryl sulfate, sodium lauryl sulfate (SDS), alkyl ether sulfates, sodium lauryl sulfate and sodium myride sulfate); amphoteric surfactants (e.g., alkylbetaines, such as lauryl betaine); sulfonates (e.g., sodium dioctyl sulfosuccinate, perfluorooctanesulfonate, perfluorobutanesulfonate and alkylbenzenesulfonate); phosphates (e.g., alkylaryl ether phosphate and alkyl ether phosphate); Carboxylates (e.g., alkyl carboxylates, fatty acid salts (soaps), sodium stearate, sodium lauroyl sarcosinate, carboxylate fluorosurfactants, perfluoronanoate and perfluorooctanoate); cationic (e.g., alkylamine salts such as laurylamine acetate); pH-dependent surfactants (primary, secondary or tertiary amines);Permanently charged quaternary ammonium cations (e.g., alkyltrimethylammonium salts, cetyltrimethylammonium bromide, cetyltrimethylammonium chloride, cetylpyridinium chloride, and benzethonium chloride); and zwitterionic surfactants, quaternary ammonium salts (e.g., lauryl trimethylammonium chloride and alkyl benzyl dimethylammonium chloride), and polyoxyethylenealkylamines.

[071] Suitable nonionic surfactants that can be used in conjunction with the binder composition include polyethers (e.g., ethylene oxide and propylene oxide condensates, which include straight and branched chain alkyl and alkyl polyethylene glycol and polypropylene glycol ethers and thioethers); alkylphenoxypoly(ethylene-oxy)ethanols with alkyl groups containing from about 7 to about 18 carbon atoms and having from about 4 to about 240 ethyleneoxy units. Petition 870240031999, dated April 12, 2024, pp. 39-60 29 / 43 (for example, heptylphenoxypoly(ethylene-oxy)ethanols and nonylphenoxypoly(ethylene-oxy)ethanols); polyoxyalkylene derivatives of hexitol including sorbitans, sorbites, mannitans and mannidos; partial esters of long-chain fatty acids (for example, polyoxyalkylene derivatives of sorbitan monolaurate, sorbitan monopalmitate, sorbitan monostearate, sorbitan tristearate, sorbitan monooleate and sorbitan trioleate); ethylene oxide condensates with a hydrophobic base, the base being formed by the condensation of propylene oxide with propylene glycol; sulfur-containing condensates (for example, those condensates prepared by condensation of ethylene oxide with higher alkyl mercaptans, such as nonyl, dodecyl or tetradecyl mercaptan, or with alkylthiophenols where the alkyl group contains from about 6 to about 15 carbon atoms);Ethylene oxide derivatives of long-chain carboxylic acids (e.g., lauric, myristic, palmitic, and oleic acids, such as fatty acids from tall oil); ethylene oxide derivatives of long-chain alcohols (e.g., octyl, decyl, lauryl, or cetyl alcohols); and ethylene oxide / propylene oxide copolymers.

[072] In at least one exemplary embodiment, the surfactants include one or more of Dynol 607, which is a 2,5,8,11-tetramethyl-6-dodecino-5,8-diol, SURFONYL® 420, SURFONYL® 440 and SURFONYL® 465, which are ethoxylated 2,4,7,9-tetramethyl-5-decin-4,7-diol surfactants (commercially available from Evonik Corporation (Allentown, Pa.)), Stanfax (a sodium lauryl sulfate), Surfinol 465 (an ethoxylated 2,4,7,9-tetramethyl 5-decin-4,7-diol), Triton™ GR-PG70 (1,4-bis(2-ethylhexyl) sodium sulfosuccinate) and Triton™ CF-10 (poly(oxy-1,2-ethanedi-yl), alpha-(phenylmethyl)omega-(1,1,3,3-tetramethylbutyl)phenoxy).

[073] Optionally, the aqueous binder composition may contain a dust suppressant to reduce or eliminate the presence of inorganic and / or organic particles that may have an adverse impact on the subsequent manufacture and installation of the insulation materials. The dust suppressant may be Petition 870240031999, dated April 12, 2024, pages 40 / 60 30 / 43 any conventional mineral oil, mineral oil emulsion, natural or synthetic oil, bio-based or lubricating oil, such as, but not limited to, silicone and silicone emulsions, polyethylene glycol, as well as any oil or non-petroleum oil with a high flash point to minimize oil evaporation inside the furnace.

[074] The aqueous binder composition may include up to about 15% by weight of a dust suppressant, including up to about 14% by weight or up to about 13% by weight. In any of the embodiments disclosed in this document, the aqueous binder composition may include between 1.0% by weight and 15% by weight of a dust suppressant, including from about 3.0% by weight to about 13.0% by weight or from about 5.0% by weight to about 12.8% by weight.

[075] The aqueous binder composition may also optionally include organic and / or inorganic acids and bases as pH adjusters in a sufficient quantity to adjust the pH to a desired level. The pH may be adjusted depending on the intended application, to facilitate compatibility of the binder composition ingredients, or to work with various types of fibers. In some exemplary embodiments, the pH adjuster is used to adjust the pH of the binder composition to an acidic pH. Examples of suitable acidic pH adjusters include inorganic acids such as, but not limited to, sulfuric acid, phosphoric acid, and boric acid, and also organic acids such as ptoluenesulfonic acid, mono- or polycarboxylic acids such as, but not limited to, citric acid, acetic acid and their anhydrides, adipic acid, oxalic acid, and their corresponding salts. In addition, inorganic salts that may be precursors of acids.The acid adjusts the pH and, in some cases, as discussed above, acts as a crosslinking agent. Organic and / or inorganic bases may be included to increase the pH of the binder composition. Bases can be volatile or non-volatile. Examples of volatile bases include, for example, ammonia and substituted amines. Petition 870240031999, dated April 12, 2024, pp. 41-60 31 / 43 Alkyl compounds, such as methylamine, ethylamine or 1-aminopropane, dimethylamine and ethyl methylamine. Examples of non-volatile bases include, for example, sodium hydroxide, potassium hydroxide, sodium carbonate and t-butylammonium hydroxide.

[076] When in an uncured state, the pH of the binder composition may vary from about 2.0 to about 5.0, including all intermediate amounts and ranges. In any of the embodiments disclosed in this document, the pH of the binder composition, when in an uncured state, is about 2.2 to 4.0, including about 2.5 to 3.8 and about 2.6 to 3.5. After curing, the pH of the binder composition may rise to at least a pH of 5.0, including levels between about 6.5 and 8.8 or between about 6.8 and 8.2.

[077] The binder also includes water to dissolve or disperse active solids for application to reinforcing fibers. Water may be added in sufficient quantity to dilute the aqueous binder composition to a viscosity suitable for its application to reinforcing fibers and to achieve a desired solids content in the fibers. The present binder composition has been found to contain a lower solids content than traditional phenol-urea formaldehyde or carbohydrate-based binder compositions. In particular, the binder composition may comprise 5% to 35% by weight of binder solids, including, without limitation, 10% to 30%, 12% to 20% and 15% to 19% by weight of binder solids. This solids level indicates that the binder composition in question may include more water than traditional binder compositions.

[078] In some exemplary embodiments, the binder composition can be processed at a high ramp moisture level (about 8% to 10%) and requires less moisture removal than traditional binder compositions. However, in some exemplary embodiments, the binder composition may have low viscosity, which allows for a reduction in the moisture level of Petition 870240031999, dated April 12, 2024, pp. 42-60 32 / 43 ramp. In some exemplary embodiments, the aqueous binder composition exhibits a viscosity, at a temperature of 25 °C, not exceeding 70 cP at 25 °C and 40% solids or less, such as not exceeding 65 cP, not exceeding 60 cP, not exceeding 55 cP or not exceeding 50 cP. A low viscosity of the binder allows a reduction in ramp moisture to less than 8%, less than 7%, less than 6%, less than 5%, less than 4%, less than 3%, less than 2% or less than 1% ramp moisture level. In some exemplary embodiments, the ramp moisture is zero or essentially zero, which means a ramp moisture level not exceeding 0.5%. A binder composition with as low a viscosity as possible, applied at high concentration, allows for the removal of large amounts of moisture during the ramping process, enabling the preparation of a strong binder without brittleness.

[079] In other exemplary embodiments, the aqueous binder composition demonstrates a viscosity, at a temperature of 25 °C, between 200 cP and 600 cP at 25 °C and 40% solids, including between 300 cP and 500 cP at 25 °C and 40% solids and between 350 cP and 450 cP at 25 °C and 40% solids.

[080] The binder content can be measured as loss on ignition (LOI). In any of the embodiments disclosed in this document, the LOI is 1% to 20%, including, without limitation, 5.5% to 17%, 8% to 15% and 10% to 14.5%. The specific LOI of a product depends largely on the type of product being produced.

[081] The binder composition may be present in an amount less than or equal to 10% by weight of the fibrous insulation product 100, or less than or equal to 8% by weight of the fibrous insulation product 100, or less than or equal to 6% by weight of the fibrous insulation product 100. In one exemplary embodiment, the fibrous insulation product 100 includes a collection of non-woven glass fibers and less than 10% by weight of a formaldehyde-free binder. In some exemplary embodiments, the cured fibrous insulation product 100 has in Petition 870240031999, dated April 12, 2024, pp. 43-60 33 / 43 range of 2% by weight to 10% by weight of the binder composition. In some exemplary embodiments, the cured fibrous insulation product 100 has a binder composition in the range of 3.5% by weight to 6% by weight or in the range of 3.5% to 4% by weight of the binder composition. The relatively low amount of binder contributes to the flexibility of the final insulation product.

[082] In an exemplary embodiment, the 100 fibrous insulation product may be formed as a residential insulation product, such as an insulation blanket, which has properties such as recovery, stiffness, handling, etc., that are suitable for use as residential insulation. The 100 fibrous insulation product, however, utilizes 130 glass fibers with a smaller diameter than the glass fibers used in conventional residential fiberglass insulation products, which typically have fiber diameters greater than 4 μm (15.7 HT). In particular, the exemplary fibrous insulation product 100 may include glass fibers 130 with an average fiber diameter in the range of 2.03 μm (12.0 HT) to 3.81 μm (15.0 HT), or in the range of 3.30 μm (13.0 HT) to 3.81 μm (15.0 HT), or in the range of 3.04 μm (12.0 HT) to 3.55 μm (14.0 HT).

[083] The procedure used to measure the glass fiber diameters 130 uses a scanning electron microscope (SEM) to directly measure the fiber diameter. In general, a sample of the fibrous insulation product 100 is heated to remove any organic materials (e.g., binder composition), the glass fibers in the sample are then reduced in length and photographed by the SEM. The fiber diameters are then measured from the images saved by the imaging software associated with the SEM.

[084] More specifically, a sample of the fibrous insulation product 100 is heated to 426.6 degrees C (800 degrees F) for a minimum of 30 minutes. The sample may be heated for longer, if necessary, to ensure the removal of any organic materials. The sample is cooled to room temperature and the Petition 870240031999, dated April 12, 2024, pp. 44 / 60 34 / 43 glass fibers are shortened to fit on an SEM board. The glass fibers can be shortened by any suitable method, such as, for example, cutting with scissors, cutting with a razor blade, or grinding in a mortar and pestle. The glass fibers are then adhered to the surface of the SEM board so that the fibers do not overlap or are too far apart.

[085] Once the sample is prepared for imaging, the sample is mounted in the SEM using normal operating procedures and photographed by the SEM at appropriate magnification for the fiber diameter size being measured. A sufficient number of images are collected and saved to ensure that sufficient fibers are available for measurement. For example, 10 to 13 images may be required where 250 to 300 fibers are being measured. Fiber diameters are then measured using an SEM image analysis software program, such as, for example, the Scandium SIS imaging software. The average fiber diameter of the sample is then determined from the number of fibers measured. The fibrous insulation product sample may include glass fibers that are fused (i.e., two or more fibers joined along their lengths). For purposes of calculating the average fiber diameter of the samples in this disclosure, fused fibers are treated as single fibers.

[086] An alternative procedure used to measure the average fiber diameter of glass fibers 130 utilizes a device that measures airflow resistance to indirectly determine the average or “effective” fiber diameter of randomly distributed fibers in a sample. More specifically, in one embodiment of the alternative procedure, a sample of the fibrous insulation product 100 is heated to 426.6 to 537.7 degrees C (800 to 1000 degrees F) for 30 minutes. The sample may be heated for longer, if necessary, to ensure the removal of any organic materials. The sample is then cooled to room temperature. Petition 870240031999, dated April 12, 2024, pages 45 / 60 A test sample weighing approximately 7.50 grams is loaded into the device's chamber. A constant airflow is applied through the chamber, and once the airflow stabilizes, the differential pressure, or pressure drop, is measured by the device. Based on the airflow and differential pressure measurements, the device can calculate the average fiber diameter of the sample.

[087] Using fine glass fibers 130, as described above, the exemplary fibrous insulation product 100 can be formed as a blanket or mat with appropriate R-values, such as in the range of 10 to 54, and thicknesses, such as in the range of 5.08 centimeters to 45.72 centimeters (2 inches to 18 inches), for use as residential or commercial insulation, by adapting certain product properties such as fiber diameter, density (cfg), product area weight (pounds per square foot) and binder content. For example, an insulation blanket with a thickness of 8.89 centimeters (3.5 inches) and an R-value of 11 can be formed using glass fibers 130 with an average fiber diameter less than or equal to 4 μm by matching the density (cfg) and product area weight (pounds per square foot) for a specific fiber diameter and binder content.

[088] The density of the fibrous insulation product 100 may vary in different embodiments. As used in this application, the density of the fibrous insulation product is the density after the binder composition has been cured and the cured product is in a free state (i.e., not compressed or stretched). In various embodiments, the density of the fibrous insulation product 100 is in the range of 0.3 pcf to 2.7 pcf. Table 4 lists the original density, in pcf, for various exemplary embodiments of fibrous insulation products 100 with fine fibers in the range of 3.04 μm (12.0 HT) to 3.81 μm (15.0 HT). In Table 4, fiber diameters refer to an average fiber diameter, before application of the binder composition, as measured by the airflow resistance method described above. Original thickness and density refer to the thickness and density of the Petition 870240031999, dated April 12, 2024, pp. 46-60 36 / 43 product after the binder composition has been cured and the cured product is in a free state (i.e., not compressed or stretched). Table 4: Original Density (pcf) by Fiber Diameter, R-value, Binder Content and Thickness ___________________________________________________ Thickness in centimeters (inches) 8.89 (3.50) 8.89 (3.50) 8.89 (3.50) 15.87 (6.25) 13.97 (5.50) 13.97 (5.50) 22.86 (9.50) 30.48 (12.00) 35.56 (14.00) Binder Content (% by weight) 5.50 5.50 4.00 5.50 5.50 4.00 5.50 5.50 4.00 R-value R11 R13 R15 R19 R20 R21 R30 R38 R49 Fiber Diameter (HT) 12 0.401 0.627 1.097 0.371 0.585 0.674 0.403 0.406 0.515 13 0.411 0.645 1.135 0.382 0.602 0.694 0.416 0.418 0.531 14 0.425 0.665 1.173 0.392 0.622 0.716 0.428 0.430 0.547 15 0.435 0.686 1.214 0.403 0.639 0.737 0.440 0.443 0.563

[089] The data in Table 4 show fibrous insulation products with R-values ​​from 11 to 49 produced with average fiber diameters less than or equal to 15 HT, original densities in the range of 0.371 pcf to 1.214 pcf and less than or equal to 6% by weight of the binder composition. In exemplary embodiments, the fibrous insulation product may be a blanket with an uncompressed thickness of 8.89 centimeters (3.5 inches) or less, an R-value of 11 or greater and an original density less than or equal to 0.44 pcf; an uncompressed thickness of 8.89 centimeters (3.5 inches) or less, an R-value of 13 or greater and an original density less than or equal to 0.69 pcf; an uncompressed thickness of 8.89 centimeters (3.5 inches) or less, an R-value of 15 or higher, and an original density less than or equal to 1.22 pcf; an uncompressed thickness of 15.87 centimeters (6.25 inches) Petition 870240031999, dated April 12, 2024, pp. 47-60 37 / 43 inches) or less, an R-value of 19 or higher and an original density less than or equal to 0.41 pcf; an uncompressed thickness of 13.97 centimeters (5.5 inches) or less, an R-value of 20 or higher and an original density less than or equal to 0.65 pcf; an uncompressed thickness of 13.97 centimeters (5.5 inches) or less, an R-value of 21 or higher and an original density less than or equal to 0.75 pcf; an uncompressed thickness of 22.86 centimeters (9.5 inches) or less, an R-value of 30 or higher and an original density less than or equal to 0.45 pcf; an uncompressed thickness of 30.48 centimeters (12.0 inches) or less, an R-value of 38 or higher and an original density less than or equal to 0.45 pcf; or an uncompressed thickness of 35.56 centimeters (14.0 inches) or less, an R-value of 49 or higher, and an original density less than or equal to 0.57 pcf.In another exemplary embodiment, the fibrous insulation product may be a blanket with an uncompressed thickness of 8.89 centimeters (3.5 inches) or less, an R-value of 16 or more, average fiber diameters in the range of 3.04 μm (12.0 HT) to 3.81 μm (15.0 HT), less than or equal to 3.5% by weight of the binder, and an original density less than or equal to 1.90 pcf or less than or equal to 2.0 pcf. In other exemplary embodiments, the fibrous insulation product may be a blanket with average fiber diameters in the range of 3.04 μm (12.0 HT) to 3.81 μm (15.0 HT) and less than or equal to 10% by weight of the binder.

[090] Table 5 illustrates the original area weights, in pounds per square foot (psf), of exemplary embodiments of 100 fibrous insulation products with fine fibers in the range of 3.04 µm (12.0 HT) to 3.81 µm (15.0 HT). In Table 5, fiber diameters refer to an average fiber diameter, before application of the binder composition, as measured by the airflow resistance method described above and measured as discussed above, and the original area thickness and weight refer to the area thickness and weight (pounds per square foot) of the product after the binder composition has been cured and the cured product is in a state Petition 870240031999, dated April 12, 2024, pages 48 / 60 38 / 43 loose (i.e., not compressed or stretched). Table 5: Original Area Weight (psf) by Fiber Diameter, R-value, Binder Content and Thickness ___________________________________________________ Thickness in centimeters (inches) 8.89 (3.50) 8.89 (3.50) 8.89 (3.50) 15.87 (6.25) 13.97 (5.50) 13.97 (5.50) 22.86 (9.50) 30.48 (12.00) 35.56 (14.00) Binder Content (% by weight) 5.50 5.50 4.00 5.50 5.50 4.00 5.50 5.50 4.00 R-value R11 R13 R15 R19 R20 R21 R30 R38 R49 Fiber Diameter (HT) 12 0.117 0.183 0.320 0.193 0.268 0.309 0.319 0.406 0.601 13 0.120 0.188 0.331 0.199 0.276 0.318 0.329 0.418 0.620 14 0.124 0.194 0.342 0.204 0.285 0.328 0.339 0.430 0.638 15 0.127 0.200 0.354 0.210 0.293 0.338 0.348 0.443 0.657

[091] The data in Table 5 show fibrous insulation products with R values ​​from 11 to 49 produced with average fiber diameters in the range of 3.04 μm (12.0 HT) to 3.81 μm (15.0 HT), original area weights in the range of 0.117 psf to 0.657 psf and less than or equal to 6% by weight of the binder composition.

[092] In some embodiments, the disclosed fiberglass insulation products produced with fibers having an average fiber diameter in the range of 3.04 μm (12.0 HT) to 3.81 μm (15.0 HT), original densities in the range of 0.3 pcf to 2.0 pcf, and less than or equal to 10% by weight of the binder composition may be less stiff than conventional fiberglass insulation products with similar binder compositions but produced with fibers having an average fiber diameter greater than 15 HT.

[093] In some exemplary embodiments, the disclosed fiberglass insulation product 100 has a stiffness of 75 degrees or less, or 60 degrees or Petition 870240031999, dated April 12, 2024, pp. 49-60 39 / 43 less, or 45 degrees or less, or 30 degrees or less. The stiffness of the 100 fiberglass insulation product is measured by suspending a sample of the fiberglass insulation product over a central support and measuring the angle that the ends of the sample deflect downward. The procedure is applicable to coated and uncoated insulation products and samples approximately 48 inches long and up to approximately 60.96 centimeters (24 inches) wide. In particular, the procedure uses a 2x6 beam 60.96 centimeters (24 inches) long (13.97 centimeters (5.5 inches) wide) laid parallel to the floor. A 48-inch-long sample of the 100 insulation product is placed on top of the 2x6 beam parallel to the floor, so that the middle of the sample is centered on the 2x6 beam and the two ends of the sample are free to hang along the side of the beam.The angle of each end of the sample is then measured as it hangs freely on the 2x6 beam, for example, by providing a 90-degree angle scale perpendicular to and below the 2x6 beam to visually determine the angle of each end. Stiffer insulation products have stiffness angles closer to 0 degrees, as the two free ends of the 100 insulation product remain more parallel to the floor when freely supported by the 2x6 beam in the center. Less stiff products sag along the 2x6 beam, and the ends become more perpendicular to the floor with stiffness angles closer to 90 degrees.

[094] In an exemplary embodiment, the fibrous insulation product 100 is formed as a mat with a plurality of randomly oriented glass fibers held together by a binder composition. The glass fibers have an average fiber diameter of less than or equal to 15 HT and the fibrous insulation product has less than 10% by weight of a formaldehyde-free binder. In an exemplary embodiment, the fibrous insulation product 100 has in the range of 3.0% to 4.0% by weight of a formaldehyde-free binder. Petition 870240031999, dated April 12, 2024, pages 50 / 60 40 / 43

[095] In some exemplary embodiments, the blanket has a width in the range of 28.57 centimeters to 61.59 centimeters (11.25 inches to 24.25 inches), a length in the range of 119.38 centimeters to 276.86 centimeters (47 inches to 106 inches), and a thickness in the range of 7.62 centimeters to 10.16 centimeters (3 inches to 4 inches). In one exemplary embodiment, the blanket is not encapsulated (i.e., not surrounded by a covering, such as a vapor barrier). The blanket has a maximum R-value per inch greater than or equal to 4.6 and a stiffness less than or equal to 30 degrees.

[096] In some exemplary embodiments, the fibrous insulation product 100 is designed to produce less tingling than known comparable fibrous insulation products. As used in this application, “tingling” refers to the mechanical stimulation of nerve endings in a person’s skin. The specific nerve endings associated with tingling are triggered by sufficient force applied perpendicularly to the skin surface. The presence of a relatively small number of these stimuli per unit area of ​​skin surface is sufficient to trigger the tingling sensation. For example, the ends of the fibers that form a fibrous insulation product may protrude from the surface of the fibrous insulation product. These fiber ends, upon contact with a person’s skin, such as an installer, act mechanically as Euler rods.If the fiber ends can withstand sufficient force before buckling, the ends can trigger nerve endings and cause tingling. Thus, fiber diameter, fiber stiffness, and the number of projecting fiber ends are among the variables that can impact tingling.

[097] The propensity of a fibrous insulation product to cause tingling can be measured by a Wool Comfort Meter (WCM) according to the standard. Petition 870240031999, dated April 12, 2024, pages 51 / 60 41 / 43 of the International Wool Textile Organization (IWTO) IWTO-66-2017 test. The WCM measures a test sample and produces a single numerical comfort factor (CF) value. The comfort factor is measured at five different locations on the sample, and the average reading is recorded as the comfort factor value for the sample. A lower comfort factor value indicates a lower propensity to produce tingling.

[098] Table 6 illustrates the comfort factor values ​​for five prior art fibrous insulation samples (A1-A5) and five exemplary embodiments of fibrous insulation products according to this disclosure (B1-B5). The samples were tested according to IWTO-66-2017 with some minor modifications. Minor modifications to the sample preparation were made to test the largest possible insulation sample size with the WCM. In particular, the insulation samples were cut to L 40 cm x W 22.02 cm (L 15.75” x W 8.67”) and then divided into 3.81 cm (1.5”) thick pieces to fit under the WCM test head. This is a minor modification to the length and width for IWTO-66-2017 which uses 300 mm x 300 mm (11.8” x 11.8”) samples and nominal thicknesses for fabrics.The only modification to the instrument required was that the WCM sample stage needed to be removed to accommodate the relatively thicker 3.81 cm (1.5”) sample under the test head. No other modifications were made to the test method or instrument.

[099] Table 6 also includes the average fiber diameter / density (Fd / D) values ​​for the listed samples. Fiber diameters are listed in HT and density is listed in pcf. The average fiber diameter was measured using the SEM method described above. Density is measured after the binder composition has been cured and the cured product is in a free state (i.e., not compressed or stretched). Table 6: R-value, Average Diameter / Fiber Density Ratio, and Comfort Factor Petition 870240031999, dated April 12, 2024, pages 52 / 60 42 / 43 Sample Value R Average Fiber Diameter / Density (HT / pcf) Comfort Factor, CF A1 19 50.0 267 A2 30 32.0 243 A3 30 28.8 170 A4 13 30.2 192 A5 17.6 14.6 150 B1 19 35.8 131 B2 28 32.3 74 B3 12 28.8 75 B4 24 14.5 57 B5 20 35.1 140

[0100] With reference to FIG. 3, the comfort factor is plotted versus mean Fd / D for the data in Table 5. As shown in FIG. 3, the least squares regression line LA for samples A1-A5 and the least squares regression line LB for samples B1-B5 generally show that the comfort factor increases with increasing Fd / D values. The least squares regression line LB is defined by the equation CF = 3.417(Fd / D) - 4.8, having a coefficient of determination (R2) of 90% and p-values ​​of 0.004 or less. FIG. 3 illustrates a first zone that is representative of the comfort factor values ​​for exemplary embodiments of fibrous insulation products according to this disclosure. The first zone is bounded on the X-axis by a maximum Fd / D of 40 HT / pcf, as shown by the dashed line Z1, and is bounded on the Y-axis by the dashed line Z2 defined by the equation CF = 3.417(Fd / D) + 60, which is a line parallel to the least squares regression line LB.As shown in FIG. 3, the first zone encompasses all samples B1-B5 and excludes all prior art fibrous insulation samples (A1-A5). Petition 870240031999, dated April 12, 2024, pp. 53-60 43 / 43

[0101] The fiberglass insulation materials of the present invention may have any combination or subcombination of the disclosed properties and the ranges for those properties disclosed in this document. Although the present invention has been illustrated by the description of its embodiments, it is not the applicant's intention to restrict or in any way limit the scope of the claims appended to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Although the fibrous insulation product has been illustrated in this document as a flexible blanket or mat, other configurations and geometries may be used. Furthermore, the fibrous insulation product may be used in various ways and is not limited to any specific application. Therefore, the invention, in its broadest aspects, is not limited to the specific details, representative apparatus, and illustrative examples shown and described.Thus, deviations from such details can be made without departing from the spirit or scope of the overall inventive concepts.

Claims

1. Fibrous insulation blanket CHARACTERIZED in that it comprises: a plurality of randomly oriented glass fibers; and a cured binder composition that holds the glass fibers together, wherein the cured binder composition is formed from an aqueous binder composition comprising a polymeric polycarboxylic acid crosslinking agent and a monomeric polyol having at least four hydroxyl groups present in an amount to provide a molar ratio of carboxylic acid groups to hydroxyl groups between 0.60 / 1 and 1 / 0.6, wherein the aqueous binder composition has a pH of 2.2 to 4.0; wherein the amount of binder is in the range of 2% to 10% by weight of the fibrous insulation product; wherein the R-value of the fibrous insulation blanket is in the range of 10 to 54; wherein the glass fibers have an average fiber diameter in the range of 3.04 μm (12 HT) to 3.81 μm (15 HT);and wherein the fibrous insulation blanket, after curing, has a density, when not compressed, in the range of 4.81 kg / m3 (0.30 pcf) to 43.25 kg / m3 (2.7 pcf), and a stiffness of 45 degrees or less.

2. Fibrous insulation blanket, according to claim 1, CHARACTERIZED in that the fibrous insulation blanket has a thickness in the range of 5.08 centimeters to 45.72 centimeters (2 inches to 18 inches) and is formed by a single layer of randomly oriented glass fibers.

3. Fibrous insulation blanket, according to claim 1, CHARACTERIZED in that the fibrous insulation blanket has a thickness in the range of 5.08 centimeters to 45.72 centimeters (2 inches to 18 / 5 inches) and is formed by no more than two layers of randomly oriented glass fibers.

4. Fibrous insulation blanket, according to claim 1, CHARACTERIZED in that the aqueous binding composition comprises polyacrylic acid, sorbitol and sodium hypophosphite.

5. Fibrous insulation blanket, according to claim 1, CHARACTERIZED in that the R-value of the fibrous insulation blanket is in the range of 10 to 16.

6. Fibrous insulation blanket, according to claim 1, CHARACTERIZED in that the R-value of the fibrous insulation blanket is in the range of 32 to 54.

7. Fibrous insulation blanket, according to claim 1, CHARACTERIZED in that the fibrous insulation blanket has an uncompressed thickness in the range of 5.08 centimeters to 8.89 centimeters (2 inches to 3.5 inches), wherein the R-value of the blanket is greater than or equal to 11, and wherein the density of the blanket is less than or equal to 7.05 kg / m3 (0.44 pcf).

8. Fibrous insulation blanket, according to claim 1, CHARACTERIZED in that the fibrous insulation blanket has an uncompressed thickness in the range of 5.08 centimeters to 8.89 centimeters (2 inches to 3.5 inches), wherein the R-value of the blanket is greater than or equal to 13, and wherein the density of the blanket is less than or equal to 11.05 kg / m3 (0.69 pcf).

9. Fibrous insulation blanket, according to claim 1, CHARACTERIZED in that the fibrous insulation blanket has an uncompressed thickness in the range of 5.08 centimeters to 8.89 centimeters (2 inches to 3.5 inches), wherein the R-value of the blanket is greater than or equal to 15, and wherein the density of the blanket is less than or equal to 22.59 kg / m3 (1.41 pcf).

10. Fibrous insulation blanket, according to claim 1, Petition 870260060315, dated 06 / 19 / 2026, p. 12 / 21 3 / 5 CHARACTERIZED in that the fibrous insulation blanket has an uncompressed thickness in the range of 5.08 centimeters to 15.88 centimeters (2 inches to 6.25 inches), wherein the R-value of the blanket is greater than or equal to 19, and wherein the density of the blanket is less than or equal to 6.57 kg / m3 (0.41 pcf).

11. Fibrous insulation blanket, according to claim 1, CHARACTERIZED in that the fibrous insulation blanket has an uncompressed thickness in the range of 5.08 centimeters to 13.97 centimeters (2 inches to 5.5 inches), wherein the R-value of the blanket is greater than or equal to 20, and wherein the density of the blanket is less than or equal to 10.41 kg / m3 (0.65 pcf).

12. Fibrous insulation blanket, according to claim 1, CHARACTERIZED in that the fibrous insulation blanket has an uncompressed thickness in the range of 5.08 centimeters to 13.97 centimeters (2 inches to 5.5 inches), wherein the R-value of the blanket is greater than or equal to 21, and wherein the density of the blanket is less than or equal to 12.01 kg / m3 (0.75 pcf).

13. Fibrous insulation blanket, according to claim 1, CHARACTERIZED in that the fibrous insulation blanket has an uncompressed thickness in the range of 5.08 centimeters to 24.13 centimeters (2 inches to 9.5 inches), wherein the R-value of the blanket is greater than or equal to 30, and wherein the density of the blanket is less than or equal to 7.21 kg / m3 (0.45 pcf).

14. Fibrous insulation blanket, according to claim 1, CHARACTERIZED in that the fibrous insulation blanket has an uncompressed thickness of 30.48 centimeters (12.0 inches), where the R-value of the blanket is greater than or equal to 38, and where the density of the blanket is less than or equal to 7.21 kg / m3 (0.45 pcf).

15. Fibrous insulation blanket, according to claim 1, CHARACTERIZED in that the fibrous insulation blanket has an uncompressed thickness in the range of 5.08 centimeters to 35.56 centimeters (2 Petition 870260060315, dated 06 / 19 / 2026, p. 13 / 21 4 / 5 inches to 14 inches), wherein the R-value of the blanket is greater than or equal to 49, and wherein the density of the blanket is less than or equal to 9.13 kg / m3 (0.57 pcf).

16. Fibrous insulation blanket, according to claim 1, CHARACTERIZED in that the fibrous insulation blanket has an uncompressed thickness in the range of 5.08 centimeters to 8.89 centimeters (2 inches to 3.5 inches), wherein the R-value of the blanket is greater than or equal to 11, and wherein the area weight of the blanket is less than or equal to 0.63 kg / m2 (0.13 psf).

17. Fibrous insulation blanket, according to claim 1, CHARACTERIZED in that the fibrous insulation blanket has a stiffness that is less than or equal to 30 degrees.

18. Construction frame CHARACTERIZED in that it comprises: a plurality of parallel and spaced frame elements; a fiberglass insulation blanket received between two of the frame elements, the fiberglass insulation blanket comprising: a plurality of randomly oriented glass fibers; and a cured binder composition that holds the glass fibers together, wherein the cured binder composition is formed from an aqueous binder composition comprising a polymeric polycarboxylic acid crosslinking agent and a monomeric polyol having at least four hydroxyl groups present in an amount to provide a molar ratio of carboxylic acid groups to hydroxyl groups between 0.60 / 1 and 1 / 0.6, wherein the aqueous binder composition has a pH of 2.2 to 4.0; wherein the glass fibers have an average fiber diameter in the range of 3.04 μm (12 HT) to 3.81 μm (15 HT);wherein the fibrous insulation blanket, after curing, has a density, when not compressed, in the range of 4.81 kg / m3 (0.30 pcf) to 43.25 kg / m3 (2.7 pcf), and a stiffness of 45 degrees or less; Petition 870260060315, dated 06 / 19 / 2026, page 14 / 21 5 / 5 wherein the amount of binder is in the range of 2% to 10% by weight of the fibrous insulation product; and wherein the R-value of the fibrous insulation blanket is in the range of 10 to 54.

19. Construction frame, according to claim 18, CHARACTERIZED in that the fiberglass insulation blanket has an uncompressed thickness in the range of 5.08 centimeters to 8.89 centimeters (2 inches to 3.5 inches), wherein the R-value of the fiberglass insulation blanket is greater than or equal to 11, and wherein the density of the fiberglass insulation blanket is less than or equal to 7.05 kg / m3 (0.44 pcf).

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