Binder system

Abstract

Environmentally friendly aqueous binder compositions including a metal salt and a polyol are provided. The metal salt can be a water-soluble salt including salts of boron, aluminum, gallium, indium, tin, zirconium, thallium, lead, and bismuth. The polyol can include a water-miscible or water-soluble polymeric alcohol including polyvinyl alcohol. The binder compositions can be used to form products such as insulation materials and nonwoven mats.

Description

[0001] This invention patent application is a divisional application of the invention patent application with application number 201780042850.X, application date June 6, 2017, and invention title "Adhesive System".

[0002] Related applications

[0003] This application claims priority and interest in U.S. Provisional Application No. 62 / 345,885, filed June 6, 2016, the contents of which are incorporated herein by reference in their entirety as set forth herein. Technical Field

[0004] The present invention relates generally to fibrous insulation and non-woven mats, and more particularly to adhesives for manufacturing fibrous insulation and non-woven mats. Background Technology

[0005] Common fibers such as glass fiber, mineral wool, and basalt can be used in a wide variety of applications, including reinforcements, textiles, and sound and heat insulation materials. Fiber insulation is typically manufactured as follows: a molten composition of polymer, glass, or other minerals is fiberized and spun into fine fibers by fiberizing equipment, such as a rotary spinning machine. To form the insulation product, the fibers produced by the rotary spinning machine are drawn down from the spinning machine to a conveyor by a blower. As the fibers move downward, a binder material is applied to the fibers via spraying or dipping. The fibers are then collected on the conveyor into a high-loft, continuous blanket. The binder material imparts elasticity to the insulation product for recovery after packaging and provides rigidity and maneuverability, allowing the insulation product to be processed as needed and applied, for example, to insulating openings in buildings. The binder composition also provides protection to the fibers from inter-filament abrasion and promotes compatibility between individual fibers.

[0006] The blanket containing the adhesive-coated fibers is then passed through a curing oven, where the adhesive is cured to shape the blanket to the desired thickness. After the adhesive has cured, the fiber insulation can be cut to lengths to form individual insulation products, which can then be packaged for delivery to consumers. A typical insulation product produced is insulating batt or blanket, suitable for use as wall insulation in residences or as insulation in attics and floor cavities in buildings. Another type of insulation product is insulating board. Insulating boards can be used in a similar manner to insulating batt or blanket, but are stiffer and generally denser.

[0007] Nonwoven mats, such as those used in soundproof ceilings, can be formed using conventional wet web-forming methods. In one such method, wet chopped fibers are dispersed in a water slurry containing surfactants, viscosity modifiers, defoamers, and / or other chemical agents. The slurry containing the chopped fibers is then stirred so that the fibers are more evenly dispersed throughout the slurry. The fiber-containing slurry is deposited onto a moving screen, where most of the water is removed to form a web. A binder is then applied, and the resulting fiber mat is dried to remove any residual water and cure the binder. The resulting nonwoven mat is an aggregate of dispersed, individual glass filaments.

[0008] Nonwoven mats can also be prepared from chopped dry fibers and / or continuous filaments. For example, fibers are spread from a bushing and cut to the desired length. Certain chemical reagents may or may not be applied to the fibers before cutting. The chopped fibers are then applied to a surface, for example, via a conveyor belt, to form a fiber mat. An adhesive is applied to the fiber mat as it is conveyed to a curing oven.

[0009] In the realm of continuous filament fiber products, fibers are spread onto a surface (with or without prior application of chemical agents) and allowed to form a fiber mat. An adhesive composition is then applied to the fiber mat, which is subsequently conveyed to an oven for curing. Generally, the cured fiber mat thus consists of fewer fibers than a chopped fiber mat.

[0010] Various attempts have been made to reduce unwanted formaldehyde emissions from formaldehyde-based resins such as phenolic resins. For example, in attempts to reduce formaldehyde emissions from insulation products, various formaldehyde scavengers such as ammonia and urea have been added to formaldehyde-based resins.

[0011] Polyacrylic acid adhesives offer some advantages over phenolic resins. However, most adhesives formed from polyacrylic acid inherently have problems due to their acidity and associated corrosion of components. Additionally, polyacrylic acid adhesives have high viscosity, high curing temperatures, and high associated curing costs. Certain systems based on natural substances are also known, but are hampered by their own specific drawbacks. For example, starch / carbohydrate-based products (or those relying on the Maillard reaction) may have an undesirable dark brown color after curing. Furthermore, the use of large amounts of ammonia required to manufacture adhesives poses safety risks and potential emissions problems.

[0012] Alternative polymeric adhesive systems to those described above for fiberglass products have also been proposed. However, these alternative polymeric adhesive systems remain problematic in certain situations. For example, low molecular weight, low viscosity adhesives that allow for maximum vertical expansion of the insulating package in the transfer zone typically cure in the finished product to form a non-rigid plastic matrix, thus reducing the achievable vertical height recovery of the finished insulation product during installation. Conversely, high viscosity adhesives that typically cure in the finished product to form a rigid matrix do not allow for the required maximum vertical expansion of the coated, uncured package.

[0013] In addition to the components that react to bind the fibers together, most conventional adhesive systems contain many other components to adjust various properties of the finished product (e.g., dust resistance, antistatic properties). Besides not hindering the final bonding of the fibers, each of these individual components must also be proven safe and compatible with the other components.

[0014] Given the existing problems with current adhesives, there is still a need in the art for an adhesive system that is non-corrosive to machine parts, does not contain added formaldehyde, is environmentally friendly, is stable in storage after production, is simpler in terms of the total composition required to prepare the finished product, and / or provides processing advantages. Summary of the Invention

[0015] The general inventive concept relates to adhesive compositions for forming insulators, insulating boards, nonwoven mats, carbon fiber products, and for use as binders for organic fibers such as cellulose and wood-based fibers in these products. Generally, the adhesive comprises a metal salt and a polyol. In some embodiments, the metal salt and the polyol are present in the adhesive composition in a weight ratio of 1:99 to 1:1.

[0016] In some embodiments, the general inventive concept relates to a fiber insulation product comprising a plurality of randomly oriented fibers and an adhesive composition applied to at least a portion of the fibers and interconnecting the fibers. The adhesive comprises a metal salt and a polyol in a weight ratio of 1:99 to 1:1.

[0017] In some embodiments, the general inventive concept relates to a nonwoven mat formed from a plurality of randomly oriented fibers and an adhesive composition, the randomly oriented fibers having discrete lengths entangled in a mat-like manner with a first primary surface and a second primary surface, the adhesive composition at least partially coating the first primary surface of the mat, or in some embodiments, at least partially impregnating the mat. The adhesive comprises a metal salt and a polyol. The metal salt and the polyol are generally present in a weight ratio of 1:99 to 1:1. Any suitable fiber can be used. In some embodiments, the fiber is glass fiber. The fiber has an average diameter of 6.5 micrometers to 24 micrometers. In some embodiments, the fiber is mineral wool fiber. The adhesive composition is present in the nonwoven mat at a loss on ignition of 1% to 25%.

[0018] In some embodiments, the general inventive concept relates to a method of manufacturing a fiber insulation product. The method includes forming a fiber blanket comprising a plurality of randomly oriented fibers, applying an adhesive composition to at least a portion of the glass fibers, the adhesive composition comprising a metal salt and a polyol in a weight ratio of 1:99 to 1:1, passing the fiber blanket through an oven to at least partially cure the adhesive on the fibers and form an insulation product, wherein the adhesive composition is present in the fiber insulation product at a loss on ignition of 1% to 25%.

[0019] Various embodiments of the overall inventive concept will typically exhibit one or more of the following exemplary features.

[0020] The key feature of the overall inventive concept is that the adhesive composition of the present invention does not contain added formaldehyde.

[0021] The overall inventive concept is characterized by the fact that the adhesive composition of the present invention requires fewer components to produce a qualified product.

[0022] The overall inventive concept is characterized by the fact that insulating products and nonwoven mats using the adhesive compositions of the present invention can be manufactured using current manufacturing lines, thereby saving time and money. In some embodiments, insulating products and nonwoven mats using the adhesive compositions of the present invention can be prepared at lower temperatures than those typically used for curing conventional adhesive systems while still maintaining overall performance standards.

[0023] The overall inventive concept is characterized by the fact that insulating products and nonwoven mats using the adhesive composition of the present invention can be manufactured using an increased amount of added water and cured at a temperature equal to or below the current temperature / time. This is attributed to the fact that the adhesive composition of the present invention "sheds" excess moisture in a manner not seen in conventional adhesive systems, allowing additional water to be added to the adhesive composition (for ease of processing) if necessary, without significantly increasing production time or cost and without significantly affecting performance.

[0024] The overall inventive concept is characterized by the final insulating product made from the exemplary aqueous binder composition provided herein having a light color at the desired loss on ignition (LOI) level, which allows the use of dyes, pigments or other colorants to give the insulating product a wide variety of colors.

[0025] The overall inventive concept is characterized by the bonding of mineral wool by the adhesive composition of the present invention under acidic conditions. Generally, adhesives requiring an acidic environment for proper crosslinking / curing are inefficient or have reduced performance when bonding mineral wool. Surprisingly, the adhesive of the present invention described herein is found to be effective in bonding mineral wool to form an insulating felt at pH values ​​of 1-4.5 (including pH values ​​of 2.5-3).

[0026] In some embodiments, the adhesive compositions of the present invention can be cured at lower temperatures than conventional adhesive compositions. Adhesive compositions containing polyols and metal salts allow water to be released more easily from the pre-cured product. The reduced water content thus requires less heat to remove excess moisture from the product during curing.

[0027] The general inventive concept is characterized by the ability of an adhesive composition (e.g., polyvinyl alcohol and metal salt) to form an aqueous mixture that can be applied by conventional adhesive applicators (including sprayers).

[0028] Another feature of the overall inventive concept is that the adhesive composition of the present invention can be used to manufacture pads containing composite reinforcing materials.

[0029] The above and other objects, features, and advantages of the overall inventive concept will become more fully apparent from the following detailed description. However, it should be clearly understood that these drawings are for illustrative purposes and should not be considered as limiting the scope of the invention.

[0030] In particular, the present invention relates to the following aspects:

[0031] Item 1. An adhesive composition for forming fiber insulation and nonwoven mats, said adhesive composition comprising:

[0032] water;

[0033] Metal salts;

[0034] and polyols;

[0035] The metal salt and the polyol are present in a weight ratio of 1:99 to 1:1.

[0036] Item 2. The aqueous adhesive composition of Item 1, wherein the weight ratio of the metal salt to the polyol is in the range of 1:9 to 1:1.

[0037] Item 3. The aqueous binder composition of Item 1, wherein the metal salt comprises a metal selected from boron, aluminum, gallium, indium, tin, iron, zinc, titanium, bismuth, zirconium, and combinations thereof.

[0038] Item 4. The aqueous adhesive composition of Item 3, wherein the metal salt is an aluminum salt.

[0039] Item 5. The aqueous adhesive composition of Item 4, wherein the metal salt is selected from aluminum chloride, aluminum nitrate, aluminum sulfate, aluminum dihydrogen phosphate, sodium aluminate, and combinations thereof.

[0040] Item 6. The aqueous adhesive composition of Item 1, wherein the polyol is selected from aromatic alcohols, glycerol, polyglycerol, ethylene glycol, propylene glycol, polyethylene glycol, aliphatic alcohols, unmodified polyvinyl alcohol, modified polyvinyl alcohol, polyvinyl alcohol copolymer, polyvinyl acetate, polyacrylic acid, and combinations thereof.

[0041] Item 7. The aqueous adhesive composition of Item 6, wherein the polyol is polyvinyl alcohol.

[0042] Item 8. The aqueous adhesive composition of Item 7, wherein the polyvinyl alcohol has a viscosity of 3-5 centipoise.

[0043] Item 9. The aqueous adhesive composition of Item 8, wherein the polyvinyl alcohol is at least 50% hydrolyzed.

[0044] Item 10. Fiber insulation products, including:

[0045] Multiple fibers; and

[0046] An adhesive composition applied to at least a portion of the fibers, the adhesive composition comprising:

[0047] water;

[0048] Metal salts;

[0049] and polyols;

[0050] The weight ratio of the metal salt to the polyol is in the range of 1:99 to 1:1; and

[0051] The adhesive composition is present in the fiber insulation product at a loss on ignition of 1%-25%.

[0052] Item 11. The fiber insulation product of Item 10, wherein the weight ratio of the metal salt to the polyol is in the range of 1:9 to 1:1.

[0053] Item 12. The fiber insulation product of Item 10, wherein the metal salt comprises a metal selected from boron, aluminum, gallium, indium, tin, iron, zinc, titanium, bismuth, zirconium and combinations thereof.

[0054] Item 13. The fiber insulation product of Item 12, wherein the metal salt is an aluminum salt.

[0055] Item 14. The fiber insulation product of Item 13, wherein the metal salt is selected from aluminum chloride, aluminum nitrate, aluminum sulfate, aluminum dihydrogen phosphate, sodium aluminate, and combinations thereof.

[0056] Item 15. The fiber insulation product of Item 10, wherein the polyol is selected from aromatic alcohols, glycerol, polyglycerol, sorbitol, ethylene glycol, propylene glycol, polyethylene glycol, pentaerythritol, aliphatic alcohols, unmodified polyvinyl alcohol, modified polyvinyl alcohol, polyvinyl alcohol copolymer, polyvinyl acetate, polyacrylic acid, and combinations thereof.

[0057] Item 16. The fiber insulation product of Item 15, wherein the polyol is polyvinyl alcohol.

[0058] Item 17. The fiber insulation product of Item 16, wherein the polyvinyl alcohol has a viscosity of 3-5 centipoise.

[0059] Item 18. The aqueous adhesive composition of Item 17, wherein the polyvinyl alcohol is at least 50% hydrolyzed.

[0060] Item 19. The fiber insulation products of Item 10, wherein the insulation products do not contain added formaldehyde.

[0061] Item 20. The fiber insulation product of Item 10, wherein the fiber is glass fiber.

[0062] Item 21. Nonwoven mats, including:

[0063] Multiple fibers in the form of a pad having a first primary surface and a second primary surface; and

[0064] An adhesive composition that at least partially coats the first primary surface of the pad, the adhesive composition comprising:

[0065] water;

[0066] Metal salts;

[0067] and polyols;

[0068] The weight ratio of the metal salt to the polyol is in the range of 1:99 to 1:1; and

[0069] The adhesive composition is present in the nonwoven pad at a loss on ignition of 1%-25%.

[0070] Item 22. The nonwoven mat of Item 21, wherein the fiber is glass fiber, wherein the fiber has an average diameter of 6.5 micrometers to 24 micrometers.

[0071] Item 23. Methods for manufacturing fiber insulation products, including:

[0072] Forming a fiber blanket consisting of multiple fibers;

[0073] An adhesive composition is applied to at least a portion of the glass fiber, the adhesive composition comprising:

[0074] water;

[0075] Metal salts;

[0076] and polyols;

[0077] The weight ratio of the metal salt to the polyol is in the range of 1:99 to 1:1;

[0078] The fiber blanket is passed through an oven to allow the adhesive on the fiber blanket to at least partially cure and form an insulating product.

[0079] The adhesive composition is present in the fiber insulation product at a loss on ignition of 1%-25%.

[0080] The method of item 24.23, wherein the fiber is glass fiber. Attached Figure Description

[0081] Various exemplary advantages of the present invention will become apparent upon consideration of the following detailed disclosure, particularly when taken in conjunction with the accompanying drawings, wherein:

[0082] Figure 1 It is a graph showing the tensile strength of a handsheet sample made with several adhesive compositions divided by the corrected LOI (tensile strength / corrected LOI).

[0083] Figure 2 This is a graph showing the tensile strength of handmade paper samples made with several adhesives including the adhesive composition of the present invention divided by the corrected LOI (tensile strength / corrected LOI), wherein the adhesive composition of the present invention comprises polyvinyl alcohol / aluminum chloride and polyvinyl alcohol / aluminum nitrate.

[0084] Figure 3 This is a diagram showing the dynamic mechanical analysis of several adhesive compositions including the adhesive of the present invention, wherein the adhesive of the present invention comprises polyvinyl alcohol / aluminum nitrate.

[0085] Figure 4 This is a diagram showing the dynamic mechanical analysis of several adhesive compositions including the adhesive of the present invention, wherein the adhesive of the present invention comprises polyvinyl alcohol / aluminum chloride.

[0086] Figure 5 This is a diagram showing the dynamic mechanical analysis of several adhesive compositions containing polyvinyl alcohol / aluminum nitrate.

[0087] Figure 6 This is a diagram showing the dynamic mechanical analysis of several adhesive compositions containing polyvinyl alcohol / aluminum sulfate.

[0088] Figure 7 This is a graph showing the recovery percentage of several binder compositions containing polyvinyl alcohol and aluminum nitrate.

[0089] Figure 8 It is a graph showing the recovery percentage of several adhesive compositions.

[0090] Figure 9 This is a diagram showing the maximum load (for LOI correction) of a laboratory plate made with the adhesive composition of the present invention containing polyvinyl alcohol / aluminum nitrate.

[0091] Figure 10 This is a diagram showing the corrected LOI of the adhesive composition of the present invention containing polyvinyl alcohol / aluminum nitrate.

[0092] Figure 11 This is a diagram showing the tensile strength of a series of handmade papers made using the adhesive composition of the present invention, which is cured at temperatures of 250°F-450°F.

[0093] Figure 12 This is a diagram showing the tensile strength of a series of handmade papers made using the adhesive composition of the present invention, cured at temperatures of 250°F-450°F, to the normalized LOI.

[0094] Figure 13 This is a diagram showing the LOI of handmade paper made using the adhesive composition of the present invention, which is cured at a temperature of 250°F-450°F.

[0095] Figure 14 It is a graph showing the recovery percentage of samples prepared using the adhesive composition of the present invention, which is cured at a temperature of 300°F-400°F.

[0096] Figure 15 This is a graph showing the percentage of recovery per area weight normalized to a sample prepared using the adhesive composition of the present invention, which is cured at a temperature of 300°F-400°F.

[0097] Figure 16 This is a diagram showing the corrected LOI of a sample prepared using the adhesive composition of the present invention, which is cured at a temperature of 300°F-400°F.

[0098] Figure 17 It is a graph showing the measured stiffness of a series of sample felts prepared using the adhesive composition of the present invention with a target LOI of 4.65%, cured at high temperature (415-425°F as felt) or low temperature (350-360°F as felt).

[0099] Figure 18 It is a graph showing the bond strength of a series of samples prepared using the adhesive composition of the present invention with a target LOI of 4.65%, cured at high temperature (415-425°F as felt) or low temperature (350-360°F as felt).

[0100] Figure 19 It is a diagram showing the tensile strength of a series of samples prepared using the adhesive composition of the present invention with a target LOI of 4.65%, cured at high temperature (415-425°F as felt) or low temperature (350-360°F as felt).

[0101] Figure 20 This is a graph showing the measured tensile strength of handmade paper made using various binder compositions. The binder composition of the present invention (labeled PVA), containing PV and aluminum chloride in a 90:10 weight ratio, is compared with the control MDCA binder composition. Other binder compositions are PVGAF (polyvinyl alcohol, gallic acid, and ferric nitrate); and PGAA (polyvinyl alcohol, gallic acid, and aluminum chloride).

[0102] Figure 21 It is a diagram showing the tensile strength of handmade paper made using a binder composition (labeled PVA) containing PV and aluminum chloride in a weight ratio of 90:10.

[0103] Figure 22 This is a diagram showing the results of Example 25, which was adjusted for LOI correction.

[0104] Figure 23 It is a graph showing the measured tensile strength of handmade paper made using various adhesive compositions.

[0105] Figure 24This is a graph showing the measured stiffness of the adhesive composition of the present invention compared to the control MDCA adhesive and two additional adhesives including polyvinyl alcohol, namely, polyvinyl alcohol, gallic acid, aluminum chloride (labeled PVGAAl); and polyvinyl alcohol, gallic acid, ferric nitrate (labeled PVGAFe).

[0106] Figure 25 This is a graph showing the average LOI of the adhesive composition tested in Example 28.

[0107] Figure 26 This is a graph showing the percentage of recovery of the binder composition in Example 28. PVAl is polyvinyl alcohol and aluminum chloride, polyvinyl alcohol, gallic acid, aluminum chloride (labeled PVGAAl); and polyvinyl alcohol, gallic acid, ferric nitrate (labeled PVGAFe).

[0108] Figure 27 It is a diagram showing the measured sag of a mineral wool felt with various adhesives applied to it.

[0109] Figure 28 It is a graph showing the measured pull strength of mineral wool felt with various adhesives applied to it.

[0110] Figure 29 It is a diagram showing the measured resilience of mineral wool felt with various adhesives applied to it.

[0111] Figure 30 It is a diagram showing the measured compressive strength of mineral wool felt with various adhesives applied to it.

[0112] Figure 31 It is a diagram showing the amount of adhesive solids in the adhesive.

[0113] Figure 32 It is a diagram showing the tensile strength of mineral wool handmade paper prepared with PV / Al(NO3)3 binder system after storage.

[0114] Figure 33 It is a diagram showing the tensile strength of mineral wool handmade paper prepared with PV / Al(NO3)3 binder system after storage.

[0115] Figure 34 This is a drawing based on the dynamic mechanical analysis of the PV membrane.

[0116] Figure 35 This is a drawing of the dynamic mechanical analysis of PV / Al(NO3)3 binder.

[0117] Figure 36This is a drawing of the dynamic mechanical analysis of the PV / KNO3 adhesive used for comparison. Detailed Implementation

[0118] Unless otherwise defined, all technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. While any methods and materials similar or equivalent to those described herein may be used in the practice or testing of this invention, preferred methods and materials are described herein. All references cited herein, including published or corresponding U.S. or foreign patent applications (issued U.S. or foreign patents), and any other references, are incorporated herein by reference in their entirety, including all data, tables, figures, and texts set forth in the cited references.

[0119] It should be understood that when an element, such as a layer, region, substrate, or sheet, is referred to as being "on" another element, it may be directly on that other element or there may be intervening elements. Similarly, when an element is referred to as being "adjacent" to another element, that element may be directly adjacent to that other element or there may be intervening elements. The terms "top," "bottom," "side," and similar terms are used herein for illustrative purposes only. Similar numerals appearing throughout the figures denote similar elements.

[0120] The terminology used herein is for the purpose of describing exemplary embodiments only and should not be construed as limiting the disclosure as a whole. All references to a single characteristic or limitation in this disclosure should include the corresponding plural characteristic or limitation, and vice versa, unless otherwise specified or expressly implied to be contrary to the context of the reference. Unless otherwise specified, “a(a)”, “an”, “the”, and “at least one” are used interchangeably. Furthermore, as used in the specification and appended claims, the singular forms “a(a)”, “an”, and “the” include their plural forms unless the context clearly indicates otherwise.

[0121] If the terms "includes" or "including" are used in the specification or claims, they should be interpreted in a manner similar to the term "comprising," as when used as a transitional word in a claim. Additionally, if the term "or" (e.g., A or B) is used, it means "A or B or both."

[0122] All percentages, parts, and proportions used herein are by weight of the total composition unless otherwise specified. All ranges and parameters disclosed herein, including but not limited to percentages, parts, and proportions, are to be understood to cover any and all subranges presented and contained herein, and every number between the endpoints. For example, a given range of “1-10” should be considered to include any and all subranges (e.g., 1-6.1, or 2.3-9.4) starting from a minimum value of 1 or greater and ending at a maximum value of 10 or less, and to every integer contained within the range (1, 2, 3, 4, 5, 6, 7, 8, 9, and 10).

[0123] Any combination of methods or process steps used herein may be performed in any order unless otherwise specified or expressly implied to be contrary to the context of the reference.

[0124] Various embodiments of the compositions described herein may also be substantially free of any of the non-essential or optional components or features described herein, provided that the remainder of the composition still contains all of the essential components or features described herein. In this context, and unless otherwise specified, the term “substantially free” means that the selected adhesive composition contains less than a functional amount of non-essential ingredients, typically less than 1% by weight, including less than 0.5% by weight, including less than 0.1% by weight, and including 0% by weight of such non-essential or optional essential ingredients.

[0125] The compositions described herein may comprise, consist of, or consist essentially of, the basic elements of the products and methods described herein, and any additional or non-essential elements described herein or otherwise applicable to adhesive applications or related applications.

[0126] The overall inventive concept relates to more environmentally friendly adhesive compositions. In some embodiments, the adhesive is an aqueous adhesive composition. The adhesive composition typically consists of a metal salt and a polyol. The adhesive can be used to form products comprising fibers such as glass fibers, mineral wool, carbon fibers, and organic fibers including cellulose and wood-based fibers.

[0127] In some exemplary embodiments, the adhesive of the present invention comprises at least one polyol. In some exemplary embodiments, the polyol comprises compounds such as aliphatic alcohols, glycerol, triethanolamine, ethylene glycol, polyethylene glycol, unmodified polyvinyl alcohol, modified polyvinyl alcohol, copolymers of polyvinyl alcohol, polyvinyl acetate, and polyacrylic acid. In some exemplary embodiments, the polyol may be a polymeric alcohol. The term polyol as used herein means a compound having an aliphatic or aromatic backbone and at least two hydroxyl functional groups. However, it should be understood that other functional groups may be present in addition to hydroxyl functional groups, or in some embodiments, other functional groups may replace one or more of the hydroxyl functional groups, provided that the functional groups are expected to interact with the glass surface and the metal salt in a similar manner. Therefore, in some embodiments, the term polyol may refer to compounds with few or no hydroxyl functional groups, but which are associated with a polyol and maintain similar interactions, such as polyvinyl acetate, polyacrylic acid, and modified polyvinyl alcohol. The terms “polyol” and “polymeric alcohol” are used interchangeably herein and refer to chemical compounds having at least two hydroxyl functional groups. Although the terminology refers to compounds by specific functional groups, those skilled in the art will recognize that a wide variety of other functional groups may be present in the compounds, provided that such other groups do not prevent or significantly interfere with the overall inventive concept discussed herein.

[0128] In some exemplary embodiments, the adhesive composition does not contain added formaldehyde.

[0129] In some exemplary embodiments, fiber insulation products and nonwoven mats using the adhesive composition of the present invention can be manufactured using existing manufacturing lines, thereby saving time and money.

[0130] In some exemplary embodiments, the final insulation product made with the exemplary adhesive compositions provided herein has a light color at the desired loss on burn (LOI) level, which allows the use of dyes, pigments or other colorants to give the insulation product a wide variety of colors.

[0131] In some exemplary embodiments, the adhesive composition (e.g., polyvinyl alcohol and aluminum salt having a degree of hydrolysis of at least 50%) can be formed into an aqueous mixture that can be applied by a conventional adhesive applicator (including a sprayer).

[0132] In some exemplary embodiments, the binder composition is used to form insulations (e.g., insulating felt), insulating sheets, nonwoven mats, carbon fiber products, and as a binder for use in products as organic fibers such as cellulose and wood-based fibers. Generally, binders include metal salts and polyols.

[0133] In some exemplary embodiments, the general inventive concept relates to a fiber insulation product comprising a plurality of fibers and an adhesive composition applied to at least a portion of the fibers and interconnecting the fibers. In some exemplary embodiments, the fibers are randomly oriented.

[0134] In some exemplary embodiments, the general inventive concept relates to a nonwoven mat formed of a plurality of randomly oriented glass fibers and an adhesive composition, the randomly oriented glass fibers being cut to discrete lengths entangled in a mat form having a first primary surface and a second primary surface, the adhesive composition at least partially coating the first primary surface of the mat, or in some embodiments, at least partially impregnating the first primary surface of the mat.

[0135] In some exemplary embodiments, the general inventive concept relates to a nonwoven mat formed of a plurality of randomly oriented glass fibers and an adhesive composition, the randomly oriented glass fibers being entangled in a mat form having a first primary surface and a second primary surface, the adhesive composition at least partially coating the first primary surface of the mat, or in some embodiments, at least partially impregnating the first primary surface of the mat.

[0136] In some exemplary embodiments, the general inventive concept relates to a nonwoven mat formed from a plurality of randomly oriented mineral wool fibers and an adhesive composition, the randomly oriented mineral wool fibers being in the form of a mat having a first primary surface and a second primary surface, the adhesive composition at least partially coating the first primary surface of the mat, or in some embodiments, at least partially impregnating the first primary surface of the mat.

[0137] In some exemplary embodiments, the binder composition comprises at least one metal salt. In some exemplary embodiments, the metal is at least one of a Group 13 element, a transition metal, a metalloid, or any other metal that readily coordinates with oxygen. In some embodiments, the metal is selected from boron, aluminum, gallium, indium, tin, thallium, lead, bismuth, zinc, iron, zirconium, and titanium. In some embodiments, the metal salt may comprise more than one metal, such as a combination or complex of aluminum and zirconium. In some exemplary embodiments, the metal salt is composed of at least one salt of aluminum. In some exemplary embodiments, the metal salt is selected from aluminum chloride, aluminum nitrate, aluminum sulfate, aluminum dihydrogen phosphate, sodium aluminate, and combinations thereof.

[0138] In some embodiments, the polyol is a polymeric alcohol, including water-miscible synthetic polymeric alcohols. In some embodiments, the polyol is a water-soluble polymeric alcohol, such as polyvinyl alcohol.

[0139]

[0140] Those skilled in the art will understand that PV (or PVOH) generally refers to compounds produced by the hydrolysis of the ester functional groups of polyvinyl acetate. While other materials can be used to form polyvinyl alcohol, generally, PV is manufactured by polymerizing vinyl acetate into polyvinyl acetate. The polyvinyl acetate is then subjected to hydrolysis to produce PV with the desired degree of hydrolysis (relative to the polyvinyl acetate polymer). Therefore, although PV with different degrees of hydrolysis is called polyvinyl alcohol, those skilled in the art will acknowledge that the term polyvinyl alcohol refers to a "polymer" composed of acetate and alcohol structural moieties, having a precise composition determined by the degree of hydrolysis.

[0141] One way to characterize a PV is by referring to its degree of hydrolysis. In some embodiments, the PV has a degree of hydrolysis of at least 50%. In some embodiments, the PV has a degree of hydrolysis of 50%-98% or higher. In some embodiments, the PV has a high degree of hydrolysis, including polymers with 75% hydrolysis, 80% hydrolysis, 85% hydrolysis, 90% hydrolysis, 95% hydrolysis, 98% hydrolysis, 99% hydrolysis, or higher.

[0142] In some exemplary embodiments, the PV may be modified after hydrolysis. In some exemplary embodiments, the polyol is the unmodified PV. Unmodified PV can be considered as polyvinyl acetate that has been hydrolyzed to obtain the PV and used without further modification of the hydroxyl groups of the polymer. Modified polyvinyl alcohol is a PV that has been reacted and modified to form the PV by modifying at least a portion of the side functional groups that will be retained after major hydrolysis. The PV may be modified (e.g., grafted) with silanes or acids to form copolymers. In some embodiments, the polyol is modified polyvinyl alcohol.

[0143] Another way to characterize PV is by measuring the viscosity of a solution containing a certain percentage of PV. The viscosity of PV can be measured as follows: a 4% solution of PV is prepared and the viscosity is measured using a Hoeppler falling ball viscometer at ambient temperature (i.e., approximately 20°C). In some exemplary embodiments, PV has a viscosity of 3 centipoise. In some exemplary embodiments, PV has a viscosity of 4 centipoise. In some exemplary embodiments, PV has a viscosity of 5 centipoise.

[0144] While not wishing to be bound by theory, it is believed that metal salts can form coordination complexes between, for example, the hydroxyl functional groups of glass (e.g., glass fiber) and the hydroxyl groups of polyols (e.g., polyvinyl alcohol), as explained below. Additionally, during heating, metal ions can catalyze a reaction between the glass fiber and the polyol to form covalent bonds between them, or "crosslink" adjacent polyol molecules. Below is a representative schematic diagram illustrating one possible interaction between aluminum, a glass surface, and a polyol (e.g., polyvinyl alcohol). Furthermore, aluminum can also interact with adjacent polyol molecules (as shown in the lower right), thereby further enhancing the overall strength of the fiber material.

[0145]

[0146] This coordination or crosslinking helps form a three-dimensional network between the components, thereby providing additional bond strength to the final product (e.g., insulating felt or board). Boron, which has electrons similar to aluminum in terms of valence, forms an insoluble gel when combined with PV in an aqueous medium. Surprisingly, it was found that combinations of aluminum salts (e.g., aluminum nitrate) and PV did not exhibit this gelation and in fact yielded aqueous mixtures suitable as adhesive compositions for application to glass fibers and mineral wool, even after the mixtures had been stored for a considerable period of time.

[0147] Despite the proposed interaction mechanism, and although the foregoing discussion pertains to the interaction between the adhesive of the present invention and the surface of the glass substrate, the adhesive composition of the present invention can similarly bond other materials (e.g., mineral wool or slag wool), including those without hydroxyl functional groups on their surfaces.

[0148] In some exemplary embodiments, the metal salt and the polyol are present in the aqueous adhesive composition in a specific weight ratio. In some exemplary embodiments, the metal salt and the polyol are present in the adhesive composition in a weight ratio of 1:99 to 1:1. In some exemplary embodiments, the metal salt and the polyol are present in the adhesive composition in a weight ratio of 1:50 to 1:1. In some exemplary embodiments, the metal salt and the polyol are present in the adhesive composition in a weight ratio of 1:20 to 1:1. In some exemplary embodiments, the metal salt and the polyol are present in the adhesive composition in a weight ratio of 1:10 to 1:1. In some exemplary embodiments, the metal salt and the polyol are present in the adhesive composition in a weight ratio of 1:9 to 1:1. In some exemplary embodiments, the metal salt and the polyol are present in the adhesive composition in a weight ratio of 1:4 to 1:1. In some exemplary embodiments, the metal salt and the polyol are present in the adhesive composition in a weight ratio of 3:7 to 1:1. In some exemplary embodiments, the metal salt and the polyol are present in the adhesive composition in a weight ratio of 2:3 to 1:1. In some exemplary embodiments, the metal salt and the polyol are present in the adhesive composition in a weight ratio of 1:4 to 3:7. In some exemplary embodiments, the metal salt and the polyol are present in the adhesive composition in a weight ratio of 1:4 to 2:3.

[0149] In some exemplary embodiments, the binder composition is present in the fiber insulation product or nonwoven mat at a loss on ignition (LOI) of 1%–25%. The term loss on ignition refers to a method of heating the product to pyrolyze the binder, thereby removing combustible materials. For example, fiber insulation products can be prepared according to some of the methods described herein. The product is then subjected to high heat to remove any pyrolyzable materials, leaving, for example, the glass fiber substrate and any materials that may not be expected to pyrolyze. The weight lost in this process is then reported as a percentage of the product's original weight (i.e., LOI). In some exemplary embodiments, the loss on ignition value is corrected after the primary measurement to account for non-combustible materials, such as metal salts from the binder.

[0150] In some exemplary embodiments, the adhesive composition may optionally contain additional components, including but not limited to one or more of the following: a secondary adhesive composition, a crosslinking agent, a coupling agent, a moisture-proofing agent, a dust suppressant, a catalyst, an inorganic acid or base, and an organic acid or base. The adhesive composition does not contain added formaldehyde and is therefore generally more environmentally friendly than similar formaldehyde-containing adhesives.

[0151] Additionally, in some exemplary embodiments, the binder may optionally contain conventional additives, such as, but not limited to, one or more of the following: preservatives, dyes, pigments, fillers, colorants, UV stabilizers, heat stabilizers, defoamers, antioxidants, emulsifiers, preservatives (e.g., sodium benzoate), biocides, and fungicides. Other additives may be added to the binder composition to improve processing and product performance. Such additives include lubricants, wetting agents, surfactants, antistatic agents, and / or waterproofing agents. Additives may be present in the binder composition in trace amounts (e.g., < about 0.1 wt% of the total solids in the binder composition) up to about 10 wt%. In some embodiments, additives are present in amounts ranging from about 0.1 wt% to about 5 wt%, about 1 wt% to about 4 wt%, or about 1.5 wt% to about 3 wt% of the total solids in the binder composition.

[0152] The adhesive composition further includes water to dissolve or disperse the active solids for application to the fibers. Water may be added in a sufficient amount to dilute the aqueous adhesive composition to a viscosity suitable for its application to the fibers and to achieve the desired solids content on the fibers. Specifically, the adhesive composition may contain water in an amount of approximately 50% to approximately 98% by weight of the adhesive composition. In some exemplary embodiments, the adhesive composition contains water in an amount of more than 60% by weight of the adhesive composition. In some exemplary embodiments, the adhesive composition contains water in an amount of more than 70% by weight of the adhesive composition. In some exemplary embodiments, the adhesive composition contains water in an amount of more than 80% by weight of the adhesive composition. In some exemplary embodiments, the adhesive composition contains water in an amount of more than 90% by weight (including 90% to 97% by weight of the adhesive composition).

[0153] In one exemplary embodiment, the adhesive composition is used to form an insulating product. Generally, fiber-based insulating products are formed from padded inorganic fibers (e.g., glass fibers) bonded together by a cured thermosetting polymer material. Examples of suitable inorganic fibers include glass wool, asbestos, slag wool, mineral wool, and ceramics. Alternatively, other reinforcing fibers such as natural and / or synthetic fibers (e.g., carbon fiber, polyester, polyethylene, polyethylene terephthalate, polypropylene, polyamide, aramid, and / or polyaramid fibers) may be present in the insulating product to combine with or replace them, for example, glass fibers or mineral wool. The term "natural fiber" as used herein refers to plant fibers extracted from any part of a plant, including but not limited to stems, seeds, leaves, roots, or phloem. Insulating products may be formed entirely of one type of fiber, or they may be formed from a combination of two or more different types of fibers. For example, insulating products may be formed from combinations of various types of glass fibers or various combinations of different inorganic fibers and / or natural fibers, depending on the desired application of the insulation. The embodiments described herein refer to insulating products formed entirely of glass fibers.

[0154] The manufacture of glass fiber insulation can be carried out in a continuous process as follows: molten glass is fiberized, glass fiber mat is immediately formed on a moving conveyor belt, and the binder on the glass fiber mat is cured to form an insulating blanket. Glass can be melted in a tank and fed into fiber-forming equipment, such as a fiber spinning machine. The spinning machine is rotated at high speed. Centrifugal force forces the molten glass through holes in the circumferential sidewalls of the fiber spinning machine to form glass fibers. Glass fibers of random length can be thinned from the fiber spinning machine and are typically blown downwards by a blower located in the forming chamber. The blower deflects the fibers downwards to form a fiber mat. Those skilled in the art will understand that glass fibers can have various diameters based on the intended application of the final product.

[0155] The aqueous binder composition of the present invention is sprayed onto glass fibers that are still in the forming chamber during transport and are still hot from the drawing operation. Water can also be applied to the glass fibers in the forming chamber.

[0156] Glass fibers with uncured resin adhesive adhered to them can be gathered on the molding conveyor in the molding chamber and formed into uncured insulating packaging by means of a vacuum drawn from below the molding conveyor through the fiber packaging.

[0157] The coated fibrous pack, compressed by the airflow passing through it in the forming chamber, is then transferred from the forming chamber to a transfer zone where it expands vertically due to the elasticity of the glass fibers. The expanded insulating pack is then heated in a curing oven, where heated air is blown through it to evaporate any remaining water in the adhesive, curing the adhesive and rigidly bonding the fibers together. The insulating pack can be compressed to form a fiber insulation blanket. Needless to say, the insulation blanket has an upper surface and a lower surface. In some embodiments, the pack can be compressed to any of a variety of densities.

[0158] The facing material can then be placed on the insulating blanket to form a facing layer. Non-limiting examples of suitable facing materials include kraft paper, foil-scrim-Kraft paper laminate, recycled paper, and calendared paper. The facing material can be bonded to the surface of the insulating blanket with an adhesive to form a facing insulation product. Suitable adhesives include adhesives, polymer resins, asphalt, and bituminous materials, which can be coated or additionally applied to the facing material. The facing fiber insulation can then be rolled up for storage and / or shipment. In some embodiments, the facing fiber insulation can be cut to predetermined lengths using a cutting device before packaging. Such facing insulation products can, for example, be used as panels in a substrate finishing system, as pipe wraps, pipe sheets, as facing residential insulation, and as pipe insulation.

[0159] In one exemplary embodiment, the binder composition of the present invention can be used to form a nonwoven mat. Specifically, the binder is added during the chopped fiber mat formation process in a wet-laid mat processing line. Chopped glass fibers can be supplied from a storage container to a conveying device for transport to a mixing tank under stirring containing various surfactants, viscosity modifiers, defoamers, and / or other chemical reagents to disperse the fibers and form a chopped glass fiber slurry. The glass fiber slurry can be transferred to a headbox, where the slurry is deposited onto a conveying device such as a moving screen or a perforated conveyor, and most of the water from the slurry is removed to form a web of entangled fibers (fiber mat). In some exemplary embodiments, water can be removed from the web using a conventional vacuum or suction system. It will be understood that while glass fiber or glass wool is referred to herein, the fiber mat can be formed from or include non-glass fibers such as mineral wool. Those skilled in the art will appreciate that while insulating products incorporating materials other than glass fiber will involve certain necessary changes in the details of forming the insulating product, these changes will remain within the overall inventive concept described herein.

[0160] The adhesive of the present invention is applied to the web using a suitable adhesive applicator, such as a sprayer or curtain coater. Once the adhesive has been applied to the mat, the adhesive-coated mat is passed through at least one drying oven to remove any remaining water and cure the adhesive composition. The molded nonwoven mat emerging from the drying oven is an assembly of randomly oriented, dispersed individual glass fibers. The chopped filament mat can be wound onto winding rollers for storage for later use. Exemplary applications of the nonwoven mat include, but are not limited to, roofing, flooring, ceiling, and wall applications, as a filter, and in ground vehicles and aircraft.

[0161] Although the invention has been generally described, further understanding can be obtained by referring to certain specific embodiments described below. These embodiments are provided for illustrative purposes only and are not intended to be exhaustive or limiting, unless otherwise specified.

[0162] Example

[0163] Example 1:

[0164] A binder composition comprising a mixture of polyvinyl alcohol (PV) and aluminum chloride (AlCl3) (collectively referred to as PVAl) in a weight ratio of 90:10 was compared with a control binder composition (MDCA) comprising a mixture of maltodextrin and citric acid in a weight ratio of 70:30 (including 3.5% sodium hypophosphite). Unless otherwise specified, the total solids of all binder compositions remained constant. The binder was used to form handmade paper as described in detail below. The nonwoven glass fiber handmade paper was dried and cured at 475°F for 3 minutes. Tensile strength, LOI, and tensile strength divided by corrected LOI (tensile strength / corrected LOI) were determined for each sample under ambient conditions and heat / humidity conditions, and the results are presented. Figure 1 The LOI (Lower Intake) of reinforcing fibers is the reduction in their weight after heating the glass fiber product to a temperature sufficient to cause the organic portion of the binder derived from the fibers to burn or pyrolyze. Corrected LOI corrects for the presence of aluminum salts from the binder that are not expected to pyrolyze. The hot / humid conditions involved placing the samples in an autoclave at 90°F and 90% humidity for 30 minutes. These results confirm that the binder of the present invention, comprising polyvinyl alcohol and aluminum chloride, can prepare effective glass fiber binders.

[0165] Example 2:

[0166] Figure 2 The results of tensile strength measurements on handmade paper made with several binder compositions are shown. The diagram shows the results for first and second control binders at the top and bottom. PV and AlCl3 (90:10) are compared with several binders comprising polyvinyl alcohol and aluminum nitrate Al(NO3)3 (i.e., 90:10, 85:15, and 80:20). The handmade paper was cured at 400°F for 3 minutes. The samples were then tested according to the procedure described in Example 1. Figure 2 The data provided indicate that the binder composition combining polyvinyl alcohol and aluminum salt achieves good performance on handmade paper.

[0167] Example 3:

[0168] Figure 3 This is a graph showing the dynamic mechanical analysis of polyvinyl alcohol (PVOH) itself and an adhesive containing PV and Al(NO3)3 at a weight ratio of 70:30 (70-30PVAl) compared to a control MDCA adhesive (containing 3.5% sodium hypophosphite). As can be seen from the graph, the adhesive of the present invention performs significantly better than polyvinyl alcohol itself and is similar to the control adhesive. Figure 3 The data presented in the study concluded that the binder composition combining polyvinyl alcohol and aluminum salts achieved good performance for dynamic mechanical analysis.

[0169] Example 4:

[0170] Figure 4 This is a graph showing the dynamic mechanical analysis of an adhesive containing PV and AlCl3 at a weight ratio of 70:30 (labeled as 70-30 chloride) compared to a control MDCA adhesive. As can be seen from the graph, the adhesive of the present invention exhibits similar behavior to the control adhesive.

[0171] Example 5:

[0172] Figure 5 This is a graph showing the dynamic mechanical analysis of three binder compositions containing PV and Al(NO3)3 in weight ratios of 70:30, 80:20, and 90:10, respectively. The graph shows the improvement in storage modulus with increasing Al(NO3)3 content.

[0173] Example 6:

[0174] Figure 6 This is a graph showing the dynamic mechanical analysis of three binder compositions containing PV and aluminum sulfate (Al2(SO4)3) at weight ratios of 70:30, 80:20, and 90:10. The graph shows the improvement in storage modulus with increasing Al2(SO4)3 content.

[0175] Example 7:

[0176] Figure 7 This shows the recovery percentages of two binder compositions (PVAl) containing PV and Al(NO3)3 at weight ratios of 90:10 and 80:20, respectively, compared to polyvinyl alcohol itself (labeled as 100PV) and the control MDCA binder. The recovery percentages were determined under ambient conditions and under heat / humid conditions. The heat / humid conditions consisted of placing the samples in a humidity chamber at 90°F and 90% humidity for 7 days. Under ambient conditions, the recovery percentages of the PV-containing binders were similar to or better than those of the control binder. Increasing the aluminum salt content improved the heat / humidity performance.

[0177] Example 8:

[0178] Figure 8 This study shows the recovery percentage of a binder composition containing PV along with several aluminum salts compared to a control MDCA binder under both ambient and hot / humid conditions. The aluminum salts are aluminum chloride (70:30 PV:Al weight ratio), aluminum nitrate (80:20 and 70:30 PV:Al weight ratios), and aluminum sulfate (80:20 and 70:30 weight ratios). The recovery percentages were determined under both ambient and hot / humid conditions. The hot / humid conditions consisted of placing the sample in a humidity chamber at 90°F and 90% humidity for 7 days. Figure 8 The data provided indicate that these binder formulations achieve good performance in terms of recovery percentage.

[0179] Example 9:

[0180] The corrosion of mechanical equipment used to form, for example, fiber insulation products is an important factor to consider when comparing adhesive systems. The pH value of an adhesive system indicates its potential to corrode metal mechanical equipment. Furthermore, the pH value of an adhesive system can change during heating (curing) because components (e.g., acids in the adhesive) can be consumed during curing, resulting in a less acidic final composition. Table 1 shows the measured pH values ​​of several adhesive systems in triplicate. The initial pH value is the pH value of the adhesive solution before spraying in the application method. The final pH value is the pH value of the solution generated by immersing the test material in water after curing. The less acidic curing of the adhesive system of the present invention indicates a lower potential for machine corrosion.

[0181] Table 1

[0182]

[0183] Example 10:

[0184] Figure 9 This is a graph showing the maximum measured load capacity of the two adhesive systems of the present invention for LOI correction adjustment. The maximum load was measured under ambient conditions and under hot / humid conditions (as described for Example 1). The adhesive systems of the present invention comprise PVAl(NO3)3 in weight ratios of 90:10 and 80:20, respectively. The adhesive compositions of the present invention are compared with a control phenolic resin (labeled PUF) and polyvinyl alcohol itself. All adhesive systems are normalized for total solids. The 80:20 weight ratio PVAl(NO3)3 performed as well as or better than the control adhesive system.

[0185] Example 11:

[0186] Figure 10 This is a diagram showing the corrected LOI of the adhesive system used in Example 10.

[0187] Example 12:

[0188] Handmade paper was formed using two PV aluminum salt binders in a 70:30 weight ratio. The handmade paper was formed using binders including Al(NO3)3 or Al2(SO4)3 and cured at temperatures of 250°F, 300°F, 350°F, 400°F, and 450°F. Figure 11 The tensile strength of handmade paper under environmental conditions and hot / humid conditions (as described for Example 1) is shown.

[0189] Example 13:

[0190] Figure 12The measured tensile strength of the handmade paper described in Example 12 is shown, along with the tensile strength corrected for the measured LOI.

[0191] Example 14:

[0192] Figure 13 This is a graph showing the measured LOI of the handmade paper described in Example 12. From Figure 12 , Figure 13 and Figure 14 The data provided in the paper indicate that these binder formulations achieve good performance on handmade paper at the lower temperatures typically used in exemplary manufacturing methods.

[0193] Example 15:

[0194] Figure 14 This is a graph showing the recovery percentages of two adhesive systems at different curing temperatures. The adhesive composition, containing PVAl(NO3)3 in a 70:30 weight ratio, was cured at 300°F, 350°F, and 400°F. The adhesive of the present invention was compared with a control MDCA adhesive cured at 300°F and 400°F. The recovery percentages were measured under environmental conditions and heat / humidity conditions. The heat / humidity conditions included placing the samples in a humidity chamber at 90°F and 90% humidity for 3 days.

[0195] Example 16:

[0196] Figure 15 The percentage of adhesive recovery tested in Example 14 is shown compared with the percentage of recovery normalized by area weight.

[0197] Example 17:

[0198] Figure 16 This shows the corrected LOI of the adhesive tested in Example 14. From Figure 14 , Figure 15 and Figure 16 The data presented in the study concludes that these adhesive formulations achieve good performance in terms of recovery percentage even when correcting for LOI at low (300°F) and high (400°F) curing temperatures, while MDCA only maintains its performance at high curing temperatures.

[0199] Example 18:

[0200] R-15 insulating felt is manufactured using several adhesive compositions in a manner known to those skilled in the art. Figure 17This is a graph showing the measured stiffness (angular deflection) of the insulating felt under environmental and thermal / humid conditions. Thermal / humid conditions included placing the sample in an autoclave at 90°F and 90% humidity for 3 days. The adhesive composition was cured at a target LOI of 4.65% at either high temperature (415-425°F, measured in the felt) or low temperature (350-360°F, measured in the felt). The adhesive composition of the present invention was compared with control MDCA adhesive, a mixture of PAG (polyacrylate / glycerol) and PVAl2(SO4)3, and a mixture of PAG (polyacrylate / glycerol) and PVAl2(SO4)3.

[0201] Example 19:

[0202] The bond strength of the insulating felt made with the adhesive composition described in Example 18 was measured. The results are shown in Figure 18 The bond strength was measured under environmental and thermal / humid conditions. The thermal / humid conditions included placing the sample in an autoclave at 90°F and 90% humidity for 3 days.

[0203] Example 20:

[0204] Figure 19 This is a graph showing the measured tensile strength of an insulating felt made with the adhesive composition described in Example 18. The tensile strength was measured under ambient conditions and hot / humid conditions. The hot / humid conditions included placing the sample in an autoclave at 90°F and 90% humidity for 3 days.

[0205] Example 21:

[0206] The average percentage loss on ignition was measured and corrected for the weight of the aluminum salts in the insulating felt described in Example 18. The results are shown in Table 2. The target LOI is 4.65%.

[0207] Table 2

[0208]

[0209] Example 22:

[0210] The amount of moisture absorbed by fiber insulation products is an important measure of the loss of insulating capacity over time. Moisture adsorption of the insulating felt described in Example 18 was measured. The measured moisture adsorption of the samples is shown in Table 3. All samples were below the target value of 5% moisture adsorption.

[0211] Table 3

[0212]

[0213]

[0214] Example 23:

[0215] The insulating felt samples described in Example 18 were subjected to corrosion tests according to the ASTM C665 method. According to this standard, the three PVOH:Al(NO3)3 adhesive compositions demonstrated acceptable corrosion performance. Data provided in Examples 18-23 indicate that the adhesive compositions of the present invention can cure under typical manufacturing conditions and achieve product performance as good as adhesives used in fiber insulation products.

[0216] Example 24:

[0217] Handmade paper was manufactured using various binder compositions. The binder composition of the present invention (labeled PVA), containing PV and aluminum chloride at a weight ratio of 90:10, was compared with a control MDCA binder composition. The nonwoven glass fiber handmade paper was dried and cured at 475°F for 3 minutes. The tensile strength of each sample was determined under ambient conditions and heat / humidity conditions, and the results are presented. Figure 20 Medium. Hot / humid conditions include placing the sample in an autoclave at 90°F and 90% humidity for 30 minutes.

[0218] Example 25:

[0219] Handmade paper was manufactured using a binder composition (labeled PVA) containing PV and aluminum chloride at a weight ratio of 90:10 and cured at various temperatures. The tensile strength of each sample was determined under ambient conditions and hot / humid conditions. The hot / humid conditions involved placing the samples in an autoclave at 90°F and 90% humidity for 30 minutes. Results are provided in... Figure 21 middle.

[0220] Example 26:

[0221] The results of Example 25 were adjusted for LOI correction. The measured tensile strength / LOI results are shown in... Figure 22 middle.

[0222] Example 27:

[0223] Handmade paper was manufactured using various binder compositions. The binder composition of the present invention (labeled PVA), containing PV and aluminum chloride in a 90:10 weight ratio, was compared with a control MDCA binder composition. Other formulations included MDCAPV = maltodextrin, citric acid, and polyvinyl alcohol; PVCA = polyvinyl alcohol and citric acid; and PVSi = polyvinyl alcohol and sodium silicate. The nonwoven glass fiber handmade paper was dried and cured at 425°F for 3 minutes. The tensile strength of each sample was determined under ambient and heat / humid conditions. The tensile strength was then corrected for LOI. The heat / humid conditions included placing the samples in an autoclave at 90°F and 90% humidity for 30 minutes. The results are shown in… Figure 23 middle.

[0224] Example 28:

[0225] Figure 24 This is a graph showing the measured stiffness of the adhesive composition of the present invention compared to the control MDCA adhesive and two additional adhesives including polyvinyl alcohol, namely polyvinyl alcohol, gallic acid, aluminum chloride (labeled PVGAAl) and polyvinyl alcohol, gallic acid, ferric nitrate (labeled PVGAFe).

[0226] Example 29:

[0227] The average LOI of the adhesive compositions tested in Example 28 is shown in Figure 25 middle.

[0228] Example 30:

[0229] The percentage of adhesive recovery described in Example 28 is shown in Figure 26 middle.

[0230] Examples 31-38:

[0231] A series of binder formulations were prepared for side-by-side testing of various properties. The binders were applied to mineral wool to prepare a lightweight felt (i.e., 3 lbs / ft). 3 -4lbs / ft 3 Table 4 shows the composition of the adhesive and the corresponding flow rate of the adhesive during application.

[0232] Table 4

[0233]

[0234] Flow rate refers to the rate (gallons per minute) of water sprayed during the set point. Inc fan refers to the increase in airflow rate through the insulation pack during curing. Additives A and B are included in SP6 and SP6A, respectively, as processing aids to improve the processing and flow of the binder formulation.

[0235] Example 31:

[0236] Figure 27 This is a diagram showing the measured sag of the eight mineral wool felts described in Table 4. The felt dimensions are as follows: length = 48”, width = 16”, thickness = 3”. Sag was measured as follows: each end of the felt was supported and the deviation (in inches) of the midpoint of the felt was measured. The heat / humidity conditions were 3 days at 90°F and 90% relative humidity.

[0237] Example 32:

[0238] Peel strength is a measure of the force required to pull apart a cured felt. Figure 28 This is a graph showing the measured peel strength of the eight mineral wool felts described in Table 4.

[0239] Example 33:

[0240] Resilience is determined as follows: Measure the thickness of the felt, compress it under a certain load for a given period of time under environmental or hot / humid conditions, remove the load, and measure the thickness again. Divide the compressed thickness by the initial thickness and multiply by 100 to give the % resilience. Resilience is similar to restoring force, but for light-density felts. Figure 29 This is a graph showing the measured resilience of the eight mineral wool felts described in Table 4.

[0241] Example 34:

[0242] Compressive strength is the amount of force (lbs / ft) required to compress a felt to 10% of its height. 2 ). Figure 30 This is a graph showing the measured compressive strength of the eight mineral wool felts described in Table 4.

[0243] Example 35:

[0244] Figure 31 This is a graph showing the amount of binder solids for the eight binders described in Table 4.

[0245] Example 36:

[0246] Some adhesive systems are known to behave differently after storage. Generally, adhesive premixes are known to have a shorter shelf life. Figure 32This is a diagram showing the tensile strength of mineral wool handmade paper prepared using a 70:30 PV / Al(NO3)3 binder system applied at 20% and 25% after storage. As can be seen from the diagram, the binder system of the present invention shows little or no performance degradation after two months.

[0247] Example 37:

[0248] Figure 33 This is a graph showing the tensile strength of mineral wool handmade paper prepared using the PV / Al(NO3)3 binder system after storage. The tensile strength is corrected for the amount of binder (measured by loss on ignition).

[0249] Example 38:

[0250] Dynamic mechanical analysis (DMA) of films formed from binder formulations is a helpful indicator for estimating the glass transition temperature (Tg) of the film. A shift in Tg towards higher temperatures indicates crosslinking. Figure 34 This is a drawing of the DMA of the film formed by PVOH itself. Figure 35 This is a DMA plot of the PV / Al(NO3)3 binder. The addition of Al(NO3)3 shifts the Tg of the film toward higher temperatures. Figure 36 This is a plot of the DMA of PV / KNO3. Replacing aluminum with potassium results in a Tg closer to that of the PVOH film. Similar measurements were performed by adding phosphoric acid to simulate acidic conditions. This also did not perform as well as the PV / Al(NO3)3 binder system. These results all indicate the necessary role of aluminum in the overall performance of the binder system.

[0251] As can be seen from the examples, the adhesive compositions of the present invention can be used to prepare insulating products that, in some cases, meet or exceed the performance of conventional adhesive systems. In some cases, lowering the curing temperature provides products with qualitative improvements, but does not demonstrate statistically significant performance changes. The addition of processing aids such as polyethylene glycol and glycerin improves product performance in some tests. Overall, the adhesive systems of the present invention do not sacrifice performance when tested under hot / humid conditions.

[0252] The general inventive concept has been described above in terms of both general and specific embodiments. While some preferred embodiments have been described, various alternatives known to those skilled in the art can be chosen within the broader disclosure. The invention is not limited except as set forth in the claims below.

Claims

1. An aqueous adhesive composition for forming fiber insulation and nonwoven mats, said adhesive composition comprising: water; Metal salts selected from aluminum chloride, aluminum nitrate, aluminum sulfate, aluminum and zirconium complexes and combinations thereof; and polyols containing polyvinyl alcohol; The metal salt and the polyvinyl alcohol are present in a weight ratio of 1:99 to 1:1, and the polyvinyl alcohol is at least 50% hydrolyzed. The adhesive composition is cured to form a network containing the metal salt.

2. The aqueous binder composition of claim 1, wherein the weight ratio of the metal salt to the polyol is in the range of 1:19 to 1:

1.

3. The aqueous binder composition of claim 2, wherein the weight ratio of the metal salt to the polyol is in the range of 1:9 to 1:

1.

4. The aqueous adhesive composition of claim 1, wherein the metal salt is aluminum chloride.

5. The aqueous adhesive composition of claim 1, wherein the metal salt is aluminum nitrate.

6. The aqueous adhesive composition of claim 1, wherein the polyvinyl alcohol has a viscosity of 3-5 centipoise.

7. The aqueous adhesive composition of claim 1, wherein the aqueous adhesive composition comprises: Metal salts selected from aluminum chloride and aluminum nitrate; Polyvinyl alcohol, and The weight ratio of the metal salt to the polyol is in the range of 1:19 to 1:

1.

8. An aqueous adhesive composition for forming fiber insulation and nonwoven mats, said aqueous adhesive composition comprising: water; Metal salts selected from aluminum chloride, aluminum nitrate, aluminum sulfate, aluminum and zirconium complexes and combinations thereof; and polyols containing polyvinyl alcohol, wherein the polyvinyl alcohol is at least 75% hydrolyzed; The metal salt and the polyvinyl alcohol are present in a weight ratio of 1:19 to 1:1, and The adhesive composition is cured to form a network containing the metal salt.

9. The aqueous adhesive composition of claim 8, wherein the polyvinyl alcohol is at least 90% hydrolyzed.

10. The aqueous adhesive composition of claim 8, wherein the polyvinyl alcohol is at least 98% hydrolyzed.

11. The aqueous adhesive composition of claim 8, wherein the aqueous adhesive composition comprises: Metal salts selected from aluminum chloride and aluminum nitrate; and Polyvinyl alcohol.

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