Additives for binder compositions used in fibrous insulation products

Abstract

This invention discloses a low-contact viscosity aqueous adhesive composition comprising at least 30.0 wt% of a polymer crosslinker containing at least two carboxylic acid groups based on the total solids content of the adhesive composition; 10.0 wt% to 50.0 wt% of a polyol having at least two hydroxyl groups based on the total solids content of the adhesive composition, wherein the polyol comprises sugar alcohols, alkanolamines, pentaerythritol, or mixtures thereof; 1.5 wt% to 15.0 wt% of an additive blend containing one or more processing aids based on the total solids content of the adhesive composition; and 0 to 3.0 wt% of a silane coupling agent based on the total solids content of the adhesive composition. The aqueous adhesive composition has an uncured pH between 4.0 and 7.0 and an uncured peak tack of no more than 80 g at 60% adhesive solids.

Description

[0001] Cross-references to related applications

[0002] This application claims priority and any rights to U.S. Provisional Application No. 63 / 086,271, filed October 1, 2020, the contents of which are incorporated herein by reference in their entirety.

[0003] background

[0004] Aqueous binder compositions are commonly used to form woven and nonwoven fiber products, such as insulation products, composite products, wood fiberboard, etc. Insulation products, such as those formed from inorganic fibers, are typically manufactured by fiberizing a glass or mineral-based molten composition and spinning the fibers from a fiberizing device such as a rotary spinneret. To form the insulation product, the fibers produced by the rotary spinneret are drawn down from the spinneret by a blower onto a conveyor belt. As the fibers move downward, a binder material is sprayed onto the fibers, and the fibers are collected into a high-loft, continuous blanket on the conveyor belt. The binder material imparts elasticity to the insulation product after packaging and provides stiffness and handleability, allowing the insulation product to be handled and applied as needed in the insulation cavities of buildings. The binder composition also protects the fibers from interfilament abrasion and promotes compatibility between the individual fibers. The blanket containing the binder-coated fibers then passes through a curing oven, where the binder is cured to achieve the desired thickness.

[0005] After the adhesive has cured, the fiber insulation material can be cut to length to form individual insulation products, which can then be packaged for shipment to customer locations. Insulation products prepared in this way can be supplied in various forms, including fleece, blankets, and boards (heat- and compressed fleece) for different applications.

[0006] Mineral fiber products typically contain man-made glass fibers (MMVF), such as glass fiber, ceramic fiber, basalt fiber, slag wool, mineral wool, and asbestos, which are bonded together by polymer binder compositions. Traditional binder compositions used for mineral fiber insulation materials, particularly certain mineral wool insulation materials, are based on phenolic (PF) resins and urea-replenished PF resins (PUF resins). However, while such binder compositions provide suitable properties for insulation products, formaldehyde binders release undesirable emissions during manufacturing, and there has been a growing desire to eliminate the use of formaldehyde-based binders.

[0007] As alternatives to formaldehyde-based adhesives, certain formaldehyde-free compounding agents have been developed for use as adhesives in insulation products. Such formaldehyde-free compounding agents may include polycarboxylic acids and polyhydroxy components intended for crosslinking via esterification. Such polycarboxylic acid-based adhesive compositions are often acidic, with a pH less than 5. However, mineral wool fibers are highly alkaline, with higher concentrations of divalent and trivalent metal oxides than other inorganic fibers such as glass fibers. Therefore, the polycarboxylic acid groups in conventional adhesive compositions irreversibly react with the metal oxides of the mineral wool fibers during application, preventing the acidic groups from being used for esterification with polyhydroxy crosslinking agents. Consequently, acidic adhesives often lack the strength of PF adhesives when used with mineral wool, and products formed from them exhibit insufficient performance.

[0008] Furthermore, formaldehyde-free binder compositions tend to be viscous and have contact tack that can cause problems on the production line. For example, contact tack of binder-coated fibers on a ramp within the production line can cause the fibers to stick to the ramp, resulting in defects in downstream insulation products when removed from the processing equipment. Previous attempts to reduce binder contact tack (e.g., by increasing binder moisture content) have produced highly hydrophilic insulation products with increased and unacceptable levels of water absorption.

[0009] Therefore, there is a need for non-acidic, formaldehyde-free binder compositions for the production of fiber insulation products, which have reduced contact tack while improving hydrophobicity and overall insulation product performance.

[0010] Overview

[0011] Various exemplary aspects of the present invention relate to low-tack aqueous adhesive compositions comprising at least 30.0 wt% of a polymer crosslinker containing at least two carboxylic acid groups based on the total solids content of the adhesive composition; 10.0 wt% to 50.0 wt% of a polyol having at least two hydroxyl groups based on the total solids content of the adhesive composition, wherein the polyol comprises sugar alcohols, alkanolamines, pentaerythritol, or mixtures thereof; 1.5 wt% to 15.0 wt% of an additive blend containing one or more processing aids based on the total solids content of the adhesive composition; and 0 to 3.0 wt% of a silane coupling agent based on the total solids content of the adhesive composition. The aqueous adhesive composition is free of added formaldehyde. In any embodiment disclosed herein, the aqueous adhesive composition may have an uncured pH between 4.0 and 7.0 and an uncured peak tack of no more than 80 g at 60% adhesive solids.

[0012] In any exemplary embodiment, the processing aid may comprise surfactants, glycerin, 1,2,4-butanetriol, 1,4-butanediol, 1,2-propanediol, 1,3-propanediol, polyethylene glycol, polyethylene glycol monooleate, polysiloxane, polydimethylsiloxane, mineral oil, paraffin oil or vegetable oil, wax, hydrophobic silica or ammonium phosphate, or mixtures thereof.

[0013] In any exemplary embodiment, the additive blend comprises at least two processing aids.

[0014] In any exemplary embodiment, the additive blend may contain glycerol in an amount of 5.0% to 15.0% by weight, based on the total solids content of the binder composition.

[0015] In any exemplary embodiment, the additive blend may contain 0.5% to 2.0% by weight of a silane coupling agent, based on the total solids content of the binder composition.

[0016] In any exemplary embodiment, the additive blend may comprise 7.0% to 12% by weight of glycerol and 0.5% to 5.0% by weight of polydimethylsiloxane, based on the total solids content of the binder composition.

[0017] In any exemplary embodiment, the sugar alcohol may comprise glycerol, erythritol, arbitol, xylitol, sorbitol, maltitol, mannitol, idutol, isomaltitol, lactitol, cellobiol, isomaltitol, maltitol, syrups thereof, or mixtures thereof.

[0018] In any exemplary embodiment, the polymer crosslinking agent may comprise a homopolymer or copolymer of acrylic acid.

[0019] In any exemplary embodiment, the composition may comprise: 50% to 85% of a polymeric carboxylic acid having at least two carboxylic acid groups, based on the total solids content of the binder composition; 1.5% to 15% by weight of an additive blend, based on the total solids content of the binder composition, wherein the additive blend comprises one or more of the following: 6.5% to 13.0% by weight of glycerol based on the total solids content of the binder composition, and 1.2% to 3.5% by weight of polydimethylsiloxane based on the total solids content of the binder composition; and 0.5% to 3.0% by weight of a silane coupling agent.

[0020] Another exemplary aspect of the present invention relates to a fiber insulation product comprising a plurality of randomly oriented fibers and a crosslinked, formaldehyde-free adhesive composition at least partially coated with the fibers. Prior to crosslinking, the adhesive composition has an uncured pH between 4.0 and 7.0 and comprises an aqueous composition comprising: at least 30% by weight of a polymeric crosslinking agent containing at least two carboxylic acid groups based on the total solids content of the adhesive composition; 10.0% to 50.0% by weight of a polyol having at least two hydroxyl groups based on the total solids content of the adhesive composition, wherein the polyol comprises sugar alcohols, alkanolamines, pentaerythritol, or mixtures thereof; 1.5% to 15.0% by weight of an additive blend containing one or more processing aids based on the total solids content of the adhesive composition; and 0 to 3.0% by weight of a silane coupling agent, wherein the aqueous adhesive composition is free of added formaldehyde. In any exemplary embodiment, the fiber product has a longitudinal tensile strength between 3.0 kPa and 8 kPa at a LOI of 2.4% or less, as determined according to EN1608.

[0021] In any exemplary embodiment, the processing aid may comprise one or more of the following: surfactant, glycerin, 1,2,4-butanetriol, 1,4-butanediol, 1,2-propanediol, 1,3-propanediol, polyethylene glycol, polyethylene glycol monooleate, polysiloxane, polydimethylsiloxane, mineral oil, paraffin oil or vegetable oil, wax, hydrophobic silica or ammonium phosphate.

[0022] In any exemplary embodiment, the processing aid may comprise one or more of glycerol or polydimethylsiloxane.

[0023] In any exemplary embodiment, the additive blend may contain at least two processing aids.

[0024] In any exemplary embodiment, the additive blend may contain glycerol in an amount of 5.0% to 15% by weight based on the total solids content of the binder composition.

[0025] In any exemplary embodiment, the additive blend may contain 0.5% to 2.0% by weight of a silane coupling agent, based on the total solids content of the binder composition.

[0026] The fiber insulation products may include mineral wool insulation products or glass fiber insulation products.

[0027] In any exemplary embodiment, the bottom surface of the insulation product can exhibit 0.2 kg / m² after 1 day. 2 Or even less water absorption, as determined according to EN1609.

[0028] In any exemplary embodiment, the fiber product may have a compressive strength of at least 1.0 kPa at a LOI of 2.4% or lower.

[0029] Another exemplary aspect of the present invention relates to a method for producing a fiber insulation product with reduced product tackiness, the method comprising applying an aqueous adhesive composition to a plurality of fibers, collecting the fibers onto a substrate to form an adhesive-injected fiber package; and curing the adhesive-injected fiber package. The aqueous adhesive composition comprises an additive blend of 1.5 wt% to 15.0 wt% solids, comprising one or more processing aids selected from the group consisting of: surfactants, glycerol, 1,2,4-butanetriol, 1,4-butanediol, 1,2-propanediol, 1,3-propanediol, polyethylene glycol, polyethylene glycol monooleate, polysiloxane, polydimethylsiloxane, mineral oil, paraffin oil or vegetable oil, wax, hydrophobic silica, ammonium phosphate, or mixtures thereof; and 0.5 wt% to 3.0 wt% silane coupling agent. Prior to curing, the aqueous adhesive composition may have a peak tack of no more than 80 g at 60% adhesive solids.

[0030] In any exemplary embodiment, the fiber insulation product may have a longitudinal tensile strength between 3.0 kPa and 8 kPa at a LOI of 2.4% or less, as determined according to EN1608.

[0031] The above method may further include the step of applying a silane coupling agent to the plurality of fibers before collecting the fibers onto the substrate.

[0032] In any exemplary embodiment, the additive blend comprises at least two processing aids.

[0033] Another exemplary aspect of the present invention relates to a formaldehyde-free aqueous adhesive composition having reduced contact tack, comprising: at least 30% by weight of a polymeric polycarboxylic acid crosslinker comprising at least two carboxylic acid groups based on the total solids content of the aqueous adhesive composition; 10.0% to 50.0% by weight of a polyol comprising at least two hydroxyl groups based on the total solids content of the aqueous adhesive composition, wherein the polyol comprises sugar alcohols, alkanolamines, pentaerythritol, or mixtures thereof; 1.5% to 15.0% by weight of an additive blend based on the total solids content of the aqueous adhesive composition, the additive blend comprising one or more processing aids; and 0.5% to 3.0% by weight of a silane coupling agent based on the total solids content of the aqueous adhesive composition.

[0034] In any exemplary embodiment, the aqueous adhesive composition may have an uncured pH between 4 and 7 and an uncured peak tack of no more than 80 grams at 60% adhesive solids.

[0035] Many other aspects, advantages, and / or features of the general concept of the invention will become more readily apparent from the following detailed description of exemplary embodiments and from the accompanying drawings.

[0036] Brief description of the attached figures

[0037] The overall inventive concept, its illustrative embodiments, and advantages are described in more detail below with reference to examples and accompanying drawings, wherein:

[0038] Figure 1 An exemplary esterification reaction is shown, resulting in limited crosslinking due to the formation of a carboxylic acid metal complex between mineral wool fibers and unprotected carboxylic acids.

[0039] Figure 2 An exemplary esterification reaction with a partially protected carboxylic acid-based binder is shown.

[0040] Figure 3 An exemplary method for producing the mineral wool product of the present invention is shown.

[0041] Figure 4 A graphical overview of the methods provided in this paper for measuring the contact tack of adhesives is shown.

[0042] Figure 5 The illustrations show the contact tack test results for various exemplary adhesive compositions.

[0043] Detailed description

[0044] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which these exemplary embodiments pertain. The terminology used in the description herein is for descriptive purposes only and is not intended to limit the exemplary embodiments. Therefore, the general inventive concept is not intended to be limited to the specific embodiments illustrated herein. While other methods and materials similar to or equivalent to those described herein may be used in the practice or testing of the invention, preferred methods and materials are described herein.

[0045] The singular forms “a,” “an,” and “the” used in this specification and the appended claims are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0046] The term "substantially free of" means that the composition comprises less than 1.0% by weight of the component, including no more than 0.8% by weight, no more than 0.6% by weight, no more than 0.4% by weight, no more than 0.2% by weight, no more than 0.1% by weight, and no more than 0.05% by weight. In any exemplary embodiment, "substantially free of" means that the composition comprises no more than 0.01% by weight of the component.

[0047] Unless otherwise specified, all figures representing amounts of components, chemical and molecular properties, reaction conditions, etc., as used in the specification and claims should be understood to be modified by the term "about" in all cases. Therefore, unless otherwise stated, the numerical parameters given in the specification and appended claims are approximations and can vary depending on the desired performance sought to be obtained by the exemplary embodiments of the invention. Each numerical parameter should be interpreted, at least in terms of the number of significant figures and common rounding techniques.

[0048] Unless otherwise specified, any element, property, feature, or combination of elements, properties, and features may be used in any embodiment disclosed herein, whether or not such element, property, feature, or combination of elements, properties, and features is explicitly disclosed in said embodiment. It is readily understood that features described with respect to any particular aspect described herein may be applied to other aspects described herein, provided that the feature is compatible with that aspect. In particular, features described herein with respect to methods may be applied to fiber products and vice versa; features described herein with respect to methods may be applied to aqueous adhesive compositions and vice versa; and features described herein with respect to fiber products may be applied to aqueous adhesive compositions and vice versa.

[0049] Each numerical range given throughout the specification and claims will include every narrower numerical range falling within such a wider range, as if such narrower numerical ranges were explicitly stated herein.

[0050] This disclosure relates to formaldehyde-free or "formaldehyde-free" aqueous adhesive compositions for use with inorganic fibers such as glass fibers or mineral wool fibers. The terms "adhesive composition," "aqueous adhesive composition," "adhesive compound," "adhesive," and "adhesive system" as used herein are used interchangeably and are synonymous. Additionally, the terms "formaldehyde-free" or "formaldehyde-free" as used herein are used interchangeably and are synonymous.

[0051] The adhesive composition can be used to manufacture fiber insulation products and related products, such as fiber-reinforced mats, thin coverings, nonwovens, etc. (hereinafter collectively referred to as fiber products). The adhesive composition is particularly useful for asbestos or mineral wool products made with the cured adhesive composition, such as mineral wool insulation products. Other products may include composite material products, wood fiberboard products, metal building insulation materials, pipe insulation materials, ceilings, roofing tiles, "high-density" products such as board products (including, for example, ceilings, pipe boards, floor boards, pipe and tank insulation materials, sound-absorbing boards, sound-insulating boards, general-purpose board products, pipe linings) and "light-density" products (including, for example, residential insulation materials, pipe wrapping materials, metal building insulation materials, flexible pipe media). Other fiber products include nonwoven fiber mats and particleboard, and composite material products made therefrom.

[0052] This invention relates to improved formaldehyde-free adhesive compositions for manufacturing insulating products, particularly fiber-insulated products. Due to the inclusion of novel additive blends, these adhesive compositions exhibit improved processability, hydrophobicity, and product performance.

[0053] Suitable fibers for use in the fiber products of this disclosure include, but are not limited to, mineral fibers (e.g., mineral wool, rock wool, asbestos, slag wool, etc.), glass fibers, carbon fibers, ceramic fibers, natural fibers, and synthetic fibers. In some exemplary embodiments, the plurality of randomly oriented fibers are mineral wool fibers, including but not limited to mineral wool fibers, rock wool fibers, slag wool fibers, asbestos fibers, or combinations thereof.

[0054] The fiber insulation products may be formed entirely of one type of fiber, or they may be formed of a combination of two or more types of fibers. For example, depending on the desired application, the insulation products may be formed of a combination of various types of mineral fibers or various combinations of different inorganic fibers and / or natural fibers. In some exemplary embodiments, the insulation products are formed entirely of mineral wool fibers.

[0055] Compared to glass fiber used in the manufacture of insulation products, mineral wool typically contains a higher percentage of divalent and trivalent metal oxides. Table 1 provides typical glass wool formulation ranges and typical asbestos (or mineral wool) formulation ranges. See Guldberg, Marianne, et al. “The Development of Glass and Stone Wool Compositions with Increased Biosolubility” Regulatory Toxicology and Pharmacology 32, 184-189 (2000). As shown below, glass wool has a total weight percentage of no more than 25% by weight of divalent and trivalent oxides (CaO / MgO / Al2O3 / FeO). In contrast, mineral wool or asbestos contains at least 25% by weight of divalent and trivalent metal oxides, or in some cases more than 30% by weight, and in some cases at least 50% by weight of divalent and trivalent metal oxides. Such metal oxides (especially aluminum oxides) have a strong tendency to complex with acidic functional groups such as carboxylic acids, which inhibits the wetting of the binder on the fibers and prevents sufficient esterification and crosslinking. Therefore, conventional acidic formaldehyde-free binders used in the manufacture of glass fiber insulation exhibit reduced performance when used with mineral wool fibers.

[0056] Table 1

[0057]

[0058] The binder composition is typically applied to the fibers in the form of an aqueous solution or dispersion shortly after fiber formation, and then cured at elevated temperatures. As used herein, “dispersion” includes all forms of solids dispersed in a liquid medium, regardless of particle size or the nature of the dispersion, including true “solutions” in which the solids are soluble and dissolved in the liquid medium. The curing conditions of the binder composition are chosen to evaporate any residual solvent and cure the binder to a thermosetting state. The resulting product often has fibers at least partially coated with a thin layer of thermosetting resin, and exhibits accumulation of the binder composition at points where fibers meet or are closely adjacent to each other.

[0059] Previous methods for reducing the contact tack of formaldehyde-free adhesive compositions involved adding moisture, which increased the moisture content of the adhesive by up to 50%. However, this increase in moisture content makes it difficult to fully cure the insulation product under conventional curing conditions. Additionally, increasing the moisture content of the adhesive composition increases its hydrophilicity, which can cause problems. Therefore, an alternative method is needed for reducing the contact tack of formaldehyde-free adhesive compositions that does not lead to incomplete curing or increased water absorption levels.

[0060] Therefore, a novel additive blend containing one or more processing additives has been surprisingly discovered that improves the processability of the adhesive composition by reducing the contact tack of the binder, thereby producing a more uniform insulating product with increased tensile strength and hydrophobicity. While various additives may exist that can reduce the contact tack of the adhesive composition, conventional additives are inherently hydrophilic, meaning that including such additives would increase the overall water absorption of the adhesive composition.

[0061] Therefore, the novel additive blend provides a precise balance between reduced adhesive contact tack and improved hydrophobicity of the insulating product formed using the adhesive composition. This additive blend also provides improved overall tensile strength of the insulating product compared to insulating products manufactured using adhesive compositions that are otherwise equivalent without the novel additive blend.

[0062] As mentioned above, the additive blend may contain one or more processing additives. Examples of processing additives include surfactants, 1,2,4-butanetriol, 1,4-butanediol, 1,2-propanediol, 1,3-propanediol, and polyethylene glycol (e.g., Carbowax). TM Dispersions of polyethylene glycol monooleate (MOPEG), polysiloxanes, and polydimethylsiloxane (PDMS); emulsions and / or dispersions of mineral oils, paraffin oils, or vegetable oils; waxes such as amide waxes (e.g., ethylene bis-stearamide (EBS)) and carnauba wax (e.g., ML-155); hydrophobic silica; ammonium phosphate; short-chain acids (i.e., monomeric acids or acids with a molecular weight less than 1000 Daltons) such as succinic acid, glutaric acid, maleic acid, citric acid, 1,2,3,4-butanetetracarboxylic acid, adipic acid, etc. Short-chain alcohols (i.e., alcohols with a molecular weight less than 2000 Daltons, including those less than 750 Daltons, 500 Daltons, 250 Daltons, 200 Daltons, or 175 Daltons) such as glycerol, erythritol, aritol, xylitol, sorbitol, maltitol, mannitol, idotitol, isomaltitol, lactitol, cellobitol, palatinitol, maltotriol, their syrups, etc.), or combinations thereof. The surfactant may include nonionic surfactants, including nonionic surfactants having alcohol functional groups. Exemplary surfactants include... Alkyl polyglucosides (e.g.) ) and alcohol ethoxides (e.g. ).

[0063] In any of the embodiments disclosed herein, the additive blend may comprise 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 herein, the additive blend comprises a mixture of glycerol and polydimethylsiloxane.

[0064] The additive blend may be present in the adhesive composition in amounts of 1.0 wt% to 20 wt%, 1.25 wt% to 17.0 wt%, 1.5 wt% to 15.0 wt%, about 3.0 wt% to 12.0 wt%, or 5.0 wt% to 10.0 wt%, based on the total solids content of the adhesive composition. In any exemplary embodiment, the adhesive composition may contain at least 7.0 wt% (including at least 8.0 wt% and at least 9 wt%) of the additive blend, based on the total solids content of the adhesive composition. Therefore, in any exemplary embodiment, the aqueous adhesive composition may contain 7.0 wt% to 15 wt% (including 8.0 wt% to 13.5 wt% and 9.0 wt% to 12.5 wt%) of the additive blend, based on the total solids content of the adhesive composition.

[0065] In embodiments where the additive blend 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 exemplary embodiment, the binder composition may comprise 5.0% by weight to 15% by weight of glycerol, including 6.5% by weight to 13.0% by weight, 7.0% by weight to 12.0% by weight, and 7.5% by weight to 11.0% by weight of glycerol, based on the total solids content of the binder composition.

[0066] In embodiments where the additive blend comprises polydimethylsiloxane, the polydimethylsiloxane may be present in an amount of at least 0.2 wt%, or at least 0.5 wt%, or at least 0.8 wt%, or at least 1.0 wt%, or at least 1.5 wt%, or at least 2.0 wt%, based on the total solids content of the adhesive composition. In any exemplary embodiment, the adhesive composition may comprise 0.5 wt% to 5.0 wt% of polydimethylsiloxane, including 1.0 wt% to 4.0 wt%, 1.2 wt% to 3.5 wt%, 1.5 wt% to 3.0 wt%, and 1.6 wt% to 2.3 wt% of polydimethylsiloxane, based on the total solids content of the adhesive composition.

[0067] In any of the embodiments disclosed herein, the additive blend may comprise a mixture of glycerol and polydimethylsiloxane, wherein the glycerol comprises 5.0% to 15% by weight of the adhesive composition and the polydimethylsiloxane comprises 0.5% to 5.0% by weight of the adhesive composition, based on the total solids content of the adhesive composition. In any of the embodiments disclosed herein, the additive blend may comprise a mixture of glycerol and polydimethylsiloxane, wherein the glycerol comprises 7.0% to 12% by weight of the adhesive composition and the polydimethylsiloxane comprises 1.2% to 3.5% by weight of the adhesive composition, based on the total solids content of the adhesive composition.

[0068] In any of the embodiments disclosed herein, the additive blend may contain an increased concentration of silane coupling agent. Conventional binder compositions typically contain 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. Higher silane concentrations are generally associated with glass fiber products compared to mineral wool, as glass fibers are more hydrophilic than mineral wool, and therefore silanes both protect glass fibers from moisture and improve hydrophobicity. However, mineral wool is more hydrophobic than glass fibers and therefore does not require silanes to protect the fibers from moisture. Instead, silanes are typically included at lower levels in the manufacture of mineral wool insulation compared to glass fibers. However, it has been surprisingly found that an increased silane concentration (at least 0.5%) in mineral wool products based on the total solids content of the binder composition is beneficial for improving the tensile strength of insulation products made from it. Therefore, in any of the embodiments disclosed herein, the silane coupling agent may be present in the adhesive composition in an amount of 0.5% to 5.0% by weight (including about 0.7% to 2.5% by weight, 0.85% to 2.0% by weight, or 0.95% to 1.5% by weight) of the total solids in the adhesive composition. In any of the embodiments disclosed herein, the silane coupling agent may be present in the adhesive composition in an amount of up to 1.0% by weight.

[0069] Silane concentration can also be characterized by the amount of silane on the fibers in fiber insulation products. Typically, glass fiber insulation products contain between 0.001 wt% and 0.03 wt% of silane coupling agent on the glass fibers. However, by increasing the amount of silane coupling agent applied to the fibers, the amount of silane on the glass fibers increases to at least 0.10 wt%. For mineral wool insulation products, the amount of silane on the fibers is typically between about 0.0006 wt% and about 0.0015 wt% at a 0.3% LOI, and typically between about 0.01 wt% and 0.02 wt% at a 5% LOI. By increasing the amount of silane coupling agent applied to the fibers, the amount of silane on the fibers increases to at least 0.003 wt% at a 0.3% LOI and to at least 0.05 wt% at a 5% LOI.

[0070] Alternatively, or in addition to including the additive blend or silane coupling agent in the binder composition, the additive blend and / or silane may be added separately from the binder composition to the fiber and / or processing line. For example, the additive blend and / or silane coupling agent may be sprayed onto the fibers before or after the application of the binder composition, prior to the fibers contacting the conveyor belt.

[0071] Alternatively, the adhesive composition may contain a conventional amount of silane coupling agent, if present. In such an embodiment, the silane coupling agent may be present in the adhesive composition in an amount ranging from 0 to less than 0.5% by weight (including 0.05% to 0.4% by weight, 0.1% to 0.35% by weight, or 0.15% to 0.3% by weight) of the total solids in the adhesive composition.

[0072] Non-limiting examples of silane coupling agents that can be used in the adhesive compositions may be characterized by functional groups such as alkyl, aryl, amino, epoxy, vinyl, methacryloxy, urea, isocyanate, and mercapto. In some exemplary embodiments, the silane coupling agent comprises a silane containing one or more nitrogen atoms having one or more functional groups such as amines (primary, secondary, tertiary, and quaternary amines), amino, imino, amide, imide, urea, or isocyanate. Specific, 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), epoxytrialkoxysilanes (e.g., 3-glycidoxypropyltrimethoxysilane and 3-glycidoxypropyltriethoxysilane), methacryltrialkoxysilanes (e.g., 3-methacryloyloxypropyltrimethoxysilane and 3-methacryloyloxypropyltriethoxysilane), alkyltrialkoxysilanes, aminotrihydroxysilanes, epoxytrihydroxysilanes, methacryltrihydroxysilanes, and / or alkyltrihydroxysilanes. In one or more exemplary embodiments, the silane is an aminosilane, such as γ-aminopropyltriethoxysilane.

[0073] The additive blends described herein can be used in any conventional formaldehyde-free adhesive composition, such as the carboxylic acid-based adhesive composition described in U.S. Patent Application 2019 / 0106564 by Zhang et al., which teaches an aqueous adhesive composition comprising a polycarboxylic acid crosslinker, a short-chain polyol, and a long-chain polyol, and is incorporated herein by reference in its entirety. Another formaldehyde-free adhesive composition is disclosed in U.S. Patent 8,864,893 by Chen et al., which teaches an adhesive composition comprising at least one carbohydrate and at least one crosslinker, the entire contents of which are incorporated herein by reference. U.S. Patent Application 17 / 460,805 by Chen et al. discloses an aqueous adhesive composition comprising a crosslinker containing at least two carboxylic acid groups, a polyol component containing at least two hydroxyl groups, and a nitrogen-based protecting agent, the entire contents of which are incorporated herein by reference. Typically, formaldehyde-free adhesive compositions comprising polycarboxylic acid crosslinkers are acidic in nature, which is acceptable for use with glass fibers; however, such acidic adhesive compositions are generally incompatible with mineral wool.

[0074] Although the additive blends mentioned above can be used in any formaldehyde-free adhesive composition, exemplary adhesive compositions are provided below in more detail.

[0075] In any of the embodiments disclosed herein, the binder composition may include a crosslinking agent suitable for crosslinking with a polyol component via an esterification reaction. In any exemplary embodiment, the crosslinking agent may have a number average molecular weight greater than 90 Daltons, for example, from about 90 Daltons to about 10,000 Daltons, or from about 190 Daltons to about 5,000 Daltons. In any exemplary embodiment, the crosslinking agent has a number average molecular weight of about 2,000 Daltons to 5,000 Daltons or about 4,000 Daltons.

[0076] Non-limiting examples of suitable crosslinking agents include materials having one or more carboxylic acid groups (-COOH), such as monomeric and polymeric polycarboxylic acids, including their salts or anhydrides, and mixtures thereof. In any exemplary embodiment, the polycarboxylic acid may be a polymeric polycarboxylic acid, such as a homopolymer or copolymer of acrylic acid. Non-limiting examples of suitable crosslinking agents include dicarboxylic acids, tricarboxylic acids, and polycarboxylic acids (and their salts), anhydrides, monomeric and polymeric polycarboxylic acids, malonic acid, succinic acid, glutaric acid, maleic acid, citric acid (including its salts such as ammonium citrate), 1,2,3,4-butanetetracarboxylic acid, adipic acid, and mixtures thereof. Polymeric polycarboxylic acids may comprise polyacrylic acid (including its salts or anhydrides) and polyacrylic acid-based resins, such as QR-1629S and Acumer 9932 (both commercially available from The Dow Chemical Company), polyacrylic acid compositions (commercially available from CH Polymer), and polyacrylic acid compositions (commercially available from Coatex). Acumer 9932 is a polyacrylic acid / sodium hypophosphite resin having a molecular weight of about 4000 and a sodium hypophosphite content of 6-7% by weight based on the total weight of the polyacrylic acid / sodium hypophosphite resin. QR-1629S is a polyacrylic acid / glycerol resin composition. For each type of acid, it should be understood that an acid salt can also be used instead of the acid. It should also be understood that mixtures or blends of two or more different polycarboxylic acids can be used.

[0077] In any of the exemplary embodiments disclosed herein, the crosslinking agent may be present in the adhesive composition in an amount of at least 25.0% by weight (including, but not limited to, at least 30% by weight, at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 54% by weight, at least 56% by weight, at least 58% by weight, at least 60% by weight, at least 62% by weight, at least 64% by weight, at least 66% by weight, at least 68% by weight, and at least 70% by weight) based on the total solids content of the adhesive composition. In any of the embodiments disclosed herein, the crosslinking agent may be present in the adhesive composition in an amount of from 27% by weight to 87% by weight (including, but not limited to, from 30% by weight to 85% by weight, 50% by weight to 80% by weight, greater than 50% by weight to 78% by weight, including, but not limited to, from 59% by weight to 75% by weight, 61% by weight to 72% by weight, and 63% by weight to 70% by weight, including all endpoints and sub-combinations therein) based on the total solids content of the adhesive composition.

[0078] Optionally, a protective agent may be used to temporarily block all or a certain percentage of the acid functional groups in the polycarboxylic acid, temporarily preventing the acid functional groups from complexing with the mineral wool fibers. The protective agent is then removed during the curing process by heating the binder composition to a temperature of at least 150°C, releasing the acid functional groups to crosslink with the polyol component and complete the esterification process. In any exemplary embodiment, 10% to 100% of the carboxylic acid functional groups may be temporarily blocked by the protective agent, including about 25% to about 99%, about 30% to about 90%, and about 40% to 85%, including all subranges and combinations thereof. In any exemplary embodiment, at least 40% of the acid functional groups may be temporarily blocked by the protective agent.

[0079] The protective agent is capable of reversibly binding to the carboxylic acid group of the crosslinking agent. In any exemplary embodiment, the protective agent comprises any compound containing a molecule capable of forming at least one reversible ionic bond with an acid functional group. In any exemplary embodiment disclosed herein, the protective agent may comprise a nitrogen-based protective agent, such as an ammonium-based protective agent, an amine-based protective agent, or a mixture thereof. Exemplary ammonium-based protective agents include ammonium hydroxide. Exemplary amine-based protective agents include alkylamines and diamines, such as ethyleneimine, ethylenediamine, 1,6-hexanediamine; alkanolamines, such as ethanolamine, diethanolamine, triethanolamine; ethylenediamine-N,N'-disuccinic acid (EDDS), ethylenediaminetetraacetic acid (EDTA), etc., or mixtures thereof. Furthermore, it has been surprisingly found that alkanolamines can function both as protective agents and as participants in the crosslinking reaction that forms esters in the cured adhesive. Thus, alkanolamines possess the dual function of a protective agent and a polyol for crosslinking with polycarboxylic acids via esterification reactions.

[0080] like Figure 1 As shown, without protection, the carboxylic acid groups in the polycarboxylic acid components will react with metal ions (Mg) in the mineral wool fibers. 2+ Al 3+ Ca 2+ Fe 3+ Fe 2+ This forms a carboxylic acid-metal complex. In such cases, when the adhesive composition cures, very limited amounts of polyol will crosslink with the carboxylic acid groups, resulting in weak adhesive properties. Conversely, Figure 2 The experiment demonstrates a pre-reaction of polycarboxylic acids with nitrogen-protecting agents such as ammonium hydroxide or amines. This pre-reaction temporarily prevents the acid functional groups from permanently reacting with metal ions. Upon curing of the binder, ammonia is released, thereby releasing the acid functional groups to react with polyols via esterification.

[0081] In contrast to conventional pH adjusters, the protectants defined herein only temporarily and reversibly block the acid functional groups in the polymer polycarboxylic acid component. Conversely, conventional pH adjusters such as sodium hydroxide permanently block acid functional groups, which prevents crosslinking between the acid and hydroxyl groups due to the blocked acid functional groups. Therefore, including conventional pH adjusters such as sodium hydroxide does not provide the desired effect of temporarily blocking acid functional groups and subsequently releasing those functional groups during the curing process to allow crosslinking via esterification. Therefore, in any of the exemplary embodiments disclosed herein, the binder composition may be free of or substantially free of conventional pH adjusters such as sodium hydroxide and potassium hydroxide. Such conventional pH adjusters for high-temperature applications will permanently bind to the carboxylic acid groups and will not release the carboxylic acid functional groups to allow crosslinking esterification reactions.

[0082] Furthermore, in addition to providing a temporary sealing function, the protective agent also raises the pH value of the binder composition to provide compatibility with the pH value of the mineral wool fibers. If the pH value of the binder composition is significantly lower than the pH value of the fibers, the binder composition can damage the mineral fibers, which will alter the composition and weaken the fibers. The function of the binder composition is to bind the fibers together and should not react with the fibers themselves.

[0083] The pH of the uncured adhesive composition can be adjusted according to the intended application to promote compatibility of the components of the adhesive composition or to function with various types of fibers. As mentioned above, in any of the exemplary embodiments disclosed herein, the adhesive composition has a pH of at least about 4 when in the uncured state. In such exemplary embodiments, the pH of the adhesive composition when in the uncured state can be about 4.0-7.0, including about 4.2-6.8 and about 4.5-6.5. After curing, the pH of the adhesive composition can rise to at least 6.5 and up to 8.5. In any of the exemplary embodiments disclosed herein, the cured pH of the adhesive composition is between 7.2 and 7.8.

[0084] The protective agent may be present in the adhesive composition in an amount of 0 to 50.0% by weight based on the total solids in the adhesive composition, including but not limited to amounts of 1.50% to 25.0% by weight or 2.5% to 15.5% by weight. In any exemplary embodiment disclosed herein, the protective agent may be present in the adhesive composition in an amount of at least 3.5% by weight, including amounts of at least 4.0% by weight, at least 5.0% by weight, at least 5.5% by weight, and at least 6.0% by weight. In any exemplary embodiment, the protective agent may be used in an amount sufficient to block at least 40% of the acid functional groups of the polycarboxylic acid.

[0085] In any exemplary embodiment, the adhesive composition comprises a carboxylic acid group to amine group ratio of about 6:1 to about 1:1 or about 4:1 to about 1.5:1.

[0086] In any exemplary embodiment, the adhesive composition further includes at least one polyol having two or more hydroxyl groups (also referred to herein as a polyhydroxy compound). In any exemplary embodiment, the polyol comprises one or more monomeric or polymeric polyhydroxy compounds.

[0087] In any exemplary embodiment, the polyol can be a monomeric compound, such as a sugar alcohol, pentaerythritol, alkanolamine, etc. A sugar alcohol should be understood as a compound obtained when the aldehyde or ketone group of a sugar is reduced (e.g., by hydrogenation) to the corresponding hydroxyl group. The starting sugar can be selected from monosaccharides, oligosaccharides, and polysaccharides, as well as 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 are very similar to their corresponding starting sugars, they are not sugars. Therefore, for example, sugar alcohols do not have reducing power and cannot participate in the Maillard reaction, which is typical for reducing sugars. In any exemplary embodiment, sugar alcohols include any one of glycerol, erythritol, araitol, xylitol, sorbitol, maltitol, mannitol, idoteol, isomaltitol, lactitol, cellobiol, palatiniol, maltotriol, syrups thereof, and mixtures thereof. In various exemplary embodiments, the sugar alcohol is selected from sorbitol, xylitol, and mixtures thereof. In any exemplary embodiment, the polyol may be a dimer or oligomerization condensation product of the sugar alcohol. In any exemplary embodiment, the condensation product of the sugar alcohol may be isosorbide. In any exemplary embodiment, the sugar alcohol may be a diol or a glycol.

[0088] In other embodiments, the polyol may be a synthetic or naturally occurring polymer, such as polyvinyl alcohol, polyglycerol, poly(ether) polyol, poly(ester) polyol, polyethylene glycol, polyols, and hydroxyl-functional acrylic resins in solution or emulsion form. (BASF Resins) (Cytec Industries) (Dow Coating Materials) and (NuplexResins, LLC); or disaccharides, trisaccharides and higher polysaccharides.

[0089] In any exemplary embodiment, the polyol comprises sorbitol, pentaerythritol, alkanolamines, mixtures thereof, or derivatives thereof. In any exemplary embodiment, the alkanolamine may comprise triethanolamine, or derivatives thereof. Therefore, in any exemplary embodiment, the polyol comprises one or more of the following: sorbitol, pentaerythritol, triethanolamine, derivatives thereof, or mixtures thereof.

[0090] In any exemplary embodiment, the polyol may include at least one carbohydrate of a natural and renewable source. For example, the carbohydrate may be derived from plant sources such as legumes, corn, maize, glutinous corn, sugarcane, sorghum, white sorghum, potatoes, sweet potatoes, cassava, rice, glutinous rice, peas, sago, wheat, oats, barley, rye, amaranth, and / or sweet cassava, as well as other plants with high starch content. The carbohydrate may also be derived from crude starch products, which are derived from plant residues containing proteins, peptides, lipids, and low molecular weight carbohydrates. The carbohydrate may be selected from monosaccharides (e.g., xylose, glucose, and fructose), disaccharides (e.g., sucrose, maltose, and lactose), oligosaccharides (e.g., glucose syrup and fructose syrup), and polysaccharides and water-soluble polysaccharides (e.g., pectin, dextrin, maltodextrin, starch, modified starch, and mixtures thereof).

[0091] The carbohydrate may be a carbohydrate polymer with a number-average molecular weight of about 1,000 to about 8,000. Additionally, the carbohydrate polymer may have a glucose equivalent (DE) number of 2 to 20, 7 to 11, or 9 to 14. In at least one exemplary embodiment, the carbohydrate is a water-soluble polysaccharide, such as dextrin or maltodextrin.

[0092] The polyol may be present in the adhesive composition in an amount of up to about 75% by weight or about 70% by weight of total solids, including but not limited to amounts of up to about 68% by weight, 65% by weight, 60% by weight, 55% by weight, 50% by weight, 45% by weight, 40% by weight, 35% by weight, 33% by weight, 30% by weight, 27% by weight, 25% by weight, and 20% by weight of total solids. In any exemplary embodiment, the polyol may be present in the adhesive composition in an amount of 2.0% by weight to 69.0% by weight of total solids, including but not limited to amounts of 5.0% to about 50%, 10% to 45%, 13% to 40%, 15% to 38%, 18% to 35%, 20% to 32%, 22% to 30%, and 17% to 27% by weight of total solids, including all endpoints and sub-combinations therebetween. In any exemplary embodiment, the polyol may be present in an amount providing a carboxylic acid group to hydroxyl group ratio of 10:1 to 0.2:1 or 3:1 to 0.5:1.

[0093] In any of the embodiments disclosed herein, the aqueous adhesive composition may be free of or substantially free of polyols containing fewer than three hydroxyl groups, or free of or substantially free of polyols containing fewer than four hydroxyl groups. In any of the embodiments disclosed herein, the aqueous adhesive composition is free of or substantially free of polyols with a number average molecular weight of 2,000 Daltons or more, for example, polyols with a molecular weight between 3,000 and 4,000 Daltons. Therefore, in any of the embodiments disclosed herein, the aqueous adhesive composition is free of or substantially free of diols such as glycols; triols such as glycerol and triethanolamine; and / or polymeric polyhydroxy compounds such as polyvinyl alcohol, partially or completely hydrolyzed polyvinyl acetate, or mixtures thereof.

[0094] In any exemplary embodiment, the adhesive composition may be free of reducing sugars. Reducing sugars are a type of carbohydrate or sugar that includes a free aldehyde or ketone group and is capable of donating an electron to another molecule. Because the adhesive composition does not contain reducing sugars, it cannot participate in the Maillard reaction (the process that occurs when a reducing sugar reacts with an amine). The Maillard reaction results in an adhesive composition with a brown color, which is undesirable for the subject adhesive composition.

[0095] Optionally, the binder composition may 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), Brønsted acids (i.e., sulfuric acid, p-toluenesulfonic acid, and boric acid), organometallic complexes (i.e., lithium carboxylate, sodium carboxylate), and / or Lewis bases (i.e., polyethyleneimine, diethylamine, or triethylamine). Additionally, the catalyst may include alkali metal salts of phosphorus-containing organic acids, particularly alkali metal salts of phosphorous acid, hypophosphite, 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 tetramethonium phosphate, and mixtures thereof. Furthermore, the catalyst or curing accelerator may be a fluoroborate compound, such as fluoroboric acid, sodium tetrafluoroborate, potassium tetrafluoroborate, calcium tetrafluoroborate, magnesium tetrafluoroborate, zinc tetrafluoroborate, ammonium tetrafluoroborate, and mixtures thereof. Furthermore, the catalyst may be a mixture of phosphorus and fluoroborate compounds. Other sodium salts, such as sodium sulfate, sodium nitrate, and sodium carbonate, can also be used as catalysts or alternatively as catalysts.

[0096] The catalyst may be present in the binder composition in an amount of about 0% to about 10% of the total solids in the binder composition, including but not limited to about 0% to about 5% by weight, or about 0.5% to about 4.5% by weight, or about 1.0% to about 4.0% by weight, or about 1.15% to about 3.8% by weight, or about 1.35% to about 2.5% by weight.

[0097] The adhesive composition may further include a surfactant, independent of or as a supplement to any surfactant included in the additive blend. The adhesive composition may include one or more surfactants to aid in adhesive atomization, wetting, and interfacial adhesion.

[0098] There are no particular limitations on the surfactants mentioned, and the surfactants include, but are not limited to, for example: ionic surfactants (e.g., sulfates, sulfonates, phosphates, and carboxylates); sulfates (e.g., alkyl sulfates, ammonium lauryl sulfate, sodium lauryl sulfate (SDS), alkyl ether sulfates, sodium lauryl polyether sulfate, and sodium tetradecyl polyether sulfate); amphoteric surfactants (e.g., alkyl betaines, such as lauryl betaine); sulfonates (e.g., sodium dioctyl succinate sulfonate, perfluorooctane sulfonate, perfluorobutane sulfonate, and alkylbenzene sulfonate); phosphates (e.g., alkyl aryl ether phosphates and alkyl ether phosphates); carboxylates ( Examples include alkyl carboxylates, fatty acid salts (soaps), sodium stearate, sodium lauroyl sarcosinate, fluorinated carboxylates, perfluorononanoates, and perfluorooctanoates; cationic surfactants (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, hexadecyltrimethylammonium bromide, hexadecyltrimethylammonium chloride, hexadecylpyridine chloride, and benzyl ammonium chloride); and zwitterionic surfactants, quaternary ammonium salts (e.g., lauryltrimethylammonium chloride and alkylbenzyldimethylammonium chloride), polyoxyethylene alkylamines, and mixtures thereof.

[0099] Suitable nonionic surfactants that can be used in conjunction with the adhesive composition include polyethers (e.g., ethylene oxide and propylene oxide condensates comprising linear and branched alkyl and alkylaryl polyethylene glycols and polypropylene glycol ethers and thioethers); alkylphenoxy poly(ethyleneoxy)ethanols having an alkyl group containing about 7 to about 18 carbon atoms and having about 4 to about 240 ethyleneoxy units (e.g., heptaylphenoxy poly(ethyleneoxy)ethanol and nonylphenoxy poly(ethyleneoxy)ethanol); polyoxyethylene derivatives of hexitols including sorbitol, desorbitol, demannitol, and desorbitol; and partially long-chain fatty acid esters (e.g., sorbitol monolaurate and sorbitol monopalmitate). Esters, polyoxyethylene derivatives of sorbitol monostearate, sorbitol tristearate, sorbitol monooleate, and sorbitol trioleate; condensates of ethylene oxide with a hydrophobic base formed by the condensation of propylene oxide with propylene glycol; sulfur-containing condensates (e.g., those prepared by condensing ethylene oxide with higher alkyl thiols such as nonyl, dodecyl, or tetradecyl thiols, or with alkylbenzene thiophenols wherein the alkyl group contains about 6 to about 15 carbon atoms); ethylene oxide derivatives of long-chain carboxylic acids (e.g., lauric acid, myristic acid, palmitic acid, and oleic acid such as tall oil fatty acids); ethylene oxide derivatives of long-chain alcohols (e.g., octanol, decanol, lauryl alcohol, or cetyl alcohol); and ethylene oxide / propylene oxide copolymers.

[0100] In any exemplary embodiment, the surfactant may include one or more of the following: Dynol 607 (which is 2,5,8,11-tetramethyl-6-dodecyne-5,8-diol), 420, 440 and 465 (these are ethoxylated 2,4,7,9-tetramethyl-5-decyn-4,7-diol surfactants (commercially available from Evonik Corporation (Allentown, Pa.)), Stanfax (a sodium lauryl sulfate), Surfynol465 (an ethoxylated 2,4,7,9-tetramethyl-5-decyn-4,7-diol), Triton TM GR-PG70 (sodium 1,4-bis(2-ethylhexyl)sulfosuccinate), and Triton TM CF-10(α-(phenylmethyl)-ω-(1,1,3,3-tetramethylbutyl)phenoxy-poly(oxy-1,2-ethylenedimethyl)).

[0101] The surfactant may be present in the adhesive composition in an amount of 0 to about 10% by weight, about 0.1% by weight to about 5.0% by weight, about 0.15% by weight to about 2.0% by weight, or about 0.2% by weight to 1.0% by weight, based on the total solids content in the adhesive composition.

[0102] Optionally, the binder composition may contain a dust suppressant to reduce or eliminate the presence of inorganic and / or organic particles that may adversely affect the subsequent manufacturing and installation of the insulation material. The dust suppressant may be any conventional mineral oil, mineral oil emulsion, natural or synthetic oil, bio-based oil, or lubricant, such as, but not limited to, polysiloxanes and polysiloxane emulsions with high flash points to minimize oil evaporation in the oven, polyethylene glycol, and any petroleum or non-petroleum oil.

[0103] In any exemplary embodiment, the adhesive composition may include up to about 10% by weight of a dust suppressant, including up to about 8% by weight or up to about 6% by weight. In any exemplary embodiment, the adhesive composition may include between 0 and 10% by weight of a dust suppressant, including about 1.0% by weight to about 7.0% by weight, or about 1.5% by weight to about 6.5% by weight, or about 2.0% by weight to about 6.0% by weight, or about 2.5% by weight to 5.8% by weight, based on the total solids content in the adhesive composition.

[0104] The adhesive composition further includes water to dissolve or disperse the active solids for application to the reinforcing fibers. Water may be added in an amount sufficient to dilute the adhesive composition to a viscosity suitable for its application to the reinforcing fibers and to achieve the desired solids content on the fibers. It has been found that the adhesive compositions of the present invention can contain lower solids content than conventional phenol-urea-formaldehyde or carbohydrate-based adhesive compositions. In particular, the adhesive composition may contain 3% to 35% by weight of adhesive solids, including but not limited to 10% to 30%, 12% to 20%, and 15% to 19% by weight of adhesive solids.

[0105] The binder content on a product can be measured as loss on ignition (LOI). In any exemplary embodiment, the LOI on the glass fibers forming the insulating product can be from 0.1% to 50%, including but not limited to 0.15% to 10%, 0.2% to 8%, and 0.3% to 5%.

[0106] In any exemplary embodiment, the adhesive composition may further include one or more additives, such as extenders, crosslinking density enhancers, deodorizers, antioxidants, microbial agents, moisture-proofing agents, or combinations thereof. Optionally, the adhesive may contain, but is not limited to, dyes, pigments, additional fillers, colorants, UV stabilizers, heat stabilizers, defoamers, emulsifiers, preservatives (e.g., sodium benzoate), corrosion inhibitors, and mixtures thereof. Other additives may be added to the adhesive composition to improve process and product performance. Additives may be present in the adhesive composition in trace amounts (e.g., less than about 0.1% by weight of the adhesive composition) to about 10% by weight of the total solids in the adhesive composition.

[0107] In any exemplary embodiment, the adhesive composition may be free of or substantially free of monomeric carboxylic acid components. Exemplary monomeric polycarboxylic acid components include aconitic acid, adipic acid, azelaic acid, butanetetracarboxylic acid dihydrate, butanetricarboxylic acid, chlorogenic anhydride, citraconic acid, citric acid, dicyclopentadiene-maleic acid adduct, diethylenetriaminepentaacetic acid pentasodium salt, dipentene and maleic anhydride adduct, methylene hexachlorophthalic anhydride, fully maleic acidified rosin, maleic acidified tall oil fatty acid, fumaric acid, glutaric acid, isophthalic acid, itaconic acid, maleic acidified rosin (unsaturated rosin is first oxidized to alcohol with potassium peroxide and then oxidized to carboxylic acid), malic acid, maleic anhydride, mesocarboxylic acid, oxalic acid, phthalic anhydride, polylactic acid, sebacic acid, succinic acid, tartaric acid, terephthalic acid, tetrabromophthalic anhydride, tetrachlorophthalic anhydride, tetrahydrophthalic anhydride, trimellitic anhydride, and pyromellitic acid.

[0108] The adhesive compositions disclosed herein can be used to manufacture fiber insulation products, such as glass fiber or mineral wool insulation products. Therefore, some aspects of the inventive concept also relate to methods for producing insulation products, including the step of contacting mineral wool and / or glass fiber with the adhesive compositions disclosed herein. The insulation product may include a finish on one or both of its main surfaces. The finish can be any type of finish substrate known in the art, such as nonwoven mats, foil mats, polymer surface mats, woven fabrics, etc.

[0109] Figure 3An exemplary method for producing the mineral wool product of the present invention is outlined. A melt of mineral raw materials is prepared in a pool 12, and the melt stream 14 descends into a spinning machine 16 (e.g., a centrifugal spinning machine), where the melt is fiberized and blown into a collection chamber 18, forming a mineral wool web on a collection belt 20. A binder composition may be applied to the mineral wool fibers before, during, or after the formation of the mineral wool web, by means of known methods, such as spraying. The binder-coated mineral wool web is then heated in a conventional curing oven to cure the binder-coated mineral wool web, thereby forming the mineral wool product. The mineral wool web may be compressed to obtain the desired final product thickness.

[0110] Curing can be carried out in a curing oven at normal temperatures, such as about 200°C to about 400°C, about 225°C to about 350°C, and about 230°C to about 300°C.

[0111] Fiber insulation products can be characterized and classified by many different properties, one of which is density. Density can range from approximately 3.2 kg / m³. 3 Up to approximately 350 kg / m 3 The range is wide, depending on the product. Low-density or light-density insulating fleece and insulating blankets typically have a density between approximately 3.2 kg / m². 3 Approximately 128.15 kg / m 3 The density between (more commonly about 4.8 kg / m³) 3 Approximately 64 kg / m 3 (The density), and has an application rate of approximately 0.1-5% LOI. Products such as residential insulation linings can belong to this group.

[0112] Fiber insulation products can be supplied in other forms for different applications, including sheets (heat- and compressed layers) and molded media (another form of heat- and compressed layers). Fiber insulation products also include those with a density of approximately 160 kg / m³. 3 Approximately 320.40 kg / m 3 Higher density products (typically with about 1%-5% binder LOI) and more typically with a density of about 16 kg / m³ 3 Approximately 160 kg / m 3 Medium-density products (with approximately 1%-5% binder LOI) such as boards and panels. Medium-density and higher-density insulation products can be used in industrial and / or commercial applications, including but not limited to metal building insulation, pipe or tank insulation, insulated ceilings and wall panels, roof panels, pipe panels and HVAC insulation, household appliance and automotive insulation, etc.

[0113] Another useful attribute for classification is the product's rigidity. Residential insulation layers are typically very flexible and can be compressed into rolls or layers while regaining their "fluff" upon decompression. This can be referred to as "recovery" in this context. In contrast, other fiber products such as ceiling, wall, floor, and certain pipe insulation materials are designed to be very stiff and inflexible. These products hardly bend and are unlikely to adapt to or conform to a particular space.

[0114] Molded or shaped products may include further steps, optionally during curing, that compress, shape, or mold the product to its specific final shape. Rigid sheets are a type of shaped product whose shape is planar. Other shapes can be formed using molds or dies or other forming equipment. Rigidity can be imparted by using higher-density fibers and / or by applying higher levels of binder. As an alternative to rotational fiberization, some fiber insulation products, particularly higher-density nonwoven insulation products, can be manufactured using pre-prepared glass fibers, mineral wool fibers, or polymer fibers via air-laid or wet-laid processes, where the fibers are randomly oriented and contacted with a binder to form the product.

[0115] "Product performance" or "mechanical properties" refers to the various testable physical properties of an insulating product. These properties may include at least the following common properties: "Resilience," which is the ability of a fleece or blanket to recover its original or designed thickness after being released from compression during packaging or storage. It can be tested by measuring the height of a product after compression with a known or expected nominal thickness, or by other suitable methods. "Stiffness" or "deflection," which refers to the ability of a fleece or blanket to maintain its rigidity and linear shape. It is measured by suspending a fixed length of the fleece over a fulcrum and measuring the range of angles of bending deflection or sag. Lower values ​​indicate stiffer and more desirable product performance. "Tensile strength," which is the force required to tear a fiber product in half. It is typically measured in the longitudinal direction (MD or X-axis) and transverse direction ("CD" or "XMD" or Y-axis); sometimes it is also measured in the depth or Z-axis direction. "Compressive strength," which is the force required to compress a fiber insulation product. This can be measured as the force required to compress a fleece (or packing) a predetermined distance, or as the distance compressed by a predetermined force. It can be measured in any of the three directions, just like tensile strength, but CD is the most typical.

[0116] Of course, other product performance characteristics can also be used to evaluate the final product, but the above-mentioned performance characteristics are those that consumers of insulation products consider important. Mechanical product performance can be tested relatively quickly after manufacturing—this time is referred to in this document as "initial" or "end of the production line." However, mechanical performance may degrade over time, so a more relevant test is one that measures "aged" mechanical performance. Aging can be natural, real-time aging over months or years. More typically, "aging" is simulated under surrogate, accelerated aging conditions, such as under heat and humidity testing conditions. While any form of aging will produce measurable "aged" performance, accelerated versions are reasonable surrogates that can be tested in days rather than months.

[0117] It should be understood that, to some extent, the absolute measurements of the performance of these mechanical products can depend on how much binder is applied to the fibers. Generally, denser and stiffer products are manufactured in part by using higher levels of binder. The measure of how much binder is applied to a fiber product is called LOI, or loss on ignition, which is measured by the weight difference after the organic binder component has been burned off.

[0118] Fiber insulation products manufactured according to the inventive concept exhibit improved performance compared to fiber insulation products formed with the same binder composition excluding the aforementioned additive blends. One such improved performance includes tensile strength under heat / humid conditions (65°C / 95% relative humidity), including tensile strength immediately after manufacturing (end of production line) and after aging.

[0119] For example, regarding the production of products based on the present invention, having an LOI of approximately 2.5%-3.7% and a density higher than 50 kg / m³, 3 Mineral wool insulation products of a certain density exhibit a tensile strength in the Y direction of at least 40 kPa (measured according to EN1607) immediately after manufacture and retain at least 50% of said tensile strength after 28 days under heat / humid conditions, including at least 53%, at least 55%, at least 58%, and at least 60% of said tensile strength. In any exemplary embodiment disclosed herein, mineral wool insulation products of the inventive concept having a LOI of about 2.5% to 3.7% may have a tensile strength in the Y direction of immediately after manufacture (measured according to EN1607) between 40 kPa and 80 kPa, including between 42 kPa and 75 kPa and between 45 kPa and 72 kPa.

[0120] Regarding the production based on the concept of the present invention, having an LOI of about 2.4% or less and 52 kg / m³ 3Mineral wool insulation products with a density of 3.0 kPa or less, exhibiting a longitudinal tensile strength of at least 3.0 kPa, for example, between 3.5 kPa and 8 kPa, between 3.8 kPa and 7.5 kPa, and between 4.0 kPa and 6.0 kPa, as measured according to EN1608. In the transverse direction, products manufactured according to the present invention have a LOI of about 2.4% or less and a tensile strength of 52 kg / m³. 3 Mineral wool insulation products of a certain density exhibit a tensile strength of at least 7.0 kPa, for example, between 7.5 kPa and 20 kPa, between 8.0 kPa and 15.0 kPa, and between 10.0 kPa and 14.0 kPa, as measured according to EN1608.

[0121] Compared to mineral wool insulation products formed with the same binder composition excluding the aforementioned additive blends, mineral wool insulation products produced according to the present invention also exhibit improved compressive strength. This compressive strength is measured and tested on samples using the standard EN826 test method. Mineral wool insulation board products formed according to the present invention, having a LOI of 2.5% to 3.7%, exhibit a compressive strength of at least 12 kPa (including at least 13 kPa and at least 15 kPa). Mineral wool insulation board products formed according to the present invention, having a LOI of 2.4% or less, exhibit a compressive strength of at least 1.0 kPa (including at least 1.3 kPa and at least 1.5 kPa).

[0122] Furthermore, compared to mineral wool insulation products formed using the same binder composition excluding the aforementioned additive blends, the mineral wool insulation products produced according to the present invention also exhibit reduced contact tack. The mineral wool insulation board products formed according to the present invention exhibit a peak tack of no more than 80 grams at 60% binder solids.

[0123] Although the adhesive composition exhibits reduced contact tack, this is achieved without sacrificing the hydrophobicity of the insulating product formed therefrom. The hydrophobicity of the insulating product is measured by the product's water absorption rate.

[0124] The invention has been generally described above, and a further understanding can be obtained by referring to certain specific embodiments illustrated below. These embodiments are provided for illustrative purposes only and are not intended to include all or all of them or to limit the scope of the invention, unless otherwise stated.

[0125] Example 1

[0126] Exemplary adhesive compositions were prepared, comprising novel additive blends and / or increased concentrations of silanes as described in Table 2. Comparative adhesive compositions comprising conventional amounts of silane (0.2 wt%) were also prepared (see Comparative Example 1 in Table 2). Each adhesive composition comprised a polyacrylic acid crosslinking agent, a polyol, and a sodium hypophosphite catalyst. Examples 1-6 and Comparative Example 1 also included a protective agent, which was first mixed with the polyacrylic acid crosslinking agent to form an adhesive premix. The adhesive premix was diluted with water and comprised various additives listed in Table 2 below to produce the final adhesive composition. Each exemplary adhesive composition is listed below:

[0127] Table 2

[0128]

[0129] The above-described binder composition was prepared and diluted to a specific LOI as described in detail below, and applied to the mineral wool at a throughput of 4.5 tons / hour through a typical mineral wool production line. Additional water was added via an injection system to minimize fiber adhesion to the collection conveyor belt. The primary mineral wool layer was cross-overlapped with other mineral wool layers to produce the desired product density, and then the mineral wool board was fed into a curing oven. The curing oven temperature was set to 250°C to 300°C.

[0130] Collect mineral wool board products and conduct comprehensive standard tests. The results provided in Tables 3-6 illustrate the improved performance of mineral wool products imparted by the binder compositions of the present invention containing protective agents, compared to the performance imparted by similar acidic binder compositions that do not contain such protective agents. Test methods for each performance are provided below.

[0131] Compressive strength at 10% strain: Sample preparation and testing were performed using the standard EN826 test method. The mineral wool board was 100 mm thick. The mineral wool board was placed centered between the two plates of an Instron or equivalent compression testing instrument. The sample was compressed using the instrument until 10% strain was reached to provide the compressive stress at 10% strain. The compressive strength at 10% strain was calculated according to the following equation:

[0132] σ m =103·F m / A0[kPa]*

[0133] *F 10 = Force [N] corresponding to -10% deformation

[0134] F m =Maximum force [N]

[0135] A0 = Initial cross-sectional area [m 2 ].

[0136] Swelling (%): The swelling potential of a product is determined using a pressure cooker (or autoclave). This treatment complements the behavior of the product stored in a tropical box and can indicate problems related to product aging in a shorter time. In a pressure cooker, the product is stored at 0.8–1 bar pressure and 121°C for 15 minutes (or in an autoclave at 2 bar and 134°C for 2.5 hours). Swelling (%) is the net increase in volume after treatment in a pressure cooker (or autoclave).

[0137] Water absorption rate (W) p (EN1609 and EN12087): Weigh a sample product with dimensions of 200 mm x 200 mm to determine the initial mass (m0) of the sample. Then place the sample on the water surface and apply weight so that the lower surface of the sample is 1 cm below the water surface. For short-term partial immersion, leave the sample in the water for 24 hours. For long-term partial immersion, leave the sample in the water for 28 days. Then dry the sample for 10 minutes and weigh it again to determine the final mass (m1) of the sample. The water absorption rate is the difference between the initial and final mass of the sample (Δm) divided by the bottom surface area of ​​the sample product (A(kg / m²)). 2 Therefore, the water absorption rate can be determined by the following formula:

[0138] W p = (m1-m0) / A.

[0139] Y-direction tensile strength (EN1607): Prepare a 100mm x 100mm Y-oriented sample product and glue plywood to both ends in the Y direction of the machine. Attach the sample to the tensile testing fixture and record the maximum force as the tensile strength. Test the sample product as follows: 1) at the end of the production line (EOL), 2) after aging and heat / humidity conditioning in a tropical chamber for 1 day, 3) after aging and heat / humidity conditioning in a tropical chamber for 7 days, and 4) after aging and heat / humidity conditioning in a tropical chamber for 28 days. Conditions in the tropical chamber include a temperature of 65°C and a relative humidity of 95%. The percentage of tensile strength retained after 28 days in the tropical chamber is listed as the retention % (tensile strength after 28 days divided by the end-of-production-line tensile strength).

[0140] Table 3

[0141]

[0142] As shown in Table 3, each of Examples 1-5 and 7-8 exhibited increased compressive strength compared to Comparative Example 1, which did not contain the additive blend or had an increased concentration of silane. Additionally, each of Examples 1-5 and 7-8 showed comparable or reduced water absorption at the top of the mineral wool board after 1 day (EN 1609) and 28 days (EN 12087). Furthermore, Examples 2 and 4, which included both a high concentration of silane (1.0 wt%) and 2.0 wt% PDMS, showed comparable or reduced water absorption at the bottom of the mineral wool board after 1 day and 28 days. Moreover, compared to Example 1, which included 1.0 wt% silane, Examples 2, 4, and 7, which included 1.0 wt% silane and 2.0 wt% PDMS, and Example 8, which included 1.0 wt% silane, 2.0 wt% PDMS, and 10 wt% glycerol, Comparative Example 1, which had a conventional concentration of silane (0.2 wt%) and did not contain the additive blend, showed high swelling (0.9%). Since the compositions do not contain polysiloxane (PDMS), Examples 3 and 5 show a slight increase in swelling.

[0143] Table 4

[0144]

[0145] As shown in Table 4, each of Examples 5 and 8, containing 1.0 wt% silane and 10 wt% glycerol, exhibited a significant improvement in tensile strength in both the Y and Z directions, starting from the end of the forming line and after 1 day and 28 days under heat / humid conditions. Additionally, although Examples 1 and 7 showed slightly lower tensile strength in the Y and Z directions at the end of the production line, both mineral wool boards maintained higher tensile strength after 1 day and 28 days under heat / humid conditions compared to Comparative Example 1. Examples 3 and 4 exhibited higher tensile strength in the Y direction at the end of the production line compared to Comparative Example 1, and maintained higher tensile strength in both the Y and Z directions after 1 day and 28 days under heat / humid conditions.

[0146] As shown in Table 5 below, the binder compositions from Examples 3-6 (see Table 2 for details) were diluted to 0.7%-2.4% LOI, then applied to mineral fibers and cured to produce densities between 39 and 52 kg / m³. 3 Mineral wool insulation products between. The samples described below by (a) or (b) indicate that the same binder composition was used under two different LOIs.

[0147] Table 5

[0148]

[0149] As shown in Table 5, each of Examples 3 and 4b-6 exhibits similar compressive strength compared to Example 4a, which has a low LOI of 0.7. Example 4 does not include glycerol, which contributes to the lower compressive strength at a low LOI (compared to Example 6a). Examples 4a and 6a show higher swelling, which is due to the low LOI. However, a swelling percentage below 20% is acceptable performance.

[0150] Table 6

[0151]

[0152] As shown in Table 6, Examples 4a and 6a, with an LOI of only 0.7%, exhibited relatively low tensile strength, but still demonstrated acceptable performance.

[0153] Example 2

[0154] Exemplary adhesive compositions comprising blends of various additives were prepared and applied to a glass fiber substrate to form an adhesive-injected glass fiber substrate (BIFS). The adhesive compositions are provided in Table 7 below.

[0155] Table 7

[0156]

[0157] The BIFS was analyzed to measure the contact tack of the substrate with the injected adhesive. To obtain results from the contact tack measuring instrument, the adhesive concentration needed to be increased from 31% to 60%. For this purpose, 5 grams of a 31% adhesive solution was applied to the glass fiber substrate. The adhesive-injected glass fiber substrate was then placed in a moisture balance at 140°C for 4 minutes and 30 seconds, which increased the adhesive solution concentration to approximately 60%. To initiate the contact tack test, the peak tack force of the BIFS was measured using a physical property analyzer (TA XTPlus). A stainless steel probe (TA-57R, 7 mm - 1”R) was lowered onto the sample at a speed of 0.5 mm / s and a force of 500 g was applied for 10 seconds, then removed at a speed of 10 mm / s.

[0158] like Figure 5 As shown, Comparative Example A exhibited a peak tack of approximately 124 g, while each of Examples A and B showed a reduction in peak tack. Additionally, each example comprising a blend of 10% additives showed a peak tack of less than approximately 100 g. Examples A, B, and F exhibited the lowest levels of contact tack, with peak tacks of approximately 64 g, approximately 40 g, and approximately 43 g, respectively.

[0159] The BIFS were then cured in an oven at 430°F and their water absorption was tested. Although the binder composition containing 10% MOPEG exhibited the lowest contact tack, the cured BIFS produced from it had high water absorption. In contrast, the BIFS produced using ML-155 wax (Examples C, D, and F) were highly water-resistant with a contact angle of approximately 90°.

[0160] It should be understood that many more detailed aspects of the products and methods illustrated are known in the art to a large extent, and these aspects have been omitted for the purpose of presenting the overall inventive concept concisely. Although the invention has been described in conjunction with specific means, materials and embodiments, those skilled in the art can readily identify the essential features of the invention from the foregoing description, and various changes and modifications can be made to suit various uses and characteristics without departing from the spirit and scope of the invention as described above and set forth in the appended claims.

[0161] The following paragraphs provide further exemplary implementations.

[0162] Paragraph 1. A low-contact, water-based adhesive composition comprising:

[0163] Based on the total solids content of the binder composition, at least 50.0% by weight of a polymer crosslinker containing at least two carboxylic acid groups;

[0164] Based on the total solids content of the adhesive composition, 10.0% to 35.0% by weight of a polyol having at least two hydroxyl groups, wherein the polyol comprises sugar alcohols, alkanolamines, pentaerythritol, or mixtures thereof;

[0165] Based on the total solids content of the adhesive composition, 1.5% to 15.0% by weight of an additive blend containing one or more processing aids; and

[0166] Based on the total solids content of the binder composition, 0 to 3.0% by weight of silane coupling agent,

[0167] The aqueous adhesive composition is free of added formaldehyde, and the aqueous adhesive composition has an uncured pH between 4.0 and 7.0, and has an uncured peak tack of no more than 80 grams at 60% adhesive solids.

[0168] Paragraph 2. The low-contact viscous aqueous adhesive composition described in Paragraph 1, wherein the processing aid comprises surfactants, glycerin, 1,2,4-butanetriol, 1,4-butanediol, 1,2-propanediol, 1,3-propanediol, polyethylene glycol, polyethylene glycol monooleate, polysiloxane, polydimethylsiloxane, mineral oil, paraffin oil or vegetable oil, wax, hydrophobic silica or ammonium phosphate, or mixtures thereof.

[0169] Paragraph 3. The low-contact viscous aqueous binder composition described in paragraph 1 or paragraph 2, wherein the processing aid comprises glycerol, polydimethylsiloxane, or a mixture thereof.

[0170] Paragraph 4. The low-contact tack aqueous binder composition described in any one of paragraphs 1 to 3, wherein the additive blend comprises at least two processing aids.

[0171] Paragraph 5. The low-contact viscous aqueous adhesive composition described in any one of paragraphs 1 to 4, wherein the additive blend comprises glycerol in an amount of 5.0% to 15.0% by weight, based on the total solids content of the adhesive composition.

[0172] Paragraph 6. The low-contact viscous aqueous adhesive composition described in any one of paragraphs 1 to 5, wherein the additive blend comprises 0.5% to 2.0% by weight of a silane coupling agent, based on the total solids content of the adhesive composition.

[0173] Paragraph 7. The low-contact viscous aqueous adhesive composition described in any one of paragraphs 1 to 6, wherein the additive blend comprises 7.0% to 12% by weight of glycerol and 0.5% to 5.0% by weight of polydimethylsiloxane, based on the total solids content of the adhesive composition.

[0174] Paragraph 8. The low-contact viscous aqueous adhesive composition described in any one of paragraphs 1 to 7, wherein the sugar alcohol comprises glycerol, erythritol, aritol, xylitol, sorbitol, maltitol, mannitol, idotitol, isomaltitol, lactitol, cellobiol, isomaltitol, maltitol, syrups thereof, or mixtures thereof.

[0175] Paragraph 9. The low-contact tack aqueous adhesive composition described in any of paragraphs 1 to 8, wherein the polymer crosslinking agent comprises a homopolymer or copolymer of acrylic acid.

[0176] Paragraph 10. The low-contact tack aqueous adhesive composition described in any one of paragraphs 1 to 9, wherein the composition comprises:

[0177] 50% to 85% of polyols having at least two hydroxyl groups, based on the total solids content of the binder composition;

[0178] 1.5% to 15% by weight of an additive blend, based on the total solids content of the binder composition, wherein the additive blend comprises one or more of the following:

[0179] 6.5% to 13.0% by weight of glycerol, based on the total solids content of the binder composition; and

[0180] 1.2% to 3.5% by weight of polydimethylsiloxane, based on the total solids content of the adhesive composition; and

[0181] 0.5% to 3.0% by weight of silane coupling agent.

[0182] Paragraph 11. Fiber insulation products, which include:

[0183] Multiple randomly oriented fibers; and

[0184] A crosslinked, formaldehyde-free adhesive composition at least partially coating the fibers, wherein prior to crosslinking, the adhesive composition has an uncured pH value between 4.0 and 7.0 and comprises an aqueous composition including the following components:

[0185] Based on the total solids content of the binder composition, at least 50% by weight of a polymer crosslinker containing at least two carboxylic acid groups;

[0186] Based on the total solids content of the adhesive composition, 10.0% to 35.0% by weight of a polyol having at least two hydroxyl groups, wherein the polyol comprises sugar alcohols, alkanolamines, pentaerythritol, or mixtures thereof;

[0187] Based on the total solids content of the adhesive composition, 1.5% to 15.0% by weight of an additive blend containing one or more processing aids; and

[0188] 0 to 3.0% by weight of silane coupling agent,

[0189] The aqueous binder composition is free of added formaldehyde, and the fiber product has a longitudinal tensile strength between 3.0 kPa and 8 kPa at a LOI of 2.4% or less, as determined according to EN1608.

[0190] Paragraph 12. The fiber insulation product described in paragraph 11, wherein the processing aid comprises one or more of the following: surfactant, glycerin, 1,2,4-butanetriol, 1,4-butanediol, 1,2-propanediol, 1,3-propanediol, polyethylene glycol, polyethylene glycol monooleate, polysiloxane, polydimethylsiloxane, mineral oil, paraffin oil or vegetable oil, wax, hydrophobic silica or ammonium phosphate.

[0191] Paragraph 13. The fiber insulation product described in any of paragraphs 11 or 12, wherein the processing aid comprises one or more of glycerol or polydimethylsiloxane.

[0192] Paragraph 14. The fiber insulation product described in any of paragraphs 11-13, wherein the additive blend comprises at least two processing aids.

[0193] Paragraph 15. The fiber insulation product described in any of paragraphs 11-14, wherein the additive blend comprises glycerol in an amount of 5.0% to 15% by weight, based on the total solids content of the binder composition.

[0194] Paragraph 16. The fiber insulation product described in any of paragraphs 11-15, wherein the additive blend comprises 0.5% to 2.0% by weight of a silane coupling agent, based on the total solids content of the binder composition.

[0195] Paragraph 17. The fiber insulation products described in any of paragraphs 11-16, wherein the fiber products include mineral wool insulation products.

[0196] Paragraph 18. The fiber insulation product described in any of paragraphs 11-17, wherein the bottom surface of the insulation product exhibits 0.2 kg / m² after 1 day. 2 Or even less water absorption, as determined according to EN1609.

[0197] Paragraph 19. The fiber insulation products described in any of paragraphs 11-18, wherein the fiber products have a compressive strength of at least 1.0 kPa at a LOI of 2.4% or less.

[0198] Paragraph 20. A method for producing fiber insulation products with reduced product adhesion, the method comprising:

[0199] An aqueous adhesive composition is applied to multiple fibers, the aqueous adhesive composition being formaldehyde-free and comprising:

[0200] An additive blend of 1.5% to 15.0% by weight solids, comprising one or more processing aids selected from the group consisting of: surfactants, glycerol, 1,2,4-butanetriol, 1,4-butanediol, 1,2-propanediol, 1,3-propanediol, polyethylene glycol, polyethylene glycol monooleate, polysiloxane, polydimethylsiloxane, mineral oil, paraffin oil or vegetable oil, wax, hydrophobic silica, ammonium phosphate or mixtures thereof; and

[0201] 0.5% to 3.0% by weight of silane coupling agent;

[0202] The fibers are collected onto a substrate to form a fiber package infused with adhesive; and

[0203] The fiber-encapsulated adhesive that has been cured by the injected adhesive

[0204] Prior to curing, the aqueous binder composition has a peak tack of no more than 80 g at 60% binder solids, and the fiber insulation product has a longitudinal tensile strength between 3.0 kPa and 8 kPa at 2.4% or lower LOI, as determined according to EN1608.

[0205] Paragraph 21. The method described in paragraph 20 further includes the step of applying a silane coupling agent to the plurality of fibers before collecting the fibers onto a substrate.

[0206] Paragraph 22. The method described in any of paragraphs 20-21, wherein the additive blend comprises at least two processing aids.

[0207] Paragraph 23. A formaldehyde-free aqueous adhesive composition having reduced contact tack, comprising:

[0208] Based on the total solids content of the aqueous binder composition, at least 50% by weight of a polymeric polycarboxylic acid crosslinker containing at least two carboxylic acid groups;

[0209] Based on the total solids content of the aqueous binder composition, 10.0% to 35.0% by weight of a polyol having at least two hydroxyl groups, wherein the polyol comprises sugar alcohol, alkanolamine, pentaerythritol, or a mixture thereof;

[0210] Based on the total solids content of the aqueous binder composition, an additive blend of 1.5% to 15.0% by weight, wherein the additive blend comprises one or more processing aids; and

[0211] The aqueous binder composition contains 0.5% to 3.0% by weight of a silane coupling agent based on its total solids content.

[0212] The aqueous adhesive composition has an uncured pH between 4 and 7 and an uncured peak tack of no more than 80 grams at 60% adhesive solids.

Claims

1. A low-tack aqueous binder composition comprising: at least 30.0 wt% of a polymeric crosslinker comprising at least two carboxylic acid groups, based on the total solids content of the binder composition; 10.0 wt% to 50.0 wt% of a polyol having at least two hydroxyl groups, based on the total solids content of the binder composition, wherein the polyol comprises a sugar alcohol, an alkanolamine, pentaerythritol, or a mixture thereof; 1.5 wt% to 15.0 wt% of an additive blend comprising one or more processing aids, based on the total solids content of the binder composition; and 0 to 3.0 wt% of a silane coupling agent, based on the total solids content of the binder composition, the total amount of all components of the aqueous binder composition on a dry basis is 100 wt%, wherein the sugar alcohol comprises erythritol, arabitol, xylitol, sorbitol, maltitol, mannitol, iditol, isomaltitol, lactitol, palatinitol, isomaltulose, maltotriitol, a syrup thereof, or a mixture thereof, wherein the processing aid comprises a surfactant, glycerol, 1,2,4-butanetriol, 1,4-butanediol, 1,2-propanediol, 1,3-propanediol, polyethylene glycol, polyethylene glycol monooleate, a polysiloxane, a mineral oil, a paraffinic or vegetable oil, a wax, a hydrophobic silica, an ammonium phosphate, or a mixture thereof, wherein the low-tack aqueous binder composition is substantially free of a polyol having a number average molecular weight of 2,000 Daltons or more, wherein the aqueous binder composition is free of added formaldehyde, and wherein the aqueous binder composition has an uncured pH of between 4.0 and 7.0 and an uncured peak tack of no greater than 80 grams at 60% binder solids.

2. The low-tack aqueous binder composition of claim 1, wherein the polysiloxane is a polydimethylsiloxane.

3. The low-tack aqueous binder composition of claim 1, wherein the low-tack aqueous binder composition comprises 0.5 to 3.0 wt% of a silane coupling agent, based on the total solids content of the binder composition.

4. The low-tack aqueous binder composition of claim 1, wherein the processing aid comprises glycerol, a polydimethylsiloxane, or a mixture thereof.

5. The low-tack aqueous binder composition of claim 1, wherein the additive blend comprises at least two processing aids.

6. The low-tack aqueous binder composition of claim 1, wherein the additive blend comprises glycerol in an amount of 5.0 wt% to 15.0 wt%, based on the total solids content of the binder composition.

7. The low-tack aqueous binder composition of claim 1, wherein the additive blend comprises 0.5 wt% to 5.0 wt% of a polydimethylsiloxane, based on the total solids content of the binder composition.

8. The low-tack waterborne adhesive composition of claim 1, wherein the additive blend comprises 7.0 wt% to 12 wt% glycerol and 0.5 wt% to 5.0 wt% polydimethylsiloxane, based on the total solids content of the adhesive composition.

9. The low-tack waterborne adhesive composition of claim 1, wherein the sugar alcohol comprises sorbitol.

10. The low-tack waterborne adhesive composition of claim 1, wherein the polymeric crosslinker comprises a homopolymer or copolymer of acrylic acid.

11. The low-tack waterborne adhesive composition of claim 1, wherein the composition comprises: 50% to 85% of a polymeric crosslinker having at least two carboxylic acid groups, based on the total solids content of the adhesive composition; 1.5 wt% to 15 wt% of an additive blend, based on the total solids content of the adhesive composition, wherein the additive blend comprises one or more of: 6.5 wt% to 13.0 wt% glycerol, based on the total solids content of the adhesive composition; and 1.2 wt% to 3.5 wt% polydimethylsiloxane, based on the total solids content of the adhesive composition; and 0.5 wt% to 3.0 wt% of a silane coupling agent, the total amount of all components of the waterborne adhesive composition on a dry basis is 100 wt%.

12. A fibrous insulation product comprising: a plurality of randomly oriented fibers; and a crosslinked formaldehyde-free binder composition at least partially coating the fibers, wherein prior to crosslinking, the binder composition has an uncured pH value of between 4.0 and 7.0 and comprises a waterborne binder composition including the following components: at least 30 wt% of a polymeric crosslinker comprising at least two carboxylic acid groups, based on the total solids content of the binder composition; 10.0 wt% to 50.0 wt% of a polyol having at least two hydroxyl groups, based on the total solids content of the binder composition, wherein the polyol comprises a sugar alcohol, an alkanolamine, pentaerythritol, or a mixture thereof; 1.5 wt% to 15.0 wt% of an additive blend comprising one or more processing aids, based on the total solids content of the binder composition; and 0 to 3.0 wt% of a silane coupling agent, the total amount of all components of the binder composition on a dry basis is 100 wt%, wherein the sugar alcohol comprises erythritol, arabitol, xylitol, sorbitol, maltitol, mannitol, iditol, isomaltitol, lactitol, stachyose, isomaltulose, maltotriitol, a syrup thereof, or a mixture thereof, wherein the processing aid comprises a surfactant, glycerol, 1,2,4-butanetriol, 1,4-butanediol, 1,2-propanediol, 1,3-propanediol, polyethylene glycol, polyethylene glycol monooleate, polysiloxane, mineral oil, paraffinic or vegetable oil, a wax, hydrophobic silica, ammonium phosphate, or a mixture thereof, wherein the waterborne binder composition is substantially free of a polyol having a number average molecular weight of 2,000 Daltons or more, wherein the aqueous binder composition is free of added formaldehyde, and wherein the fibrous insulation product has a longitudinal tensile strength of between 3.0 kPa and 8 kPa at an LOI of 2.4% or less, as determined according to EN 1608.

13. The fibrous insulation product of claim 12, wherein the polysiloxane is polydimethylsiloxane.

14. The fibrous insulation product of claim 12, wherein the aqueous binder composition comprises 0.5 to 3.0 weight percent silane coupling agent, based on the total solids content of the binder composition.

15. The fibrous insulation product of claim 12, wherein the processing aid comprises one or more of glycerol or polydimethylsiloxane.

16. The fibrous insulation product of claim 12, wherein the additive blend comprises at least two processing aids.

17. The fibrous insulation product of claim 12, wherein the additive blend comprises glycerol in an amount of 5.0 weight percent to 15 weight percent, based on the total solids content of the binder composition.

18. The fibrous insulation product of claim 12, wherein the additive blend comprises 0.5 weight percent to 5.0 weight percent polydimethylsiloxane, based on the total solids content of the binder composition.

19. The fibrous insulation product of claim 12, wherein the fibrous insulation product comprises a mineral wool insulation product.

20. The fibrous insulation product of claim 12, wherein the bottom surface of the fibrous insulation product exhibits a water sorption of 0.2 kg / m2 2 or less after 1 day, as determined by EN 1609.

21. The fibrous insulation product of claim 12, wherein the fibrous insulation product has a compressive strength of at least 1.0 kPa at an LOI of 2.4% or less.

22. A method for producing a fibrous insulation product having reduced product stickiness, the method comprising: applying an aqueous binder composition to a plurality of fibers, the aqueous binder composition being free of added formaldehyde and comprising, based on the total solids content of the aqueous binder composition: at least 30.0 weight percent of a polymeric crosslinking agent comprising at least two carboxylic acid groups; 10.0 weight percent to 50.0 weight percent of a polyol having at least two hydroxyl groups, wherein the polyol comprises a sugar alcohol, an alkanolamine, pentaerythritol, or a mixture thereof; 1.5 weight percent to 15.0 weight percent of a solid additive blend comprising one or more processing aids selected from the group consisting of a surfactant, glycerol, 1,2,4-butanetriol, 1,4-butanediol, 1,2-propanediol, 1,3-propanediol, polyethylene glycol, monooleate polyethylene glycol, polysiloxane, mineral oil, paraffinic or vegetable oil, a wax, hydrophobic silica, ammonium phosphate, or a mixture thereof; and 0.5 weight percent to 3.0 weight percent of a silane coupling agent, the total amount of all components of the aqueous binder composition being 100 weight percent on a dry basis; collecting the fibers onto a substrate to form an injected binder fibrous package; and curing the injected binder fibrous package, wherein the sugar alcohol comprises erythritol, arabitol, xylitol, sorbitol, maltitol, mannitol, iditol, isomaltitol, lactitol, stachyose, isomaltulose, maltotriitol, a syrup thereof, or a mixture thereof, wherein the aqueous binder composition is substantially free of polyols having a number average molecular weight of 2,000 Daltons or more, wherein the aqueous binder composition has a peak pick force of no greater than 80 grams at 60% binder solids prior to curing, and the fibrous insulation product has a machine direction tensile strength of between 3.0 kPa and 8 kPa at an LOI of 2.4% or less, as determined according to EN 1608.

23. The method of claim 22, wherein the polysiloxane is polydimethylsiloxane.

24. The method of claim 22, further comprising the step of applying a silane coupling agent to the plurality of fibers prior to collecting the fibers onto a substrate.

25. The method of claim 22, wherein the additive blend comprises at least two processing aids.

26. A formaldehyde-free aqueous binder composition having reduced pick adhesion, comprising: at least 54 weight percent, based on the total solids content of the aqueous binder composition, of a polymeric polycarboxylic acid crosslinker comprising at least two carboxylic acid groups; from 10.0 weight percent to 35.0 weight percent, based on the total solids content of the aqueous binder composition, of a polyol having at least two hydroxyl groups, wherein the polyol comprises a sugar alcohol, an alkanolamine, pentaerythritol, or a mixture thereof; from 1.5 weight percent to 15.0 weight percent, based on the total solids content of the aqueous binder composition, of an additive blend comprising one or more processing aids; and from 0.5 weight percent to 3.0 weight percent, based on the total solids content of the aqueous binder composition, of a silane coupling agent, the total amount of all components of the aqueous binder composition is 100 weight percent on a dry basis; wherein the sugar alcohol comprises erythritol, arabitol, xylitol, sorbitol, maltitol, mannitol, iditol, isomaltitol, lactitol, stachyose, isomaltulose, maltotriitol, a syrup thereof, or a mixture thereof, wherein the processing aid comprises a surfactant, glycerol, 1,2,4-butanetriol, 1,4-butanediol, 1,2-propanediol, 1,3-propanediol, polyethylene glycol, polyethylene glycol monooleate, polysiloxane, mineral oil, paraffinic or vegetable oil, a wax, hydrophobic silica, ammonium phosphate, or a mixture thereof, wherein the aqueous binder composition is substantially free of polyols having a number average molecular weight of 2,000 Daltons or more, and wherein the aqueous binder composition has an uncured pH of between 4 and 7, and an uncured peak pick force of no greater than 80 grams at 60% binder solids.

27. The aqueous binder composition of claim 26, wherein the polysiloxane is polydimethylsiloxane.

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