Fine fiber thermal insulation product

Abstract

Disclosed is an insulation product comprising a plurality of glass fibers and a crosslinked, formaldehyde-free binder composition at least partially coating the glass fibers. The glass fibers have an average fiber diameter in the range of 8 HT (2.03 µm) to 15 HT (3.81 µm). The insulation product is configured such that at least 30 wt% of the glass fibers in the insulation product are oriented within + / - 15° of a common plane defined by a length and a width of the insulation product. The insulation product has a density, when uncompressed, of between 0.2 pcf and 1.6 pcf.

Description

[0001] Related applications

[0002] This application claims priority and any rights to U.S. Provisional Application No. 63 / 196,882, filed June 4, 2021, the contents of which are incorporated herein by reference in their entirety.

[0003] field

[0004] This application relates generally to glass fiber insulation products, and more particularly to glass fiber insulation products with improved performance properties.

[0005] background

[0006] The term "fiber insulation products" encompasses a wide range of compositions, articles of manufacture, and manufacturing processes. Mineral fibers (such as glass fibers) are commonly used in insulation products and nonwoven mats. Fiber insulation is typically manufactured by fiberizing a molten composition of polymers, glass, or other mineral fibers from a fiberizing device (such as a rotary spinneret). To form the insulation product, fibers produced by the rotary spinneret are blown downwards from the spinneret onto a conveyor by a blower. As the fibers move downwards, an adhesive composition is sprayed onto the fibers, and the fibers are collected on the conveyor to form a thick, fluffy, continuous felt layer. The fiber adhesive matrix gives the insulation product resilience for recovery after packaging and provides stiffness and maneuverability, allowing the insulation product to be handled and applied as needed into the insulation cavities of buildings. The adhesive composition also protects the fibers from interfilament abrasion and promotes compatibility between individual fibers.

[0007] The felt containing adhesive-coated fibers is then passed through a curing oven, where the adhesive is cured to set the felt to the desired thickness. After the adhesive composition has cured, the fiber insulation can be cut to length to form individual insulation products, which can then be packaged for transport to the customer's location. A typical insulation product produced is an insulation pad or felt, suitable for insulation of cavities (e.g., walls, floors, ceilings) in residential dwellings or other buildings, and can also be used to insulate lofts or other parts of buildings. This pad or felt is typically a relatively soft or rollable monolithic structure. Another common insulation product is blown or loosely filled insulation, suitable for use as sidewall and loft insulation in residential and commercial buildings, as well as in hard-to-reach locations. This loosely filled insulation is often formed as many relatively small discrete pieces, clusters, etc., which may or may not have an adhesive applied to them. Loosely filled insulation can also be formed from small squares cut from insulation felt, compressed, and packaged in bags.

[0008] The thermal insulation performance of an insulation material is primarily determined by the ratio of its thickness to its thermal conductivity (k), which measures the amount of heat (in BTUs per hour) transferred through one square foot of 1-inch-thick insulation to cause a temperature rise or fall of one degree Celsius from one side of the insulation to the other. A greater thickness and a lower k value result in better insulation performance.

[0009] Fiber insulations used in building products require low thermal conductivity to be effective insulations in wall and ceiling cavities. Reducing the overall product weight is also desirable, although weight reduction typically negatively impacts thermal performance. In particular, attempts are made to reduce product weight by decreasing the diameter of the fibers used to form the insulation, which typically has an average fiber diameter of about 4 micrometers (1 micrometer equals 3.94 ten-thousandths of an inch or HT) or greater.

[0010] However, it has been traditionally found that such a reduction in fiber diameter negatively impacts the insulation value (R-value) of a product at a given area weight and product thickness. Therefore, reducing the average fiber diameter of insulation products to less than 4 micrometers was previously impractical, as such products would not meet performance requirements while remaining economical. Consequently, there is an unmet need for insulation products formed from fibers thinner than 4 micrometers, which effectively meet essential performance requirements (e.g., thermal performance) and also improve overall material efficiency.

[0011] content

[0012] Various aspects of this invention relate to a thermal insulation product comprising a plurality of glass fibers; and a crosslinked, formaldehyde-free adhesive composition at least partially coated with the glass fibers, wherein the thermal insulation product has a length, a width, and a thickness, the length being greater than each of the width and the thickness. The glass fibers have an average fiber diameter in the range of 8HT (2.03 μm) to 15HT (3.81 μm). The thermal insulation product is configured such that at least 30% by weight of the glass fibers in the thermal insulation product are oriented within + / -15° of a common plane defined by the length and width of the thermal insulation product. In some exemplary embodiments, at least 40% of the glass fibers are oriented within + / -15° of the common plane. In any exemplary embodiment disclosed herein, the common plane may be a plane parallel to the length and width of the thermal insulation product. The thermal insulation product has a density between 0.2 pcf and 1.6 pcf when uncompressed.

[0013] In any exemplary embodiment disclosed herein, at least 15% by weight of the glass fiber in the insulation product may be at least partially bonded to at least one other glass fiber in the insulation product in a substantially parallel orientation.

[0014] In any of the exemplary embodiments disclosed herein, prior to crosslinking, the formaldehyde-free adhesive composition may comprise at least one monomeric polyol and at least one polycarboxylic acid in a combined amount of at least 45% by weight based on the total weight of the adhesive composition. In these or other embodiments, the formaldehyde-free adhesive composition is free of Maillard reactants.

[0015] In some exemplary embodiments, the glass fiber orientation is such that no more than 35% by weight of the adhesive composition is present in the form of gussets.

[0016] Another exemplary embodiment relates to a thermal insulation product comprising a plurality of glass fibers having an average fiber diameter in the range of 8HT (2.03 μm) to 15HT (3.81 μm) and a crosslinked, formaldehyde-free adhesive composition at least partially coated with the glass fibers, wherein, prior to crosslinking, the adhesive composition has a viscosity of less than 40,000 cP at a solids content of up to 65% to 70%, and comprises at least one monomeric polyol. The thermal insulation product comprises a length, a width, and a thickness, wherein the length is greater than each of the width and the thickness. The thermal insulation product is configured such that at least 55% by weight, or in some cases at least 65% by weight, of the glass fibers are oriented within + / - 30° of a common plane defined by the length and width of the thermal insulation product, and at least 15% by weight of the glass fibers in the thermal insulation product are at least partially bonded to at least one other glass fiber in the thermal insulation product in a substantially parallel orientation. The thermal insulation product has a density between 0.2 pcf and 1.6 pcf when uncompressed.

[0017] In any of the exemplary embodiments disclosed herein, the glass fiber orientation is such that no more than 35% by weight of the adhesive composition is present in the form of clumps.

[0018] In any of the exemplary embodiments disclosed herein, at least 80% by weight of the glass fibers are oriented within + / -50° of the common plane.

[0019] In any of the exemplary embodiments disclosed herein, the common plane may be a plane parallel to the length of the insulation product.

[0020] Another exemplary embodiment relates to a thermal insulation product comprising a plurality of glass fibers having an average fiber diameter of less than 15 HT (3.81 μm) and a crosslinked, formaldehyde-free adhesive composition at least partially coated with the glass fibers, wherein the crosslinked, formaldehyde-free adhesive composition is formed from an aqueous adhesive composition comprising at least one monomeric polyol. The thermal insulation product is configured such that at least 15% by weight of the glass fibers in the thermal insulation product are at least partially bonded to at least one other glass fiber in the thermal insulation product in a substantially parallel orientation. Furthermore, the glass fibers may be oriented such that no more than 35% by weight of the adhesive composition is present in a clump form.

[0021] In these or other exemplary embodiments, the insulation product is configured such that at least 30% by weight, and in some cases at least 40% by weight, of the glass fibers are oriented within + / -15° of a common plane defined by the width and length of the insulation product. In some exemplary embodiments, the common plane is parallel to the length and width of the product.

[0022] In any of the exemplary embodiments disclosed herein, the glass fiber may have an average fiber diameter in the range of 12HT to 14.5HT.

[0023] Another exemplary embodiment relates to a method of forming an insulating product. The method includes fiberizing molten glass into a plurality of glass fibers, coating the glass fibers with an aqueous, formaldehyde-free adhesive composition, randomly depositing the glass fibers on a moving conveyor to form an uncured glass fiber mat, and passing the uncured glass fiber mat through a curing oven to crosslink the adhesive composition and form an insulating product. The insulating product includes a length, a width, and a thickness, wherein the length is greater than each of the width and the thickness.

[0024] When entering the curing oven, the uncured glass fiber mat may have a reduced moisture content, for example, not more than 3% by weight or not more than 2% by weight.

[0025] In any of the exemplary embodiments disclosed herein, the insulation product may be configured such that at least 30% by weight of the glass fibers are oriented within + / - 15° of a common plane. Furthermore, the insulation product has a density between 0.2 and 1.6 pcf when uncompressed.

[0026] Brief description of the attached diagram

[0027] The features and advantages of the present invention will become apparent to those skilled in the art from the following description, together with the accompanying drawings, wherein:

[0028] Figure 1This is a perspective view of an exemplary embodiment of a fiber insulation product;

[0029] Figure 2 It is used for production Figure 1 A front view of an exemplary embodiment of a manufacturing line for fiber insulation products;

[0030] Figure 3 This is a scanning electron microscope (“SEM”) image of a cross section of an exemplary fiber insulation product formed from glass fibers having an average fiber diameter of 14.5 HT;

[0031] Figure 4 This is a SEM image showing a cross-section of an exemplary fiber insulation product formed from glass fibers with an average fiber diameter of 14.5 HT.

[0032] Figure 5 This is a SEM image showing a cross-section of a conventional fiber insulation product made of glass fibers with an average fiber diameter of 16.7HT and an insulation value of R-21.

[0033] Figure 6 It is a graphical representation of the fiber orientation distribution within + / -15° of a plane parallel to the product length L1 (0°) taken from a cross section along the machine direction of an exemplary fiber insulation product formed of glass fibers with an average fiber diameter of 14.5HT.

[0034] Figure 7 It is a graphical representation of the fiber orientation distribution within + / -30° of a plane parallel to the product length L1 (0°) taken from a cross section along the machine direction of an exemplary fiber insulation product formed of glass fibers with an average fiber diameter of 14.5HT.

[0035] Figure 8 It is a graphical representation of the fiber orientation distribution within + / -50° of a plane parallel to the product length L1 (0°) taken from a cross section along the machine direction of an exemplary fiber insulation product formed of glass fibers with an average fiber diameter of 14.5HT.

[0036] Figure 9(a) is a SEM image showing the fiber orientation of a 24 mm × 16 mm cross section of an exemplary fine fiber insulation product formed from glass fibers with an average fiber diameter of about 14 HT.

[0037] Figure 9(b) is a graphical representation of the fiber orientation distribution curve (measured in degrees, based on a plane parallel to the product length L1 (0°) taken from the cross section of the fiber insulation product in Figure 9(a) along the machine direction).

[0038] Figure 10(a) is a SEM image showing the fiber orientation of a 24 mm × 16 mm cross section of an exemplary fine fiber insulation product formed from glass fibers with an average fiber diameter of about 14 HT.

[0039] Figure 10(b) is a graphical representation of the fiber orientation distribution curve (measured in degrees, based on a plane parallel to the product length L1 (0°) taken from the cross section along the machine direction of the fiber insulation product in Figure 10(a).

[0040] Figures 11(a)-11(c) This is an SEM image showing parallel fiber bundles present in an exemplary fiber insulation product formed of glass fibers with an average fiber diameter of 14.5 HT.

[0041] Figures 12(a)-12(c) This is an SEM image showing parallel fiber bundles present in an exemplary fiber insulation product formed of glass fibers with an average fiber diameter of 14.5 HT.

[0042] Figures 13(a)-13(b) This is a SEM image showing adhesive clumps present in an exemplary fiber insulation product formed from glass fibers with an average fiber diameter of 14.5 HT;

[0043] Figure 14 The figure shows the predicted thermal conductivity (k-value) curve per product density compared to the actual thermal conductivity (k-value) curve per product density.

[0044] Figure 15 The figure shows the predicted material efficiency curve per product density compared to the actual material efficiency curve per product density; and

[0045] Figure 16 The figure shows the predicted material efficiency curve per product density compared to the material efficiency curve adjusted for per product density.

[0046] Detailed description

[0047] 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 the purpose of describing exemplary embodiments only and is not intended to limit the exemplary embodiments. Therefore, the overall inventive concept is not intended to be limited to the specific embodiments shown herein. Although 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.

[0048] As used in the specification and appended claims, unless the context clearly indicates otherwise, the singular forms “a”, “an” and “the” are also intended to include the plural forms.

[0049] Unless otherwise stated, all figures used in the specification and claims representing quantities of components, chemical and molecular properties, reaction conditions, and physical and measurement properties should in all cases be understood to be modified by the term "about". Therefore, unless otherwise stated to the contrary, the numerical parameters set forth in the specification and appended claims are approximations that may vary depending on the desired properties sought to be obtained from this exemplary embodiment. At least each numerical parameter should be interpreted according to significant digits and common rounding methods.

[0050] Unless otherwise stated, 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 that embodiment. It will be readily understood that features described with respect to any particular aspect described herein may be applied to other aspects described herein, provided that the features are compatible with that aspect. In particular: features described herein in relation to the method are applicable to fiber products and vice versa; features described herein in relation to the method are applicable to aqueous adhesive compositions and vice versa; and features described herein in relation to fiber products are applicable to aqueous adhesive compositions and vice versa.

[0051] While the numerical ranges and parameters described in the exemplary embodiments are approximate, the values ​​described in the specific examples are reported as precisely as possible. However, any numerical value inherently contains some error, which is necessarily caused by the standard deviation found in its respective test measurement. Every numerical range given throughout this specification and claims will include every narrower numerical range falling within such a wider range, as if such narrower numerical ranges were explicitly written herein.

[0052] As used herein, the terms “adhesive composition,” “aqueous adhesive composition,” “adhesive formulation,” “adhesive,” and “adhesive system” are used interchangeably and are synonyms. Furthermore, as used herein, the terms “formaldehyde-free” or “formaldehyde-free” are used interchangeably and are synonyms.

[0053] All numerical ranges should be understood as subranges that include all possible increments within the outer boundary of the range. Thus, for example, a density range of 0.2 pcf to 2.0 pcf discloses, for example, 0.5 pcf to 1.2 pcf, 0.7 pcf to 1.0 pcf, etc.

[0054] "Substantially none" means that the composition comprises less than 1.0% by weight of the described component, including not more than 0.8% by weight, not more than 0.6% by weight, not more than 0.4% by weight, not more than 0.2% by weight, not more than 0.1% by weight, not more than 0.5% by weight, and not more than 0.01% by weight.

[0055] As used in this article, the unit “pound” or “lb” refers to pounds of mass.

[0056] This disclosure relates to glass fiber insulation products formed from fine-diameter glass fibers (i.e., fibers having an average fiber diameter of less than or equal to 15 HT) to achieve more favorable fiber orientation and product structure. The glass fiber insulation products exhibit remarkably improved thermal performance and overall material efficiency.

[0057] The fiber insulation products disclosed herein comprise a plurality of fibers, such as organic or inorganic fibers. In some exemplary embodiments, the plurality of fibers are inorganic fibers, including but not limited to glass fibers, glass wool fibers, mineral wool fibers, slag wool fibers, asbestos fibers, ceramic fibers, metal fibers, and combinations thereof.

[0058] Optionally, the fibers may comprise natural and / or synthetic fibers, such as carbon, polyester, polyethylene, polyethylene terephthalate, polypropylene, polyamide, aramid, and / or polyaramid fibers. As used herein, the term "natural fiber" refers to plant fibers extracted from any part of a plant, including but not limited to stems, seeds, leaves, roots, or phloem. Examples of natural fibers suitable for use in insulation products include wood fibers, cellulose fibers, straw, sawdust, woodstrand, cotton, jute, bamboo, ramie, bagasse, hemp, coconut husk, flax, kenaf, ramie, flax, sisal, and combinations thereof. Fiber insulation products can be formed entirely from one type of fiber, or they can be formed from combinations of different types of fibers. For example, depending on the desired application, fiber insulation products can be formed from combinations of various types of glass fibers or various combinations of different inorganic fibers and / or natural fibers. In any embodiment disclosed herein, the insulation product can be formed substantially or entirely from glass fibers.

[0059] Fiber insulation products utilize glass fibers with a smaller diameter than those used in conventional glass fiber insulation products, particularly residential insulation products typically having an average fiber diameter greater than 4 μm (15.7HT), such as 16HT or 18HT. Specifically, exemplary fiber insulation products disclosed or suggested herein may include glass fibers having an average fiber diameter equal to or less than 3.81 μm (15HT) prior to the application of the adhesive composition, including average fiber diameters not greater than 3.76 μm (14.8HT), not greater than 3.68 μm (14.5HT), not greater than 3.61 μm (14.2HT), not greater than 3.56 μm (14HT), not greater than 3.43 μm (13.5HT), not greater than 3.30 μm (13HT), not greater than 3.18 μm (12.5HT), and not greater than 3.05 μm (12HT). In any exemplary embodiment, the fiber insulation product may include glass fibers having an average fiber diameter in the range of 3.05 μm (12.0HT) to 3.81 μm (15.0HT), or 3.30 μm (13.0HT) to 3.76 μm (14.8HT), or 3.43 μm (13.5HT) to 3.61 μm (14.2HT). In other exemplary embodiments, the insulation product may include glass fibers having an average fiber diameter in the range of 2.03 μm (8.0HT) to 3.05 μm (12.0HT), or 2.29 μm (9.0HT) to 2.79 μm (11.0HT), or 2.03 μm (8.0HT) to 2.54 μm (10.0HT).

[0060] An exemplary procedure for measuring the diameter of glass fibers utilizes a scanning electron microscope (SEM) to directly measure the fiber diameter. Typically, a sample of the fiber insulation product is heated to remove any organic materials (such as adhesive compositions), and then the glass fibers from the sample are shortened and photographed using an SEM. The fiber diameter is then measured from the saved image using image processing software associated with the SEM.

[0061] More specifically, heat the sample of the fiber insulation product to 800°F for at least 30 minutes. If necessary, the sample can be heated for a longer period to ensure the removal of any organic material. Then cool the sample to room temperature and shorten the glass fibers to fit it onto the SEM stage (planchette). The glass fibers can be shortened using any suitable method (e.g., cutting with scissors, shredding with a razor blade, or grinding in a mortar and pestle). The glass fibers are then adhered to the surface of the SEM stage, ensuring that the fibers do not overlap or are too far apart.

[0062] Once the sample is ready for imaging, it is mounted in the SEM using normal operating procedures, and the diameter of the fibers being measured is photographed using the SEM at an appropriate magnification. A sufficient number of images are collected and saved to ensure that enough fibers are available for measurement. For example, 10 to 13 images may be required when measuring 250 to 300 individual fibers. The fiber diameter is then measured using SEM image analysis software (e.g., Scandium SIS imaging software). The average fiber diameter of the sample is then determined from the number of fibers measured. Fiber insulation product samples may include glass fibers fused together (i.e., two or more fibers joined along their length). For the purpose of calculating the average fiber diameter of the samples in this disclosure, the fused fibers are considered as a single fiber.

[0063] An alternative process for measuring the average fiber diameter of glass fibers utilizes a device for measuring airflow resistance to indirectly determine the average or “effective” fiber diameter of the fibers distributed in the sample. More specifically, in one embodiment of the alternative process, a sample of the fiber insulation product is heated to 800-1000°F for 30 minutes. If necessary, the sample can be heated for a longer period to ensure the removal of any organic material from the fiber surface. The sample is then cooled to room temperature, and a test sample weighing approximately 7.50 grams is placed into the chamber of the device. A constant airflow is applied through the chamber, and once the airflow stabilizes, the pressure difference or pressure drop across the sample is measured by the device. Based on the airflow and pressure difference measurements, the device can calculate the average fiber diameter of the sample.

[0064] The fiber insulation products disclosed herein comprise a formaldehyde-free or “formaldehyde-free” aqueous adhesive composition for bonding inorganic fibers during the manufacture of the insulation products. The phrase “adhesive composition” refers to an organic agent or chemical, often a polymeric resin, used to adhere inorganic fibers to each other in a three-dimensional structure. The adhesive composition can be in any form, such as a solution, emulsion, or dispersion. Therefore, “adhesive dispersion” or “adhesive emulsion” refers to a mixture of adhesive chemicals in a medium or carrier. As used herein, the terms “adhesive composition,” “aqueous adhesive composition,” “adhesive formulation,” “adhesive,” and “adhesive system” are used interchangeably and are synonyms. Furthermore, as used herein, the terms “formaldehyde-free” or “formaldehyde-free” are used interchangeably and refer to an adhesive composition containing less than about 1 ppm of formaldehyde when cured or otherwise dried. 1 ppm is based on the weight of the product from which formaldehyde release is measured.

[0065] A wide variety of adhesive compositions can be used with the glass fibers of the present invention. For example, adhesive compositions fall into two broad, mutually exclusive categories: thermoplastic and thermosetting. Both thermoplastic and thermosetting adhesive compositions can be used in the present invention. Thermoplastic materials can be repeatedly heated to a softened or molten state and will return to their previous state upon cooling. In other words, heating may cause a reversible change in the physical state of the thermoplastic material (e.g., from solid to liquid), but it does not cause any irreversible chemical reaction. Exemplary thermoplastic polymers suitable for use in fiber insulation product 100 include, but are not limited to, polyethylene (e.g., polyvinyl acetate, polyvinyl alcohol, polyvinyl butyral, etc.), polyethylene terephthalate (PET), polypropylene or polyphenylene sulfide (PPS), nylon, polycarbonate, polystyrene, polyamide, polyolefin, acrylic and methacrylate resins, and some copolymers of polyacrylates.

[0066] In contrast, the term thermosetting polymers refer to a range of systems that initially exist as liquids but react upon heating to form a solid, highly cross-linked matrix. Therefore, thermosetting compounds consist of reactant systems (often reactant pairs) that are irreversibly cross-linked upon heating. When cooled, they do not revert to their previous liquid state but remain irreversibly cross-linked.

[0067] Reactants that can be used in thermosetting compounds typically have one or more of several reactive functional groups: for example, amines, amides, carboxyl groups, or hydroxyl groups. As used herein, “thermosetting compound” (and its derivatives, such as “thermosetting compound,” “thermosetting adhesive,” or “thermosetting binder”) means at least one such reactant, and it should be understood that two or more may be necessary for the properties of the crosslinking system forming the thermosetting compound. In addition to the main reactant of the thermosetting compound, catalysts, process aids, and other additives may also be present.

[0068] One class of thermosetting adhesives includes various phenolic, urea-formaldehyde, melamine-formaldehyde, and other condensation polymers. Phenolic / formaldehyde adhesive compositions are known thermosetting adhesive systems and have historically been favored due to their low cost and ability to transform a low-viscosity liquid in an uncured state into a rigid thermosetting polymer upon curing.

[0069] Formaldehyde-free thermosetting adhesive systems may include those based on polycarboxylic acid polymers and polyols. One example is the polyacrylic acid / polyol / polyacid adhesive system described in U.S. Patent Nos. 6,884,849 and 6,699,945 to Chen et al., the entire contents of which are expressly incorporated herein by reference. Another example is the polymeric polycarboxylic acid / long-chain polyol / short-chain polyol adhesive system described in U.S. Patent Publication No. 2019 / 0106564 to Zhang et al., the disclosure of which is entirely incorporated herein by reference. Yet another example is the polymeric polycarboxylic acid / monomer polyol adhesive system described in U.S. Provisional Patent Application No. 63 / 086,267, the disclosure of which is entirely incorporated herein by reference. And yet another example is the polycarboxylic acid / polyol / nitrogen-based protective agent adhesive system described in U.S. Provisional Patent Application No. 63 / 073,013, the disclosure of which is entirely incorporated herein by reference.

[0070] The second category of formaldehyde-free thermosetting adhesive compositions is referred to as “bio-based” or “natural” adhesives. The terms “bio-based adhesive” and “natural adhesive” are used interchangeably herein and refer to adhesive compositions made from nutrient compounds (such as carbohydrates, proteins, or fats) that possess a variety of reactive properties. Because they are made from nutrient compounds, they are environmentally friendly. Bio-based adhesive compositions are described in more detail in U.S. Patent Publication No. 2011 / 0086567, filed October 8, 2010, by Hawkins et al., the entire contents of which are expressly incorporated herein by reference.

[0071] In some exemplary embodiments, the adhesive includes Owens-Corning's EcoTouch. TM Adhesive or EcoPure TM Adhesive, Sustaina of Owens Corning TM Adhesive or Knauf Adhesive.

[0072] Alternative reactants that can be used as thermosetting compounds are triammonium citrate-glucose systems derived from a mixture of glucose monohydrate, anhydrous citric acid, water, and ammonia. Furthermore, carbohydrate reactants and polyamine reactants are useful thermosetting compounds, the disclosures of which are described in more detail in U.S. Patents 8,114,210, 9,505,883, and 9,926,464, the contents of which are incorporated herein by reference.

[0073] Surprisingly, it was found that fiber-reinforced thermal insulation products manufactured using glass fibers with an average fiber diameter of less than 15 HT exhibit improved properties when using formaldehyde-free adhesive compositions comprising polyols and primary crosslinking agents (e.g., polycarboxylic acids or their salts). Particularly significant improvements were observed when the polyol included in the adhesive composition was a monomeric polyol.

[0074] The primary crosslinking agent can be any compound suitable for crosslinking polyols. Non-limiting examples of suitable crosslinking agents include polycarboxylic acid materials having one or more carboxylic acid groups (-COOH), such as monomers and polymeric polycarboxylic acids, including their salts or anhydrides, and mixtures thereof. In any exemplary embodiment, the polycarboxylic acid can be a polymeric polycarboxylic acid, such as a homopolymer or copolymer of acrylic acid. The polymeric polycarboxylic acid can comprise polyacrylic acid (including its salts or anhydrides) and polyacrylic acid resins (e.g., QR-1629S and Acumer 9932, both commercially available from Dow Chemical Company), polyacrylic acid compositions commercially available from CHPolymer, 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. Aquaset-529 is a composition containing polyacrylic acid crosslinked with glycerol.

[0075] Polycarboxylic acids may include polymeric polycarboxylic acids, such as polyacrylic acid, poly(meth)acrylic acid, polymaleic acid and similar polymeric polycarboxylic acids, acid anhydrides, salts or mixtures thereof, and copolymers of acrylic acid, methacrylic acid, maleic acid and similar carboxylic acids, acid anhydrides, salts or mixtures thereof.

[0076] In any exemplary embodiment, the polycarboxylic acid may comprise monomeric polycarboxylic acids, such as citric acid, itaconic acid, maleic acid, fumaric acid, succinic acid, adipic acid, glutaric acid, tartaric acid, trimellitic acid, benzotricarboxylic acid, benzopyridinic acid, trimethylcarboxylic acid, etc., including their salts or anhydrides, and mixtures thereof.

[0077] In some cases, the crosslinking agent can be pre-neutralized with a neutralizing agent. Such a neutralizing agent may include organic and / or inorganic bases, such as sodium hydroxide, ammonium hydroxide, and diethylamine, as well as any kind of primary, secondary, or tertiary amine (including alkanolamines). In various exemplary embodiments, the neutralizing agent may include at least one of sodium hydroxide and triethanolamine.

[0078] The crosslinking agent is present in the adhesive composition in an amount of at least 30.0% by weight based on the total solids content of the adhesive composition, including but not limited to at least 40% by weight, at least 45% by weight, at least 50% by weight, at least 52.0% by weight, at least 54.0% by weight, at least 56.0% by weight, at least 58.0% by weight, and at least 60.0% by weight. In any embodiment disclosed herein, the crosslinking agent may be present in the adhesive composition in an amount of from 30% by weight to 85% by weight based on the total solids content of the aqueous adhesive composition, including but not limited to 50.0% by weight to 70.0% by weight, greater than 50% by weight to 65% by weight, 52.0% by weight to 62.0% by weight, 54.0% by weight to 60.0% by weight, and 55.0% by weight to 59.0% by weight.

[0079] Optionally, in addition to the polycarboxylic acid crosslinking agents discussed above, the adhesive composition may include amine reactants, such as ammonium salts (e.g., ammonium salts of polycarboxylic acids), amines, diammonium sulfate, proteins, peptides, amino acids, etc. Such amine reactants are capable of participating in Maillard reactions with reducing sugars to produce protein melanin (high molecular weight, furan ring, and nitrogen-containing polymer). Therefore, in some exemplary embodiments, the adhesive composition may contain protein melanin produced by the reaction of an amine reactant with one or more reducing sugars.

[0080] The aqueous adhesive composition may further comprise at least one polyol. In any exemplary embodiment, the polyol may comprise a monomeric polyol. The monomeric polyol may comprise a water-soluble compound having a molecular weight of less than 2000 Daltons (including less than 1000 Daltons, less than 750 Daltons, and less than 500 Daltons) and having at least two hydroxyl groups (-OH). Exemplary monomeric polyols include glucose, sucrose, ethylene glycol, sugar alcohols, pentaerythritol, primary alcohols, 2,2-bis(hydroxymethyl)propionic acid, tris(hydroxymethyl)propane (TMP), 1,2,4-butanetriol, trimethylolpropane, fructose, high-fructose corn syrup (HFCS), and short-chain alkanolamines (e.g., triethanolamine) that comprise at least three hydroxyl groups. In any embodiment disclosed herein, the polyol may comprise at least three, at least four, or at least five hydroxyl groups.

[0081] Sugar alcohols are understood to be compounds obtained when the aldehyde or ketone group of a sugar is reduced (e.g., by hydrogenation) to the corresponding hydroxyl group. Starting sugars can be selected from monosaccharides, oligosaccharides, and polysaccharides, as well as mixtures of those products, such as syrups, molasses, and starch hydrolysates. Starting sugars can also be dehydrated forms of sugars. Although sugar alcohols are very similar to their corresponding starting sugars, they are not sugars, and in particular, are not reducing sugars. Therefore, for example, sugar alcohols have no reducing power and cannot participate in the Maillard reaction typical of reducing sugars. In some exemplary embodiments, sugar alcohols include glycerol, erythritol, arabinitol, xylitol, sorbitol, maltitol, mannitol, iderol, isomaltitol, lactitol, cellobitol, palatinitol, maltotritol, syrups thereof, and mixtures thereof. In various exemplary embodiments, sugar alcohols are selected from glycerol, sorbitol, xylitol, and mixtures thereof. In some exemplary embodiments, the monomeric polyol is a dimer or oligomerization condensation product of a sugar alcohol. In various exemplary embodiments, the condensation product of the sugar alcohol is isosorbide. In some exemplary embodiments, the sugar alcohol is a diol or glycol.

[0082] In some exemplary embodiments, the monomeric polyol is present in the aqueous adhesive composition in an amount of up to about 70% by weight of total solids, including but not limited to up to about 60% by weight, 55% by weight, 50% 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 some exemplary embodiments, the monomeric polyol is present in the aqueous adhesive composition in an amount of 2.0% by weight to 65.0% by weight of total solids, including but not limited to 5.0% by weight to 40.0% by weight, 8.0% by weight to 37.0% by weight, 10.0% by weight to 34.0% by weight, 12.0% by weight to 32.0% by weight, 15.0% by weight to 30.0% by weight, and 20.0% by weight to 28.0% by weight of total solids.

[0083] In various exemplary embodiments, the crosslinking agent and the monomeric polyol are present in amounts such that the ratio of the molar equivalent number of carboxylic acid groups, anhydride groups or their salts to the molar equivalent number of hydroxyl groups is about 0.3 / 1 to about 1 / 0.3, for example about 0.5 / 1 to about 1 / 0.5, about 0.6 / 1 to about 1 / 0.6, about 0.8 / 1 to about 1 / 0.8, or about 0.9 / 1 to about 1 / 0.9.

[0084] In any of the embodiments disclosed herein, the adhesive composition may be free of or substantially free of polyols with fewer than three hydroxyl groups, or free of or substantially free of polyols with fewer than four hydroxyl groups. In any of the embodiments disclosed herein, the adhesive composition is free of or substantially free of polyols having a number average molecular weight of 2000 Daltons or greater, for example, a molecular weight between 3000 Daltons and 4000 Daltons. Therefore, in any of the embodiments disclosed herein, the adhesive composition is free of or substantially free of diols, such as ethylene glycol; triols, such as glycerol and triethanolamine; and / or partially or completely hydrolyzable polymeric polyhydroxy compounds, such as polyvinyl alcohol, polyvinyl acetate, or mixtures thereof.

[0085] In any of the embodiments disclosed herein, the aqueous adhesive composition may comprise a polymeric polycarboxylic acid crosslinking agent and a monomeric polyol having at least four hydroxyl groups, or may consist of a polymeric polycarboxylic acid crosslinking agent and a monomeric polyol having at least four hydroxyl groups, wherein the ratio of carboxylic acid groups to hydroxyl OH groups is between 0.60 / 1 and 1 / 0.6.

[0086] However, in some exemplary embodiments, the polyol may comprise a polymeric polyol having at least two hydroxyl groups and a number-average molecular weight of at least 2000 Daltons. The polymeric polyol may be included as the sole polyol in the adhesive composition, or it may be included as a second polyol in addition to the monomeric polyols described above.

[0087] In some exemplary embodiments, the second polyol comprises one or more polymeric polyhydroxy compounds that can be partially or completely hydrolyzed, such as polyvinyl alcohol, polyvinyl acetate, or mixtures thereof. For example, when partially hydrolyzed polyvinyl acetate is used as a polyol component, 80%-89% hydrolyzed polyvinyl acetate can be used, for example… (Kuraray America, Inc.) and Sevol TM 502 (Sekisui Specialty Chemicals America, LLC), which has approximately 85% and 88% (Selvol) TM 502) Hydrolysis. Another alternative is ELVANOL 51-05 or other partially hydrolyzed polyvinyl acetate, which is available from DuPont and has a molecular weight of about 22,000 to about 26,000 Daltons and a viscosity of about 5.0-6.0 centipoise.

[0088] The second polyol may be present in the aqueous adhesive composition in an amount of up to about 30% by weight of total solids, including but not limited to up to about 28% by weight, 25% by weight, 20% by weight, 18% by weight, 15% by weight, and 13% by weight of total solids. In any exemplary embodiment, the second polyol may be present in the aqueous adhesive composition in an amount of 2.5% by weight to 30% by weight of total solids, including but not limited to 5% by weight to 25% by weight, 8% by weight to 20% by weight, 9% by weight to 18% by weight, and 10% by weight to 16% by weight of total solids.

[0089] In these embodiments of the adhesive composition comprising a second polyol, the crosslinking agent, the monomeric polyol, and the second polyol may be present in amounts such that the ratio of the molar equivalents of carboxylic acid groups, anhydride groups, or their salts to the molar equivalents of hydroxyl groups is from about 1 / 0.05 to about 1 / 5, for example from about 1 / 0.08 to about 1 / 2.0, from about 1 / 0.1 to about 1 / 1.5, and from about 1 / 0.3 to about 1 / 0.66. Within this ratio, the ratio of the second polyol to the monomeric polyol affects the properties of the adhesive composition, such as the tensile strength and water solubility of the cured adhesive. For example, a ratio of the second polyol to the monomeric polyol between about 0.1 / 0.9 and about 0.9 / 0.1, for example between about 0.3 / 0.7 and 0.7 / 0.3, or between about 0.4 / 0.6 and 0.6 / 0.4, provides a desired balance of mechanical and physical color properties. In various exemplary embodiments, the ratio of the second polyol to the monomeric polyol is about 0.5 / 0.5.

[0090] In any aqueous adhesive composition disclosed herein, a protective agent may be used to temporarily block all or a certain percentage of the acid functional groups in a polycarboxylic acid, which temporarily prevents the acid functional groups from complexing with mineral wool fibers and is subsequently removed by heating the adhesive composition to a temperature of at least 150°C, releasing the acid functional groups during the curing process 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 between about 25% and about 99%, about 30% and about 90%, and about 40% and about 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.

[0091] The protective agent can reversibly bind to the carboxylic acid group of the crosslinking agent. In any exemplary embodiment, the protective agent comprises any compound that contains a molecule capable of forming at least one reversible ionic bond with a single 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, hexamethylenediamine; alkanolamines, such as ethanolamine, diethanolamine, triethanolamine; ethylenediamine-N,N'-disuccinic acid (EDDS), ethylenediaminetetraacetic acid (EDTA), etc., or mixtures thereof. Furthermore, alkanolamines can be used both as protective agents and as participants in the crosslinking reaction to form esters in the cured adhesive. Thus, alkanolamines have a dual function as both a protective agent and a polyol for crosslinking with polycarboxylic acids via esterification.

[0092] The protective agent functions differently from conventional pH adjusters. As defined herein, the protective agent only temporarily and reversibly blocks the acid functional groups in the polymerized polycarboxylic acid component. In contrast, conventional pH adjusters (e.g., sodium hydroxide) permanently terminate acid functional groups, preventing crosslinking between the acid and hydroxyl groups due to the blocked acid functional groups. Therefore, the addition of a conventional pH adjuster (e.g., 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 exemplary embodiment disclosed herein, the adhesive 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.

[0093] Any adhesive composition disclosed herein may further include an additive blend comprising one or more processing additives that improve the processability of the adhesive composition by reducing the viscosity and tackiness of the adhesive, thereby producing a more uniform insulating product with increased tensile strength and hydrophobicity. While various additives capable of reducing the viscosity and / or tackiness of adhesive compositions are available, conventional additives are inherently hydrophilic, making the inclusion of such additives increase the overall water absorption of the adhesive composition. The additive blend may contain one or more processing additives. Examples of processing additives include surfactants, glycerin, 1,2,4-butanetriol, 1,4-butanediol, 1,2-propanediol, 1,3-propanediol, and polyethylene glycol (e.g., Carbowax). TMThe surfactant may include dispersions of monooleate polyethylene glycol (MOPEG), silicone, polydimethylsiloxane (PDMS), emulsions and / or dispersions of mineral oil, paraffin oil, or vegetable oil, waxes such as amide waxes (e.g., ethylene bis-stearamide (EBS)) and carnauba wax (e.g., ML-155), hydrophobic silica, ammonium phosphate, or combinations thereof. Surfactants may include nonionic surfactants, including nonionic surfactants having alcohol functional groups. Exemplary surfactants include... Alkyl polyglucosides (e.g.) ) and ethoxylated alcohols (e.g. ).

[0094] Additive blends may include a single processing additive, a mixture of at least two processing additives, a mixture of at least three processing additives, or a mixture of at least four processing additives. In any of the embodiments disclosed herein, the additive blend may comprise a mixture of glycerol and polydimethylsiloxane.

[0095] The additive blend may be present in the adhesive composition in amounts ranging from 1.0 wt% to 20 wt%, 1.25 wt% to 17.0 wt%, or 1.5 wt% to 15.0 wt%, or about 3.0 wt% to about 12.0 wt%, or about 5.0 wt% to about 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. Thus, 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.

[0096] In embodiments where the additive blend contains glycerol, 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 adhesive composition. In any exemplary embodiment, the adhesive composition may contain 5.0% to 15% by weight of glycerol based on the total solids content of the adhesive composition, including 6.5% to 13.0% by weight, 7.0% to 12.0% by weight, and 7.5% to 11.0% by weight of glycerol.

[0097] In embodiments where the additive blend comprises polydimethylsiloxane, the polydimethylsiloxane may be present in an amount of at least 0.2% by weight, or at least 0.5% by weight, or at least 0.8% by weight, or at least 1.0% by weight, or at least 1.5% by weight, or at least 2.0% by weight, based on the total solids content of the adhesive composition. In any exemplary embodiment, the adhesive composition may comprise from 0.5% by weight to 5.0% by weight of polydimethylsiloxane based on the total solids content of the adhesive composition, including from 1.0% by weight to 4.0% by weight, 1.2% by weight to 3.5% by weight, 1.5% by weight to 3.0% by weight, and 1.6% by weight to 2.3% by weight of polydimethylsiloxane.

[0098] In any of the embodiments disclosed herein, the additive blend may comprise a mixture of glycerol and polydimethylsiloxane, wherein, based on the total solids content of the adhesive composition, glycerol comprises 5.0% to 15% by weight of the adhesive composition, and polydimethylsiloxane comprises 0.5% to 5.0% by weight of the adhesive composition. In any of the embodiments disclosed herein, the additive blend may comprise a mixture of glycerol and polydimethylsiloxane, wherein, based on the total solids content of the adhesive composition, glycerol comprises 7.0% to 12% by weight of the adhesive composition, and polydimethylsiloxane comprises 1.2% to 3.5% by weight of the adhesive composition.

[0099] In any of the embodiments disclosed herein, the additive blend may contain an increased concentration of silane coupling agent. Conventional adhesive compositions typically contain less than 0.5% by weight and more typically about 0.2% by weight or less of silane based on the total solids content of the adhesive composition. Therefore, in any of the embodiments disclosed herein, the silane coupling agent may be present in the adhesive composition in an amount of about 0.5% by weight to about 5.0% by weight (including about 0.7% by weight to about 2.5% by weight, about 0.85% by weight to about 2.0% by weight, or about 0.95% by weight to about 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 about 1.0% by weight.

[0100] The 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% and 0.03% by weight of silane coupling agent on the glass fibers. However, by increasing the amount of the included silane coupling agent applied to the fibers, the amount of silane on the glass fibers increases to at least 0.10% by weight.

[0101] Alternatively, the adhesive composition may contain a conventional amount of silane coupling agent (if any). In such embodiments, the silane coupling agent may be present in the adhesive composition in an amount from 0% by weight to less than 0.5% by weight (including from about 0.05% by weight to about 0.4% by weight, from about 0.1% by weight to about 0.35% by weight, or from about 0.15% by weight to about 0.3% by weight) of the total solids in the adhesive composition.

[0102] Non-limiting examples of silane coupling agents that can be used in adhesive compositions, characterized by functional groups of alkyl, aryl, amino, epoxy, vinyl, methacryloxy, urea, isocyanate, and mercapto. In 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), 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), hydrocarbontrialkoxysilanes, aminotrihydroxysilanes, epoxytrihydroxysilanes, methacryloxytrihydroxysilanes, and / or hydrocarbontrihydroxysilanes. In one or more exemplary embodiments, the silane is an aminosilane, such as γ-aminopropyltriethoxysilane.

[0103] Any aqueous adhesive composition disclosed herein may further include an esterification catalyst, also known as a curing accelerator. The catalyst may include inorganic salts, Lewis acids (i.e., aluminum chloride or boron trifluoride), Bronsted acids (i.e., sulfuric acid, p-toluenesulfonic acid, and boric acid), organometallic complexes (i.e., lithium carboxylate, sodium carboxylate), and / or Lewis bases (i.e., polyethyleneimine, diethylamine, or triethylamine). Furthermore, the catalyst may include alkali metal salts of phosphoric acid-containing organic acids; particularly alkali metal salts of phosphoric acid, hypophosphoric acid, or polyphosphoric acid. Examples of such phosphorus catalysts include, but are not limited to, sodium hypophosphite, sodium phosphate, potassium phosphate, disodium pyrophosphate, tetrasodium pyrophosphate, sodium tripolyphosphate, sodium hexametaphosphate, potassium phosphate, potassium tripolyphosphate, sodium trimetaphosphate, and sodium tetramethonium phosphate, and mixtures thereof. Additionally, 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 (or alternatively) be used as catalysts.

[0104] The catalyst may be present in the aqueous adhesive composition in an amount of about 0% to about 10% of the total solids in the adhesive composition, including but not limited to about 1% to about 5% by weight, or about 2% to about 4.5% by weight, or about 2.8% to about 4.0% by weight, or about 3.0% to about 3.8% by weight.

[0105] Optionally, the aqueous adhesive composition may contain at least one coupling agent. In at least one exemplary embodiment, the coupling agent is a silane coupling agent. The coupling agent may be present in the adhesive composition in an amount of about 0.01% to about 5% by weight, about 0.01% to about 2.5% by weight, about 0.05% to about 1.5% by weight, or about 0.1% to about 1.0% by weight of the total solids in the adhesive composition.

[0106] Non-limiting examples of silane coupling agents that can be used in adhesive compositions can be characterized by functional groups such as alkyl, aryl, amino, epoxy, vinyl, methacryloxy, urea, isocyanate, and mercapto. In any embodiment, the silane coupling agent may comprise a silane containing one or more nitrogen atoms having one or more functional groups, such as amines (primary, secondary, tertiary, and quaternary), 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), hydrocarbontrialkoxysilanes, aminotrihydroxysilanes, epoxytrihydroxysilanes, methacryloxytrihydroxysilanes, and / or hydrocarbontrihydroxysilanes. In any of the embodiments disclosed herein, the silane may comprise an aminosilane, such as γ-aminopropyltriethoxysilane.

[0107] The aqueous adhesive composition may further include process aids. There are no particular limitations on the process aids, as long as they function to promote fiber formation and / or orientation. These process aids can be used to improve the uniformity of adhesive application distribution, reduce adhesive viscosity, increase the ramp height after formation, improve the uniformity of vertical weight distribution, and / or accelerate adhesive dehydration during both the formation and oven curing processes. The process aids may be present in the adhesive composition in amounts from 0% to about 10.0% by weight, from about 0.1% to about 5.0% by weight, or from about 0.3% to about 2.0% by weight, or from about 0.5% to about 1.0% by weight, based on the total solids content in the adhesive composition. In some exemplary embodiments, the aqueous adhesive composition contains substantially no or no process aids.

[0108] Examples of process aids include defoamers, such as emulsions and / or dispersions of mineral oil, paraffin oil, or vegetable oil; dispersions of polydimethylsiloxane (PDMS) fluids; and silica hydrophobically treated with PDMS or other materials. Additional process aids may include particles made of amide waxes, such as ethylene bis-stearamide (EBS) or hydrophobically treated silica. Further process aids that can be used in adhesive compositions are surfactants. Adhesive compositions may include one or more surfactants to aid in adhesive atomization, wetting, and interfacial adhesion.

[0109] Surfactants are not particularly limited and include, for example, but not limited to, ionic surfactants (e.g., sulfates, sulfonates, phosphates, and carboxylates); sulfate esters / salts (e.g., alkyl sulfate esters / salts, ammonium lauryl sulfate, sodium lauryl sulfate (SDS), alkyl ether sulfate esters / salts, sodium laureth sulfate, and sodium myristyl ether sulfate). sulfates); amphoteric surfactants (e.g., alkyl betaines, such as lauryl betaine); sulfonates / salts (e.g., sodium dioctyl sulfosuccinate, perfluorooctane sulfonate / salt, perfluorobutane sulfonate / salt, and alkylbenzene sulfonate / salt); phosphates / salts (e.g., alkyl aryl ether phosphates / salts and alkyl ether phosphates / salts); carboxylic acid esters / salts (e.g., alkyl carboxylic acid esters / salts, fatty acid salts (soaps), sodium stearate, sodium lauroyl sarcosinate, carboxylic acid ester / salt fluorosurfactants, perfluoronanoate / salt, and perfluorooctanoate / salt); 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 chloride); and zwitterionic surfactants, quaternary ammonium salts (e.g. lauryl trimethyl ammonium chloride and alkyl benzyl dimethyl ammonium chloride) and polyoxyethylene alkylamines.

[0110] Suitable nonionic surfactants that can be used in conjunction with adhesive compositions 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., heptaphenoxy poly(ethyleneoxy)ethanol and nonylphenoxy poly(ethyleneoxy)ethanol); polyoxyethylene derivatives of hexitol, including sorbitol, sorbitan, monomannitol, and dimannitol; and partially long-chain fatty acid esters (e.g., sorbitol monolaurate, sorbitol monopalmitate, sorbitol monostearate). Polyoxyethylene derivatives of sorbitol esters, sorbitol tristearate, sorbitol monooleate, and sorbitol trioleate; condensates of ethylene oxide with a hydrophobic base, the base being 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 (e.g., 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., octyl alcohol, decyl alcohol, lauryl alcohol, or hexadecyl alcohol); and ethylene oxide / propylene oxide copolymers.

[0111] In at least one exemplary embodiment, the surfactant comprises one or more Dynol 607s, which are 2,5,8,11-tetramethyl-6-dodecyne-5,8-diols. and It consists of ethoxylated 2,4,7,9-tetramethyl-5-decyn-4,7-diol surfactant (commercially available from Evonik Corporation (Allentown, Pa.)), Stanfax (sodium lauryl sulfate), Surfynol 465 (ethoxylated 2,4,7,9-tetramethyl-5-decyn-4,7-diol), and Triton. TM GR-PG70 (sodium 1,4-bis(2-ethylhexyl)sulfosuccinate) and Triton TM CF-10 (poly(oxy-1,2-ethanediyl), α-(phenylmethyl)-ω-(1,1,3,3-tetramethylbutyl)phenoxy).

[0112] Optionally, the aqueous adhesive composition may contain a dust suppressant to reduce or eliminate the presence of inorganic and / or organic particles that can adversely affect the subsequent manufacturing and installation of the insulation material. The dust suppressant can be any conventional mineral oil, mineral oil emulsion, natural or synthetic oil, bio-based oil, or lubricant, such as, but not limited to, silicones and silicone emulsions, polyethylene glycol, and any petroleum or non-petroleum oil with a high flash point, to minimize oil evaporation within the oven.

[0113] The aqueous adhesive composition may include up to about 15% by weight of a dust suppressant, including up to about 14% by weight or up to about 13% by weight. In any embodiment disclosed herein, the aqueous adhesive composition may include between 1.0% and 15% by weight of a dust suppressant, including about 3.0% by weight to about 13.0% by weight, or about 5.0% by weight to about 12.8% by weight.

[0114] The aqueous adhesive composition may optionally include organic and / or inorganic acids and bases as pH adjusters, in an amount sufficient to adjust the pH to a desired level. The pH can be adjusted according to the intended application to promote compatibility of the components of the adhesive composition or to work with various types of fibers. In some exemplary embodiments, the pH adjuster is used to adjust the pH of the adhesive composition to an acidic pH. Examples of suitable acidic pH adjusters include inorganic acids, such as, but not limited to, sulfuric acid, phosphoric acid, and boric acid, and organic acids, such as p-toluenesulfonic acid, monocarboxylic acids, or polycarboxylic acids, such as, but not limited to, citric acid, acetic acid and its anhydrides, adipic acid, oxalic acid, and their corresponding salts. Furthermore, inorganic salts may be acid precursors. Acids adjust the pH, and in some cases, as described above, acids act as crosslinking agents. Organic and / or inorganic bases may be included to increase the pH of the adhesive composition. Bases may be volatile or non-volatile. Exemplary volatile bases include, for example, ammonia and alkyl-substituted amines, such as methylamine, ethylamine, or 1-aminopropane, dimethylamine, and ethylmethylamine. Exemplary non-volatile bases include, for example, sodium hydroxide, potassium hydroxide, sodium carbonate, and tert-butylammonium hydroxide.

[0115] In any exemplary embodiment, when in an uncured state, the adhesive composition may have an acidic pH, for example, a pH in the range of about 2.0 to about 5.0, including all amounts and ranges between therewith. In any embodiment disclosed herein, when in an uncured state, the pH of the adhesive composition is about 2.2 to about 4.0, including about 2.5 to about 3.8 and about 2.6 to about 3.5. After curing, the pH of the adhesive composition may rise to at least about 5.0, including levels between about 6.5 and about 8.8 or between about 6.8 and about 8.2.

[0116] Alternatively, when in an uncured state, the adhesive composition can be adjusted to a more alkaline pH, such as between about 5 and about 10, or between about 6 and about 9, or between about 7 and about 8.

[0117] The adhesive further includes water to dissolve or disperse the active solids for application to the reinforcing fibers. Water can be added in an amount sufficient to dilute the aqueous adhesive composition to a viscosity suitable for its application to the reinforcing fibers and to obtain the desired solids content on the fibers. It has been found that this adhesive composition can contain a lower solids content than conventional phenol-urea-formaldehyde or carbohydrate-based adhesive compositions. Specifically, the adhesive composition can contain 5% to 35% by weight of adhesive solids, including but not limited to 10% to 30% by weight, 12% to 20% by weight, and 15% to 19% by weight of adhesive solids. This solids level indicates that the subject adhesive composition can include more water than conventional adhesive compositions.

[0118] Table 1 below provides exemplary adhesive compositions comprising the materials described above. The exemplary compositions listed in Table 1 may include optional additives or materials, as described above.

[0119] Table 1

[0120]

[0121] Example fiber insulation product 100 Figure 1 As shown. Fiber insulation product 100 can be configured in various ways. Figure 1 In the illustrated embodiment, the fiber insulation product 100 is an integrally box-shaped fiberglass insulation pad; however, the insulation product can be any suitable shape or size, such as a rolled product or felt. As an insulation pad or felt, the fiber insulation product 100 can be placed within an insulation cavity of a building. For example, the fiber insulation product 100 can be placed in a space or cavity between two parallel, spaced-apart frame members in the wall, roof, or floor frame of a building.

[0122] The fiber insulation product 100 includes an insulation layer 102 comprising nonwoven glass fibers and an adhesive composition for adhering the glass fibers together. Optionally, the fiber insulation product 100 may also include a surface 104 attached or otherwise adhered to the insulation layer 102. The fiber insulation product 100 includes a first side surface 106, a second side surface 108 spaced apart from and opposite to the first side surface 106, a third side surface 110 extending between the first side surface 106 and the second side surface 108, and a fourth side surface 112 spaced apart from and opposite to the third side surface 110 and extending between the first side surface 106 and the second side surface 108. The fiber insulation product 100 also includes a first surface 114 connecting the side surfaces 106, 108, 110, and 112, and a second surface 116 parallel or substantially parallel to and opposite to the first surface 114 and connecting the side surfaces 106, 108, 110, and 112. The fiber insulation product 100 has a length L1, a width W1, and a thickness T1 when uncompressed. In some embodiments, the length L1 is greater than the width W1, and the width W1 is greater than the thickness T1.

[0123] A cover 104 may be disposed on the insulation layer 102 to cover all or part of the first side 114, the second side 116, or both sides of the fiber insulation product 100. The cover 104 can take a variety of different forms. The cover 104 can be a single sheet or multiple different sheets or plates of material, and can comprise a single layer or multiple layers of material. Figure 1 In an exemplary embodiment, the cover 104 is a single sheet of material that covers all of the first surface 114 of the fiber insulation product 100.

[0124] The cover 104 can be made of a variety of different materials. Any material suitable for use with fiber insulation products can be used. For example, the cover 104 can comprise nonwoven glass fibers and polymeric media; woven glass fibers and polymeric media; protective materials, such as protective films made of polymeric materials; base fabric; cloth; textiles; glass fiber reinforced kraft paper (FRK); foil-base fabric-kraft paper laminates; recycled paper; and calendared paper.

[0125] The bulk insulation placed in the insulation cavity of a building is in the form of rolled insulation felt from insulation products (such as those described herein). The surface insulation product is fitted with a cover 104, which is laid flat on the edge of the insulation cavity, typically on the inner side of the cavity. Insulation products with a vapor inhibitor cover are commonly used to insulate wall, floor, or ceiling cavities that separate warm interior spaces from cold exterior spaces. A vapor inhibitor is placed on one side of the insulation product to impede or prevent the movement of water vapor through the insulation.

[0126] Figure 2An exemplary embodiment of an apparatus 118 for manufacturing a fiber insulation product 100 is shown. The process involves fiberizing molten glass, coating the molten glass fibers with an adhesive, forming a fiberglass layer on a porous moving conveyor (also referred to as a “forming chain”), and curing the adhesive composition to form a fiberglass layer as shown. Figure 2 The insulation felt shown can be manufactured in a continuous process as fiber insulation product 100. Glass can be melted in a tank (not shown) and supplied to a fiber forming apparatus, such as one or more fiberizing spindles 119. Although the spindle 119 is shown as a fiber forming apparatus in the exemplary embodiment, it should be understood that other types of fiber forming units can also be used to form fiber insulation product 100. The spindle 119 rotates at a high speed. Centrifugal force causes the molten glass to pass through small holes in the circumferential sidewalls of the fiberizing spindle 119 to form glass fibers. Glass fibers 130 of random length can be drawn from the fiberizing spindle 119 and blown generally downward (i.e., generally perpendicular to the plane of the spindle 119) by a blower 120 located in the forming chamber 125.

[0127] Blower 120 moves glass fiber 130 downwards. Before entering and while being conveyed downwards in forming chamber 125, and while still hot from the drawing operation, glass fiber 130 is sprayed with an aqueous adhesive composition via an annular spray ring 135, resulting in a relatively uniform distribution of the adhesive composition throughout the glass fiber 130. Water may also be applied to the glass fiber 130 in forming chamber 125, for example, by spraying, before applying the adhesive composition to at least partially cool the glass fiber 130.

[0128] Glass fibers 130 with an uncured aqueous adhesive composition adhered thereto can be collected and formed into a fiber layer 140 on an annular forming conveyor 145 within a forming chamber 125, by means of a vacuum (not shown) drawn through the fiber layer 140 from below the forming conveyor 145. During the forming operation, residual heat from the glass fibers 130 and the airflow through the fiber layer 140 are generally sufficient to evaporate most of the water from the adhesive composition before the glass fibers 130 leave the forming chamber 125, thus leaving the remaining components of the adhesive composition as a viscous or semi-viscous liquid with a high solids content on the glass fibers 130.

[0129] The resin-coated fiber layer 140 (compressed due to the airflow passing through it in the molding chamber 125) is then transferred from the molding chamber 125 to the transfer zone 155 under the exit roller 150, where the fiber layer 140 expands vertically due to the elasticity of the glass fibers 130. The expanded fiber layer 140 is then heated, for example by conveying it through a curing oven 160, in which heated air is blown through it to evaporate any remaining water in the adhesive composition, thereby curing the adhesive composition and rigidly bonding the glass fibers 130 together. The curing oven 160 includes a perforated upper oven conveyor 165 and a perforated lower oven conveyor 170, between which the fiber layer 140 is drawn. Heated air is forced through the lower oven conveyor 170, the fiber layer 140, and the upper oven conveyor 165 by a fan 175. The heated air exits the curing oven 160 through an exhaust device 180.

[0130] Furthermore, in the curing oven 160, the fiber layer 140 can be compressed by the upper and lower perforated oven conveyors 165 and 170 to form the insulation layer 102 of the fiber insulation product 100. The distance between the upper and lower oven conveyors 165 and 170 can be used to compress the fiber layer 140 so that the insulation layer 102 has its predetermined thickness T1. It should be understood that, although Figure 2 Conveyors 165 and 170 are depicted as being in a substantially parallel orientation, but they may alternatively be positioned at an angle relative to each other (not shown).

[0131] The cured adhesive composition imparts strength and elasticity to the insulation layer 102. It should be understood that the drying and curing of the adhesive composition can be carried out in one or two different steps. A two-stage (two-step) process is commonly referred to as Stage B. The curing oven 160 can be operated at temperatures ranging from 100°C to 325°C or from 250°C to 300°C. The fiber layer 140 can be held within the curing oven 160 for a sufficient period to crosslink (cur) the adhesive composition and form the insulation layer 102.

[0132] Once the insulation layer 102 exits the curing oven 160, a cover material 193 can be placed on the insulation layer 102 to form a cover layer 104. The cover material 193 can be adhered to a first side 114, a second side 116, or both sides of the insulation layer 102 by an adhesive (not shown) or some other means (e.g., stitching, mechanical winding) to form a fiber insulation product 100. Suitable adhesives include adhesives, polymeric resins, bitumen, and bitumen-containing materials, which can be coated or otherwise applied to the cover material 193. The fiber insulation product 100 can then be rolled for storage and / or transport, or cut to a predetermined length by a cutting device (not shown). It should be understood that in some exemplary embodiments, the insulation layer 102 exiting the curing oven 160 is rolled onto a take-up roller or cut into sections of the desired length and does not face the cover material 193.

[0133] Surprisingly, it has been found that, with lower-than-expected product weight and thickness, fiber insulation products with desired thermal and material efficiencies can be manufactured using fine glass fibers with a diameter of less than 3.81 micrometers or 15 HT. Insulation products formed with fibers with an average diameter of less than 15 HT are, interchangeably, referred to below as “fine fiber” insulation products or “invented” fiber insulation products.

[0134] Without being bound by theory, it is believed that a unique combination of thin fibers with a diameter of less than 15HT, a low-viscosity formaldehyde-free adhesive composition, and certain processing parameters contributes to the orientation of more fibers (or fiber segments) within certain degrees along a plane generally parallel to the forming chain (referred to herein as the L1 direction or machine direction). Therefore, the fiber insulation products of the invention produced therefrom have a more aligned fiber orientation along the L1 direction than seen in other comparable insulation products formed with fibers having an average fiber diameter greater than 15HT. Consequently, when the fiber insulation products of the invention are installed in wall cavities, ceilings, floors, or similar building structures, the oriented fibers are aligned in a plane more perpendicular to the direction of heat flow, thereby reducing the product's ability to conduct heat through the thickness of the material.

[0135] Figure 3 The image is a SEM image showing the aforementioned orientation of fibers (or fiber segments) along a plane that is generally more parallel to the L1 direction. The SEM image was obtained from a microfiber insulation product 200 with an R value of 22, which comprises glass fibers having an average fiber diameter of 14.5 HT and a formaldehyde-free adhesive composition comprising a monomeric polyol and a polycarboxylic acid crosslinking agent. Figure 3 The SEM image shows a 2.5mm × 1.5mm product sample and measures local fiber vectors (fiber segments in a specific plane).

[0136] Figure 4and Figure 5 Further SEM images of fiber insulation product samples are shown, in which... Figure 4 The product sample contained glass fibers with an average fiber diameter of 14.5 HT and an R-value of 22 (hereinafter referred to as Sample A); and Figure 5 The product sample in the sample contains glass fibers with an average fiber diameter of 16.7 HT and has an insulation value of R21 (hereinafter referred to as Sample B). SEM images of Samples A and B were obtained using Thermo Scientific Prisma SEM and the images were stitched together using Thermo Scientific MAPS software. The samples were cut in cross-section in the machine orientation, mounted on SEM posts using carbon glue and carbon paste, and coated with Au sputtering. Fiber orientation measurements and quantifications were obtained using the Orientation J plugin from Image J software. The Gaussian window σ was set to 1 pixel, and a Gaussian gradient was selected for the structural tensor.

[0137] The surface region (5.24 mm × 3.14 mm) of each sample A and B in the machine direction was imaged and the orientation distribution was analyzed. To analyze the orientation distribution, local glass fibers (or their fiber vectors or segments) were measured. The relationship between orientation frequency (normalized) and orientation (degree) was plotted and provided for each sample. Figure 6-8 The following shows the weight percentage of fibers (or their fiber vectors or segments) in sample A within a range of + / -50°, + / -30°, and + / -15° starting from the common plane (0°) level with the product length L1.

[0138] Surprisingly, it was found that, compared to insulation products with glass fibers having the same R-value but an average diameter greater than 15HT, an increased proportion of the glass fibers (or their fiber vectors or segments) are oriented along a common plane. In particular, in any exemplary embodiment, at least 30% by weight of the fibers (or their fiber vectors or segments) in the microfiber insulation product may be oriented within + / -15° of the common plane. Figure 6 A diagram is shown outlining an exemplary fiber orientation distribution within + / -15° of a common plane in a fiber insulation product of the invention, the fiber insulation product comprising glass fibers having an average fiber diameter of 14.5 HT. In these embodiments, the fine fiber insulation product may comprise or be composed of fibers, wherein at least 35 wt%, at least 40 wt%, and at least 44 wt% of the fibers (or fiber vectors or segments thereof) are oriented within + / -15° of the common plane. In any exemplary embodiment, the common plane may be a plane parallel to the length and width of the insulation product.

[0139] It has been further discovered that, in any exemplary embodiment, at least 50% by weight or at least 55% by weight of glass fiber (or its fiber vector or segments) in the fiber insulation product may be oriented within + / -30° of a common plane. Figure 7 A diagram outlining an exemplary fiber orientation distribution within a common plane of + / -30° in a fiber insulation product of the invention is shown, the fiber insulation product comprising glass fibers having an average fiber diameter of 14.5 HT. In these embodiments, the fiber insulation product may comprise or be composed of fibers, wherein at least 57 wt%, at least 60 wt%, at least 65 wt%, and at least 69 wt% of the fibers (or fiber vectors or segments thereof) are oriented within + / -30° of the common plane. In any exemplary embodiment, the common plane may be a plane parallel to the length and width of the insulation product.

[0140] In another exemplary embodiment, at least 75% by weight of the fibers (or fiber vectors or segments thereof) in the microfiber insulation product are oriented within + / - 50° of the common plane. Figure 8 A diagram outlining an exemplary fiber orientation distribution within a common plane of + / -50° in a fiber insulation product of the invention is shown, the fiber insulation product comprising glass fibers having an average fiber diameter of 14.5 HT. In these embodiments, the fiber insulation product may comprise or be composed of fibers, wherein at least 78 wt%, at least 80 wt%, at least 82 wt%, and at least 85 wt% of the fibers (or fiber vectors or segments thereof) are oriented within + / -50° of the common plane. In any exemplary embodiment, the common plane may be a plane parallel to the length and width of the insulation product.

[0141] Figure 9(a) is a magnified SEM image of the fiber orientation of a sample-sized region (24 mm × 16 mm) of an exemplary fine-fiber thermal insulation product (hereinafter referred to as Sample C) formed according to the present invention. Sample C has an R value of 22 and comprises glass fibers having an average fiber diameter of about 14 HT and a formaldehyde-free adhesive composition comprising about 25-30% by weight of sorbitol and about 65-70% by weight of polyacrylic acid crosslinking agent, having a viscosity of about 2000-3000 cps at a solids content of 60%-65%. The aqueous adhesive composition of Sample C has a viscosity of less than 12000 cps at a solids content of 74.5%, and a viscosity of less than 6000 cps at solids content of 70% and less than 70%.

[0142] The adhesive composition, the SEM image in Figure 9(a) is used to measure local fiber vector orientation (fiber segments in a specific plane).

[0143] In contrast, but also within the scope of the present invention, Figure 10(a) is a SEM image showing the fiber orientation of a microfiber insulation product with an R-value of 22, the microfiber insulation product comprising glass fibers having an average fiber diameter of about 14 HT and a formaldehyde-free adhesive composition comprising about 35-45 wt% sorbitol and about 35-45 wt% polyacrylic acid crosslinking agent, having a viscosity of less than 2000 cps at a solids content of 60%-65% (hereinafter referred to as Sample D). The aqueous adhesive composition of Sample D has a viscosity of less than 12000 cps at a solids content of 74.5%, and a viscosity of less than 6000 cps at solids content of 70% and less than 70%.

[0144] SEM images of samples C and D were obtained using the Thermo Scientific Prisma SEM, and the images were stitched together using Thermo Scientific MAPS software. Samples were cut in cross-section along the machine orientation, mounted on SEM studs using carbon glue and carbon paste, and coated with Au sputtering. Fiber orientation measurements and quantifications were obtained using the Orientation J plugin from Image J software. The Gaussian window σ was set to 1 pixel, and a Gaussian gradient was selected for the structure tensor.

[0145] Image and analyze the orientation distribution of each surface region (24 mm * 16 mm) in the machine direction for samples C and D. Similar to samples A and D, measure and analyze the orientation distribution of local glass fibers (or their fiber vectors or segments) from samples C and D. Plot and provide the relationship between orientation frequency (normalized) and orientation (degree) for each sample. Figure 9(b) and 10(b) The weight percentages of fibers (or their fiber vectors or segments) in samples C and D are shown respectively, within a range of + / -50°, + / -30°, and + / -15° from the common plane (0°) level with the product length L1.

[0146] Surprisingly, reducing the viscosity of the adhesive used to form sample D increased the proportion of glass fibers (or fiber vectors or segments thereof) oriented along a common plane. Specifically, as shown in Figure 9(b) and Table 2 below, in sample C, 32.94 wt% of the fibers (or fiber vectors or segments thereof) were oriented within + / -15° of the common plane, 57.07 wt% within + / -30°, and 78.87 wt% within + / -50°. Further, as shown in Figure 10(b) and Table 2 below, in sample D, 45.14 wt% of the fibers (or fiber vectors or segments thereof) were oriented within + / -15° of the common plane, 66.23 wt% within + / -30°, and 84.03 wt% within + / -50°. As mentioned above, the common plane can be a plane parallel to the length and width of the insulation product.

[0147] Table 2

[0148] + / -15° 32.94％ 45.14％ + / -30° 57.07％ 66.23％ + / -50° 78.87％ 84.03％

[0149] Furthermore, although at least a portion of the fibers (or fiber vectors or segments thereof) within the fiber insulation product are oriented in a planar manner generally parallel to the forming chain or the "L1 direction," the fiber insulation product may further include a portion of fibers (or fiber vectors or segments thereof) oriented in a planar manner generally perpendicular to the L1 direction. This "dual-oriented" fiber insulation product exhibits excellent thermal properties, while also demonstrating improved recyclability and / or resistance to compressive forces. The dual-oriented fiber insulation product may contain at least 10% by weight of fibers (or fiber vectors or segments thereof) oriented in a planar manner generally perpendicular to the L1 direction, including at least 15% by weight, at least 18% by weight, at least 20% by weight, at least 25% by weight, at least 28% by weight, and at least 30% by weight of fibers (or fiber vectors or segments thereof).

[0150] In some exemplary embodiments, the fiber insulation product has the presence of an additional parallel fiber bundle 202, which comprises at least two fibers oriented in substantially parallel directions and bonded to each other at one or more points along the fiber length. Figures 11(a)-11(c) The magnified SEM image shows parallel fiber bundles present in the fiber insulation product. Figures 12(a)-12(c) Provided Figure 3 The further magnified SEM image of the fiber insulation product shown further illustrates the prevalence of parallel fiber bundles. The parallel fiber bundles 202 can form joints with individual fibers 204 or with other parallel fiber bundles 202.

[0151] In any exemplary embodiment, at least 15% by weight of the fibers in the fiber insulation product 200 may be at least partially included in parallel fiber bundles. In other exemplary embodiments, at least 20% by weight of the fibers in the fiber insulation product are at least partially included in parallel fiber bundles, including at least 25% by weight, at least 28% by weight, at least 30% by weight, at least 35% by weight, at least 40% by weight, at least 45% by weight, and at least 50% by weight of the fibers in the fiber insulation product.

[0152] Further findings indicate that, in any of the exemplary embodiments disclosed herein, the fiber insulation product may have a reduced presence of adhesive clumps extending between at least two fibers. As defined herein, an adhesive "clump" refers to a portion of the cured adhesive composition extending between at least two fibers, typically triangular or elongated rhomboid, resembling an angled support. Adhesive clumps are measured using a microscope (e.g., an optical microscope or a scanning electron microscope). In the case of optical microscopy, using a refractive index solution to "hide" the glass fibers helps confirm the adhesive-fiber joints and clumps. Figure 13(a) and 13(b) The document provides an SEM image illustrating an exemplary adhesive clump.

[0153] The formation of adhesive clumps between non-parallel fibers indicates that the fibers are oriented in different planes. Without being bound by theory, it is believed that minimizing adhesive clumps and increasing the presence of the adhesive composition along the fiber length is beneficial both for improving uniform orientation and for increasing the presence of parallel fiber bundles.

[0154] Due to the increased uniformity of fiber orientation, in some exemplary embodiments, no more than 40% by weight of the adhesive composition present in the fiber insulation product is located within the adhesive agglomerates. In any exemplary embodiment, no more than 35% by weight of the adhesive composition is located within the adhesive agglomerates, including no more than 30% by weight, no more than 25% by weight, no more than 20% by weight, no more than 15% by weight, no more than 10% by weight, and no more than 5% by weight.

[0155] Furthermore, due to the increased uniformity of fiber orientation, no more than 75% by weight of the adhesive is located within adhesive knots, which are portions of the adhesive composition distributed at the intersections between two or more intersecting fibers. In some exemplary embodiments, the amount of adhesive located within the adhesive knots is limited to no more than 60% by weight, including no more than 50% by weight, no more than 45% by weight, and no more than 40% by weight.

[0156] As stated above, various products and product parameters are believed to influence the fiber orientation in microfiber insulation products. Not intended to be theoretically constrained, it is believed that an increase in the number of fibers (or fiber vectors or segments thereof) oriented in a plane substantially parallel to the L1 direction is at least partially caused by the synergistic combination of small-diameter glass fibers (i.e., an average fiber diameter less than or equal to 3.81 micrometers (or 15 HT)) with a low-viscosity, formaldehyde-free adhesive composition. Specifically, at a temperature of 25°C and a solids concentration of 65-70 wt%, the adhesive composition has a viscosity not exceeding 90,000 cP, including viscosities not exceeding 50,000 cP, 25,000 cP, 15,000 cP, 10,000 cP, and 4,000 cP at 25°C and a solids concentration of 65-70 wt%.

[0157] In addition to affecting fiber orientation, the low viscosity of the adhesive composition also allows for reduced moisture in the fiber layer on the "ramp" as the package moves from the molding chamber to the curing oven. Importantly, the ramp moisture must be low enough as the fiber layer enters the curing oven to ensure complete and consistent curing of the product across the entire thickness of the package. In some exemplary embodiments, the viscosity of the adhesive composition is adjusted to ensure ramp moisture levels of no more than 7%, including levels of no more than 5%, no more than 3%, and no more than 2%.

[0158] The fiber insulation product has an adhesive content (LOI) of less than or equal to 10% by weight, or less than or equal to 8.0% by weight, or less than or equal to 6.0% by weight, or less than or equal to 3.0% by weight. In any exemplary embodiment, the insulation product has an adhesive content (LOI) of 1.0% to 10.0% by weight, including between 2.0% and 8.0% by weight, 2.5% to 6.0% by weight, or 3.0% to 5.0% by weight. Relatively low amounts of adhesive contribute to the flexibility of the final insulation product. In any exemplary embodiment, the fiber insulation product has an LOI of less than 4.5%, including less than 4.2%, less than 4.0%, less than 3.8%, and less than 3.5%.

[0159] Not intended to be theoretically constrained, the orientation of fine-diameter fibers (i.e., fibers with an average fiber diameter less than or equal to 15 HT or 3.81 micrometers) in a plane that is generally more parallel to the plane of the L1 (or machine) direction results in fiber-reinforced insulation products with surprisingly improved thermal performance and overall material efficiency. The thermal performance of glass fiber insulation products is based on the R-value of the glass fiber insulation product, which is a measure of the product's resistance to heat flow. The R-value is defined by equation (1):

[0160] Equation (1): R = T1 / k (1)

[0161] Where "T1" refers to the thickness of the insulation product in inches, and "k" refers to the thickness in BTU·in / hr·ft. 2 •°F represents the thermal conductivity of the insulation product, and “R” is expressed in hr·ft. 2 ·°F / BTU represents the thermal insulation R value.

[0162] As used in this article, the thickness (T1) of the insulation product can be determined according to ASTM C167-18, and the k value and area weight (in lb / ft) are also relevant. 2 (Units) Both can be determined according to ASTM C518-17 or ASTM C177-19.

[0163] The R-value, thermal conductivity, and material efficiency of thermal insulation products are parameters that provide indications of the thermal performance of thermal insulation products.

[0164] Material efficiency (“ME”) can be defined by equation (2):

[0165] Equation (2): ME = R value / W,

[0166] With R·ft 2 / lb indicates that "R" is the R-value of the insulation product and "W" is the area weight of the insulation product, expressed in lb / ft. 2 The unit is ME. ME measures how effectively a thermal insulation product resists heat flow and is a metric that can be used to quantify the performance of fiberglass insulation pads. To obtain a larger R·ft... 2 In terms of value, insulation suppliers typically increase the quantity of insulation material (in pounds-mass (lb)). Therefore, each pound of material provides a higher R·ft. 2 The insulation material is desirable, and this is measured by ME (i.e., the insulation benefit of the product divided by the amount of material used to provide the insulation benefit).

[0167] thermal conductivity

[0168] The fine fiber insulation products of this invention exhibit a surprisingly greater decrease in thermal conductivity at a given density. For example, Saint Gobain's 1995 publication (Langlais, C., Guilbert, G., Banner, D., and Klarsfeld, S. (1995). Influence of the Chemical Composition of Glass on Heat Transfer through Glass Fiber Insulations in Relation to Their Morphology and Temperature. J. Thermal Insulation and Building Envs., 18, 350-376) (hereinafter referred to as the "SG Publication") details a theoretical approach to predicting the thermal properties of fiber insulations. The SG Publication shows that, in addition to temperature and density, the average diameter of the fiber is found to be a means of reducing thermal conductivity and provides data demonstrating the effect of fiber diameter on thermal conductivity. The applicant has developed proprietary modeling teachings independent of the SG Publication, which predict curves nearly identical to those shown in the SG Publication. Therefore, the data presented in the SG publications (hereinafter referred to as “Expected Results”) are considered to indicate the expected thermal performance of glass fiber insulations at various densities and fiber diameters.

[0169] However, based on the expected results, the thermal conductivity of the invented glass fiber insulation product with an average fiber diameter of 3.6 micrometers in the density range of 0.2 pcf to 1.6 pcf was unexpectedly lower than the predicted thermal conductivity. Figure 14 The difference between the expected results (based on a glass fiber insulation product with an average fiber diameter of 3 micrometers) and the measured thermal conductivity of the invented 3.6-micrometer glass fiber insulation product is shown. As illustrated, the thermal conductivity value established from the expected results corresponds to equation (I):

[0170] Equation (I) y = 0.116x 2 -0.3002x+0.4319

[0171] Where y is the thermal conductivity (k value), expressed in BTU-in / (hr·ft). 2 ·°F) represents the density of the product, and x is the product density in lb / ft. 3 (“pcf”) represents this. Equation (I) has R 2 =0.9804, indicating high accuracy in this equation. In contrast, the measured thermal conductivity value of the invented 3.6-micron insulation product is derived from equation (II):

[0172] Equation (II) y = 0.1013x 2-0.2438x+0.3763

[0173] Where y is the thermal conductivity (k value), expressed in BTU-in / (hr·ft). 2 ·°F) represents the density of the product, and x is the product density in lb / ft. 3 Or pcf representation. Equation (II) has R 2 =0.9803, indicating high precision in the equation.

[0174] Therefore, at a given density, based on insulation products with even smaller average fiber diameters (3.0 μm vs. 3.6 μm), the invented 3.6 μm insulation product exhibits a significantly lower thermal conductivity than expected. For example, at a density of 0.8 pcf, Equation (I) outputs 0.2660 BTU-in / (hr·ft). 2 The thermal conductivity predicted for 0.2461 BTU-in / (hr·ft) is lower than that predicted for 0.2461 BTU-in / (hr·ft). 2 The thermal conductivity (k value) was measured at ·°F. A decrease of 0.0199 in the k value is statistically significant.

[0175] In some embodiments, within a density range of 0.2 pcf to 1.35 pcf, the fiber insulation products of this disclosure exhibit at least 0.01 BTU-in / (hr·ft) compared to the expected results. 2 The k value decreased by at least 0.015, at least 0.03, at least 0.05, at least 0.075, at least 0.1, at least 0.15, at least 0.2, and at least 0.23 BTU-in / (hr·ft). 2 The k value of ·°F decreases.

[0176] In any of the exemplary embodiments provided herein, the fiber insulation product may have a BTU-in / (hr·ft) 2 Thermal conductivity expressed in °F is equal to or less than the thermal conductivity (k value (y)) satisfying equation (III):

[0177] Equation (III): y = 0.116x 2 -0.3002x+0.4219

[0178] Where x is the product density in the range of 0.2 pcf and 1.6 pcf. Equation (III) is based on Equation (I), but reduced by 0.01 to ensure sufficient separation beyond the expected results. In these or other exemplary embodiments, the fiber insulation product may have a thermal conductivity (in BTU-in / (hr·ft)) within 10% or at least 5% of the value (y) satisfying Equation (IV). 2 ·°F) represents the value of k(y):

[0179] Equation (IV) y = 0.1013x 2 -0.2438x+0.3763

[0180] Where x is the product density in the range of 0.2 pcf and 1.6 pcf.

[0181] While specific benefits can be illustrated in low-density insulation products (i.e., less than 1.6 pcf), the density of fiber insulation products can vary in different embodiments. As used in this application, the density of the fiber insulation product is the density of the product after the adhesive composition has cured and the cured product is in a free state (i.e., not compressed or stretched). In various embodiments, the density of the fiber insulation product ranges from 0.2 pcf to 2.7 pcf. Table 3 lists the original densities (in pcf) of various exemplary embodiments of fiber insulation products having fine fibers ranging from 2.03 μm (8.0 HT) to 3.81 μm (15 HT). In Table 3, fiber diameter refers to the average fiber diameter measured by the airflow resistance method described above before the application of the adhesive composition. Thickness and original density refer to the thickness and density of the product after the adhesive composition has cured and the cured product is in a free state (i.e., not compressed or stretched).

[0182] Table 3

[0183]

[0184] The data in Table 3 shows fiber insulation products with R values ​​of 11 to 49, an average fiber diameter of less than or equal to 15 HT, an initial density in the range of 0.371 pcf to 1.214 pcf, and less than or equal to 6% by weight of an adhesive composition.

[0185] Material efficiency

[0186] As mentioned above, material efficiency is the product insulation value per pound of insulation material (R·ft). 2 The measure of R·ft 2 / lb represents the weight. By maximizing material efficiency, insulation products can provide high insulation performance at the lowest possible weight. In other words, due to its improved material efficiency, the invented insulation product can achieve equivalent insulation performance at a lower weight / density. Reducing product weight allows for a reduction in the amount of glass fiber and adhesive materials required, and thus lowers overall costs (e.g., production, storage, transportation, and / or disposal costs). Furthermore, for the same square foot of product (bag), the lower-density product is lighter and easier to handle than the higher-density product.

[0187] Unexpectedly, based on the anticipated results, the fiber insulation products of this disclosure exhibit a remarkable improvement in material efficiency compared to expectations. With this higher material efficiency, the fiber insulation products of the invention can provide the desired insulation performance (R-value) at a lower than predicted areal weight.

[0188] Figure 15 The material efficiency difference is shown between the expected results of a glass fiber insulation product with an average fiber diameter of 3 micrometers and a thickness of 5.5 inches and the actual material efficiency of the inventive 3.6-micrometer insulation product at a thickness of 5.5 inches. Figure 15 As shown, the predicted material efficiency of the fiber insulation product, determined by the expected results, corresponds to the following equation (V):

[0189] Equation (V) y=35.7480145x 2 -112.2450311x+123.2764898

[0190] Where y is the material efficiency, expressed as R·ft 2 / lb represents the product density, and x is the product density in the density range of about 0.5 pcf to about 1.5 pcf. Formula (V) has R 2 =0.9980374, indicating a high degree of accuracy in the model. In contrast, the actual material efficiency of the invented 3.6-micron thermal insulation product corresponds to equation (VI):

[0191] Equation (VI) y = 40.1916068x 2 -120.5813540x+131.7360668

[0192] Where y is the material efficiency, expressed as R·ft 2 / lb represents the density, and x is the product density in the density range of about 0.7 pcf to about 1.35 pcf. Formula (V) has R 2 =0.9980374, indicating a high degree of accuracy in the equation.

[0193] At a given density, based on insulation products with even smaller average fiber diameters (3.0 μm vs. 3.6 μm), the invented 3.6 μm insulation product exhibits higher material efficiency than predicted. For example, at a density of 0.8 pcf, Equation (V) predicts 56.36 R·ft. 2 The material efficiency is / lb, while the invented 3.6-micron glass fiber insulation product achieves 60.99 R·ft. 2 The actual material efficiency is increased by more than 4 units per lb. Similarly, at a density of 0.6 pcf, Equation (V) predicts 68.80 R·ft. 2The material efficiency is / lb, while the invented 3.6-micron glass fiber insulation product exhibits 73.86 R·ft. 2 The actual material efficiency is increased by more than 5 units per lb.

[0194] Therefore, compared to expectations, the fiber insulation products of this disclosure exhibit an increase in material efficiency of at least 4.0 units, and in some cases at least 5.0 units, at least 5.5 units, at least 5.8 units and at least 6.0 units in the density range of 0.2 pcf to 1.6 pcf.

[0195] In any of the exemplary embodiments provided herein, the R value is between 19 and 24, and the area weight is 0.3 lb / ft. 2 and 0.5 lb / ft 2 Fiber insulation products with densities between 0.7 pcf and 1.35 pcf can have a material efficiency of at least 50, for example at least 55, at least 58, at least 60, at least 63, at least 65, at least 68, at least 70, at least 75 and at least 80 according to the formula ME = R value / area weight (W).

[0196] Since a single thermal insulation product may include a certain degree of variation within the product itself, it should be understood that the thermal performance values ​​provided above are average predicted values ​​that do not take into account such natural variations. Therefore, to account for natural product variations, the above equation (VI) can be adjusted by a variation value calculated at a 95% confidence level as 2.1076693. Therefore, taking into account this variation value, the adjusted material efficiency of the thermal insulation product of the invention corresponds to equation (VII):

[0197] Equation (VII) y = 40.1916068x 2 -120.5813540x+129.628397 where y is the adjusted material efficiency, expressed in R·ft 2 / lb represents the product density, and x is the product density in the density range of about 0.5pcf to about 1.5pcf.

[0198] Figure 16 The illustration shows the material efficiency difference between the expected output of a glass fiber insulation product with an average fiber diameter of 3 micrometers and a thickness of 5.5 inches and the material efficiency of the invention's 3.6-micrometer insulation product at a thickness of 5.5 inches, including the adjusted material efficiency of the variable.

[0199] like Figure 16As shown, based on insulation products with even smaller average fiber diameters (3.0 μm vs. 3.6 μm), the adjusted material efficiency of the invented 3.6 μm insulation product is higher than expected. For example, at a density of 0.8 pcf, Formula (V) (expected result) predicts a material efficiency of 56.36 R·ft² / lb, while the invented 3.6 μm glass fiber insulation product demonstrates an adjusted material efficiency of 58.89 R·ft² / lb, an increase of more than 2 units. Similarly, at a density of 0.6 pcf, Formula (V) predicts a material efficiency of 68.80 R·ft² / lb, while the invented 3.6 μm glass fiber insulation product demonstrates an adjusted material efficiency of 71.75 R·ft² / lb, an increase of nearly 3 units.

[0200] While specific benefits can be exemplified in products with varying areal weights, specific benefits can be achieved while maintaining desired thermal properties at relatively low areal weights. As used herein, the areal weight of a fiber insulation product is the weight of the insulation product per square foot (lb / ft) after the adhesive composition has cured. 2 In various implementations, the areal weight of fiber insulation products is 0.1 lb / ft. 2 Up to 2.0 lb / ft 2 Within the range, including 0.2 lb / ft 2 and 1.8 lb / ft 2 Between, 0.25 lb / ft 2 and 1.5 lb / ft 2 Between, 0.3 lb / ft 2 and 1.2 lb / ft 2 Between, 0.35 lb / ft 2 and 1.0 lb / ft 2 Between and 0.38 lb / ft 2 and 0.6 lb / ft 2 In any exemplary embodiment, the areal weight of the fiber insulation product can be less than 0.55 lb / ft. 2 including less than 0.5 lb / ft 2 Less than 0.48 lb / ft 2 Less than 0.45 lb / ft 2 and less than 0.42 lb / ft 2 .

[0201] Furthermore, as mentioned above, improved thermal and material efficiency benefits can be obtained at any insulation product thickness, and specific benefits can be seen at relatively low product thicknesses. Typically, the R-value of an insulation product can be improved by increasing its thickness (T1), which in turn reduces the product's density (assuming no other changes to the product). However, for constrained products (i.e., those installed within a wall cavity of fixed thickness), increasing the product thickness is not feasible. Therefore, since the insulation product can only expand to the thickness of the wall opening, there is no R-value advantage gained by making the product thicker than the wall cavity. In any exemplary embodiment, the fiber insulation product thickness T1 can be less than about 20 inches, including thicknesses not greater than 18 inches, not greater than 15 inches, not greater than 12 inches, not greater than 10 inches, not greater than 8 inches, not greater than 7 inches, not greater than 6.5 inches, and not greater than 6 inches. For example, in some thickness-constrained products, the fiber insulation product can have a thickness less than 7 inches, including less than 6.5 inches, less than 6 inches, less than 5.5 inches, less than 5 inches, less than 4.5 inches, and less than 4 inches. In these or other embodiments, the fiber insulation product may have a thickness of, for example, 0.5 inches to 8 inches, including between 0.75 inches and 7.5 inches, between 0.9 inches and 7.0 inches, between 1.0 inches and 6.8 inches, between 1.5 inches and 6.3 inches, and between 2.0 inches and 6.0 inches.

[0202] Table 4 shows the structure and thermal properties of two exemplary fiber insulation products (Examples 1 and 2) formed from fibers with average fiber diameters of 14.5 HT and 14.4 HT, respectively. Each of the products in Examples 1 and 2 was formed using a formaldehyde-free adhesive composition comprising a monomeric polyol and a polymeric polycarboxylic acid crosslinking agent. Examples 1 and 2 have a thickness of 5.5 inches and an R-22 insulation value. As shown in Table 4 below, at a k-value of 0.25 BTU·in / hr·ft²·°F, Examples 1 and 2 exhibit 0.746 lb / ft, respectively. 3 and 0.759 lb / ft 3 The low density results in an LOI value of less than 4%. In contrast, Comparative Example 1 was formed using 15.9HT glass fiber and an adhesive composition comprising a polymeric polyol and a monomeric polycarboxylic acid crosslinking agent. It achieved a thickness of 5.5 inches and a density of 0.25 BTU·in / hr·ft. 2 At a k value of °F, the product of Comparative Example 1 showed 0.830 lb / ft. 3 The density is at least 7% higher and, in particular, at least 9% higher than that of Examples 1 and 2.

[0203] Even more surprisingly, Comparative Example 2 was formed from 14.3HT glass fiber (therefore considered "fine fiber" as defined herein) and an adhesive composition comprising a polymeric polyol and a monomeric polycarboxylic acid crosslinking agent. It achieved a thickness of 5.5 inches and a flow rate of 0.23 BTU·in / hr·ft. 2 At a k value of °F, the product of Comparative Example 2 exhibited 1.25 lb / ft. 3 Its density is at least 39% higher than that of Examples 1 and 2.

[0204] Table 4

[0205]

[0206] Furthermore, at the same thickness and substantially the same R value, the material efficiency of Examples 1 and 2 is improved by more than 5 units compared to the products of Comparative Examples 1 and 2. These differences can be attributed at least to the increased areal weight required in Comparative Examples 1 and 2 to obtain k values ​​comparable to those of Examples 1 and 2. Therefore, it can be seen that the fiber insulation products of this disclosure are capable of providing improved thermal properties with reduced areal weight, thereby improving the overall efficiency of the product.

[0207] The glass fiber insulation material of the present invention can have any combination or sub-combination of the properties disclosed herein and the scope of those properties. While the invention has been described through the description of its embodiments, the applicant does not intend to limit the scope of the appended claims or restrict it in any way to such details. Further advantages and modifications will be readily apparent to those skilled in the art. Although fiber insulation products are referred to herein as flexible mats or felts, other configurations and geometries may also be used. Furthermore, fiber insulation products can be used in a variety of ways and are not limited to any particular application. Therefore, the invention, in its broader aspects, is not limited to the specific details, representative devices, and illustrative examples shown and described. Therefore, deviations from these details may be made without departing from the spirit or scope of the overall inventive concept.

Claims

1. Thermal insulation products, including: Multiple glass fibers; and A cross-linked, formaldehyde-free adhesive composition that at least partially coats the glass fibers; The glass fibers described herein have an average fiber diameter in the range of 8 HT (2.03 μm) to 15 HT (3.81 μm); The fiber product has a length, width, and thickness, wherein the length is greater than each of the width and the thickness; In the fiber product, at least 30% by weight of the glass fibers are oriented within + / -15° of the common plane defined by the length and width of the insulation product; Prior to crosslinking, the formaldehyde-free adhesive composition comprises at least one monomeric polyol and a polymeric polycarboxylic acid in a combined amount of at least 45% by weight based on the total weight of the adhesive composition; and The insulation product described herein has a density between 0.2 pcf and 1.6 pcf when uncompressed.

2. The thermal insulation product according to claim 1, wherein at least 15% by weight of the glass fiber in the thermal insulation product is at least partially bonded to at least one other glass fiber in the thermal insulation product in a substantially parallel orientation.

3. The thermal insulation product according to claim 1 or 2, wherein at least 40% by weight of the glass fibers are oriented within + / -15° of the common plane.

4. The thermal insulation product according to any one of claims 1 to 3, wherein, prior to crosslinking, the adhesive composition has a viscosity of less than 40,000 cP at a solid content of 65% to 70% by weight.

5. The thermal insulation product according to any one of claims 1 to 4, wherein, prior to crosslinking, the adhesive composition has a viscosity of less than 1000 cP at a solid content of 60% by weight.

6. The thermal insulation product according to any one of claims 1 to 5, wherein the common plane is parallel to the length and width of the thermal insulation product.

7. The thermal insulation product according to any one of claims 1 to 6, wherein the average fiber diameter of the glass fiber is in the range of 12 HT (3.05 μm) to 14.5 HT (3.68 μm).

8. The thermal insulation product according to any one of claims 1 to 7, wherein the formaldehyde-free adhesive composition has a pH in the range of 2 to 5 prior to crosslinking.

9. The thermal insulation product according to any one of claims 1 to 8, wherein the glass fiber orientation is such that no more than 35% by weight of the adhesive composition is present in the form of clumps.

10. The thermal insulation product according to any one of claims 1 to 9, wherein the crosslinked formaldehyde-free adhesive composition is free of Maillard reactants.

11. Thermal insulation products, including: Multiple glass fibers having an average fiber diameter in the range of 8 HT (2.03 μm) to 15 HT (3.81 μm); and A cross-linked, formaldehyde-free adhesive composition that at least partially coats the glass fibers; Prior to crosslinking, the formaldehyde-free adhesive composition comprises at least one monomeric polyol and a polymeric polycarboxylic acid in a combined amount of at least 45% by weight based on the total weight of the adhesive composition; Prior to crosslinking, the formaldehyde-free adhesive composition has a viscosity of less than 40,000 cP at a solid content of 65% to 70% by weight. The thermal insulation product described herein includes a length, a width, and a thickness, wherein the length is greater than each of the width and the thickness; Wherein at least 55% by weight of the glass fibers are oriented within + / -30° of the common plane defined by the length and width of the insulation product; and In the thermal insulation product, at least 15% by weight of the glass fiber is at least partially bonded to at least one other glass fiber in the thermal insulation product in a substantially parallel orientation.

12. The thermal insulation product of claim 11, wherein the thermal insulation product has a density between 0.2 pcf and 1.6 pcf when uncompressed.

13. The thermal insulation product according to any one of claims 11 or 12, wherein the glass fiber orientation is such that no more than 35% by weight of the adhesive composition is present in the form of clumps.

14. The thermal insulation product according to any one of claims 11 to 13, wherein at least 65% by weight of the glass fibers are oriented within + / -30° of the common plane.

15. The thermal insulation product according to any one of claims 11 to 14, wherein at least 75% by weight of the glass fibers are oriented within + / - 50° of the common plane.

16. The thermal insulation product according to any one of claims 11 to 15, wherein, prior to crosslinking, the adhesive composition has a viscosity of less than 20 cP at a solid content of 10% by weight.

17. The thermal insulation product according to any one of claims 11 to 16, wherein the common plane is parallel to the length of the thermal insulation product.

18. Thermal insulation products, including: Multiple glass fibers having an average fiber diameter of less than 15 HT; and A cross-linked, formaldehyde-free adhesive composition that at least partially coats the glass fibers; Prior to crosslinking, the formaldehyde-free adhesive composition comprises at least one monomeric polyol and a polymeric polycarboxylic acid in a combined amount of at least 45% by weight based on the total weight of the adhesive composition; The fiber insulation product has an adhesive content (LOI) of less than or equal to 4% by weight of the insulation product. In the aforementioned thermal insulation product, at least 15% by weight of the glass fiber is at least partially bonded to at least one other glass fiber in the thermal insulation product in a substantially parallel orientation; and The glass fiber orientation is such that no more than 35% by weight of the adhesive composition is present in the form of clumps.

19. The thermal insulation product of claim 18, wherein at least 30% by weight of the glass fiber is oriented within + / -15° of a common plane defined by the width and length of the thermal insulation product.

20. The thermal insulation product according to any one of claims 18 or 19, wherein at least 40% by weight of the glass fiber is oriented within + / -15° of a common plane defined by the width and length of the thermal insulation product.

21. The thermal insulation product according to any one of claims 18 to 20, wherein, prior to crosslinking, the adhesive composition has a viscosity of less than 40,000 cP at a solid content of 65% to 70% by weight.

22. The thermal insulation product according to any one of claims 18 to 21, wherein the common plane is parallel to the length and width of the thermal insulation product.

23. The thermal insulation product according to any one of claims 18 to 22, wherein the plurality of glass fibers have an average fiber diameter in the range of 12 HT to 14.5 HT.

24. The thermal insulation product according to any one of claims 18 to 23, wherein the formaldehyde-free adhesive composition has a pH of 2 to 5 prior to crosslinking.

25. A method for forming a thermal insulation product, the method comprising: The molten glass is fiberized into multiple glass fibers; The glass fiber is coated with a water-based, formaldehyde-free adhesive composition. The glass fibers are randomly deposited on a moving conveyor to form an uncured glass fiber mat. and The uncured glass fiber mat is passed through a curing oven to crosslink the adhesive composition and form the thermal insulation product. When the uncured glass fiber mat enters the curing oven, it has a moisture content of no more than 3% by weight. The thermal insulation product described herein includes a length, a width, and a thickness, wherein the length is greater than each of the width and the thickness; At least 30% by weight of the glass fibers are oriented within + / -15° of the common plane of the insulation product. Prior to crosslinking, the aqueous formaldehyde-free adhesive composition comprises at least one monomeric polyol and a polymeric polycarboxylic acid in a combined amount of at least 45% by weight based on the total weight of the adhesive composition; and The insulation product described herein has a density between 0.2 pcf and 1.6 pcf when uncompressed.

26. The method of claim 25, wherein the aqueous formaldehyde-free adhesive composition has a viscosity of less than 40,000 cP at a solids content of 65% to 70% by weight.

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