Formaldehyde scavenging formulations

Abstract

The present invention relates to improved formaldehyde scavenging formulations and their use in coverings and building products, the building products comprising: a ceiling panel; a panel comprising a thermal insulation panel, in particular a phenolic thermal insulation panel; and panels and panels, including wood panels and wood boards, as well as methods for reducing formaldehyde emissions from building products.

Description

Technical Field

[0001] The present invention relates to improved formaldehyde scavenging formulations and uses thereof. Specific uses include use in coverings (particularly nonwoven coverings) and building products, including ceiling tiles, boards (including insulation boards, particularly phenolic insulation boards), and panels and boards (including wood-based panels, fabrics, textiles) and on or applied to other substrates. Methods for reducing formaldehyde emissions from building products are also disclosed. Background Art

[0002] Formaldehyde has a high toxic potential and is an irritant that can cause allergic reactions and other health problems, including irritation to the skin, respiratory tract, or eyes in humans. The publication "WHO Guidelines for Indoor Air Quality: Selected Pollutants" (World Health Organization, 2010, ISBN 978 92 890 0213 4, pp. 103-156) further details the health effects of formaldehyde. Golden, R. (Crit Rev Toxicol 2011 Sep; 41(8): 672–721; doi: 10.3109 / 10408444.2011.573467; PMID: 21635194) provides recommendations for indoor air exposure limits for formaldehyde.

[0003] Emission standards are set by various national laws, including the French law Decree No. 2011-321 (published on March 25, 2011). The French emission levels are defined in the Journal of Public Science (Journal of French Public Science) AISE), JORF No. 01112011, May 13, 2011, NOR: DEVL1104875A, Appendix ID - "2011 Report (Arrêté etiquette 2011)". The "A+" category for VOC (Volatile Organic Compound) emissions includes the requirement that formaldehyde emissions <10ug / m^3 within 28 days. The "A" category for VOC emissions includes the requirement that formaldehyde emissions <60ug / m^3 within 28 days.

[0004] Therefore, formaldehyde emissions from building products must be controlled / reduced to minimize health risks and comply with standards. Therefore, reducing formaldehyde emissions from building products is important.

[0005] It is also highly desirable that any new or improved formaldehyde scavenger or composition (i.e., formulation): (i) does not inherently present additional environmental or health and safety issues, including in a manufacturing environment; and (ii) is compatible with existing building product manufacturing protocols and process conditions, such that a switch to a formaldehyde scavenger or composition (i.e., formulation) can be made without having to modify existing building product manufacturing protocols and process conditions.

[0006] Furthermore, agglomeration of components in the formulation is undesirable and inconvenient, but has been observed to occur in various formaldehyde scavenger formulations. It is desirable to reduce, minimize or avoid agglomeration altogether, as it may have undesirable effects. In particular, it may, for example, lead to filter clogging when filters are used as part of the manufacturing process. Similarly, agglomeration may lead to undesirable texture effects / lumps in the final product.

[0007] Publications include WO 2012 / 076489 A1, WO 2006 / 104455 A1, WO 2015 / 041791 A1, and WO 2016 / 009054 A1.

[0008] The present inventors have discovered that the use of anionically stabilized binders and anionically stabilized flame retardants (e.g., alumina trihydrate (ATH) slurries stabilized with anionic dispersants) in combination with cation scavengers (such as NH + Combinations of polyvinylamines (PVAm) in the form of 2-(4-oxo)-2-nitrogen may in particular lead to agglomeration.

[0009] The present invention seeks to overcome one or more of the shortcomings of the prior art and to provide improved formaldehyde scavenging formulations.

[0010] In the following description, all ranges include lower limits and upper limits. The singular should be understood to also represent the plural form. Summary of the invention

[0011] According to the present invention, there is provided a formaldehyde scavenging preparation, the formaldehyde scavenging preparation comprising:

[0012] (a) polyvinylamine (PVAm) formaldehyde scavenger or its copolymer;

[0013] (b) optionally nonionically or cationically stabilized binders and / or crosslinkers; and

[0014] (c) Nonionic stabilized flame retardants.

[0015] In certain embodiments, the formulation comprises 1% to 90% by dry mass of the PVAm scavenger or copolymer thereof.

[0016] In certain embodiments, the formulation comprises from 1% to 60% by dry mass of a non-ionic or cationically stabilized binder and / or crosslinker.

[0017] In certain embodiments, the formulation comprises <= 96% by weight of a non-ionic stabilized flame retardant by dry mass. In certain embodiments, the formulation comprises 1% to 96% by weight of a non-ionic stabilized flame retardant by dry mass. In certain embodiments, the formulation comprises 10% to 90% by weight of a non-ionic stabilized flame retardant.

[0018] According to a preferred first embodiment, the formaldehyde scavenging formulation comprises:

[0019] (a) 1% to 90% by dry mass of a polyvinylamine (PVAm) formaldehyde scavenger or a copolymer thereof;

[0020] (b) 0 to 60% by weight, preferably 1 to 60% by dry mass, of a non-ionic or cationically stabilized binder and / or crosslinker; and

[0021] (c) 10% to 90% of a nonionic stabilized flame retardant.

[0022] PVAm formaldehyde scavenger or its copolymer

[0023] In certain embodiments, polyvinylamine (PVAm) or its copolymer has a weight average molecular weight (Mw) in the range of 50,000g / mol to 800,000g / mol. In certain embodiments, the weight average molecular weight is in the range of 200,000g / mol to 600,000g / mol. In certain embodiments, it is in the range of 300,000g / mol to 500,000g / mol. In certain embodiments, it is in the range of 350,000g / mol to 450,000g / mol. In certain embodiments, it is about 400,000g / mol. The weight average molecular weight (Mw) is measured by size exclusion chromatography.

[0024] In certain embodiments, the dry weight percentage of polyvinylamine or its copolymer is in the range of 1% to 90%, advantageously in the range of 1% to 60%. In certain embodiments, it is in the range of 1% to 45%. In certain embodiments, it is in the range of 1% to 30%. In other embodiments, it is in the range of 5% to 25%. In certain embodiments, it is in the range of 6% to 20%. In certain embodiments, it is in the range of 7% to 15%. In other embodiments, it is in the range of 10% to 20%. In certain embodiments, it is in the range of 2% to 11%. In some embodiments, it is in the range of 2.5% to 7%. In some embodiments, it is in the range of 3% to 5%.

[0025] Polyvinylamine can exist in a form other than pure polyvinylamine. It can exist, for example, in the form of a copolymer, such as polyvinylamine-polyvinyl alcohol (PVAm-PVOH) copolymer. Other copolymers include PVAm-PVF (polyvinylamine-polyvinyl formamide) copolymers.

[0026] Polyvinylamine or its copolymers are advantageously in their cationic form, which means that they have NH3 + The counter ion may be Cl - or any other equivalent counterion. The pH of the polyvinylamine or its copolymer is advantageously about 8 at 25°C in water.

[0027] Binder and / or crosslinker

[0028] As detailed above, the binder and / or crosslinker is a non-ionically or cationically stabilized binder and / or crosslinker.

[0029] By "nonionic or cationic stabilized" it is understood that the binder and / or crosslinker is in the form of an emulsion or dispersion in water containing a nonionic or cationic surfactant. The nonionic or cationic surfactant may be selected from the group consisting of polyoxyethylated alkylphenols, monoglycerides of long-chain fatty acids, polyoxyethylated alcohols, quaternary ammonium compounds, trimethylalkylammonium chlorides, benzalkonium chloride. In certain embodiments, it is a polyoxyethylated alcohol.

[0030] The binder is generally non-reactive to the other chemical elements in the formulation and is used to bond the mineral filler to the glass to form the obscuration.

[0031] The crosslinking agent is reactive to at least one other element of the formulation and / or glass. In some cases, it helps increase the dimensional stability of the covering and may also have a clean-out functionality.

[0032] In certain embodiments, the non-ionically or cationically stabilized binder and / or cross-linker is a non-ionically or cationically stabilized binder. In certain embodiments, it is a non-ionically stabilized binder.

[0033] Suitable examples of nonionically stabilized binders include vinyl acetate ethylene (VAE), acrylic binders or self-crosslinking dispersions of polyurethane.

[0034] Other suitable binders include cationically stabilized acrylic binders, such as cationic dispersions from copolymers of acrylates.Other suitable binders and crosslinkers will be apparent to those skilled in the art, provided they are cationically or nonionically stabilized.

[0035] In certain embodiments, the nonionic or cationic stabilized binder and / or crosslinking agent is a binder, and the dry weight percentage of the binder is less than or equal to 60%, that is, 0% to 60%, preferably in the range of 1% to 60%. In certain such embodiments, the dry weight percentage of the binder is in the range of 1% to 40%. In other such embodiments, it is in the range of 2% to 30%. In other such embodiments, it is in the range of 3% to 20%. In other such embodiments, it is in the range of 4% to 20%. In other such embodiments, it is in the range of 5% to 10%.

[0036] In alternative embodiments, the nonionic or cationic stabilized binder and / or crosslinker is in the form of a crosslinker, the dry weight percentage of the crosslinker is in the range of 0% to 30%, preferably 1% to 30%. In certain such embodiments, it is in the range of 2% to 20%. In other such embodiments, it is in the range of 3% to 15%. In other such embodiments, it is in the range of 4% to 10%. In other embodiments, it is in the range of 5% to 9%. In other embodiments, it is in the range of 6% to 8%.

[0037] Suitable examples of crosslinking agents include: polyacrylic acid, carbodiimide, epoxide, isocyanate, silane, dialdehyde.

[0038] In the specific case of a crosslinking agent, it can be used as such or in the form of an aqueous solution in a formulation without any stabilizer, provided that it is itself cationic or nonionic.

[0039] In some embodiments, both the binder and the cross-linking agent are present. In certain embodiments, the total dry weight percentage of the binder and the cross-linking agent is in the range of 1% to 30%. In certain such embodiments, it is in the range of 2% to 20%. In other such embodiments, it is in the range of 3% to 15%. In other such embodiments, it is in the range of 4% to 10%. In other embodiments, it is in the range of 5% to 9%. In other embodiments, it is in the range of 6% to 8%. In certain embodiments, the dry weight ratio of the binder to the cross-linking agent is in the range of 2: 1 to 20: 1. In certain embodiments, the ratio is in the range of 5: 1 to 15: 1. In other embodiments, the ratio is in the range of 8: 1 to 12: 1. In specific embodiments, the ratio is about 10: 1.

[0040] Nonionic stabilized flame retardant

[0041] The term "non-ionically stabilized flame retardant" is understood to mean a flame retardant in the presence of a non-ionic dispersant in the form of a slurry or dispersion in water.

[0042] The nonionic dispersant may be selected from the group consisting of polyoxyethylated alkylphenols, glycerol monoesters of long chain fatty acids and polyoxyethylated alcohols. In certain embodiments, it is a polyoxyethylated alcohol.

[0043] In certain embodiments, the non-ionically stabilized flame retardant (also referred to as a "flame retardant") is selected from the group consisting of non-ionically stabilized alumina trihydrate (ATH) (Al(OH)3), non-ionically stabilized phosphorus-nitrogen, non-ionically stabilized magnesium oxide (MgO), non-ionically stabilized magnesium hydroxide (Mg(OH)2). Non-ionically stabilized ATH is a preferred flame retardant.

[0044] In certain embodiments, the non-ionically stabilized flame retardant (preferably, ATH) is in the form of a slurry.

[0045] The slurry form is preferred because it is easier to handle than a powder for safety reasons.

[0046] In certain embodiments, the dry weight percentage of the nonionic stabilized flame retardant is less than or equal to 96%. In certain embodiments, it is in the range of 1% to 96%. In certain embodiments, it is in the range of 10% to 95%. In certain embodiments, it is in the range of 10% to 90%. In certain embodiments, it is in the range of 20% to 90%. In certain embodiments, it is in the range of 30% to 85%. In certain embodiments, it is in the range of 40% to 80%. In certain embodiments, it is in the range of 50% to 75%. In certain embodiments, it is in the range of 60% to 70%.

[0047] The total dry weight percentage of the flame retardant and the PVAm formaldehyde scavenger can be at least 50%. In certain embodiments, it is at least 60%. In other embodiments, it is at least 70%. In other embodiments, it is at least 80%. In certain embodiments, it is at least 90%. In other embodiments, it is at least 95%. In certain embodiments, it is at least 96%.

[0048] In certain embodiments, the total dry weight percentage of flame retardant and PVAm formaldehyde scavenger is between 50% and 95%. In certain embodiments, it is between 60% and 90%. In certain embodiments, it is between 70% and 85%.

[0049] In certain embodiments, the dry weight ratio of flame retardant to PVAm formaldehyde scavenger is at least 2: 1. In certain embodiments, it is at least 3: 1. In certain embodiments, it is at least 4: 1. In certain embodiments, it is at least 5: 1. In certain embodiments, it is between 4: 1 and 15: 1. In certain embodiments, it is between 6: 1 and 10: 1. In certain embodiments, it is between 7: 1 and 9: 1.

[0050] Defoaming agent

[0051] In certain embodiments, the formulation further comprises a defoamer. Defoamers are well known in the art. Suitable defoamers include, but are not limited to, silicone-based defoaming emulsions and those based on polydimethylsiloxane (PDMS) oils and emulsions. Other suitable defoamers are mineral oils and silicon-free polymer defoamers. Therefore, in certain embodiments, the defoamer is a defoamer emulsion (i.e., an emulsion). The defoamer emulsion can be nonionic stabilized. In particular, the defoamer emulsion can include a nonionic emulsifier.

[0052] In certain embodiments, the formulation comprises <= 1.5% dry mass by weight of defoamer. In certain embodiments, it comprises <= 1% dry mass by weight. In certain embodiments, it comprises <= 0.5% dry mass by weight of defoamer. In certain embodiments, it comprises between 0.01% and 1.5% dry mass by weight of defoamer.

[0053] In certain embodiments, there is <= 0.1% dry mass by weight of antifoaming agent. In certain embodiments, there is <= 0.05% dry mass by weight of antifoaming agent.

[0054] In certain embodiments, the amount of antifoaming agent is >= 0.001% by weight and < 0.1% dry mass.

[0055] In certain embodiments, the amount of defoamer is >= 0.01% by weight and < 0.1% dry mass. In certain embodiments, the amount of defoamer is >= 0.01% by weight and <= 0.05% dry mass. In certain embodiments, there is between 0.01% and 0.02% dry mass by weight of defoamer.

[0056] Repellent

[0057] In certain embodiments, the formulation further comprises a repellent. Suitable repellents include cationic repellents, for example non-fluorinated cationic aqueous emulsions, such as acrylic repellents, silicone repellents and waxes. Therefore, in certain embodiments, the repellent is cationic. In other embodiments, the repellent is nonionic. Therefore, in certain embodiments, the repellent is nonionic or cationic. Other repellents include, but are not limited to, fluorocarbons and perfluoroalkyl functionalized acrylates.

[0058] In certain embodiments, the formulation comprises <= 20% dry mass of repellent by weight. In certain embodiments, it comprises 1% to 20% dry mass of repellent by weight. In certain embodiments, it comprises 1% to 15% dry mass of repellent by weight. In certain embodiments, it comprises 1% to 10% dry mass of repellent by weight. In certain embodiments, it comprises 2% to 20% dry mass of repellent by weight.

[0059] Aminosilane

[0060] The formulation may also include a coupling agent, particularly an aminosilane. The coupling agent imparts improved moisture and heat resistance to the screen. Aminosilanes include primary aminosilanes, i.e., primary amine functionalized silanes. Examples include aminoalkylsilanes. An exemplary aminosilane is γ-aminopropyltriethoxysilane (H2NCH2CH2CH2Si(OCH2CH3)3).

[0061] In certain embodiments, the formulation comprises aminosilanes of <=30% dry mass by weight. In certain embodiments, the formulation comprises aminosilanes of between 1% and 30% dry mass by weight. In certain embodiments, the formulation comprises aminosilanes of between 2% and 20% dry mass by weight. In certain embodiments, the formulation comprises aminosilanes of between 3% and 15% dry mass by weight. In certain embodiments, the formulation comprises aminosilanes of between 4% and 10% dry mass by weight.

[0062] pigment

[0063] In certain embodiments, the formulation further comprises a pigment. In a specific embodiment, it comprises a pigment of <=5% dry mass by weight. In certain embodiments, it comprises a pigment of 0.1% to 5% dry mass by weight. In certain embodiments, it comprises a pigment of between 0.5% and 4.5% dry mass by weight. In certain embodiments, it comprises a pigment of between 1% and 4% dry mass by weight. In certain embodiments, it comprises a pigment of between 1.5% and 3.0% dry mass by weight.

[0064] Pigments can be particularly useful for hiding or masking discoloration caused by, for example, thermal effects from subsequent processing / use of the formulation. The pigment can be an organic pigment or an inorganic pigment, preferably an organic pigment, in particular carbon black. For example, in certain embodiments, a black pigment is used to hide discoloration caused by subsequent heating of the formulation.

[0065] The formulation may optionally further comprise one or more (i.e. at least one) of the following:

[0066] (A) a dispersant;

[0067] (B) a viscosity modifier; and

[0068] (C) Formula -[MPO3]- n Polyphosphates of (OH)2, wherein M is selected from the group consisting of Na, K and NH4, and wherein n is an integer greater than 100, preferably greater than 1000.

[0069] In certain embodiments, the formulation comprises a dispersant (0% to 3% dry mass by weight). Suitable dispersants include, but are not limited to, polycarboxylic acid dispersants, particularly salt solutions, such as sodium salt solutions of polycarboxylic acid dispersants. In certain embodiments, the formulation comprises a dispersant of 0.1% to 3% dry mass by weight.

[0070] In certain embodiments, the formulation comprises a viscosity modifier (0% to 5% dry mass by weight). In certain embodiments, the formulation comprises 0.1% to 5% dry mass by weight of a viscosity modifier.

[0071] In certain embodiments, the polyphosphate salt is ammonium polyphosphate.

[0072] In certain embodiments, the formulation comprises sodium polyphosphate (0% to 20% dry mass by weight).

[0073] In certain embodiments, the formulation comprises ammonium polyphosphate (0% to 20% dry mass by weight). In certain embodiments, the formulation comprises ammonium polyphosphate (0.1% to 20% dry mass by weight). In certain embodiments, the formulation comprises ammonium polyphosphate (1%=20% dry mass by weight). In certain embodiments, n>1000.

[0074] Formaldehyde scavenging formulations are usually water-based formulations.

[0075] Alkali

[0076] In certain embodiments, the formulation further comprises a base. Suitable bases will be apparent to one of ordinary skill in the art and include, but are not limited to, Ca(OH)2, NaOH, KOH, Na2CO3, Mg(OH)2, and Na3PO4. A particularly preferred base is sodium carbonate (Na2CO3). If necessary, a base may be introduced to adjust the pH of the formulation to avoid agglomeration problems, but in an amount that does not cause corrosion to the equipment.

[0077] In certain embodiments, the dry weight percentage of base is <= 50%. In certain embodiments, it is in the range of 0% to 25%, ie <= 25%.

[0078] In other embodiments, the dry weight percentage of base ranges from 0.5% to 25%.

[0079] In other embodiments, the dry weight percentage of base ranges from 1% to 20%. In other embodiments, it ranges from 1.5% to 15%.

[0080] In embodiments comprising a base, the dry weight ratio of polyvinylamine or its copolymer to base may be in the range of 1:3 to 3: 1. It may be in the range of 1:2 to 2: 1. It may be in the range of 1: 1 to 2: 1.

[0081] Thus, in certain embodiments, the formaldehyde scavenging formulation comprises:

[0082] Polyvinylamine (PVAm) formaldehyde scavenger (1% to 90% dry mass by weight);

[0083] Non-ionically stabilized binders and / or crosslinkers (<=60% dry mass by weight);

[0084] and

[0085] Non-ionic stabilized alumina trihydrate (ATH) flame retardant (<=96% by weight

[0086] dry mass); and

[0087] Also includes:

[0088] Defoaming agent (<=1% dry mass by weight); and

[0089] · Repellents (<=20% dry mass by weight); and

[0090] Aminosilane.

[0091] Second aspect

[0092] According to a second aspect of the present invention, there is provided a formaldehyde scavenging preparation, the formaldehyde scavenging preparation comprising:

[0093] (a) polyvinylamine (PVAm) formaldehyde scavenger or its copolymer; and

[0094] (b) Defoaming agent (<=1.0% dry mass by weight).

[0095] In certain embodiments, the formulation does not include a binder and / or a cross-linking agent. In certain embodiments, the formulation does not include a non-ionic or cationically stabilized binder and / or a cross-linking agent.

[0096] In certain embodiments, the formulation does not include a flame retardant. In specific embodiments, the formulation does not include a non-ionically stabilized flame retardant.

[0097] PVAm or its copolymer formaldehyde scavenger

[0098] As previously discussed, in certain embodiments, polyvinylamine (PVAm) has a weight average molecular weight (Mw) in the range of 50,000 g / mol to 800,000 g / mol. In certain embodiments, the weight average molecular weight is in the range of 200,000 g / mol to 600,000 g / mol. In certain embodiments, it is in the range of 300,000 g / mol to 500,000 g / mol. In certain embodiments, it is in the range of 350,000 g / mol to 450,000 g / mol. In certain embodiments, it is about 400,000 g / mol.

[0099] Polyvinylamine can exist in a form other than pure polyvinylamine. It can exist, for example, in the form of a copolymer, such as polyvinylamine-polyvinyl alcohol (PVAm-PVOH) copolymer. Other copolymers include PVAm-PVF (polyvinylamine-polyvinyl formamide) copolymers.

[0100] Polyvinylamine or its copolymers are advantageously in their cationic form, which means that they have NH3 + The counter ion may be Cl - or any other equivalent counterion. The pH of the polyvinylamine or its copolymer is advantageously about 8 at 25°C in water.

[0101] Defoaming agent

[0102] As mentioned above, defoamers are well known in the art. Suitable defoamers include, but are not limited to, silicone-based defoaming emulsions and those based on polydimethylsiloxane (PDMS) oils and emulsions. The defoamer may be nonionic. In particular, the defoamer may comprise a nonionic emulsifier.

[0103] Other suitable defoamers are mineral oil and silicone-free polymer defoamers. Therefore, in certain embodiments, the defoamer is a defoamer emulsion (i.e., an emulsion). The defoamer emulsion may be non-ionic stabilized. In particular, the defoamer emulsion may contain a non-ionic emulsifier.

[0104] As previously mentioned, the present inventors have found that the use of anionic materials in combination with cationic scavengers (such as PVAm) can particularly lead to agglomeration. Therefore, the use of nonionic or cationic components is particularly desirable in preventing aggregation.

[0105] In certain embodiments, the formulation comprises <= 0.5% dry mass by weight of antifoaming agent. In certain embodiments, it comprises between 0.001% and 1.5% dry mass by weight of antifoaming agent.

[0106] In certain embodiments, there is <=0.1% dry mass of defoamer by weight. In certain embodiments, there is <=0.05% dry mass of defoamer by weight. In certain embodiments, the amount of defoamer is >=0.001% and <=0.1% dry mass by weight. In certain embodiments, the amount of defoamer is >=0.01% and <=0.1% dry mass by weight. In certain embodiments, the amount of defoamer is >=0.01% and <=0.1% dry mass by weight. In certain embodiments, the amount of defoamer is >=0.01% and <=0.05% dry mass by weight. In certain embodiments, there is between 0.01% and 0.02% dry mass by weight of defoamer.

[0107] pigment

[0108] In a certain embodiment, the preparation also includes a pigment. In certain embodiments, the preparation also includes a pigment of <=5% dry mass by weight. In certain embodiments, it includes a pigment of 0.1% to 5% dry mass by weight. In certain embodiments, it includes a pigment of between 0.5% and 4.5% dry mass by weight. In certain embodiments, it includes a pigment of between 1% and 4% dry mass by weight. In certain embodiments, it includes a pigment of between 1.5% and 3.0% dry mass by weight.

[0109] Nonionic stabilized flame retardant

[0110] In certain embodiments, the formulation further comprises a non-ionic stabilized flame retardant (<=96% dry mass by weight) in the form of a slurry or dispersion in water in the presence of a non-ionic dispersant.

[0111] The nonionic dispersant may be selected from the group consisting of polyoxyethylated alkylphenols, glycerol monoesters of long chain fatty acids and polyoxyethylated alcohols. In certain embodiments, it is a polyoxyethylated alcohol.

[0112] According to the first aspect, in certain embodiments, the non-ionically stabilized flame retardant (also referred to as "flame retardant") is selected from the group consisting of non-ionically stabilized alumina trihydrate (ATH) (Al(OH)3), non-ionically stabilized phosphorus-nitrogen, non-ionically stabilized magnesium oxide (MgO), non-ionically stabilized magnesium hydroxide (Mg(OH)2). Non-ionically stabilized ATH is a preferred flame retardant.

[0113] In certain embodiments, the non-ionically stabilized flame retardant (preferably, ATH) is in the form of a slurry.

[0114] In certain embodiments, the dry weight percentage of the nonionic stabilized flame retardant is in the range of 10% to 95%. In certain embodiments, it is in the range of 20% to 90%. In certain embodiments, it is in the range of 30% to 85%. In certain embodiments, it is in the range of 40% to 80%. In certain embodiments, it is in the range of 50% to 75%. In certain embodiments, it is in the range of 60% to 75%.

[0115] PVAm formaldehyde scavenger

[0116] In certain embodiments, the formulation comprises >= 10% by weight dry mass of a PVAm formaldehyde scavenger or copolymer thereof.

[0117] In certain embodiments, it comprises>=15% by weight of PVAm formaldehyde scavenger or copolymer thereof in dry mass. In certain embodiments, it comprises>=20% by weight of formaldehyde scavenger or copolymer thereof in dry mass. In certain embodiments, it comprises>=25% by weight of formaldehyde scavenger or copolymer thereof in dry mass.

[0118] According to a first aspect, the polyvinylamine may be present in a form other than pure polyvinylamine. It may be present, for example, in the form of a copolymer, such as a polyvinylamine-polyvinyl alcohol (PVAm-PVOH) copolymer. Other copolymers include PVAm-PVF (polyvinylamine-polyvinyl formamide) copolymers.

[0119] Polyvinylamine or its copolymers are advantageously in their cationic form, which means that they have NH3 + The counter ion may be Cl - or any other equivalent counterion. The pH of the polyvinylamine or its copolymer is advantageously about 8 at 25°C in water.

[0120] Binder and / or crosslinker

[0121] In certain embodiments, the formulation further comprises a non-ionic or cationically stabilized binder and / or cross-linker (<=60% dry mass by weight). Options for non-ionic or cationically stabilized binders and / or cross-linkers are as previously discussed for the first aspect.

[0122] Repellent

[0123] In certain embodiments, the formulation further comprises a repellent.Options for the repellent are as previously discussed for the first aspect.

[0124] Aminosilane

[0125] In certain embodiments, the formulation further comprises an aminosilane.Options for the aminosilane are as previously discussed for the first aspect.

[0126] In certain embodiments, the formulation further comprises one or more (i.e., at least one) of the following:

[0127] (A) a dispersant;

[0128] (B) a viscosity modifier; and

[0129] (C) Formula -[MPO3]- n Polyphosphates of (OH)2, wherein M is selected from the group consisting of Na, K and NH4, and wherein n is an integer greater than 100, preferably greater than 1000.

[0130] Options for these are as discussed previously for the first aspect.

[0131] Formaldehyde scavenging formulations are usually water-based formulations.

[0132] Alkali

[0133] In certain embodiments, the formulation further comprises a base.Options for this are as previously discussed for the first aspect.

[0134] use

[0135] The formaldehyde scavenging formulations of the present invention can be used in (e.g., applied to or contained in) coverings (particularly nonwoven NW coverings) and building products, including ceiling tiles, boards (including insulation boards, particularly phenolic insulation boards), and panels and boards (including wood substrates, fabrics, textiles), as well as on or applied to other substrates.

[0136] Shelter

[0137] According to the present invention there is also provided a nonwoven covering coated with or containing the formaldehyde scavenging formulation according to the present invention.

[0138] Nonwoven screens for building products are well known in the art and typically include intertwined, randomly oriented reinforcing fibers. The fiber component of the screen can be any of the following: metal fibers, ceramic fibers, mineral fibers, glass fibers, carbon fibers, graphite fibers, polymer fibers such as aramid, polyester, polyacrylic acid, polyamide, polyacrylonitrile, natural fibers, and combinations thereof. In particular, the fiber component of the screen can be glass fibers. The screen can include fibers of 20 g / m^2 to 130 g / m^2.

[0139] The shield may contain up to 40 g / m^2 of formaldehyde scavenger. It may contain 0.5 g / m^2 to 20 g / m^2 of formaldehyde scavenger. It may contain 1 g / m^2 to 15 g / m^2 of formaldehyde scavenger. It may contain 2 g / m^2 to 10 g / m^2 of formaldehyde scavenger. It may contain 3 g / m^2 to 6 g / m^2 of formaldehyde scavenger. As detailed in the examples below, excellent results have been achieved using these amounts of formaldehyde scavenger.

[0140] In particular, the mask may contain 5 g / m^2 to 250 g / m^2 of formaldehyde scavenging formulation, of which 0.5 g / m^2 to 20 g / m^2 is formaldehyde scavenger.

[0141] Building Products

[0142] According to the present invention there is also provided a building product having (ie comprising / containing) a nonwoven covering according to the present invention on at least one surface.

[0143] In certain embodiments, the building product is selected from the group consisting of: ceiling panels, wall panels, insulation panels, gypsum boards, and wood substrates. In certain embodiments, the building product is selected from the group consisting of: ceiling panels, wall panels, insulation panels, and wood substrates

[0144] In particular, the building product may have a nonwoven covering according to the invention on at least one of the front and back sides.

[0145] In certain embodiments, the building product is made of wool selected from the group consisting of glass wool, rock wool, stone wool, and mineral wool.

[0146] Products that include wood substrates include, but are not limited to, floor tiles and furniture. Ceiling panels include, but are not limited to, wet felt panels.

[0147] In the case of ceiling tiles, they may have a nonwoven covering according to the invention on at least one of the front and back sides. The ceiling tiles may contain a formaldehyde-releasing binder. The ceiling tiles may be made of wool fabric. The wool fabric may be glass wool, rock wool, rock wool or mineral wool.

[0148] In the case of a wall panel, it may have a nonwoven covering according to the invention on at least one of the front and back sides. The wall panel may contain a formaldehyde-releasing binder. The ceiling panel may be made of wool fabric. The wool fabric may be glass wool, rock wool, rock wool or mineral wool.

[0149] As for the insulation board, it may have the nonwoven covering according to the invention on at least one of the front and back sides.The insulation board may be a phenolic foam board or a mineral wool board.

[0150] As for the wood based substrate (WBP), it may have the nonwoven covering according to the invention on at least one of the front and back sides, or be included in a laminate.

[0151] According to the present invention, there is also provided a method for reducing formaldehyde emissions from a building product, the method comprising the step of attaching a nonwoven covering according to the present invention to at least one exterior surface of a building product. As previously discussed, in certain embodiments, the building product is selected from the group consisting of: ceiling panels, wall panels, insulation panels, and wood substrates.

[0152] The at least one exterior surface may be at least one major surface of the product, such as the front surface, or both the front surface and the rear surface. Examples of building products are tiles (e.g. ceiling tiles) and panels and boards (e.g. wall panels, ceiling panels and insulation boards).

[0153] Particular and preferred aspects of the invention are set out in the accompanying independent claims. Combinations of features from the dependent claims may be combined with features of the independent claims as required and appropriate, and not just as explicitly set out in the claims. As used herein, the term "comprising" designating a component includes also embodiments in which the other component is not present.

[0154] Embodiments of the invention will now be described by way of example only. DETAILED DESCRIPTION

[0155] The % values ​​by weight used throughout the specification are based on the total dry weight.

[0156] In the following examples, formaldehyde scavenging formulations and building products according to the present invention show excellent results.

[0157] Agglomeration is measured with a filter on a fine mesh. The formulation enters the can while traveling through a fine mesh filter. The filter can capture larger particles (agglomerates), and if these particles accumulate, they can clog the filter. We consider "no agglomeration" if the filter is not clogged after the formulation has traveled through the fine mesh filter for 8 hours.

[0158] The preparation of the formulation of Example 1 did not result in agglomeration.

[0159] Similarly, preparation of the formulations of Example 2 and Example 3 did not result in agglomeration.

[0160] Example 1

[0161]

[0162] The formulation gave a wet mass of 5000 kg, including components having a dry weight of 1300 kg.

[0163] No agglomeration of the formulation was observed in the production machine. The formulation was added to the nonwoven veil at 45 g / m^2 (ie 4.62 g / m^2 PVAm formaldehyde scavenger).

[0164] The formulation alone with anionically stabilized ATH (instead of nonionic ATH) resulted in agglomeration.

[0165] The formulation alone with anionic binders (instead of nonionic binders) resulted in agglomeration.

[0166] Example 2

[0167]

[0168] The formulation gave a wet mass of 5000 kg, including components having a dry weight of 1067 kg.

[0169] The formulation did not agglomerate. The formulation was added to the nonwoven veil at 5 g / m^2 (ie 4.90 g / m^2 PVAm formaldehyde scavenger).

[0170] The formulation alone with anionic defoamer (instead of nonionic defoamer) resulted in agglomeration.

[0171] Example 3

[0172]

[0173] The formulation gave a wet mass of 5000 kg, including components having a dry weight of 850 kg.

[0174] The formulation did not agglomerate. The formulation was added to the nonwoven veil at 18 g / m^2 (ie 4.89 g / m^2 PVAm formaldehyde scavenger).

[0175] The formulation alone with anionically stabilized ATH resulted in agglomeration.

[0176] in conclusion

[0177] The Example 1 formulation did not result in agglomeration. Similarly, the Example 2 and Example 3 formulations did not result in agglomeration.

[0178] Various modifications and variations to the described embodiments of the invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Although the invention has been described in conjunction with specific embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, the invention is intended to cover various modifications of the described modes of carrying out the invention that would be apparent to those skilled in the art.

Claims

1. A formaldehyde scavenging preparation, comprising: (a) polyvinylamine (PVAm) formaldehyde scavenger or its copolymer; (b) optionally nonionically or cationically stabilized binders and / or crosslinkers; and (c) Nonionic stabilized flame retardants.

2. The formaldehyde scavenging preparation according to claim 1, comprising: (a) 1% to 90% by dry mass of a polyvinylamine (PVAm) formaldehyde scavenger or a copolymer thereof; (b) 0 to 60 %, preferably 1 to 60 % by dry mass, of a non-ionic or cationically stabilized binder and / or crosslinker; and (c) 10% to 90% of a nonionic stabilized flame retardant.

3. The formaldehyde scavenging formulation according to claim 1 or 2, wherein the non-ionically or cationically stabilized binder and / or cross-linker is a non-ionically stabilized binder.

4. A formaldehyde scavenging formulation according to any preceding claim, wherein the non-ionically stabilized flame retardant is a non-ionically stabilized alumina trihydrate (ATH) (Al(OH)3) slurry or dispersion.

5. A formaldehyde scavenging formulation according to any preceding claim, further comprising a base, preferably in an amount lower than or equal to 50% dry mass by weight.

6. The formaldehyde scavenging formulation according to claim 4, comprising alkali in the range of 0.5% to 25% dry mass by weight.

7. A formaldehyde scavenging formulation according to any one of the preceding claims, further comprising a defoamer, preferably in an amount lower than or equal to 1.5% dry mass by weight.

8. A formaldehyde scavenging formulation according to any one of the preceding claims, further comprising a repellent, preferably in an amount lower than or equal to 20% dry mass by weight.

9. The formaldehyde scavenging formulation according to any one of the preceding claims, further comprising at least one of the following: (A) a dispersant; (B) a viscosity modifier; and (C) Sodium polyphosphate -[MPO3]- n (OH)2, wherein M is selected from the group consisting of Na, K and NH4, and wherein n is an integer greater than 100, preferably greater than 1000.

10. A formaldehyde scavenging formulation according to any one of the preceding claims, further comprising a pigment.

11. The formaldehyde scavenging formulation according to any one of the preceding claims, wherein the formaldehyde scavenging formulation is an aqueous formulation.

12. A formaldehyde scavenging formulation according to any preceding claim, wherein the formaldehyde scavenging formulation comprises: Polyvinylamine (PVAm) formaldehyde scavenger (1% to 90% dry mass by weight); Non-ionically stabilized binders and / or crosslinkers (<=60% dry mass by weight); and Non-ionically stabilized alumina trihydrate (ATH) flame retardant (<=96% dry mass by weight); and The formaldehyde removal preparation further comprises: Defoaming agent (<=1% dry mass by weight); and · Repellents (<=20% dry mass by weight); and Aminosilane.

13. The formaldehyde scavenging formulation according to any one of the preceding claims, wherein the polyvinylamine (PVAm) has a weight average molecular weight (Mw) in the range of 50,000 g / mol to 800,000 g / mol.

14. A nonwoven covering coated with or containing a formaldehyde scavenging formulation according to any one of the preceding claims.

15. The nonwoven shroud of claim 14, wherein the shroud is a fiberglass nonwoven shroud.

16. A building product having a nonwoven covering according to claim 14 or 15 on at least one surface.

17. The building product of claim 16, wherein the building product is made of wool selected from the group consisting of glass wool, rock wool, rock wool and mineral wool.

18. The building product of claim 16 or 17, wherein the building product is selected from the group consisting of: ceiling panels, wall panels, insulation panels, and wood substrates.

19. A method of reducing formaldehyde emissions from a building product, the method comprising the step of attaching a nonwoven covering according to claim 14 or 15 to at least one exterior surface of the building product.

Images