Formaldehyde scavenging agent

Abstract

The present invention relates to an improved formaldehyde scavenging formulation and its use in veils and building products, including ceiling tiles, insulation boards, particularly boards including phenolic insulation boards, and panels and boards including wood panels and boards, as well as methods for reducing formaldehyde emissions from building products.

Description

[Technical field]

[0001] The present invention relates to an improved formaldehyde scavenging formulation and its use.Specific applications include veils (especially nonwoven veils) and building products (including ceiling tiles, insulation boards, especially boards, including phenolic insulation boards, as well as panels and boards, including wood-based panels, fabrics, textiles, and those applied on or to other substrates).A method for reducing formaldehyde emissions from building products is also disclosed. [Background technology]

[0002] Formaldehyde is an irritant with high toxicity potential that can cause allergic reactions and other health problems, including irritation of 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 to formaldehyde.

[0003] Emission standards are set by various national legislations, including the French legislation Decret n°2011-321 (published 25 March 2011). The French emission classes are defined in the JOURNAL OFFICIEL DE LA REPUBLIQUE FRANCAISE,JORF no 0111,13 May 2011,NOR:DEVL1104875A at Annex ID-the "Arrete etiquetage 2011". Class "A+" VOC (Volatile Organic Compounds) emissions include a requirement for formaldehyde emissions of less than 10μg / m^3 over a 28 day period. Class "A" VOC emissions include a requirement for formaldehyde emissions of less than 60μg / m^3 over a 28 day period.

[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 would also be highly desirable for any new or improved formaldehyde scavenging agents or compositions (i.e., formulations) to (i) not present, per se, additional environmental or health and safety concerns, including in the manufacturing environment, and (ii) be compatible with existing building product manufacturing protocols and process conditions, such that switching between formaldehyde scavenging agents or compositions (i.e., formulations) can be accomplished without the need to modify existing building product manufacturing protocols and process conditions.

[0006] Furthermore, although agglomeration of ingredients in a formulation is undesirable and inconvenient, it has been observed to occur in various formaldehyde scavenger formulations.Since agglomeration can have undesirable effects, it is desirable to reduce, minimize, or completely avoid agglomeration.In particular, agglomeration can result in, for example, clogging of filters when filters are used as part of the manufacturing process.Similarly, agglomeration can result in 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 inventors have synthesized an anionic stabilized binder and an anionic stabilized flame retardant (e.g., an anionic dispersant stabilized aluminum trihydrate (ATH) slurry) using NH 3 + It has been found that aggregation can occur especially when used in combination with a cationic scavenger such as polyvinylamine (PVAm) in the form of

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

[0010] In the following description, all ranges include lower and upper limits, and the singular is understood to also mean the plural. Summary of the Invention

[0011] According to the present invention there is provided a formaldehyde scavenging formulation comprising: (a) a polyvinylamine (PVAm) formaldehyde scavenger or a copolymer thereof; (b) optionally, a nonionic or cationic stabilizing binder and / or crosslinker, and (c) Non-ionic stabilized flame retardants.

[0012] In certain embodiments, the formulation comprises 1-90% by weight of the PVAm scavenger or copolymer thereof by dry mass.

[0013] In certain embodiments, the formulation comprises 1-60% by weight of a nonionic or cationic stabilizing binder and / or crosslinker by dry mass.

[0014] In certain embodiments, the formulation comprises up to 96% by weight of the non-ionic stabilized flame retardant by dry weight. In certain embodiments, the formulation comprises 1-96% by weight of the non-ionic stabilized flame retardant by dry weight. In certain embodiments, the formulation comprises 10-90% by weight of the non-ionic stabilized flame retardant.

[0015] According to a first preferred embodiment, the formaldehyde scavenging formulation comprises: (a) 1 to 90% by weight, based on the dry mass, of a polyvinylamine (PVAm) formaldehyde scavenger or copolymer thereof; (b) 0 to 60% by weight, preferably 1 to 60% by weight, of a nonionic or cationic stabilizing binder and / or crosslinker, based on the dry mass; and (c) 10 to 90 percent nonionic stabilized flame retardants.

[0016] PVAm formaldehyde scavenger or its copolymer In certain embodiments, the polyvinylamine (PVAm) or copolymers thereof have a weight average molecular weight (Mw) in the range of 50,000 to 800,000 g / mol. In certain embodiments, in the range of 200,000 to 600,000 g / mol. In certain embodiments, in the range of 300,000 to 500,000 g / mol. In certain embodiments, in the range of 350,000 to 450,000 g / mol. In certain embodiments, about 400,000 g / mol. The weight average molecular weight (Mw) is measured by size exclusion chromatography.

[0017] In certain embodiments, the dry weight percentage of polyvinylamine or copolymers thereof is in the range of 1-90%, advantageously in the range of 1-60%. In certain embodiments, it is in the range of 1-45%. In certain embodiments, it is in the range of 1-30%. In other embodiments, it is in the range of 5-25%. In certain embodiments, it is in the range of 6-20%. In certain embodiments, it is in the range of 7-15%. In other embodiments, it is in the range of 10-20%. In certain embodiments, it is in the range of 2-11%. In some embodiments, it is in the range of 2.5-7%. In some embodiments, it is in the range of 3-5%.

[0018] Polyvinylamine may exist in forms other than pure polyvinylamine. It may, for example, exist in the form of a copolymer, such as polyvinylamine-polyvinyl alcohol (PVAm-PVOH) copolymer. Other copolymers include PVAm-PVF (polyvinylamine-polyvinylformamide) copolymer.

[0019] The polyvinylamines or copolymers thereof are advantageously in their cationic form, which means that some or all of their amine functions are linked to NH 3 + The counter ion is Cl. - , or any other equivalent counter ion. The pH of the polyvinylamine or copolymer thereof is advantageously about 8 in water at 25° C.

[0020] Binder and / or Crosslinker As detailed above, the binder and / or crosslinker may be a non-ionic or cationic stabilizing binder and / or crosslinker.

[0021] By "non-ionic or cationic stabilization" it is understood that the binder and / or crosslinker are in the form of an emulsion or dispersion in water, said emulsion or dispersion containing a non-ionic or cationic surfactant. The non-ionic or cationic surfactant may be selected from the group consisting of polyoxyethylenated alkylphenols, monoglycerides of long chain fatty acids, polyoxyethylenated alcohols, quaternary ammonium compounds, trimethylalkylammonium chloride, benzalkonium chloride. In certain embodiments, it is a polyoxyethylenated alcohol.

[0022] Binders are generally non-reactive towards the other chemical components of the formulation and are used to bind the inorganic fillers to the glass into a veil.

[0023] The crosslinker is reactive towards at least one other component of the formulation and / or towards glass. It may in some cases serve to increase the dimensional stability of the veil and may also have a scavenging function.

[0024] In certain embodiments, the non-ionic or cationic stabilizing binder and / or crosslinker is a non-ionic or cationic stabilizing binder. In certain embodiments, the non-ionic stabilizing binder is a non-ionic stabilizing binder.

[0025] Suitable examples of non-ionic stabilizing binders include self-crosslinking dispersions of vinyl acetate ethylene (VAE), acrylic binders, or polyurethanes.

[0026] Other suitable binders include cationically stabilized acrylic binders, such as cationic dispersions of copolymers derived from acrylic esters. Other suitable binders and crosslinkers, whether they are cationically or non-ionically stabilized, will be readily apparent to those skilled in the art.

[0027] In certain embodiments, the nonionic or cationic stabilizing binder and / or crosslinker is a binder, and the dry weight percentage of the binder is 60% or less, i.e., in the range of 0-60%, preferably 1-60%. In certain such embodiments, the dry weight percentage of the binder is in the range of 1-40%. In other such embodiments, in the range of 2-30%. In other such embodiments, in the range of 3-20%. In other such embodiments, in the range of 4-20%. In other such embodiments, in the range of 5-10%.

[0028] In alternative embodiments, the nonionic or cationic stabilizing binder and / or crosslinker is in the form of a crosslinker, and the dry weight percentage of the crosslinker ranges from 0 to 30%, preferably from 1 to 30%. In certain such embodiments, it ranges from 2 to 20%. In other such embodiments, it ranges from 3 to 15%. In other such embodiments, it ranges from 4 to 10%. In a further embodiment, it ranges from 5 to 9%. In a further embodiment, it ranges from 6 to 8%.

[0029] Suitable examples of the crosslinking agent include polyacrylic acid, carbodiimide, epoxy compounds, isocyanates, silanes, and dialdehydes.

[0030] In the particular case of the cross-linking agent, if it is itself cationic or non-ionic, it can be used without any stabilizer, either as it is or in the form of an aqueous solution in the formulation.

[0031] In some embodiments, both a binder and a crosslinker are present. In certain embodiments, the total dry weight percentage of binder and crosslinker ranges from 1 to 30%. In certain such embodiments, it ranges from 2 to 20%. In other such embodiments, it ranges from 3 to 15%. In other such embodiments, it ranges from 4 to 10%. In further embodiments, it ranges from 5 to 9%. In further embodiments, it ranges from 6 to 8%. The dry weight ratio of binder to crosslinker in certain embodiments ranges from 2:1 to 20:1. In certain embodiments, this ratio ranges from 5:1 to 15:1. In other embodiments, this ratio ranges from 8:1 to 12:1. In certain embodiments, this ratio is about 10:1.

[0032] Non-ionic stabilized flame retardants By "non-ionic stabilized flame retardant" it is to be understood that the flame retardant is in the form of a slurry or dispersion in water in the presence of a non-ionic dispersing agent.

[0033] The non-ionic dispersing agent may be selected from the group consisting of polyoxyethylated alkylphenols, monoglycerides of long chain fatty acids, and polyoxyethylated alcohols, and in certain embodiments, polyoxyethylated alcohols.

[0034] In certain embodiments, the non-ionic stabilized flame retardant (also called a "flame retardant") is non-ionic stabilized aluminum trihydrate (ATH) (Al(OH) 3 ), non-ionic stabilized phosphorus-nitrogen, non-ionic stabilized magnesium oxide (MgO), non-ionic stabilized magnesium hydroxide (Mg(OH) 2 ). Non-ionic stabilized ATH is the preferred flame retardant.

[0035] In certain embodiments, the non-ionic stabilized flame retardant, preferably ATH, is in the form of a slurry.

[0036] For safety reasons, the slurry form is preferred as it is easier to handle compared to a powder.

[0037] In certain embodiments, the dry weight percentage of the non-ionic stabilized flame retardant is 96% or less. In certain embodiments, it is in the range of 1-96%. In certain embodiments, it is in the range of 10-95%. In certain embodiments, it is in the range of 10-90%. In certain embodiments, it is in the range of 20-90%. In certain embodiments, it is in the range of 30-85%. In certain embodiments, it is in the range of 40-80%. In certain embodiments, it is in the range of 50-75%. In certain embodiments, it is in the range of 60-70%.

[0038] The total dry weight percentage of the flame retardant and PVAm formaldehyde scavenger may be at least 50%. In certain embodiments, it is at least 60%. In other embodiments, it is at least 70%. In further 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%.

[0039] In certain embodiments, the total dry weight percentage of the flame retardant and PVAm formaldehyde scavenger is between 50% and 95%, in certain embodiments between 60% and 90%, and in certain embodiments between 70% and 85%.

[0040] 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.

[0041] Defoamer In certain embodiments, the formulation further comprises an antifoaming agent. Antifoaming agents are well known in the art. Suitable antifoaming agents include (but are not limited to) silicone-based antifoaming emulsions and those based on polydimethylsiloxane (PDMS) oils and emulsions. Other suitable antifoaming agents are mineral oils and silicon-free polymeric antifoaming agents. Thus, in certain embodiments, the antifoaming agent is an antifoaming agent emulsion (i.e., an emulsion). The antifoaming agent emulsion can be non-ionic stabilized. In particular, the antifoaming agent emulsion can include a non-ionic emulsifier.

[0042] In certain embodiments, the formulation comprises no more than 1.5% by dry weight of antifoaming agent. In certain embodiments, no more than 1% by dry weight of antifoaming agent. In certain embodiments, no more than 0.5% by dry weight of antifoaming agent. In certain embodiments, the formulation comprises between 0.01% and 1.5% by dry weight of antifoaming agent.

[0043] In certain embodiments, no more than 0.1% by weight of antifoaming agent is present by dry weight.In certain embodiments, no more than 0.05% by weight of antifoaming agent is present by dry weight.

[0044] In certain embodiments, the amount of antifoaming agent is greater than or equal to 0.001% and less than 0.1% by weight on a dry weight basis.

[0045] In certain embodiments, the amount of antifoaming agent is from 0.01% to less than 0.1% by weight on a dry weight basis. In certain embodiments, the amount of antifoaming agent is from 0.01% to 0.05% by weight on a dry weight basis. In certain embodiments, between 0.01% and 0.02% by weight on a dry weight basis is present of antifoaming agent.

[0046] Repellents In certain embodiments, the formulation further comprises a repellent. Suitable repellents include cationic repellents, such as acrylic repellents, silicone repellents, and non-fluorinated cationic water emulsions, such as waxes. Thus, in certain embodiments, the repellent is cationic. In other embodiments, the repellent is non-ionic. Thus, in certain embodiments, the repellent is non-ionic or cationic. Other repellents include, but are not limited to, fluorocarbons and perfluoroalkyl functionalized acrylates.

[0047] In certain embodiments, the formulation comprises up to 20% repellent by dry weight. In certain embodiments, the formulation comprises 1-20% repellent by dry weight. In certain embodiments, the formulation comprises 1-15% repellent by dry weight. In certain embodiments, the formulation comprises 1-10% repellent by dry weight. In certain embodiments, the formulation comprises 2-20% repellent by dry weight.

[0048] Aminosilane The formulation may further include a coupling agent, particularly an aminosilane. The coupling agent provides improved moist heat resistance to the veil. Aminosilanes include primary aminosilanes, i.e., primary amine functionalized silanes. Examples include aminoalkylsilanes. An exemplary aminosilane is gamma-aminopropyltriethoxysilane (H 2 NCH 2 CH 2 CH 2 Si(OCH 2 CH 3 ) 3 ).

[0049] In certain embodiments, the formulation comprises up to 30% aminosilane by dry weight. In certain embodiments, the formulation comprises 1-30% aminosilane by dry weight. In certain embodiments, the formulation comprises 2-20% aminosilane by dry weight. In certain embodiments, the formulation comprises 3-15% aminosilane by dry weight. In certain embodiments, the formulation comprises 4-10% aminosilane by dry weight.

[0050] Pigments In certain embodiments, the formulation further comprises a pigment. In particular embodiments, the formulation comprises up to 5% by dry weight of a pigment. In certain embodiments, the formulation comprises 0.1-5% by dry weight of a pigment. In certain embodiments, the formulation comprises 0.5-4.5% by dry weight of a pigment. In certain embodiments, the formulation comprises 1-4% by dry weight of a pigment. In certain embodiments, the formulation comprises 1.5-3.0% by dry weight of a pigment.

[0051] Pigments may be particularly useful for hiding or masking discoloration due to, for example, thermal shock from subsequent processing / use of the formulation. Pigments may be organic or inorganic pigments, preferably organic, especially carbon black. For example, black pigments are used in certain embodiments to hide discoloration due to subsequent heating of the formulation.

[0052] The formulation may optionally further comprise one or more (i.e., at least one) of the following: (A) a dispersant, (B) a viscosity modifier, and (C) Formula - [MPO 3 ]- n (OH) 2 (Wherein, M is Na, K, or NH 4 and n is an integer greater than 100, preferably greater than 1000.

[0053] In certain embodiments, the formulation comprises a dispersant (0-3% by weight on a dry basis). 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 0.1-3% by weight on a dry basis of the dispersant.

[0054] In certain embodiments, the formulation comprises a viscosity modifier (0-5% by dry weight). In certain embodiments, the formulation comprises 0.1-5% by dry weight of a viscosity modifier.

[0055] In certain embodiments, the polyphosphate salt is an ammonium polyphosphate salt.

[0056] In certain embodiments, the formulation comprises a sodium polyphosphate salt (0-20% by weight on a dry mass basis).

[0057] In certain embodiments, the formulation comprises an ammonium polyphosphate salt (0-20% by weight on a dry basis). In certain embodiments, the formulation comprises an ammonium polyphosphate salt (0.1-20% by weight on a dry basis). In certain embodiments, the formulation comprises an ammonium polyphosphate salt (1=20% by weight on a dry basis. In certain embodiments, n>1000.

[0058] Formaldehyde scavenging formulations are typically aqueous formulations.

[0059] base In certain embodiments, the formulation further comprises a base. Suitable bases will be readily apparent to those of skill in the art and include, but are not limited to, Ca(OH) 2 , NaOH, KOH, Na 2 CO 3 , Mg(OH) 2 , and Na 3 PO 4 A particularly preferred base is sodium carbonate (Na 2 CO 3) A base can be introduced, if necessary, to adjust the pH of the formulation to avoid aggregation problems, but in an amount that does not cause corrosion to the equipment.

[0060] In certain embodiments, the dry weight percentage of base is 50% or less, in certain embodiments, in the range of 0-25%, i.e., 25% or less.

[0061] In other embodiments, the dry weight percentage of the base ranges from 0.5 to 25%.

[0062] In other embodiments, the dry weight percentage of the base ranges from 1 to 20%, and in other embodiments, from 1.5 to 15%.

[0063] In embodiments that include a base, the dry weight ratio of polyvinylamine or copolymer thereof to base can be in the range of 1:3 to 3:1. It can be in the range of 1:2 to 2:1. It can be in the range of 1:1 to 2:1.

[0064] Thus, in certain embodiments, the formaldehyde scavenging formulation comprises: Polyvinylamine (PVAm) formaldehyde scavengers (1-90% by dry weight), Non-ionic stabilizing binders and / or crosslinkers (up to 60% by dry weight), and Contains non-ionic stabilized aluminum trihydrate (ATH) flame retardants (96% or less by dry weight); Additionally includes: Antifoaming agents (not to exceed 1% by weight on a dry basis), and Repellents (not to exceed 20% by dry weight), and Aminosilanes.

[0065] Second Aspect According to a second aspect of the present invention there is provided a formaldehyde scavenging formulation comprising: (a) a polyvinylamine (PVAm) formaldehyde scavenger or a copolymer thereof, and (b) Antifoaming agent (not more than 1.0% by weight on a dry basis).

[0066] In certain embodiments, the formulation does not include a binder and / or a crosslinking agent.In certain embodiments, the formulation does not include a non-ionic or cationic stabilizing binder and / or a crosslinking agent.

[0067] In certain embodiments, the formulation is flame retardant-free, hi certain embodiments, the formulation is non-ionic stabilized flame retardant-free.

[0068] PVAm or its copolymer formaldehyde scavenger As previously discussed, in certain embodiments, the polyvinylamine (PVAm) has a weight average molecular weight (Mw) in the range of 50,000 to 800,000 g / mol. In certain embodiments, in the range of 200,000 to 600,000 g / mol. In certain embodiments, in the range of 300,000 to 500,000 g / mol. In certain embodiments, in the range of 350,000 to 450,000 g / mol. In certain embodiments, about 400,000 g / mol.

[0069] Polyvinylamine may exist in forms other than pure polyvinylamine. It may, for example, exist in the form of a copolymer, such as polyvinylamine-polyvinyl alcohol (PVAm-PVOH) copolymer. Other copolymers include PVAm-PVF (polyvinylamine-polyvinylformamide) copolymer.

[0070] The polyvinylamines or copolymers thereof are advantageously in their cationic form, which means that some or all of their amine functions are linked to NH 3 + The counter ion is Cl. - , or any other equivalent counter ion. The pH of the polyvinylamine or copolymer thereof is advantageously about 8 in water at 25° C.

[0071] Defoamer As detailed above, antifoaming agents are well known in the art.Suitable antifoaming agents include (but are not limited to) silicone-based antifoaming emulsions and those based on polydimethylsiloxane (PDMS) oils and emulsions.Antifoaming agents can be non-ionic.In particular, antifoaming agents can include non-ionic emulsifiers.

[0072] Other suitable defoamers are mineral oils and silicon-free polymeric defoamers.Thus, in certain embodiments, the defoamer is a defoamer emulsion (i.e., an emulsion).The defoamer emulsion can be non-ionic stabilized.In particular, the defoamer emulsion can include a non-ionic emulsifier.

[0073] As mentioned above, the inventors have found that the use of anionic species in combination with a cationic scavenger such as PVAm can be particularly conducive to flocculation. Thus, the use of non-ionic or cationic components is particularly desirable in preventing flocculation.

[0074] In certain embodiments, the formulation comprises up to 0.5% by dry weight of an antifoaming agent, hi certain embodiments, the formulation comprises 0.001% to 1.5% by dry weight of an antifoaming agent.

[0075] In certain embodiments, 0.1 wt% or less of antifoaming agent is present by dry weight. In certain embodiments, 0.05 wt% or less of antifoaming agent is present by dry weight. In certain embodiments, the amount of antifoaming agent is from 0.001 to 0.1 wt% by dry weight. In certain embodiments, the amount of antifoaming agent is from 0.01 to 0.1 wt% by dry weight. In certain embodiments, the amount of antifoaming agent is from 0.01 to 0.1 wt% by dry weight. In certain embodiments, the amount of antifoaming agent is from 0.01 to 0.05 wt% by dry weight. In certain embodiments, 0.01 to 0.02 wt% of antifoaming agent is present by dry weight.

[0076] Pigments In certain embodiments, the formulation further comprises a pigment. In certain embodiments, the formulation further comprises up to 5% by dry weight of a pigment. In certain embodiments, the formulation comprises 0.1-5% by dry weight of a pigment. In certain embodiments, the formulation comprises 0.5-4.5% by dry weight of a pigment. In certain embodiments, the formulation comprises 1-4% by dry weight of a pigment. In certain embodiments, the formulation comprises 1.5-3.0% by dry weight of a pigment.

[0077] Non-ionic stabilized flame retardants In certain embodiments, the formulation further comprises a non-ionic stabilized flame retardant (up to 96% by weight on a dry basis) in the form of a slurry or dispersion in water in the presence of a non-ionic dispersant.

[0078] The non-ionic dispersing agent may be selected from the group consisting of polyoxyethylated alkylphenols, monoglycerides of long chain fatty acids, and polyoxyethylated alcohols, and in certain embodiments, polyoxyethylated alcohols.

[0079] According to a first aspect, in certain embodiments, the non-ionic stabilized flame retardant (also called a "flame suppressant") is non-ionic stabilized aluminum trihydrate (ATH) (Al(OH) 3 ), non-ionic stabilized phosphorus-nitrogen, non-ionic stabilized magnesium oxide (MgO), non-ionic stabilized magnesium hydroxide (Mg(OH) 2 ). Non-ionic stabilized ATH is the preferred flame retardant.

[0080] In certain embodiments, the non-ionic stabilized flame retardant, preferably ATH, is in the form of a slurry.

[0081] In certain embodiments, the dry weight percentage of the non-ionic stabilized flame retardant is in the range of 10-95%. In certain embodiments, it is in the range of 20-90%. In certain embodiments, it is in the range of 30-85%. In certain embodiments, it is in the range of 40-80%. In certain embodiments, it is in the range of 50-75%. In certain embodiments, it is in the range of 60-75%.

[0082] PVAm formaldehyde scavenger In certain embodiments, the formulation comprises 10% or more by weight of a PVAm formaldehyde scavenger or copolymer thereof by dry weight.

[0083] In certain embodiments, the formulation comprises 15% or more by dry weight of a PVAm formaldehyde scavenger or copolymer thereof. In certain embodiments, the formulation comprises 20% or more by dry weight of a formaldehyde scavenger or copolymer thereof. In certain embodiments, the formulation comprises 25% or more by dry weight of a formaldehyde scavenger or copolymer thereof.

[0084] According to the first aspect, polyvinylamine may be present in a form other than pure polyvinylamine. It may, for example, be present in the form of a copolymer, such as polyvinylamine-polyvinyl alcohol (PVAm-PVOH) copolymer. Other copolymers include PVAm-PVF (polyvinylamine-polyvinylformamide) copolymer.

[0085] The polyvinylamines or copolymers thereof are advantageously in their cationic form, which means that some or all of their amine functions are linked to NH 3 + The counter ion is Cl. - , or any other equivalent counter ion. The pH of the polyvinylamine or copolymer thereof is advantageously about 8 in water at 25° C.

[0086] Binder and / or Crosslinker In certain embodiments, the formulation further comprises a non-ionic or cationic stabilizing binder and / or crosslinker (up to 60% by weight on a dry mass basis). Options for the non-ionic or cationic stabilizing binder and / or crosslinker are as described above for the first aspect.

[0087] Repellents In certain embodiments, the formulation further comprises a repellent, with repellent options as described above for the first aspect.

[0088] Aminosilane In certain embodiments, the formulation further comprises an aminosilane, the aminosilane options being as described above for the first aspect.

[0089] In certain embodiments, the formulation further comprises one or more (i.e., at least one) of the following: (A) a dispersant, (B) a viscosity modifier, and (C) Formula - [MPO 3 ]- n (OH) 2 (Wherein, M is Na, K, or NH 4 and n is an integer greater than 100, preferably greater than 1000.

[0090] These options are as described above for the first embodiment.

[0091] Formaldehyde scavenging formulations are typically aqueous formulations.

[0092] base In certain embodiments, the formulation further comprises a base, options for the base being as described above for the first aspect.

[0093] use The formaldehyde scavenging formulations of the present invention may be used in (e.g., applied to or contained in) veils (especially nonwoven (NW) veils) and building products (including ceiling tiles, insulation boards, particularly boards including phenolic insulation boards, as well as wood-based panels, fabrics, textiles, and panels and boards on or applied to other substrates).

[0094] Veil The present invention also provides a nonwoven veil coated with or containing a formaldehyde scavenging formulation according to the present invention.

[0095] Nonwoven veils for building products are well known in the art and typically comprise interwoven, randomly oriented reinforcing fibers. The fiber component of the veil may be any of metal fibers, ceramic fibers, mineral fibers, glass fibers, carbon fibers, graphite fibers, polymeric fibers such as aramid, polyester, polyacrylic, polyamide, polyacrylonitrile, natural fibers, and combinations thereof. In particular, the fiber component of the veil may be glass fibers. The veil may comprise 20-130 g / m^2 of fibers.

[0096] The veil may contain up to 40 g / m^2 of formaldehyde scavenger. The veil may contain 0.5 to 20 g / m^2 of formaldehyde scavenger. The veil may contain 1 to 15 g / m^2 of formaldehyde scavenger. The veil may contain 2 to 10 g / m^2 of formaldehyde scavenger. The veil may contain 3 to 6 g / m^2 of formaldehyde scavenger. Excellent results have been achieved with these amounts of formaldehyde scavenger, as detailed in the examples below.

[0097] In particular, the veil may comprise 5-250g / m^2 of a formaldehyde scavenging formulation, of which 0.5-20g / m^2 is a formaldehyde scavenger.

[0098] building products The present invention also provides a building product having (ie, comprising / comprising) on ​​at least one surface thereof a nonwoven veil according to the present invention.

[0099] In certain embodiments, the building product is selected from the group consisting of ceiling tiles, wall panels, insulation boards, gypsum boards, and wood-based panels.In certain embodiments, the building product is selected from the group consisting of ceiling tiles, wall panels, insulation boards, and wood-based panels.

[0100] In particular, the building product may have a nonwoven veil according to the invention on at least one of the front and back surfaces.

[0101] In certain embodiments, the building product is made from wool selected from the group consisting of glass wool, rock wool, stone wool, and mineral wool.

[0102] Products that include wood-based panels include, but are not limited to, floor tiles and furniture. Ceiling tiles include, but are not limited to, wet felt boards.

[0103] In the case of a ceiling tile, it may have a nonwoven veil according to the present invention on at least one of its front and back sides. The ceiling tile may contain a formaldehyde-releasing binder. The ceiling tile may be made of wool. The wool may be glass wool, rock wool, stone wool or mineral wool.

[0104] In the case of a wall panel, it may have a nonwoven veil according to the invention on at least one of its front and back sides. The wall panel may contain a formaldehyde releasing binder. The ceiling tile may be made of wool. The wool may be glass wool, rock wool, stone wool or mineral wool.

[0105] In the case of an insulation board, it may have a nonwoven veil according to the invention on at least one of its front and back sides. The insulation board may be a phenolic foam board or a mineral wool board.

[0106] In the case of a wood-based panel (WBP), it may have a nonwoven veil according to the invention on at least one of its front and back sides or may be included in a laminate.

[0107] The present invention also provides a method of reducing formaldehyde emissions from a building product, the method comprising attaching a nonwoven veil according to the present invention to at least one exterior surface of the building product. As previously mentioned, in certain embodiments, the building product is selected from the group consisting of ceiling tiles, wall panels, insulation boards, and wood-based panels.

[0108] The at least one exterior surface may be at least one major surface of the product, for example, the front surface, or both the front and back surfaces. Examples of building products include tiles (e.g., ceiling tiles) and panels and boards (e.g., wall panels, ceiling panels, and insulation boards).

[0109] 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 desired and appropriate and not just as explicitly set out in the claims. The term "comprising" as used herein to specify the inclusion of an ingredient also includes embodiments in which no further ingredient is present.

[0110] Embodiments of the present invention will now be described, by way of example only. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0111] Weight percentages used throughout this specification are based on total dry weight.

[0112] In the following examples, formaldehyde scavenging formulations and building products according to the present invention demonstrate excellent results.

[0113] Flocculation was measured with a filter on a fine mesh. The formulation passes through a fine mesh filter before entering the tank. This filter can trap larger particles (flocculants) that can accumulate and clog the filter. We considered "no flocculation" if the filter did not clog after the formulation was run through the fine mesh filter for 8 hours.

[0114] The preparation of the formulation of Example 1 does not result in aggregation.

[0115] Similarly, the preparation of the formulations of Examples 2 and 3 does not result in aggregation.

[0116] Example 1

[0117] [Table 1]

[0118] This formulation gives a wet mass of 5000 kg containing ingredients with a dry weight of 1300 kg.

[0119] No clumping of the formulation was observed in the manufacturing machine. The formulation was added to the nonwoven veil at 45 g / m^2 (i.e., 4.62 g / m^2 of PVAm formaldehyde scavenger).

[0120] A separate formulation with anionically stabilized ATH (instead of non-ionic ATH) results in aggregation.

[0121] A separate formulation with an anionic binder (instead of a non-ionic binder) results in flocculation.

[0122] Example 2

[0123] [Table 2]

[0124] This formulation gives a wet mass of 5000 kg containing ingredients with a dry weight of 1067 kg.

[0125] No clumping occurs with this formulation. The formulation is added to a nonwoven veil at 5 g / m^2 (i.e., 4.90 g / m^2 of PVAm formaldehyde scavenger).

[0126] A separate formulation with an anionic antifoam (instead of a nonionic antifoam) results in flocculation.

[0127] [Table 3]

[0128] This formulation gives a wet mass of 5000 kg containing ingredients with a dry weight of 850 kg.

[0129] No clumping occurs with this formulation. The formulation is added to a nonwoven veil at 18 g / m^2 (i.e., 4.89 g / m^2 of PVAm formaldehyde scavenger).

[0130] A separate formulation with anionically stabilized ATH results in aggregation.

[0131] conclusion The formulation of Example 1 does not result in aggregation. Similarly, the formulations of Examples 2 and 3 do not result in aggregation.

[0132] 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 connection with specific embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes of carrying out the invention that are obvious to those skilled in the art are intended to be covered by the present invention.

Claims

1. (a) Polyvinylamine (PVAm) formaldehyde scavenger or copolymer thereof (b) Optionally, a nonionic or cationic stabilizing binder and / or crosslinking agent, (c) Nonionic stabilized flame retardants A formaldehyde scavenging preparation containing [the specified ingredient].

2. (a) 1 to 90% by weight by dry mass of the polyvinylamine (PVAm) formaldehyde scavenger or copolymer thereof (b) 1 to 60% by weight by dry mass of the nonionic or cationic stabilizing binder and / or crosslinking agent, (c) 10-90% of the nonionic stabilized flame retardant A formaldehyde scavenging preparation according to claim 1, comprising the above.

3. The formaldehyde scavenging formulation according to claim 1 or 2, wherein the nonionic or cationic stabilizing binder and / or crosslinking agent is a nonionic stabilizing binder.

4. The aforementioned nonionic stabilized flame retardant is a nonionic stabilized aluminum trihydrate (ATH) (Al(OH) 3 The formaldehyde scavenging preparation according to claim 1 or 2, which is a slurry or dispersion.

5. The formaldehyde scavenging preparation according to claim 1 or 2, further comprising a base in an amount of 50% by weight or less by dry mass.

6. The formaldehyde scavenging preparation according to claim 1 or 2, further comprising an antifoaming agent in an amount of 1.5% by weight or less by dry mass.

7. The formaldehyde scavenging preparation according to claim 1 or 2, further comprising a repellent in an amount of 20% by weight or less by dry mass.

8. (A) Dispersant, (B) Viscosity modifiers, and (C) Sodium polyphosphate salt - [MPO 3 ]- n (OH) 2 (In the formula, M is Na, K, and NH) 4 (Selected from the group consisting of, where n is an integer greater than 100) A formaldehyde scavenging preparation according to claim 1 or 2, further comprising at least one of the following.

9. A nonwoven veil coated with or containing the formaldehyde scavenging formulation described in claim 1 or 2.

10. The nonwoven veil according to claim 9, which is a glass fiber nonwoven veil.

11. A building product having the nonwoven veil described in claim 10 on at least one surface.