Amino Acid Polymer Binder for Low Formaldehyde Emissions

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Solution Overview

Problem

Conventional binder compositions for lignocellulose-based composite articles, such as OSB and MDF, face challenges with formaldehyde and isocyanate emissions, requiring the development of binder compositions that are formaldehyde-free or have low formaldehyde emissions while maintaining excellent mechanical properties and swelling values.

Innovation Solution

A binder composition comprising amino acid polymers with a weight average molecular weight between 800 g/mol and 10,000 g/mol, combined with pentoses, hexoses, or disaccharides, which are stored separately and reacted to form a crosslinked polymer, providing a formaldehyde-free or low formaldehyde emission solution for lignocellulose-based composite articles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If conventional binder compositions (phenol formaldehyde, urea formaldehyde, isocyanates) are used, then excellent mechanical properties and structural integrity are achieved, but formaldehyde emissions and harmful factors increase

Engineering Contradiction:

Improveformaldehyde emissionsVSAvoidmechanical properties

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The invention changes the chemical composition parameters of the binder by using amino acid polymers with specifically controlled molecular weights (800-10,000 g/mol) and precise amino acid ratios (30-70% lysine, 10-50% arginine, 10-50% ornithine), thereby achieving low formaldehyde emissions while maintaining mechanical strength

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite binder system combining multiple amino acid polymers with complementary properties, where lysine provides bonding strength, arginine enhances adhesion, and ornithine improves structural integrity, achieving both environmental sustainability and mechanical performance

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If amino acid polymers with low molecular weight are used, then formaldehyde emissions are reduced, but mechanical strength and structural integrity deteriorate

Engineering Contradiction:

Improveformaldehyde emissionsVSAvoidmechanical strength

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The invention optimizes the molecular weight parameter of amino acid polymers to the specific range of 800-10,000 g/mol, which provides sufficient mechanical strength while ensuring low formaldehyde emissions, avoiding both high and low molecular weight extremes

Inventive Principle:

Principle #35Parameter changes

3Strength

If amino acid polymers with high molecular weight are used, then mechanical strength is improved, but formaldehyde emissions increase and processing difficulty increases

Engineering Contradiction:

Improvemechanical strengthVSAvoidformaldehyde emissions

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention sets the molecular weight upper limit at 10,000 g/mol to prevent excessive formaldehyde emissions while maintaining adequate mechanical strength, and controls the lower limit at 800 g/mol to ensure sufficient bonding capability

Inventive Principle:

Principle #35Parameter changes

4Strength

If precise amino acid composition ratios are used, then mechanical properties are optimized, but manufacturing complexity increases

Engineering Contradiction:

Improvemechanical propertiesVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The invention defines specific compositional ranges (30-70% lysine, 10-50% arginine, 10-50% ornithine) that optimize mechanical properties while remaining practical for manufacturing, balancing performance requirements with production feasibility

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The binder composition achieves improved mechanical properties and reduced formaldehyde emissions, enhancing the structural integrity and environmental sustainability of lignocellulose-based composite articles like OSB and MDF.

Implementation Method 1

reacted binder composition comprising a crosslinked polymer formed by reacting a) Component A comprising amino acid polymer(s) A1 with b) Component B comprising component B1 selected from the group consisting of pentoses, hexoses, disaccharides of pentoses and/or hexoses and mixtures thereof

Methodology Applied

Scientific EffectCrosslinking reaction: Chemical Bonding

Data Source

PatentEP4267638B1Binder composition comprising amino acid polymer(s) as well as carbohydrates for composite articles

Publication Date: 2024.10.30 BASF SE

AI summary

The present invention relates to a binder composition comprising a) Component A comprising amino acid polymer(s) A1 and b) Component B comprising component B1 selected from the group consisting of pentoses, hexoses, disaccharides of pentoses and/or hexoses and mixtures thereof, wherein the amino acid polymer(s) A1 has(have) a total weight average molecular weight Mw,total of at least 800 g/mol and at most 10.000 g/mol and wherein the binder composition comprises at least 55 wt.-% amino acid polymer(s) A1 based on the total weight of the amino acid poly- mer(s) A1 and component B1.