Aqueous Binder Composition for Formaldehyde-Free Inorganic Fiber Curing
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Solution Overview
Problem
Conventional inorganic-fiber heat-insulating sound-absorbing members face issues with formaldehyde emission during curing and insufficient heat insulation due to inadequate binder curing, leading to variations in quality and performance.
Innovation Solution
An aqueous binder comprising a polycarboxylic acid and a crosslinking agent, specifically a polyamine and polyol, is used, which reacts without releasing formaldehyde and provides excellent peel strength, ensuring thorough curing and improved physical properties without increasing curing temperature or time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a phenol resin is used as a binder, then good binding performance is achieved, but formaldehyde is generated during and after curing
Solution Approach 1:
The invention extracts and removes the harmful formaldehyde component from the binder system by replacing phenol resin with an aqueous binder composed of polycarboxylic acid and crosslinking agent, thereby eliminating formaldehyde generation while maintaining binding performance
Solution Approach 2:
The invention uses a composite binder system comprising polycarboxylic acid and crosslinking agent that work together to provide effective binding without formaldehyde, creating a new material composition that replaces the traditional phenol resin
2Temperature
If the thickness of the inorganic-fiber heat-insulating sound-absorbing member is increased to enhance heat insulating performance, then heat insulating performance is improved, but the curing degree of the binder at the center portion becomes insufficient
Solution Approach 1:
The invention changes the chemical parameters of the binder system by using polycarboxylic acid with specific molecular weight (1000-20000) and acid value (500-900 mgKOH/g), and controlling the molar ratio of functional groups, which enables thorough curing even in thick sections without requiring increased temperature or time
Solution Approach 2:
The binder composition is designed to provide different reactivity characteristics at different locations within the product, ensuring that the center portion receives adequate curing action while the surface portion is properly protected, achieving uniform curing throughout the thickness
3Object-generated harmful factors
If conventional aqueous binders are used to avoid formaldehyde, then environmental burden is reduced, but peel strength of the inorganic-fiber heat-insulating sound-absorbing member is insufficient
Solution Approach 1:
The invention creates a composite binder system combining polycarboxylic acid and crosslinking agent that work synergistically to provide both environmental benefits (no formaldehyde) and mechanical performance (excellent peel strength), overcoming the limitations of conventional single-component aqueous binders
Solution Approach 2:
The invention optimizes the molecular weight and functional group ratios of the binder components to achieve the desired balance between environmental compatibility and mechanical strength, specifically controlling the molar ratio of hydroxyl, amino, and imino groups to carboxyl groups
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 achieves high peel strength and consistent quality in inorganic-fiber heat-insulating sound-absorbing members, reducing environmental impact and maintaining performance across varying environmental conditions.
Implementation Method 1
the aqueous binder is cured by the reaction between a polycarboxylic acid and a curing agent
Implementation Method 2
inorganic-fiber heat-insulating sound-absorbing member
Data Source
AI summary
Disclosed is an aqueous binder for an inorganic-fiber heat-insulating sound-absorbing member, comprising a polycarboxylic acid and a crosslinking agent for the polycarboxylic acid, in which the polycarboxylic acid comprises a polycarboxylic acid having a weight average molecular weight of 1000 to 20000 and an acid value of 500 to 900 mgKOH/g; the crosslinking agent at least comprises a polyamine without a hydroxyl group, the polyamine having at least one of an amino group and an imino group and having a weight average molecular weight of 100 to 500 and an amine value of 1150 to 1650 mgKOH/g, and a polyol without an amino group and an imino group, the polyol having a hydroxyl group and having a weight average molecular weight of 90 to 250 and an alcohol valence of 3 or more; the ratio of the total mole of the hydroxyl group, amino group and imino group in the crosslinking agent relative to the mole of the carboxy group in the polycarboxylic acid is 0.3 to 1.2; and the ratio of the total mole of the amino group and imino group in the crosslinking agent relative to the total mole of the hydroxyl group, amino group and imino group in the crosslinking agent is 0.01 to 0.2.