Formaldehyde-Free Aqueous Binder for Durable Inorganic Fiber Insulation
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Solution Overview
Problem
Existing inorganic-fiber heat-insulating sound-absorbing members face challenges with phenol resin binders that generate formaldehyde, leading to insufficient curing and reduced compressive strength and durability, while formaldehyde-free aqueous binders struggle to achieve optimal heat-insulating performance without compromising environmental impact.
Innovation Solution
An aqueous binder comprising a polycarboxylic acid with a specific molecular weight range and a crosslinking agent, including branched polyethyleneimine and alkanolamine, is used, which reacts without releasing formaldehyde, ensuring excellent compressive strength and durability by controlling the mole ratios of functional groups, thereby improving crosslinking density and curing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a phenol resin is used as a binder, then the inorganic-fiber heat-insulating sound-absorbing member achieves sufficient compressive strength and durability, but formaldehyde is generated during and after curing, increasing environmental burden
Solution Approach 1:
The invention changes the chemical composition parameters of the binder by using a polycarboxylic acid with specific molecular weight (1000-20000) and acid value (500-900 mgKOH/g) combined with a crosslinking agent in controlled mole ratios, achieving both high reliability and formaldehyde-free operation
Solution Approach 2:
The invention creates a composite binder system combining polycarboxylic acid and crosslinking agent, where the crosslinking agent with specific functional group ratios (0.30-0.75 relative to carboxy group, 0.34-0.80 amino/imino to total groups) provides both structural integrity and environmental safety
2Temperature
If a thick inorganic-fiber heat-insulating sound-absorbing member is produced to enhance heat insulating performance, then heat insulating performance is improved, but the center portion heating becomes insufficient leading to inadequate binder curing
Solution Approach 1:
The invention optimizes the molecular weight parameter of the polycarboxylic acid (1000-20000) and acid value (500-900 mgKOH/g) to achieve rapid curing kinetics that can penetrate through thick member centers, ensuring uniform curing throughout the entire thickness
Solution Approach 2:
The binder composition is designed with specific crosslinking agent ratios that enable the curing reaction to proceed effectively at different locations within the member, ensuring both surface and center portions achieve adequate curing degree even in thick configurations
3Reliability
If the mole ratio of functional groups in the crosslinking agent is not optimized, then the curing reaction may be incomplete or excessive, but achieving the optimal ratio requires precise control to maximize compressive strength and durability
Solution Approach 1:
The invention establishes specific parameter ranges for the crosslinking agent composition: the ratio of total mole of hydroxyl, amino and imino groups to carboxy group (0.30-0.75) and the ratio of amino and imino groups to total functional groups (0.34-0.80), providing clear manufacturing guidelines that balance performance and controllability
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 provides inorganic-fiber heat-insulating sound-absorbing members with enhanced compressive strength, durability, and reduced environmental impact, maintaining performance across varying environmental conditions without the need for increased temperature or curing time, making it suitable for heat-insulating and sound-absorbing applications.
Implementation Method 1
the aqueous binder of the present invention 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 comprises a branched polyethyleneimine having a weight average molecular weight of 300 to 2000, and an alkanolamine having a lower molecular weight than the polyethyleneimine and an alcohol valence of 2 or less; the ratio of the total mole of a hydroxyl group, an amino group and an imino group in the crosslinking agent relative to the mole of a carboxy group in the polycarboxylic acid is 0.30 to 0.75; 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 0.34 to 0.80.