Benzoic Sulfimide Binders for Insulation

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Solution Overview

Problem

There is a need for environmentally friendly, renewable binder compositions that offer improved curing rates and reduced production time, particularly in industries like mineral wool and fiberboard manufacturing, while avoiding the use of undesirable reactants like formaldehyde.

Innovation Solution

An aqueous curable binder composition comprising a benzoic sulfimide component and a carbohydrate or alcohol component, with specific ratios and optional additives, that can cure at lower temperatures and enhance bonding strength, suitable for use in mineral wool and fiberboard applications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If phenol formaldehyde based binder systems are used, then commercially acceptable binding and adhesion properties are achieved, but environmental concerns and regulatory restrictions increase

Engineering Contradiction:

Improvebinding and adhesion propertiesVSAvoidenvironmental impact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention changes the chemical composition parameters by replacing phenol formaldehyde with alternative binder systems comprising carbohydrate-based binders (such as dextrose, sucrose, or starch) combined with amine components (such as ammonium sulfate, diammonium phosphate, or melamine). This substitution maintains binding performance while eliminating formaldehyde and reducing environmental harm.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses composite binder systems that combine multiple components: carbohydrate-based binders, amine components, and optional accelerators or modifiers. This composite approach achieves the required binding and adhesion properties while avoiding the harmful effects of phenol formaldehyde systems.

Inventive Principle:

Principle #40Composite materials

2Strength

If conventional binder systems are used, then binding strength is achieved, but production time increases

Engineering Contradiction:

Improvebinding strengthVSAvoidproduction time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The binder composition is formulated with pre-selected components and ratios that enable faster curing. The carbohydrate-based binders combined with specific amine components are designed to react more rapidly than conventional phenol formaldehyde systems, reducing the time required to achieve adequate binding strength during manufacturing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention optimizes curing parameters by adjusting the chemical composition to achieve faster cure rates. The specific ratio of carbohydrate to amine component, along with optional accelerators, creates a system that reaches sufficient binding strength more quickly than conventional binders, thereby reducing production time.

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If formaldehyde-free binders are used, then environmental friendliness is improved, but cure rate decreases

Engineering Contradiction:

Improveformaldehyde contentVSAvoidcure rate

Core Design Contradiction:

Object-affected harmful factorsVSSpeed

Solution Approach 1:

The invention changes the chemical parameters of formaldehyde-free binders by selecting specific carbohydrate types (dextrose, sucrose, starch) and amine components (ammonium sulfate, diammonium phosphate, melamine) in optimized ratios. This formulation achieves faster cure rates while maintaining zero formaldehyde content, overcoming the limitation of conventional formaldehyde-free binders.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention introduces intermediary substances such as accelerators or modifying agents that facilitate the curing reaction between carbohydrate-based binders and amine components. These intermediaries enhance the reaction kinetics, improving cure rate without compromising the formaldehyde-free status of the binder system.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 provides faster curing rates and enhanced bonding strength, reducing production time and environmental impact while eliminating the use of formaldehyde, making it suitable for various industrial applications.

Implementation Method 1

An aqueous curable binder composition comprising (a) a benzoic sulfimide component, (b) a carbohydrate or alcohol component, (c) the reaction product of (a) and (b)

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS10927246B2Benzoic sulfimide binders and insulation articles comprising the same

Publication Date: 2021.02.23 KNAUF INSULATION LLC

AI summary

The present disclosure generally relates to an aqueous curable binder composition comprising (i) a benzoic sulfimide, (ii) a carbohydrate or alcohol, and (iii) the reaction product of (i) and (ii), at a defined ratio of carbohydrate or alcohol compound to benzoic sulfimide compound. In some embodiments, the aqueous curable binder is produced using renewable materials and is characterized by improved cure rates. In additional embodiments, the composition is disposed onto an assembly of fibers or particles for the production of an insulation product.