Bio-based binders including carbohydrates and a pre-reacted product of an alcohol or polyol and a monomeric or polymeric polycarboxylic acid

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Solution Overview

Problem

Conventional binders for fiberglass insulation and non-woven mats face issues such as formaldehyde emissions, machine corrosion, high viscosity, and undesirable color, which affect the properties and safety of the insulation products, and there is a need for an environmentally friendly binder that does not corrode machine parts and emits no formaldehyde.

Innovation Solution

A bio-based binder composition using natural carbohydrates, a crosslinking agent, and a pre-reacted product of an alcohol or polyol and a monomeric or polymeric polycarboxylic acid, which forms a polyester thermoset resin, is developed, including components like pectin, dextrin, maltodextrin, and glycerol, and citric acid derivatives, to create a stable and environmentally friendly binder.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional binders (formaldehyde-based resins) are used to provide binding strength and resiliency, then the insulation product achieves desired mechanical properties, but formaldehyde emissions occur causing harmful effects

Engineering Contradiction:

Improvebinding strengthVSAvoidformaldehyde emissions

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent replaces harmful formaldehyde-based resins with beneficial bio-based alternatives (carbohydrates like dextrin, maltodextrin, or starch combined with polycarboxylic acids like citric acid) that provide equivalent binding strength without formaldehyde emissions. This converts the harmful chemical system into a beneficial natural system.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention changes the chemical composition parameters by using bio-based carbohydrates and polycarboxylic acids instead of formaldehyde-based resins. The binder system transitions from synthetic formaldehyde chemistry to natural polymer chemistry, fundamentally altering the chemical parameters while maintaining functional performance.

Inventive Principle:

Principle #35Parameter changes

2Strength

If conventional binders are used to provide stiffness and handleability, then the insulation product achieves desired mechanical properties, but machine corrosion occurs

Engineering Contradiction:

ImprovestiffnessVSAvoidmachine corrosion

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent eliminates the corrosive effect of conventional binders by using non-corrosive bio-based alternatives. The carbohydrate-polycarboxylic acid system provides the necessary stiffness and mechanical properties without the corrosive chemicals that damage manufacturing equipment, converting a harmful system into a beneficial one.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If conventional binders are used to achieve proper curing, then the insulation product achieves desired properties, but high viscosity causes processing difficulties

Engineering Contradiction:

Improvecuring performanceVSAvoidviscosity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The invention changes the rheological parameters by using bio-based carbohydrate polymers and polycarboxylic acids that inherently provide lower viscosity compared to conventional formaldehyde resins. This parameter change improves ease of application and processing while maintaining reliable curing performance through the natural crosslinking chemistry of the bio-based components.

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 bio-based binder composition reduces formaldehyde emissions, minimizes machine corrosion, achieves faster curing, decreases viscosity, and allows for maximum vertical expansion of insulation packs, while being cost-effective and suitable for current manufacturing lines, with the added benefit of a light color for the final products.

Implementation Method 1

The carbohydrate and crosslinking agent form a polyester thermoset resin

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 2

a pre-reacted product of an alcohol or polyol and a monomeric or polymeric polycarboxylic acid

Methodology Applied

Scientific EffectEsterification reaction: Chemical Bonding

Data Source

PatentUS11066535B2Bio-based binders including carbohydrates and a pre-reacted product of an alcohol or polyol and a monomeric or polymeric polycarboxylic acid

Publication Date: 2021.07.20 OWENS CORNING INTELLECTUAL CAPITAL LLC

AI summary

An environmentally friendly, formaldehyde-free, aqueous binder composition that includes a carbohydrate, a crosslinking agent, and a pre-reacted product of an alcohol or polyol and monomeric or polymeric polycarboxylic acid or polyglycerol is provided. The pre-reacted product may include glycerol and esters of citric acid such a monoglyceryl citrate, diglyceryl citrate, and triglyceryl citrate as well as other higher molecular weight citric acid-based esters. The inclusion of the pre-reacted product in the binder composition helps to speed the crosslinking reaction, induces faster water evaporation, decreases the viscosity of the binder, helps to reduce the amount of water needed for application of the binder, decreases tackiness, and helps to achieve a maximum vertical expansion of the insulation pack in the transfer zone. The binder composition may be used in the formation of insulation materials and non-woven chopped strand mats.