Mineral Fiber Binder Composition Without Formaldehyde Emissions
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Solution Overview
Problem
Existing mineral fibre binders are costly, require expensive starting materials, involve corrosive and harmful components, and emit unwanted substances during curing, necessitating complex machinery and safety measures, while also being based on non-renewable fossil fuels.
Innovation Solution
A binder composition for mineral fibres using lignosulfonate lignins and cross-linkers, free of phenol and formaldehyde, which does not require pre-oxidation and includes optional plasticizers, reducing complexity and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional binders based on phenol-formaldehyde resins or other synthetic polymers are used, then good binding properties are achieved, but the products contain formaldehyde emissions and are based on fossil fuels
Solution Approach 1:
The invention changes the chemical composition parameters of the binder by using lignosulfonate lignins with controlled carboxylic acid group content (0.03 to 2.0 mmol/g) and specific cross-linkers, replacing conventional phenol-formaldehyde resins. This parameter change eliminates formaldehyde emissions while maintaining binding properties through the controlled chemical structure of the lignin-based binder system.
Solution Approach 2:
The invention creates a composite binder system combining lignosulfonate lignins with specific cross-linkers (such as polyamines, epoxies, or anhydrides). This composite approach leverages the renewable lignin backbone with cross-linking agents to achieve both environmental benefits (no formaldehyde, renewable) and technical performance (adequate binding strength) simultaneously.
2Reliability
If pre-oxidation of lignin components is performed to create suitable binders, then good binding properties are achieved, but the production process becomes more complex and costly
Solution Approach 1:
The invention performs preliminary selection and characterization of lignosulfonate lignins with specific carboxylic acid group content ranges (0.03 to 2.0 mmol/g) before the binding process. By pre-defining the acceptable range of lignin properties, the need for complex post-manufacturing oxidation processes is eliminated, as suitable lignins are selected from the outset to work directly in the binder composition.
Solution Approach 2:
The lignosulfonate lignins inherently possess the necessary functional groups (carboxylic acid groups within the specified range) that enable them to serve as effective binders without requiring additional oxidation treatment. The lignin's natural chemical structure provides the binding capability, making the process self-sufficient and eliminating complex external processing steps.
3Object-affected harmful factors
If expensive renewable starting materials are used for binder production, then environmental sustainability is improved, but production costs increase
Solution Approach 1:
The invention optimizes the chemical parameters of the lignosulfonate lignins, specifically controlling the carboxylic acid group content within the range of 0.03 to 2.0 mmol/g. This parameter optimization ensures that the binder achieves effective performance with the minimum necessary renewable material input, avoiding excessive use of expensive lignin while maintaining environmental sustainability and cost-effectiveness.
Solution Approach 2:
The invention creates a composite system where lignosulfonate lignins are combined with cross-linkers and other components to achieve synergistic effects. This composite approach allows the use of renewable materials at optimized concentrations, reducing the overall quantity of expensive renewable starting materials needed while maintaining both environmental sustainability and cost-effectiveness through efficient material utilization.
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 is economically produced, uses renewable materials, minimizes corrosive agents, and reduces emissions, offering improved processing and shelf life with lower transport costs and environmental impact.
Implementation Method 1
a binder resulting from the curing of an aqueous binder composition free of phenol and formaldehyde comprising: a component (i) in form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol/g
Data Source
AI summary
The invention is directed to a mineral fibre product, comprising mineral fibres in contact with a binder resulting from the curing of an aqueous binder composition free of phenol and formaldehyde.