Mineral Fiber Mat Binder Composition for Low Yellowing Curing
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Solution Overview
Problem
There is a need for binder compositions in mineral fiber mats that utilize non-petrochemical, renewable resources, reduce hazardous substances like formaldehyde and isocyanates, maintain mechanical properties, minimize yellowing during curing, and limit water solubility to prevent weight loss.
Innovation Solution
The use of amino acid polymers, particularly polylysine, and alpha-hydroxy carbonyl compounds in the binder mixture, which are cured at temperatures between 80 to 250°C, to produce mineral fiber mats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional binder mixtures are used, then mineral fiber mats can be produced, but yellowing occurs during curing and water solubility increases causing weight loss
Solution Approach 1:
The patent changes the chemical composition parameters of the binder by using amino acid polymers with specific molecular weights (1,000-10,000 g/mol) and controlled amino group content (2-10 mmol/g), along with alpha-hydroxy carbonyl compounds in specific ratios. These parameter changes result in a cured binder that exhibits reduced yellowing and lower water solubility while maintaining effective fiber bonding.
Solution Approach 2:
The invention creates a composite binder system combining amino acid polymers (such as polylysine) with alpha-hydroxy carbonyl compounds (such as hydroxyacetone). This composite material approach allows the synergistic interaction between the polymer matrix and the crosslinking agent, producing a cured binder with improved properties including reduced yellowing and enhanced water resistance compared to conventional single-component binders.
2Object-generated harmful factors
If renewable resource-based binder constituents are used, then hazardous substances are reduced, but mechanical properties may deteriorate
Solution Approach 1:
The patent specifies precise parameter ranges for the amino acid polymer including molecular weight (1,000-10,000 g/mol), amino group content (2-10 mmol/g), and viscosity (10-1,000 cP). These controlled parameters ensure optimal bonding strength and mechanical properties. The alpha-hydroxy carbonyl compound is used in specific amounts (1-10 parts by weight per 100 parts amino acid polymer) to achieve effective crosslinking while maintaining mechanical integrity, proving that renewable-based binders can meet mechanical property requirements.
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 solution reduces yellowing and water solubility, maintaining mechanical integrity and preventing weight loss, while eliminating the release of undesirable chemicals like phenol or formaldehyde.
Implementation Method 1
curing the binder mixture at a temperature in a range of from 80 to 250° C.
Data Source
AI summary
The invention relates to a process for producing a mineral fiber mat. The mineral fiber mat comprises a mineral fiber component A comprising minerals fibers selected from stone fibers, glass fibers, and mixtures thereof, and a cured binder component B. Cured binder component B is prepared by curing, at a temperature in a range of from 80 to 250° C., of a binder mixture comprising as binder constituents c1) one or more amino acid polymers having two or more primary amino groups and c2) one or more alpha-hydroxy carbonyl compounds. The invention further relates to the mineral fiber mat and a mineral fiber composite mat. The mats of the invention are used as or in a construction product, or in a transportation vehicle.