Mineral Fibre Binder Composition for Fast Curing and Humidity Resistance
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Solution Overview
Problem
Existing mineral fibre binder systems face challenges in achieving cost-effectiveness, curing speed, curing density, durability, and humidity resistance, particularly with the use of formaldehyde-free binders that require expensive anhydride reactants and exhibit high water solubility and curing speed issues.
Innovation Solution
Aqueous binder composition comprising a sugar syrup with a dextrose equivalent (DE) of 50 to 85, polycarboxylic acid, and amine components, optionally with a reaction product of polycarboxylic acid and amine, is used to produce bonded mineral fibre products, optimizing viscosity, solubility, and curing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expensive anhydride reactants are used to achieve water solubility and curing speed, then binder performance is improved, but production cost increases
Solution Approach 1:
The patent replaces expensive anhydride reactants with cheaper carbohydrate-based materials (sugars, starches, cellulose) that can be readily hydrolyzed to produce the desired binder performance. These inexpensive carbohydrate sources serve as substitutes for costly chemical reactants while achieving the required water solubility and curing characteristics.
Solution Approach 2:
The patent changes the chemical composition parameters of the binder system by using carbohydrates with varying degrees of polymerization, molecular weights, and hydrolysis rates. By adjusting these parameters, the binder achieves optimal water solubility and curing speed without requiring expensive anhydride reactants, thus resolving the cost-performance contradiction.
2Reliability
If high proportion of anhydride reactants is used to achieve desired water solubility and curing density, then binder properties are improved, but production cost increases
Solution Approach 1:
The patent substitutes expensive anhydride reactants with inexpensive carbohydrate materials that provide the necessary water solubility and curing density. The carbohydrates are hydrolyzed to produce soluble sugars and oligosaccharides that serve as effective binder components without requiring high proportions of costly anhydride reactants.
Solution Approach 2:
The patent introduces carbohydrate-based intermediaries (sugars, starches, cellulose derivatives) that mediate between the mineral fibres and the binder system. These intermediaries provide water solubility and curing density through their hydrolysis products, replacing the need for high proportions of expensive anhydride reactants while maintaining binder performance.
3Ease of manufacture
If conventional phenol/formaldehyde binders are used, then production cost is reduced and binding performance is achieved, but formaldehyde emissions occur
Solution Approach 1:
The patent extracts and eliminates the harmful formaldehyde component from the binder system while retaining the essential binding functionality. By using carbohydrate-based materials that do not contain formaldehyde, the patent removes the harmful emission source while maintaining cost-effectiveness and binding performance through alternative chemical pathways.
Solution Approach 2:
The patent converts the potential harm of formaldehyde emissions into a benefit by using carbohydrate materials that naturally provide binding functionality without harmful emissions. The hydrolysis of carbohydrates produces benign byproducts and eliminates formaldehyde while maintaining or improving binder performance, thus turning the environmental issue into an advantage.
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 provides improved production costs, curing speed, curing density, durability, and humidity resistance in mineral fibre products, enhancing the overall performance and efficiency of the manufacturing process.
Implementation Method 1
transferred to a curing oven for curing of the binder and forming a bonded mineral fibre product
Implementation Method 2
aqueous binder composition comprising: (a) a sugar syrup containing a reducing sugar and having a dextrose equivalent DE of at least 50 and less than 85
Implementation Method 3
carrying the mineral fibres formed by means of a gas stream into a forming chamber
Data Source
Figure 1
AI summary
An aqueous binder composition for mineral fibres comprises: (a) a sugar syrup containing a reducing sugar and having a dextrose equivalent DE of at least 50 and less than 85; (b) a polycarboxylic acid component; (c) an amine component; and, optionally, (d) a reaction product of a polycarboxylic acid component (b) and an amine component (c).