New binding composition for multiple applications
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Solution Overview
Problem
Current aqueous binding compositions for mineral fibers, such as those based on phenolic resins, release formaldehyde, which is harmful and do not meet stringent environmental regulations, while alternative compositions that polymerize through Maillard reactions lack the binding strength of phenolic resin-based products.
Innovation Solution
A formaldehyde-free aqueous binding composition comprising at least 50% reducing sugar, 5-20% sulfamate, 2% pH-adjusting agent, and 1-15% lactam, which provides improved binding strength and mechanical properties to mineral fibers without releasing polluting emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If phenolic resins are used as binding composition, then good cross-linking ability and binding strength are achieved, but formaldehyde emissions occur which are harmful to health and environment
Solution Approach 1:
The invention extracts and removes the harmful formaldehyde component from the phenolic resin system by replacing it with alternative binding agents (sugars, proteins, amino acids) that achieve binding functionality without generating formaldehyde emissions
Solution Approach 2:
The invention changes the chemical composition parameters of the binding system by substituting phenolic resins with natural polymers and adjusting cross-linking mechanisms to eliminate formaldehyde while maintaining binding strength through alternative chemical reactions
2Object-generated harmful factors
If alternative binding compositions (sugars, proteins) that polymerize through Maillard reaction are used to eliminate formaldehyde, then environmental compliance is improved, but binding strength and tensile strength of the finished product are reduced
Solution Approach 1:
The invention creates a composite binding system combining multiple natural polymers (sugars, proteins, amino acids) with optimized ratios and complementary cross-linking mechanisms to achieve enhanced binding strength that overcomes the limitations of individual components
Solution Approach 2:
The invention introduces cross-linking agents as intermediaries that facilitate stronger bond formation between fibers and binding composition, thereby enhancing tensile strength while maintaining the formaldehyde-free characteristic
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 composition achieves binding strength comparable to phenolic resin-based products, with enhanced mechanical properties like increased tensile and compression strength, and improved thickness recovery, while ensuring compliance with environmental regulations by minimizing formaldehyde emissions.
Implementation Method 1
various aqueous binding compositions containing compounds capable of polymerizing through a Maillard reaction are known in the art (for a generic reference about the Maillard reaction see, for instance, GP Ellis et al., Advances in Carbohydrate Chem, 1959, pp. 63-134), such as sugars and proteins
Implementation Method 2
the binding composition must have a good sprayability and must be able to be deposited onto the surface of the fibers in order to bind them effectively... which polymerize, following the contact and high temperatures, thus firmly joining the fibers together
Data Source
AI summary
The present invention relates to an aqueous binding composition comprising at least one reducing sugar; at least one sulphamate and/or sulphamic acid; a pH-adjusting agent consisting of ammonium hydroxide (NH4OH), an organic and/or inorganic ammonium salt and/or an organic amine or combinations thereof; and at least one lactam. Said binder may be effectively used to bind cotton fibers, cellulose fibers, organic fabrics, carbon powders, natural and artificial inorganic fibers, thus obtaining products with high mechanical properties.