Oxidized Dextrin Thermosetting Binders for Fiber Insulation
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Solution Overview
Problem
Current thermosetting binder resins, such as urea-formaldehyde (UF) and phenol-formaldehyde (PF), are costly and pose health risks due to formaldehyde classification as a carcinogen, necessitating a cost-effective, formaldehyde-free alternative with improved wet tensile strength and shelf stability for fiber insulation applications.
Innovation Solution
Development of aqueous thermosetting binder compositions using oxidized dextrins with aldehyde groups and polyamines, specifically oxidized maltodextrins and diprimary diamines, which provide a stable, formaldehyde-free binder system with enhanced wet tensile strength and shelf life, suitable for use in fiber insulation and mats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If oxidized starch and urea are used as binder formulation, then thermoset is formed, but shelf life is only hours before gelation occurs
Solution Approach 1:
The patent changes the chemical parameters of the oxidized polysaccharide by controlling the degree of oxidation and molecular weight, and adjusts the pH and ionic strength parameters to prevent premature gelation while maintaining shelf stability
Solution Approach 2:
The patent uses an intermediary approach by selecting specific diamine compounds that react controllably with oxidized polysaccharides, allowing extended shelf life before the curing reaction occurs
2Stability of the object's composition
If oxidized starch dispersion is used, then thermoset binder is formed, but the material is not water soluble and forms a dispersion rather than homogenous solution
Solution Approach 1:
The patent changes the molecular weight parameter of the oxidized polysaccharide to a specific range that enables water solubility while maintaining thermosetting properties, and controls the degree of oxidation to achieve homogeneity
3Strength
If (poly)saccharide and amine aqueous thermosetting binders are used, then formaldehyde-free binder is provided, but wet tensile strength is poor to fair when cured
Solution Approach 1:
The patent creates a composite binder system combining oxidized polysaccharides with specific diamine compounds to achieve both high wet tensile strength and formaldehyde-free composition
Solution Approach 2:
The patent optimizes the molecular weight and degree of oxidation parameters of the polysaccharide to maximize wet tensile strength while maintaining the formaldehyde-free advantage
4Object-generated harmful factors
If (poly)saccharide and amine binders are used, then formaldehyde-free alternative is provided, but offgas to large extent increasing amount needed and cost
Solution Approach 1:
The patent develops a composite binder formulation where oxidized polysaccharides react with diamines to form a crosslinked network that minimizes offgassing while maintaining formaldehyde-free composition
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 compositions exhibit high retention of dry tensile properties under hot, wet conditions, comparable to commercial UF resins, with improved shelf stability and reduced formaldehyde emission, making them a viable drop-in replacement for existing binders.
Implementation Method 1
oxidizing a dextrin having a dextrose equivalent (DE) value of from 1 to 25, preferably, from 1 to 20, preferably oxidized maltodextrin
Data Source
AI summary
The present invention provides thermosetting aqueous binder compositions comprising a diprimary amine or poly(primary amine) and one or more water soluble oxidized dextrin made by oxidizing a dextrin having a DE value of from 2 to 25 and having from 2 to 10 millieq CHO/g of dry oxidized dextrin or a larger oxidized dextrin or an oxidized dextrin made by oxidizing a dextrin having a DE value of below 2 and having from 0.25 to 5 millieq CHO/g of dry oxidized dextrin. The aqueous biobased binders provide hot wet tensile strength when heat cured.