Pre-Reacted Carbohydrate Binder Composition for Longer Shelf Life
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Solution Overview
Problem
Existing carbohydrate polyamine binders have high solid concentrations leading to quick gelling and recrystallization, resulting in short shelf-life and storage/shipment issues, and require reaction conditions different from traditional phenol formaldehyde binders.
Innovation Solution
A water-soluble pre-reacted binder composition is developed, comprising a reaction product of carbohydrate and nitrogen-containing components, with a high content of pre-polymers and controlled viscosity, allowing for improved stability and compatibility with established processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carbohydrate polyamine binders are prepared with high solid concentration, then binding performance is improved, but shelf-life deteriorates due to quick gelling and recrystallization
Solution Approach 1:
The invention divides the binder system into two separate components: a carbohydrate component and a polyamine component. These components are kept separate during storage to prevent premature reaction, and are mixed only shortly before application. This segmentation allows each component to maintain stability independently while still achieving effective binding when combined, thus resolving the contradiction between high solid concentration for binding performance and storage stability for shelf-life.
Solution Approach 2:
The invention performs preliminary preparation of stable, low-viscosity stock solutions of carbohydrate and polyamine components separately. These pre-prepared solutions can be stored for extended periods without degradation. The actual binding action occurs when these pre-prepared components are mixed and applied to the substrate, allowing the system to achieve high binding performance without compromising shelf-life during storage.
2Strength
If carbohydrate polyamine binders are prepared with high solid concentration, then binding performance is improved, but storage and shipment become problematic
Solution Approach 1:
The binder system is segmented into separate carbohydrate and polyamine components that can be stored and shipped independently in stable, low-viscosity forms. This eliminates the storage and shipment problems associated with high-solid Concentration binders, while still enabling high binding performance when the components are mixed and applied together.
Solution Approach 2:
The invention changes the concentration parameter of the binder components during storage versus application. During storage and shipment, components are maintained at low solid concentrations (e.g., 5-20% solids) to ensure stability and ease of handling. At the time of application, the components are mixed in optimized ratios to achieve the desired binding performance, effectively decoupling storage ease from binding strength.
3Reliability
If traditional phenol formaldehyde binders are replaced with carbohydrate-based binders, then sustainability is improved, but reaction conditions must be substantially different
Solution Approach 1:
The invention optimizes the reaction parameters of carbohydrate-polyamine binders to align more closely with traditional phenol formaldehyde processing conditions. By adjusting factors such as pH, temperature, and component ratios, the binder achieves effective curing in conventional equipment and process flows, thereby improving adaptability while maintaining the sustainability advantages of carbohydrate-based materials.
Solution Approach 2:
The polyamine component acts as an intermediary that facilitates the reaction between carbohydrate components under conditions more compatible with established industrial processes. This intermediary enables the sustainable carbohydrate-based system to function effectively within existing manufacturing frameworks, bridging the gap between environmental sustainability and process compatibility.
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 pre-reacted binder composition maintains stability over time, enabling efficient handling and storage, and can be further crosslinked to form a polymeric binder with improved properties, overcoming the limitations of traditional carbohydrate polyamine binders.
Implementation Method 1
comprising the reaction product(s) of (i) at least one carbohydrate component, and (ii) at least one nitrogen-containing component
Implementation Method 2
can be further crosslinked to form a polymeric binder with improved properties
Data Source
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AI summary
The present invention relates to a water-soluble pre-reacted binder composition, a method of its manufacture, a use of said pre-reacted binder composition, a method of manufacturing a collection of matter bound by a polymeric binder, a binder solution or dispersion comprising said pre-reacted binder composition, as well as products comprising the pre-reacted binder composition in a cured state.