Solid State Binder Composition for Mineral Fibres
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Solution Overview
Problem
Existing mineral fibre binders are costly, often derived from fossil fuels, and emit formaldehyde, while lacking long-term mechanical strength and eco-friendly properties.
Innovation Solution
A solid-state binder composition combining compounds like ascorbic acid and carbohydrates, which are non-toxic, renewable, and economically priced, eliminating the need for aqueous forms and pre-reactions, and providing excellent bonding properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional phenol-formaldehyde resin binders are used, then good bonding properties are achieved, but formaldehyde emission occurs and cost is high
Solution Approach 1:
The invention changes the chemical composition parameters of the binder by replacing phenol-formaldehyde resin with a new composition consisting of polyol, isocyanate, and starch or cellulose. This parameter change eliminates formaldehyde emission while maintaining bonding properties through the formation of polyurethane crosslinked structures with starch or cellulose.
Solution Approach 2:
The invention creates a composite binder system combining polyol, isocyanate, and starch or cellulose. This composite material approach integrates the adhesive properties of polyurethane with the renewable, formaldehyde-free characteristics of starch or cellulose, achieving both good bonding and environmental compatibility.
2Strength
If phenol-formaldehyde resin with hardener material is used, then bonding is achieved, but the starting materials are expensive chemicals
Solution Approach 1:
The invention replaces expensive phenol-formaldehyde resin with a more cost-effective binder system based on polyol, isocyanate, and starch or cellulose. The use of starch or cellulose as a renewable, low-cost material significantly reduces the overall binder cost while maintaining adequate bonding performance for mineral wool products.
Solution Approach 2:
The invention changes the economic parameters of binder production by selecting raw materials (polyol, isocyanate, starch/cellulose) that are either commodity chemicals or renewable resources with lower cost compared to phenol-formaldehyde resin and its hardeners, thereby reducing overall manufacturing cost.
3Strength
If conventional binders are used, then bonding is achieved, but most starting materials stem from fossil fuels
Solution Approach 1:
The invention changes the origin parameter of the binder materials by replacing fossil fuel-derived phenol-formaldehyde resin with a system incorporating starch or cellulose from renewable plant resources. This parameter change reduces fossil fuel dependency while maintaining bonding functionality through polyurethane-starch/cellulose crosslinking.
Solution Approach 2:
The invention creates a composite binder where starch or cellulose from renewable resources serves as the crosslinking agent, reducing reliance on fossil fuels. The combination of polyol, isocyanate, and biobased starch or cellulose creates a partially renewable binder system that maintains bonding properties.
4Strength
If conventional binders are used, then bonding is achieved, but long term mechanical properties are insufficient
Solution Approach 1:
The invention changes the chemical structure parameters of the cured binder by forming polyurethane crosslinked with starch or cellulose, creating a three-dimensional network structure. This structural parameter change enhances long-term mechanical properties and durability compared to conventional binders, while the crosslinking mechanism ensures stable bonding performance over time.
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 composition achieves high mechanical strength, low formaldehyde emission, and cost-effectiveness, with improved long-term performance and eco-friendliness, surpassing conventional binders in reaction loss and aging conditions.
Implementation Method 1
curing the binder composition
Implementation Method 2
a component (i) in form of one or more compounds selected from compounds of the formula, and any salts thereof... a component (ii) in the form of one or more carbohydrates
Data Source
AI summary
The present invention is directed to a solid state binder composition, wherein the binder comprises a component (i) in form of one or more compounds selected from compounds of the formula, and any salts thereof, such as ammonium salts and/oramine salts thereof: (formula I) in which R1 corresponds to H, alkyl, monohydroxyalkyl, dihydroxyalkyl, polyhydroxyalkyl, alkylene, alkoxy, amine; compounds of the formula, and any salts thereof, such as ammonium salts and/oramine salts thereof: (formula II) in which R2 corresponds to H, alkyl, monohydroxyalkyl, dihydroxyalkyl, polyhydroxyalkyl, alkylene, alkoxy, amine; a component (ii) in the form of one or more carbohydrates.