Solid State Mineral Wool Binder Using Carbohydrates and Sulfamic Acid
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mineral wool binder technologies face challenges in producing formaldehyde-free, economically viable, and renewable materials with good bonding properties and long-term mechanical properties, while also being environmentally friendly.
Innovation Solution
A solid-state binder composition comprising carbohydrates and sulfamic acid or its derivatives, which does not require aqueous form application, offering excellent bonding properties and reduced reaction loss compared to conventional binders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional dry binders (phenol-formaldehyde resin) are used, then good bonding properties are achieved, but formaldehyde emission occurs and renewable materials are not utilized
Solution Approach 1:
The patent changes the chemical composition parameters of the binder by replacing phenol-formaldehyde resin with a new system comprising carbohydrates (component i) and sulfamic acid or derivatives (component ii), eliminating formaldehyde emission while maintaining bonding effectiveness through the curable reaction between these components
Solution Approach 2:
The patent creates a composite binder system combining carbohydrates and sulfamic acid derivatives that work synergistically to provide both environmental benefits (no formaldehyde) and technical performance (good bonding), with the carbohydrate providing the base structure and sulfamic acid providing curable crosslinking functionality
2Reliability
If expensive chemical starting materials are used, then good bonding properties are achieved, but production cost increases
Solution Approach 1:
The patent employs inexpensive, readily available starting materials including carbohydrates (such as sugars or starch derivatives) and sulfamic acid or its salts, replacing expensive specialized chemicals while achieving comparable or superior bonding performance through the curable reaction system
Solution Approach 2:
The binder system utilizes readily available, low-cost materials that can be easily handled and processed, with the curable reaction occurring in-situ during product manufacturing, eliminating the need for complex preprocessing or specialized handling procedures
3Reliability
If liquid binder compositions are used, then bonding properties are improved, but the binder must be brought into aqueous form which complicates the process
Solution Approach 1:
The patent changes the physical state parameter of the binder from liquid/aqueous to solid state, allowing direct application to mineral fibres without requiring dissolution in water or other solvents, simplifying the application process while maintaining effective bonding through the curable reaction of the solid components
Solution Approach 2:
The patent extracts the water/solvent component from traditional liquid binder formulations, using only the essential active ingredients (carbohydrate and sulfamic acid derivative) in solid form, which then react together during the curing process to achieve bonding without requiring aqueous preparation
4Reliability
If pre-reaction is performed for binder preparation, then bonding properties are improved, but reaction loss increases and process complexity increases
Solution Approach 1:
The patent performs preliminary mixing of the carbohydrate and sulfamic acid derivative components in solid state before application, creating a stable, free-flowing mixture that reacts upon contact with mineral fibres or during curing, avoiding the need for preliminary aqueous reaction steps that cause material loss
Solution Approach 2:
The patent converts what would traditionally be a harmful loss (reaction loss during pre-reaction) into a benefit by designing a system where the reaction occurs in-situ during the intended application process, eliminating wasted material while achieving the necessary bonding through the curable reaction between components
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 provides economically produced, renewable, and environmentally friendly mineral wool products with improved mechanical and fire resistance properties, eliminating the need for pre-reaction and associated losses.
Implementation Method 1
a component (i) in form of one or more carbohydrates; a component (ii) in form of one or more compounds selected from sulfamic acid, derivatives of sulfamic acid or any salt thereof
Data Source
AI summary
The present invention is directed to a solid state binder composition for binding mineral fibers comprising a component (i) in form of one or more carbohydrates; a component (ii) in form of one or more compounds selected from sulfamic acid, derivatives of sulfamic acid or any salt thereof.