Cellulose Hydrolysate Sugar Binder for Formaldehyde-Free Bonding

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Solution Overview

Problem

Existing binder compositions for bonding fibers and particulate materials lack sufficient mechanical strength and sustainability, particularly in weathered conditions, and often rely on formaldehyde-based chemistries that are not environmentally friendly.

Innovation Solution

A curable binder composition based on cellulose hydrolysate sugars and an inorganic ammonium salt, which forms a highly cross-linked resin upon curing, providing improved mechanical strength and being formaldehyde-free, suitable for bonding various fibers and particulate materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If formaldehyde-based chemistries are used for binder composition, then bonding strength is improved, but environmental friendliness deteriorates

Engineering Contradiction:

Improvebonding strengthVSAvoidenvironmental friendliness

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters by replacing formaldehyde-based chemistries with sugar-based chemistries (specifically pentoses and hexoses). This substitution maintains the cross-linking mechanism and bonding strength while eliminating the harmful formaldehyde emissions, thus resolving the contradiction between strength and environmental friendliness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses readily available, inexpensive sugars (pentoses and hexoses) as binder components instead of expensive or harmful chemicals. These sugar-based binders provide effective bonding while being environmentally benign, addressing both the strength requirement and the environmental concern

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Ease of manufacture

If conventional binder compositions are used, then manufacturing simplicity is maintained, but mechanical strength deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmechanical strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent creates a composite binder system combining sugars (pentoses and/or hexoses) with optional additives such as metal salts, enzymes, or other compounds. This composite approach enhances mechanical strength while maintaining manufacturing simplicity, as the core sugar-based formulation remains straightforward to produce and apply

Inventive Principle:

Principle #40Composite materials

3Productivity

If rapid curing is achieved, then productivity is improved, but bond strength after weathering deteriorates

Engineering Contradiction:

Improvecuring speedVSAvoidbond strength after weathering

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent optimizes the chemical parameters of the sugar-based binder and curing conditions to achieve rapid curing while maintaining weathering resistance. By controlling factors such as sugar type, concentration, moisture content, and curing temperature, the system attains both fast setting speed and durable, weather-resistant bonds

Inventive Principle:

Principle #35Parameter changes

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 enhanced dry and wet bond strength, reduced loss of strength after weathering, and meets stringent environmental and health requirements, making it suitable for large-volume production and diverse applications.

Implementation Method 1

curable binder composition based on condensation products of a nitrogenous compound, such as ammonium salt of inorganic acids

Methodology Applied

Scientific EffectCondensation reaction:

Implementation Method 2

Upon curing, such binder composition produces a highly cross-linked resin which confers improved bond strength to the assembly of matter

Methodology Applied

Scientific EffectCross-linking:

Implementation Method 3

curable binder composition based on cellulose hydrolysate sugars

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Data Source

PatentUS11248108B2Binder compositions and uses thereof

Publication Date: 2022.02.15 KNAUF INSULATION SPRL

AI summary

The present invention relates to improved curable binder compositions comprising cellulose hydrolysate sugars and an inorganic ammonia salt, products making use thereof and a process for making such products. The invention binders show improved bond strength under dry and wet conditions.