Insulative products having bio-based binders

Patent metadata

Field	Value
Publication number	US-10000666-B2
Application number	US-201414302604-A
Country	US
Kind code	B2
Filing date	Jun 12, 2014
Priority date	Oct 9, 2009
Publication date	Jun 19, 2018
Grant date	Jun 19, 2018

Abstract

Fibrous insulation products have an aqueous binder composition that includes a carbohydrate and a crosslinking agent. In exemplary embodiments, the carbohydrate-based binder composition may also include a catalyst, a coupling agent, a process aid, a crosslinking density enhancer, an extender, a moisture resistant agent, a deducting oil, a colorant, a corrosion inhibitor, a surfactant, a pH adjuster, and combinations thereof. The carbohydrate may be natural in origin and derived from renewable resources. Additionally, the carbohydrate polymer may have a dextrose equivalent (DE) number from 2 to 20. In at least one exemplary embodiment, the carbohydrate is a water-soluble polysaccharide such as dextrin or maltodextrin and the crosslinking agent is citric acid. Advantageously, the carbohydrates have a low viscosity and cure at moderate temperatures. The environmentally friendly, formaldehyde-free binder may be used in the formation of insulation materials and non-woven chopped strand mats. A method of making fibrous insulation products is also provided.

First claim

What is claimed is:

1. A soy-containing binder composition for use in the formation of fibrous insulation products, the soy-containing binder composition comprising:
a monosaccharide,
a crosslinking agent comprising a polyamine,
a catalyst comprising a Lewis acid,
an acidic pH adjuster, and
a soy protein,
wherein the soy-containing binder composition is formaldehyde-free;
wherein the monosaccharide comprises 60 wt. % to 90 wt. % of the binder composition; and
wherein the pH of the soy-containing binder composition is from 2 to 5.

2. The soy-containing binder composition of claim 1 , wherein the soy protein comprises soy flour.

3. The soy-containing binder composition of claim 1 , wherein the soy protein comprises an amount up to and including 70 wt. % of the binder composition.

4. The soy-containing binder composition of claim 1 , wherein the soy protein comprises 5 wt. % to 50 wt. % of the binder composition.

5. The soy-containing binder composition of claim 1 , wherein the soy protein comprises 10 wt. % to 40 wt. % of the binder composition.

6. The soy-containing binder composition of claim 1 , wherein the monosaccharide is selected from the group consisting of xylose, glucose, and fructose.

7. The soy-containing binder composition of claim 1 , wherein the monosaccharide comprises 70 wt. % to 85 wt. % of the binder composition.

8. The soy-containing binder composition of claim 1 , wherein the catalyst comprises 1 wt. % to 5 wt. % of the binder composition.

9. A fibrous insulation product comprising the soy-containing binder composition of claim 1 .

10. The fibrous insulation product of claim 9 , wherein the fibrous insulation product further comprises glass fibers.

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Hawkins Christopher M
• Hernandez-Torres Jesus Manuel
• Chen Liang
• Martine Edward Alan
• Chacko Jacob

Classifications

• Y10T428/1314

  Contains fabric, fiber particle, or filament made of glass, ceramic, or sintered, fused, fired, or calcined metal oxide, or metal carbide or other inorganic compound [e.g., fiber glass, mineral fiber, sand, etc.] · CPC title

• Y10T442/2992

  Coated or impregnated glass fiber fabric · CPC title

• C09D189/00 Primary

  Coating compositions based on proteins; Coating compositions based on derivatives thereof (foodstuff preparations A23J3/00) · CPC title

• C09J105/06

  Pectin; Derivatives thereof · CPC title

• C03C25/32

  obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds · CPC title