Aqueous binder comprising reaction products of itaconic acid

Patent metadata

Field	Value
Publication number	US-10544300-B2
Application number	US-201615742125-A
Country	US
Kind code	B2
Filing date	Jul 7, 2016
Priority date	Jul 7, 2015
Publication date	Jan 28, 2020
Grant date	Jan 28, 2020

Abstract

An aqueous binder composition is provided for use in the formation of fiber insulation and non-woven mats that comprises a reaction product of one or more Liquid Polyol Monomers; itaconic acid, its salts or anhydride; and a C4 to C6 polyol selected from the group consisting of pentaerythritol, trimethylol propane, neopentyl glycol, and mixtures thereof. The molar ratio of the combined alcohols (Liquid Polyol Monomers and C4 to C6 polyols) to itaconic acid is at least 2:1, wherein the molar ratio of Liquid Polyol Monomers to C4 to C6 polyols is from about 1:1 to about 30:1.

First claim

What is claimed is:

1. An aqueous binder composition for use in the formation of fiber insulation and non-woven mats comprising water and a reaction product of:
a) one or more Liquid Polyol Monomers having a melting point below 23° C. (73° F.);
b) itaconic acid, or its salt or anhydride; and
c) a C4 to C6 polyol selected from the group consisting of pentaerythritol, trimethylol propane, neopentyl glycol, and mixtures thereof;
wherein the molar ratio of the combined Liquid Polyol Monomers and C4 to C6 polyols to itaconic acid is at least 2:1, wherein the molar ratio of Liquid Polyol Monomers to C4 to C6 polyols is from about 1:1 to about 30:1.

2. The aqueous binder composition of claim 1 , wherein the molar ratio of the combined Liquid Polyol Monomers and C4 to C6 polyols to itaconic acid is from 2:1 to about 5:1, wherein the molar ratio of Liquid Polyol Monomers to C4 to C6 polyols is from about 1:1 to about 30:1.

3. The aqueous binder composition of claim 1 , wherein the molar ratio of the combined Liquid Polyol Monomers and C4 to C6 polyols to itaconic acid is from 2:1 to about 4:1, wherein the molar ratio of Liquid Polyol Monomers to C4 to C6 polyols is from about 1:1 to about 30:1.

4. The aqueous binder composition of claim 1 , wherein the molar ratio of the combined Liquid Polyol Monomers and C4 to C6 polyols to itaconic acid is from 2:1 to about 3:1, wherein the molar ratio of Liquid Polyol Monomers to C4 to C6 polyols is from about 1:1 to about 30:1.

5. The aqueous binder composition of claim 1 , wherein the molar ratio of Liquid Polyol Monomers to C4 to C6 polyols is from about 2:1 to about 25:1.

6. The aqueous binder composition of claim 1 , wherein the molar ratio of Liquid Polyol Monomers to C4 to C6 polyols is from about 4:1 to about 20:1.

7. The aqueous binder composition of claim 1 , wherein the molar ratio of Liquid Polyol Monomers to C4 to C6 polyols is from about 4:1 to about 10:1.

8. The aqueous binder composition of claim 1 wherein at least about 90% by weight of the Liquid Polyol Monomers used in preparation of the reaction product is glycerol.

9. The aqueous binder composition of claim 1 wherein at least about 90% by weight of the Liquid Polyol Monomers used in preparation of the reaction product is propylene glycol.

10. The aqueous binder composition of claim 1 wherein at least about 90% by weight of the C4 to C6 polyol used in preparation of the reaction product is pentaerythritol.

11. The aqueous binder composition of claim 1 wherein at least about 90% by weight of the C4 to C6 polyol used in preparation of the reaction product is trimethylol propane.

12. The aqueous binder composition of claim 1 wherein at least about 90% by weight of the C4 to C6 polyol used in preparation of the reaction product is neopentyl glycol.

13. The aqueous binder composition of claim 1 wherein the aqueous binder composition comprises unreacted glycerol.

14. The aqueous binder composition of claim 1 wherein the aqueous binder composition has a solids content of from about 30 to 80% by weight.

15. The aqueous binder composition of claim 1 wherein the aqueous binder composition further comprises an accelerant oligomer/polymer that is reactive with a vinyl functionality on the reaction product.

16. The aqueous binder composition of claim 15 wherein the accelerant oligomer/polymer has a molecular weight of from about 520 to about 4900.

17. The aqueous binder composition of claim 15 wherein the accelerant oligomer/polymer is present in an amount of from about 0.5 wt % to about 15 wt % of the composition based on solids content.

18. The aqueous binder composition of claim 1 wherein the aqueous binder composition contains less than 500 ppm chloride ions.

19. The aqueous binder composition of claim 1 wherein the aqueous binder composition is adjusted in pH during or after formulation by addition of base in an amount sufficient to provide a pH of from about 5 to 9.

20. The aqueous binder composition of claim 1 wherein the aqueous binder composition comprises a catalyst capable of initiating a polymerization reaction of vinyl functionalities present in the binder composition.

21. The aqueous binder composition of claim 20 , wherein the catalyst is ferric ammonium sulfate.

Assignees

• Cargill Inc

Inventors

• Anderson Kevin R
• Flynn Ryan L
• Lochel Frank P

Classifications

• E04B1/78

  Heat insulating elements {(E04B1/7662 takes precedence)} · CPC title

• C03C25/323 Primary

  Polyesters, e.g. alkyd resins · CPC title

• D04H1/4218

  Glass fibres · CPC title

• C09K3/22

  for dust-laying or dust-absorbing · CPC title

• C08J2367/06

  Unsaturated polyesters · CPC title