Formaldehyde free binder compositions with urea-aldehyde reaction products

Patent metadata

Field	Value
Publication number	US-10815402-B2
Application number	US-201414273986-A
Country	US
Kind code	B2
Filing date	May 9, 2014
Priority date	Jun 7, 2012
Publication date	Oct 27, 2020
Grant date	Oct 27, 2020

Abstract

Binder compositions are described that contain (1) a reducing sugar and (2) a reaction product of a urea compound and an aldehyde-containing compound. A specific example of the binder compositions include dextrose and an imidazolidine compound such as 4,5-dihydroxyimidazolidin-2-one. The binder compositions may be applied to collections of fibers and cured to form a fiber-containing composite, such as fiberglass insulation.

First claim

What is claimed is:

1. A fiber-containing composite comprising:
woven or non-woven fibers; and
a cured binder formed from a binder composition comprising:
reducing sugar; and
a crosslinking agent comprising:

wherein R 1 and R 2 are independently —H, —OH, —NH 2 , an alkyl group, an aromatic group, an alcohol group, an aldehyde group, a ketone group, a carboxylic acid group, or an alkoxy group,
wherein the cured binder includes crosslinked polymers formed by direct reaction of the crosslinking agent with the reducing sugar, and the cured binder substantially lacks crosslinked polymers formed by the reaction of free glyoxal with the reducing sugar; and
wherein a molar ratio of the crosslinking agent to the reducing sugar ranges from 1:2 to 1:50.

2. The fiber-containing composite of claim 1 , wherein the fibers include one or more types of fibers chosen from glass fibers, mineral fibers, and organic polymer fibers.

3. The fiber-containing composite of claim 1 , wherein the reducing sugar is chosen from glucose, dextrose, fructose, maltose, xylose, and amylose.

4. The fiber-containing composite of claim 1 , wherein the reducing sugar consists essentially of dextrose.

5. The fiber-containing composite of claim 1 , wherein the molar ratio of the crosslinking agent to the reducing sugar ranges from 1:5 to 1:10.

6. The fiber-containing composite of claim 1 , wherein the crosslinking agent comprises 4,5-dihydroxyimidazolidin-2-one.

7. The fiber-containing composite of claim 1 , wherein the binder composition further comprises a catalyst to catalyze a crosslinking reaction between the reducing sugar and the crosslinking agent.

8. The fiber-containing composite of claim 7 , wherein the catalyst is chosen from a Lewis acid, a protic acid and a latent acid.

9. The fiber-containing composite of claim 8 , wherein the Lewis acid is chosen from aluminum sulfate, ferric sulfate, aluminum chloride, ferric chloride, aluminum phosphate, and ferric phosphate.

10. The fiber-containing composite of claim 8 , wherein the protic acid is chosen from sulfuric acid, phosphoric acid, hydrochloric acid, nitric acid, toluene sulfonic acid, methane sulfonic acid, and a carboxylic acid.

11. The fiber-containing composite of claim 8 , wherein the latent acid is chosen from ammonium sulfate, ammonium hydrogen sulfate, monoammonium phosphate, diammonium phosphate, ammonium chloride, and ammonium nitrate.

12. The fiber-containing composite of claim 7 , wherein the catalyst is an organo-metallic salt chosen from an organo-titanate salt, an organo-zirconate salt, and organo-tin salt, and an organo-aluminum salt.

13. The fiber-containing composite of claim 1 , wherein the binder composition further comprises one or more non-reducing carbohydrates chosen from starch, modified starch, cellulose, modified cellulose, and dextrins.

14. The fiber-containing composite of claim 1 , wherein the fiber-containing composite comprises a fiberglass building insulation.

15. The fiber-containing composite of claim 1 , wherein the binder composition further comprises one or more additional compounds chosen from polymerization catalysts, adhesion promoters, flame retardants, organic fillers, inorganic fillers, waxes, colorants, and release agents.

16. A fiber-containing composite comprising:
woven or non-woven fibers; and
a cured binder formed from a binder composition comprising:
reducing sugar; and
a crosslinking agent comprising:

wherein R 1 and R 2 are independently —H, —OH, or —NH 2 ,
wherein the cured binder includes crosslinked polymers formed by direct reaction of the crosslinking agent with the reducing sugar, and the cured binder substantially lacks crosslinked polymers formed by the reaction of free glyoxal with the reducing sugar; and
wherein a molar ratio of the crosslinking agent to the reducing sugar ranges from 1:2 to 1:50.

17. A fiber-containing composite comprising:
woven or non-woven fibers; and
a cured binder formed from a binder composition comprising:
reducing sugar; and
a crosslinking agent comprising:

wherein R 1 and R 2 are independently —H, —OH, —NH 2 , an alkyl group, an aromatic group, an alcohol group, an aldehyde group, a ketone group, a carboxylic acid group, or an alkoxy group,
wherein the cured binder includes crosslinked polymers formed by direct reaction of the crosslinking agent with the reducing sugar, and the cured binder substantially lacks crosslinked polymers formed by the reaction of free glyoxal with the reducing sugar; and
wherein a molar ratio of the crosslinking agent to the reducing sugar ranges from 1:4 to 1:5.

Assignees

• Shooshtari Kiarash Alavi
• Johns Manville

Inventors

• Shooshtari Kiarash Alavi

Classifications

• D04H1/64 Primary

  the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions · CPC title

• D04H3/16

  with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion · CPC title

• C08L1/02

  Cellulose; Modified cellulose · CPC title

• C08L3/02

  Starch; Degradation products thereof, e.g. dextrin · CPC title

• C08L1/00

  Compositions of cellulose, modified cellulose or cellulose derivatives · CPC title