Aqueous binder compositions

Patent metadata

Field	Value
Publication number	US-11136451-B2
Application number	US-201816154794-A
Country	US
Kind code	B2
Filing date	Oct 9, 2018
Priority date	Oct 9, 2017
Publication date	Oct 5, 2021
Grant date	Oct 5, 2021

Abstract

An aqueous binder composition is disclosed that comprises at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons; a primary cross-linking agent comprising at least two carboxylic acid groups; and a secondary cross-linking agent comprising a short-chain polyol having at least two hydroxyl groups and a number average molecular weight less than 2,000 Daltons.

First claim

What is claimed is:

1. An aqueous binder composition comprising:
from about 5 wt.% to about 30 wt.% of at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons;
at least 63 wt. % of a cross-linking agent comprising at least two carboxylic acid groups;
from about 3 wt. % to about 30 wt. % of a short-chain polyol having at least two hydroxyl groups and a number average molecular weight less than 2,000 Daltons; and
a catalyst,
wherein a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is from 1/0.05 to 1.0/5.0 and a ratio of long-chain polyol to short-chain polyol is from 0.1/0.9 to 0.9/0.1, and wherein the wt. % is based on the total solids content of the aqueous binder composition.

2. The aqueous binder composition of claim 1 , wherein said cross-linking agent is a polymeric polycarboxylic acid.

3. The aqueous binder composition of claim 1 , wherein said cross-linking agent comprises a homopolymer of copolymer of acrylic acid.

4. The aqueous binder composition of claim 1 , wherein said cross-linking agent is present in the binder composition in an amount from 65 wt. % to 80 wt. %, based on the total solids content of the aqueous binder composition.

5. The aqueous binder composition of claim 1 , wherein said long-chain polyol is selected from the group consisting of polyvinyl alcohol and polyvinyl acetate.

6. The aqueous binder composition of claim 1 , wherein said short-chain polyol comprises one or more of a sugar alcohol, 2,2-bis(methylol)propionic acid, tri(methylol)propane, and a short-chain alkanolamine.

7. The aqueous binder composition of claim 6 , wherein said short-chain polyol comprises a sugar alcohol selected from the group consisting of glycerol, erythritol, arabitol, xylitol, sorbitol, maltitol, mannitol, iditol, isomaltitol, lactitol, cellobitol, palatinitol, maltotritol, syrups thereof, and mixtures thereof.

8. The aqueous binder composition of claim 1 , wherein the ratio of long-chain polyol to short-chain polyol is between 0.3/0.7 0.7/0.3.

9. The aqueous binder composition of claim 1 , wherein the binder composition has water soluble material content after cure of no greater than 6.0 wt. %.

10. An insulation product comprising:
a plurality of randomly oriented fibers; and
an aqueous binder composition at least partially coating said fibers, said binder composition comprising:
from 5 wt. % to 30 wt. % of at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons;
at least 63 wt. % of a cross-linking agent comprising at least two carboxylic acid groups;
from about 3 wt. % to about 30 wt. % of a short-chain polyol having at least two hydroxyl groups and a number average molecular weight less than 2,000 Daltons; and
a catalyst, wherein a ratio of long-chain polyol to short-chain polyol is from 0.1/0.9 to 0.9/0.1, and wherein the wt. % is based on the total solids content of the aqueous binder composition.

11. The insulation product of claim 10 , wherein the fibers comprise one or more of mineral fibers, natural fibers, and synthetic fibers.

12. The insulation product of claim 10 , wherein the fibers comprise glass fibers.

13. The insulation product of claim 10 , wherein when said product after cure has a thickness of 1 inch and a density of 6 lbs/ft 3 , said product has a flexural elastic modulus of at least 40 psi.

14. The insulation product of claim 10 , wherein when said product after cure has a thickness of 1 inch and a density of 6 lbs/ft 3 , said product has a compressive strength at 10% deformation of at least 200 lbs./ft2.

15. The insulation product of claim 10 , wherein when said product after cure has a thickness of 1 inch and a density of 6 lbs/ft 3 , said product has a bond strength at break of at least 7.5 lbs./ft 2 /LOI.

16. The insulation product of claim 13 , wherein a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups in the binder composition is from 1/0.05 to 1.0/5.0.

17. The aqueous binder composition of claim 4 , wherein said cross-linking agent is present in the binder composition in an amount from 70 wt. % to 80 wt. %, based on the total solids content of the aqueous binder composition.

18. The insulation product of claim 10 , wherein said cross-linking agent is present in the binder composition in an amount from 65 wt. % to 85 wt. %, based on the total solids content of the aqueous binder composition.

19. An aqueous binder composition comprising:
at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons;
at least 63 wt. % of a cross-linking agent comprising polymeric polycarboxylic acid, based on the total solids content of the aqueous binder composition;
a short-chain polyol having at least two hydroxyl groups and a number average molecular weight less than 2,000 Daltons; and
a catalyst,
wherein a ratio of long-chain polyol to short-chain polyol is from 0.1/0.9 to 0.9/0.1.

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Zhang Xiujuan
• Mueller Gert
• Smith Kendel

Classifications

• C03C25/285

  Acrylic resins · CPC title

• D04H1/587 Primary

  characterised by the bonding agents used · CPC title

• D04H1/64

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

• C08K5/053

  Polyhydroxylic alcohols · CPC title

• C08K5/092

  Polycarboxylic acids · CPC title