Binder compositions and uses thereof

Patent metadata

Field	Value
Publication number	US-11384264-B2
Application number	US-201615771779-A
Country	US
Kind code	B2
Filing date	Oct 26, 2016
Priority date	Oct 30, 2015
Publication date	Jul 12, 2022
Grant date	Jul 12, 2022

Abstract

The present disclosure provides for aqueous, curable binder compositions, as well as articles and products comprising assemblies of matter comprising mineral fibers, synthetic fibers, natural fibers, cellulosic particles and sheet materials comprising the binder compositions disclosed herein.

First claim

What is claimed is:

1. An assembly of matter selected from mineral fibers, cellulosic particle material and cellulosic sheet material bonded together by:
a) an aqueous curable binder composition comprising a polysaccharide and an azetidinium crosslinker and optionally at least one reaction product resulting from crosslinking between the polysaccharide and the azetidinium crosslinker, or
b) a binder composition obtained by subjecting to curing conditions an aqueous curable binder composition comprising a polysaccharide and an azetidinium crosslinker and optionally at least one reaction product resulting from crosslinking between the polysaccharide and the azetidinium crosslinker;
wherein the aqueous curable binder composition is characterized by one or more of the following features:
i) wherein the binder composition further comprises a crosslinker capable of undergoing radical polymerization and optionally a free radical initiator for initiation of crosslinking reactions between saccharide residues, where the crosslinker capable of undergoing radical polymerization is selected from the group consisting of acrylamide, methacrylamide, acrylate, acrylonitrile, bisphenol acrylics, carbohydrate monomers, fluorinated acrylics, maleimide and mixtures thereof:
ii) wherein the binder composition further comprises a crosslinker capable of undergoing radical polymerization, where the further crosslinker comprises 1-40% by weight (wt. %) of the total dry weight of the binder composition; and
iii) wherein the binder composition further comprises a crosslinker capable of undergoing radical polymerization and optionally a free radical initiator selected from the group consisting of inorganic peroxides, organic peroxides, reducing agents, azo compounds, redox initiators, photo-initiators, and mixtures thereof, where the further crosslinker comprises 0.05-5% by weight (wt. %) of the total dry weight of the binder composition;

wherein the assembly of matter comprises a mineral fiber insulation article or a composite wood board article;
wherein the polysaccharide comprises 2-10,000 naturally occurring saccharide units selected from the group consisting of cellulose, partially hydrolysed cellulose, fully hydrolysed cellulose, chitin, crude starch, starch derivatives and mixtures thereof; and
wherein the dry weight ratio of the polysaccharide to the azetidinium crosslinker in the curable binder composition comprises a ratio of 98/2 to 60/40.

2. The assembly of matter of claim 1 , wherein the polysaccharide comprises 2-5000 naturally sourced saccharide units selected from the group consisting of cellulose, partially hydrolyzed cellulose, fully hydrolyzed cellulose, chitin, crude starch, starch derivatives and mixtures thereof.

3. The assembly of matter of claim 1 , wherein the azetidinium crosslinker comprises a polyazetidinium comprising at least two monomeric units of the general formula

wherein R 1 comprises a C 1 -C 25 alkanediyl group optionally substituted with a hydroxyl group, a carboxyl group or an amino group,
R 2 comprises independently R 1 or —R 3 —NH—C(O)—R 4 —, wherein R 3 and R 4 comprise independently C 1 -C 25 alkanediyl,
Y 1 and Y 3 comprise independently H or a C 1 -C 5 alkyl group optionally substituted with a hydroxyl group, a carboxyl group or an amino group,
Y 2 comprises a hydroxyl group or independently Y 1 , and
X − comprises a halogen counter ion.

4. The assembly of matter of claim 1 , wherein the dry weight ratio of the polysaccharide to the azetidinium crosslinker comprises a ratio of 98/2 to 70/30.

5. The assembly of matter of claim 1 , further comprising one or more coupling agents, dyes, antifungal agents, antibacterial agents, hydrophobes, metal oxide nanoparticles of MgO, CaO, Al 2 O 3 and/or CaCO 4 , nanoclays of montmorillonite, bentonite, kaolinite, hectorite, halloysite and/or organically modified nanoclays, and mixtures thereof.

6. The assembly of matter of claim 1 , wherein the mineral fiber insulation article comprises a mineral wool mat.

7. The assembly of matter of claim 1 , wherein the composite wood board article comprises a wood fiber board, a wood particle board, or plywood.

8. The assembly of matter of claim 1 , wherein the dry weight ratio of the polysaccharide to the azetidinium crosslinker in the curable binder composition comprises a ratio of 95/5 to 75/25.

Assignees

• Knauf Insulation Sprl

Inventors

• Hampson Carl
• Khan Ferdous

Classifications

• C08B31/003 Primary

  Crosslinking of starch · CPC title

• C08J5/249 Primary

  characterised by the additives used in the prepolymer mixture · CPC title

• B27N3/002

  characterised by the type of binder (compositions of macromolecular compounds C08L) · CPC title

• C08L3/04 Primary

  Starch derivatives {, e.g. crosslinked derivatives} · CPC title

• C08J5/245

  using natural fibres · CPC title