Uncured articles with improved shelf-life

Patent metadata

Field	Value
Publication number	US-11401204-B2
Application number	US-201515116254-A
Country	US
Kind code	B2
Filing date	Feb 6, 2015
Priority date	Feb 7, 2014
Publication date	Aug 2, 2022
Grant date	Aug 2, 2022

Abstract

Disclosed are formaldehyde-free, thermally-curable, alkaline, aqueous binder compositions. Also disclosed are compositions comprising formaldehyde-free, thermally-curable binder compositions, as described herein, applied to non-woven fibers. Uses of the disclosed binder compositions as binders for non-woven fibers are also disclosed.

First claim

What is claimed is:

1. A composition comprising an uncured binder disposed on mineral fibers, wherein the uncured binder consists of an aqueous mixture of (a) at least two reducing sugars comprising 1) at least one aldohexose sugar selected from the group consisting of dextrose, mannose, galactose, allose, altrose, talose, gulose, and idose; and 2) at least one ketohexose sugar selected from the group consisting of fructose, psicose, sorbose and tagatose, wherein the mixture has a lower crystallization point than a carbohydrate mixture consisting of dextrose; and (b) an acid precursor derivable from an inorganic salt selected from the group consisting of ammonium sulfate salts, ammonium phosphate salts, ammonium nitrate salts, ammonium carbonate salts and combinations thereof and/or (c) an ammonium salt of a polycarboxylic acid; optionally (d) a silicon-containing compound; and optionally (e) a corrosion inhibitor.

2. The composition of claim 1 , wherein the inorganic salt is selected from the group consisting of ammonium sulfate salts, ammonium phosphate salts, ammonium carbonate salts, and combinations thereof.

3. The composition of claim 1 , wherein the polycarboxylic acid is selected from the group consisting of unsaturated aliphatic polycarboxylic acids, saturated aliphatic polycarboxylic acids, aromatic polycarboxylic acids, unsaturated cyclic polycarboxylic acids, saturated cyclic polycarboxylic acids, and combinations thereof.

4. The composition of claim 1 , wherein the silicon-containing compound is selected from the group consisting of gamma-aminopropyltriethoxysilane, gamma-glycidoxypropyltrimethoxysilane, and mixtures thereof.

5. The composition of claim 1 , wherein the corrosion inhibitor is capable of decreasing the corrosivity of the composition.

6. The composition of claim 5 , wherein the corrosion inhibitor is selected from the group consisting of dedusting oil, monoammonium phosphate, sodium metasilicate pentahydrate, and melamine.

7. The composition of claim 1 , wherein the composition is a fiberglass insulation product.

8. The composition of claim 1 , wherein the mineral fibers comprise fibers selected from glass fibers and stone wool fibers.

9. The composition of claim 8 , wherein the mineral fibers comprise glass fibers.

10. The composition of claim 1 , wherein the mixture of at least two reducing sugars is provided as high fructose corn syrup (HFCS).

11. The composition of claim 1 , wherein the binder has a moisture content of 1.5-3%.

12. The composition of claim 1 , wherein the binder has a pH of 7.5-9.5.

13. The composition of claim 1 , wherein the mineral fibers comprise glass fibers at a compositional concentration of 80-99% by weight.

14. The composition of claim 1 , wherein the binder compriscs has 5-25% by dry weight of an acid precursor derivable from an inorganic salt selected from the group consisting of ammonium sulfate salts, ammonium phosphate salts, ammonium nitrate salts, ammonium carbonate salts and combinations thereof.

15. The composition of claim 1 , wherein the binder has 10-20% by dry weight of an acid precursor derivable from an inorganic salt selected from the group consisting of ammonium sulfate salts, ammonium phosphate salts, ammonium nitrate salts, ammonium carbonate salts and combinations thereof.

16. The composition of claim 1 , wherein the aqueous mixture is a viscous or tacky liquid.

Assignees

• Knauf Insulation Sprl
• Knauf Insulation Inc

Inventors

• Appley Charles Fitch
• Mueller Gert

Classifications

• C07H3/02

  Monosaccharides · CPC title

• C03C25/1095 Primary

  to obtain coated fabrics · CPC title

• C03C25/32

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

• F16L59/028

  Compositions for or methods of fixing a thermally insulating material · CPC title

• C03C13/06 Primary

  Mineral fibres, e.g. slag wool, mineral wool, rock wool · CPC title