Binder compositions and uses thereof

Patent metadata

Field	Value
Publication number	US-11802222-B2
Application number	US-202217835126-A
Country	US
Kind code	B2
Filing date	Jun 8, 2022
Priority date	Oct 30, 2015
Publication date	Oct 31, 2023
Grant date	Oct 31, 2023

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

The invention claimed is:

1. An assembly of matter selected from insulation products comprising mineral fibers and composite wood boards comprising cellulosic particulate or sheet material, bonded together by an aqueous curable binder composition consisting of (a) a monosaccharide, (b) an azetidinium cross-linker, optionally (a) cross-linked by (b), optionally (c) a cross-linker capable of undergoing free radical polymerization to further cross-link (a), optionally together with (d) a free radical initiator, optionally 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, and water, or by a binder obtained by subjecting to curing conditions said aqueous curable binder composition.

2. The assembly of matter of claim 1 , wherein the (b) azetidinium cross-linker 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, carboxyl functional 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, an amino group or a carboxyl group,
Y 2 comprises a hydroxyl group or independently Y 1 , and
X − comprises a halogen counter ion.

3. The assembly of matter of claim 1 , wherein the dry weight ratio of the (a) monosaccharide to the (b) azetidinium cross-linker comprises a ratio of 99/1 to 60/40.

4. The assembly of matter of claim 1 characterized by one or more of the following features:
wherein the aqueous curable binder composition consists of the (a) monosaccharide, the (b) azetidinium cross-linker, (a) cross-linked with (b), the (c) cross-linker capable of undergoing free radical polymerization, the (d) free radical initiator, and water;
wherein the aqueous curable binder composition consists of the (a) monosaccharide, the (b) azetidinium cross-linker, (a) cross-linked with (b), the (c) cross-linker capable of undergoing free radical polymerization, the (d) free radical initiator, and water, wherein the (c) cross-linker capable of undergoing free radical polymerization is selected from the group consisting of polycarboxylic acids, acrylamide, methacrylamide, acrylate, acrylic acids and their salts, acrylonitrile, bisphenol acrylics, carbohydrate monomers, fluorinated acrylics, maleimide and mixtures thereof;
wherein the aqueous curable binder composition consists of the (a) monosaccharide, the (b) azetidinium cross-linker, (a) cross-linked with (b), the (c) cross-linker capable of undergoing free radical polymerization, and water, wherein the (c) cross-linker capable of undergoing free radical polymerization is present in the range of 1-40 wt. % based on the total dry weight of the aqueous curable binder composition;
wherein the aqueous curable binder composition consists of the (a) monosaccharide, the (b) azetidinium cross-linker, (a) cross-linked with (b), the (c) cross-linker capable of undergoing free radical polymerization, the (d) free radical initiator, and water, wherein the (d) free radical initiator is (i) selected from the group consisting of inorganic peroxides, organic peroxides, reducing agents, azo compounds, redox initiators, photo-initiators, and mixtures thereof, and (ii) present in the range of 0.05-5 wt. % based on the total dry weight of the aqueous curable binder composition.

5. The assembly of matter of claim 1 being an insulation product comprising a mineral wool mat.

6. The assembly of matter of claim 1 being a composite wood board selected from wood fiber board, wood particle board, or plywood.

7. A process for the manufacture of a product which comprises a bonded assembly of fibrous material or cellulosic particulate or sheet material, said method comprising (i) the provision of (a) a monosaccharide, (ii) the provision of (b) an azetidinium cross-linker, (iii) the application of (a) and (b) as an aqueous curable binder composition consisting of (a), (b), optionally (a) cross-linked by (b), optionally (c) a cross-linker capable of undergoing free radical polymerization to further cross-link (a), optionally together with (d) a free radical initiator, optionally 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, and water onto fibrous material or cellulosic particulate or sheet material to produce resinated material, and (iv) subjecting the resulting resinated material to curing conditions and allowing for evaporation of excess water.

8. The process of claim 7 characterized by one or more of the following features:
wherein the cross-linking between (a) and (b) and optional further cross-linking with (c), in the presence of (d), is effected at a temperature ranging from ambient temperature to 200° C., during a period of time to generate the desired cross-linked material;
wherein the cross-linking between (a) and (b) is effected by free radical initiation;
wherein the resinated material is subjected to UV radiation prior to being subjected to temperature curing as the curing conditions;
wherein the resinated material is subjected to temperature curing at a temperature ranging from 90-200° C. as the curing conditions.

9. An aqueous binder composition consisting of (a) a monosaccharide cross-linked with (b) an azetidinium cross-linker, (c) a cross-linker capable of undergoing free radical polymerization, optionally (d) a free radical initiator, and water.

10. The aqueous binder composition of claim 9 , wherein the (c) cross-linker capable of undergoing free radical polymerization is selected from the group consisting of polycarboxylic acids, acrylamide, methacrylamide, acrylate, acrylic acids and their salts, acrylonitrile, bisphenol acrylics, carbohydrate monomers, fluorinated acrylics, maleimide and mixtures thereof.

11. The aqueous binder composition of claim 9 , wherein the (b) azetidinium cross-linker 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, carboxyl functional 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, an amino group or a carboxyl group,
Y 2 comprises a hydroxyl group or independently Y 1 , and
X − comprises a halogen counter ion.

12. The aqueous binder composition of claim 9 , wherein the (d) free radical initiator is (i) selected from the group consisting of inorganic peroxides, organic peroxides, reducing agents, azo compounds, redox initiators, photo-initiators, and mixtures thereof, and (ii) present in the range of 0.05-5 wt. % based on the total dry weight of the aqueous binder composition.

Assignees

• Knauf Insulation Sprl

Inventors

• Hampson Carl
• Khan Ferdous

Classifications

• C09J103/04 Primary

  Starch derivatives · CPC title

• B27N3/00

  Manufacture of substantially flat articles, e.g. boards, from particles or fibres · CPC title

• B27N3/002

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

• C08B31/003 Primary

  Crosslinking of starch · CPC title

• C08J5/249 Primary

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