Bio-based binder systems

Patent metadata

Field	Value
Publication number	US-11814549-B2
Application number	US-202016740901-A
Country	US
Kind code	B2
Filing date	Jan 13, 2020
Priority date	May 27, 2011
Publication date	Nov 14, 2023
Grant date	Nov 14, 2023

Abstract

An environmentally friendly, bio-based binder system that is useful for the formation of fiberglass insulation, the system includes: A) an aqueous curable binder composition, which includes a carbohydrate and a crosslinking agent; and B) a dedust composition, which includes a blown, stripped plant-based oil and optionally at least one emulsifying agent. The bio-based binder system is typically heated to form a cured binder system.

First claim

What is claimed is:

1. A bio-based binder system useful for the formation of rotary fiber insulation (for example fiberglass insulation), the system comprising:
A) an aqueous curable binder composition comprising:
(i) at least one carbohydrate;
(ii) at least one crosslinking agent; and

B) a dedust composition comprising:
(i) a blown, stripped plant-based oil having a viscosity of at least 200 cSt at 40° C., a flash point of at least 293° C., and having an acid value less than 5.0 mg KOH/gram,

wherein dedust composition B) comprises an oil-in-water emulsion, wherein a first emulsifier component is mixed into the blown, stripped plant-based oil of (i) and a second emulsifying component comprising carboxymethyl cellulose is mixed into an aqueous solution before the oil-in-water emulsion is formed by mixing the aqueous solution containing the second emulsifying component and the blown, stripped plant-based oil containing the first emulsifier component; and
wherein the bio-based binder system comprises 10 part per million sulfur or less based on the weight of components A) and B), excluding water.

2. The binder system of claim 1 , wherein the dedust composition has less than 100 part per million sulfur, based on the weight of component B), excluding water.

3. The binder system of claim 2 , wherein the dedust composition has less than 40 part per million sulfur, based on the weight of component B), excluding water.

4. The binder system of claim 3 , wherein dedust composition has less than 20 part per million sulfur, based on the weight of component B), excluding water.

5. The binder composition of claim 4 , wherein the dedust composition has less than 10 part per million sulfur, based on the weight of component B)).

6. The binder composition of claim 1 , wherein the first emulsifying component is selected from the group consisting of non-ionic emulsifiers, ionic emulsifiers, and mixtures thereof.

7. The binder system of claim 1 , wherein the binder system comprises 5 part per million sulfur or less based on the weight of components A) and B), excluding water.

8. The curable binder system of claim 1 , wherein the blown, stripped plant-based oil has a viscosity of at least 250 cSt at 40° C.

9. The binder system of claim 1 , wherein the blown, stripped plant-based oil has an acid value less than 4.0 mg KOH/gram.

10. The binder system of claim 1 , wherein the blown, stripped plant-based oil comprises a blown, stripped, bodied plant-based oil.

11. The binder system of claim 1 , wherein the blown, stripped plant-based oil is made from a blend of corn stillage oil and soybean oil in a weight ratio of corn stillage oil to soybean oil of from 5:95 to 95:5.

12. The binder system of claim 1 , wherein the blown, stripped plant-based oil has an hydroxyl number from about 1 mg KOH/gram to about 50 mg KOH/gram.

13. The binder system of claim 1 , wherein the blown, stripped plant based oil has less than 50 ppm sulfur.

14. The binder system of claim 1 , wherein the weight ratio of binder composition A) to dedust composition B) is from about 100:1 to 100:34.

Assignees

• Cargill Inc

Inventors

• Lochel Jr Frank P
• Tolfa John Carl

Classifications

• C09J103/02 Primary

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

• C03C25/321

  Starch; Starch derivatives · CPC title

• C08K5/0025

  Crosslinking or vulcanising agents; including accelerators · CPC title

• C08L3/02

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

• C08L91/00

  Compositions of oils, fats or waxes; Compositions of derivatives thereof · CPC title