Binders and associated products

Patent metadata

Field	Value
Publication number	US-12104089-B2
Application number	US-202318233831-A
Country	US
Kind code	B2
Filing date	Aug 14, 2023
Priority date	Apr 5, 2012
Publication date	Oct 1, 2024
Grant date	Oct 1, 2024

Abstract

The present invention relates to a water-soluble pre-reacted binder composition, a method of its manufacture, a use of said pre-reacted binder composition, a method of manufacturing a collection of matter bound by a polymeric binder, a binder solution or dispersion comprising said pre-reacted binder composition, as well as products comprising the pre-reacted binder composition in a cured state.

First claim

The invention claimed is:

1. A method of manufacturing a collection of matter bound by a polymeric binder comprising:
(i) providing a collection of matter, the collection of matter comprising matter selected from the group consisting of mineral fibers, slag wool fibers, stone wool fibers, glass fibers, aramid fibers, ceramic fibers, metal fibers, carbon fibers, polyimide fibers, polyester fibers, rayon fibers, cellulosic fibers, coal, sand, wood shavings, sawdust, wood pulp, ground wood, wood chips, wood strands, wood layers, jute, flax, hemp, straw, wood veneers, facings, wood facings, particles, and woven or non-woven materials,
(ii) providing a water-soluble pre-reacted binder composition in the form of an aqueous solution or dispersion, the aqueous solution or dispersion containing no more than 80 wt.-% of said pre-reacted binder composition, and the pre-reacted binder composition comprising the reaction product(s) of
(a) at least one carbohydrate component comprising a reducing sugar and/or a component which yields a reducing sugar in situ, and
(b) at least one nitrogen-containing component wherein the at least one nitrogen-containing component comprises polylysine,
wherein the pre-reacted binder composition comprises at least one pre-polymer having a molecular weight in the range of 1 to 500 kDa in an amount of 2 wt.-% or more, based on the total weight of the pre-reacted binder composition,

(iii) applying the aqueous solution or dispersion to the collection of matter, and
(iv) applying energy to the collection of matter containing said aqueous solution or dispersion to cure the binder composition.

2. The method of claim 1 wherein providing a water-soluble pre-reacted binder composition in the form of an aqueous solution or dispersion comprises reacting (a) the at least one carbohydrate component and (b) at least one nitrogen-containing component at temperature(s) of at least 30° C. during period(s) of at least 5 minutes.

3. The method of claim 1 , wherein said method has at least one of the following features:
said at least one pre-polymer having a molecular weight in the range of 1 to 500 kDa is contained in the pre-reacted binder composition in an amount of 5 wt.-% or more based on the total weight of the binder composition;
said at least one pre-polymer having a molecular weight in the range of 1 to 500 kDa is contained in the pre-reacted binder composition in an amount of 10 wt.-% or more based on the total weight of the binder composition;
said at least one pre-polymer having a molecular weight in the range of 1 to 500 kDa is contained in the pre-reacted binder composition in an amount of 20 wt.-% or more based on the total weight of the binder composition;
said at least one pre-polymer having a molecular weight in the range of 1 to 500 kDa is contained in the pre-reacted binder composition in an amount of 35 wt.-% or more based on the total weight of the binder composition;
said at least one pre-polymer having a molecular weight in the range of 1 to 500 kDa is contained in the pre-reacted binder composition in an amount of 50 wt.-% or more based on the total weight of the binder composition.

4. The method of claim 1 , wherein said method has at least one of the following features:
said pre-reacted binder composition comprises at least one pre-polymer having a molecular weight in the range of more than 80 to 500 kDa (high molecular-weight pre-polymer)
said pre-reacted binder composition comprises at least one pre-polymer having a molecular weight in the range of more than 80 to 500 kDa in an amount of 0.2 wt.-% or more, based on the total weight of the pre-reacted binder composition;
said pre-reacted binder composition comprises at least one pre-polymer having a molecular weight in the range of more than 80 to 500 kDa in an amount of 0.5 wt.-% or more, based on the total weight of the pre-reacted binder composition;
said pre-reacted binder composition comprises at least one pre-polymer having a molecular weight in the range of more than 80 to 500 kDa in an amount of 0.75 wt.-% or more, based on the total weight of the pre-reacted binder composition.

5. The method of claim 1 , wherein said method has at least one of the following features:
said pre-reacted binder composition comprises at least one pre-polymer having a molecular weight in the range of more than 10 to 80 kDa (mid molecular weight pre-polymer);
said pre-reacted binder composition comprises at least one pre-polymer having a molecular weight in the range of more than 10 to 80 kDa in an amount of 0.3 wt.-% or more, based on the total weight of the pre-reacted binder composition;
said pre-reacted binder composition comprises at least one pre-polymer having a molecular weight in the range of more than 10 to 80 kDa in an amount of 1 wt.-% or more, based on the total weight of the pre-reacted binder composition;
said pre-reacted binder composition comprises at least one pre-polymer having a molecular weight in the range of more than 10 to 80 kDa in an amount of 5 wt.-% or more, based on the total weight of the pre-reacted binder composition;
said pre-reacted binder composition comprises at least one pre-polymer having a molecular weight in the range of more than 10 to 80 kDa in an amount of 10 wt.-% or more, based on the total weight of the pre-reacted binder composition;
said pre-reacted binder composition comprises at least one pre-polymer having a molecular weight in the range of more than 10 to 80 kDa in an amount of 30 wt.-% or more, based on the total weight of the pre-reacted binder composition;
said pre-reacted binder composition comprises at least one pre-polymer having a molecular weight in the range of more than 10 to 80 kDa in an amount of 50 wt.-% or more, based on the total weight of the pre-reacted binder composition.

6. The method of claim 1 , wherein said method has at least one of the following features:
said pre-reacted binder composition comprises one or more compounds having a molecular weight of 10 kDa or less (low molecular-weight compounds), and which are different from (a) the at least one carbohydrate component and (b) at least one nitrogen-containing component;
said pre-reacted binder composition comprises one or more compounds having a molecular weight of 10 kDa or less (low molecular-weight compounds), and which are different from (a) the at least one carbohydrate component and (b) at least one nitrogen-containing component, in which the low molecular-weight compounds comprise one or more of a glycolaldehyde, glyceraldehyde, 2-oxopropanal, acetol, dihydroxyacetone, acetoin, butanedione, ethanal, glucosone, 1-desoxyhexosulose, 3-desoxyhexosulose, 3-desoxy-pentosulose, 1,4-didesoxyhexosulose, glyoxal, methylglyoxal, diacetyl and 5-(hydroxymethyl)furfural.

7. The method of claim 1 , wherein said method has at least one of the following features:
said aqueous solution or dispersion contains at least 30 wt.-% of said pre-reacted binder composition;
said aqueous solution or dispersion contains at least 40 wt.-% of said pre-reacted binder composition;
said aqueous solution or dispersion contains at least 50 wt.-% of said pre-reacted binder composition;
said aqueous solution or dispersion contains at least 55 wt.-% of said pre-reacted binder composition.

8. The method of claim 1 , wherein when the water-soluble pre-reacted binder composition in the form of an aqueous solution or dispersion contains 70 wt.-% of said pre-reacted binder composition, the viscosity at 20° C. is of at most 2000 cP.

9. The method of claim 1 , in which the viscosity of an aqueous solution containing 70 wt.-% of said pre-reacted binder composition does not increase by more than 500 cP when left to stand at 20° C. for 12 hours.

Assignees

• Knauf Insulation Sprl
• Knauf Insulation Inc

Inventors

• Hampson Carl
• Pacorel Benedicte
• Jackson Roger

Classifications

• F16L59/028

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

• B27N3/002

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

• B29K2405/00

  Use of polysaccharides or derivatives as filler · CPC title

• B29K2079/00

  Use of polymers having nitrogen, with or without oxygen or carbon only, in the main chain {, not provided for in groups B29K2061/00 - B29K2077/00}, as moulding material · CPC title

• B29C71/00

  After-treatment of articles without altering their shape; Apparatus therefor (B29C44/56, B29C73/00 take precedence; surface shaping B29C59/00 {; for joined or sealed parts B29C66/03; after-treatment specially adapted for vulcanising tyres B29D30/0633}) · CPC title