Fiberglass insulation product

Patent metadata

Field	Value
Publication number	US-12297342-B2
Application number	US-202017114820-A
Country	US
Kind code	B2
Filing date	Dec 8, 2020
Priority date	Dec 9, 2019
Publication date	May 13, 2025
Grant date	May 13, 2025

Abstract

A fibrous insulation product comprising a plurality of randomly oriented glass fibers and a cross-linked formaldehyde-free binder composition at least partially coating the fibers is disclosed. The cross-linked formaldehyde-free binder composition is formed from an aqueous binder composition comprising 5.0% by weight to 37.0% by weight of at least one monomeric polyol having at least four hydroxyl groups and at least 50.0% by weight of a cross-linking agent comprising a polymeric polycarboxylic acid having at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition. The glass fibers have an average fiber diameter in the range of 8 HT to 12 HT. The fibrous insulation product, after curing, has a density, when uncompressed, in the range of 0.30 pcf to 2.7 pcf.

First claim

The invention claimed is:

1. A fibrous insulation product comprising:
a plurality of randomly oriented glass fibers; and
a cross-linked formaldehyde-free binder composition at least partially coating the fibers, wherein the cross-linked formaldehyde-free binder composition is formed from an aqueous binder composition comprising:
5.0% by weight to 37.0% by weight of at least one monomeric polyol having at least four hydroxyl groups, based on the total solids content of the aqueous binder composition; and
at least 55% by weight of a cross-linking agent comprising a polymeric polycarboxylic acid having at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition, wherein said binder composition has a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.60/1.0 and 1.0/0.6,

wherein the quantity of cross-linked formaldehyde-free binder is in the range of 2% to 10% by weight of the fibrous insulation product;
wherein an R-value of the fibrous insulation product is in the range of 10 to 54;
wherein the glass fibers have an average fiber diameter in the range of 8 HT to 12 HT;
wherein the fibrous insulation product, after curing, has a density, when uncompressed, in the range of 0.30 pcf to 2.7 pcf, and a stiffness of 45 degrees of less.

2. The fibrous insulation product of claim 1 , wherein the cross-linking agent is polyacrylic acid.

3. The fibrous insulation product of claim 1 , wherein the cross-linking agent is present in the binder composition in an amount from 50.0% by weight to 85% by weight, based on the total solids content of the aqueous binder composition.

4. The fibrous insulation product of claim 1 , wherein the monomeric polyol comprises at least five hydroxyl groups.

5. The fibrous insulation product of claim 1 , wherein the ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.80/1.0 and 1.0/0.8.

6. The fibrous insulation product of claim 1 , wherein the monomeric polyol comprises one or more of a sugar alcohols, pentaerythritol, primary alcohols, 1,2,4-butanetriol, trimethylolpropane, short-chain alkanolamines, and mixtures thereof.

7. The fibrous insulation product of claim 1 , wherein the monomeric polyol has a number average molecular weight less than 2,000 Daltons.

8. The fibrous insulation product of claim 1 , wherein the aqueous binder composition further includes at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons.

9. The fibrous insulation product of claim 8 , wherein the long-chain polyol is selected from the group consisting of polyvinyl alcohol and polyvinyl acetate.

10. The fibrous insulation product of claim 8 , wherein the long-chain polyol is present in the binder composition in an amount from about 2.5 wt. % to about 30 wt. %, based on the total solids content of the aqueous binder composition.

11. The fibrous insulation product of claim 1 , wherein the aqueous binder composition has a viscosity at 40% solids and 25° C. of 10 cP to 65 cP.

12. The fibrous insulation product of claim 1 , wherein the aqueous binder composition has a viscosity at 40% solids and 25° C. of 300 cP to 500 cP.

13. The fibrous insulation product of claim 1 , wherein the R-value of the fibrous insulation product is in the range of 11 to 15.

14. The fibrous insulation product of claim 1 , wherein the R-value of the fibrous insulation product is in the range of 30 to 49.

15. The fibrous insulation product of claim 1 , wherein the fibrous insulation product has an average fiber diameter to density ratio (Fd/D) of less than or equal to 40 and a comfort factor of less than or equal to 3.417 (Fd/D)+60.

16. A fibrous insulation product comprising:
a plurality of randomly oriented glass fibers; and
a cross-linked formaldehyde-free binder composition at least partially coating the fibers, wherein the cross-linked formaldehyde-free binder composition is formed from an aqueous binder composition comprising:
5.0% by weight to 37.0% by weight of at least one monomeric polyol having at least four hydroxyl groups, based on the total solids content of the aqueous binder composition; and
at least 55% by weight of a cross-linking agent comprising a polymeric polycarboxylic acid having at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition, wherein said binder composition has a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.60/1.0 and 1.0/0.6,

wherein the quantity of cross-linked formaldehyde-free binder is in the range of 2% to 10% by weight of the fibrous insulation product;
wherein an R-value of the fibrous insulation product is in the range of 10 to 54;
wherein the glass fibers have an average fiber diameter in the range of 12 HT to 15 HT; and
wherein the fibrous insulation product, after curing, has a density, when uncompressed, in the range of 0.30 pcf to 2.7 pcf, and a stiffness of 45 degrees or less.

17. The fibrous insulation product of claim 16 , wherein the cross-linking agent is polyacrylic acid.

18. The fibrous insulation product of claim 16 , wherein the cross-linking agent is present in the binder composition in an amount from 50.0% by weight to 85% by weight, based on the total solids content of the aqueous binder composition.

19. The fibrous insulation product of claim 16 , wherein the monomeric polyol comprises at least five hydroxyl groups.

20. The fibrous insulation product of claim 16 , wherein the ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.80/1.0 and 1.0/0.8.

21. The fibrous insulation product of claim 16 , wherein the monomeric polyol comprises one or more of a sugar alcohols, pentaerythritol, primary alcohols, 1,2,4-butanetriol, trimethylolpropane, short-chain alkanolamines, and mixtures thereof.

22. The fibrous insulation product of claim 16 , wherein the monomeric polyol has a number average molecular weight less than 2,000 Daltons.

23. The fibrous insulation product of claim 16 , wherein the aqueous binder composition further includes at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons.

24. The fibrous insulation product of claim 23 , wherein the long-chain polyol is selected from the group consisting of polyvinyl alcohol and polyvinyl acetate.

25. The fibrous insulation product of claim 23 , wherein the long-chain polyol is present in the binder composition in an amount from about 2.5 wt. % to about 30 wt. %, based on the total solids content of the aqueous binder composition.

26. The fibrous insulation product of claim 16 , wherein the aqueous binder composition has a viscosity at 40% solids and 25° C. of 10 cP to 60 cP.

27. The fibrous insulation product of claim 16 , wherein the aqueous binder composition has a viscosity at 40% solids and 25° C. of 300 cP to 500 cP.

28. The fibrous insulation product of claim 16 , wherein the R-value of the fibrous insulation product is in the range of 11 to 15.

29. The fibrous insulation product of claim 16 , wherein the R-value of the fibrous insulation product is in the range of 30 to 49.

30. A fibrous insulation product comprising:
a plurality of randomly oriented glass

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Mueller Gert
• Broderick Andrew
• Zhang Xiujuan
• Chen Liang
• Smith Kendel
• Grant Larry J
• Houpt Ronald A
• Boone Teno
• Newsome Toni Elwell

Classifications

• C08L29/04

  Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids · CPC title

• C08F2810/20

  leading to a crosslinking, either explicitly or inherently · CPC title

• E04B1/7662

  comprising fiber blankets or batts · CPC title

• C08L29/14

  Homopolymers or copolymers of acetals or ketals obtained by polymerisation of unsaturated acetals or ketals or by after-treatment of polymers of unsaturated alcohols · CPC title

• C08L2312/00

  Crosslinking · CPC title