Insulation products formed with aqueous binder compositions

Patent metadata

Field	Value
Publication number	US-12359355-B2
Application number	US-202017601982-A
Country	US
Kind code	B2
Filing date	Apr 7, 2020
Priority date	Apr 9, 2019
Publication date	Jul 15, 2025
Grant date	Jul 15, 2025

Abstract

A fibrous insulation product is discloses comprising a plurality of randomly oriented fibers and a thermoset aqueous binder composition at least partially coating said fibers. The binder composition comprises at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons, a cross-linking agent comprising at least two carboxylic acid groups, and a short-chain polyol having at least two hydroxyl groups and a number average molecular weight less than 2,000 Daltons, wherein a ratio of long-chain polyol to short-chain polyol is from 0.1/0.9 to 0.9/0.1.

First claim

What is claimed is:

1. A low-density fibrous insulation product comprising:
a plurality of randomly oriented fibers; and
a thermoset aqueous binder composition at least partially coating said fibers, said binder composition comprising:
at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons;
at least 65 wt. % of a cross-linking agent comprising polymeric polycarboxylic acid, based on the total solids content of the aqueous binder composition; and
a short-chain polyol having at least two hydroxyl groups and a number average molecular weight less than 2,000 Daltons, wherein a ratio of long-chain polyol to short-chain polyol is from 0.1/0.9 to 0.9/0.1,
wherein the low-density fibrous insulation product has a density between 0.1 and 2.5 lbs/ft 3 .

2. The low-density fibrous insulation product of claim 1 , wherein the fibers comprise one or more of mineral fibers, natural fibers, and synthetic fibers.

3. The low-density fibrous insulation product of claim 1 , wherein the low-density insulation product has a thickness between 0.5 and 25 inches.

4. The fibrous insulation product of claim 1 , wherein the low-density insulation product is an insulation batt, insulation blanket, duct wrap, or metal building insulation.

5. The low-density fibrous insulation product of claim 1 , further including one or more reinforcement or scrim materials adhered to the fibrous insulation product.

6. The low-density fibrous insulation product of claim 1 , wherein the fibrous insulation product has a binder LOI between 0.5% and 9%.

7. The low-density fibrous insulation product of claim 1 , wherein a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups in the binder composition is from 1/0.05 to 1.0/5.0.

8. A high-density fibrous insulation product comprising:
a plurality of randomly oriented fibers; and
a thermoset aqueous binder composition at least partially coating said fibers, said binder composition comprising:
at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons;
at least 65 wt. % of a cross-linking agent comprising polymeric polycarboxylic acid, based on the total solids content of the aqueous binder composition; and
a short-chain polyol having at least two hydroxyl groups and a number average molecular weight less than 2,000 Daltons, wherein a ratio of long-chain polyol to short-chain polyol is from 0.1/0.9 to 0.9/0.1,
wherein the high-density fibrous insulation product has a density between 2.5 and 10 lbs/ft 3 .

9. The high-density fibrous insulation product of claim 8 , wherein the high-density fibrous insulation product has a thickness between 0.2 and 5.0 inches.

10. The high-density fibrous insulation product of claim 8 , wherein the high-density fibrous insulation product comprises wall or ceiling insulation, pipe or tank insulation, duct board, industrial board, or acoustic board.

11. A ceiling board product comprising the high-density fibrous insulation product of claim 8 .

12. The ceiling board product of claim 11 , wherein the high-density fibrous insulation product comprises glass fiber having a diameter between 35 HT and 50 HT.

13. The ceiling board product of claim 11 , wherein the high-density fibrous insulation product includes a binder LOI between 8% and 16%.

14. The ceiling board product of claim 11 , wherein the board has a finished ceiling tile sag rating of less than 0.3″ under both ambient and hot/humid conditions.

15. The ceiling board product of claim 11 , wherein the board achieves a flame spread of no greater than 5, according to ASTM E84.

16. A duct board product comprising the high-density fibrous insulation product of claim 8 .

17. The duct board product of claim 16 , wherein the high-density fibrous insulation product comprises glass fiber having a diameter between 20 HT and 80 HT.

18. The duct board product of claim 16 , wherein the high-density fibrous insulation product comprises a density between 2.5 lbs/ft 3 and 6.0 lbs/ft 3 .

19. The duct board product of claim 16 , wherein the high-density fibrous insulation product has a thickness between 0.5 and 5.0 inches.

20. The duct board product of claim 16 , wherein the high-density fibrous insulation product includes a binder LOI between 13% and 23%.

21. The duct board product of claim 16 , further including a facer adhered to the first major surface.

22. The duct board product of claim 21 , wherein the facer comprises a coated fiber mat facer or a foil-scrim-kraft (FSK) facer.

23. The duct board product of claim 16 , further including a veil adhered to the second major surface.

24. The duct board product of claim 23 , wherein the veil comprises a fiberglass veil comprising glass fibers with diameters between 10 and 15 microns.

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Smith Kendel
• Zhang Xiujuan
• Mueller Gert

Classifications

• E04B1/80 Primary

  slab-shaped · CPC title

• D04H1/4209

  Inorganic fibres · CPC title

• C08L33/02

  Homopolymers or copolymers of acids; Metal or ammonium salts thereof · CPC title

• C08L29/04

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

• C08K7/14

  Glass · CPC title