Aqueous binder compositions

Patent metadata

Field	Value
Publication number	US-12565568-B2
Application number	US-202017602005-A
Country	US
Kind code	B2
Filing date	Apr 7, 2020
Priority date	Apr 9, 2019
Publication date	Mar 3, 2026
Grant date	Mar 3, 2026

Abstract

An aqueous binder composition is disclosed that 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 primary cross-linking agent comprising at least two carboxylic acid groups; and a secondary cross-linking agent comprising a short-chain polyol having at least two hydroxyl groups and a number average molecular weight less than 2,000 Daltons.

First claim

What is claimed is:

1 . An aqueous binder composition comprising:
at least 65 wt. % of a polymeric cross-linking agent comprising at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition; at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons; and optionally, at least one short-chain polyol having at least two hydroxyl groups and a number average molecular weight of less than 2,000 Daltons; wherein a ratio of molar equivalents of carboxylic acid groups, anhydride groups, or salts thereof to molar equivalents of hydroxyl groups is from 1/0.75 to 1/5; and wherein the binder composition, once cured, includes no greater than 6.0 wt. % water soluble material.

2 . The aqueous binder composition of claim 1 , wherein the short-chain polyol is present in an amount from 1.0 to 30 wt. %, based on the total solids content of the aqueous binder composition.

3 . The aqueous binder composition of claim 1 , wherein the short-chain polyol is present in an amount from 10.0 to 25 wt. %, based on the total solids content of the aqueous binder composition.

4 . The aqueous binder composition of claim 1 , wherein said short-chain polyol comprises one or more of a sugar alcohol, 2,2-bis(methylol)propionic acid, tri(methylol)propane, pentaerythritol, and an alkanolamine.

5 . The aqueous binder composition of claim 4 , wherein said short-chain polyol comprises a sugar alcohol selected from the group consisting of glycerol, erythritol, arabitol, xylitol, sorbitol, maltitol, mannitol, iditol, isomaltitol, lactitol, cellobitol, palatinitol, maltotritol, syrups thereof, and mixtures thereof.

6 . The aqueous binder composition of claim 4 , wherein the alkanolamine comprises triethanolamine.

7 . The aqueous binder composition of claim 1 , wherein a ratio of long-chain polyol to short-chain polyol is between 1/50 and 20/1.

8 . The aqueous binder composition of claim 1 , wherein a ratio of long-chain polyol to short-chain polyol is between 1/20 and 10/1.

9 . The aqueous binder composition of claim 1 , wherein once cured, the binder composition includes no greater than 5.0 wt. % water soluble material.

10 . The aqueous binder composition of claim 1 , wherein once cured, the binder composition includes no greater than 4.0 wt. % water soluble material.

11 . The aqueous binder composition of claim 1 , wherein the binder composition has a viscosity of 175 cP at 30% solids or less.

12 . The aqueous binder composition of claim 1 , wherein the binder composition, once cured, has a pH between 5 and 9.0.

13 . An aqueous 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 polymeric cross-linking agent comprising at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition; and at least one short-chain polyol having at least two hydroxyl groups and a number average molecular weight of less than 2,000 Daltons, wherein a ratio of molar equivalents of carboxylic acid groups, anhydride groups, or salts thereof to molar equivalents of hydroxyl groups is from 1/0.75 to 1/5 and a ratio of long-chain polyol to short-chain polyol is between 1/50 and 20/1.

14 . The aqueous binder composition of claim 13 , wherein the long chain polyol is present in an amount from 1.0 to 30 wt. %, based on the total solids content of the aqueous binder composition.

15 . The aqueous binder composition of claim 13 , wherein the short-chain polyol is present in an amount from 10.0 to 25 wt. %, based on the total solids content of the aqueous binder composition.

16 . The aqueous binder composition of claim 13 , wherein said short-chain polyol comprises one or more of a sugar alcohol, 2,2-bis(methylol)propionic acid, tri(methylol)propane, and an alkanolamine.

17 . The aqueous binder composition of claim 16 , wherein said short-chain polyol comprises a sugar alcohol selected from the group consisting of glycerol, erythritol, arabitol, xylitol, sorbitol, maltitol, mannitol, iditol, isomaltitol, lactitol, cellobitol, palatinitol, maltotritol, syrups thereof, and mixtures thereof.

18 . The aqueous binder composition of claim 16 , wherein the alkanolamine comprises triethanolamine.

19 . The aqueous binder composition of claim 13 , wherein a ratio of long-chain polyol to short-chain polyol is between 1/10 and 5/1.

20 . The aqueous binder composition of claim 13 , wherein a ratio of long-chain polyol to short-chain polyol is between 1/20 and 10/1.

21 . The aqueous binder composition of claim 13 , wherein once cured, the binder composition includes no greater than 5.0 wt. % water soluble material.

22 . The aqueous binder composition of claim 13 , wherein once cured, the binder composition includes no greater than 4.0 wt. % water soluble material.

23 . A fibrous product comprising:
a plurality of randomly oriented fibers; and an aqueous binder composition at least partially coating said fibers, said binder composition comprising: at least 65 wt. % of a polymeric cross-linking agent comprising at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition; at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons; and optionally, at least one short-chain polyol having at least two hydroxyl groups and a number average molecular weight of less than 2,000 Daltons; wherein a ratio of molar equivalents of carboxylic acid groups, anhydride groups, or salts thereof to molar equivalents of hydroxyl groups is from 1/0.75 to 1/5; and wherein the binder composition, once cured, includes no greater than 6.0 wt. % water soluble material.

24 . The fibrous product of claim 23 , wherein once cured, the binder composition includes no greater than 5.0 wt. % water soluble material.

25 . The fibrous product of claim 23 , wherein once cured, the binder composition includes no greater than 4.0 wt. % water soluble material.

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Mueller Gert
• Zhang Xiujuan
• Chen Liang
• Mendez-Andino Jose

Classifications

• C08K5/17

  Amines; Quaternary ammonium compounds · CPC title

• C08K5/053

  Polyhydroxylic alcohols · CPC title

• C08J2329/04

  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

• C08F16/06

  Polyvinyl alcohol {; Vinyl alcohol} · CPC title