Uncured articles with improved shelf-life

Patent metadata

Field	Value
Publication number	US-2016347652-A1
Application number	US-201515116254-A
Country	US
Kind code	A1
Filing date	Feb 6, 2015
Priority date	Feb 7, 2014
Publication date	Dec 1, 2016
Grant date	—

Abstract

Disclosed are formaldehyde-free, thermally-curable, alkaline, aqueous binder compositions. Also disclosed are compositions comprising formaldehyde-free, thermally-curable binder compositions, as described herein, applied to non-woven fibers. Uses of the disclosed binder compositions as binders for non-woven fibers are also disclosed.

First claim

1 . A composition comprising a substantially uncured binder disposed on mineral fibers, wherein the binder comprises:
(a) a mixture of at least two carbohydrates; and (b) an acid precursor derivable from an inorganic salt; and/or (c) an ammonium salt of a polycarboxylic acid.

2 . The composition of claim 1 , wherein the mixture of at least two carbohydrates includes two or more reducing sugars, two or more carbohydrates which yield two or more reducing sugars in situ under thermal curing conditions, and combinations thereof.

3 . The composition of claim 1 , wherein the acid precursor derivable from an inorganic salt is selected from the group consisting of ammonium sulphate salts, ammonium phosphate salts, ammonium nitrate salts, ammonium carbonate salts, and combinations thereof

4 . The composition of claim 1 , wherein the polycarboxylic acid is selected from the group consisting of unsaturated aliphatic polycarboxylic acids, saturated aliphatic polycarboxylic acids, aromatic polycarboxylic acids, unsaturated cyclic polycarboxylic acids, saturated cyclic polycarboxylic acids, hydroxy-substituted derivatives thereof, anhydrides thereof, and combinations thereof.

5 . The composition of claim 1 further comprising a silicon-containing compound.

6 . The composition of claim 5 , wherein the silicon-containing compound is selected from the group consisting of gamma-aminopropyltriethoxysilane, gamma- glycidoxypropyltrimethoxysilane, and mixtures thereof.

7 . The composition of claim 1 further comprising a corrosion inhibitor, said inhibitor capable of decreasing the corrosivity of the glass fibers.

8 . The composition of claim 7 , wherein the corrosion inhibitor is selected from the group consisting of dedusting oil, monoammonium phosphate, sodium metasilicate pentahydrate, and melamine.

9 . The composition of claim 1 , wherein the composition is a fiberglass insulation product.

10 . The composition of claim 14 , wherein the mixture of at least two carbohydrates includes one or more aldoses.

11 . The composition of claim 10 , wherein the one or more aldoses includes an aldohexose.

12 . The composition of claim 11 , wherein the aldohexose is dextrose

13 . The composition of claim 14 , wherein the mixture of at least two carbohydrates includes one or more ketoses.

14 . The composition of claim 13 , wherein the one or more ketoses includes a ketohexose.

15 . The composition of claim 14 , wherein the ketohexose is fructose.

16 . The composition of claim 1 , wherein the mineral fibers comprise fibers selected from glass fibers and stone wool fibers.

17 . The composition of claim 16 , wherein the mineral fibers comprise glass fibers.

18 . The composition of claim 16 , wherein the mineral fibers comprise stone wool fibers.

19 . The composition of claim 1 , wherein the mixture of at least two carbohydrates in the binder has a lower crystallization point than dextrose.

20 . The composition of claim 1 , wherein the mixture of at least two carbohydrates in the binder is provided as high fructose corn syrup (HFCS).

Assignees

• Knauf Insulation Inc
• Knauf Insulation Sprl

Inventors

• Appley Charles Fitch
• Mueller Gert

Classifications

• C03C25/32

  obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds · CPC title

• C07H3/02

  Monosaccharides · CPC title

• C03C13/06 Primary

  Mineral fibres, e.g. slag wool, mineral wool, rock wool · CPC title

• F16L59/028

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

• C03C25/1095 Primary

  to obtain coated fabrics · CPC title