Formaldehyde-scavenging formulation

Patent metadata

Field	Value
Publication number	US-2025332568-A1
Application number	US-202318860802-A
Country	US
Kind code	A1
Filing date	May 16, 2023
Priority date	May 16, 2022
Publication date	Oct 30, 2025
Grant date	—

Abstract

The present invention is concerned with improved formaldehyde-scavenging formulations, and uses of same in veils and construction products including ceiling tiles, boards including insulation boards, particularly phenolic insulation boards, and panels and boards including wood panels and wood boards, together with methods for reduction of formaldehyde emissions from a construction product.

First claim

1 . A formaldehyde-scavenging formulation comprising:
(a) a polyvinylamine (PVAm) formaldehyde scavenger or a copolymer thereof; (b) optionally a non-ionic or cationic stabilized binder and/or crosslinker; and (c) a non-ionic stabilized fire retardant.

2 . A formaldehyde-scavenging formulation according to claim 1 , comprising:
(a) 1 to 90% by weight dry mass of the polyvinylamine (PVAm) formaldehyde scavenger or a copolymer thereof; (b) 1 to 60% by weight dry mass of the non-ionic or cationic stabilized binder and/or crosslinker; and (c) 10 to 90% of the non-ionic stabilized fire retardant.

3 . A formaldehyde-scavenging formulation according to claim 1 , wherein the non-ionic or cationic stabilized binder and/or crosslinker is a non-ionic stabilized binder.

4 . A formaldehyde-scavenging formulation according to claim 1 , wherein the non-ionic stabilized fire retardant is non-ionic stabilized aluminium trihydrate (ATH) (Al(OH) 3 ) slurry or dispersion.

5 . A formaldehyde-scavenging formulation according to claim 1 , additionally comprising base in an amount of less than or equal to 50% by weight dry mass.

6 . A formaldehyde-scavenging formulation according to claim 5 , wherein the base is present in an amount of 0.5-25% by weight dry mass.

7 . A formaldehyde-scavenging formulation according to claim 1 , additionally comprising antifoaming agent in an amount below of less than or equal to 1.5% by weight dry mass.

8 . A formaldehyde-scavenging formulation according to any of the preceding claims, claim 1 , additionally comprising repellent agent in an amount below or of less than or equal to 20% by weight dry mass.

9 . A formaldehyde-scavenging formulation according to claim 1 , additionally comprising at least one of:
(A) dispersing agent; (B) viscosity modifier; and (C) polyphosphate sodium salts —[MPO 3 ]— n (OH) 2 wherein M is selected from the group consisting of Na, K, and NH 4 , and wherein n is an integer greater than 100.

10 . A formaldehyde-scavenging formulation according to claim 1 , additionally comprising a pigment.

11 . A formaldehyde-scavenging formulation according to claim 1 , wherein the formulation is an aqueous formulation.

12 . A formaldehyde-scavenging formulation comprising:
a polyvinylamine (PVAm) formaldehyde scavenger; a non-ionic stabilized binder and/or crosslinker; and a non-ionic stabilized aluminium trihydrate (ATH) fire retardant; an antifoaming agent; a repellent agent; and an aminosilane.

13 . A formaldehyde-scavenging formulation according to claim 12 , wherein the polyvinylamine (PVAm) has a weight average molecular weight (Mw) in the range 50,000-800,000 g/mol.

14 . A non-woven veil coated with or containing a formaldehyde-scavenging formulation according to claim 12 .

15 . A non-woven veil according to claim 14 , wherein the veil is a glass fibre non-woven veil.

16 . A construction product having a non-woven veil according to claim 15 on at least one surface.

17 . A construction product according to claim 16 , wherein the construction product is made of a wool selected from the group consisting of: glass wool, rock wool, stone wool and mineral wool.

18 . A construction product according to claim 17 , wherein it is selected from the group consisting of: a ceiling tile, a wall panel, an insulation board, and a wood based panel.

19 . A method of reducing formaldehyde emissions from a construction product, the method comprising the step of attaching a non-woven veil according to claim 14 to at least one outer surface of the construction product.

20 . The formaldehyde-scavenging formulation of claim 12 , wherein the formulation comprises:
from 1 to 90% by weight dry mass of the polyvinylamine (PVAm) formaldehyde scavenger; less than or equal to 60% by weight dry mass of the non-ionic stabilized binder and/or crosslinker; less than or equal to 96% by weight dry mass of the non-ionic stabilized aluminium trihydrate (ATH) fire retardant; less than or equal to 1% by weight dry mass of the antifoaming agent; and less than or equal to 20% by weight dry mass of the repellant agent.

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Geel Paul A
• Rouillon Camille
• Cuijk Bert Van

Classifications

• B01J20/28035

  with more than one layer, e.g. laminates, separated sheets · CPC title

• B01J20/2803

  Sorbents comprising a binder, e.g. for forming aggregated, agglomerated or granulated products · CPC title

• C08K2003/2227

  of aluminium · CPC title

• D04H1/4218

  Glass fibres · CPC title

• D04H1/64

  the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions · CPC title