Bio-based flame resistant thermosetting binders with improved wet resistance

Patent metadata

Field	Value
Publication number	US-9487642-B2
Application number	US-201313901630-A
Country	US
Kind code	B2
Filing date	May 24, 2013
Priority date	May 29, 2012
Publication date	Nov 8, 2016
Grant date	Nov 8, 2016

Abstract

The invention provides aqueous thermosetting binder compositions exhibiting both of improved flame retardation and wet tensile strength comprising a reducing sugar, a diprimary diamine or a polyprimary diamine, a phosphorus acid salt and from 3 to 20 wt. %, based on total solids, of an aqueous polymeric polyacid solution polymer containing phosphorus or its salt, wherein the aqueous thermosetting binder composition comprises from 0.7% P (s/s) to 5% P (s/s).

First claim

We claim:

1. An aqueous thermosetting binder composition comprising i) from 50 to 87 wt. %, based on total solids, of reducing sugar, ii) diprimary diamine or polyprimary amine in a ratio of from 1.1:1 to 0.3:1 moles of primary amine per mole of the reducing sugar, the ratio based on solids iii) from 0.5 to 15 wt. %, based on total solids, of a phosphorus acid salt which is a divalent metal salt, an alkali metal salt, ammonium tripolyphosphate, diammonium hydrogen phosphate, or ammonium pyrophosphate, and iv) from 3 to 20 wt. % , based on total solids, of an aqueous polymeric polyacid solution polymer containing phosphorus or its salt, wherein the aqueous thermosetting binder composition comprises from 0.7% P (s/s) to 5% P (s/s).

2. The composition as claimed in claim 1 , wherein the composition comprises at least 1.0% P (s/s).

3. The composition as claimed in claim 1 , wherein the aqueous polymeric polyacid comprises a polyacrylic acid or a polymethacrylic acid with a phosphinate endgroup.

4. The composition as claimed in claim 1 , further comprising from 0.02 to 5 wt %, based on total solids, of a non-phosphorus containing flame retardant.

5. The composition as claimed in claim 1 , further comprising one or more stabilizer acid or salt having a pKa of 8.5 or less.

6. The composition as claimed in claim 1 , wherein the one or more reducing sugar is a 5-carbon or a 6-carbon monosaccharide.

7. A method of using the aqueous thermosetting binder composition as claimed in claim 1 comprising applying the binder compositions to or mixing them with a substrate and then heating the thus treated substrates or mixtures to cure the binder at from 100 to 400° C.

8. The method of claim 7 wherein the substrates include fibers, slivers, chips, particles, and combinations thereof.

9. The method of claim 8 , wherein the substrate includes glass, glass fiber, stone fibers, composites and composite fibers.

10. A fiber matt containing a cured binder resulting from applying the compositions of claim 1 thereto, wherein the density of the fiber matt is from 5 kg/m 3 to 220 kg/m 3 .

Assignees

• Rohm & Haas

Inventors

• Lee Haksu
• Rand Charles J
• Weinstein Barry
• Zwolak Thomas T

Classifications

• C08K5/1545 Primary

  Six-membered rings · CPC title

• C08K5/17 Primary

  Amines; Quaternary ammonium compounds · CPC title

• C08K3/32

  Phosphorus-containing compounds · CPC title

• Y10T428/249921

  Web or sheet containing structurally defined element or component · CPC title