Carbohydrate binders and materials made therewith

Patent metadata

Field	Value
Publication number	US-9493603-B2
Application number	US-201113696452-A
Country	US
Kind code	B2
Filing date	May 7, 2011
Priority date	May 7, 2010
Publication date	Nov 15, 2016
Grant date	Nov 15, 2016

Abstract

A binder comprising a polymeric binder comprising the products of a carbohydrate reactant and nucleophile is disclosed. The binder is useful for consolidating loosely assembled matter, such as fibers. Fibrous products comprising fibers in contact with a carbohydrate reactant and a nucleophile are also disclosed. The binder composition may be cured to yield a fibrous product comprising fibers bound by a cross-linked polymer. Further disclosed are methods for binding fibers with the carbohydrate reactant and polyamine based binder.

First claim

The invention claimed is:

1. A method of making a composite wood board comprising a collection of matter comprising cellulosic fibers bound with a cured thermoset polymeric binder, the method comprising:
(i) preparing an aqueous binder solution containing reactants for producing the cured thermoset polymeric binder, wherein the reactants include a reducing sugar and a nucleophile R 1 -Q-R 2 , wherein;
Q is alkyl, cycloalkyl, heteroalkyl, or cycloheteroalkyl, each of which is optionally substituted,
R 1 is selected from the group consisting of an amine, an azide, a cyanate, an isocyanate, a thiol, a disulfide, a thiocyanate, a halogen, a haloformyl, a carboxyl, a carboxylate, a hydroxyl, and an alkoxide, and
R 2 is selected from the group consisting of an amine, an amide, an imine, an imide, a nitro, a nitrate, a pyridine, a phosphate, a phosphono, a hydroxyl, a sulphono, a sulpho, a sulfinyl, and a sulfhydryl,
provided that when the nucleophile consists of polyethylenimine, the mole ratio of the reducing sugar to the nucleophile is in the range of 1:1 to 30:1;

(ii) disposing the aqueous binder solution onto a collection of matter;
(iii) drying the aqueous binder solution to form an uncured product; and
(iv) thermally curing the uncured product which comprises 3% to 25% of dry binder solids (total uncured solids by weight) to form the composite wood board bound with the cured thermoset polymeric binder.

2. The method of claim 1 , wherein preparing the aqueous binder solution includes at least one of the steps selected from the group consisting of:
a) adding an amount of the reducing sugar and an amount of the nucleophile so a weight ratio of the reducing sugar to the nucleophile is in the range of about 2:1 to about 10:1;
b) adding the reducing sugar and the nucleophile to an aqueous solution; and
c) adjusting the pH of the solution to within the range of about 8 to about 12.

3. The method of claim 1 , in which the cured thermoset polymeric binder is formaldehyde free.

4. The method of claim 1 , in which neither formaldehyde nor phenol is used as a reagent.

5. The method of claim 1 , wherein the cellulosic fibers comprises matter selected from the group consisting of wood shavings, sawdust, wood pulp, ground wood, jute, flax, hemp and straw.

6. The method of claim 1 , wherein the weight ratio of the reducing sugar to the nucleophile is in the range of 2:1 to 10:1.

7. The method of claim 1 , wherein the reducing sugar is selected from the group consisting of dextrose, xylose, fructose, dihydroxyacetone, and mixtures thereof.

8. The method of claim 1 , wherein R 1 and R 2 form covalent bonds with the reducing sugar to form the polymeric binder.

9. The method of claim 1 , wherein
R 1 is selected from the group consisting of an azide, a cyanate, an isocyanate, a thiol, a disulfide, a thiocyanate, a halogen, a haloformyl, a carboxyl, a carboxylate, a hydroxyl, and an alkoxide, and
R 2 is selected from the group consisting of an amine, an amide, an imine, an imide, a nitro, a nitrate, a pyridine, a phosphate, a phosphono, a hydroxyl, a sulphono, a sulpho, a sulfinyl, and a sulfhydryl.

10. The method of claim 1 , wherein
R 1 is selected from the group consisting of an amine, an azide, a cyanate, an isocyanate, a thiol, a disulfide, a thiocyanate, a halogen, a haloformyl, a carboxyl, a carboxylate, a hydroxyl, and an alkoxide, and
R 2 is a selected from the group consisting of an amide, an imine, an imide, a nitro, a nitrate, a pyridine, a phosphate, a phosphono, a hydroxyl, a sulphono, a sulpho, a sulfinyl, and a sulfhydryl.

11. The method of claim 1 , wherein
R 1 is selected from the group consisting of an azide, a thiol, a halogen, a carboxyl, a carboxylate, a hydroxyl, and an alkoxide, and
R 2 is a selected from the group consisting of an imine, a pyridine, a phosphate, a phosphono, a hydroxyl, a sulfinyl, and a sulfhydryl.

12. The method of claim 1 , wherein R 1 -Q-R 2 does not consist of polyethylenimine.

13. The method of claim 1 , wherein neither R 1 nor R 2 is an amine.

14. The method of claim 1 , wherein R 1 -Q-R 2 is a primary amine having only one primary amine group.

15. The method of claim 1 , wherein Q is an alkyl selected from the group consisting of C 2 -C 24 .

16. The method of claim 1 , wherein Q is an alkyl selected from the group consisting of C 2 -C 8 .

17. The method of claim 1 , wherein Q is an alkyl selected from the group consisting of C 3 -C 7 .

18. The method of claim 1 , wherein Q is a C 6 alkyl.

19. The method of claim 1 , wherein Q is a cycloalkyl selected from the group consisting of a cyclohexyl, cyclopentyl and cyclobutyl.

20. The method of claim 1 , wherein R 1 -Q-R 2 is 2-[(2-aminoethyl)amino]ethanol.

21. The method of claim 1 , wherein each of R 1 and R 2 is thiol.

22. The method of claim 1 , wherein R 1 is an amine and R 2 is an amine, an amide, an imine, or an imide.

23. The method of claim 1 , wherein R 1 is an amine and R 2 is an amine.

24. The method of claim 1 , wherein the mole ratio of the reducing sugar to the nucleophile is in the range of 1:1 to 30:1.

25. The method of claim 1 , wherein the mole ratio of the reducing sugar to the nucleophile is in the range of 2:1 to 10:1.

26. The method of claim 1 , wherein the mole ratio of the reducing sugar to nucleophile is in the range of 3:1 to 6:1.

27. The method of claim 1 , wherein preparing the aqueous binder solution includes adjusting the pH of the aqueous binder solution to within the range of 8 to 12.

28. The method of claim 1 , wherein the aqueous binder solution has an alkaline pH.

29. The method of claim 1 , wherein the cured thermoset polymeric binder is water insoluble.

30. The method of claim 1 , wherein the cured thermoset polymeric binder strongly absorbs light at 420 nm.

31. The method of claim 1 , wherein the aqueous binder solution is acid-free.

32. The method of claim 1 , wherein the collection of matter and the cured thermoset polymeric binder further comprises a material selected from the group consisting of a silicon-containing compound, gamma-aminopropyltriethoxysilane, gamma-glycidoxypropyltrimethoxysilane, aminoethylaminopropyltrimethoxysilane, an aminofunctional oligomeric siloxane and mixtures thereof.

33. The method of claim 1 , wherein the collection of matter and the cured thermoset polymeric binder further comprises a corrosion inhibitor selected from the group consisting of dedusting oil, monoammonium phosphate, sodium metasilicate pentahydrate, melamine, tin (II)oxalate, and a methylhydrogen silicone fluid emulsion.

34. The method of claim 1 , wherein the binder further comprises a non-aqueous moisturizer.

Assignees

• Mueller Gert R
• Appley Charles Fitch
• Pacorel Benedicte
• Hampson Carl A
• Knauf Insulation Sprl
• Knauf Insulation Inc

Inventors

• Mueller Gert R
• Appley Charles Fitch
• Pacorel Benedicte
• Hampson Carl A

Classifications

• C08J5/04

  Reinforcing macromolecular compounds with loose or coherent fibrous material · CPC title

• C08G16/00 Primary

  Condensation polymers of aldehydes or ketones with monomers not provided for in the groups C08G4/00 - C08G14/00 (with polynitriles C08G69/38) · CPC title

• C08G12/00

  Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen (aminophenols C08G8/16) · CPC title

• C08G14/00

  Condensation polymers of aldehydes or ketones with two or more other monomers covered by at least two of the groups C08G8/00 - C08G12/00 · CPC title

• C07H5/06 Primary

  Aminosugars · CPC title