Binder for granular and/or fibrous substrates

Patent metadata

Field	Value
Publication number	US-9499657-B2
Application number	US-201113116737-A
Country	US
Kind code	B2
Filing date	May 26, 2011
Priority date	May 27, 2010
Publication date	Nov 22, 2016
Grant date	Nov 22, 2016

Abstract

Binder for granular and/or fibrous substrates.

First claim

I claim:

1. A binder, comprising:
a polymer A obtained by a process comprising a free-radical addition polymerization,
a crosslinker B which is an organic compound comprising at least two functional groups selected from the group consisting of a hydroxyl group, an epoxy group, a primary amino group, and a secondary amino group, and
an isocyanate C which is an organic compound comprising at least two isocyanate groups,
wherein the polymer A consists of, in polymerized form:
from 5% to 100% by weight of at least one monomer A1, which is at least one ethylenically unsaturated C 3 to C 6 mono- or dicarboxylic acid, and
from 0% to 95% by weight of at least one monomer A2, which is at least one other ethylenically unsaturated compound which is copolymerizable with the at least one monomer A1.

2. The binder according to claim 1 wherein the polymer A is dissolved or dispersed in an aqueous medium.

3. The binder according to claim 1 , wherein the polymer A consists of, in polymerized form:
from 70% to 100% by weight of the at least one monomer A1, and
from 0% to 30% by weight of the at least one monomer A2.

4. The binder according to claim 1 , wherein the polymer A consists of, in polymerized form:
from 85% to 100% by weight of at least one selected from the group consisting of acrylic acid, methacrylic acid, maleic acid, maleic anhydride, and itaconic acid, and
from 0% to 15% by weight of at least one selected from the group consisting of methyl acrylate, ethyl acrylate, n-butyl acrylate, 2-ethyl hexyl acrylate, methyl methacrylate, and styrene.

5. The binder according to claim 1 , wherein the crosslinker B is triethanolamine.

6. The binder according to claim 1 , wherein the isocyanate C is diphenylmethane diisocyanate, a more highly nuclear homolog of diphenylmethane diisocyanate, or both.

7. The binder according to claim 1 , wherein a weight ratio of the polymer A to the crosslinker B is in a range from 100:1 to 1:3.

8. The binder according to claim 1 , wherein a weight ratio of a sum of the polymer A and the crosslinker B to the isocyanate C is from 20:1 to 1:20.

9. A process for producing a shaped article from a granular substrate, a fibrous substrate, or a granular and fibrous substrate, the process comprising:
applying the binder according to claim 1 to a granular substrate, a fibrous substrate, or a granular and fibrous substrate, thereby obtaining a binder-treated substrate,
optionally shaping the binder-treated substrate, and then
thermally treating the binder-treated substrate at a temperature of at least 100° C.

10. The process according to claim 9 , further comprising:
mixing the polymer A, the crosslinker B or a mixture of the polymer A and the crosslinker B with the isocyanate C, thereby obtaining the binder, immediately before or during the applying to the substrate.

11. The process according to claim 9 , wherein, in the applying, at least 0.1 g and at most 100 g of binder, defined as a sum total of the polymer A, the crosslinker B, and the isocyanate C, based on solids, is applied per 100 g of the substrate.

12. The process according to claim 9 , wherein the thermally treating consists of a drying and a curing.

13. The process according to claim 9 , wherein the substrate comprises cellulose.

14. The process according to claim 9 , wherein the substrate comprises lignocellulose.

15. A shaped article obtained by the process according to claim 9 .

Assignees

• Kalbe Michael
• Basf Se

Inventors

• Kalbe Michael

Classifications

• C08L75/04

  Polyurethanes · CPC title

• C08G18/6492

  Lignin containing materials; Wood resins; Wood tars; Derivatives thereof · CPC title

• C08L33/064

  containing anhydride, COOH or COOM groups, with M being metal or onium-cation · CPC title

• C08L97/02

  Lignocellulosic material, e.g. wood, straw or bagasse {(manufacture of articles made from lignocellulosic material by dry processes B27N)} · CPC title

• C08G18/3206

  aliphatic · CPC title