Binders and materials made therewith

Patent metadata

Field	Value
Publication number	US-9828287-B2
Application number	US-52453907-A
Country	US
Kind code	B2
Filing date	Jan 25, 2007
Priority date	Jan 25, 2007
Publication date	Nov 28, 2017
Grant date	Nov 28, 2017

Abstract

Binders to produce or promote cohesion in non-assembled or loosely assembled matter.

First claim

The invention claimed is:

1. A thermal or acoustical fiberglass insulation material comprising:
(a) a collection of glass fibers; and
(b) a binder disposed on the collection of glass fibers, wherein the binder comprises i) at least one reaction product of a reducing sugar reactant and an amine reactant, wherein the percent by dry weight of the reducing sugar reactant with respect to the total weight of reactants ranges from about 73% to about 96%, ii) a silicon-containing coupling agent, and iii) optionally, a corrosion inhibitor, wherein the fiberglass material comprises less than 99% by weight and more than 75% by weight glass fibers, and wherein the fiberglass material has a density of from about 0.4 lbs/ft 3 to about 6 lbs/ft 3 .

2. The fiberglass material of claim 1 , wherein the amine reactant is an ammonium salt of a polycarboxylic acid.

3. The fiberglass material of claim 1 , wherein the amine reactant is an ammonium salt of a monomeric polycarboxylic acid.

4. The fiberglass material of claim 1 , wherein the density is from about 0.75 lbs/ft 3 to about 2.5 lbs/ft 3 .

5. The fiberglass material of claim 1 , wherein the density is from about 2.25 lbs/ft 3 to about 4.25 lbs/ft 3 .

6. The fiberglass material of claim 1 , wherein the density is from about 0.4 lbs/ft 3 to about 1.5 lbs/ft 3 .

7. The fiberglass material of claim 1 , wherein the density is from about 3.75 lbs/ft 3 to about 5.2 lbs/ft 3 .

8. A thermal or acoustical fiberglass insulation material comprising:
(a) a collection of glass fibers; and
(b) a binder disposed on the collection of glass fibers, the binder comprising i) a mixture of Maillard reactants, wherein the percent by dry weight of a reducing sugar reactant with respect to the total weight of reactants ranges from about 73% to about 96%, ii) a silicon-containing coupling agent, and iii) optionally, a corrosion inhibitor, wherein the fiberglass material comprises less than 99% by weight and more than 75% by weight glass fibers, and wherein the fiberglass material has a density in the range from about 0.4 lbs/ft 3 to about 6 lbs/ft 3 .

9. A thermal or acoustical fiberglass insulation material comprising:
(a) a collection of glass fibers; and
(b) a binder disposed on the collection of glass fibers, wherein the binder comprises i) at least one reaction product of a reducing sugar reactant and a polycarboxylic acid ammonium salt reactant, wherein the percent by dry weight of the reducing sugar reactant with respect to the total weight of reactants ranges from about 73% to about 96%, ii) a silicon-containing coupling agent, and iii) optionally, a corrosion inhibitor, wherein the fiberglass material comprises less than 99% by weight and more than 75% by weight glass fibers, and wherein the fiberglass material has a density in the range from about 0.4 lbs/ft 3 to about 6 lbs/ft 3 .

10. The fiberglass material of claim 1 , where pyrolysis thereof results in the release of gaseous compounds of which about 12 percent by peak area are furan-based as determined by GC/MS.

11. The fiberglass material of claim 1 , where thermal curing of the binder results in the release of gaseous compounds of which about 15 percent by peak area are furan-based as determined by GC/MS.

12. The fiberglass material of claim 1 , where ignition thereof results in the development of less smoke than a phenol-formaldehyde bound fiberglass material as measured by ASTM E 1354.

13. The fiberglass material of claim 12 , where average smoke development measured as specific extinction area is about 2,500 m 2 /kg at an external heat flux of 35 kW/m 2 .

14. The fiberglass material of claim 12 , where average smoke development measured as specific extinction area is about 2,300 m 2 /kg at an external heat flux of 50 kW/m 2 .

15. The fiberglass material of claim 1 , where the ratio of mean weathered tensile strength to mean dry tensile strength is in the range from about 0.7 to about 1.

16. The fiberglass material of claim 1 , wherein the binder contains about 4 percent to about 5 percent nitrogen by mass as determined by elemental analysis.

17. The fiberglass material of claim 1 , wherein the at least one reaction product is generated during thermal curing that consists essentially of a Maillard reaction.

Assignees

• Swift Brian Lee
• Kissell Ronald E
• Xu Ruijian
• Knauf Insulation Inc
• Knauf Insulation Sprl

Inventors

• Swift Brian Lee
• Kissell Ronald E
• Xu Ruijian

Classifications

• C08H1/00

  Macromolecular products derived from proteins (food proteins A23; glue, gelatine C09H) · CPC title

• C03C25/26

  Macromolecular compounds or prepolymers · CPC title

• C03C25/325 Primary

  Polycarbonates · CPC title