Binder compositions with polyvalent phosphorus crosslinking agents

Patent metadata

Field	Value
Publication number	US-9957409-B2
Application number	US-201113187650-A
Country	US
Kind code	B2
Filing date	Jul 21, 2011
Priority date	Jul 21, 2011
Publication date	May 1, 2018
Grant date	May 1, 2018

Abstract

An fibrous insulation product is provided that includes a binder comprising a polyol and a phosphorus crosslinking agent derived from a phosphonic or phosphoric acid, salt, ester or anhydride to form crosslinked phosphodiester linkages. The polyol is polyvalent, but may be monomeric or preferably polymeric; and may be synthetic or natural in origin. Carbohydrate polysaccharides are exemplary polyols, including water-soluble polysaccharides such as dextrin, maltodextrin, starch, modified starch, etc. Additionally, the carbohydrate polymer may have a dextrose equivalent (DE) number from 2 to 20. In exemplary embodiments, the binder may also include a catalyst, a coupling agent, a process aid, and other additives. The environmentally friendly, formaldehyde-free binder may be used in the formation of residential and commercial insulation materials and non-woven chopped strand mats. A method of making fibrous products is also provided.

First claim

What is claimed is:

1. A fibrous product comprising:
a plurality of randomly oriented fibers; and
a cured phosphodiester binder composition distributed on at least a portion of the fibers, wherein the cured phosphodiester binder composition is free of added formaldehyde and comprises:
at least one water soluble polysaccharide having a dextrose equivalent number from 9 to 14, and
a polyvalent phosphorus crosslinking agent comprising acids or ammonium salts of phosphoric acid, phosphonic acid, phosphorus acid, or polyphosphoric acid;

wherein the cured phosphodiester binder composition has an acidic pH from 1 to 6;
wherein the cured phosphodiester binder composition comprises hydroxyl groups of the at least one water soluble polysaccharide crosslinked by phosphodiester linkages; and
wherein the fibrous product has a density from 0.2 pcf to 4 pcf and has no added formaldehyde.

2. The fibrous product of claim 1 , wherein the cured phosphodiester binder composition comprises from 20% to 99% by weight of the at least one water soluble polysaccharide, and from 1% to 40% by weight of the polyvalent phosphorus crosslinking agent, wherein the weight percentages are based on the total solids of the cured phosphodiester binder composition.

3. The fibrous product of claim 1 , wherein the fibrous product contains the cured phosphodiester binder composition at a concentration from 2% to 40% by weight of the fibrous product.

4. The fibrous product of claim 1 , wherein the fibrous product is an insulation product having the cured phosphodiester binder composition at a concentration from 2% to 10% by weight of the fibrous product.

5. The fibrous product of claim 4 , wherein the fibrous product is an insulation product having a density from 0.3 pcf to 4 pcf.

6. The fibrous product of claim 1 , wherein the fibrous product is an insulation product having cured phosphodiester binder composition at a concentration from 5% to 25% by weight of the fibrous product.

7. The fibrous product of claim 6 , wherein the fibrous product is an insulation product having a density from 1.5 pcf to 4 pcf.

8. The fibrous product of claim 7 , wherein the fibrous product is an insulation product having a density from 3 pcf to 4 pcf.

9. The fibrous product of claim 1 , wherein the fibrous product is a non-woven mat.

10. The fibrous product of claim 9 , wherein the non-woven mat contains the cured phosphodiester binder composition at a concentration from 5% to 20% by weight of the fibrous product.

11. The fibrous product of claim 1 , wherein the cured phosphodiester binder composition does not include a catalyst to assist in the formation of the phosphodiester linkages.

12. An aqueous phosphodiester binder composition for use in the formation of fiberglass insulation and non-woven chopped strand mats, the aqueous phosphodiester binder composition comprising:
a water soluble maltodextrin having a dextrose equivalent number from 9 to 14; and
a polyvalent phosphorus crosslinking agent selected from the group consisting of acids or ammonium salts of phosphoric acid, phosphonic acid, phosphorus acid, and polyphosphoric acid;
wherein the aqueous phosphodiester binder composition is free of added formaldehyde;
wherein the aqueous phosphodiester binder composition comprises hydroxyl groups of the water soluble maltodextrin crosslinked by phosphodiester linkages; and
wherein the aqueous phosphodiester binder composition has a pH from 1 to 6.

13. The aqueous phosphodiester binder composition of claim 12 , wherein the water soluble maltodextrin has a number average molecular weight from 1,000 to 8,000.

14. The aqueous phosphodiester binder composition of claim 12 , wherein the aqueous phosphodiester binder composition does not include a catalyst to assist in the formation of the phosphodiester linkages.

Assignees

• Quinn Robert E
• Owens Corning Intellectual Capital Llc

Inventors

• Quinn Robert E

Classifications

• C08K5/053

  Polyhydroxylic alcohols · CPC title

• Y10T442/60

  Nonwoven fabric [i.e., nonwoven strand or fiber material] · CPC title

• C09D105/06

  Pectin; Derivatives thereof · CPC title

• C09D103/02

  Starch; Degradation products thereof, e.g. dextrin · CPC title

• C08K5/49

  Phosphorus-containing compounds {(C08K5/0091 takes precedence)} · CPC title