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Bio-based binder systems

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Bio-based binder systems


An environmentally friendly, bio-based binder system that is useful for the formation of fiberglass insulation, the system includes: A) an aqueous curable binder composition, which includes a carbohydrate and a crosslinking agent; and B) a dedust composition, which includes a blown, stripped plant-based oil and optionally at least one emulsifying agent. The bio-based binder system is typically heated to form a cured binder system.
Related Terms: Glass Emulsifying Emulsifying Agent

Browse recent Cargill, Incorporated patents - Wayzata, MN, US
USPTO Applicaton #: #20140083328 - Class: 1061628 (USPTO) -
Compositions: Coating Or Plastic > Miscellaneous >Carbohydrate Or Derivative Containing >With Cellulose Ether Or Salt Thereof (i.e., Mixture Of (a) A Cellulose Ether Or Salt Thereof And (b) A Carbohydrate Material Which Is Other Than Cellulose Ether Or Salt Of The Same Etherifying Radical As In (a) Differing Only In The Degree Of Etherification)

Inventors: Frank P. Lochel, Jr., John Carl Tolfa

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The Patent Description & Claims data below is from USPTO Patent Application 20140083328, Bio-based binder systems.

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CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of the U.S. Provisional Patent Application, Ser. No. 61/490,695 filed 27 May 2011, entitled BIO-BASED BINDER SYSTEMS, which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

AND INDUSTRIAL APPLICABILITY OF THE INVENTION

The present invention relates generally to rotary fiber insulation and more particularly, to a bio-based binder system for use in manufacturing mineral fiber insulation (such as fiberglass insulation and stone wool insulation) that preferably contain no added formaldehyde, and are environmentally friendly.

BACKGROUND OF THE INVENTION

Conventional fibers are useful in a variety of applications including reinforcements, textiles, and acoustical and thermal insulation materials. Although mineral fibers (e.g., glass fibers and fibers made from stone) are typically used in insulation products, depending on the particular application, organic fibers such as polypropylene, polyester, and multi-component fibers may be used alone or in combination with mineral fibers in forming the insulation product.

Fibrous insulation is typically manufactured by fiberizing a molten composition of polymer, glass, or other mineral (e.g. stone) and spinning fine fibers from a fiberizing apparatus, such as a rotating spinner. To form an insulation product, fibers produced by the rotating spinner are drawn downwardly from the spinner towards a conveyor by a blower. As the fibers move downward, a binder material is sprayed onto the fibers and the fibers are collected into a high loft, continuous blanket on the conveyor. The binder material gives the insulation product resiliency for recovery after packaging and provides stiffness and handleability so that the insulation product can be handled and applied as needed in the insulation cavities of buildings. The binder material also provides protection to the fibers from interfilament abrasion and promotes compatibility between the individual fibers.

During the formation of fiberglass insulation (or stone wool insulation), dust can be liberated by the process. A dedust fluid is often applied to the glass fibers during the process to reduce this dust. Mineral-oil based fluids are often utilized as dedust fluids.

The blanket containing the binder-coated fibers is passed through a curing oven and the binder is cured to set the blanket to a desired thickness. After the binder has cured, the fiber insulation may be cut into lengths to form individual insulation products, and the insulation products may be packaged for shipping to customer locations. One typical insulation product produced is an insulation batt or blanket, which is suitable for use as wall insulation in residential dwellings or as insulation in the attic and floor insulation cavities in buildings.

Formaldehyde-based resins have often been utilized as binding material for fiberglass insulation (and stone wool insulation). However, recently attempts have been made to reduce undesirable formaldehyde emissions from formaldehyde-based resins. For example, various formaldehyde scavengers such as ammonia and urea have been added to the formaldehyde-based resin in an attempt to reduce formaldehyde emission from the insulation product. Because of its low cost, urea is added directly to the uncured resin system to act as a formaldehyde scavenger. The addition of urea to the resin system produces urea-extended phenol-formaldehyde resole resins. These resole resins can be further treated or applied as a coating or binder and then cured. Unfortunately, the urea-extended resoles are unstable, and because of this instability, the urea-extended resoles must be prepared on site. In addition, the binder inventory must be carefully monitored to avoid processing problems caused by undesired crystalline precipitates of dimer species that may form during storage. Ammonia is not a particularly desirable alternative to urea as a formaldehyde scavenger because ammonia generates an unpleasant odor and may cause throat and nose irritation to workers. Further, the use of a formaldehyde scavenger in general is undesirable due to its potential adverse affects to the properties of the insulation product, such as lower recovery and lower stiffness.

SUMMARY

OF THE INVENTION

The inventors have surprisingly discovered that a bio-based binder system comprising a aqueous curable binder composition together with a dedust composition comprising a blown, stripped plant-based oil, wherein the total sulfur content of the system is minimized will result in a cured binder system that exhibits lower odor than a comparable binder system that has greater than 30 ppm sulfur, preferably a comparable binder system that has greater than 20 ppm sulfur (for example, greater than 15 ppm sulfur). This will provide for the manufacture of fibrous insulation product exhibiting an excellent low odor profile. This is surprising, since the sulfur content in typical binder systems utilizing formaldehyde-based binders with petroleum-based dedust oils or with plant-based dedust oils seems to have little effect on the odor properties of fibrous insulation products (e.g. fibreglass insulation and stone wool insulation) made with such formaldehyde-based binder systems.

In a first embodiment, the present invention provides a bio-based binder system useful for the formation of rotary fiber insulation (for example fiberglass insulation), the system comprising:

A) an aqueous curable binder composition comprising: (i) at least one carbohydrate, for example maltodextrin, having a dextrose equivalent number from 2 to 20; (ii) at least one crosslinking agent, for example citric acid ; and

B) a dedust composition comprising: (i) a blown, stripped plant-based oil having a viscosity of at least 200 cSt at 40° C. (for example, at least 300 cSt at 40° C.), a flash point of at least 293° C., and having an acid value less than 5.0 mg KOH/gram,

wherein the bio-based binder system comprises 10 part per million sulfur or less based on the weight of components A) and B). excluding water.

In this first embodiment, the binder composition may also include a coupling agent, a moisture resistant agent, a catalyst, an inorganic acid or base, and/or an organic acid or base. In some preferred aspects, the binder system is free of added formaldehyde and is environmentally friendly. In exemplary embodiments, the crosslinking agent includes any monomeric or polymeric polycarboxylic acid and/or their corresponding salts.

In a second embodiment, the present invention provides a cured binder system resulting from heating the binder system of the first embodiment at a temperature and for a sufficient period of time sufficient to react the carbohydrate (i) with the crosslinking agent (ii) of the binder composition A). The binder may have a light color upon curing, is environmentally friendly, and is free of added formaldehyde.

In a third embodiment, the present invention provides a fibrous insulation product comprising:

A) a plurality of randomly oriented fibers; and

B) a cured binder system applied to at least a portion of said fibers, the cured binder system comprising: (i) a cured binder composition comprising a reaction product of at least one carbohydrate (for example a maltodextrin having a dextrose equivalent number from 2 to 20), and at least one crosslinking agent(for example citric acid); and (ii) the residue from a dedust composition comprising: (a) a blown, stripped plant-based oil having a viscosity of at least 200 cSt at 40° C. (for example, at least 250 cSt, at least 300 eSt, at least 350 cSt, at least 400 cSt, at least 450 cSt, or at least 500 cSt at 40° C.) and having an acid value less than 5.0 mg KOH/gram, wherein the fibrous insulation product comprises less than 1 parts per million sulfur based on the weight of the fiberglass insulation product (for example less than 0.5 parts per million sulfur, less than 0.1 parts per million sulfur).

In a fourth embodiment, the present invention provides an insulation product formed by the process comprising: forming a plurality of randomly oriented glass fibers; applying a binder system of the first embodiment of the invention to the glass fibers to form a fibrous insulation blanket; and heating the fibrous insulation blanket to form an insulation product.

In some aspects of the invention, the dedust oil composition comprises a blown, stripped plant-based oil manufactured from oils, such as, soybean oil, canola oil, rapeseed oil, cottonseed oil, sunflower oil, palm oil, peanut oil, safflower oil, corn oil, safflower oil, corn stillage oil (as further described below), and mixtures thereof.



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stats Patent Info
Application #
US 20140083328 A1
Publish Date
03/27/2014
Document #
14122329
File Date
05/21/2012
USPTO Class
1061628
Other USPTO Classes
1061621, 10620501, 1062177
International Class
03C25/32
Drawings
2


Glass
Emulsifying
Emulsifying Agent


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