U.S. patent application number 13/495356 was filed with the patent office on 2013-12-19 for use of surfactants to improve aged properties of fiberglass insulation products.
This patent application is currently assigned to OWENS CORNING INTELLECTUAL CAPITAL, LLC. The applicant listed for this patent is Christopher M. Hawkins, Jesus M. Hernandez-Torres. Invention is credited to Christopher M. Hawkins, Jesus M. Hernandez-Torres.
Application Number | 20130334726 13/495356 |
Document ID | / |
Family ID | 49755164 |
Filed Date | 2013-12-19 |
United States Patent
Application |
20130334726 |
Kind Code |
A1 |
Hernandez-Torres; Jesus M. ;
et al. |
December 19, 2013 |
Use of Surfactants To Improve Aged Properties of Fiberglass
Insulation Products
Abstract
Fibrous insulation products manufactured with surfactants and
methods for making are disclosed. The surfactant may be neutral or
charged and, if charged, may be anionic, cationic or zwitterionic,
although neutral or non-ionic provide suitable results. The
surfactant may be of any chemical structure class, although
ethoxylated alcohols and ethoxylated ethers have been found most
suitable. Surfactant may be sprayed onto mineral fibers as a
separate dispersion or as part of a binder dispersion. The
surfactant my optionally be used with an organo-silane coupling
agent, such as an amino-silane.
Inventors: |
Hernandez-Torres; Jesus M.;
(Pataskala, OH) ; Hawkins; Christopher M.;
(Alexandria, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hernandez-Torres; Jesus M.
Hawkins; Christopher M. |
Pataskala
Alexandria |
OH
OH |
US
US |
|
|
Assignee: |
OWENS CORNING INTELLECTUAL CAPITAL,
LLC
Toledo
OH
|
Family ID: |
49755164 |
Appl. No.: |
13/495356 |
Filed: |
June 13, 2012 |
Current U.S.
Class: |
264/128 ;
264/129 |
Current CPC
Class: |
D04H 1/64 20130101 |
Class at
Publication: |
264/128 ;
264/129 |
International
Class: |
D04H 1/64 20120101
D04H001/64 |
Claims
1. A method for manufacturing a fibrous insulation product having
improved mechanical properties upon aging, the method comprising:
forming a fibrous product from a plurality of mineral fibers,
applying a thermosetting binder to the fibers of the fibrous
product, the thermosetting binder including a polyhydroxyl compound
and a polycarboxylic acid, the polyhydroxyl compound and the
polycarboxylic acid being capable of forming crosslinks, and
applying a surfactant to the fibers of the fibrous product, the
surfactant being applied to achieve a normalized concentration of
about 0.01% to about 10% based on the dry weight of the fibrous
product.
2. The method of claim 1, wherein the thermosetting binder is a
natural binder comprising a carbohydrate-based polyhydroxyl
compound and a polycarboxylic acid.
3. The method of claim 2, wherein the carbohydrate-based
polyhydroxyl compound comprises a polysaccharide selected from a
starch, a maltodextrin, a dextrin and a syrup.
4. The method of claim 2, wherein the carbohydrate-based
polyhydroxyl compound has a dextrose equivalent (DE) from about 2
to about 20.
5. The method of claim 2, wherein the polycarboxylic acid is
selected from a polyacrylic acid and an organic di- or
tri-carboxylic acid.
6. The method of claim 2, wherein the surfactant is applied as a
dispersion also containing the natural binder.
7. The method of claim 1, wherein the surfactant is applied at a
normalized concentration from about 0.05% to about 1%, based on the
dry weight of the fibrous product.
8. The method of claim 1, wherein the surfactant is a non-ionic
surfactant.
9. The method of claim 8, wherein the non-ionic surfactant is an
ethoxylated polyalcohol.
10. The method of claim 9, wherein the non-ionic surfactant is
selected from the Surfynol.RTM. series 420, 440, 465, and 485.
11. The method of claim 1, further comprising improving a
mechanical property selected from recovery, sag, compressive
strength, and tensile strength.
12. The method of claim 1, further comprising improving an aged
mechanical property selected from recovery, sag, compressive
strength, and tensile strength.
13. The method of claim 12, wherein recovery is improved by at
least 2% compared to the same product made with without
surfactant.
14. The method of claim 12, wherein sag is improved by at least 10%
compared to the same product made with without surfactant.
15. The method of claim 12, wherein compressive strength is
improved by at least 5% compared to the same product made with
without surfactant.
16. The method of claim 1, wherein the surfactant is applied in
combination with a silane coupling agent.
17. A method for improving the aged mechanical properties of a
fibrous insulation product, the method comprising: forming a
fibrous product from a plurality of mineral fibers and a natural,
thermosetting binder, the binder including a carbohydrate-based
polyhydroxyl compound and a polycarboxylic acid, the polyhydroxyl
compound and the polycarboxylic acid being capable of forming
crosslinks, and applying a surfactant to the fibers of the fibrous
product, the surfactant being applied to achieve a normalized
concentration of about 0.05% to about 5% based on the dry weight of
the fibrous product; wherein at least one aged mechanical property
is improved by at least 2% compared to fibrous product not
containing the surfactant.
18. The method of claim 17, wherein the aged mechanical property is
selected from recovery, sag, compressive strength, and tensile
strength.
19. The method of claim 17, wherein the surfactant is a non-ionic
ethoxylated polyalcohol.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to the field of
fiberglass insulation, including panels and methods to improve the
product properties thereof, more specifically, mechanical
properties such as sag and recovery after aging. The invention
applies to all forms of fibrous insulation, including ceiling
boards and tiles, wall panels, duct boards, pipe and molded or
formed insulation products, but has most relevance for light to
medium density fibrous insulation batts, such as used in the wall
and ceiling cavities of homes and buildings.
[0002] Fibrous insulation and construction panels are typically
manufactured by fiberizing a molten composition of polymer, glass
or other mineral material to form fine fibers and depositing the
fibers on a collecting conveyor to form a batt or a blanket.
Mineral fibers, such as glass fibers, are typically used in
insulation products. A binder composition may optionally be used to
bond the fibers together where they contact each other. During the
manufacturing process some insulation products are formed and cut
to provide sizes generally dimensioned to be compatible with
standard construction practices, e.g. standard sized wall or
ceiling panels having widths and/or length adapted for specific
building practices. Some insulation products also incorporate a
facing layer or material on at least one of the major surfaces. In
many cases the facing material is provided as a vapor barrier,
while in other insulation products, such as binderless products,
the facing material improves the product integrity. Other
insulation products may be used on structures such as, for example,
pipes, ducts, appliances and other devices. The use of insulation
on these structures assists to maintain a thermal difference
between the structure and the environment. However, in some
environments, moisture may be present and may infiltrate the
insulation. This can cause the insulation to be less effective than
intended and cause other issues.
[0003] Surfactants have been used in fibrous insulation
products--as a component of a binder composition--primarily as a
wetting agent to promote the distribution of binder throughout the
fibrous product (see e.g. WO 2011/044490 to Hawkins, et al.)
Hawkins et al characterize the surfactant as a process aid "to
assist in binder atomization, wetting, and interfacial adhesion."
This is because natural or bio-based binders comprising starch or
other polysaccharides exhibit extensive hydrogen bonding and can
become very viscous and sticky, particularly at high
concentrations. A surfactant or wetting agent can reduce the
surface tension and more readily allow the thick binder dispersion
to flow along and wet the glass fibers. In Example 11, Hawkins et
al. disclose data showing a reduced surface tension in binder
compositions containing various surfactants.
[0004] In Table 30, Hawkins et al. show the impact of steam aging
(a form of accelerating testing) on tensile strength and tensile
strength normalized by LOI content, for handsheets containing
various titanate coupling agents. All coupling agent except Tyzor
TPT reduced the initial ambient tensile strength/LOI ratio; and all
titanate coupling agents reduced the steam-aged tensile
strength/LOI ratio. Furthermore, the disparity between ambient and
aged tensile strength/LOI ratios is the least when no coupling
agent is used; each coupling agent tested broadened the disparity
between ambient and steam-aged properties, most egregiously with
Tyzor TPT.
[0005] The present invention seeks to address these problems and
others.
SUMMARY OF THE INVENTION
[0006] In general, the invention relates to the addition of
surfactant additives to fibrous insulation products. The addition
results in certain improved properties that are unexpected; for
example, improved mechanical properties of products that have been
aged in hot and humid conditions.
[0007] Thus, in a first aspect, the invention provides a method for
manufacturing a fibrous insulation product having improved
mechanical properties upon aging, the method comprising:
[0008] forming a fibrous product from a plurality of mineral
fibers,
[0009] applying a thermosetting binder to the fibers of the fibrous
product, the thermosetting binder including a polyhydroxyl compound
and a polycarboxylic acid, the polyhydroxyl compound and the
polycarboxylic acid being capable of forming crosslinks, and
[0010] applying a surfactant to the fibers of the fibrous product,
the surfactant being applied to achieve a normalized concentration
of about 0.01% to about 10% based on the dry weight of the fibrous
product.
[0011] In a second aspect, the invention provides a method for
improving the aged mechanical properties of a fibrous insulation
product, the method comprising:
[0012] forming a fibrous product from a plurality of mineral fibers
and a natural, thermosetting binder, the binder including a
carbohydrate-based polyhydroxyl compound and a polycarboxylic acid,
the polyhydroxyl compound and the polycarboxylic acid being capable
of forming crosslinks, and
[0013] applying a surfactant to the fibers of the fibrous product,
the surfactant being applied to achieve a normalized concentration
of about 0.05% to about 5% based on the dry weight of the fibrous
product; wherein at least one aged mechanical property is improved
by at least 2% compared to fibrous product not containing the
surfactant
[0014] The following optional features may be provided in either
aspect of the invention. The surfactant may be applied at a
normalized concentration (based on the dry weight of the fibrous
product) from about 0.05% to about 1%, from about 0.01% to about
5.0% by weight, or from about 0.05% to about 0.5% by weight, or
from about 0.1% to about 0.5%. The surfactant may be applied as
part of a binder dispersion or independently. The surfactant may be
an ionic (anionic, cationic or zwitterionic) or a non-ionic
surfactant. In some embodiments, the surfactant is an ethoxylated
polyalcohol, such as one selected from the Surfynol.RTM. series
420, 440, 465, and 485. In some embodiments, the surfactant is
applied in combination with a silane coupling agent.
[0015] The binder may be a natural binder, such as one comprising a
carbohydrate-based polyhydroxyl compound and a polycarboxylic acid.
The carbohydrate-based polyhydroxyl compound may comprise a
polysaccharide selected from a starch, a maltodextrin, a dextrin
and a syrup; or it may be a monosaccharide or disaccharide
carbohydrate. In some embodiments, the carbohydrate-based
polyhydroxyl compound has a dextrose equivalent (DE) from about 2
to about 20. In some embodiments, the polycarboxylic acid is
selected from a polyacrylic acid or an organic di- or
tri-carboxylic acid.
[0016] A feature of the invention is the surprising ability to
improve a mechanical property of the fibrous insulation product.
Such a mechanical property may be any one or more of: e.g.
recovery, sag, compressive strength, and tensile strength. While an
initial or ambient mechanical property may be affected, it is the
improvement of aged properties that is most surprising. When the
aged property is recovery, it may be improved by at least 2%, at
least 5%, at least 10%, or more compared to the same product made
with without surfactant. When the aged property is sag, it may be
improved by at least 5%, at least 10%, at least 20% or more
compared to the same product made with without surfactant. When the
aged property is compressive strength, it may be improved by at
least 5%, at least 10% or at least 15% compared to the same product
made with without surfactant.
[0017] Other advantages and features and variations will become
apparent to those skilled in the art from the following detailed
description of various embodiments, when read in light of the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The accompanying drawings, incorporated herein and forming a
part of the specification, illustrate the present invention in its
several aspects and, together with the description, serve to
explain the principles of the invention. In the drawings, the
thickness of the lines, layers, and regions may be exaggerated for
clarity.
[0019] FIG. 1 is a diagrammatic side elevation view of fibrous
product manufacturing line; and
[0020] FIGS. 2-4, are charts of data described in the examples;
DETAILED DESCRIPTION
[0021] Unless defined otherwise, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which the invention belongs. Although
any methods and materials similar or equivalent to those described
herein can be used in the practice or testing of the present
invention, the preferred methods and materials are described
herein. All references cited herein, including books, journal
articles, published U.S. or foreign patent applications, issued
U.S. or foreign patents, and any other references, are each
incorporated by reference in their entireties, including all data,
tables, figures, and text presented in the cited references.
[0022] Unless otherwise indicated, all numbers expressing ranges of
magnitudes, such as angular degrees or web speeds, quantities of
ingredients, properties such as molecular weight, reaction
conditions, dimensions and so forth as used in the specification
and claims are to be understood as being modified in all instances
by the term "about." Accordingly, unless otherwise indicated, the
numerical properties set forth in the specification and claims are
approximations that may vary depending on the desired properties
sought to be obtained in embodiments of the present invention.
Notwithstanding that the numerical ranges and parameters setting
forth the broad scope of the invention are approximations, the
numerical values set forth in the specific examples are reported as
precisely as possible. Any numerical values, however, inherently
contain certain errors necessarily resulting from error found in
their respective measurements. All numerical ranges are understood
to include all possible incremental sub-ranges within the outer
boundaries of the range. Thus, a range of 30 to 90 degrees
discloses, for example, 35 to 50 degrees, 45 to 85 degrees, and 40
to 80 degrees, etc.
[0023] Fibrous insulation products are designed to block the
transfer of heat. Heat may be transferred through a fibrous glass
pack by three distinct methods: convection, conduction and
radiation. Convection, i.e. flow of fluid (air) through the pack
includes flow driven by external forces, such as wind, fans or
blowers and natural or free flow driven by conditions within the
pack, such as thermal or density gradients; similarly, conduction
includes conduction by air, glass or any other compounds present
within the pack. The term "R-value" is the commercial unit used to
measure the effectiveness of thermal insulation and is the
reciprocal of its thermal conductance which, for "slab" materials
having substantially parallel faces, is defined as the rate of flow
of thermal energy (BTU/hr or Watt) per unit area (square
foot=ft.sup.2 or square meter=m.sup.2) per degree of temperature
difference (Fahrenheit or Kelvin) across the thickness of the slab
material (inches or meters). Inconsistencies in the literature
sometimes confuse the intrinsic thermal properties resistivity, r,
(and conductivity, k), with the total material properties
resistance, R, (and conductance, C), the difference being that the
intrinsic properties are defined as being per unit thickness,
whereas resistance and conductance (often modified by "total") are
dependent on the thickness of the material, which may or may not be
1 unit. This confusion, compounded by multiple measurement systems,
produces an array of complex and confusing units the most common of
which are:
TABLE-US-00001 English (inch-pound) Metric/SI units Intrinsic
resistivity, r (conductivity, k, is reciprocal) hr * ft 2 *
.degree.F . BTU * in ##EQU00001## K * m W ##EQU00002## Total
material resistance, R (conductance, C, is reciprocal) hr * ft 2 *
.degree.F . BTU ##EQU00003## K * m 2 W ##EQU00004##
[0024] For ease of comparisons of materials of differing
thicknesses, the building industry sometimes reports thermal
resistance (or conductance) per unit thickness (e.g. per inch)
effectively converting it to thermal resistivity (conductivity),
but retains the traditional symbol, R or R-value. It is further
observed that the "conductivity" referenced above includes the
total heat transfer by any of the mechanisms described above, not
just by conduction. Thermal conductivity and resistivity may be
measured using commercial instruments like the FOX instruments
(LaserComp, Saugus, Mass.) according to ASTM C518 or other standard
protocols.
Fibrous Product Manufacture
[0025] Although other types of fibrous products and manufacturing
processes are known, the invention is well exemplified by the
manufacture of glass fiber insulation carried out in a continuous
process by rotary fiberization of molten glass as depicted in FIG.
1. Glass or other mineral material may be melted in a tank or
melter (not shown) and supplied by a forehearth (not shown) to a
"fiberizer" or fiber forming device such as a fiberizing spinner
15. The spinners 15 are rotated at high speeds so that centrifugal
force causes the molten glass to pass through holes in the
circumferential sidewalls of the fiberizing spinners 15 to form
primary glass fibers. Secondary glass fibers 30 of random lengths
may be attenuated from the fiberizing spinners 15 and blown
generally downwardly, that is, generally perpendicular to the plane
of the spinners 15, by blowers 20 positioned within a forming
chamber 25. It is to be appreciated that the glass fibers 30 may
all be the same type of glass or they may be formed of different
types of glass, or even of other molten mineral materials. It is
also within the purview of the present invention that at least one
of the fibers 30 formed from the fiberizing spinners 15 is a dual
glass fiber where each individual fiber is formed of two different
glass compositions. The glass fibers 30 may have a diameter from
about 2 to about 9 microns, or from about 3 to about 6 microns.
[0026] The blowers 20 direct the fibers 30 toward a foraminous
chain or conveyor 45 to form a fibrous pack 40. The glass fibers,
while in transit in the forming chamber 25 and while still hot from
the drawing operation, are sprayed with a binder composition by an
annular spray ring 35 so as to result in a distribution of the
binder composition throughout the formed insulation pack 40 of
fibrous glass. Coolant such as water may also be applied to the
glass fibers 30 in the forming chamber 25, typically by spraying
using a ring system similar to ring 35. Often coolant water is
applied prior to the application of the aqueous binder composition
to at least partially cool the glass fibers 30. The binder is
typically applied in an amount from about 1% to 30% by weight of
the total fibrous product, more usually from about 2% to about 20%
or from about 3% to about 17%.
[0027] The glass fibers 30 having the uncured resinous binder
adhered thereto may be gathered and formed into an uncured
insulation pack 40 on an endless forming conveyor 45 within the
forming chamber 25 with the aid of a vacuum (not shown) drawn
through the fibrous pack 40 from below the forming conveyor 45. The
residual heat from the glass fibers 30 and the flow of air through
the fibrous pack 40 during the forming operation are generally
sufficient to volatilize a majority of the water from the binder
before the glass fibers 30 exit the forming chamber 25, thereby
leaving the remaining components of the binder on the fibers 30 as
a viscous or semi-viscous high-solids liquid.
[0028] The coated fibrous pack 40, which is in a compressed state
due to the flow of air through the pack 40 in the forming chamber
25, is then transferred out of the forming chamber 25 under exit
roller 50 to a transfer zone 55 where the pack 40 vertically
expands due to the resiliency of the glass fibers. The expanded
insulation pack 40 is then heated, such as by conveying the pack 40
through a curing oven 60 where heated air is blown through the
insulation pack 40 to evaporate any remaining water in the binder,
cure the binder, and rigidly bond the fibers together. Heated air
is forced though a fan 75 through the lower oven conveyor 70, the
insulation pack 40, the upper oven conveyor 65, and out of the
curing oven 60 through an exhaust apparatus 80. Although only one
oven zone is depicted in FIG. 1, there may be multiple zones used
to dry and cure the fibrous product. The cured binder imparts
strength and resiliency to the insulation blanket 10, depending on
the nature and properties of the particular insulation product
being manufactured.
[0029] Also, in the curing oven 60, the insulation pack 40 may be
compressed by upper and lower foraminous oven conveyors 65, 70 to
form a fibrous insulation blanket 10. It is to be appreciated that
the insulation blanket 10 has an upper surface and a lower surface.
In particular, the insulation blanket 10 has two major surfaces,
typically a top and bottom surface, and two minor or side surfaces
with fiber blanket 10 oriented so that the major surfaces have a
substantially horizontal orientation. The upper and lower oven
conveyors 65, 70 may be used to compress the insulation pack 40 to
give the insulation blanket 10 a predetermined thickness. It is to
be appreciated that although FIG. 1 depicts the conveyors 65, 70 as
being in a substantially parallel orientation, they may
alternatively be positioned at an angle relative to each other (not
illustrated).
[0030] The curing oven 60 may be operated at a temperature from
about 100.degree. C. to about 325.degree. C., or from about
250.degree. C. to about 300.degree. C. The insulation pack 40 may
remain within the oven for a period of time sufficient to drive off
excess water and to crosslink (cure) the binder and form the
insulation blanket 10.
[0031] A facing material 93 may optionally be placed on the
insulation blanket 10 to form a facing layer 95. It should be
appreciated that a flexible "blanket" insulation product is
depicted in FIG. 1, but the insulation product may also be a rigid
panel or board-type insulation product. Non-limiting examples of
suitable facing materials 93 include fiberglass mats, Kraft paper,
a foil-scrim-Kraft paper laminate, recycled paper, and calendared
paper. The facing material 93 may be adhered to the surface of the
insulation blanket 10 (board) by a bonding agent (not shown in FIG.
1) to form a faced insulation product 97. When sufficiently
flexible, the faced fibrous insulation 97 may subsequently be
rolled for storage and/or shipment or cut into predetermined
lengths by a cutting device (not illustrated). Such faced
insulation products may be used, for example, as panels in basement
finishing systems, as ductwrap, ductboard, as faced residential
insulation, as construction panels for walls and ceilings, and as
pipe insulation.
[0032] Fibrous products are generally formed of matted fibers,
often bonded together by a cured thermoset or thermoplastic
polymeric material. Examples of suitable fibers include mineral
fibers such as glass fibers, wool glass fibers, rock, basalt, slag
and ceramic fibers. For example, the glass fibers may be produced
from a variety of natural minerals or manufactured chemicals such
as silica sand, limestone, and soda ash. Other ingredients may
include calcined alumina, borax, feldspar, nepheline syenite,
magnesite, and kaolin clay. Optionally, other fibers such as
natural fibers and/or synthetic fibers such as polyester,
polyethylene, polyethylene terephthalate, polypropylene, polyamide,
polyvinyl alcohol, aramid, and/or polyaramid fibers may be present
in the insulation product in addition to the glass fibers. The term
"natural fiber" as used in conjunction with the present invention
refers to plant fibers extracted from any part of a plant,
including, but not limited to, the stem, seeds, leaves, roots, or
phloem. Examples of natural fibers suitable for use as the
reinforcing fiber material include cellulose, basalt, cotton, jute,
bamboo, ramie, bagasse, hemp, coir, linen, kenaf, sisal, flax,
henequen, and combinations thereof. Insulation products may be
formed entirely of one type of fiber, or they may be formed of a
combination of types of fibers. For example, the insulation product
may be formed of combinations of various types of glass fibers or
various combinations of different inorganic fibers and/or natural
fibers depending on the desired application for the insulation.
While other natural, polymeric and mineral fibers are known, the
embodiments described herein are primarily with reference to glass
fiber insulation products.
[0033] The term "fibrous products" is general and encompasses a
variety of articles of manufacture. This has already been noted and
is evident from table B, below. "Fibrous products" may be
characterized and categorized by many different properties, one of
which is density. Density may range broadly from about 0.2
pounds/cubic foot ("pcf") to as high as about 10 pcf, depending on
the product. Low or light density insulation batts and blankets
typically have densities between about 0.2 pcf and about 5 pcf,
more commonly from about 0.3 to about 4 pcf, and have applications
rates of about 2-13% LOI. Products such as residential insulation
batts may fall in this group.
[0034] Fiberglass insulation products can be provided in other
forms including board (a heated and compressed batt) and molding
media (an alternative form of heated and compressed batt) for use
in different applications. Fibrous products also include higher
density products having densities from about 10 to about 20 pcf,
(and often having binder LOI in excess of 12%) and medium density
products more typically having a density from about 1 pcf to about
10 pcf, (and having binder LOI of about 7-16 wt % LOI) such as
boards and panels. Medium and higher density insulation products
may be used in industrial and/or commercial applications, including
but not limited to metal building insulation, pipe or tank
insulation, insulative ceiling and wall panels, duct boards and
HVAC insulation, appliance and automotive insulation, etc.
[0035] Another property useful for categorization is the rigidity
of the product. Residential insulation batts are typically quite
flexible and they can be compressed into rolls or batts while
recovering their "loft" upon decompression. In contrast, other
fibrous products, such as ceiling tiles, wall panels, foundation
boards and certain pipe insulation to mention a few, are quite
rigid and inflexible by design. These products will flex very
little and are unlikely to be adapted or conformed to a particular
space.
[0036] Formed or shaped products may include a further step,
optionally during cure, that compresses, molds or shapes the
product to its specific final shape. Rigid boards are a type of
shaped product, the shape being planar. Other shaped products may
be formed by dies or molds or other forming apparatus. Rigidity may
be imparted by the use of higher density of fibers and/or by higher
levels of binder application. As an alternative to rotary
fiberizing, some fibrous insulation products, particularly higher
density, non-woven insulation products, may be manufactured by an
air-laid or wet-laid process using premade fibers of glass, other
minerals or polymers that are scattered into a random orientation
and contacted with binder to form the product.
[0037] Some exemplary fibrous products that can be manufactured
according to the invention include those illustrated in Table A
below.
TABLE-US-00002 TABLE A Bio-based binder formulations for
representative products* Flexible Metal Building Warm & Dry
Ceiling Tile boards Duct Media Insulation boards A B C Maltodextrin
65-70 65-70 65-70 65-70 45-60 10-50 Citric Acid 25-30 25-30 25-30
25-30 30-35 20-40 Polyacrylic Acid 10-60 Sodium 2-5 2-5 2-5 2-5 2-5
2-10 hypophosphite Glycerol 10-15 5-15 Surfactant (e.g. 0-0.5 0-0.5
0.1-0.5 0.1-0.5 0.1-0.5 0.1-0.5 SURFYNOL 465) Reactive 0.01-5.0
0.01-5.0 0.4-3.0 0.01-3.0 0.01-3.0 0.01-3.0 polysiloxane *In Table
A above, each ingredient of the binder composition is given as a
range of typical values of percentage of dry weight of the binder
composition.
[0038] A further listing of insulation fibrous products that can be
manufactured using a bio-based binder composition according to the
invention is set forth in Table B, below. Insulation products such
as ceiling tiles, wall panels and other construction panels may
have having finished facings layers 93. These products generally
have finished surfaces designed to be the outermost layer of
ceilings or walls in buildings such as homes, offices, etc.
TABLE-US-00003 TABLE B Selected Commercial and Industrial Fibrous
Products which may use a Bio-Based Binder Flexible, Light Density
Rigid Pipe Insulation Textile E-glass Rigid Boards Insulation and
pipe rolls Nonwoven Density Wide range of densities- Light density
- Ranging from 0.3 to Ranging from 3-6 pcf Ranging from 0.8 to 4
pcf from 1.5 to 10 pcf 4.0 pcf Binder content about 2 to about 20%
LOI about 2 to about 13% LOI about 3 to about 15% LOI about 5 to
about 20% LOI Manufacturing Rotary fiber forming Rotary fiber
forming process Rotary fiber forming Air-laid nonwoven process
method process process plus on or offline molding/pipe formation
process Exemplary QUIET R Duct Board Certified R Metal Building
EVOLUTION Paper-Free QUIET R Textile Duct Owens Corning QUIET R
Duct Liner Insulation ASJ Liner Products Board ELAMINATOR .RTM.
Pre-Engineered VAPORWICK Insulation DURAFLEX 700 Series Insulation
Metal Roof Insulation FIBERGLAS .TM. Pipe and Transportation
Insul-Quick Insulation MBI Plus Tank Insulation rolls SCR
Insulation Board Metal Bldg Utility Blanket Curtainwall Unfaced
Metal Building Insulation QuietZone Shaftwall for Canada Warm-N-Dri
Flexible Duct Media Insulation Energy Board QUIET R Rotary Duct
Liner TremDrain SOFTR Duct Wrap FRK Exterior Foundation TTW Types I
and II Barrier Board FLEX-Wrap for pipes and tanks Ceiling Board
Blanks H2V Series RA Series Select Sound Thermorange FlameSpread 25
Sonobatts Thermal Batts
[0039] "Product properties" or "mechanical properties" refers to a
battery of testable physical properties that insulation products
possess. These may include at least the following common
properties: [0040] "Recovery" --which is the ability of the batt or
blanket to resume its original or designed thickness following
release from compression during packaging or storage. It may be
tested by measuring the post-compression height of a product of
known or intended nominal thickness, or by other suitable means.
[0041] "Restoring Force" --which is like Recovery in measuring the
batt's ability to resume its original thickness. However, for
Restoring Force, the height of expansion is restricted and the
force exerted by expansion is measured by a scale or other force
measuring device or gauge. [0042] "Stiffness" or "sag" --which
refers to the ability of a batt or blanket to remain rigid and hold
its linear shape. It is measured by draping a fixed length section
over a fulcrum and measuring the angular extent of bending
deflection, or sag. Lower values indicate a stiffer and more
desirable product property. Other means may be used. [0043]
"Tensile Strength" --which refers to the force that is required to
tear the fibrous product in two. It is typically measured in both
the machine direction (MD or X-axis) and in the cross machine
direction ("CD" or "XMD" or Y-axis); and sometimes in a depth or
Z-axis direction as well. [0044] "Compressive Strength" --which
refers to the force that is required compress the fibrous
insulation product. This may be measured as the force required to
compress the batt (or package) a predetermined distance, or as the
distance compressed by a predetermined force. It may be measured in
any of three directions as with tensile strength, but CD is most
typical. [0045] "Lateral weight distribution" (LWD or "cross
weight") --which is the relative uniformity or homogeneity of the
product throughout its width. It may also be thought of as the
uniformity of density of the product, and may be measured by
sectioning the product longitudinally into bands of equal width
(and size) and weighing the band, by a nuclear density gauge, or by
other suitable means. [0046] "Vertical weight distribution" (VWD)
--which is the relative uniformity or homogeneity of the product
throughout its thickness. It may also be thought of as the
uniformity of density of the product, and may be measured by
sectioning the product horizontally into layers of equal thickness
(and size) and weighing the layers, by a nuclear density gauge, or
by other suitable means.
[0047] Of course, other product properties may also be used in the
evaluation of final product, but the above product properties are
ones found important to consumers of insulation products.
Mechanical product properties may be tested relatively soon after
manufacture--a time referred to herein as "initial" or "ambient"
even if it is days or weeks due to shipping lag. But over time, the
mechanical properties may degrade so that a more relevant test is
one that measures "aged" mechanical properties. Aging may be
natural, real-time aging over the course of several months or
years. More typically "aging" is simulated in proxy, accelerated
aging conditions, as in the case of hot and humid test conditions.
While either type of aging produced "aged" properties that can be
measured, the accelerated versions are reasonable proxies that can
be tested in a matter of days rather than months.
[0048] It should be appreciated that, so some extent, the absolute
measures of these mechanical product properties may be dependent on
how much binder is applied to the fibers. Denser and more rigid
products are typically manufactured, in part, by using higher
levels of binder. The measure of how much binder is applied to
glass fiber products is known as LOI, or loss on ignition, measured
by the weight difference after burning off the organic binder
components.
[0049] In some cases it is desirable to compute a percent
improvement in a mechanical property. This is calculated as the
difference in the measured property divided by the property in the
control product. Depending on the specific property and the level
of loading of the surfactant in accordance with the invention, one
finds improvement of mechanical properties of at least 2%, at least
5%, at least 10%, at least 15%, at least 20% or at least 25%.
Binder Compositions
[0050] Binder compositions are well known in the industry. Binders
are typically applied to the fibers as an aqueous solution or
dispersion shortly after the fibers are formed and then cured at
elevated temperatures. The curing conditions are selected both to
evaporate any remaining solvent and cure the binder to a thermoset
state. The fibers in the resulting product tend to be partially
coated with a thin layer of the thermoset resin and exhibit
accumulations of the binder composition at points where fibers
touch or are positioned closely adjacent to each other. In one
embodiment, phenol-formaldehyde binders are used with polysiloxane
additives to provide increased water and stain resistance to the
insulation product. Phenol-formaldehyde binders are generally
characterized by relatively low viscosity when uncured, and the
formation of a rigid thermoset polymeric matrix with the fibers
when cured. A low-viscosity uncured binder simplifies binder
application and allows the binder-coated batt to expand more easily
when the forming chamber compression is removed. Similarly, the
rigid matrix formed by curing the binder allows a finished fiber
product to be compressed for packaging and shipping and then
recover to substantially its full original dimension when unpacked
for installation. As used herein, "dispersion" includes all forms
of solids dispersed in a liquid medium, regardless of the size of
the particle or properties of the dispersion, including true
"solutions" in which the solids are soluble and dissolved in the
liquid medium.
[0051] In other embodiments, formaldehyde-free binders may also be
used in combination with additives that increase the insulation
products resistance to water. Nonphenol/formaldehyde binders
exhibit low uncured viscosity and structural rigidity when cured.
One such binder composition is disclosed in U.S. Pat. No.
5,318,990, which is herein incorporated, in its entirety, by
reference, and utilizes a polycarboxy polymer, a monomeric
trihydric alcohol and a catalyst comprising an alkali metal salt of
a phosphorous containing organic acid. Other binder compositions
have also been developed to provide reduced emissions during the
coating and curing processes utilizing compounds such as
polyacrylic acid as disclosed in U.S. Pat. Nos. 5,670,585 and
5,538,761, which are herein incorporated, in their entirety, by
reference.
[0052] Although the invention may be employed with traditional
phenol-formaldehyde (PF) or phenol-urea-formaldehyde (PUF) binders,
in other embodiments, the invention is employed with
formaldehyde-free binders, such as polyacrylic acid binders
utilizing as described in U.S. Pat. Nos. 6,884,849 and 6,699,945 to
Chen, et al. Another polyacrylic binder composition is disclosed in
U.S. Pat. No. 5,661,213, which teaches an aqueous composition
comprising a polyacid, a polyol and a phosphorous-containing
accelerator, wherein the ratio of the number of equivalents of the
polyacid to the number of equivalents of the polyol is from about
100:1 to about 1:3 and is hereby fully incorporated by reference.
As disclosed in U.S. Pat. No. 6,399,694, which hereby also fully
incorporated by reference, another alternative to the PUF binders
utilizes polyacrylic acid and either glycerol (PAG) or
triethanolamine (PAT) as a binder. PAG/PAT binders are relatively
odorless, more uniformly coat each fiber and have a generally white
or light color.
[0053] Also useful are binders made from natural starches (or
dextrins, maltodextrins or other polysaccharides of varying length)
and polyfunctional carboxylic acids like citric acid (MD/CA), such
as those disclosed in US2011/0086567 and WO 2011/044490, published
Apr. 14, 2011, all incorporated by reference. These
polyhydroxyl-carboxylic acid-based binder systems, however, are
also described herein.
[0054] Polyhydroxyl Compounds
[0055] By definition, the polyhydroxy compound or polyol is
polyvalent, having two or more hydroxyl groups that can be
available for reaction. While a polyol has a minimum of two
hydroxyl groups, there is no theoretical maximum number of hydroxyl
groups. Diols, triols, tetraols, penta-ols, hexa-ols and higher
polyols are all encompassed, particularly in polymeric compounds.
The polyol may be monomeric or polymeric; and may be natural or
synthetic. In some embodiments, the polyol may be smaller monomeric
compounds like glycerol, ethylene glycol, propanediols,
propanetriols, trimethylol propane, erythritol or other
butane-based polyols, pentaeythritol, triethanolamine (TEOA), or
1,2,6-hexane-triol; or any monosaccharide having at least 4
carbons, including pentoses and hexoses.
[0056] In other embodiments, the polyol may be a synthetic or
naturally occurring polymer, such as polyvinyl alcohol,
polyglycerol, poly(ether) polyols, poly(ester) polyols,
polyethylene glycol, polyol- and hydroxy-functional acrylic resins
such as JONCRYL.RTM. (BASF Resins), MACRYNAL.RTM. (Cytec
Industries) PARALOID.RTM. (Dow Coating Materials), G-CURE.RTM.,
TSAX.RTM. and SETALUX.RTM. (Nuplex Resins, LLC) in solution or
emulsion form; or di-, tri- and higher polysaccharides.
[0057] Due to the wide variability in molecular weights of the
polyol component and (as discussed below) the crosslinking agent,
the weight ratios of the various components of the binder
composition can vary tremendously. Thus, polyol (polyhydroxyl)
component may be present in the binder composition in an amount
from about 1% to about 99% by weight of the total solids in the
binder composition, more likely from about 20% to about 99% by
weight of the total solids in the binder composition. As is common
in the industry and as used herein, % by weight indicates % by
weight of the total solids (i.e. dry weight, without water) in the
binder composition. For purposes of this application, this is
synonymous with "% binder solids" and "% total solids" where
discussing binder dispersions.
[0058] In some exemplary embodiments, the polyol component is a
carbohydrate, such as a starch or maltodextrin, and the binder
further includes a crosslinking agent. In some exemplary
embodiments, the carbohydrate-based binder composition also
includes a coupling agent, a process aid agent, an extender, a pH
adjuster, a catalyst, a crosslinking density enhancer, a deodorant,
an antioxidant, a dust suppressing agent, a biocide, a moisture
resistant agent, a surfactant, or combinations thereof. The binder
may be used in the formation of many insulation materials,
including but not limited to batts, rolls, construction panels,
etc. In addition, the binder is free of added formaldehyde.
Further, the binder composition has a reduction in particulate
emission compared to conventional phenol/urea/formaldehyde binder
compositions. The inventive binder may also be useful in forming
particleboard, plywood, and/or hardboards.
[0059] In one or more exemplary embodiments, the binder includes at
least one polyol that is natural in origin and derived from
renewable resources. For instance, the polyol may be a carbohydrate
derived from plant sources such as legumes, maize, corn, waxy corn,
sugar cane, milo, white milo, potatoes, sweet potatoes, tapioca,
rice, waxy rice, peas, sago, wheat, oat, barley, rye, amaranth,
and/or cassaya, as well as other plants that have a high starch
content. As is well known in the arts, starches can be degraded
into a wide variety of polysaccharides of various length, molecular
weight and other properties, specifically including but not limited
to dextrins, maltodextrins, and syrups of varying conversion from
low to very high. The carbohydrate polymer may also be derived from
crude starch-containing products derived from plants that contain
residues of proteins, polypeptides, lipids, and low molecular
weight carbohydrates.
[0060] As noted, the carbohydrate may be selected from
monosaccharides, including but not limited to erythrose,
erythulose, threose, ribose, ribulose, arabinose, xylose, xylulose,
glucose, dextrose (or D-glucose), mannose, glactose, fructose, and
sorbose; disaccharides, including but not limited to maltose,
sucrose, lactose, cellobiose and trehalose; oligosaccharides (e.g.,
glucose syrup and fructose syrup); and polysaccharides (e.g.,
pectin, dextrin, maltodextrin, starch, modified starch, and starch
derivatives), provided they can be prepared as water dispersions,
which includes emulsions, suspensions, colloids and true solutions.
All isomeric and stereochemical forms of these saccharides are
encompassed in the invention. Furthermore, derivatives of
saccharides may also be suitable, provided they retain their
polyvalent polyol nature after derivatization. Thus, the polyol may
include O-glycosides, N-glycosides, S-glycosides, C-glycosides,
O-alkyl (e.g. methyl, ethyl), O-acylated sugars, amino sugars,
sugar alcohols (like sorbitol, xylitol, erythritol, etc.) and the
like.
[0061] The carbohydrate polymer may have a number average molecular
weight from about 1,000 to about 8,000. Additionally, the
carbohydrate polymer may have a dextrose equivalent (DE) number
from 2 to 20, from 5 to 15, or from 7 to 12. The carbohydrate
dispersions beneficially have a low viscosity and cure at moderate
temperatures (e.g., 80-250.degree. C.) alone or with additives. The
low viscosity enables the carbohydrate to be utilized in a binder
composition. The use of a carbohydrate in the inventive binder
composition is advantageous in that carbohydrates are readily
available or easily obtainable and are low in cost.
[0062] In at least one exemplary embodiment, the carbohydrate is a
water-soluble polysaccharide such as dextrin or maltodextrin. The
carbohydrate polymer may be present in the binder composition in an
amount from about 20% to about 90% by weight of the total solids in
the binder composition, from about 45% to about 85% by weight of
the total solids in the binder composition, from about 50% to about
80%, or from about 55% to about 75%.
[0063] It will be understood that mixtures or blends of two or more
polyhydroxyl compounds of the same or different type may be used in
a binder composition. For example, but not as a limitation, blends
of any of the following may be envisioned: [0064] Two different
monosaccharides, such as glucose with fructose or sorbose; [0065]
Two different polysaccharides, such as dextrin and a maltodextrin
or syrup; [0066] A polysaccharide and a mono- or oligosaccharide;
[0067] A polysaccharide and a synthetic polyol such as glycerol;
and [0068] A mono- or oligosaccharide with a synthetic polyol such
as glycerol.
[0069] Polycarboxylic Acid Crosslinking Agents
[0070] In addition, the binder composition contains a
polycarboxylic acid crosslinking agent suitable for crosslinking
the polyhydroxyl compound. In exemplary embodiments, the
crosslinking agent has a number average molecular weight greater
than 90, from about 90 to about 10,000, or from about 190 to about
4,000. In some exemplary embodiments, the crosslinking agent has a
number average molecular weight less than about 1000. Non-limiting
examples of suitable crosslinking agents include di-, tri- and
polycarboxylic acids (and salts thereof), anhydrides, monomeric and
polymeric polycarboxylic acid with anhydride (i.e., mixed
anhydrides), malonic acid, succinic acid, glutaric acid, maleic
acid, citric acid (including salts thereof, such as ammonium
citrate), 1,2,3,4-butane tetracarboxylic acid, adipic acid,
polyacrylic acid, and polyacrylic acid based resins such as QXRP
1734, 1629 and Acumer 9932, all commercially available from The Dow
Chemical Company. In exemplary embodiments, the crosslinking agent
may be any monomeric or polymeric polycarboxylic acid, citric acid,
and their corresponding salts. For each type of acid, it should be
understood that acid salts may also be used in place of the acids.
It should also be understood that mixtures or blends of two or more
different polycarboxylic acids may be used.
[0071] The nomenclature of the polycarboxylic acid as the
crosslinking agent is somewhat arbitrary. The polyhydroxyl compound
and polycarboxylic acid react and it is a matter of convenience to
think of the typically smaller polycarboxylic acid as crosslinking
the typically larger polyhydroxyl polymer. However, it is equally
plausible to consider a larger polymeric polycarboxylic acid that
is crosslinked by a smaller polyhydroxyl molecule (e.g. glycerol or
TEOA).
[0072] The crosslinking agent may be present in the binder
composition in an amount up to about 50% by weight of the binder
composition. In exemplary embodiments, the crosslinking agent may
be present in the binder composition in an amount from about 20% to
about 40% by weight of the total solids in the binder composition
or from about 25% to about 35% by weight.
[0073] It should be understood that application of surfactant
and/or optional silane coupling agent, as described in sections
below, may conveniently be done through incorporation of those
agents into a binder dispersion. Consequently, the concentration of
these agents is often expressed on the basis of a binder
composition weight. However, this is not the only means for
applying surfactant or silane to the fibrous materials. Other known
spray nozzles, dispensers, or roll coating operations are also
suitable mechanisms for applying these agents to the mineral
fibers.
Surfactants
[0074] Surfactants have been used in fibrous products--generally as
a component of a binder composition--as a wetting agent to promote
the distribution of binder within the spray systems and throughout
the fibrous product (see e.g. WO 2011/044490). Surfactants are
available in a wide variety of configurations for different
purposes. In general, surfactants have a polar region, or head, and
a non-polar region, or tail. This provides them with a portion that
likes water or other polar solvents; and a portion that likes oils
or non-polar solvents. Due to their dual functionality (both polar
and non-polar) surfactants generally reside at the interfaces
between dissimilar media, such as at water-oil interfaces or
water-air interfaces. In this way, they can reduce the surface
tension at these interfaces. After a certain surfactant
concentration is reached however, the interfaces are saturated with
surfactant molecules and additional surfactant will form micelles
in the medium rather than crowding in at the interface. This
concentration is known as the critical micelle concentration
("CMC") and is typically published for each surfactant. Above this
CMC, surface tension is not significantly reduced.
[0075] Surfactants may be classified into groups, in part, based on
the degree or magnitude of this affinity for polar solvents
(hydrophilicity) or for non-polar solvents (lipophilicity) to
produce a HLB number (known as the hydrophilic lipophilic balance)
of the surfactant. The polar head may be neutral (non-ionic) or
charged (e.g. anionic(-), cationic(+) or zwitterionic (both)),
which provides a way to classify surfactants based on electronic
charge. Electronic charge may be dependent on pH however. Finally,
the chemical structure of the surfactants provides yet another way
to classify surfactants, such as the "alkyl sulfates" or
"quaternary ammonium salts" or ethoxylated or polyethoxylated
alcohols or ethers.
[0076] Neutral or non-ionic surfactants have been found suitable
for the present invention, including for example the alkyl
glucosides, alkyl thioglucosides, ethoxylated alcohols, ethoxylated
ethers, the polyoxyethylenes (e.g TRITON X.TM., PLURONICS.TM.,
BRIJ.TM. and TWEEN.TM. series), ethylene oxide, and 1,4 dioxane.
Non-limiting examples of suitable surfactants include the
Surfynol.RTM. series 420, 440, 465, and 485, which are ethoxylated
2,4,7,9-tetramethyl-5-decyn-4,7-diol surfactants (commercially
available from Air Products and Chemicals, Inc. (Allentown, Pa.));
Triton.TM. X-100 and Triton.TM. X-405, which are polyethoxylated
p-(I,I,3,3-tetramethylbutyl) phenyl ethers (sold commercially by
The Dow Chemical Co. (Midland, Mich.)); Polysorbate 20 (ethoxylated
sorbitan monolaurate) and Polysorbate 80 (ethoxylated sorbitan
monooleate) sold commercially by Sigma-Aldrich (St. Louis, Mo.);
and sulfates (e.g., alkyl sulfates, ammonium lauryl sulfate, sodium
lauryl sulfate (SDS), alkyl ether sulfates, sodium laureth sulfate,
and sodium myreth sulfate
[0077] The surfactant may be present in the binder composition in a
concentration from about 0.01% to about 10% by weight of the total
solids in the binder composition, and all subranges within this
range. For example, in various embodiments, the surfactant is from
about 0.01% to about 5.0% by weight, or from about 0.05% to about
1% by weight, or from about 0.05% to about 0.5% by weight, or from
about 0.1% to about 0.5% by weight all based on the total solids in
the binder. The surfactant concentration in the fibrous product may
be calculated as the percent in the binder times the application
rate of binder or LOI (loss on ignition--which is an assay for
binder concentration on glass fibers). Target LOI varies greatly
depending on the specific product as noted in table B above; for
example from about 2% to 20% or more, which gives a broad range of
very small absolute concentrations of surfactant in product. For
example, a 0.1% binder dispersion applied with a target LOI of 6%
results in a calculated final product concentration of just 0.006%.
While possible to calculate these small numbers, applicants define
instead a "normalized" surfactant concentration in product which is
the absolute concentration divided by the LOI. As with some
measures of mechanical properties, this normalization vs LOI is a
fairer way to compare the surfactant content of products with
differing binder LOI levels. Mathematically, the "normalized"
surfactant concentration of a fibrous product is the same as the
surfactant concentration of the binder that is used to manufacture
it; multiplying by the LOI and then dividing by it cancels this
term. Those skilled in the art will recognize that the CMC of any
specific surfactant can further inform the decision regarding
concentration in the upper ranges of concentrations given
above.
Silane Coupling Agent
[0078] Silane coupling agents or organosilanes are well known in
the glass fiber forming industry. They have been used in sizings
for protection of long filaments, and as additives to binder
compositions. It is thought that the silane portion bonds to silica
of the glass, and the organic portion helps to bind or hold resins,
binders or other organic materials to the glass. Organosilanes have
thus thought to provide a protective function for glass fibers,
although they are optional in the present invention. In some
embodiments of the invention, a silane coupling agent may
optionally be used in combination with a surfactant to improve the
aged mechanical properties of a fibrous insulation product
[0079] Non-limiting examples of silane coupling agents that may
optionally be used in the binder composition may be characterized
by the functional groups alkyl, aryl, amino, epoxy, vinyl,
methacryloxy, ureido, isocyanato, and mercapto. In exemplary
embodiments, the silane coupling agent(s) include silanes
containing one or more nitrogen atoms that have one or more
functional groups such as amine (primary, secondary, tertiary, and
quaternary), amino, imino, amido, imido, ureido, or isocyanato.
Specific, non-limiting examples of suitable silane coupling agents
include, but are not limited to, aminosilanes (e.g.,
3-aminopropyl-triethoxysilane and 3-aminopropyl-trihydroxysilane),
epoxy trialkoxysilanes (e.g., 3-glycidoxypropyltrimethoxysilane and
3-glycidoxypropyltriethoxysilane), methyacryl trialkoxysilanes
(e.g., 3-methacryloxypropyltrimethoxysilane and
3-methacryloxypropyltriethoxysilane), hydrocarbon trialkoxysilanes,
amino trihydroxysilanes, epoxy trihydroxysilanes, methacryl
trihydroxy silanes, and/or hydrocarbon trihydroxysilanes. In one or
more exemplary embodiments, the silane is an aminosilane, such as
.gamma.-aminopropyltriethoxysilane.
[0080] Further exemplary coupling agents (including silane coupling
agents) suitable for use in the binder composition are set forth
below: [0081] Acryl: 3-acryloxypropyltrimethoxysilane;
3-acryloxypropyltriethoxysilane;
3-acryloxypropylmethyldimethoxysilane;
3-acryloxypropylmethyldiethoxysilane;
3-methacryloxypropyltrimethoxysilane;
3-methacryloxypropyltriethoxysilane [0082] Amino:
aminopropylmethyldimethoxysilane; aminopropyltriethoxysilane;
aminopropyltrimethoxysilane/EtOH; aminopropyltrimethoxysilane;
N-(2-aminoethyl)-3-aminopropyltrimethoxysilane;
N-(2-aminoethyl)-3-aminopropylmethyldimethoxysilane;
(2-aminoethyl)-(2-aminoethyl) 3-aminopropyltrimethoxysilane;
N-phenylaminopropyltrimethoxysilane [0083] Epoxy:
3-Glycidoxypropylmethyldiethoxysilane;
3-glycidoxypropylmethyldimethoxysilane;
3-glycidoxypropyltriethoxysilane;
2-(3,4-eoxycyclohexyl)ethylmethyldimethoxysilane;
2-(3,4-epoxycyclohexyl)ethylmethyldiethoxysilane;
2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane;
2-(3,4-Epoxycyclohexyl)ethyltriethoxysilane [0084] Mercapto:
3-mercaptopropyltrimethoxysilane; 3-Mercaptopropyltriethoxysilane;
3-mercaptopropylmethyldimethoxysilane;
3-Mercaptopropylmethyldiethoxysilane [0085] Sulfide:
bis[3-(triethoxysilyl)propyl]-tetrasulfide;
bis[3-(triethoxysilyl)propyl]-disulfide [0086] Vinyl:
vinyltrimethoxysilane; vinyltriethoxysilane; vinyl
tris(2-methoxyethoxy)silane; vinyltrichlorosilane;
trimethylvinylsilane [0087] Alkyl: methyltrimethoxysilane;
methyltriethoxysilane; dimethyldimethoxysilane;
dimethyldiethoxysilane; tetramethoxysilane; tetraethoxysilane;
ethyltriethoxysilane; n-propyltrimethoxysilane;
n-propyltriethoxysilane; isobutyltrimethoxysilane;
hexyltrimethoxysilane; hexyltriethoxysilane; octyltrimethoxysilane;
decyltrimethoxysilane; decyltriethoxysilane; octyltriethoxysilane;
tert-butyldimethylchlorosilane; cyclohexylmethyldimethoxysilane;
dicylohexyldimethoxysilane; cyclohexylethyldimethoxysilane;
t-butylmethyldimethoxysilane [0088] Chloroalkyl:
3-chloropropyltriethoxysilane; 3-chloropropyltrimethoxysilane;
3-chloropropylmethyldimethoxysilane [0089] Perfluoro:
decafluoro-1,1,2,2-tetrahydrodecyl)trimethoxysilane;
((heptadecafluoro-1,1,2,2-tetrahydrodecyl)trimethoxysilane [0090]
Phenyl: phenyltrimethoxysilane; phenyltriethoxysilane;
diphenyldiethoxysilane; diphenyldimethoxysilane;
diphenyldichlorosilane [0091] Hydrolyzates of the silanes listed
above [0092] Zirconates: zirconium acetylacetonate; zirconium
methacrylate [0093] Titanates: tetra-methyl titanate; tetra-ethyl
titanate; tetra-n-propyl titanate; tetra-isopropyl titanate;
tetra-isobutyl titanate; tetra-sec-butyl titanate; tetra-tert-butyl
titanate; mono n-butyl, trimethyl titanate; mono ethyl
tricyclohexyl titanate; tetra-n-amyl titanate; tetra-n-hexyl
titanate; tetra-cyclopentyl titanate; tetra-cyclohexyl titanate;
tetra-n-decyl titanate; tetra n-dodecyl titanate; tetra (2-ethyl
hexyl) titanate; tetra octylene glycol titanate ester;
tetrapropylene glycol titanate ester; tetra benzyl titanate;
tetra-p-chloro benzyl titanate; tetra 2-chloroethyl titanate; tetra
2-bromoethyl titanate; tetra 2-methoxyethyl titanate; tetra
2-ethoxyethyl titanate.
[0094] The coupling agent(s), when present, may be present in the
binder composition in an amount from about 0.01% to about 5.0% by
weight of the total solids in the binder composition, from about
0.01% to about 2.5% by weight, or from about 0.1% to about 0.5% by
weight. Absolute silane coupling agent concentrations in product
may calculated as described above for surfactants, however, the
"normalized" concept is useful here again.
Other Optional Ingredients of the Binder Compositions
[0095] Typically, the binder composition may include a cure
accelerator or catalyst to assist in the crosslinking. A cure
accelerator may be consumed in the reaction whereas a pure catalyst
is not. As used herein the term "catalyst" encompasses cure
accelerators as well as pure catalysts. The catalyst may include
inorganic salts, Lewis acids (i.e., aluminum chloride or boron
trifluoride), Bronsted acids (i.e., sulfuric acid,
p-toluenesulfonic acid and boric acid) organometallic complexes
(i.e., lithium carboxylates, sodium carboxylates), and/or Bronsted
or Lewis bases (i.e., polyethyleneimine, diethylamine, or
triethylamine). Additionally, the catalyst may include an alkali
metal salt of a phosphorous-containing organic acid; in particular,
alkali metal salts of phosphorus acid, hypophosphorus acid, or
polyphosphoric acids. Examples of such phosphorus catalysts
include, but are not limited to, sodium hypophosphite, sodium
phosphate, potassium phosphate, disodium pyrophosphate, tetrasodium
pyrophosphate, sodium tripolyphosphate, sodium hexamethaphosphate,
potassium phosphate, potassium tripolyphosphate, sodium
trimetaphosphate, sodium tetramethaphosphate, and mixtures thereof.
In addition, the catalyst may be a fluoroborate compound such as
fluoroboric acid, sodium tetrafluoroborate, potassium
tetrafluoroborate, calcium tetrafluoroborate, magnesium
tetrafluoroborate, zinc tetrafluoroborate, ammonium
tetrafluoroborate, and mixtures thereof. Further, the catalyst may
be a mixture of phosphorus and fluoroborate compounds. Other sodium
salts such as, sodium sulfate, sodium nitrate, sodium carbonate may
also or alternatively be used as the catalyst, as well as some
lithium and zirconium complexes. Carbodiimide based coupling agents
like and not limited to 1-ethyl-3-(3-dimethylaminopropyl)
carbodiimide (EDCI) or N,N'-Dicyclohexylcarbodiimide (DCC) could be
used as well. The catalyst may be present in the binder composition
in an amount from about 0% to about 10% by weight of the total
solids in the binder composition, or from about 1.0% to about 5.0%
by weight, or from about 3.0% to about 5.0% by weight.
[0096] Binder compositions may contain reactive polysiloxanes as
moisture resistance agents, lubricants or for other purposes.
Reactive polysiloxanes (also known as reactive silicones) are
silicon polyethers having at least one of the typical alkyl
substituents of inert silanes replaced by a reactive functional
group. For purposes of this invention in the context of a reactive
polysiloxane, a "reactive functional group" includes hydride (--H),
hydroxyl (--OH), amino (--NH.sub.2), carboxyl (--COOH).
Polysiloxanes having a reactive hydrogen are among the most common
and are referred to as polyalkylhydrogensiloxanes. Polysiloxanes
having a reactive amino group are polyalkylaminosiloxanes;
polysiloxanes having a reactive hydroxyl group are
polyalkylhydroxylsiloxanes; and polysiloxanes having a reactive
carboxyl group are polyalkylcarboxylsiloxanes; regardless whether
the reactive functional group is attached directly to the silicon
atom or to a lower alkyl or aryl attached to the silicon atom.
[0097] In addition, the binder composition may include a processing
aid to facilitate the processing of the fibers formation and
orientation. Examples of processing aids include viscosity
modifiers, defoaming agents and lubricants. Additionally, binder
compositions may optionally include; a biocide; a crosslinking
density enhancer to improve the degree of crosslinking; organic
and/or inorganic acids and bases in an amount sufficient to adjust
and/or buffer the pH to a desired level; a moisture resistant
agent; a dust suppressing agent to reduce or eliminate the presence
of inorganic and/or organic particles; fillers or extenders to
improve the binder's appearance and/or to lower the overall
manufacturing cost; and conventional additives such as, but not
limited to dyes, pigments, colorants, UV stabilizers, thermal
stabilizers, lubricants, anti-foaming agents, anti-oxidants,
emulsifiers, preservatives (e.g., sodium benzoate), corrosion
inhibitors, and mixtures thereof.
EXAMPLES
[0098] The following examples serve to further illustrate the
invention.
Example 1
Preparation of R-19 Fibrous Batts
[0099] Fibrous insulation batts designated with R-value 19 are
prepared by rotary fiberization and coated with a
maltodextrin--citric acid binder (70:30 ratio) containing oil,
0.18% gamma-aminopropyltrihydroxy silane and varying amounts of a
surfactant (Surfynol.RTM. 465), expressed herein as a percent of
binder solids. Binder was applied at a target level of 6.3% LOI,
making the calculated amount of surfactant in the fibrous product
as shown in Table 1 below. The normalized concentration of
surfactant in the fibrous product is the same as the concentration
of surfactant in the binder composition.
TABLE-US-00004 TABLE 1 Surfactant concentrations Surfactant as % of
binder Surfactant as % of fibrous solids in binder composition
product (assuming 6.3% LOI) 0.09 0.0056 0.27 0.0168 0.44 0.0279
Example 2
Testing R-19 Batts for Sag/Stiffness
[0100] R-19 fibrous batts prepared as in Example 1 are exposed to
an accelerated hot and humid treatment conditions designed to be a
proxy for real-time aging in warm and humid climates. The proxy
test exposes the batts to 90.degree. F. and 90% relative humidity
(RH) for 3 days. Sag or stiffness is a mechanical product property
that indicates the strength of the fibrous batt as a fixed length
is draped over a fulcrum. The degree to which its ends deviate from
a straight line constitutes the sag. Sag was tested both before
(Ambient) and after (H/H) hot and humid test conditions. The
results of N=120 measurements are depicted in FIG. 2 which includes
95% confidence interval (CI) bars about the means, as well as a
linear trend line; and in Table 2 below
TABLE-US-00005 TABLE 2 Sag/Stiffness (degrees) and percent change
vs no surfactant Avg Sag (deg) under % improvement under % Surfynol
Ambient Hot/Humid Ambient Hot/Humid 0.0 25.38 38.07 -- -- 0.09
24.84 31.60 2.1% 17.0% 0.27 24.79 27.77 2.3% 27.1% 0.44 24.94 27.69
1.7% 27.3%
[0101] The results show that with no surfactant, the aged H/H
product performed considerably worse than the ambient product,
which is typical and not unexpected. But with increasing amounts of
surfactant, this disparity grew smaller and smaller. Curiously,
increasing amounts of surfactant did not significantly improve the
performance of the ambient product. If surfactant were merely
functioning as a wetting agent to distribute the binder more
uniformly throughout the fibers of the pack, one would expect
stronger batts right from cure (i.e. the ambient curve would be
expected to slope downwardly more like the HH curve). Therefore
this supposed mechanism does not explain the unexpected HH sag
result
Example 3
Testing R-19 batts for Recovery
[0102] R-19 fibrous batts prepared as in Example 1 are exposed to
an accelerated hot and humid treatment conditions as described in
Example 2. Recovery is a mechanical product property that indicates
the ability of the fibrous batt to regain its original or nominal
thickness after compression simulating packaging. In this case,
nominal thickness was 6.25 inches, for standard R-19 batts.
Recovery was tested according to ASTM Std C167-09, both before
(ambient) and after (H/H) hot and humid test conditions. The
results of N=150 measurements are depicted in FIG. 3, which
includes 95% confidence interval (CI) bars about the means, as well
as a linear trend line; and in Table 3, below:
TABLE-US-00006 TABLE 3 Recovery (inches) and percent change vs no
surfactant Avg Recovery (inches) under % improvement under %
Surfynol Ambient Hot/Humid Ambient Hot/Humid 0.0 6.20 5.65 -- --
0.09 6.08 5.83 -1.9% 3.1% 0.27 6.10 5.80 -1.6% 2.6% 0.44 6.12 5.87
-1.2% 3.9%
[0103] The results show that with no surfactant, the aged H/H
product performed considerably worse than the ambient product. But
with increasing amounts of surfactant, this disparity grew smaller.
Curiously, increasing amounts of surfactant did not significantly
improve the performance of the ambient product. If surfactant were
merely functioning as a wetting agent to distribute the binder more
uniformly throughout the fibers of the pack, one would expect
stronger batts right from cure (i.e. the ambient curve would be
expected to slope upwardly more like the H/H curve). Therefore this
supposed mechanism does not explain the unexpected H/H recovery
result.
Example 4
Testing R-30 Batts for Sag
[0104] Fibrous insulation batts designated with R-value 30 are
prepared by rotary fiberization and coated with the binder of
Example 1 having 0.45% of a surfactant (Surfynol.RTM. 465). Binder
was applied at a target level of 6.5% LOI, making the calculated
amount of surfactant in the fibrous product equal to 0.0289%.
[0105] R-30 batts having a nominal thickness of 9 inches are
exposed to an accelerated hot and humid treatment conditions and
tested for Sag as described in Example 2 both before (ambient) and
after (H/H) hot and humid test conditions. The results of N=8
measurements are shown in Table 4, below:
TABLE-US-00007 TABLE 4 R-30 Sag (degrees) and % improvement Average
Sag (deg) % improvement Ambient (CI) Hot/Humid (CI) Ambient
Hot/Humid control 18.9 +/- 1.54 29.0 +/- 2.28 -- -- 0.45% 18.7 +/-
1.66 25.3 +/- 1.32 1.3% 12.9% Surfactant
[0106] The data show that 0.45% normalized surfactant in R-30 batts
improved the mechanical property of stiffness or sag by more than
10% (nearly 13%) after the aged hot/humid condition treatment. The
surfactant modestly improved the sag properties in the ambient
condition as well.
Example 5
Testing R-30 Batts for Recovery
[0107] R-30 fibrous batts having a nominal thickness of 9 inches
are prepared and exposed to an accelerated hot and humid treatment
conditions as in Example 4. They are tested for Recovery as
described in Example 3 both before (ambient) and after (H/H) hot
and humid test conditions. The results of N=200 measurements are
shown in Table 4, below:
TABLE-US-00008 TABLE 5 R-30 Recovery (inches) and % improvement
Average Recovery (in) % improvement Ambient (CI) Hot/Humid (CI)
Ambient Hot/Humid control 8.9 +/- 0.065 8.4 +/- 0.061 -- -- 0.45%
8.9 +/- 0.061 8.6 +/- 0.053 0.9% 1.7% surfactant
[0108] The data show that 0.45% normalized surfactant in R-30 batts
improved the mechanical property of recovery by nearly 2% after the
aged hot/humid condition treatment. The surfactant modestly
improved the sag properties in the ambient condition as well.
Example 6
Testing R-19 Batts for Compressive Strength
[0109] R-19 fibrous batts are prepared as in Example 1. A package
contains 5 bags of batts, each bag containing a plurality of batts.
Packages are tested for Compressive Strength in the cross machine
direction (CD) by measuring the width after compression to a
standardized force of 1800 psi. The ambient results of N=8
measurements are shown in FIG. 4 and Table 6, below:
TABLE-US-00009 TABLE 6 Compression of R-19 batts Mean % Improve- %
Improve- % Width, Std ment, ment, Surfactant Compressed Min Dev
Compr. Width Variability 0 = control 17.85 16.00 1.44 -- -- 0.09
19.08 17.63 0.69 6.9% 52.2% 0.27 19.83 18.50 0.97 11.1% 32.7% 0.44
20.80 20.63 0.17 16.5% 87.8%
[0110] The data show that the addition of surfactant in R-19 batts
improved the mechanical property of compressive strength, with
0.44% normalized surfactant level improving compressive strength by
at least 5%, at least 10% or even more than 15%. Interestingly, not
only does compressive strength improve, but the variability of the
data also improved a great deal; the standard deviation of the data
points decreased nearly 10 fold. This is very important since, in
at least the situation where compressive strength is important for
stacking of packages, it is not the mean compression strength that
matters, but the minimum. In stacks of packages, the weakest
package will cause the stack to lean and possibly tumble.
Example 7
Surface Tension with Various Surfactants
[0111] Several binder formulations were prepared with different
types and amounts of binders as shown below in Table 7. Surface
tension of the binder compositions were measured using a Surface
Tensionmeter 6000 (manufactured by the SensaDyne Instrument
Division of the Chem-Dyne Research Group). The instrument was
calibrated with deionized water. Data was recorded every 5 seconds.
After the system was stabilized and the testing had begun, the
average value over a one-minute testing period was obtained for
each sample. The results are set forth in Table 7.
TABLE-US-00010 TABLE 7 Surface tension of binder formulations with
various surfactants % on Surface Binder Mixture total Tension (10%
total solids) Surfactant solids (dyne/cm) phenol/urea/formaldehyde
None None 72.0 (Control) 80:20 MD-CA w/5% SHP None None 77.7 80:20
MD-CA w/5% SHP Stanfax.sup.(1) 0.1 46.0 (anionic) 0.3 41.3 0.5 41.9
80:20 MD-CA w/5% SHP Surfynol 465.sup.(2) 0.1 51.0 (nonionic) 0.3
49.4 0.5 46.2 80:20 MD-CA w/5% SHP Triton .TM. GR- 0.1 35.6
PG70.sup.(3) 0.3 31.3 (anionic) 0.5 30.1 80:20 MD-CA w/5% SHP
Sodium Dodecyl- 0.1 60 Sulfate 0.3 51.9 (anionic) 0.5 50.8 80:20
MD-CA w/5% SHP Triton .TM. CF-10 0.1 39.1 (nonionic) 0.3 39.3 0.5
40 .sup.(1)Stanfax - sodium lauryl sulfate .sup.(2)Surfynol 465 -
ethoxylated 2,4,7,9-tetramethyl 5 decyn-4,7-diol .sup.(3)Triton
.TM. GR-PG70 - 1,4-bis(2-ethylhexyl) sodium sulfosuccinate
.sup.(4)Triton .TM. CF-10 - poly(oxy-1,2-ethanediyl),
alpha-(phenylmethyl)-omega-(1,1,3,3-tetramethylbutyl)phenoxy ** MD
= maltodextrin, CA = citric acid, SHP = sodium hypophosphite
[0112] The results set forth in Table 7 show that all surfactants
reduced the surface tension of the bio-based binder compared to
both phenolic and carbohydrate-based control binders not having
surfactants by an average of 40% plus/minus .about.6% (95% CI). The
magnitude of reduction ranged from about 17% for lowest
concentration of sodium dodecyl sulfate surfactant to about 60% for
the highest concentration of Triton GR-PG70. The two non-ionic
surfactants produced surface tension reductions in the range of
about 30-45% against the phenolic control and about 35-50% against
the MD:CA control.
Example 8
Flexible Duct Media (FDM)
[0113] Flexible Duct Media (FDM) is made on a rotary fiberizing
line and bisected to top and bottom portions, and rolled for
packaging. Samples were made with and without 0.18% Surfynol, and
targeting 6.0% LOI, making the calculated amount of surfactant in
the fibrous product equal to 0.0106%. Samples are tested for
recovery at an initial or ambient time, and again after an
accelerated hot and humid (H/H) aging test. Individual data for top
and bottom are averaged. The accelerated test exposed the FDM to
73.degree. F. and 92% relative humidity for 7 days. The results are
shown in Table 8, below.
TABLE-US-00011 TABLE 8 H/H aged recovery data (inches) for FDM Am-
73 F./92 73 F./92 Degradation bient RH @ 3 RH @ 7 at 7 (inches)
days, (inches) days, (inches) days (%) No Surfactant, 2.38 2.14
2.04 13.96 control 0.18% 2.31 2.23 2.11 8.78 Surfactant
[0114] The results show that 0.18% surfactant improved aged
recovery. Recovery suffered almost 14% degradation without
surfactant but less than 9% with surfactant.
[0115] The foregoing description of the various aspects and
embodiments of the present invention has been presented for
purposes of illustration and description. It is not intended to be
exhaustive or all embodiments or to limit the invention to the
specific aspects disclosed. Additional advantages and modifications
will readily appear to those skilled in the art. Obvious
modifications or variations are possible in light of the above
teachings and such modifications and variations may well fall
within the scope of the invention as determined by the appended
claims when interpreted in accordance with the breadth to which
they are fairly, legally and equitably entitled.
* * * * *