U.S. patent application number 17/541409 was filed with the patent office on 2022-06-16 for binder system.
The applicant listed for this patent is Owens Corning Intellectual Capital, LLC. Invention is credited to Bryan Alan Albani, Jesus M. Hernandez-Torres, Jose Mendez-Andino, Scott William Schweiger.
Application Number | 20220185972 17/541409 |
Document ID | / |
Family ID | |
Filed Date | 2022-06-16 |
United States Patent
Application |
20220185972 |
Kind Code |
A1 |
Albani; Bryan Alan ; et
al. |
June 16, 2022 |
BINDER SYSTEM
Abstract
An environmentally friendly, aqueous binder composition that
includes a metal salt and a polyol is provided. The metal salt may
be a water soluble salt, including salts of boron, aluminum,
gallium, indium, tin, zirconium, thallium, lead, and bismuth. The
polyol may include water miscible or water soluble polymeric
alcohols including polyvinyl alcohol. The binder composition may be
used in the formation of insulation materials and non-woven mats,
among other products.
Inventors: |
Albani; Bryan Alan;
(Columbus, OH) ; Hernandez-Torres; Jesus M.;
(Pataskala, OH) ; Mendez-Andino; Jose; (Columbus,
OH) ; Schweiger; Scott William; (Newark, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Owens Corning Intellectual Capital, LLC |
Toledo |
OH |
US |
|
|
Appl. No.: |
17/541409 |
Filed: |
December 3, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15614797 |
Jun 6, 2017 |
11192986 |
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17541409 |
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62345885 |
Jun 6, 2016 |
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International
Class: |
C08J 5/04 20060101
C08J005/04; D04H 1/587 20060101 D04H001/587; D04H 1/4218 20060101
D04H001/4218; C03C 13/00 20060101 C03C013/00; C08K 3/28 20060101
C08K003/28; C08K 3/30 20060101 C08K003/30; D04H 3/004 20060101
D04H003/004; D04H 3/12 20060101 D04H003/12 |
Claims
1. A binder composition for use in the formation of fibrous
insulation and non-woven mats, the binder composition comprising:
water; a metal salt; and a polyol; wherein the metal salt and the
polyol are present in a weight ratio of 1:99 to 1:1.
2. The aqueous binder composition of claim 1, wherein the weight
ratio of the metal salt to the polyol is in the range of 1:9 to
1:1.
3. The aqueous binder composition of claim 1, wherein the metal
salt comprises a metal selected from the group consisting of boron,
aluminum, gallium, indium, tin, iron, zinc, titanium, bismuth,
zirconium, and combinations thereof.
4. The aqueous binder composition of claim 3, wherein the metal
salt is a salt of aluminum.
5. The aqueous binder composition of claim 4, wherein the metal
salt is selected from the group consisting of aluminum chloride,
aluminum nitrate, aluminum sulfate, aluminum phosphate monobasic,
sodium aluminate, and combinations thereof.
6. The aqueous binder composition of claim 1, wherein the polyol is
selected from the group consisting of aromatic alcohols, glycerol,
polyglycerol, ethylene glycol, propylene glycol, polyethylene
glycol, aliphatic alcohols, unmodified polyvinyl alcohol, modified
polyvinyl alcohol, polyvinyl alcohol copolymer, polyvinyl acetate,
polyacrylic acid, and combinations thereof.
7. The aqueous binder composition of claim 6, wherein the polyol is
polyvinyl alcohol.
8. The aqueous binder composition of claim 7, wherein the polyvinyl
alcohol has a viscosity of 3-5 centipoise.
9. The aqueous binder composition of claim 8, wherein the polyvinyl
alcohol is at least 50% hydrolyzed.
10. A fibrous insulation product comprising: a plurality of fibers;
and a binder composition applied to at least a portion of the
fibers, the binder composition comprising: water; a metal salt; and
a polyol; wherein a weight ratio of the metal salt to the polyol is
in the range of 1:99 to 1:1; and wherein the binder composition is
present in the fibrous insulation product in an amount of 1% to 25%
loss on ignition.
11. The fibrous insulation product of claim 10, wherein the weight
ratio of the metal salt to the polyol is in the range of 1:9 to
1:1.
12. The fibrous insulation product of claim 10, wherein the metal
salt comprises a metal selected from the group consisting of boron,
aluminum, gallium, indium, tin, iron, zinc, titanium, bismuth,
zirconium, and combinations thereof.
13. The fibrous insulation product of claim 12, wherein the metal
salt is a salt of aluminum.
14. The fibrous insulation product of claim 13, wherein the metal
salt is selected from the group consisting of aluminum chloride,
aluminum nitrate, aluminum sulfate aluminum phosphate monobasic,
sodium aluminate, and combinations thereof.
15. The fibrous insulation product of claim 10, wherein the polyol
is selected from the group consisting of aromatic alcohols,
glycerol, polyglycerol, sorbitol, ethylene glycol, propylene
glycol, polyethylene glycol, pentaerythritol, aliphatic alcohols,
unmodified polyvinyl alcohol, modified polyvinyl alcohol, polyvinyl
alcohol copolymer, polyvinyl acetate, polyacrylic acid, and
combinations thereof.
16. The fibrous insulation product of claim 15, wherein the polyol
is polyvinyl alcohol.
17. The fibrous insulation product of claim 16, wherein the
polyvinyl alcohol has a viscosity of 3-5 centipoise.
18. The aqueous binder composition of claim 17, wherein the
polyvinyl alcohol is at least 50% hydrolyzed.
19. The fibrous insulation product of claim 10, wherein the
insulation product is free of added formaldehyde.
20. The fibrous insulation product of claim 10, wherein the fibers
are glass fibers.
21-24. (canceled)
Description
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 15/614,797, filed on Jun. 6, 2017, which claims priority to and
the benefit of U.S. Provisional Application No. 62/345,885, filed
on Jun. 6, 2016, the contents of which are hereby incorporated by
reference in their entirety as if recited herein.
FIELD
[0002] The present invention relates generally to fibrous
insulation and non-woven mats, and more particularly, to a binder
for use in manufacturing fibrous insulation and non-woven mats.
BACKGROUND
[0003] Conventional fibers such as fiberglass, mineral wool, and
basalt are useful in a variety of applications including
reinforcements, textiles, and acoustical and thermal insulation
materials. Fibrous insulation is typically manufactured by
fiberizing a molten composition of polymer, glass, or other mineral
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 applied through spraying or dipping the fibers. The
fibers are then 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, for example, in the insulation cavities of
buildings. The binder composition also provides protection to the
fibers from interfilament abrasion and promotes compatibility
between the individual fibers.
[0004] The blanket containing the binder-coated fibers is then
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. Another type
of insulation product is an insulation board. Insulation boards may
be used in a similar fashion to insulative batts or blankets, but
are stiffer and generally more dense.
[0005] Non-woven mats, such as those used in acoustic ceiling
boards, may be formed by conventional wet-laid processes. In one
such process, wet chopped fibers are dispersed in a water slurry
that contains surfactants, viscosity modifiers, defoaming agents,
and/or other chemical agents. The slurry containing the chopped
fibers is then agitated so that the fibers become more evenly
dispersed throughout the slurry. The slurry containing the fibers
is deposited onto a moving screen where a substantial portion of
the water is removed to form a web. A binder is then applied, and
the resulting mat is dried to remove any remaining water and cure
the binder. The formed non-woven mat is an assembly of dispersed,
individual glass filaments.
[0006] Non-woven mats may also be prepared from dry chopped fibers
and/or continuous filaments. For example, fibers are dispensed from
a bushing and are chopped to a desired length. The fibers may or
may not have certain chemical agents applied prior to chopping. The
chopped fibers are then applied to a surface, for example, a
conveyor belt to form a mat. Binder is applied to the mat which is
conveyed to a curing oven.
[0007] In the context of continuous filament fiber products, a
fiber is dispensed to a surface (either with or without chemical
agents applied first) and is allowed to form a mat. A binder
composition is then applied to the mat which is then conveyed to an
oven for cure. Generally, the cured mat is thus comprised of fewer
fibers than a chopped fiber mat.
[0008] Various attempts have been made to reduce undesirable
formaldehyde emissions from formaldehyde-based resins such as
phenolic 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.
[0009] Polyacrylic acid binders offer some benefits over phenolic
resins. However, a binder that is formed mostly of polyacrylic acid
inherently has problems due to its acidity and associated corrosion
of machine parts. In addition, polyacrylic acid binders have a high
viscosity, high curing temperatures, and high associated curing
costs. Certain natural-based systems are known as well, but suffer
from particular drawbacks of their own. For example, the
starch/carbohydrate based products (or those that rely on the
Maillard reaction) may have an undesirable dark brown color after
curing. Also, the use of large amounts of ammonia needed to make
the binder presents a safety risk and possible emission
problems.
[0010] Alternative polymeric binder systems to those described
above for fibrous glass products have also been proposed. However,
these alternative polymeric binder systems remain problematic in
certain instances. For example, low molecular weight, low viscosity
binders which allow maximum vertical expansion of the insulation
pack in the transfer zone generally cure to form a non-rigid
plastic matrix in the finished product, thereby reducing the
attainable vertical height recovery of the finished insulation
product when installed. Conversely, high viscosity binders, which
generally cure to form a rigid matrix in the finished product, do
not allow the desired maximum vertical expansion of the coated,
uncured pack.
[0011] In addition to the components that react to bind the fibers
together, most conventional binder systems comprise a number of
other components to adjust various properties of the finished
product (e.g., anti-dust, anti-static). Each of these individual
components must be verified as safe and compatible with the other
components, in addition to not interfering with ultimate binding of
the fibers.
[0012] In view of the existing problems with current binders, there
remains a need in the art for a binder system that does not corrode
machine parts, does not include added formaldehyde, is
environmentally friendly, is shelf stable after production, is
simpler in terms of total ingredients required to produce a
finished product, and/or provides processing advantages.
SUMMARY
[0013] The general inventive concepts relate to a binder
composition for use in the formation of insulation, insulation
boards, non-woven mats, carbon fiber products, and for use in
products as a binder for organic fibers such as cellulose and
wood-based fibers. Generally, the binder includes a metal salt and
a polyol. In certain embodiments, the metal salt and the polyol are
present in the binder composition in a weight ratio of 1:99 to
1:1.
[0014] In certain embodiments, the general inventive concepts
relate to a fibrous insulation product that includes a plurality of
randomly oriented fibers and a binder composition applied to at
least a portion of the fibers and interconnecting the fibers. The
binder includes a metal salt and a polyol in a weight ratio of 1:99
to 1:1.
[0015] In certain embodiments, the general inventive concepts
relate to a non-woven mat formed of a plurality of randomly
oriented fibers having a discrete length enmeshed in the form of a
mat having a first major surface and a second major surface and a
binder composition at least partially coating the first major
surface of the mat, or in certain embodiments, at least partially
impregnating the mat. The binder includes a metal salt and a
polyol. The metal salt and the polyol are generally present in a
weight ratio of 1:99 to 1:1. Any suitable fibers may be used. In
certain embodiments, the fibers are glass fibers. The fibers have
an average diameter within the range of 6.5 microns to 24 microns.
In certain embodiments, the fibers are mineral wool fibers. The
binder composition is present in the non-woven mat in an amount of
1% to 25% loss on ignition.
[0016] In certain embodiments, the general inventive concepts
relate to a method of making a fibrous insulation product. The
method comprises forming a fibrous blanket including a plurality of
randomly oriented fibers, applying a binder composition to at least
a portion of the glass fibers, the binder composition comprising a
metal salt and a polyol in a weight ratio of 1:99 to 1:1, passing
the fibrous blanket through an oven to at least partially cure the
binder on the fibers and form an insulation product, wherein the
binder composition is present in the fibrous insulation product in
an amount of 1% to 25% loss on ignition.
[0017] Various embodiments of the general inventive concepts will
typically exhibit one or more of the following exemplary
features.
[0018] It is a feature of the general inventive concepts that the
inventive binder composition is free from added formaldehyde.
[0019] It is a feature of the general inventive concepts that the
inventive binder composition requires fewer ingredients to generate
a satisfactory product.
[0020] It is a feature of the general inventive concepts that
insulation products and non-woven mats utilizing the inventive
binder composition can be manufactured using current manufacturing
lines, thereby saving time and money. In certain embodiments,
insulation products and non-woven mats utilizing the inventive
binder composition can be produced at lower temperatures than those
typically used to cure conventional binder systems and still
maintain overall performance standards.
[0021] It is a feature of the general inventive concepts that
insulation products and non-woven mats utilizing the inventive
binder composition can be manufactured using increased amounts of
added water and be cured at or below current temperatures/times.
This is due to the surprising ability of the inventive binder
compositions to "shed" excess water in a manner not seen with
conventional binder systems, allowing additional water to be added
to the binder compositions (for ease in processing), if necessary,
without substantially increasing production time or cost and
without substantially affecting performance.
[0022] It is a feature of the general inventive concepts that a
final insulation product made with the exemplary aqueous binder
compositions provided herein has a light color at desired loss on
ignition (LOI) levels that allows the use of dyes, pigments, or
other colorants to yield a variety of colors for the insulation
product.
[0023] It is a feature of the general inventive concepts that the
inventive binder compositions bind mineral wool under acidic
conditions. Generally speaking, binders that require an acidic
environment to properly crosslink/cure are ineffective or have
reduced performance when binding mineral wool. It was surprisingly
found that the inventive binders described herein were effective at
binding mineral wool to form an insulative batt at a pH of 1 to
4.5, including a pH of 2.5 to 3.
[0024] In certain embodiments, the inventive binder composition may
be cured at a lower temperature than conventional binder
compositions. A binder composition comprising a polyol and a metal
salt may allow water to more-readily release from the pre-cured
product. The reduced water content thereby requires less heat to
drive excess water from the product during the cure process.
[0025] It is a feature of the general inventive concepts that the
binder composition (e.g., polyvinyl alcohol and a metal salt) can
form an aqueous mixture that can be applied by conventional binder
applicators, including spray applicators.
[0026] It is also a feature of the general inventive concepts that
the inventive binder composition can be useful for making mats
containing composite reinforcements.
[0027] The foregoing and other objects, features, and advantages of
the general inventive concepts will appear more fully hereinafter
from a consideration of the detailed description that follows. It
is to be expressly understood, however, that the drawings are for
illustrative purposes and are not to be construed as defining the
limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Various exemplary advantages of this invention will be
apparent upon consideration of the following detailed disclosure of
the invention, especially when taken in conjunction with the
accompanying drawings wherein:
[0029] FIG. 1 is a graph showing the tensile strength divided by
the corrected LOI (tensile strength/Corr. LOI) for handsheet
samples made with several binder compositions.
[0030] FIG. 2 is a graph showing the tensile strength divided by
the corrected LOI (tensile strength/Corr. LOI) for handsheet
samples made with several binders including inventive binder
compositions comprising polyvinyl alcohol/aluminum chloride and
polyvinyl alcohol/aluminum nitrate.
[0031] FIG. 3 is a graph showing the dynamic mechanical analysis of
several binder compositions including an inventive binder
comprising polyvinyl alcohol/aluminum nitrate.
[0032] FIG. 4 is a graph showing the dynamic mechanical analysis of
several binder compositions including an inventive binder
comprising polyvinyl alcohol/aluminum chloride.
[0033] FIG. 5 is a graph showing the dynamic mechanical analysis of
several binder compositions comprising polyvinyl alcohol/aluminum
nitrate.
[0034] FIG. 6 is a graph showing the dynamic mechanical analysis of
several binder compositions comprising polyvinyl alcohol/aluminum
sulfate.
[0035] FIG. 7 is a graph showing the percent recovery for several
binder compositions of polyvinyl alcohol and aluminum nitrate.
[0036] FIG. 8 is a graph showing the percent recovery for several
binder compositions.
[0037] FIG. 9 is a graph showing the maximum load (corrected for
LOI) for lab boards made with inventive binder compositions
comprising polyvinyl alcohol/aluminum nitrate.
[0038] FIG. 10 is a graph showing the corrected LOI for inventive
binder compositions comprising polyvinyl alcohol/aluminum
nitrate.
[0039] FIG. 11 is a graph showing the tensile strength of a series
of handsheets made using inventive binder compositions which were
cured at temperatures between 250.degree. F. and 450.degree. F.
[0040] FIG. 12 is a graph showing the tensile strength normalized
for LOI of a series of handsheets made using inventive binder
compositions which were cured at temperatures between 250.degree.
F. and 450.degree. F.
[0041] FIG. 13 is a graph showing the LOI for handsheets made using
inventive binder compositions which were cured at temperatures
between 250.degree. F. and 450.degree. F.
[0042] FIG. 14 is a graph showing the percent recovery for samples
made using inventive binder compositions which were cured at
temperatures between 300.degree. F. and 400.degree. F.
[0043] FIG. 15 is a graph showing the percent recovery normalized
for area weight for samples made using inventive binder
compositions which were cured at temperatures between 300.degree.
F. and 400.degree. F.
[0044] FIG. 16 is a graph showing corrected LOI for samples made
using inventive binder compositions which were cured at
temperatures between 300.degree. F. and 400.degree. F.
[0045] FIG. 17 is a graph showing the measured stiffness of a
series of sample batts made using inventive binder compositions
which were cured at either high temperature (415-425.degree. F. as
measured in the batt) or low temperature (350-360.degree. F. as
measured in the batt) with a target LOI of 4.65%.
[0046] FIG. 18 is a graph showing the bond strength of samples made
using inventive binder compositions which were cured at either high
temperature (415-425.degree. F. as measured in the batt) or low
temperature (350-360.degree. F. as measured in the batt) with a
target LOI of 4.65%.
[0047] FIG. 19 is a graph showing the tensile strength of samples
made using inventive binder compositions which were cured at either
high temperature (415-425.degree. F. as measured in the batt) or
low temperature (350-360.degree. F. as measured in the batt) with a
target LOI of 4.65%.
[0048] FIG. 20 is a graph showing the measured tensile strength of
handsheets made using a variety of binder compositions. The
inventive binder composition comprising PV and aluminum chloride
(labeled PVA) in a weight ratio of 90:10 was compared to a control
MDCA binder composition. Other binder compositions are
PVGAF=polyvinyl alcohol, gallic acid, and iron nitrate; and
PVGAA=polyvinyl alcohol, gallic acid, and aluminum chloride.
[0049] FIG. 21 is a graph showing the tensile strength of
handsheets made using a binder composition comprising PV and
aluminum chloride (labeled PVA) in a weight ratio of 90:10.
[0050] FIG. 22 is a graph showing the results from Example 25
adjusted to correct for LOI.
[0051] FIG. 23 is a graph showing the measured tensile strength for
handsheets made using a variety of binder compositions.
[0052] FIG. 24 is a graph showing the measured stiffness of an
inventive binder composition compared to a control MDCA binder, and
two additional binders including polyvinyl alcohol, namely,
polyvinyl alcohol, gallic acid, aluminum chloride (labeled PVGAAl);
and polyvinyl alcohol, gallic acid, iron nitrate (labeled
PVGAFe).
[0053] FIG. 25 is a graph showing the average LOI for the binder
compositions tested in Example 28.
[0054] FIG. 26 is a graph showing the percent recovery for the
binders compositions in Example 28. PVAl is polyvinyl alcohol and
aluminum chloride polyvinyl alcohol, gallic acid, aluminum chloride
(labeled PVGAAl); and polyvinyl alcohol, gallic acid, iron nitrate
(labeled PVGAFe).
[0055] FIG. 27 is a graph showing the measured sag of mineral wool
batts with a variety of binders applied thereto.
[0056] FIG. 28 is a graph showing the measured pull strength of
mineral wool batts with a variety of binders applied thereto.
[0057] FIG. 29 is a graph showing the measured resilience of
mineral wool batts with a variety of binders applied thereto.
[0058] FIG. 30 is a graph showing the measured compressive strength
of mineral wool batts with a variety of binders applied
thereto.
[0059] FIG. 31 is a graph showing amounts of binder solids for the
binders.
[0060] FIG. 32 is a graph showing the tensile strength for mineral
wool handsheets prepared with PV/Al(NO.sub.3).sub.3 binder system
after storage.
[0061] FIG. 33 is a graph showing the tensile strength for mineral
wool handsheets prepared with PV/Al(NO.sub.3).sub.3 binder system
after storage.
[0062] FIG. 34 is a plot of the dynamic mechanical analysis of a PV
film.
[0063] FIG. 35 is a plot of the dynamic mechanical analysis of a
PV/Al(NO.sub.3).sub.3 binder.
[0064] FIG. 36 is a plot of the dynamic mechanical analysis of a
PV/KNO.sub.3 binder for comparison.
DETAILED DESCRIPTION
[0065] 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 published or
corresponding U.S. or foreign patent applications, issued U.S. or
foreign patents, and any other references, are each incorporated by
reference in its entirety, including all data, tables, figures, and
text presented therein.
[0066] It will be understood that when an element such as a layer,
region, substrate, or panel is referred to as being "on" another
element, it can be directly on the other element or intervening
elements may also be present. Also, when an element is referred to
as being "adjacent" to another element, the element may be directly
adjacent to the other element or intervening elements may be
present. The terms "top," "bottom," "side," and the like are used
herein for the purpose of explanation only. Like numbers found
throughout the figures denote like elements.
[0067] The terminology as set forth herein is for description of
the exemplary embodiments only and should not be construed as
limiting the disclosure as a whole. All references to singular
characteristics or limitations of the present disclosure shall
include the corresponding plural characteristic or limitation, and
vice versa, unless otherwise specified or clearly implied to the
contrary by the context in which the reference is made. Unless
otherwise specified, "a," "an," "the," and "at least one" are used
interchangeably. Furthermore, as used in the description and the
appended claims, the singular forms "a," "an," and "the" are
inclusive of their plural forms, unless the context clearly
indicates otherwise.
[0068] To the extent that the term "includes" or "including" is
used in the description or the claims, it is intended to be
inclusive in a manner similar to the term "comprising" as that term
is interpreted when employed as a transitional word in a claim.
Furthermore, to the extent that the term "or" is employed (e.g., A
or B) it is intended to mean "A or B or both."
[0069] All percentages, parts, and ratios as used herein are by
weight of the total composition, unless otherwise specified. All
ranges and parameters, including but not limited to percentages,
parts, and ratios, disclosed herein are understood to encompass any
and all sub-ranges assumed and subsumed therein, and every number
between the endpoints. For example, a stated range of "1 to 10"
should be considered to include any and all sub-ranges beginning
with a minimum value of 1 or more and ending with a maximum value
of 10 or less (e.g., 1 to 6.1, or 2.3 to 9.4), and to each integer
(1, 2, 3, 4, 5, 6, 7, 8, 9, and 10) contained within the range.
[0070] Any combination of method or process steps as used herein
may be performed in any order, unless otherwise specified or
clearly implied to the contrary by the context in which the
referenced combination is made.
[0071] The various embodiments of the compositions described herein
may also be substantially free of any optional or selected
component or feature described herein, provided that the remaining
compositions still contain all of the necessary components or
features as described herein. In this context, and unless otherwise
specified, the term "substantially free" means that the selected
binder compositions contain less than a functional amount of the
optional ingredient, typically less than 1%, including less than
0.5%, including less than 0.1%, and also including zero percent, by
weight of such optional or selected essential ingredient.
[0072] The compositions described herein may comprise, consist of,
or consist essentially of the essential elements of the products
and methods as described herein, as well as any additional or
optional element described herein or otherwise useful in binder
applications or related applications.
[0073] The general inventive concepts relate to more
environmentally friendly binder compositions. In certain
embodiments, the binder is an aqueous binder composition. The
binder composition typically will be comprised of a metal salt and
polyol. The binder may be used to form products including fibers
such as fiberglass, mineral wool, carbon fiber, and organic fibers
including cellulose and wood-based fibers.
[0074] In certain exemplary embodiments, the inventive binder
includes at least one polyol. In certain exemplary embodiments, the
polyol includes compounds such as aliphatic alcohols, glycerol,
triethanolamine, ethylene glycol, polyethylene glycol, unmodified
polyvinyl alcohol, modified polyvinyl alcohol, a copolymer of
polyvinyl alcohol, polyvinyl acetate, and polyacrylic acid. In
certain exemplary embodiments, the polyol may be a polymeric
alcohol. The term polyol as used herein is intended to refer to
compounds having an aliphatic or aromatic backbone and at least two
hydroxyl functional groups. However, it should be understood that
other functional groups may also be present in addition to the
hydroxyl functional groups, or in certain embodiments, other
functional groups may replace one or more of the hydroxyl
functional groups so long as the functional groups would be
expected to interact with the glass surface and the metal salt in a
similar fashion. Thus, the term polyol, in certain embodiments, may
refer to compounds that have few or no hydroxyl functional groups,
but which are related to polyols and retain a similar interaction,
such as, for example, polyvinyl acetate, polyacrylic acid, and
modified polyvinyl alcohol. The terms "polyol" and "polymeric
alcohol" are used interchangeably herein and refer to chemical
compounds having at least two hydroxyl functionalities. While the
terms refer to compounds by the particular functional group, those
of ordinary skill in the art will recognize that a wide variety of
other functional groups may be present in the compounds so long as
the other groups do not impede or substantially interfere with the
general inventive concepts discussed herein.
[0075] In certain exemplary embodiments, the binder composition is
free from added formaldehyde.
[0076] In certain exemplary embodiments, the fibrous insulation
products and non-woven mats utilizing the inventive binder
composition can be manufactured using existing manufacturing lines,
thereby saving time and money.
[0077] In certain exemplary embodiments, a final insulation product
made with exemplary binder compositions provided herein has a light
color at desired loss on ignition (LOI) levels that allows the use
of dyes, pigments, or other colorants to yield a variety of colors
for the insulation product.
[0078] In certain exemplary embodiments, the binder composition
(e.g., polyvinyl alcohol having a degree of hydrolysis of at least
50% and an aluminum salt) can form an aqueous mixture that can be
applied by conventional binder applicators, including spray
applicators.
[0079] In certain exemplary embodiments, the binder composition is
used in the formation of insulation (e.g., insulative batts),
insulation boards, non-woven mats, carbon fiber products, and for
use in products as a binder for organic fibers such as cellulose
and wood-based fibers. Generally, the binder includes a metal salt
and a polyol.
[0080] In certain exemplary embodiments, the general inventive
concepts relate to a fibrous insulation product that includes a
plurality of fibers and a binder composition applied to at least a
portion of the fibers and interconnecting the fibers. In certain
exemplary embodiments, the fibers are randomly oriented.
[0081] In certain exemplary embodiments, the general inventive
concepts relate to a non-woven mat formed of a plurality of
randomly oriented glass fibers having been chopped to a discrete
length enmeshed in the form of a mat having a first major surface
and a second major surface and a binder composition at least
partially coating, or in certain embodiments, at least partially
impregnating the first major surface of the mat.
[0082] In certain exemplary embodiments, the general inventive
concepts relate to a non-woven mat formed of a plurality of
randomly oriented glass fibers enmeshed in the form of a mat having
a first major surface and a second major surface and a binder
composition at least partially coating, or in certain embodiments,
at least partially impregnating the first major surface of the
mat.
[0083] In certain exemplary embodiments, the general inventive
concepts relate to a non-woven mat formed of a plurality of
randomly oriented mineral wool fibers in the form of a mat having a
first major surface and a second major surface and a binder
composition at least partially coating, or in certain embodiments,
at least partially impregnating the first major surface of the
mat.
[0084] In certain exemplary embodiments, the binder composition
comprises at least one metal salt. In certain exemplary
embodiments, the metal is at least one of a group 13 element, a
post-transition metal, a metalloid, or any other metal that readily
coordinates oxygen. In certain embodiments, the metal is selected
from boron, aluminum, gallium, indium, tin, thallium, lead,
bismuth, zinc, iron, zirconium, and titanium. In certain
embodiments, the metal salt may comprise more than one metal, such
as, for example, a combination or complex of aluminum and
zirconium. In certain exemplary embodiments, the metal salt is
comprised of at least one salt of aluminum. In certain exemplary
embodiments, the metal salt is selected from the group consisting
of aluminum chloride, aluminum nitrate, aluminum sulfate, aluminum
phosphate monobasic, sodium aluminate, and combinations
thereof.
[0085] In certain embodiments, the polyol is a polymeric alcohol,
including a water miscible synthetic polymeric alcohol. In certain
embodiments, the polyol is a water soluble polymeric alcohol such
as a polyvinyl alcohol.
##STR00001##
[0086] Those of skill in the art will understand that PV
(alternatively, PVOH) generally refers to the class of compounds
that result from hydrolysis of the ester functional groups of
polyvinyl acetate. While other materials may be used to form a
polyvinyl alcohol, generally, PV is manufactured by polymerization
of vinyl acetate to polyvinyl acetate. The polyvinyl acetate is
then subjected to hydrolysis to render a PV having a desired degree
of hydrolysis (relative to the polyvinyl acetate polymer). Thus,
while PVs having varying degrees of hydrolysis are referred to as
polyvinyl alcohol, those of skill in the art will recognize that
the term polyvinyl alcohol refers to a "copolymer" comprised of
acetate moieties and alcohol moieties, with the exact composition
determined by the degree of hydrolysis.
[0087] One way of characterizing PV is by reference to the degree
to which it is hydrolyzed. In certain embodiments, the PV has a
degree of hydrolysis of at least 50%. In certain embodiments, the
PV has a degree of hydrolysis of 50% to 98% or more. In certain
embodiments, the PV has a high degree of hydrolysis, including
polymers that are 75% hydrolyzed, including 80% hydrolyzed,
including 85% hydrolyzed, including 90% hydrolyzed, including 95%
hydrolyzed, including 98% hydrolyzed, including 99% hydrolyzed or
more.
[0088] In certain exemplary embodiments, the PV may be modified
after hydrolysis. In certain exemplary embodiments, the polyol is
an unmodified PV. Unmodified PV may be considered a polyvinyl
acetate that has been hydrolyzed to make PV and is used without
further modification of the hydroxyl groups of the polymer.
Modified polyvinyl alcohol is a PV that has been reacted to modify
at least a portion of the pendant functional groups remaining after
primary hydrolysis to form the PV. PV may be modified (e.g.,
grafted) with silanes or acids to form a copolymer. In certain
embodiments, the polyol is a modified polyvinyl alcohol.
[0089] Another way of characterizing a PV is by the measured
viscosity of a solution containing a certain percentage of the PV.
The viscosity of PV may be measured by making a 4% solution of PV
and measuring the viscosity using a Hoeppler falling-ball
viscometer at ambient temperature (i.e., approximately 20.degree.
C.). In certain exemplary embodiments, the PV has a viscosity of 3
centipoise. In certain exemplary embodiments, the PV has a
viscosity of 4 centipoise. In certain exemplary embodiments, the PV
has a viscosity of 5 centipoise.
[0090] While not wishing to be bound by theory, it is believed that
a metal salt may form a coordination complex between the hydroxyl
functionalities of, for example, glass (e.g., fiberglass) and the
hydroxyl groups of a polyol (e.g., polyvinyl alcohol) as
illustrated below. In addition, during heating, the metal ion may
catalyze reactions between the glass fibers and the polyol to form
covalent bonds between the two, or to "crosslink" adjacent polyol
molecules. Below is a representative diagram illustrating one
possible interaction between aluminum, a glass surface, and a
polyol (e.g., polyvinyl alcohol). In addition, the aluminum may
also interact with adjacent polyol molecules (as shown below right)
further increasing the overall strength of the fibrous
material.
##STR00002##
[0091] This coordination or crosslinking may aid in formation of
three-dimensional networks between the individual components,
providing additional bond strength to the finished product (e.g.,
insulative batts or boards). Boron, which is electronically similar
in valence to aluminum, forms an insoluble gel when combined with
PV in an aqueous medium. It was surprisingly found that the
combination of an aluminum salt (e.g., aluminum nitrate) and PV
demonstrated no such gelling and, in fact, resulted in an aqueous
mixture that was suitable for application to glass fibers and
mineral wool as a binder composition, even after storage of the
mixture for a significant amount of time.
[0092] Notwithstanding the proposed mechanism of interaction, while
the above discussion relates to the interaction between the
inventive binder and the surface of a glass substrate, the
inventive binder compositions may similarly bind other materials
(e.g., mineral wool or slag wool), including those without hydroxyl
functional groups on the surface.
[0093] In certain exemplary embodiments, the metal salt and the
polyol are present in the aqueous binder composition in a
particular weight ratio to one another. In certain exemplary
embodiments, the metal salt and the polyol are present in the
binder composition in a weight ratio of 1:99 to 1:1. In certain
exemplary embodiments, the metal salt and the polyol are present in
the binder composition in a weight ratio of 1:50 to 1:1. In certain
exemplary embodiments, the metal salt and the polyol are present in
the binder composition in a weight ratio of 1:20 to 1:1. In certain
exemplary embodiments, the metal salt and the polyol are present in
the binder composition in a weight ratio of 1:10 to 1:1. In certain
exemplary embodiments, the metal salt and the polyol are present in
the binder composition in a weight ratio of 1:9 to 1:1. In certain
exemplary embodiments, the metal salt and the polyol are present in
the binder composition in a weight ratio of 1:4 to 1:1. In certain
exemplary embodiments, the metal salt and the polyol are present in
the binder composition in a weight ratio of 3:7 to 1:1. In certain
exemplary embodiments, the metal salt and the polyol are present in
the binder composition in a weight ratio of 2:3 to 1:1. In certain
exemplary embodiments, the metal salt and the polyol are present in
the binder composition in a weight ratio of 1:4 to 3:7. In certain
exemplary embodiments, the metal salt and the polyol are present in
the binder composition in a weight ratio of 1:4 to 2:3.
[0094] In certain exemplary embodiments, the binder composition is
present in a fibrous insulation product or a non-woven mat in an
amount of 1% to 25% loss on ignition (LOI). The term loss on
ignition refers to a process of heating a product to pyrrolyze a
binder, driving off materials that are combustible. For example, a
fibrous insulation product may be prepared according to certain
methods described herein. The product is then subjected to high
heat to remove any pyrrolyzable material, leaving behind, for
example, a fiberglass substrate and any materials that might not be
expected to pyrrolyze. The amount of weight lost during this
process is then reported as a percentage of the original weight of
the product (i.e., the LOI). In certain exemplary embodiments, the
loss on ignition value is corrected after primary measurement to
account for non-combustible materials, such as metal salts from a
binder.
[0095] In certain exemplary embodiments, the binder composition may
optionally comprise additional components including, but not
limited to, one or more of a secondary binder composition, a
crosslinking agent, a coupling agent, a moisture resistant agent, a
dust suppression agent, a catalyst, an inorganic acid or base, and
an organic acid or base. The binder composition is free of added
formaldehyde and, thus, is generally more environmentally friendly
than a similar formaldehyde-containing binder.
[0096] In addition, in certain exemplary embodiments, the binder
may optionally contain conventional additives such as, but not
limited to, one or more of corrosion inhibitors, dyes, pigments,
fillers, colorants, UV stabilizers, thermal stabilizers,
anti-foaming agents, anti-oxidants, emulsifiers, preservatives
(e.g., sodium benzoate), biocides, and fungicides. Other additives
may be added to the binder composition for the improvement of
process and/or product performance. Such additives include
lubricants, wetting agents, surfactants, antistatic agents, and/or
water repellent agents. Additives may be present in the binder
composition from trace amounts (such as <about 0.1% by weight
the binder composition) up to about 10% by weight of the total
solids in the binder composition. In certain embodiments, the
additives are present in an amount from about 0.1% to about 5% by
weight of the total solids in the binder composition, from about 1%
to about 4% by weight, or from about 1.5% to about 3% by
weight.
[0097] The binder compositions further include water to dissolve or
disperse the active solids for application onto the fibers. Water
may be added in an amount sufficient to dilute the aqueous binder
composition to a viscosity that is suitable for its application to
the fibers and to achieve a desired solids content on the fibers.
In particular, the binder composition may contain water in an
amount from about 50% to about 98% by weight of the binder
composition. In certain exemplary embodiments, the binder
composition comprises water in an amount of greater than 60% by
weight of the binder composition. In certain exemplary embodiments,
the binder composition comprises water in an amount of greater than
70% by weight of the binder composition. In certain exemplary
embodiments, the binder composition comprises water in an amount of
greater than 80% by weight of the binder composition. In certain
exemplary embodiments, the binder composition comprises water in an
amount of greater than 90% by weight of the binder composition,
including 90% to 97% by weight of the binder composition.
[0098] In an exemplary embodiment, the binder composition is used
to form an insulation product. In general, fibrous insulation
products are formed of matted inorganic fibers (e.g., fiberglass)
bonded together by a cured thermoset polymeric material. Examples
of suitable inorganic fibers include glass wool, stone wool, slag
wool, mineral wool, and ceramic. Optionally, other reinforcing
fibers such as natural fibers and/or synthetic fibers (e.g., carbon
fibers, polyester, polyethylene, polyethylene terephthalate,
polypropylene, polyamide, aramid, and/or polyaramid fibers) may be
present in the insulation product in addition to, or instead of,
the glass fibers or mineral wool, for example. The term "natural
fiber" as used herein refers to plant fibers extracted from any
part of a plant, including, but not limited to, the stem, seeds,
leaves, roots, or phloem. Insulation products may be formed
entirely of one type of fiber, or they may be formed of a
combination of two or more different 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. The embodiments described herein
are with reference to insulation products formed entirely of glass
fibers.
[0099] The manufacture of glass fiber insulation may be carried out
in a continuous process by fiberizing molten glass, immediately
forming a fibrous glass batt on a moving conveyor, and curing a
binder applied on the fibrous glass batt to form an insulation
blanket. Glass may be melted in a tank and supplied to a fiber
forming device such as a fiberizing spinner. The spinner is rotated
at high speeds. Centrifugal force causes the molten glass to pass
through holes in the circumferential sidewalls of the fiberizing
spinner to form glass fibers. Glass fibers of random lengths may be
attenuated from the fiberizing spinner and blown generally downward
by blowers positioned within a forming chamber. The blowers turn
the fibers downward to form a fibrous batt. Those of skill in the
art will understand that the glass fibers may have a variety of
diameters based on the intended use of the final product.
[0100] The glass fibers, while in transit in the forming chamber
and while still hot from the drawing operation, are sprayed with
the inventive aqueous binder composition. Water may also be applied
to the glass fibers in the forming chamber.
[0101] The glass fibers having the uncured resinous binder adhered
thereto may be gathered and formed into an uncured insulation pack
on a forming conveyor within the forming chamber with the aid of a
vacuum drawn through the fibrous pack from below the forming
conveyor.
[0102] The coated fibrous pack, which is in a compressed state due
to the flow of air through the pack in the forming chamber, is then
transferred out of the forming chamber to a transfer zone where the
pack vertically expands due to the resiliency of the glass fibers.
The expanded insulation pack is then heated in a curing oven where
heated air is blown through the insulation pack to evaporate any
remaining water in the binder, cure the binder, and rigidly bond
the fibers together. The insulation pack may be compressed to form
a fibrous insulation blanket. It is to be appreciated that the
insulation blanket has an upper surface and a lower surface. In
certain embodiments, the pack may be compressed to any one of a
variety of densities.
[0103] A facing material may then be placed on the insulation
blanket to form a facing layer. Non-limiting examples of suitable
facing materials include Kraft paper, a foil-scrim-Kraft paper
laminate, recycled paper, and calendared paper. The facing material
may be adhered to the surface of the insulation blanket by a
bonding agent to form a faced insulation product. Suitable bonding
agents include adhesives, polymeric resins, asphalt, and bituminous
materials that can be coated or otherwise applied to the facing
material. The faced fibrous insulation may subsequently be rolled
for storage and/or shipment. In certain embodiments, the faced
fibrous insulation may be cut into predetermined lengths by a
cutting device prior to packaging. Such faced insulation products
may be used, for example, as panels in basement finishing systems,
as duct wrap, duct board, as faced residential insulation, and as
pipe insulation.
[0104] In an exemplary embodiment, the inventive binder composition
may be used to form a non-woven mat. In particular, the binder is
added during the formation of a chopped strand mat in a wet-laid
mat processing line. Chopped glass fibers may be provided to a
conveying apparatus from a storage container for conveyance to a
mixing tank that contains various surfactants, viscosity modifiers,
defoaming agents, and/or other chemical agents with agitation to
disperse the fibers and form a chopped glass fiber slurry. The
glass fiber slurry may be transferred to a head box where the
slurry is deposited onto a conveying apparatus such as a moving
screen or foraminous conveyor and a substantial portion of the
water from the slurry is removed to form a web (mat) of enmeshed
fibers. In certain exemplary embodiments, the water may be removed
from the web by a conventional vacuum or air suction system. It is
to be appreciated that while reference is made herein to glass
fibers or glass wool, the mat could be formed of, or include,
non-glass fibers such as mineral wool. Those of ordinary skill in
the art will understand that, while insulation products comprising
materials other than glass fibers will have certain necessary
changes in the details of forming an insulation product, these
changes will still fall within the general inventive concepts
described herein.
[0105] The inventive binder is applied to the web by a suitable
binder applicator, such as a spray applicator or a curtain coater.
Once the binder has been applied to the mat, the binder coated mat
is passed through at least one drying oven to remove any remaining
water and cure the binder composition. The formed non-woven mat
that emerges from the oven is an assembly of randomly oriented,
dispersed, individual glass fibers. The chopped strand mat may be
rolled onto a take-up roll for storage for later use. Exemplary
uses of the non-woven mat, include but are not limited to, roofing,
flooring applications, ceiling applications, wall applications, as
filters, in ground based vehicles, and in aircraft.
[0106] Having generally described the invention, a further
understanding can be obtained by reference to certain specific
examples illustrated below which are provided for purposes of
illustration only and are not intended to be all inclusive or
limiting unless otherwise specified.
EXAMPLES
Example 1
[0107] A binder composition comprising a mixture of polyvinyl
alcohol (PV) and aluminum chloride (AlCl.sub.3) (together PVAl) in
a weight ratio of 90:10 was compared to a control binder
composition comprising a mixture of maltodextrin and citric acid in
a weight ratio of 70:30 (MDCA) (including 3.5% sodium
hypophosphite). Unless otherwise indicated, the total solids are
kept constant across the binder compositions. The binders were
utilized to form handsheets in the manner described in detail
below. The nonwoven fiberglass handsheets were dried and cured for
three minutes at 475.degree. F. The tensile strength, the LOI, and
the tensile strength divided by the corrected LOI (tensile
strength/Corr. LOI) for each sample were determined under ambient
and hot/humid conditions and the results are shown in FIG. 1. The
LOI of the reinforcing fibers is the reduction in weight of the
fiberglass product after heating them to a temperature sufficient
to burn or pyrolyze the organic portion of the binder from the
fibers. The corrected LOI corrects for the presence of aluminum
salts from the binder that would not be expected to pyrolyze.
Hot/humid conditions include placing the samples in an autoclave at
90.degree. F. and 90% humidity for 30 minutes. From these results,
it was demonstrated that the inventive binder comprising polyvinyl
alcohol and aluminum chloride could produce an effective fiberglass
binder.
Example 2
[0108] FIG. 2 shows the results of tensile strength measurements of
handsheets made with several binder compositions. The graph shows
first and second control binder results at the top and bottom of
the graph. A PV and AlCl.sub.3 (90:10) was compared to several
binders including polyvinyl alcohol and aluminum nitrate
Al(NO.sub.3).sub.3 (i.e., 90:10, 85:15, and 80:20). The handsheets
were cured for three minutes at 400.degree. F. The samples were
then tested according to the procedures described in Example 1.
From the data set forth in FIG. 2, it was concluded that the binder
compositions combining polyvinyl alcohol and aluminum salts
achieved good performance on handsheets.
Example 3
[0109] FIG. 3 is a graph showing the dynamic mechanical analysis of
polyvinyl alcohol alone (PVOH), and a binder comprising PV and
Al(NO.sub.3).sub.3 in a weight ratio of 70:30 (70-30 PVAl),
compared to a control MDCA binder (including 3.5% sodium
hypophosphite). It can be seen from the graph that the inventive
binder performs much better than polyvinyl alcohol alone and
similar to the control binder. From the data set forth in FIG. 3,
it was concluded that the binder compositions combining polyvinyl
alcohol and aluminum salts achieved good performance for dynamic
mechanical analysis.
Example 4
[0110] FIG. 4 is a graph showing the dynamic mechanical analysis of
a binder comprising PV and AlCl.sub.3 in a weight ratio of 70:30
(labeled 70-30 Chloride) compared to a control MDCA binder. It can
be seen from the graph that the inventive binder performs similar
to the control binder.
Example 5
[0111] FIG. 5 is a graph showing the dynamic mechanical analysis of
three binder compositions comprising PV and Al(NO.sub.3).sub.3 in
weight ratios of 70:30, 80:20, and 90:10, respectively. The graph
shows an improvement in storage modulus with increasing
Al(NO.sub.3).sub.3 content.
Example 6
[0112] FIG. 6 is a graph showing the dynamic mechanical analysis of
three binder compositions comprising PV and aluminum sulfate
(Al.sub.2(SO.sub.4).sub.3) in a weight ratio of 70:30, 80:20, and
90:10. The graph shows an improvement in storage modulus with
increasing Al.sub.2(SO.sub.4).sub.3 content.
Example 7
[0113] FIG. 7 shows the percent recovery of two binder compositions
comprising PV and Al(NO.sub.3).sub.3 (PVAl) in weight ratios of
90:10 and 80:20, respectively, compared to polyvinyl alcohol alone
(labeled 100 PV) and a control MDCA binder. The percent recovery
was determined at ambient conditions and under hot/humid
conditions. Hot/humid conditions include placing the samples in a
humidity chamber at 90.degree. F. and 90% humidity for 7 days.
Percent recovery for the PV-containing binders was similar to or
better than the control binder under ambient conditions. Increasing
aluminum salt content improved hot/humid performance.
Example 8
[0114] FIG. 8 shows the percent recovery of binder compositions
comprising PV in combination with several aluminum salts compared
to a control MDCA binder, under both ambient and hot/humid
conditions. The aluminum salts are aluminum chloride (70:30 PV:Al
weight ratios), aluminum nitrate (80:20 and 70:30 PV:Al weight
ratios), and aluminum sulfate (80:20 and 70:30 weight ratio). The
percent recovery was determined at ambient conditions and under
hot/humid conditions. Hot/humid conditions include placing the
samples in a humidity chamber at 90.degree. F. and 90% humidity for
7 days. From the data set forth in FIG. 8, it was concluded that
these binder formulations achieved good performance for percent
recovery.
Example 9
[0115] Corrosion of the machinery that is used to form, for
example, a fibrous insulation product is an important factor to
consider when comparing binder systems. The pH of a binder system
is indicative of its potential to corrode metal machinery. In
addition, the pH of a binder system may change during heating
(curing) as the components (for example acid in the binder) may be
consumed during the curing process, thus leading to a less acidic
final composition. Table 1 shows the measured pH of several binder
systems in triplicate. The initial pH is the pH of the binder
solution prior to spraying in the application process. The final pH
is the pH of the solution resulting from soaking the pilot material
after cure in water. The less acidic cure for the inventive binder
systems is indicative of less potential for machine corrosion.
TABLE-US-00001 TABLE 1 Binder Specimen pH Average pH Polyvinyl
alcohol 1 9.73 (initial pH 5.76) 2 9.75 3 9.63 9.70 90:10
PVAl(NO.sub.3).sub.3 1 8.02 (initial pH 3.45) 2 8.06 3 8.04 8.04
80:20 PVAl(NO.sub.3).sub.3 1 8.02 (initial pH 3.36) 2 8.05 3 8.05
8.04
Example 10
[0116] FIG. 9 is a graph showing the maximum measured loading
capacity, adjusted for corrected LOI, for two inventive binder
systems. The max load was determined at ambient conditions and
under hot/humid conditions (as described for Example 1). The
inventive binder systems include PVAl(NO.sub.3).sub.3 in weight
ratios of 90:10 and 80:20, respectively. The inventive binder
compositions are compared to a control phenolic resin (labeled PUF)
and polyvinyl alcohol alone. All binder systems are normalized for
total solids. The 80:20 weight ratio of PVAl(NO.sub.3).sub.3
performed as good or better than the control binder systems.
Example 11
[0117] FIG. 10 is a graph showing the corrected LOI for the binder
systems that were utilized in Example 10.
Example 12
[0118] Handsheets were formed using a 70:30 weight ratio of two PV
aluminum salt binders. The handsheets were formed with binders
including Al(NO.sub.3).sub.3 or Al.sub.2(SO.sub.4).sub.3 and were
cured at temperatures of 250.degree. F., 300.degree. F.,
350.degree. F., 400.degree. F., and 450.degree. F. FIG. 11 shows
the tensile strength measurements of the handsheets under both
ambient and hot/humid conditions (as described for Example 1).
Example 13
[0119] FIG. 12 shows the measured tensile strength for the
handsheets described in Example 12, with the tensile strength
corrected for measured LOI.
Example 14
[0120] FIG. 13 is a graph showing the measured LOI for the
handsheets described in Example 12. From the data set forth in FIG.
12, FIG. 13, and FIG. 14, it was concluded that these binder
formulations achieved good performance on handsheets at lower
temperatures typically used in exemplary manufacturing
processes.
Example 15
[0121] FIG. 14 is a graph showing the percent recovery for two
binder systems at different cure temperatures. A binder composition
comprising PVAl(NO.sub.3).sub.3 in a weight ratio of 70:30 was
cured at temperatures of 300.degree. F., 350.degree. F., and
400.degree. F. The inventive binders were compared to a control
MDCA binder cured at 300.degree. F. and 400.degree. F. The percent
recovery was measured under both ambient and hot/humid conditions.
Hot/humid conditions include placing the samples in a humidity
chamber at 90.degree. F. and 90% humidity for 3 days.
Example 16
[0122] FIG. 15 shows the percent recovery for the binders tested in
Example 14 with the percent recovery normalized by area weight.
Example 17
[0123] FIG. 16 shows the corrected LOI for the binders tested in
Example 14. From the data set forth in FIG. 14, FIG. 15, and FIG.
16, it was concluded that these binder formulations achieved good
performance in percent recovery even when correcting for LOI at
both low (300.degree. F.) and high (400.degree. F.) curing
temperatures while MDCA only held performance at high curing
temperature.
Example 18
[0124] R-15 insulative batts were manufactured using several binder
compositions in a manner known by those of skill in the art. FIG.
17 is a graph showing the measured stiffness (angular deflection)
of the insulative batts under both ambient and hot/humid
conditions. Hot/humid conditions include placing the samples in an
autoclave at 90.degree. F. and 90% humidity for 3 days. The binder
compositions were cured at either high temperature (415-425.degree.
F. as measured in the batt) or low temperature (350-360.degree. F.
as measured in the batt) with a target LOI of 4.65%. The inventive
binder compositions were compared to a control MDCA binder, a
mixture of PAG (polyacrylate/glycerol) and
PVAl.sub.2(SO.sub.4).sub.3, and a mixture of PAG
(polyacrylate/glycerol) and PVAl.sub.2(SO.sub.4).sub.3.
Example 19
[0125] Bond strength of the insulative batts made with the binder
compositions described in Example 18 was measured. The results are
shown in FIG. 18. The bond strength was measured under both ambient
and hot/humid conditions. Hot/humid conditions include placing the
samples in an autoclave at 90.degree. F. and 90% humidity for 3
days.
Example 20
[0126] FIG. 19 is a graph showing the measured tensile strength of
insulative batts made with the binder compositions described in
Example 18. The tensile strength was measured under both ambient
and hot/humid conditions. Hot/humid conditions include placing the
samples in an autoclave at 90.degree. F. and 90% humidity for 3
days.
Example 21
[0127] The average percent loss on ignition was measured and
corrected for weight of the aluminum salt for the insulative batts
described in Example 18. The results are shown in Table 2. Target
LOI was 4.65%.
TABLE-US-00002 TABLE 2 Average % LOI (LOI is corrected LOI for
binders that include a Binder Composition metal salt) MDCA 70:30
(Control #1) 4.71 PAG: Al.sub.2(SO.sub.4).sub.3 80:20 High temp.
3.62 PAG: PVOH: Al.sub.2(SO.sub.4).sub.3 60:20:20 High temp. 3.59
PVOH: Al.sub.2(SO.sub.4).sub.3 70:30 High temp. 4.03 PVOH:
Al(NO.sub.3).sub.3 70:30 High temp. 4.21 PVOH: Al(NO.sub.3).sub.3
70:30 Low temp. 4.26 PVOH: Al(NO.sub.3).sub.3 80:20 Low temp. 4.51
PVOH: Al.sub.2(SO.sub.4).sub.3 70:30 Low temp. 4.07 PVOH:
Al.sub.2(SO.sub.4).sub.3 80:20 Low temp. 4.27 MDCA 70:30 (Control
#2) 4.40
Example 22
[0128] The amount of moisture that a fibrous insulation product
absorbs is an important measure in determining loss of insulative
capacity over time. Moisture sorption was measured for the
insulative batts described in Example 18. Measured moisture
sorption for the samples are shown in Table 3. All samples were
below the target value of 5% moisture sorption.
TABLE-US-00003 TABLE 3 Moisture Binder Composition Sorption % MDCA
70:30 (Control #1) 2.90 PAG: Al.sub.2(SO.sub.4).sub.3 80:20 High
temp. 2.12 PAG: PVOH: Al.sub.2(SO.sub.4).sub.3 60:20:20 High temp.
1.68 PVOH: Al.sub.2(SO.sub.4).sub.3 70:30 High temp. 1.33 PVOH:
Al(NO.sub.3).sub.3 70:30 High temp. 1.83 PVOH: Al(NO.sub.3).sub.3
70:30 Low temp. 2.21 PVOH: Al(NO.sub.3).sub.3 80:20 Low temp. 2.07
PVOH: Al.sub.2(SO.sub.4).sub.3 70:30 Low temp. 1.49 PVOH:
Al.sub.2(SO.sub.4).sub.3 80:20 Low temp. 1.59 MDCA 70:30 (Control
#2) 1.83
Example 23
[0129] Corrosion testing was performed on the insulative batt
samples described in Example 18 via an ASTM C665 method. In
accordance with this standard, the three PVOH:Al(NO.sub.3).sub.3
binder compositions demonstrated acceptable corrosion performance.
From the data presented in Examples 18-23, it was concluded that
the inventive binder compositions could be cured under typical
manufacturing conditions and achieve good product performance as
binders for fibrous insulation products.
Example 24
[0130] Handsheets were made using a variety of binder compositions.
The inventive binder composition comprising PV and aluminum
chloride (labeled PVA) in a weight ratio of 90:10 was compared to a
control MDCA binder composition. The nonwoven fiberglass handsheets
were dried and cured for three minutes at 475.degree. F. The
tensile strength for each sample were determined under ambient and
hot/humid conditions and the results are shown in FIG. 20.
Hot/humid conditions include placing the samples in an autoclave at
90.degree. F. and 90% humidity for 30 minutes.
Example 25
[0131] Handsheets using a binder composition comprising PV and
aluminum chloride (labeled PVA) in a weight ratio of 90:10 were
made and cured at a variety of temperatures. The tensile strength
for each sample was determined under ambient and hot/humid
conditions. Hot/humid conditions include placing the samples in an
autoclave at 90.degree. F. and 90% humidity for 30 minutes. The
results are provided in FIG. 21.
Example 26
[0132] The results from Example 25 were adjusted to correct for
LOI. The results for the measured tensile strength/LOI are shown in
FIG. 22.
Example 27
[0133] Handsheets were made using a variety of binder compositions.
The inventive binder composition comprising PV and aluminum
chloride (labeled PVA) in a weight ratio of 90:10 was compared to a
control MDCA binder composition. Other formulations include
MDCAPV=maltodextrin, citric acid and polyvinyl alcohol,
PVCA=polyvinyl alcohol and citric acid, PVSi=polyvinyl alcohol and
sodium silicate. The nonwoven fiberglass handsheets were dried and
cured for three minutes at 425.degree. F. The tensile strength for
each sample was determined under ambient and hot/humid conditions.
The tensile strength was then corrected for LOI. Hot/humid
conditions include placing the samples in an autoclave at
90.degree. F. and 90% humidity for 30 minutes. The results are
shown in FIG. 23.
Example 28
[0134] FIG. 24 is a graph showing the measured stiffness of an
inventive binder composition compared to a control MDCA binder and
two additional binders including polyvinyl alcohol, namely
polyvinyl alcohol, gallic acid, and aluminum chloride (labeled
PVGAAl) and polyvinyl alcohol, gallic acid, iron nitrate (labeled
PVGAFe)
Example 29
[0135] The average LOI for the binder compositions tested in
Example 28 are shown in FIG. 25.
Example 30
[0136] The percent recovery for the binders described in Example 28
are shown in FIG. 26.
Examples 31-38
[0137] A series of binder formulations were prepared for
side-by-side testing of a variety of properties. The binders were
applied to mineral wool to produce light density batts (i.e., 3
lbs/ft.sup.3 to 4 lbs/ft.sup.3). Table 4 shows the composition of
the binders and the flow rate of the respective binders during
application.
TABLE-US-00004 TABLE 4 Binder Description SP1 PUF Control 1 SP2
70:30 PVOH: Al(NO.sub.3).sub.3 (10.5 flow) SP3 70:30 PVOH:
Al(NO.sub.3).sub.3 (9.5 flow) SP4 70:30 PVOH: Al(NO.sub.3).sub.3
(10.5 flow, inc fan) SPS 70:30 PVOH: Al(NO.sub.3).sub.3 (10.5 flow,
inc fan, 50.degree. F. temp in oven zones 1 and 2) SP6 70:30 PVOH:
Al(NO.sub.3).sub.3 + Additive A SP6A 70:30 PVOH: Al(NO.sub.3).sub.3
+ Additive B SP7 PUF Control 2
[0138] Flow refers to the rate of water injected during the set
point (gallons/minute). Inc fan refers to an increase in the
airflow rate through the insulation pack while curing. Additive A
and Additive B are included in SP6 and SP6A, respectively, as
processing aids to improve processing and flow of the binder
formulation.
Example 31
[0139] FIG. 27 is a graph showing the measured sag of the eight
mineral wool batts described in Table 4. The dimensions of the
batts are as follows: length=48'', width=16'', thickness=3''. Sag
is determined by supporting the batt one each end and measuring the
deflection (inches) of the midpoint of the batt. Hot/Humid
conditions are 3 days at 90.degree. F. and 90% relative
humidity.
Example 32
[0140] Pull strength is a measurement of the force required to pull
a cured batt apart. FIG. 28 is a graph showing the measured pull
strength of the eight mineral wool batts described in Table 4.
Example 33
[0141] Resilience is determined by measuring the thickness of the
batt, compressing with a certain load for a given amount of time
under either ambient or hot/humid conditions, the load is removed,
and the thickness is re-measured. The thickness after compression
is divided by the initial thickness and multiplied by 100 to give a
% resilience. Resilience is similar to recovery but for light
density batts. FIG. 29 is a graph showing the measured resilience
of the eight mineral wool batts described in Table 4.
Example 34
[0142] Compressive strength is the amount of force required to
compress a batt by 10% of its height (lbs/ft.sup.2). FIG. 30 is a
graph showing the measured compressive strength of the eight
mineral wool batts described in Table 4.
Example 35
[0143] FIG. 31 is a graph showing amounts of binder solids for the
eight binders described in Table 4.
Example 36
[0144] Certain binder systems are known to perform differently upon
storage. Often binder pre-mixes are known to have a relatively
short shelf life. FIG. 32 is a graph showing the tensile strength
for mineral wool handsheets prepared with 70:30
PV/Al(NO.sub.3).sub.3 binder system applied at 20% and 25%, after
storage. As can be seen from the graph, after two-months, the
inventive binder system showed little or no reduction in
performance.
Example 37
[0145] FIG. 33 is a graph showing the tensile strength for mineral
wool handsheets prepared with PV/Al(NO.sub.3).sub.3 binder system,
after storage. The tensile strength is corrected for the amount of
binder (measured by loss on ignition).
Example 38
[0146] Dynamic Mechanical Analysis (DMA) of a film formed from a
binder formulation is a helpful toll to estimate the glass
transition temperature (Tg) of a film. A shift in Tg to a higher
temperature is indicative of crosslinking. FIG. 34 is a plot of the
DMA of a film formed from PVOH alone. FIG. 35 is a plot of the DMA
of a PV/Al(NO.sub.3).sub.3 binder. Addition of the
Al(NO.sub.3).sub.3 shifts the Tg of the film to a higher
temperature. FIG. 36 is a plot of the DMA of a PV/KNO.sub.3.
Substitution of potassium for the aluminum results in a Tg closer
to the PVOH film. A similar measurement was performed by adding
phosphoric acid to mimic acidic conditions. This also did not
perform as well as the PV/Al(NO.sub.3).sub.3 binder system. Both of
these results indicate a necessary role for aluminum in the overall
performance of the binder system.
[0147] As can be seen from the Examples, the inventive binder
compositions are able to produce insulative products with
performance that, in certain instances, meets or exceeds that of a
conventional binder system. In certain instances, decreasing the
curing temperature provided product with qualitative improvements,
but did not demonstrate statistically significant performance
changes. Addition of processing aids such as polyethylene glycol
and glycerol improved product performance in certain tests.
Generally, the inventive binder system did not sacrifice
performance when tested under hot/humid conditions.
[0148] The general inventive concepts have been described above
both generically and with regard to specific embodiments. Although
the invention has been set forth in what is believed to be some
preferred embodiments, a wide variety of alternatives known to
those of skill in the art can be selected within the broader
disclosure. The invention is not otherwise limited, except for the
recitation of the claims set forth below.
* * * * *