BINDER FOR INSULATION AND NON-WOVEN MATS

Abstract

A fibrous material is treated with a binder solution and then heated. The binder comprises a polyester and a biopolymer, such as starch, where the polyester is a product of reaction of a polyol with an anhydride. A method for manufacturing the treated fibrous material comprises treating it with the binder solution and then heating. A cross-linking agent may be added.

Claims

1. An article of manufacture comprising: fibrous material treated with a binder, wherein the binder comprises: a polyester or polyester copolymer, and a biopolymer.

2. The article of claim 1, wherein the article is a mat.

3. The article of claim 1, wherein the fibrous material comprises paper, loose fibers, connected fibers, compressed fibers, woven fibers, non-woven fibers, or a combination thereof.

4. The article of claim 1, wherein the fibrous material comprises mineral wool, fiberglass, polymer fibers, glass fibers, mineral fibers, paper fibers, textile fibers, natural fibers, organic fibers, synthetic fibers, cellulose, wool, jute, polyester, acrylic, nylon, polyamide, ceramics, or a combination thereof.

5. The article of claim 1, wherein the fibrous material is being immersed into, dispersed with, coated, mixed, sprayed, or impregnated with the binder.

6. The article of claim 1, wherein the treated fibrous material is temperature-cured.

7. The article of claim 1, wherein the treated fibrous material is temperature-cured at a temperature of between 180° C. and 230° C.

8. The article of claim 1, wherein the fibrous material is treated with the binder combined with a liquid.

9. The article of claim 8, wherein the binder weight is 45 to 65% of liquid weight.

10. The article of claim 1, wherein the fibrous material is treated with the binder combined with water to form a solution.

11. The article of claim 1, wherein the binder further comprises a cross-linking agent.

12. The article of claim 11, wherein the cross-linking agent comprises a polyacid, anhydride, polyol, functionalized silane, or a combination thereof.

13. The article of claim 1, wherein the binder further comprises a co-cross-linking or coupling agent, wherein the cross-linking or coupling agent comprises a polyacid, anhydride, polyol, functionalized silane, a silane of general formula R.sup.1.sub.nSi(OR.sup.2).sub.4-n, or a combination thereof, and wherein R.sup.1 and R.sup.2 are methyl, ethyl, or any organic radical.

14. The article of claim 1, wherein the biopolymer comprises starch, modified starch, water-soluble starch, flour, wheat flour, or a combination thereof.

15. The article of claim 1, wherein the polyester or polyester copolymer is a product of reaction of a polyol or polyol compound with an anhydride or anhydride compound.

16. The article of claim 15, wherein the polyol or polyol compound comprises ethylene glycol, diethylene glycol, dialkylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,2-butylene glycol, 1,3-butylene glycol, 1,4-butylene glycol, polyethylene glycol of general formula HO(CH.sub.2CH.sub.2O).sub.nH, where n is from 1 to 50, silanols, products of hydrolysis of organosiloxanes, polyols containing at least three hydroxy groups, glycerin, as well as unalkylated or partially alkylated polymeric glyoxal derived glycols, poly (N-1′,2′-dihydroxyethyl-ethylene urea, dextrans, glyceryl monostearate, ascorbic acid, erythrobic acid, sorbic acid, ascorbyl palmitate, calcium ascorbate, calcium sorbate, potassium sorbate, sodium ascorbate, sodium sorbate, monoglycerides of edible fats or oils or edible fat-forming acids, inositol, sodium tartrate, sodium potassium tartrate, glycerol monocaprate, sorbose monoglyceride citrate, polyvinyl alcohol, α-D-methylglucoside, carbohydrates, sorbitol, dextrose, or a combination thereof.

17. The article of claim 15, wherein the anhydride or anhydride compound comprises an anhydride of a nonpolymeric polyacid, maleic anhydride, succinic anhydride, phthalic anhydride, or a combination thereof.

18. The article of claim 1, wherein the binder further comprises a polyacid having at least two acidic functional groups that react with alcohol moieties on starch particles, nonpolymeric polyacids, citric acid, maleic acid, succinic acid, phthalic acid, glutaric acid, malic acid, phthalic acid, salts thereof, or a combination thereof.

19. The article of claim 1 wherein the binder further comprises urea.

20. A method comprising: treating fibrous material with a binder, wherein the binder comprises: a polyester or a polyester copolymer, and a biopolymer.

21. The article of claim 20, wherein the article is a mat.

22. The article of claim 20, wherein the fibrous material comprises paper, loose fibers, connected fibers, compressed fibers, woven fibers, non-woven fibers, or a combination thereof.

23. The article of claim 20, wherein the fibrous material comprises mineral wool, fiberglass, polymer fibers, glass fibers, mineral fibers, paper fibers, textile fibers, natural fibers, organic fibers, synthetic fibers, cellulose, wool, jute, polyester, acrylic, nylon, polyamide, ceramics, or a combination thereof.

24. The article of claim 20, wherein the fibrous material is being immersed into, dispersed with, coated, mixed, sprayed, or impregnated with the binder.

25. The article of claim 20, wherein the treated fibrous material is temperature-cured.

26. The article of claim 20, wherein the treated fibrous material is temperature-cured at a temperature of between 180° C. and 230° C.

27. The article of claim 20, wherein the fibrous material is treated with the binder combined with a liquid.

28. The article of claim 27, wherein the binder weight is 45 to 65% of liquid weight.

29. The article of claim 20, wherein the fibrous material is treated with the binder combined with water to form a solution.

30. The article of claim 20, wherein the binder further comprises a cross-linking agent.

31. The article of claim 30, wherein the cross-linking agent comprises a polyacid, anhydride, polyol, functionalized silane, or a combination thereof.

32. The article of claim 20, wherein the binder further comprises a co-cross-linking or coupling agent, wherein the cross-linking or coupling agent comprises a polyacid, anhydride, polyol, functionalized silane, a silane of general formula R.sup.1.sub.nSi(OR.sup.2).sub.4-n, or a combination thereof, and wherein R.sup.1 and R.sup.2 are methyl, ethyl, or any organic radical.

33. The article of claim 20, wherein the biopolymer comprises starch, modified starch, water-soluble starch, flour, wheat flour, or a combination thereof.

34. The article of claim 20, wherein the polyester or polyester copolymer is a product of reaction of a polyol or polyol compound with an anhydride or anhydride compound.

35. The article of claim 34, wherein the polyol or polyol compound comprises ethylene glycol, diethylene glycol, dialkylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,2-butylene glycol, 1,3-butylene glycol, 1,4-butylene glycol, polyethylene glycol of general formula HO(CH.sub.2CH.sub.2O).sub.nH, where n is from 1 to 50, silanols, products of hydrolysis of organosiloxanes, polyols containing at least three hydroxy groups, glycerin, as well as unalkylated or partially alkylated polymeric glyoxal derived glycols, poly (N-1′,2′-dihydroxyethyl-ethylene urea, dextrans, glyceryl monostearate, ascorbic acid, erythrobic acid, sorbic acid, ascorbyl palmitate, calcium ascorbate, calcium sorbate, potassium sorbate, sodium ascorbate, sodium sorbate, monoglycerides of edible fats or oils or edible fat-forming acids, inositol, sodium tartrate, sodium potassium tartrate, glycerol monocaprate, sorbose monoglyceride citrate, polyvinyl alcohol, α-D-methylglucoside, carbohydrates, sorbitol, dextrose, or a combination thereof.

36. The article of claim 34, wherein the anhydride or anhydride compound comprises an anhydride of a nonpolymeric polyacid, maleic anhydride, succinic anhydride, phthalic anhydride, or a combination thereof.

37. The article of claim 20, wherein the binder further comprises a polyacid having at least two acidic functional groups that react with alcohol moieties on starch particles, nonpolymeric polyacids, citric acid, maleic acid, succinic acid, phthalic acid, glutaric acid, malic acid, phthalic acid, salts thereof, or a combination thereof.

38. The article of claim 20 wherein the binder further comprises urea.

Description

DETAILED DESCRIPTION

[0021] The disclosed self-setting thermosetting formaldehyde-free binder compositions and systems based on interpenetrating networks of polyesters and biopolymers do not emit formaldehyde, do not corrode equipment used in their manufacturing, are stable (i.e. do not require being prepared immediately before their use), reduce total emissions, and are environmentally friendly. They may be used for manufacturing low cost, low corrosivity, low viscosity, rigid materials, which do not have to have dark color. It should be noted that starch is generally much cheaper than pure polyester by weight.

[0022] The binder also improves wet web strength of wet mats (such as glass mats) before curing, improves the production line speed, lowers the vacuum drawing requirements during the production, and provides adequate dry mat tensile strengths (for example, to improve the ability of the finished roofing product to resist stresses during its service on the roof).

[0023] Sample 1. Polyester Binder I.

An anhydride was dissolved in water at the temperature of 90-95° C.; then, after cooling, polyvinyl alcohol and starch were added at 60° C.; the mixture was heated to 90° C. and mixed until the mix became homogeneous. After cooling, urea was added at 60° C., the mixture was heated to 80° C., and mixed at this temperature for 30 min. The mixture then cooled down to 50° C., a crosslinker was added, and the mixture was cooled down to a room temperature.

[0024] Sample 2. Polyester Binder II.

An anhydride was dissolved in water at the temperature of 90-95° C.; then, after cooling, polyvinyl alcohol was added at 60° C.; the mixture was heated to 90° C. and mixed until the mix became homogeneous. After cooling, urea was added at 60° C., the mixture was heated to 80° C., and mixed at this temperature for 30 min. The mixture then cooled down to 50° C., a crosslinker was added, and the mixture was cooled down to a room temperature.

[0025] Sample 3. Polyester/Biopolymer Binder.

A modified starch was dissolved in water using mechanical agitation for 15 to 60 minutes at 45° C. using a 3-blade mixer at 200 rpm. In a separate vessel, polyvinyl alcohol was dissolved in water and maleic and phthalic anhydride were added at 60° C., the mixture was then heated to 90° C. Both solutions were mixed together at 60° C., a crosslinker was added, and the mixture cooled down to a room temperature. The obtained binder is a low-viscosity transparent liquid.

[0026] Tensile testing of cured glass fiber specimens.

[0027] The polyester/biopolymer binder of Sample 3 was diluted with water to produce a binder solution having 5% non-volatiles.

[0028] A phenol-urea-formaldehyde (PUF) binder was used for comparison

[0029] Glass microfiber paper (Whatman 934-AH) samples were soaked in each of the four binder solutions for 5 minutes, then the excess liquid was removed by vacuuming. The paper samples were put into an oven at 200° C. for 5 minutes to cure the binder resin.

[0030] The cured samples were cut into specimens having the dimensions of 6″×1″ and tested for dry tensile strength using an Instron tensile tester.

[0031] For wet tensile testing, the specimens were subsequently treated with hot water at 80° C. for 10 minutes, and then tested again for tensile strength while still wet. The retention was calculated as the wet strength to dry strength ratio. The load in kilogram-force (kgf) was measured at the break. The test results are presented in Table 1.

TABLE-US-00001 TABLE 1 Binder Dry strength, kgf Wet strength, kgf Retention, % PUF 6.398 5.772 90.2 Polyester Sample I 6.895 5.760 83.5 Polyester Sample II 8.251 7.172 86.9 Polyester/Biopolymer 6.976 5.617 80.5

[0032] It should be understood that the description and specific examples are given by way of illustration only, since various changes and modifications within the spirit and scope of the disclosure will become apparent to those skilled in the art from this disclosure.

[0033] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.