B-stageable aqueous binder compositions

1 . An aqueous binder composition comprising:

from 15% by weight to 37% by weight of a monomeric polyol having at least four-five hydroxyl groups, based on the total solids content of the aqueous binder composition; and

at least 50.0% by weight of a cross-linking agent comprising a polymeric polycarboxylic acid having at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition,

wherein a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.32/1 and 0.92/1, wherein the aqueous binder composition has a pH of 2.2 to 4.0,

wherein the monomeric polyol is selected from the group consisting of sugar alcohol, dimeric condensation product of a sugar alcohol, and oligomeric condensation product of a sugar alcohol,

wherein the aqueous binder composition is free of polyvinyl alcohol,

wherein the aqueous binder composition comprises 40% or less binder solids, and

wherein after curing the aqueous binder composition at 400° F. for 3.5 minutes, the cured binder composition includes less than 3 wt. % of water-soluble material, as determined by extracting any water-soluble materials with deionized water for 3 hours at ambient condition using about 1000 g of deionized water per about 1 gram of the cured binder.

2 . The aqueous binder composition of claim 1 , wherein the cross-linking agent is polyacrylic acid.

3 . The aqueous binder composition of claim 1 , wherein the cross-linking agent is present in the aqueous binder composition in an amount from 52.0% by weight to 72% by weight, based on the total solids content of the aqueous binder composition.

4 . The aqueous binder composition of claim 1 , wherein the ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.4/1 and 0.6/1.

5 . The aqueous binder composition of claim 1 , wherein the monomeric polyol is selected from the group consisting of xylitol, sorbitol, and mixtures thereof.

6 . The aqueous binder composition of claim 1 , wherein the composition is free of polymeric polyhydroxy compounds.

7 . The aqueous binder composition of claim 1 , wherein the composition is free of a monomeric carboxylic acid.

8 . The aqueous binder composition of claim 2 further comprising:

2.0% to 15.0% by weight of a processing aid;

0 to 5.0% by weight of a surfactant;

0 to 2.0% by weight of a pigment; and

0 to 15% by weight of silicone, each percentage being based on a total solids content of the aqueous binder composition.

9 . The aqueous binder composition of claim 1 , wherein the monomeric polyol is sorbitol.

10 . The aqueous binder composition of claim 1 , wherein after cure, the cured binder composition includes no greater than 1 wt. % of water-soluble material.

11 . A fibrous insulation product comprising:

a plurality of randomly oriented fibers; and

a cross-linked formaldehyde-free binder composition at least partially coating the fibers, wherein the cross-linked formaldehyde-free binder composition is formed from the aqueous binder composition in accordance with claim 1 .

12 . The fibrous insulation product of claim 11 , wherein the fibers comprise one or more of mineral fibers, natural fibers, and synthetic fibers.

13 . The fibrous insulation product of claim 11 , wherein the fibrous insulation product comprises one or more of a ceiling board, duct board, foundation board, pipe and tank insulation, sound absorption board, acoustical panel, duct liner, residential insulation, duct wrap, metal building insulation, and flexible duct media.

14 . The fibrous insulation product of claim 11 , wherein the fibrous insulation product includes a binder LOI of 5.5% to 17%.

15 . A B-stageable fibrous insulation product comprising:

a plurality of randomly oriented fibers; and

the aqueous binder composition in accordance with claim 1 at least partially coating said fibers,

wherein the B-stageable fibrous insulation product has a drying time, as measured by a CEM Smart 6 moisture analyzer, of at least 500 seconds.