Binders and materials made therewith
Binders to produce or promote cohesion in non-assembled or loosely assembled matter.
1. A thermal or acoustical fiberglass insulation material comprising:
(a) a collection of glass fibers; and
(b) a binder disposed on the collection of glass fibers, wherein the binder comprises i) at least one reaction product of a reducing sugar reactant and an amine reactant, wherein the percent by dry weight of the reducing sugar reactant with respect to the total weight of reactants ranges from about 73% to about 96%, ii) a silicon-containing coupling agent, and iii) optionally, a corrosion inhibitor, wherein the fiberglass material comprises less than 99% by weight and more than 75% by weight glass fibers, and wherein the fiberglass material has a density of from about 0.4 lbs/ft 3 to about 6 lbs/ft 3 .
2. The fiberglass material of claim 1 , wherein the amine reactant is an ammonium salt of a polycarboxylic acid.
3. The fiberglass material of claim 1 , wherein the amine reactant is an ammonium salt of a monomeric polycarboxylic acid.
4. The fiberglass material of claim 1 , wherein the density is from about 0.75 lbs/ft 3 to about 2.5 lbs/ft 3 .
5. The fiberglass material of claim 1 , wherein the density is from about 2.25 lbs/ft 3 to about 4.25 lbs/ft 3 .
6. The fiberglass material of claim 1 , wherein the density is from about 0.4 lbs/ft 3 to about 1.5 lbs/ft 3 .
7. The fiberglass material of claim 1 , wherein the density is from about 3.75 lbs/ft 3 to about 5.2 lbs/ft 3 .
8. A thermal or acoustical fiberglass insulation material comprising:
(a) a collection of glass fibers; and
(b) a binder disposed on the collection of glass fibers, the binder comprising i) a mixture of Maillard reactants, wherein the percent by dry weight of a reducing sugar reactant with respect to the total weight of reactants ranges from about 73% to about 96%, ii) a silicon-containing coupling agent, and iii) optionally, a corrosion inhibitor, wherein the fiberglass material comprises less than 99% by weight and more than 75% by weight glass fibers, and wherein the fiberglass material has a density in the range from about 0.4 lbs/ft 3 to about 6 lbs/ft 3 .
9. A thermal or acoustical fiberglass insulation material comprising:
(a) a collection of glass fibers; and
(b) a binder disposed on the collection of glass fibers, wherein the binder comprises i) at least one reaction product of a reducing sugar reactant and a polycarboxylic acid ammonium salt reactant, wherein the percent by dry weight of the reducing sugar reactant with respect to the total weight of reactants ranges from about 73% to about 96%, ii) a silicon-containing coupling agent, and iii) optionally, a corrosion inhibitor, wherein the fiberglass material comprises less than 99% by weight and more than 75% by weight glass fibers, and wherein the fiberglass material has a density in the range from about 0.4 lbs/ft 3 to about 6 lbs/ft 3 .
10. The fiberglass material of claim 1 , where pyrolysis thereof results in the release of gaseous compounds of which about 12 percent by peak area are furan-based as determined by GC/MS.
11. The fiberglass material of claim 1 , where thermal curing of the binder results in the release of gaseous compounds of which about 15 percent by peak area are furan-based as determined by GC/MS.
12. The fiberglass material of claim 1 , where ignition thereof results in the development of less smoke than a phenol-formaldehyde bound fiberglass material as measured by ASTM E 1354.
13. The fiberglass material of claim 12 , where average smoke development measured as specific extinction area is about 2,500 m 2 /kg at an external heat flux of 35 kW/m 2 .
14. The fiberglass material of claim 12 , where average smoke development measured as specific extinction area is about 2,300 m 2 /kg at an external heat flux of 50 kW/m 2 .
15. The fiberglass material of claim 1 , where the ratio of mean weathered tensile strength to mean dry tensile strength is in the range from about 0.7 to about 1.
16. The fiberglass material of claim 1 , wherein the binder contains about 4 percent to about 5 percent nitrogen by mass as determined by elemental analysis.
17. The fiberglass material of claim 1 , wherein the at least one reaction product is generated during thermal curing that consists essentially of a Maillard reaction.