LIQUID HIGH SOLIDS BINDER COMPOSITION
The invention described herein pertains to formaldehyde free, thermosetting liquid high solids binder compositions having rapid cure times on thermal curing and slow cure times at ambient temperatures so that the uncured binder compositions and products which comprise the uncured binder compositions have improved shelf lives.
1 . A liquid, curable, thermosetting, aqueous, substantially formaldehyde free, binder composition which is free of solid particles comprising a primary or secondary polyetheramine and a carbohydrate.
2 . The binder composition of claim 1 , wherein the approximate molecular weight of the polyetheramine does not exceed about 1000 or does not exceed 1000.
3 . The binder composition of claim 1 , wherein the polyetheramine comprises a primary amine.
4 . The binder composition of claim 1 , wherein the polyetheramine has an amine hydrogen equivalent weight (AHEW) of less than about 200 g/eq or less than 200 g/eq.
5 . The binder composition of claim 1 , wherein the polyetheramine has an amine hydrogen equivalent weight (AHEW) of less than about 125 g/eq or less than 125 g/eq.
6 . The binder composition of claim 1 , wherein the polyetheramine has an amine hydrogen equivalent weight (AHEM) of less than about 85 g/eq or less than 85 g/eq.
7 . The binder composition of claim 1 , wherein the polyetheramine has an amine hydrogen equivalent weight (AHEW) of less than about 60 g/eq or less than 60 g/eq.
8 . The binder composition of claim 1 , wherein the polyetheramine comprises a primary triamine.
9 . The binder composition of claim 8 wherein the polyetheramine has the structural formula of Jeffamine™ T-403.
10 . The binder composition of claim 1 , wherein the polyetheramine comprises a primary diamine.
11 . The binder composition of claim 10 , wherein the polyetheramine has the structural formula of Jeffamine™ EDR-148, EDR-176, D-230, D-400, HK-511, ED-600 or XTJ-542.
12 . The binder composition of claim 10 , wherein the polyetheramine has the structural formula of Jeffamine™ EDR-104.
13 . The binder composition of claim 1 , wherein the carbohydrate comprises a reducing or non-reducing carbohydrate or a combination thereof.
14 . The binder composition of claim 1 , wherein the carbohydrate comprises a monosaccharide or a disaccharide or a combination thereof.
15 . The binder composition of claim 1 , wherein the carbohydrate comprises one or more monosaccharides.
16 . The binder composition of claim 15 , wherein the carbohydrate comprises dextrose, fructose or xylose, or a mixture thereof.
17 . The binder composition of claim 16 , wherein the carbohydrate comprises a mixture of dextrose and fructose.
18 . The binder composition of claim 17 , wherein the dextrose to fructose ratio is about 80:20 to about 20:80 or is 80:20 to 20:80.
19 . The binder composition of claim 1 , wherein the ratio of carbohydrate carbonyl-group to polyetheramine amino-group is in the range of about 0.15:1 to about 6:1 or is in the range of 0.15:1 to 6:1.
20 . The binder composition of claim 1 , wherein the ratio of carbohydrate carbonyl-group to polyetheramine amino-group is in the range of about 0.5:1 to about 2:1 or is in the range of 0.5:1 to 2:1.
21 . The binder composition of claim 1 , wherein the ratio of carbohydrate carbonyl-group to polyetheramine amino-group is in the range of about 0.75:1 to about 1.33:1 or is in the range of 0.75:1 to 1.33:1.
22 . The binder composition of claim 1 , further comprising a silicon-containing compound.
23 . The binder composition of claim 22 , wherein the silicon-containing compound is selected from the group consisting of gamma-aminopropyltriethoxysilane, gamma-glycidoxypropyltrimethoxyse, amimoethylaminopropyltrimethoxysilane, an aminofunctional oligomeric silane, and mixtures thereof.
24 . The binder composition of claim 23 , wherein the silicon-containing compound is gamma-aminopropyltriethoxysilane.
25 . The binder composition of claim 1 , further comprising a corrosion inhibitor selected from the group consisting of dedusting oil, ammonium phosphates, sodium metasilicate pentahydrate, melamine, tin (II) oxalate, and a methylhydrogen silicone fluid emulsion.
26 . The binder composition of claim 1 , wherein the binder concentration is at least about 35% solids or is at least 35% solids.
27 . The binder composition of claim 1 , wherein the binder concentration is at least about 50% solids or is at least 50% solids.
28 . The binder composition of claim 1 , wherein the binder concentration is at least about 70% solids or is at least 70% solids.
29 . The binder composition of claim 1 , wherein the binder concentration is at least about 85% solids or is at least 85% solids.
30 . The binder composition of claim 1 , wherein the binder concentration is at least about 90% solids or is at least 90% solids.
31 . The binder composition of claim 1 , wherein the viscosity is less than about 5 Pa·s or is less than 5 Pa·s.
32 . The binder composition of claim 1 , wherein the viscosity is less than about 2 Pa·s or is less than 2 Pa·s.
33 . The binder composition of claim 1 , wherein the viscosity is less than about 1 Pa·s or is less than 1 Pa·s.
34 . The binder composition of claim 1 , wherein the increase in viscosity on standing for 1 week at a temperature not exceeding about 25° C. does not exceed 1 Pa·s.
35 . The binder composition of claim 1 , wherein the increase in viscosity on standing for 2 weeks at a temperature not exceeding about 25° C. does not exceed 1 Pa·s.
36 . The binder composition of claim 1 , wherein the increase in viscosity on standing for 3 weeks at a temperature not exceeding about 25° C. does not exceed 1 Pa·s.
37 . The binder composition of claim 1 , wherein the increase in viscosity on standing for 4 weeks at a temperature not exceeding about 25° C. does not exceed 1 Pa·s.
38 . The binder composition of claim 1 , wherein the cure time for wet laid mats according to the Wet Laid Mats Protocol at 400° F. (204° C.) is no greater than about 7 min or is no greater than 7 min.
39 . The binder composition of claim 1 , wherein the cure time for wet laid mats according to the Wet Laid Mats Protocol at 400° F. (204 ‘V) is no greater than about 5 min or is no greater than 5 min.
40 . The binder composition of claim 1 , wherein the cure time for wet laid mats according to the Wet Laid Mats Protocol at 400° F. (204° C.) is no greater than about 4 min or is no greater than 4 min.
41 . The binder composition of claim 1 , wherein the composition is free or substantially free of an acid component.
42 . The binder composition of claim 1 , wherein the pH is at least about 11 or is at least 11.
43 . The binder composition of claim 1 , wherein the pH is at least about 9 or is at least 9.
44 . The binder composition of claim 1 , wherein the pH is at least about 7 or is at least 7.
45 . The binder composition of claim 1 , wherein the binder composition is a commercial/merchant market binder composition or binder composition concentrate.
46 . The binder composition of claim 1 , wherein the binder composition is an about 70% solids binder or a is a 70% solids binder having a viscosity of no more than about 1.5 Pa·s or of no more than 1.5 Pa·s.
47 . The binder composition of claim 1 , further comprising a non-aqueous moisturizer.
48 . The binder composition of claim 47 , wherein the non-aqueous moisturizer comprises a polyoxyalkylene glycol or a polypropylene glycol.
49 . An uncured binder composition disposed on a collection of fibers as a viscous or semi-viscous high-solids mixture which functions as a binder to bind the fibers in the collection of fibers, wherein the uncured binder composition is a substantially dehydrated composition of the binder composition as described in claim 1 .
50 . A collection of fibers bound by an uncured aqueous curable binder composition in contact with the fibers, wherein the uncured binder composition is a substantially dehydrated composition of the binder composition as described in claim 1 .
51 . The collection of claim 50 , wherein the fibers are mineral fibers, aramid fibers, ceramic fibers, metal fibers, carbon fibers, polyimide fibers, polyester fibers, rayon fibers, or cellulosic fibers.
52 . The collection of claim 51 wherein the fibers are mineral fibers.
53 . The collection of claim 52 wherein the mineral fibers are slag wool fibers, rock wool fibers, or glass fibers.
54 . The collection of claim 50 which is an uncured glass fiber insulation blanket (wet blanket).
55 . The collection of claim 50 which is an uncured glass fiber pipe insulation (pipe insulation uncured).
56 . A method of fabricating the collection described in claim 50 , wherein the uncured aqueous curable binder composition is placed in contact with the fibers in a step in which the aqueous binder is sprayed on the fibers or applied via a roll-coat or curtain coat apparatus.
57 . The method of claim 56 wherein the aqueous binder is sprayed onto a mat of glass fibers during the production of a fiberglass insulation product.
58 . The method of claim 57 wherein the residual heat from the production of the glass fibers and the flow of air through the fibrous mat evaporate water from the binder, leaving the remaining components of the binder on the fibers as a coating of viscous or semi-viscous high-solids liquid.
59 . A composition comprising a collection of matter and a binder, the binder comprising polymeric products of a reaction between a polyetheramine and a carbohydrate of a binder composition as described in claim 1 , the polymeric products being substantially water insoluble.
60 . The composition of claim 59 , wherein the collection of matter comprises fibers selected from the group consisting of mineral fibers, aramid fibers, ceramic fibers, metal fibers, carbon fibers, polyimide fibers, polyester fibers, rayon fibers, and cellulosic fibers.
61 . The composition of claim 60 , wherein the collection of matter comprises glass fibers.
62 . The composition of claim 60 , wherein the collection of matter comprises cellulosic fibers.
63 . The composition of claim 62 , wherein the cellulosic fibers are present in a cellulosic substrate selected from the group consisting of wood shavings, sawdust, wood pulp, and ground wood.
64 . A method of fabricating a fiberglass or rockwool product, comprising spraying the aqueous binder composition as described in claim 1 on a collection of glass or rockwool fibers; dehydrating the aqueous solution while disposed on the collection of glass or rockwool fibers to form an uncured fiberglass product; and subjecting the uncured fiberglass or rockwool product to sufficient heat to turn the fiberglass product brown.
65 . The method of claim 64 comprising spraying the aqueous binder composition as described in claim 1 on a collection of glass or rockwool fibers; dehydrating the aqueous solution while disposed on the collection of glass or rockwool fibers to form an uncured fiberglass or rockwool product; storing the uncured fiberglass or rockwool product, and curing the uncured fiberglass or rockwool product by subjecting it to sufficient heat to turn the fiberglass or rockwool product brown.
66 . The method claim 65 wherein the uncured fiberglass or rockwool product is stored as a roll.
67 . The method of claim 64 wherein the uncured product is molded into the shape of a final product prior to curing.
68 . The method of claim 64 wherein the uncured product is stored at or below about 90° F. (32° C.) prior to curing.
69 . The method of claim 64 wherein the uncured product is stored at or below about 70° F. (21° C.) prior to curing.
70 . The method of claim 64 wherein the uncured product is stored at or below about 50° F. (10° C.) prior to curing.