BINDER COMPOSITIONS AND ASSOCIATED METHODS
Disclosed are formaldehyde-free, thermally-curable, alkaline, aqueous binder compositions, curable to formaldehyde-free, water-insoluble thermoset polyester resins, and uses thereof as binders for non-woven fibers and fiber material.
1 .- 25 . (canceled)
26 . A binder comprising
a polyester polymer, the polyester polymer comprising a reaction product of a polycarboxylic acid component and a polymeric polyhydroxyl component in the presence of a catalyst, wherein a solution of the polycarboxylic acid component, the polymeric polyhydroxyl component, and the catalyst has an alkaline pH and the polycarboxylic acid component is a dicarboxylic acid, tricarboxylic acid, tetracarboxylic acid, or pentacarboxylic acid, or salts or anhydride derivatives thereof, or combinations thereof.
27 . The binder of claim 26 , wherein the alkaline pH is in the range from about 7 to about 10.
28 . The binder of claim 26 , wherein the solution has the alkaline pH due to inclusion of a base in the solution.
29 . The binder of claim 28 , wherein the base is sodium hydroxide.
30 . The binder of claim 29 , wherein the polyester polymer is colorless.
31 . The binder of claim 28 , wherein the base is ammonium hydroxide.
32 . The binder of claim 29 , wherein the polyester polymer is light tan.
33 . The binder of claim 26 , wherein the polycarboxylic acid component is citric acid.
34 . The binder of claim 26 , wherein the catalyst is sodium hypophosphite.
35 . An insulation product comprising
a formaldehyde-free polymeric binder composition in contact with mineral fibers, the formaldehyde-free polymeric binder comprising a product of a dried and cured alkaline aqueous solution, the solution comprising a polymeric polyhydroxyl component, a polycarboxylic acid component selected from a dicarboxylic acid, tricarboxylic acid, tetracarboxylic acid, or pentacarboxylic acid, and a catalyst.
36 . The insulation product of claim 35 , wherein the polycarboxylic acid component is a dicarboxylic acid or a tricarboxylic acid.
37 . The insulation product of claim 35 , wherein the polycarboxylic acid component is citric acid and the catalyst is sodium hypophosphite.
38 . The insulation product of claim 35 , the solution further comprising a base.
39 . The insulation product of claim 38 , wherein the base is sodium hydroxide.
40 . The insulation product of claim 35 , wherein the solution further comprises a silicon-containing coupling agent.