Binder compositions with polyvalent phosphorus crosslinking agents
An fibrous insulation product is provided that includes a binder comprising a polyol and a phosphorus crosslinking agent derived from a phosphonic or phosphoric acid, salt, ester or anhydride to form crosslinked phosphodiester linkages. The polyol is polyvalent, but may be monomeric or preferably polymeric; and may be synthetic or natural in origin. Carbohydrate polysaccharides are exemplary polyols, including water-soluble polysaccharides such as dextrin, maltodextrin, starch, modified starch, etc. Additionally, the carbohydrate polymer may have a dextrose equivalent (DE) number from 2 to 20. In exemplary embodiments, the binder may also include a catalyst, a coupling agent, a process aid, and other additives. The environmentally friendly, formaldehyde-free binder may be used in the formation of residential and commercial insulation materials and non-woven chopped strand mats. A method of making fibrous products is also provided.
1. A fibrous product comprising:
a plurality of randomly oriented fibers; and
a cured phosphodiester binder composition distributed on at least a portion of the fibers, wherein the cured phosphodiester binder composition is free of added formaldehyde and comprises:
at least one water soluble polysaccharide having a dextrose equivalent number from 9 to 14, and
a polyvalent phosphorus crosslinking agent comprising acids or ammonium salts of phosphoric acid, phosphonic acid, phosphorus acid, or polyphosphoric acid;
wherein the cured phosphodiester binder composition has an acidic pH from 1 to 6;
wherein the cured phosphodiester binder composition comprises hydroxyl groups of the at least one water soluble polysaccharide crosslinked by phosphodiester linkages; and
wherein the fibrous product has a density from 0.2 pcf to 4 pcf and has no added formaldehyde.
2. The fibrous product of claim 1 , wherein the cured phosphodiester binder composition comprises from 20% to 99% by weight of the at least one water soluble polysaccharide, and from 1% to 40% by weight of the polyvalent phosphorus crosslinking agent, wherein the weight percentages are based on the total solids of the cured phosphodiester binder composition.
3. The fibrous product of claim 1 , wherein the fibrous product contains the cured phosphodiester binder composition at a concentration from 2% to 40% by weight of the fibrous product.
4. The fibrous product of claim 1 , wherein the fibrous product is an insulation product having the cured phosphodiester binder composition at a concentration from 2% to 10% by weight of the fibrous product.
5. The fibrous product of claim 4 , wherein the fibrous product is an insulation product having a density from 0.3 pcf to 4 pcf.
6. The fibrous product of claim 1 , wherein the fibrous product is an insulation product having cured phosphodiester binder composition at a concentration from 5% to 25% by weight of the fibrous product.
7. The fibrous product of claim 6 , wherein the fibrous product is an insulation product having a density from 1.5 pcf to 4 pcf.
8. The fibrous product of claim 7 , wherein the fibrous product is an insulation product having a density from 3 pcf to 4 pcf.
9. The fibrous product of claim 1 , wherein the fibrous product is a non-woven mat.
10. The fibrous product of claim 9 , wherein the non-woven mat contains the cured phosphodiester binder composition at a concentration from 5% to 20% by weight of the fibrous product.
11. The fibrous product of claim 1 , wherein the cured phosphodiester binder composition does not include a catalyst to assist in the formation of the phosphodiester linkages.
12. An aqueous phosphodiester binder composition for use in the formation of fiberglass insulation and non-woven chopped strand mats, the aqueous phosphodiester binder composition comprising:
a water soluble maltodextrin having a dextrose equivalent number from 9 to 14; and
a polyvalent phosphorus crosslinking agent selected from the group consisting of acids or ammonium salts of phosphoric acid, phosphonic acid, phosphorus acid, and polyphosphoric acid;
wherein the aqueous phosphodiester binder composition is free of added formaldehyde;
wherein the aqueous phosphodiester binder composition comprises hydroxyl groups of the water soluble maltodextrin crosslinked by phosphodiester linkages; and
wherein the aqueous phosphodiester binder composition has a pH from 1 to 6.
13. The aqueous phosphodiester binder composition of claim 12 , wherein the water soluble maltodextrin has a number average molecular weight from 1,000 to 8,000.
14. The aqueous phosphodiester binder composition of claim 12 , wherein the aqueous phosphodiester binder composition does not include a catalyst to assist in the formation of the phosphodiester linkages.