IP Library › Granted Patent US 12,297,342
Granted Patent B2
US 12,297,342 · App. 17/114,820 · Granted May 13, 2025

Fiberglass insulation product

Inventors: Gert Mueller (New Albany, OH); Andrew Broderick (Newark, OH); Xiujuan Zhang (New Albany, OH); Liang Chen (New Albany, OH); Kendel Smith (Westerville, OH); Larry J. Grant (Westerville, OH); Ronald A. Houpt (Newark, OH); Teno Boone (Columbus, OH); Toni Elwell Newsome (Pataskala, OH)
Assignee: Owens Corning Intellectual Capital, LLC
C08L33/02C08F20/06C08K3/40C08K7/14C08L29/04C08L29/14E04B1/7662C08F2810/20C08L2312/00
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Quick Facts
Patent No.
US 12,297,342
App. No.
17/114,820
Granted
May 13, 2025
Kind
B2
Abstract

A fibrous insulation product comprising a plurality of randomly oriented glass fibers and a cross-linked formaldehyde-free binder composition at least partially coating the fibers is disclosed. The cross-linked formaldehyde-free binder composition is formed from an aqueous binder composition comprising 5.0% by weight to 37.0% by weight of at least one monomeric polyol having at least four hydroxyl groups 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. The glass fibers have an average fiber diameter in the range of 8 HT to 12 HT. The fibrous insulation product, after curing, has a density, when uncompressed, in the range of 0.30 pcf to 2.7 pcf.

Claims (54)

1. A fibrous insulation product comprising:

a plurality of randomly oriented glass 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 an aqueous binder composition comprising:

5.0% by weight to 37.0% by weight of at least one monomeric polyol having at least four hydroxyl groups, based on the total solids content of the aqueous binder composition; and

at least 55% 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 said binder composition has a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.60/1.0 and 1.0/0.6,

wherein the quantity of cross-linked formaldehyde-free binder is in the range of 2% to 10% by weight of the fibrous insulation product;

wherein an R-value of the fibrous insulation product is in the range of 10 to 54;

wherein the glass fibers have an average fiber diameter in the range of 8 HT to 12 HT;

wherein the fibrous insulation product, after curing, has a density, when uncompressed, in the range of 0.30 pcf to 2.7 pcf, and a stiffness of 45 degrees of less.

2. The fibrous insulation product of claim 1 , wherein the cross-linking agent is polyacrylic acid.

3. The fibrous insulation product of claim 1 , wherein the cross-linking agent is present in the binder composition in an amount from 50.0% by weight to 85% by weight, based on the total solids content of the aqueous binder composition.

4. The fibrous insulation product of claim 1 , wherein the monomeric polyol comprises at least five hydroxyl groups.

5. The fibrous insulation product of claim 1 , wherein the ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.80/1.0 and 1.0/0.8.

6. The fibrous insulation product of claim 1 , wherein the monomeric polyol comprises one or more of a sugar alcohols, pentaerythritol, primary alcohols, 1,2,4-butanetriol, trimethylolpropane, short-chain alkanolamines, and mixtures thereof.

7. The fibrous insulation product of claim 1 , wherein the monomeric polyol has a number average molecular weight less than 2,000 Daltons.

8. The fibrous insulation product of claim 1 , wherein the aqueous binder composition further includes at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons.

9. The fibrous insulation product of claim 8 , wherein the long-chain polyol is selected from the group consisting of polyvinyl alcohol and polyvinyl acetate.

10. The fibrous insulation product of claim 8 , wherein the long-chain polyol is present in the binder composition in an amount from about 2.5 wt. % to about 30 wt. %, based on the total solids content of the aqueous binder composition.

11. The fibrous insulation product of claim 1 , wherein the aqueous binder composition has a viscosity at 40% solids and 25° C. of 10 cP to 65 cP.

12. The fibrous insulation product of claim 1 , wherein the aqueous binder composition has a viscosity at 40% solids and 25° C. of 300 cP to 500 cP.

13. The fibrous insulation product of claim 1 , wherein the R-value of the fibrous insulation product is in the range of 11 to 15.

14. The fibrous insulation product of claim 1 , wherein the R-value of the fibrous insulation product is in the range of 30 to 49.

15. The fibrous insulation product of claim 1 , wherein the fibrous insulation product has an average fiber diameter to density ratio (Fd/D) of less than or equal to 40 and a comfort factor of less than or equal to 3.417 (Fd/D)+60.

16. A fibrous insulation product comprising:

a plurality of randomly oriented glass 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 an aqueous binder composition comprising:

5.0% by weight to 37.0% by weight of at least one monomeric polyol having at least four hydroxyl groups, based on the total solids content of the aqueous binder composition; and

at least 55% 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 said binder composition has a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.60/1.0 and 1.0/0.6,

wherein the quantity of cross-linked formaldehyde-free binder is in the range of 2% to 10% by weight of the fibrous insulation product;

wherein an R-value of the fibrous insulation product is in the range of 10 to 54;

wherein the glass fibers have an average fiber diameter in the range of 12 HT to 15 HT; and

wherein the fibrous insulation product, after curing, has a density, when uncompressed, in the range of 0.30 pcf to 2.7 pcf, and a stiffness of 45 degrees or less.

17. The fibrous insulation product of claim 16 , wherein the cross-linking agent is polyacrylic acid.

18. The fibrous insulation product of claim 16 , wherein the cross-linking agent is present in the binder composition in an amount from 50.0% by weight to 85% by weight, based on the total solids content of the aqueous binder composition.

19. The fibrous insulation product of claim 16 , wherein the monomeric polyol comprises at least five hydroxyl groups.

20. The fibrous insulation product of claim 16 , wherein the ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.80/1.0 and 1.0/0.8.

21. The fibrous insulation product of claim 16 , wherein the monomeric polyol comprises one or more of a sugar alcohols, pentaerythritol, primary alcohols, 1,2,4-butanetriol, trimethylolpropane, short-chain alkanolamines, and mixtures thereof.

22. The fibrous insulation product of claim 16 , wherein the monomeric polyol has a number average molecular weight less than 2,000 Daltons.

23. The fibrous insulation product of claim 16 , wherein the aqueous binder composition further includes at least one long-chain polyol having at least two hydroxyl groups and a number average molecular weight of at least 2,000 Daltons.

24. The fibrous insulation product of claim 23 , wherein the long-chain polyol is selected from the group consisting of polyvinyl alcohol and polyvinyl acetate.

25. The fibrous insulation product of claim 23 , wherein the long-chain polyol is present in the binder composition in an amount from about 2.5 wt. % to about 30 wt. %, based on the total solids content of the aqueous binder composition.

26. The fibrous insulation product of claim 16 , wherein the aqueous binder composition has a viscosity at 40% solids and 25° C. of 10 cP to 60 cP.

27. The fibrous insulation product of claim 16 , wherein the aqueous binder composition has a viscosity at 40% solids and 25° C. of 300 cP to 500 cP.

28. The fibrous insulation product of claim 16 , wherein the R-value of the fibrous insulation product is in the range of 11 to 15.

29. The fibrous insulation product of claim 16 , wherein the R-value of the fibrous insulation product is in the range of 30 to 49.

30. A fibrous insulation product comprising:

a plurality of randomly oriented glass 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 an aqueous binder composition comprising:

5.0% by weight to 37.0% by weight of at least one monomeric polyol having at least four hydroxyl groups, based on the total solids content of the aqueous binder composition; and

at least 55% 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 said binder composition has a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.60/1.0 and 1.0/0.6,

wherein the quantity of cross-linked formaldehyde-free binder is in the range of 2% to 10% by weight of the fibrous insulation product;

wherein an R-value of the fibrous insulation product is in the range of 10 to 54;

wherein the glass fibers have an average fiber diameter in the range of 15 HT to 19 HT; and

wherein the fibrous insulation product, after curing, has a density, when uncompressed, in the range of 0.30 pcf to 2.7 pcf, and a stiffness of 45 degrees or less.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 5, 2021
From: MUELLER, GERT; BRODERICK, ANDREW; ZHANG, XIUJUAN; CHEN, LIANG; SMITH, KENDEL; GRANT, LARRY J.; HOUPT, RONALD A.; BOONE, TENO; NEWSOME, TONI ELWELL
To: OWENS CORNING INTELLECTUAL CAPITAL, LLC
Reel/Frame 055506/0180 →
Continuity (6)
Provisional Application 62945318 · Dec 9, 2019
Provisional Application 62945328 · Dec 9, 2019
Provisional Application 62945323 · Dec 9, 2019
Provisional Application 62945334 · Dec 9, 2019
Provisional Application 62945313 · Dec 9, 2019
Related Publication 20210171757A1 · Jun 10, 2021
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