Granted Patent B2

US 12,415,874 · App. 18/815,147 · Granted Sep 16, 2025

Inventors: Gert Mueller (New Albany, OH); Andrew Broderick (Newark, OH); Xiujuan Zhang (New Albany, OH); Liang Chen (New Albany, OH)

Assignee: Owens Corning Intellectual Capital, LLC

C08F20/06C08J3/24C08K3/013C08K5/053C08L83/04D06N3/0022E04B1/88C08J2333/08D06N2201/082D06N2203/041D06N2203/066D06N2207/08D06N2209/065

Abstract

Claims (37)

1. A fibrous product comprising:

a plurality of randomly oriented fibers; and

a binder composition comprising:

a sugar alcohol, wherein the sugar alcohol has at least four hydroxyl groups; and

a polymeric polycarboxylic acid,

wherein the sugar alcohol and the polymeric polycarboxylic acid are present in amounts such that a ratio of the number of molar equivalents of carboxylic acid groups to the number of molar equivalents of hydroxyl groups is from 0.32/1 to about 0.92/1;

wherein the binder composition is free of polymeric polyhydroxy compounds;

wherein the binder composition, once cured, comprises no greater than 6 wt. % of water-soluble material; and

wherein the fibrous product has a drying time of at least 520 seconds, measured by a CEM Smart 6 moisture balance.

2. The fibrous product of claim 1 , wherein the sugar alcohol comprises erythritol, arabitol, xylitol, sorbitol, maltitol, mannitol, iditol, isomaltitol, lactitol, cellobitol, palatinitol, maltotritol, syrups thereof, or mixtures thereof.

3. The fibrous product of claim 2 , wherein the sugar alcohol comprises sorbitol.

4. The fibrous product of claim 1 , wherein the polymeric polycarboxylic acid comprises polyacrylic acid.

5. The fibrous product of claim 1 , wherein the ratio of the number of molar equivalents of carboxylic acid groups to the number of molar equivalents of hydroxyl groups is from 0.4/1 to 0.6/1.

6. The fibrous product of claim 1 , wherein the binder composition is free of polyols containing less than 3 hydroxyl groups.

7. The fibrous product of claim 1 , wherein the binder composition, once cured, comprises no greater than 3 wt. % of water-soluble material.

8. The fibrous product of claim 1 , wherein the fibrous product is an insulation product.

9. The fibrous product of claim 8 , wherein the insulation product is in the form of batts, blankets, boards, pipe insulation, duct wrap, or duct liner.

10. The fibrous product of claim 1 , wherein the fibrous product is a non-woven fiber mat.

11. The fibrous product of claim 1 , wherein the fibers comprise glass fibers.

12. A fibrous product comprising:

a plurality of randomly oriented fibers; and

a binder composition comprising:

sorbitol; and

polyacrylic acid, wherein the sorbitol and the polymeric polycarboxylic acid are present in amounts such that a ratio of the number of molar equivalents of carboxylic acid groups to the number of molar equivalents of hydroxyl groups is from 0.26/1 to about 0.75/1,

wherein the binder composition is free of polyols containing less than 4 hydroxyl groups;

wherein the binder composition is free of polymeric polyhydroxy compounds;

wherein the binder composition, once cured, comprises no greater than 3 wt. % of water-soluble material; and

wherein the fibrous product has a drying time of at least 520 seconds, measured by a CEM Smart 6 moisture balance.

13. The fibrous product of claim 12 , wherein the ratio of the number of molar equivalents of carboxylic acid groups to the number of molar equivalents of hydroxyl groups is from 0.39/1 to 0.6/1.

14. The fibrous product of claim 12 , wherein the binder, once cured, comprises no greater than 1 wt. % of water-soluble material.

15. The fibrous product of claim 12 , wherein the fibrous product is an insulation product.

16. The fibrous product of claim 15 , wherein the insulation product is in the form of batts, blankets, boards, pipe insulation, duct wrap, or duct liner.

17. The fibrous product of claim 12 , wherein the fibrous product is a non-woven fiber mat.

18. The fibrous product of claim 12 , wherein the fibers comprise glass fibers.

19. The fibrous product of claim 12 , wherein the binder composition comprises, based on the weight of total solids content of the binder composition:

30 to 85 wt. % polyacrylic acid; and

15 wt. % to 37 wt. % sorbitol.

Assignments (1)

Continuity (3)

References Cited (301)