IP Library › Granted Patent US 12,692,328
Granted Patent B2
US 12,692,328 · App. 17/491,755 · Granted Jul 28, 2026

B-stageable aqueous binder compositions

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
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Quick Facts
Patent No.
US 12,692,328
App. No.
17/491,755
Filed
Oct 1, 2021
Granted
Jul 28, 2026
Kind
B2
Examiner
CAI, WENWEN
Art Unit
1763
USPC
524/556
Abstract

An aqueous binder composition is disclosed that includes 5.0% by weight to 50.0% by weight of a monomeric polyol having at least four hydroxyl groups, based on the total solids content of the aqueous binder composition; 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 aqueous binder composition includes a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.15/1.0 and 2.23/1 and has a pH of 2.2 to 4.0 and a viscosity at 40% solids and 25° C. of 10 cP to 60 cP.

Claims (31)

1 . An aqueous binder composition comprising:

from 15% by weight to 37% by weight of a monomeric polyol having at least four-five hydroxyl groups, based on the total solids content of the aqueous binder composition; 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,

wherein a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.32/1 and 0.92/1, wherein the aqueous binder composition has a pH of 2.2 to 4.0,

wherein the monomeric polyol is selected from the group consisting of sugar alcohol, dimeric condensation product of a sugar alcohol, and oligomeric condensation product of a sugar alcohol,

wherein the aqueous binder composition is free of polyvinyl alcohol,

wherein the aqueous binder composition comprises 40% or less binder solids, and

wherein after curing the aqueous binder composition at 400° F. for 3.5 minutes, the cured binder composition includes less than 3 wt. % of water-soluble material, as determined by extracting any water-soluble materials with deionized water for 3 hours at ambient condition using about 1000 g of deionized water per about 1 gram of the cured binder.

2 . The aqueous binder composition of claim 1 , wherein the cross-linking agent is polyacrylic acid.

3 . The aqueous binder composition of claim 1 , wherein the cross-linking agent is present in the aqueous binder composition in an amount from 52.0% by weight to 72% by weight, based on the total solids content of the aqueous binder composition.

4 . The aqueous binder composition of claim 1 , wherein the ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.4/1 and 0.6/1.

5 . The aqueous binder composition of claim 1 , wherein the monomeric polyol is selected from the group consisting of xylitol, sorbitol, and mixtures thereof.

6 . The aqueous binder composition of claim 1 , wherein the composition is free of polymeric polyhydroxy compounds.

7 . The aqueous binder composition of claim 1 , wherein the composition is free of a monomeric carboxylic acid.

8 . The aqueous binder composition of claim 2 further comprising:

2.0% to 15.0% by weight of a processing aid;

0 to 5.0% by weight of a surfactant;

0 to 2.0% by weight of a pigment; and

0 to 15% by weight of silicone, each percentage being based on a total solids content of the aqueous binder composition.

9 . The aqueous binder composition of claim 1 , wherein the monomeric polyol is sorbitol.

10 . The aqueous binder composition of claim 1 , wherein after cure, the cured binder composition includes no greater than 1 wt. % of water-soluble material.

11 . A fibrous insulation product comprising:

a plurality of randomly oriented 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 the aqueous binder composition in accordance with claim 1 .

12 . The fibrous insulation product of claim 11 , wherein the fibers comprise one or more of mineral fibers, natural fibers, and synthetic fibers.

13 . The fibrous insulation product of claim 11 , wherein the fibrous insulation product comprises one or more of a ceiling board, duct board, foundation board, pipe and tank insulation, sound absorption board, acoustical panel, duct liner, residential insulation, duct wrap, metal building insulation, and flexible duct media.

14 . The fibrous insulation product of claim 11 , wherein the fibrous insulation product includes a binder LOI of 5.5% to 17%.

15 . A B-stageable fibrous insulation product comprising:

a plurality of randomly oriented fibers; and

the aqueous binder composition in accordance with claim 1 at least partially coating said fibers,

wherein the B-stageable fibrous insulation product has a drying time, as measured by a CEM Smart 6 moisture analyzer, of at least 500 seconds.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 6, 2021
From: MUELLER, GERT; BRODERICK, ANDREW; ZHANG, XIUJUAN; CHEN, LIANG
To: OWENS CORNING INTELLECTUAL CAPITAL, LLC
Reel/Frame 057711/0145 →
Continuity (2)
Provisional Application 63086267 · Oct 1, 2020
Related Publication 20220106419A1 · Apr 7, 2022
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