Formaldehyde-free melamine carbohydrate binders for improved fire- resistant fibrous materials
Embodiments of the present technology include a formaldehyde-free binder composition. The composition may include melamine. The composition may also include a reducing sugar. In addition, the binder composition may include a non-carbohydrate aldehyde or ketone. Embodiments may also include a method of making a formaldehyde-free binder composition. The method may include dissolving melamine in an aqueous solution of a reducing sugar. The concentration of the reducing sugar may be 30 wt. % to 70 wt. % of the aqueous solution, which may be at a temperature of 50° C. to 100° C. The method may also include adding a non-carbohydrate aldehyde or ketone to the dissolved melamine in the aqueous solution to form a binder solution. The temperature of the aqueous solution of the dissolved melamine may be 50° C. to 100° C. during the addition of the non-carbohydrate aldehyde or ketone. The method may further include reducing the temperature of the binder solution.
1. A formaldehyde-free binder composition comprising:
melamine;
a reducing sugar; and
a non-carbohydrate aldehyde or ketone,
wherein:
the non-carbohydrate aldehyde or ketone is selected from the group consisting of glyoxal, acetaldehyde, butyraldehyde, glutaric dialdehyde, acetone, methyl ethyl ketone, and pentanedione, and
the binder composition forms (i) a reaction product of only the melamine and the non-carbohydrate aldehyde or ketone that reacts with (ii) the reducing sugar to make a crosslinked polymeric cured binder.
2. The formaldehyde-free binder composition of claim 1 , wherein a mole ratio of the melamine to the reducing sugar is 1:3 to 1:12.
3. The formaldehyde-free binder composition of claim 1 , wherein the formaldehyde-free binder composition further comprises a curing catalyst chosen from a sulfate salt, a phosphate salt, a borate salt, or combinations thereof.
4. The formaldehyde-free binder composition of claim 3 , wherein the sulfate salt or phosphate salt comprises an ammonium salt.
5. The formaldehyde-free binder composition of claim 3 , wherein the sulfate salt comprises ammonium sulfate.
6. The formaldehyde-free binder composition of claim 3 , wherein the phosphate salt comprises diammonium phosphate.
7. The formaldehyde-free binder composition of claim 1 , wherein the reducing sugar comprises dextrose.
8. The formaldehyde-free binder composition of claim 1 , wherein the non-carbohydrate aldehyde or ketone is chosen from acetaldehyde, butyraldehyde, glutaric dialdehyde, acetone, methyl ethyl ketone, or pentanedione.
9. The formaldehyde-free binder composition of claim 1 , wherein the non-carbohydrate aldehyde or ketone is glyoxal.
10. The formaldehyde-free binder composition of claim 9 , wherein a mole ratio of the melamine to the glyoxal is 2:1 to 1:3.
11. A binder composition comprising:
melamine;
a reducing sugar; and
an aldehyde comprising more than one aldehyde functional group,
wherein:
the aldehyde is selected from the group consisting of glyoxal and glutaric dialdehyde, and the binder composition forms (i) a reaction product of only the melamine and the aldehyde that reacts with (ii) the reducing sugar to make a crosslinked polymeric cured binder.
12. The binder composition of claim 11 , wherein the reducing sugar is a monosaccharide.
13. The binder composition of claim 12 , wherein the monosaccharide is chosen from dextrose, fructose, galactose, and combinations thereof.
14. The binder composition of claim 11 , wherein the reducing sugar is dextrose.
15. The binder composition of claim 11 , wherein the reducing sugar is a polysaccharide.
16. The binder composition of claim 15 , wherein the polysaccharide is chosen from lactose, maltose, xylose, amylose, and combinations thereof.
17. The binder composition of claim 11 , wherein the reducing sugar comprises high-fructose corn syrup.
18. The binder composition of claim 11 , wherein the aldehyde comprising more than one aldehyde functional group is glyoxal.
19. The binder composition of claim 11 , wherein the binder composition further comprises a curing catalyst.
20. The binder composition of claim 19 , wherein the curing catalyst is chosen from a sulfate salt, a phosphate salt, a borate salt, or combinations thereof.
21. The binder composition of claim 11 , wherein a mole ratio of the melamine to the reducing sugar is 1:3 to 1:12.
22. The binder composition of claim 11 , wherein a mole ratio of the melamine to the aldehyde is 2:1 to 1:3.
23. A binder composition comprising:
melamine;
a reducing sugar; and
a carbonyl-containing compound having the formula:
where R 1 and R 2 are independently selected from hydrogen, an alkyl group, an aromatic group, an alcohol group, an aldehyde group, a ketone group, a carboxylic acid group, and an alkoxy group, and
wherein:
the carbonyl-containing compounds is selected from the group consisting of glyoxal and pentanedione, and the binder composition forms (i) a reaction product of only the melamine and the carbonyl-containing compound that reacts with (ii) the reducing sugar to make a crosslinked polymeric cured binder.
24. The binder composition of claim 23 , wherein the reducing sugar is dextrose.
25. The composition of claim 23 , wherein the carbonyl-containing compound is glyoxal.
26. The composition of claim 23 , wherein the binder composition further comprises a curing catalyst.
27. The binder composition of claim 26 , wherein the curing catalyst is chosen from a sulfate salt, a phosphate salt, a borate salt, or combinations thereof.
28. The binder composition of claim 23 , wherein a mole ratio of the melamine to the reducing sugar is 1:3 to 1:12.
29. The binder composition of claim 23 , wherein a mole ratio of the melamine to the carbonyl-containing compound is 2:1 to 1:3.
30. The binder composition of claim 23 , wherein the binder composition comprises a clear dark brown appearance.
31. The binder composition of claim 23 , wherein the binder composition starts curing at 150° C.
32. The binder composition of claim 23 , wherein the binder composition cures in a range from 150° C. to 190° C.