WO2002096819A1 - Surfactant-containing insulation binder - Google Patents
Surfactant-containing insulation binder Download PDFInfo
- Publication number
- WO2002096819A1 WO2002096819A1 PCT/US2002/016958 US0216958W WO02096819A1 WO 2002096819 A1 WO2002096819 A1 WO 2002096819A1 US 0216958 W US0216958 W US 0216958W WO 02096819 A1 WO02096819 A1 WO 02096819A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- binder
- mixture
- fiberglass
- surfactant
- weight
- Prior art date
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
- C03C25/10—Coating
- C03C25/24—Coatings containing organic materials
- C03C25/26—Macromolecular compounds or prepolymers
- C03C25/28—Macromolecular compounds or prepolymers obtained by reactions involving only carbon-to-carbon unsaturated bonds
- C03C25/285—Acrylic resins
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/04—Oxygen-containing compounds
- C08K5/06—Ethers; Acetals; Ketals; Ortho-esters
Definitions
- the present invention relates to fiberglass insulation. More specifically, the present invention provides a means for obtaining improved performance of polyacrylic acid and similar fiberglass insulation binders.
- Polyacrylic acid-based fiberglass insulation binders are typically manufactured with a low molecular weight polyacrylic acid, a polyhydroxy crosslinking agent, and a cure accelerator, such as sodium hypophosphite.
- Typical embodiments include QRXP- 1564 and QRXP-1513, produced by Rohm & Haas.
- QRXP-1564 is a blend of Acumer 1020 (71.6 wt-%), glycerol (21.8 wt-%), sodium hypophosphite (5.6 wt-%), and a small amount of corrosion inhibitor. Water is added as a diluent.
- QRXP-1513 is a blend of Acumer 1020, triethanolamine, and sodium hypophosphite.
- Acumer 1020 is a polyacrylic acid produced from acrylic acid monomer and a sodium bisulfite reactant.
- Acumer 1020 has a molecular weight of approximately 2000 and a sulfur content of about 3.4 wt-%.
- One embodiment of this invention is a fiberglass insulation binder composition
- a polycarboxy polymer especially a polyacrylic acid polymer
- a polyhydroxy crosslinking agent especially a polyacrylic acid polymer
- a surfactant selected from the group consisting of cationic surfactants, amphoteric surfactants, nonionic surfactants, and mixtures thereof.
- Another embodiment of this invention is a process for producing a fiberglass insulation binder.
- the process includes the preparation of a mixture of a polycarboxy (for example, polyacrylic acid) polymer, a polyhydroxy crosslinking agent, a surfactant as described above, and sufficient water to provide a mixture comprising up to 98 wt-% water based on the total weight of solids in the mixture, and blending the mixture to form a polymeric composition useful as a fiberglass insulation binder.
- the amount of surfactant employed can ranges from about 0.01 to about 10 weight percent, preferably from about 0.2 to about 5 weight percent, based on the total weight of binder solids.
- This process can make use of a pre-mixture containing the polymer and crosslinking agent that comprises about 50 to 60 wt-% water.
- a hydrolyzed silane coupling agent can also be added to the mixture, for example in an amount of from 0.01 to 10 wt-% based upon the weight of the mixture.
- a mineral oil dust suppressing agent to the mixture, for example in an amount of up to 20 wt-% based upon the weight of the mixture.
- the product of this process is also one aspect of the present invention.
- Another important embodiment of the present invention is a process for manufacturing a fiberglass insulation product. This process comprises the step of applying a binder composition as described above onto a fiberglass substrate, and curing the fiberglass substrate so treated.
- the fiberglass insulation product so produced is yet another embodiment of the present invention.
- Figure 1 is a Scanning Electron Microscope (SEM) photograph showing poor binder dispersion in a Prior Art context.
- FIGS 2 and 3 are SEM photographs showing good binder dispersion obtained in accordance with the present invention.
- compositions of this invention are prepared by polymerization of monomers emulsified in water using conventional emulsion polymerization procedures.
- Suitable surface-active agents (“surfactants") are used for emulsification of the monomers.
- surfactants include cationic, amphoteric, and nonionic surfactants, or mixtures thereof, with nonionic surfactants being preferred. Unless otherwise noted all percentages are weight percent.
- the primary solids component of the binder of this invention is preferably acrylic acid, but may be any polycarboxy polymer.
- the binder of the present invention comprises an organic polymer or oligomer containing a plurality of pendant carboxy groups.
- the polycarboxy polymer may be a homopolymer or copolymer prepared from unsaturated carboxylic acids including acrylic acid, methacrylic acid, crotonic acid, isocrotonic acid, maleic acid, cinnamic acid, 2-methylmaleic acid, itaconic acid, 2- methylitaconic acid, and the like.
- the polycarboxy polymer may be prepared from unsaturated anhydrides including maleic anhydride, itaconic anhydride, acrylic anhydride, methacrylic anhydride, and the like, as well as mixtures thereof. Methods for polymerizing these acids and anhydrides are well known in the chemical arts.
- the low molecular weight polycarboxy polymer produced in the first step of the process of the present invention is reacted with a polyhydroxy crosslinking agent, such as triethanolamine, glycerol, trimethylolpropane, 1,2,4-butanetriol, ethyleneglycol, 1,3- propanediol, 1,4-butanediol, 1,6-hexanediol, pentaerythritoL sorbitol, and the like. No catalyst is necessary in this crosslinking step.
- a polyhydroxy crosslinking agent such as triethanolamine, glycerol, trimethylolpropane, 1,2,4-butanetriol, ethyleneglycol, 1,3- propanediol, 1,4-butanediol, 1,6-hexanediol, pentaerythritoL sorbitol, and the like. No catalyst is necessary in this crosslinking step.
- the polycarboxy polymer, polyhydroxy crosslinking agent and surfactant may be mixed in a conventional mixing device.
- the polycarboxy polymer may be present at a concentration from about 5% to about 50% by weight, preferably from about 10% to about 30% by weight, based on the total weight of the mixture. It will be readily apparent to those skilled in the art that the concentration ranges for the polycarboxy polymer and other binder components may vary over wide limits and are not sharply critical to the successful practice of the present invention.
- Water may be added to the solids mixture in any amount which would produce an aqueous binder having a viscosity and flow rate suitable for its application to a forming fibrous glass mat by any convenient method, such as by spraying. Conveniently, water may comprise up to about 98% by weight of the binder.
- Examples of useful cationic surfactants include alkylamine salts such as laurylamine acetate, quaternary ammonium salts such as lauryl trimethyl ammonium chloride and alkyl benzyl dimethylammonium chlorides, and polyoxyethylenealkylamines.
- Examples of the amphoteric surfactants are alkylbetaines such as lauryl-betaine.
- nonionic surfactants which can be used in this invention are polyethers, for example, ethylene oxide and propylene oxide condensates which include straight and branched chain alkyl and alkaryl polyethylene glycol and polypropylene glycol ethers and thioethers; alkylphenoxypoly(ethyleneoxy)ethanols having alkyl groups containing from about 7 to about 18 carbon atoms and having from about 4 to about 240 ethyleneoxy units, such as heptylphenoxypoly(ethyleneoxy) ethanols, nonylphenoxypoly(ethyleneoxy) ethanols; the polyoxyalkylene derivatives ofhexitol including sorbitans, sorbides, mannitans, and mannides; partial long-chain fatty acids esters, such as the polyoxyalkylene derivatives of sorbitan monolaurate, sorbitan monopalmitate, sorbitan monostearate, sorbitan tristearate, sorbitan monooleate, and sorbitan triole
- Particularly preferred surfactants include SURFYNOL 420, 440, and 465, which are ethoxylated 2,4,7,9-tetramethyl-5-decyn-4,7-diol surfactants produced by Air Products and Chemicals, Inc. of Allentown, Pennsylvania.
- the amounts of surfactants employed in the emulsion polymerization process will range from about 0.01 to about 10 weight percent, preferably about 0.2 to about 5 weight percent based on the total weight of monomers and water.
- the binders of the present invention may optionally contain conventional adjuvants such as, for example, coupling agents, dyes, oils, fillers, thermal stabilizers, flame retarding agents, lubricants, and the like, in conventional amounts generally not exceeding 20% of the weight of the binder.
- conventional adjuvants such as, for example, coupling agents, dyes, oils, fillers, thermal stabilizers, flame retarding agents, lubricants, and the like, in conventional amounts generally not exceeding 20% of the weight of the binder.
- the polyacrylic acid and the polyhydroxy crosslinking agent may be mixed with water in a conventional mixing device.
- Water may be added to the mixture of acrylic acid monomer and polyhydroxy crosslinking agent in any amount which produces an aqueous binder mixture having a viscosity and flow rate suitable for application to a forming fibrous glass mat by any convenient method, for example, spraying.
- Water may comprise up to about 98% by weight of the binder mixture.
- the polyacrylic acid-based binder produced as described above is applied onto fiberglass, and the fiberglass so treated is cured and formed into, for example, an insulation blanket. More specifically, the binder is applied to glass fibers as they are being produced and formed into a mat, water is volatilized from the binder, and the resulting high solids binder-coated fibrous glass mat is heated to cure the binder, thereby producing a finished fibrous glass bat.
- These cured fiberglass bats may be used as thermal or acoustical insulation products, reinforcement for subsequently produced composites, and so on.
- the glass fibers typically have a diameter from about 2 to about 9 microns and have a length from about 0.25 inch (0.635 cm) to about 3 inches (7.62 cm).
- the glass fibers range in diameter from about 3 to about 6 microns, and have a length from about 0.50 inch (1.27 cm) to about 1.50 inches (3.81 cm).
- the glass fibers are deposited onto a perforated, endless forming conveyor.
- the binder is applied to the glass fibers as they are being formed by means of suitable spray applicators so as to result in a distribution of the binder throughout the formed mat of fibrous glass.
- the glass fibers, having the uncured resinous binder adhered thereto, are gathered and formed into a mat on the endless conveyor within the forming chamber with the aid of a vacuum drawn through the mat from below the forming conveyor.
- the residual heat contained in the glass fibers as well as the air flow through the mat causes a majority of the water to volatilize from the mat before it exits the forming chamber.
- application of the binder may proceed as follows.
- Melted glass is supplied to a fiber forming device such as a spinner or a bushing. Fibers of glass are attenuated from the device and are blown generally downwardly within a forming chamber.
- the glass fibers typically have a diameter of about 2 to 9 microns and a length of about 0.25 inch (0.635 cm) to 3 inches (7.62 cm).
- the glass fibers are deposited onto a foraminous forming conveyor. Binder mixture is applied to the glass fibers as they are being formed, for example by means of spray applicators, so as to distribute the binder throughout the formed mat of fibrous glass.
- the glass fibers, having the uncured resinous binder adhered thereto, are gathered and formed into a mat on the conveyor within the forming chamber with the aid of a vacuum drawn through the mat from below the forming conveyor.
- the residual heat contained in the glass fibers, as well as air flow through the mat causes much of the water to volatilize from the mat before it exits the forming chamber.
- the mat is then conveyed through a curing oven, typically at a temperature from 200°C to 325°C (392°F to 617°F) for from 30 seconds to 3 minutes, wherein heated air is passed through the mat to cure the resin.
- Fibrous glass having a cured, rigid binder matrix emerges from the oven in the form of a bat, which may be processed and utilized in manners well known to those skilled in the art.
- Example 1 Surface Tension
- a polyacrylic acid based binder having a solids content of 2.8 weight-% was prepared by diluting QRXP 1564 with water, followed by the addition of amino silane and oil emulsion.
- small amounts (0.1 weight-%) and 0.2 weight-%) of Surfynol 465 were blended into the binder composition.
- Surface tensions of the polyacrylic acid based binder compositions of this invention and of two reference binder compositions were measured using a Surface Tensionmeter 6000, produced by the SensaDyne Instrument Division of the Chem-Dyne Research Group. The instrument was calibrated with deionized water. The data were taken every 5 seconds. After the testing started and the system stabilized, the average value over a one-minute testing period was obtained for each sample. The results are reported in Table 1.
- compositions in accordance with the present invention had surface tensions that were lower not only than that of a similar conventional polyacrylic acid binder (QRXP 1564 2.8%) but also than that of a traditional phenol formaldehyde binder.
- a polyacrylic acid binder premix was prepared composed on 74.25 parts by weight (pbw) of Acumer 9932 (a 46% solids polyacrylic acid from Rohm & Haas), 10.40 pbw glycerol, 0.45 pbw corrosion inhibitor, and 14.90 pbw water, to provide a 45% solids premix.
- the premix was added along with silane and oil emulsion to water to provide a 3.5% solids polyacrylic acid glycerol binder (PAG+).
- Surfynol 465 surfactant was added to this polyacrylic acid glycerol binder at various % levels based on the binder solids. These binder compositions were sprayed onto fiberglass as in a typical fiberglass insulation binder application to obtain a Loss On Ignition (LOI) of 1.9%.
- the binder fiberglass was formed into insulation blankets, conveyed to an oven, and cured therein at temperatures ranging from 177°C to 310°C (350°F to 590°F).
- the bond strength, a measure of mechanical strength, of the cured hindered insulation products was measured and is reported in Table 2.
- Fiberglass insulation products manufactured in accordance with the present invention have better binder coverage and protection, less glass fiber damage, and provide better working environment and better product performance than do similar products made with previously known polyacrylic acid binder systems.
- Example 4 Insulation
- the surfactant-activated polyacrylic acid-based aqueous binder of this invention is applied onto fiberglass, and the fiberglass so treated is cured and formed into an insulation blanket.
- the molten glass is supplied to a rotary fiber forming device - spinner. Fibers of glass are attenuated from the device and are blown generally downwardly within a forming chamber.
- the surfactant-activated polyacrylic acid-based binder is sprayed through nozzles attached to a binder ring by liquid or air atomization.
- the binder flow rate and solid content are determined by the product design.
- the binder is applied at ambient temperature and most of the water in the binder is volatized as the atomized binder travels through the hot forming air flow and makes contact with the heated glass fiber.
- the hindered glass fiber blanket is conveyed through a curing oven at a temperature from 200°C to 350°C (392°F to 617°F) for 30 seconds to 3 minutes.
- the cured fiber glass blanket can be used as is or can be fabricated to customer demand.
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2002303904A AU2002303904B2 (en) | 2001-05-31 | 2002-05-28 | Surfactant-containing insulation binder |
CA2444012A CA2444012C (en) | 2001-05-31 | 2002-05-28 | Surfactant-containing insulation binder |
MXPA03010932A MXPA03010932A (en) | 2001-05-31 | 2002-05-28 | Surfactant-containing insulation binder. |
NZ529050A NZ529050A (en) | 2001-05-31 | 2002-05-28 | Surfactant-containing fiberglass insulation binder |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/871,467 US7157524B2 (en) | 2001-05-31 | 2001-05-31 | Surfactant-containing insulation binder |
US09/871,467 | 2001-05-31 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2002096819A1 true WO2002096819A1 (en) | 2002-12-05 |
Family
ID=25357505
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2002/016958 WO2002096819A1 (en) | 2001-05-31 | 2002-05-28 | Surfactant-containing insulation binder |
Country Status (6)
Country | Link |
---|---|
US (3) | US7157524B2 (en) |
AU (1) | AU2002303904B2 (en) |
CA (1) | CA2444012C (en) |
MX (1) | MXPA03010932A (en) |
NZ (1) | NZ529050A (en) |
WO (1) | WO2002096819A1 (en) |
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CN111201275B (en) | 2017-10-09 | 2022-07-01 | 欧文斯科宁知识产权资产有限公司 | Aqueous adhesive composition |
JP7219270B2 (en) | 2017-10-09 | 2023-02-07 | オウェンス コーニング インテレクチュアル キャピタル リミテッド ライアビリティ カンパニー | Aqueous binder composition |
GB201804907D0 (en) | 2018-03-27 | 2018-05-09 | Knauf Insulation Ltd | Composite products |
GB201804908D0 (en) | 2018-03-27 | 2018-05-09 | Knauf Insulation Ltd | Binder compositions and uses thereof |
US11813833B2 (en) | 2019-12-09 | 2023-11-14 | Owens Corning Intellectual Capital, Llc | Fiberglass insulation product |
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US11066535B2 (en) | 2011-04-07 | 2021-07-20 | Owens Corning Intellectual Capital, Llc | Bio-based binders including carbohydrates and a pre-reacted product of an alcohol or polyol and a monomeric or polymeric polycarboxylic acid |
US9957409B2 (en) | 2011-07-21 | 2018-05-01 | Owens Corning Intellectual Capital, Llc | Binder compositions with polyvalent phosphorus crosslinking agents |
Also Published As
Publication number | Publication date |
---|---|
US20040152824A1 (en) | 2004-08-05 |
MXPA03010932A (en) | 2004-02-27 |
US20050192390A1 (en) | 2005-09-01 |
US20020188055A1 (en) | 2002-12-12 |
CA2444012A1 (en) | 2002-12-05 |
US7157524B2 (en) | 2007-01-02 |
AU2002303904B2 (en) | 2007-08-30 |
CA2444012C (en) | 2011-05-17 |
NZ529050A (en) | 2005-04-29 |
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