Insulative products having bio-based binders

Abstract

Fibrous insulation products have an aqueous binder composition that includes a carbohydrate and a crosslinking agent. In exemplary embodiments, the carbohydrate-based binder composition may also include a catalyst, a coupling agent, a process aid, a crosslinking density enhancer, an extender, a moisture resistant agent, a dedusting oil, a colorant, a corrosion inhibitor, a surfactant, a pH adjuster, and combinations thereof. The carbohydrate may be natural in origin and derived from renewable resources. Additionally, the carbohydrate polymer may have a dextrose equivalent (DE) number from 2 to 20. In at least one exemplary embodiment, the carbohydrate is a water-soluble polysaccharide such as dextrin or maltodextrin and the crosslinking agent is citric acid. Advantageously, the carbohydrates have a low viscosity and cure at moderate temperatures. The environmentally friendly, formaldehyde-free binder may be used in the formation of insulation materials and non-woven chopped strand mats. A method of making fibrous insulation products is also provided.

1 - 26 . (canceled) 
     
     
         27 . A fibrous product comprising:
 a plurality of randomly oriented glass fibers; and   a formaldehyde-free, thermosetting, bio-based binder composition applied to at least a portion of said fibers, said binder composition comprising the reaction product of:
 at least one carbohydrate having reactive hydroxyl groups; and 
 at least one crosslinking agent having reactive carboxylic acid groups. 
   
     
     
         28 . The fibrous product of  claim 27 , wherein said product is a flexible, low-density product having a density of from about 0.3 to about 4 pcf. 
     
     
         29 . The fibrous product of  claim 28 , wherein said binder composition is present in an amount from about 2% to about 13%. 
     
     
         30 . The fibrous product of  claim 27 , wherein said product is a rigid product having a density of from about 1.5 to about 10 pcf. 
     
     
         31 . The fibrous product of  claim 30 , wherein said binder composition is present in an amount from about 2% to about 20%. 
     
     
         32 . The fibrous product of  claim 27 , wherein said product has a density of from about 3 to about 8 pcf. 
     
     
         33 . The fibrous product of  claim 32 , wherein said binder composition is present in an amount from about 3% to about 15%. 
     
     
         34 . The fibrous product of  claim 27 , wherein said product is a rigid product having a density of from about 1.5 to about 10 pcf, and is shaped cylindrically to fit around a section of pipe. 
     
     
         35 . The fibrous product of  claim 27 , wherein said product is made by a rotary fiberization process. 
     
     
         36 . The fibrous product of  claim 27 , wherein said product is a non-woven product made by an air-laid process, said product having a density of from about 0.8 to about 4 pcf. 
     
     
         37 . The fibrous product of  claim 36 , wherein said binder composition is present in an amount from about 5% to about 20%. 
     
     
         38 . The fibrous product of  claim 27  wherein said at least one carbohydrate is a carbohydrate having a dextrose equivalent number from 2 to 20. 
     
     
         39 . The fibrous product of  claim 38 , wherein said at least one carbohydrate is a water-soluble polysaccharide selected from the group consisting of pectin, dextrin, maltodextrin, starch, modified starch, starch derivatives and combinations thereof. 
     
     
         40 . The fibrous product of  claim 27 , wherein said binder composition in a cured state comprises at least one polyester. 
     
     
         41 . The fibrous product of  claim 40 , wherein said crosslinking agent is selected from the group consisting of polycarboxylic acids, salts of polycarboxylic acid, anhydrides, monomeric carboxylic acid with anhydride, polycarboxylic acid with anhydride, citric acid, salts of citric acid, adipic acid, salts of adipic acid, polyacrylic acid, salts of polyacrylic acid, polyacrylic acid based resins and combinations thereof. 
     
     
         42 . The fibrous product of  claim 27 , wherein said product is free of added formaldehyde. 
     
     
         43 . The fibrous product of  claim 27 , wherein said fibrous product is an insulation product. 
     
     
         44 . The fibrous product of  claim 27 , wherein said fibrous product is a non-woven fibrous mat product having a first major surface and a second major surface; and having the binder composition at least partially coating the first major surface. 
     
     
         45 . The non-woven mat of  claim 44 , wherein said binder composition in a cured state comprises at least one polyester.