Carbohydrate polyamine binders and materials made therewith

Abstract

A binder comprising the products of a carbohydrate reactant and polyamine is disclosed. The binder is useful for consolidating loosely assembled matter, such as fibers. Uncured fibrous products comprising fibers in contact with a carbohydrate reactant and a polyamine are also disclosed. The binder composition may be cured to yield a fibrous product comprising fibers bound by a cross-linked polymer. Further disclosed are methods for binding fibers with the carbohydrate reactant and polyamine based binder.

1 . A binder comprising a polymeric product of a carbohydrate reactant and a polyamine wherein the polymeric product is phenol-free and formaldehyde-free. 
     
     
         2 . The binder of  claim 1 , wherein the carbohydrate reactant is a polysaccharide. 
     
     
         3 . The binder of  claim 1 , wherein the carbohydrate reactant is a monosaccharide or a disaccharide. 
     
     
         4 . The binder of  claim 1 , wherein the carbohydrate reactant is a monosaccharide in its aldose or ketose form. 
     
     
         5 . The binder of  claim 1 , wherein the carbohydrate reactant is selected from a group consisting of dextrose, xylose, fructose, dihydroxyacetone, and mixtures thereof. 
     
     
         6 . The binder of  claim 1 , wherein the polyamine is a primary polyamine selected from a group consisting of a diamine, triamine, tetraamine, and pentamine. 
     
     
         7 . The binder of  claim 6 , wherein the polyamine is H 2 N-Q-NH 2 , wherein Q is alkyl, cycloalkyl, heteroalkyl, or cycloheteroalkyl, each of which is optionally substituted. 
     
     
         8 . The binder of  claim 7 , wherein Q is at least one of:
 a) an alkyl selected from a group consisting of C 2 -C 24 ;   b) an alkyl selected from a group consisting of C 2 -C 8 ;   c) an alkyl selected from a group consisting of C 3 -C 7 ;   d) a C 6  alkyl;   e) selected from the group consisting of a cyclohexyl, cyclopentyl and cyclobutyl; and   f) a benzyl.   
     
     
         9 - 13 . (canceled) 
     
     
         14 . The binder of  claim 6 , wherein the polyamine is a diamine selected from the group consisting of 1,6-diaminohexane and 1,5-diamino-2-methylpentane. 
     
     
         15 . The binder of  claim 14 , wherein the diamine is 1,6-diaminohexane. 
     
     
         16 . The binder of  claim 6 , wherein
 a) the triamine is selected from the group consisting of diethylenetriamine, 1-piperazineethanamine, and bis(hexamethylene)triamine;   b) the tetraamine is triethylenetetramine; and   c) the pentamine is tetraethylenepentamine.   
     
     
         17 - 18 . (canceled) 
     
     
         19 . The binder of  claim 6 , wherein the primary polyamine is a polyether-polyamine. 
     
     
         20 . The binder of  claim 19 , wherein the polyether-polyamine is a diamine or a triamine. 
     
     
         21 . The binder of  claim 1 , wherein a weight ratio of the carbohydrate reactant to the primary polyamine is in the range of about 1:1 to about 30:1. 
     
     
         22 . The binder of  claim 1 , wherein a weight ratio of the carbohydrate reactant to the primary polyamine is in the range of about 2:1 to about 10:1. 
     
     
         23 . The binder of  claim 1 , wherein the binder is characterized by at least one of:
 a) an aqueous extract of the polymeric product has a pH in the range of about 5 to about 9;   b) an aqueous extract of the polymeric product is essentially colorless;   c) an aqueous extract of the polymeric product is a capable of reducing Benedict's reagent;   d) the carbohydrate reactant and the primary polyamine are non-volatile; and   e) the polymeric product strongly absorbs light at 420 nm.   
     
     
         24 - 29 . (canceled) 
     
     
         30 . A method of making a collection of matter bound with a polymeric binder comprising:
 preparing a solution containing reactants for producing the polymeric binder and a solvent, wherein the reactants include a carbohydrate reactant and a polyamine;   disposing the solution onto the collection of matter;   volatilizing the solvent to form an uncured product, and   subjecting the uncured product to conditions that cause the carbohydrate reactant and the polyamine to polymerize to form the polymeric binder.   
     
     
         31 . The method of  claim 30 , wherein the collection of matter comprises fibers selected from a group consisting of mineral fibers, aramid fibers, ceramic fibers, metal fibers, carbon fibers, polyimide fibers, polyester fibers, rayon fibers, and cellulosic fibers. 
     
     
         32 . The method of  claim 30 , wherein the collection of matter is coal or sand particles. 
     
     
         33 . The method of  claim 31 , wherein the glass fibers are present in the range from about 80% to about 99% by weight. 
     
     
         34 . The method of  claim 31 , wherein the collection of matter comprises cellulosic fibers. 
     
     
         35 . The method of  claim 34 , wherein the cellulosic fibers are present in a substrate selected from the group consisting of wood shavings, sawdust, wood pulp, ground wood, jute, flax, hemp, and straw. 
     
     
         36 . The method of  claim 30 , further comprising packaging the uncured product in a packaging material suitable for storage. 
     
     
         37 . The method of  claim 30 , wherein preparing the solution includes at least one of the steps selected from the group consisting of:
 a) adding an amount of the carbohydrate reactant and an amount of the primary polyamine so a weight ratio is in the range of about 2:1 to about 10:1;   b) adding the carbohydrate reactant and the polyamine to an aqueous solution; and   c) adjusting the pH of the solution to within the range of about 8 to about 12.   
     
     
         38 - 39 . (canceled) 
     
     
         40 . A composition comprising a collection of matter and a binder, the binder comprising polymeric products of a reaction between a carbohydrate reactant and a polyamine, the polymeric products being substantially water insoluble. 
     
     
         41 . The composition of  claim 40 , wherein the collection of matter comprises fibers selected from the group consisting of mineral fibers, aramid fibers, ceramic fibers, metal fibers, carbon fibers, polyimide fibers, polyester fibers, rayon fibers, and cellulosic fibers. 
     
     
         42 . The composition of  claim 41 , wherein the collection of matter comprises glass fibers. 
     
     
         43 . The composition of  claim 41 , wherein the collection of matter includes cellulosic fibers. 
     
     
         44 - 45 . (canceled) 
     
     
         46 . The composition of  claim 40 , wherein the polyamine is selected from a group consisting of a diamine, triamine, tetramine, and pentamine. 
     
     
         47 . The composition of  claim 46 , wherein the polyamine is H 2 N-Q-NH 2 , wherein Q is alkyl, cycloalkyl, heteroalkyl, or cycloheteroalkyl, each of which is optionally substituted. 
     
     
         48 - 51 . (canceled)