Bio-based binders including carbohydrates and a pre-reacted product of an alcohol or polyol and a monomeric or polymeric polycarboxylic acid

Abstract

An environmentally friendly, formaldehyde-free, aqueous binder composition that includes a carbohydrate, a crosslinking agent, and a pre-reacted product of an alcohol or polyol and monomeric or polymeric polycarboxylic acid or polyglycerol is provided. The pre-reacted product may include glycerol and esters of citric acid such a monoglyceryl citrate, diglyceryl citrate, and triglyceryl citrate as well as other higher molecular weight citric acid-based esters. The inclusion of the pre-reacted product in the binder composition helps to speed the crosslinking reaction, induces faster water evaporation, decreases the viscosity of the binder, helps to reduce the amount of water needed for application of the binder, decreases tackiness, and helps to achieve a maximum vertical expansion of the insulation pack in the transfer zone. The binder composition may be used in the formation of insulation materials and non-woven chopped strand mats.

1 - 52 . (canceled) 
     
     
         53 . An aqueous binder composition for use in the formation of fiberglass insulation and non-woven mats comprising:
 at least one carbohydrate;   at least one crosslinking agent; and   polyglycerol.   
     
     
         54 . (canceled) 
     
     
         55 . The binder composition of  claim 53 , 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. 
     
     
         56 . (canceled) 
     
     
         57 . (canceled) 
     
     
         58 . The binder composition of  claim 53 , wherein said binder composition comprises:
 from about 30.0% to about 95.0% by weight of the total solids of said at least one carbohydrate;   from about 1.0% to about 40.0% by weight of the total solids of said at least one crosslinking agent; and   from about 5.0% to about 40.0% by weight of the total solids of said polyglycerol.   
     
     
         59 . A fibrous insulation product comprising:
 a plurality of randomly oriented fibers; and   a binder composition applied to at least a portion of said fibers, said binder composition comprising the reaction product of:
 at least one carbohydrate; 
 at least one crosslinking agent; and 
 polyglycerol. 
   
     
     
         60 . The fibrous insulation product of  claim 59 , wherein said binder composition in a cured state comprises at least one polyester. 
     
     
         61 . (canceled) 
     
     
         62 . (canceled) 
     
     
         63 . (canceled) 
     
     
         64 . The fibrous insulation product of  claim 59 , wherein said insulation product is free of added formaldehyde. 
     
     
         65 . A non-woven mat comprising:
 a plurality of randomly oriented glass fibers in the form of a mat having a first major surface and a second major surface; and   a binder composition at least partially coating said first major surface of said mat, said binder composition comprising the reaction product of:
 at least one carbohydrate; 
 at least one crosslinking agent; and 
 polyglycerol. 
   
     
     
         66 . The non-woven mat of  claim 65 , wherein said binder composition in a cured state comprises at least one polyester. 
     
     
         67 . (canceled) 
     
     
         68 . The non-woven mat of  claim 65 , 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. 
     
     
         69 . The non-woven mat of  claim 65 , wherein said binder composition further comprises a member selected from the group consisting of at least one coupling agent; a moisture resistant agent, a dust suppression agent, a catalyst, an inorganic acid, an organic acid, an inorganic base, an organic base and combinations thereof. 
     
     
         70 . An insulation product formed by the process comprising:
 forming a plurality of randomly oriented glass fibers;   applying a binder composition to said glass fibers to form a fibrous insulation blanket, said binder composition comprising:
 at least one carbohydrate; 
 at least one crosslinking agent; and 
 polyglycerol; and 
   curing said fibrous insulation blanket to form an insulation product,   wherein said cured binder in said fibrous insulation product comprises at least one polyester.   
     
     
         71 . The insulation product of  claim 70 , wherein said curing step comprises:
 passing said insulation blanket through an oven.   
     
     
         72 . (canceled) 
     
     
         73 . The insulation product of  claim 70 , 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. 
     
     
         74 . The insulation product of  claim 70 , wherein said binder composition further comprises a member selected from the group consisting of at least one coupling agent; a moisture resistant agent, a dust suppression agent, a catalyst, an inorganic acid, an organic acid, an inorganic base, an organic base and combinations thereof. 
     
     
         75 . A method of making a fibrous insulation product comprising:
 forming a fibrous blanket including a plurality of randomly oriented glass fibers;   applying a binder to at least a portion of said glass fibers, said binder composition comprising:
 at least one carbohydrate; 
 polyglycerol; and 
   passing said fibrous blanket through an oven to at least partially cure said binder on said glass fibers and form an insulation product,   wherein said cured binder on said fibers in said cured insulation product comprises at least one polyester.   
     
     
         76 . The method of  claim 75 , further comprising:
 slitting said cured fibrous insulation product.   
     
     
         77 . The method of  claim 75 , further comprising:
 cutting said cured fibrous insulation product to a desired length.   
     
     
         78 . (canceled) 
     
     
         79 . The method of  claim 75 , 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. 
     
     
         80 . The method of  claim 75 , wherein said binder composition further comprises a member selected from the group consisting of at least one coupling agent; a moisture resistant agent, a dust suppression agent, a catalyst, an inorganic acid, an organic acid, an inorganic base, an organic base and combinations thereof. 
     
     
         81 . (canceled)