Binder compositions and associated methods

Abstract

Disclosed are formaldehyde-free, thermally-curable, alkaline, aqueous binder compositions, curable to formaldehyde-free, water-insoluble thermoset polyester resins, and uses thereof as binders for non-woven fibers and fiber material.

1 .- 25 . (canceled) 
     
     
         26 . A binder comprising
 a polyester polymer, the polyester polymer comprising a reaction product of a polycarboxylic acid component and a polymeric polyhydroxyl component in the presence of a catalyst, wherein a solution of the polycarboxylic acid component, the polymeric polyhydroxyl component, and the catalyst has an alkaline pH and the polycarboxylic acid component is a dicarboxylic acid, tricarboxylic acid, tetracarboxylic acid, or pentacarboxylic acid, or salts or anhydride derivatives thereof, or combinations thereof.   
     
     
         27 . The binder of  claim 26 , wherein the alkaline pH is in the range from about 7 to about 10. 
     
     
         28 . The binder of  claim 26 , wherein the solution has the alkaline pH due to inclusion of a base in the solution. 
     
     
         29 . The binder of  claim 28 , wherein the base is sodium hydroxide. 
     
     
         30 . The binder of  claim 29 , wherein the polyester polymer is colorless. 
     
     
         31 . The binder of  claim 28 , wherein the base is ammonium hydroxide. 
     
     
         32 . The binder of  claim 29 , wherein the polyester polymer is light tan. 
     
     
         33 . The binder of  claim 26 , wherein the polycarboxylic acid component is citric acid. 
     
     
         34 . The binder of  claim 26 , wherein the catalyst is sodium hypophosphite. 
     
     
         35 . An insulation product comprising
 a formaldehyde-free polymeric binder composition in contact with mineral fibers, the formaldehyde-free polymeric binder comprising a product of a dried and cured alkaline aqueous solution, the solution comprising a polymeric polyhydroxyl component, a polycarboxylic acid component selected from a dicarboxylic acid, tricarboxylic acid, tetracarboxylic acid, or pentacarboxylic acid, and a catalyst.   
     
     
         36 . The insulation product of  claim 35 , wherein the polycarboxylic acid component is a dicarboxylic acid or a tricarboxylic acid. 
     
     
         37 . The insulation product of  claim 35 , wherein the polycarboxylic acid component is citric acid and the catalyst is sodium hypophosphite. 
     
     
         38 . The insulation product of  claim 35 , the solution further comprising a base. 
     
     
         39 . The insulation product of  claim 38 , wherein the base is sodium hydroxide. 
     
     
         40 . The insulation product of  claim 35 , wherein the solution further comprises a silicon-containing coupling agent.