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 . 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, tetra-carboxylic acid, or penta-carboxylic acid, or salts or anhydride derivatives thereof, or combinations thereof.   
     
     
         2 . The binder of  claim 1 , wherein the alkaline pH is in the range from about 7 to about 10. 
     
     
         3 . The binder of  claim 1 , wherein the solution has the alkaline pH due to inclusion of a base in the solution. 
     
     
         4 . The binder of  claim 3 , wherein the base is sodium hydroxide. 
     
     
         5 . The binder of  claim 4 , wherein the polyester polymer is colorless. 
     
     
         6 . The binder of  claim 3 , wherein the base is ammonium hydroxide. 
     
     
         7 . The binder of  claim 4 , wherein the polyester polymer is light tan. 
     
     
         8 . The binder of  claim 1 , wherein the polycarboxylic acid component is citric acid. 
     
     
         9 . The binder of  claim 1 , wherein the catalyst is sodium hypophosphite. 
     
     
         10 . A method of making a formaldehyde-free binder comprising
 drying an aqueous solution comprising (a) a polycarboxylic acid component selected from a group consisting of a dicarboxylic acid, tricarboxylic acid, tetra carboxylic acid, penta carboxylic acid, and anhydride derivatives thereof, (b) a polymeric polyhydroxyl component, (c) a catalyst, and (d) a base to form a dried mixture,   curing the dried mixture to form the formaldehyde-free binder.   
     
     
         11 . The method of  claim 10 , wherein the aqueous solution includes sufficient base to have an alkaline pH. 
     
     
         12 . The method of  claim 10 , wherein the aqueous solution further comprises a silicon-containing compound. 
     
     
         13 . The method of  claim 12 , wherein the silicon-containing compound is a silylethers or an alkylsilyl ethers. 
     
     
         14 . The method of  claim 12 , wherein the silicon-containing compound is gamma-aminopropyltriethoxy silane. 
     
     
         15 . The method of  claim 10 , wherein the polycarboxylic acid component is citric acid. 
     
     
         16 . The method of  claim 10 , wherein the catalyst is selected from the group consisting of ammonium para-toluene sulfonate, ammonium naphthalene disulfonate, ammonium sulfate, ammonium chloride, sulfuric acid, lactic acid, lead acetate, sodium acetate, calcium acetate, zinc acetate, organotin compounds, titanium esters, antimony trioxide, germanium salts, sodium hypophosphite, sodium phosphite, methane sulfonic acid and para-toluene sulfonic acid, and mixtures thereof. 
     
     
         17 . The method of  claim 10 , wherein the catalyst is sodium hypophosphite. 
     
     
         18 . The method of  claim 10 , wherein the base is selected from the group consisting ammonia, sodium carbonate, sodium hydroxide, and potassium hydroxide. 
     
     
         19 . The method of  claim 10 , wherein the base is selected from the group consisting ammonia, sodium carbonate, sodium hydroxide, and potassium hydroxide. 
     
     
         20 . 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, tetra-carboxylic acid, or penta-carboxylic acid, and a catalyst.   
     
     
         21 .- 25 . (canceled)