Aqueous binder composition

Abstract

The invention is directed to an aqueous binder composition free of phenol and formaldehyde.

1 .- 22 . (canceled) 
     
     
         23 . An aqueous binder composition for mineral fibers, wherein the composition is free of phenol and formaldehyde, has a pH of ≥8 and comprises:
 a component (i) in the form of one or more kraft lignins and having a carboxylic acid group content of from 0.03 mmol/g to 0.9 mmol/g, based on a dry weight of the kraft lignins; 
 a component (ii) in the form of one or more cross-linkers; 
 a component (iii) in the form of one or more plasticizers, 
 
       provided that the composition does not comprise a cross-linker selected from epoxy compounds having a molecular weight M W  of 500 or less. 
     
     
         24 . The aqueous binder composition of  claim 23 , wherein component (i) has a carboxylic acid group content of from 0.15 mmol/g to 0.6 mmol/g, based on the dry weight of the kraft lignins. 
     
     
         25 . The aqueous binder composition of  claim 23 , wherein component (i) is in form of one or more kraft lignins having an average carboxylic acid group content of less than 1.8 groups per macromolecule considering a Mn wt. average of component (i). 
     
     
         26 . The aqueous binder composition of  claim 23 , wherein component (i) has a nitrogen content of ≤1.2 wt.-%, based on a dry weight of component (i). 
     
     
         27 . The aqueous binder composition of  claim 23 , wherein component (i) has a content of phenolic OH groups of from 2.0 mmol/g to 5.0 mmol/g, based on a dry weight of the kraft lignins. 
     
     
         28 . The aqueous binder composition of  claim 23 , wherein component (i) has a content of aliphatic OH groups of from 0.7 mmol/g to 3.0 mmol/g, based on a dry weight of the kraft lignins. 
     
     
         29 . The aqueous binder composition of  claim 23 , wherein component (ii) is in the form of one or more cross-linkers selected from
 β-hydroxyalkylamide cross-linkers and/or oxazoline cross-linkers; and/or   multifunctional organic amines; and/or   epoxy compounds having a molecular weight of more than 500 or one or more flexible oligomers or polymers which contain reactive functional groups; and/or   one or more cross-linkers selected from polyethylene imine, polyvinyl amine, fatty amines; and/or   one more cross-linkers in the form of fatty amides; and/or   one or more cross-linkers selected from dimethoxyethanal, glycolaldehyde, glyoxalic acid; and/or   one or more cross-linkers selected from polyester polyols; and/or   one or more cross-linkers selected from starch, modified starch, carboxymethylcellulose (CMC); and/or   one or more cross-linkers in the form of multifunctional carbodiimides; and/or   one or more cross-linkers selected from melamine based cross-linkers.   
     
     
         30 . The aqueous binder composition of  claim 23 , wherein component (ii) comprises one or more cross-linkers selected from β-hydroxyalkylamide cross-linkers and/or oxazoline cross-linkers. 
     
     
         31 . The aqueous binder composition of  claim 23 , wherein the composition comprises from 1 wt.-% to 50 wt.-% of component (ii), based on a dry weight of component (i). 
     
     
         32 . The aqueous binder composition of  claim 23 , wherein component (iii) is in the form of
 one or more plasticizers selected from fatty alcohols, monohydroxy alcohols; and/or   one or more plasticizers selected from alkoxylates; and/or   one or more plasticizers in the form of propylene glycols; and/or   one or more plasticizers in the form of glycol esters; and/or   one or more plasticizers selected from adipates, acetates, benzoates, cyclobenzoates, citrates, stearates, sorbates, sebacates, azelates, butyrates, valerates; and/or   one or more plasticizers selected from phenol derivatives; and/or   one or more plasticizers selected from silanols, siloxanes; and/or   one or more plasticizers selected from sulfates, sulfonates, phosphates; and/or   one or more plasticizers in the form of hydroxy acids; and/or   one or more plasticizers selected from monomeric amides; and/or   one or more plasticizers selected from quaternary ammonium compounds; and/or   one or more plasticizers selected from vegetable oils; and/or   tall oil; and/or   one or more plasticizers selected from hydrogenated oils, acetylated oils; and/or   one or more plasticizers selected from acid methyl esters; and/or   one or more plasticizers selected from alkyl polyglucosides, gluconamides, aminoglucoseamides, sucrose esters, sorbitan esters; and/or   one or more plasticizers selected from polyethylene glycols, polyethylene glycol ethers; and/or   one or more plasticizers in the form of polyols; and/or   triethanolamine.   
     
     
         33 . The aqueous binder composition of  claim 23 , wherein component (iii) is in the form of propylene glycols, phenol derivatives, silanols, siloxanes, hydroxy acids, vegetable oils, polyethylene glycols, polyethylene glycol ethers, triethanolamine, or any mixtures thereof. 
     
     
         34 . The aqueous binder composition of  claim 23 , wherein component (iii) comprises one or more plasticizers having a boiling point of from 100° C. to 380° C. 
     
     
         35 . The aqueous binder composition of  claim 23 , wherein component (iii) comprises one or more polyethylene glycols having an average molecular weight of from 150 g/mol to 50000 g/mol. 
     
     
         36 . The aqueous binder composition of  claim 23 , wherein the composition comprises from 0.5 wt.-% to 60 wt.-% of component (iii), based on a dry weight of component (i). 
     
     
         37 . The aqueous binder composition of  claim 23 , wherein the composition further comprises urea. 
     
     
         38 . The aqueous binder composition of  claim 23 , wherein the composition further comprises one or more silicone resins. 
     
     
         39 . The aqueous binder composition of  claim 23 , wherein the composition does not contain an ammonia-oxidized lignin (AOL). 
     
     
         40 . A method of producing a bonded mineral fiber product, wherein the method comprises contacting mineral fibers with the binder composition of  claim 23  and curing the binder composition. 
     
     
         41 . A mineral fiber product, wherein the product comprises mineral fibers in contact with a binder resulting from curing the binder composition of  claim 23 . 
     
     
         42 . A method for the preparation of a binder composition for mineral wool which is free of of phenol and formaldehyde, wherein the method comprises using one or more kraft lignins having a carboxylic acid group content of from 0.03 mmol/g to 0.9 mmol/g, based on a dry weight of the kraft lignins, for making the binder composition.