Dedusting oils with increased exotherm onset temperature

Abstract

Dedusting oil compositions and binder compositions including such dedusting oil compositions for use with fiberglass insulation are provided. Dedusting oil compositions are formed from an epoxidized plant oil and a high activity amine. Binders may include a polycarboxylic acid based binder, a formaldehyde-based binder, or a formaldehyde-free binder and include a dedusting oil composition. Methods of making the binders and fiber-containing composites made with the binders are also provided.

What is claimed is: 
     
         1 . A dedusting oil composition comprising:
 an epoxidized plant oil and a high activity amine;   wherein the high activity amine comprises an aromatic amine or a mercapto amine having one or more active hydrogens attached to a nitrogen.   
     
     
         2 . The dedusting oil composition of  claim 1 , wherein the aromatic amine comprises an aniline, an alkylated aniline, phenylene diamine, a hydroquinoline, a phenol amine, an aromatic mercapto amine, a mercapto amine, an imidazole, mercaptothiazole, or a combination thereof. 
     
     
         3 . The dedusting oil composition of  claim 2 , wherein the aromatic amine comprises an aminophenol, a phenylenediamine, a mercaptobenzothiazole, a 4,4′-bis(α,α-dimethylbenzyl)diphenylamine, a hydroxybenzothiazole, or a combination thereof. 
     
     
         4 . The dedusting oil of  claim 1 , wherein the epoxidized plant oil is partially or fully reacted with the high activity amine, or is mixed with the high activity amine. 
     
     
         5 . The dedusting oil of  claim 1 , wherein the dedusting oil composition exhibits an exotherm onset temperature of greater than or about 190° C. 
     
     
         6 . The dedusting oil of  claim 1 , wherein the high activity amine is present in the dedusting oil composition in an amount of less than or about 20 wt. % based upon the weight of the epoxidized plant oil and the high activity amine. 
     
     
         7 . A binder composition for fiberglass, comprising:
 a polycarboxylic acid based binder, a formaldehyde-based binder, or a formaldehyde-free binder; and   a dedusting oil composition;   wherein the dedusting oil composition comprises an epoxidized plant oil and a high activity amine.   
     
     
         8 . The composition of  claim 7 , wherein the high activity amine comprises an aniline, an alkylated aniline, phenylene diamine, a hydroquinoline, a phenol amine, an aromatic mercapto amine, a mercapto amine, an imidazole, mercaptothiazole, a mercaptobenzothiazole, a 2-hydroxybenzothiazole, a 4,4′-bis(α,α-dimethylbenzyl)diphenylamine or a combination thereof. 
     
     
         9 . The composition of  claim 7 , wherein the binder composition comprises the polycarboxylic acid based binder, and wherein the polycarboxylic acid based binder comprise a crosslinking agent, wherein the crosslinking agent comprises one or more polyol compounds. 
     
     
         10 . The composition of  claim 9 , wherein the polyol comprises sorbitol, triethanolamine, diethanolamine, polyvinyl alcohol, glycerol, propylene glycol, neopentyl glycol, trimethylol propane, pentaerythritol, polyester polyol, acrylic polyols, carbohydrates, or combinations thereof. 
     
     
         11 . The composition of  claim 7 , wherein the polycarboxylic acid based binder comprises a monomeric polycarboxylic acid, wherein the monomeric polycarboxylic acid comprises citric acid, itaconic acid, maleic acid, adipic acid, oxalic acid, trimellitic acid, butanetetracarboxylic acid, or combinations thereof or a homopolymer or copolymer formed at least in part from acrylic acid, methacrylic acid, butenedioic acid, methyl maleic acid, itaconic acid, crotonic acid, maleic anhydride, acrylic anhydride, methacrylic anhydride, itaconic anhydride, maleic acid, fumaric acid, or a combination thereof, the formaldehyde-based binder comprises a phenol-formaldehyde (PF), urea-formaldehyde (UF), melamine-formaldehyde (MF) binders, or combinations thereof, and/or the formaldehyde-free binder comprises polyesters, melanoidin-based binders, epoxy resin, acrylic resin, polyurethanes, or combinations thereof. 
     
     
         12 . The composition of  claim 7 , wherein the epoxidized plant oil comprises epoxidized soybean oil, epoxidized linseed oil, epoxidized safflower oil, epoxidized sunflower oil, epoxidized castor oil, epoxidized corn oil, epoxidized tall oil fatty acid, or a combination thereof. 
     
     
         13 . The composition of  claim 7 , wherein the dedusting oil composition is present in the binder composition in an amount of less than or about 40 wt. %. 
     
     
         14 . The composition of  claim 7 , wherein the binder composition exhibits an exotherm onset temperature of greater than or about 200° C. 
     
     
         15 . A method of forming a binder composition for fiberglass, comprising:
 combining an epoxidized plant oil with a high activity amine optionally in the presence of a catalyst to form a dedusting oil composition; and   mixing a polycarboxylic acid based binder, a formaldehyde-based binder, or a formaldehyde-free binder and the dedusting oil to form the binder composition.   
     
     
         16 . The method of  claim 15 , further comprising curing the binder composition after mixing the polycarboxylic acid based binder, formaldehyde-based binder, or formaldehyde-free binder and the dedusting oil composition. 
     
     
         17 . The method of  claim 16 , further comprising applying the binder composition to one or more woven or non-woven fibers prior to curing. 
     
     
         18 . A fiber-containing composite, comprising:
 woven or non-woven fibers consolidated with a cured binder;   wherein the cured binder comprises the binder composition according to  claim 7 .   
     
     
         19 . The fiber-containing composite of  claim 18 , wherein the high activity amine comprises an aniline, an alkylated aniline, phenylene diamine, a hydroquinoline, a phenol amine, an aromatic mercapto amine, a mercapto amine, an imidazole, mercaptothiazole, a mercaptobenzothiazole, a 2-hydroxybenzothiazole 4,4′-bis(α,α-dimethylbenzyl)diphenylamine or a combination thereof. 
     
     
         20 . The fiber-containing composite of  claim 18 , wherein the high activity amine is present in the dedusting oil in an amount of less than or about 20 wt. %. 
     
     
         21 . The fiber-containing composite of  claim 18 , wherein the fiber-containing composite comprises thermal insulation. 
     
     
         22 . The fiber-containing composite of  claim 21 , where in the thermal insulation comprises at least one of building insulation, pipe insulation, duct insulation or appliance insulation. 
     
     
         23 . The fiber-containing composite of  claim 18 , wherein the fiber-containing composite comprises acoustical insulation. 
     
     
         24 . The fiber-containing composite of  claim 23 , wherein the acoustical insulation comprises at least one of HVAC insulation, appliance insulation or office interior board insulation.