US20170174836A1 - Binders - Google Patents

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US20170174836A1
US20170174836A1 US15/310,837 US201515310837A US2017174836A1 US 20170174836 A1 US20170174836 A1 US 20170174836A1 US 201515310837 A US201515310837 A US 201515310837A US 2017174836 A1 US2017174836 A1 US 2017174836A1
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Prior art keywords
binder composition
reacted
polyamino acid
binder
reacted binder
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Carl Hampson
Richard Hand
James Robinson
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Knauf Insulation SPRL
Knauf Insulation Inc
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Knauf Insulation SPRL
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Assigned to KNAUF INSULATION, LLC, KNAUF INSULATION SPRL reassignment KNAUF INSULATION, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KNAUF INSULATION LIMITED
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N1/00—Pretreatment of moulding material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G73/00—Macromolecular compounds obtained by reactions forming a linkage containing nitrogen with or without oxygen or carbon in the main chain of the macromolecule, not provided for in groups C08G12/00 - C08G71/00
    • C08G73/02—Polyamines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/24—Coatings containing organic materials
    • C03C25/26—Macromolecular compounds or prepolymers
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07H—SUGARS; DERIVATIVES THEREOF; NUCLEOSIDES; NUCLEOTIDES; NUCLEIC ACIDS
    • C07H5/00—Compounds containing saccharide radicals in which the hetero bonds to oxygen have been replaced by the same number of hetero bonds to halogen, nitrogen, sulfur, selenium, or tellurium
    • C07H5/04—Compounds containing saccharide radicals in which the hetero bonds to oxygen have been replaced by the same number of hetero bonds to halogen, nitrogen, sulfur, selenium, or tellurium to nitrogen
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G12/00—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen
    • C08G12/02—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes
    • C08G12/04—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with acyclic or carbocyclic compounds
    • C08G12/06—Amines
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/02—Fibres or whiskers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L61/00—Compositions of condensation polymers of aldehydes or ketones; Compositions of derivatives of such polymers
    • C08L61/20—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen
    • C08L61/22—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with acyclic or carbocyclic compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L79/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen with or without oxygen or carbon only, not provided for in groups C08L61/00 - C08L77/00
    • C08L79/02—Polyamines
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J105/00—Adhesives based on polysaccharides or on their derivatives, not provided for in groups C09J101/00 or C09J103/00
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J161/00—Adhesives based on condensation polymers of aldehydes or ketones; Adhesives based on derivatives of such polymers
    • C09J161/20—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen
    • C09J161/22—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with acyclic or carbocyclic compounds
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J179/00—Adhesives based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen, with or without oxygen, or carbon only, not provided for in groups C09J161/00 - C09J177/00
    • C09J179/02—Polyamines
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2201/00—Properties
    • C08L2201/56—Non-aqueous solutions or dispersions

Definitions

  • the present invention relates to a water-soluble carbohydrate-polyamino acid-based pre-reacted binder composition, a method of its manufacture, a use of the pre-reacted binder composition, a method of manufacturing a collection of matter bound by a polymeric binder resulting from the pre-reacted binder composition, a binder solution or dispersion comprising the pre-reacted binder composition, as well as products comprising the pre-reacted binder composition in a cured state.
  • binders are useful in fabricating articles because they are capable of consolidating non-assembled or loosely-assembled matter. For example, binders enable two or more surfaces to become united. In particular, binders may be used to produce products comprising consolidated fibres. Thermosetting binders may be characterized by being transformed into insoluble and infusible materials by means of either heat or catalytic action. Examples of a thermosetting binder include a variety of phenol-aldehyde, urea-aldehyde, and melamine-aldehyde binders, as well as other condensation-polymerization materials such as, for example, furane and polyurethane resins.
  • Binder compositions containing phenol-aldehyde, resorcinol-aldehyde, phenol/aldehyde/urea, phenol/melamine/aldehyde, and the like are widely used for the bonding of fibres, textiles, plastics, rubbers, and many other materials.
  • Phenol formaldehyde type binders provide suitable properties to the final products; however, desires for greater sustainability and environmental considerations have motivated the development of alternative binders.
  • One such alternative binder is a carbohydrate-based binder derived from reacting a carbohydrate and an acid, for example, U.S. Patent Application Publication No. 2007/0027283 and published PCT Application WO2009/019235.
  • Another alternative binder is the esterification products of reacting a polycarboxylic acid and a polyol, for example, U.S. Patent Application Publication No. 2005/0202224. Because these binders do not utilize formaldehyde as a reagent, they have been collectively referred to as formaldehyde-free binders.
  • binders are relatively more expensive than phenol-formaldehyde binders, are derived essentially from petroleum-based resources, and have a tendency to exhibit lower reaction rates compared to phenol-formaldehyde-based binder compositions, thereby requiring prolonged cure times or increased cure temperatures.
  • Carbohydrate-based binder compositions are made of relatively inexpensive precursors and are derived mainly from renewable resources. These binders may also require reaction conditions for curing that are substantially different from the conditions under which the traditional phenol-formaldehyde binder system is cured.
  • a versatile alternative to the above-mentioned phenol-formaldehyde binders is the use of carbohydrate-polyamine binders, which are polymeric binders obtained upon reaction of carbohydrates with polyamines having at least one primary amine group.
  • Carbohydrate-polyamine binders are effective substitutes for phenol-formaldehyde binders, since they possess similar or superior binding characteristics and are highly compatible with established manufacturing processes.
  • carbohydrate-polyamine binders are prepared as a solution, such as an aqueous solution, and are subsequently applied onto loosely-assembled matter that is to be bound. Such wetted loosely-assembled matter is then, for example, heat treated to cure the carbohydrate-polyamine binder.
  • the rather high concentration of solids in carbohydrate-polyamine binder solutions is associated with a variety of disadvantages, however, such as quick gelling or solidification of the binder solution, as well as recrystallization of the carbohydrate component(s). Based on the rather short shelf-life, further problems regarding storage and shipment of carbohydrate-polyamine binders are often observed.
  • the technical problem underlying the present invention is to provide improved binders, particularly binders which are i) compatible with established manufacturing processes, ii) environmentally acceptable, and iii) overcome the aforementioned problems.
  • the present invention provides a water-soluble pre-reacted binder composition, comprising the reaction product(s) of (i) at least one carbohydrate component, and (ii) at least one polyamino acid component.
  • the pre-reacted binder may be in the form of an aqueous solution or dispersion containing at least 20 wt.-%, for example at least 25% wt.-, 30% wt.-, 35% wt.-, 40% wt.-, 45 wt.-%, 50 wt.-%, 55 wt.-%, 60 wt.-%, 65 wt.-%, 70 wt.-%, 75 wt.-% or 80 wt.-% of the pre-reacted binder composition and/or no more than 85 wt.-%, for example no more than 80 wt.-%, 75 wt.-% or 70 wt.-% of the pre-reacted binder composition.
  • the term “pre-reacted binder composition” is not particularly restricted and generally includes any chemical composition obtainable and/or obtained by reacting a carbohydrate component and a polyamino acid component, which composition may be used as a binder, e.g., for binding loosely-assembled matter, either as such or upon further modification.
  • Preferred embodiments of the pre-reacted binder composition of the present invention are based on an alkaline carbohydrate component/polyamino acid component binder system, i.e., the carbohydrate component(s) and polyamino acid component(s) are the major reactive components of the starting material(s). Accordingly, the total amount of the at least one carbohydrate component and the at least one polyamino acid component in the starting material used to prepare the pre-reacted binder composition may be at least 20 wt.-%, based on the total weight of the binder composition before pre-reaction.
  • the total amount of the at least one carbohydrate component and the at least one polyamino acid component may be at least 30 wt.-%, 40 wt.-%, 50 wt.-%, 60 wt.-%, 70 wt.-%, 80 wt.-%, 90 wt.-%, 95 wt.-%, or 98 wt.-% before pre-reaction.
  • the total amount of the reaction product(s) of (i) the at least one carbohydrate component, (ii) the at least one polyamino acid component, the unreacted carbohydrate component(s), and the unreacted polyamino acid component(s) in the pre-reacted binder composition is at least 20 wt.-%, based on the total weight of the pre-reacted binder composition, for example at least 30 wt.-%, 40 wt.-%, 50 wt.-%, 60 wt.-%, 70 wt.-%, 80 wt.-%, 90 wt.-%, 95 wt.-%, or 98 wt.-%.
  • the pre-reacted binder composition of the present invention is a composition that:
  • a) compared with such prior art binders as applied to loosely-assembled matter (notably prior to cross-linking by application of heat), may have intermediate reaction specie(s) such as pre-polymers, in significant quantities, and/or reduced viscosity per solid content, and/or increased average molecular weight, and/or increased colour and/or light (e.g., UV) absorption; and/or
  • pre-polymer is not specifically restricted and includes any reaction product(s) of (i) the at least one carbohydrate component and (ii) the at least one polyamino acid component.
  • the amount of the reaction product(s) of (i) the at least one carbohydrate component and (ii) the at least one polyamino acid component is at least 20 wt.-%, based on the total weight of pre-polymers in the pre-reacted binder composition, for example at least 30 wt.-%, 40 wt.-%, 50 wt.-%, 60 wt.-%, 70 wt.-%, 80 wt.-%, 90 wt.-%, 95 wt.-%, or 98 wt.-%.
  • the amount of the reaction product(s) of (i) the at least one carbohydrate component and (ii) the at least one polyamino acid component is 100 wt.-%, based on the total weight of pre-polymers in the pre-reacted binder composition.
  • the pre-reacted binder composition of the present invention comprises at least one pre-polymer having a molecular weight in the range of 1 to 100 kDa.
  • the at least one pre-polymer is contained, based on the total weight of the binder composition, in an amount of 2 wt.-% or more, e.g., 5 wt.-% or more, 10 wt.-% or more, 15 wt.-% or more, 20 wt.-% or more, 25 wt.-% or more, 30 wt.-% or more, 35 wt.-% or more, 40 wt.-% or more, 45 wt.-% or more, or 50 wt.-% or more.
  • the pre-reacted binder composition of the present invention comprises at least one pre-polymer having a molecular weight in the range of more than 80 kDa to 100 kDa (hereinafter “high molecular-weight pre-polymer”).
  • the at least one high molecular-weight pre-polymer is contained, based on the total weight of the binder composition, in an amount of 0.2 wt.-% or more, e.g., 0.5 wt.-% or more, 0.75 wt.-% or more, 1 wt.-% or more, 1.75 wt.-% or more, 2.5 wt.-% or more, 5 wt.-% or more, 10 wt.-% or more, 15 wt.-% or more, 20 wt.-% or more, 30 wt.-% or more, 40 wt.-% or more, or 50 wt.-% or more.
  • the pre-reacted binder composition of the present invention comprises at least one pre-polymer having a molecular weight in the range of more than 10 kDa to 80 kDa (hereinafter “mid molecular-weight pre-polymer”).
  • the at least one mid molecular-weight pre-polymer is contained, based on the total weight of the binder composition, in an amount of 0.3 wt.-% or more, e.g., 0.5 wt.-% or more, 1 wt.-% or more, 1.5 wt.-% or more, 2 wt.-% or more, 2.5 wt.-% or more, 5 wt.-% or more, 10 wt.-% or more, 15 wt.-% or more, 20 wt.-% or more, 30 wt.-% or more, 40 wt.-% or more, or 50 wt.-% or more.
  • the pre-reacted binder composition of the present invention comprises one or more compounds having a molecular weight in the range of 10 kDa or less, which may include pre-polymer referred to herein as low molecular-weight pre-polymer, and which are different from (i) the at least one carbohydrate component and (ii) the at least one polyamino acid component.
  • the low molecular-weight compounds comprise one or more of a glycolaldehyde, glyceraldehyde, 2-oxopropanal, acetol, dihydroxyacetone, acetoin, butanedione, ethanal, glucosone, 1-desoxyhexosulose, 3-desoxyhexosulose, 3-desoxypentosulose, 1,4-didesoxyhexosulose, glyoxal, methylglyoxal, diacetyl and 5-(hydroxymethyl)furfural.
  • water-soluble is not specifically restricted and includes all grades of water-solubility of the pre-reacted binder composition as defined above.
  • water-soluble includes water-solubility at 20° C. of 100 g/l or more, 150 g/l or more, 200 g/l or more, or 250 g/l or more.
  • water-soluble may include a water-solubility for the pre-reacted binder composition as defined above of 300 g/l or more, 400 g/l or more, 500 g/l or more or 600 g/l or more (at 20° C.). Also virtually infinite water-solubility may be regarded to be within the scope of the present invention.
  • water-insoluble relates to cases where the pre-reacted binder composition as defined above is essentially insoluble in water at 20° C.
  • insoluble includes a water-solubility at 20° C. of 50 g/l or less, 40 g/l or less, 30 g/l or less, or 20 g/l or less.
  • water-insoluble includes cases of water-solubility of 10 g/l or less, 5 g/l or less, 1 g/l or less or 0.1 g/l or less.
  • the pre-reacted binder composition may be water dilutable, where this means that 1 part by weight of pre-reacted binder composition as defined above mixed with at least 25 parts, notably at least 50 parts or 100 parts, of deionized water does not result in precipitation upon mixing.
  • an aqueous solution containing 70 wt.-% of the pre-reacted binder composition of the present invention has a viscosity at 20° C. of at most 2000 cP.
  • an aqueous solution containing 70 wt.-% of the above-defined pre-reacted binder composition i.e., an aqueous solution containing 70% wt.-% of solids
  • a preferred viscosity is in the range of 280 cP to 350 cP, where viscosity may be measured using a LV-Torque Brookfield Viscometer, spindle LV-63 at 60 rpm.
  • the viscosity would be much lower ( ⁇ 30 cP) due to the lower solids content, and measured using a Brookfield DV-II+ Pro at 20° C., Spindle SC4-18.
  • the viscosity of an aqueous solution of the pre-reacted binder composition of the present invention should preferably not increase by more than 500 cP when left to stand at 20° C. for 12 hours, 24 hours, 48 hours, 72 hours or 96 hours. According to a further preferred embodiment, the viscosity of the aqueous solution should not increase by more than 500 cP within a week, 10 days, 12 days or two weeks. Longer periods, such as three or four weeks, or even two, three or more months, where the viscosity will not increase by more than 500 cP are even more preferable.
  • the amount by which the viscosity increases within the first 12 hours when leaving a 70 wt.-% aqueous solution of the pre-reacted binder composition to stand at 20° C. should preferably not exceed 450 cP, or 400 cP or even 350 cP.
  • Preferred increases in viscosity include increases of 300 cP or less, 280 cP or less, 250 cP or less and 200 cP or less.
  • the above-defined time periods and increases in viscosity are not limited to the examples mentioned above and may be freely combined.
  • the above-mentioned 70 wt.-% aqueous solution of the pre-reacted binder composition does not increase in viscosity by more than 300 cP within the first 48 hours after its preparation, or more than 400 cP within two weeks after its preparation.
  • the viscosity of a representative aqueous solution becomes too high, e.g., caused by gelling, the pre-reacted binder composition may become unusable.
  • the above-defined pre-reacted binder composition is capable of reacting and/or reacts with a cross-linker to yield a water-insoluble composition, for example, to yield one or more melanoidins as a water-insoluble composition.
  • the pre-reacted binder composition may function as a precursor or intermediate which may be further reacted with a cross-linker to obtain a polymeric binder.
  • this polymeric binder may contain high molecular weight melanoidins as Maillard reaction products that are essentially water-insoluble.
  • the one or more melanoidins as defined above may contain the following generic structural motifs:
  • n is an integer of at least 1.
  • cross-linker is not particularly restricted and includes any chemical or physical means to further cross-link the pre-reacted binder composition as defined above to yield a polymeric binder suitable for binding loosely-assembled matter, such as wood or mineral fibres.
  • the cross-linker may be the same polyamino acid component that has been reacted with the carbohydrate component, or the cross-linker may be a different polyamino acid component(s).
  • the pre-reacted binder composition of the present invention may be prepared by reacting a carbohydrate component with lysine. Subsequently, further lysine may be added to the pre-reacted binder composition to achieve the high grade of polymerization required for a particular application.
  • a further example includes the case where the pre-reacted binder composition of the present invention is prepared by reacting a carbohydrate component with lysine, and for the final curing additional polyamino acid is added in the form of diaminopropionic acid, diaminobutyric acid, ornithine, histidine, arginine, and/or homolysine.
  • the cross-linker is not limited to the polyamino acid components defined herein and includes, as an example, Lewis acids, isocyanates, blocked isocyanates, epoxides, blocked epoxides, carbonyl-containing compounds (e.g., ketones and aldehydes), polyamines, and organic carbonates.
  • cross-linkers include glyoxal, citric acid, other polycarboxylic acids and anhydrides (e.g., succinic acid, maleic anhydride, tetra- and hexa-hydrophthalic anhydrides, styrene-maleic-anhydride copolymers), hexamethylene diamine (as well as shorter and longer homologs thereof), and solutions of polycarboxylic acid and anhydride derivatives (e.g., ammonium salts thereof).
  • polycarboxylic acids and anhydrides e.g., succinic acid, maleic anhydride, tetra- and hexa-hydrophthalic anhydrides, styrene-maleic-anhydride copolymers
  • hexamethylene diamine as well as shorter and longer homologs thereof
  • polycarboxylic acid and anhydride derivatives e.g., ammonium salts thereof.
  • the ratio of the total carbonyl groups in the carbohydrate component to total reactive amino groups in the polyamino acid component ranges from 5:1 to 1:5.
  • the ratio of carbonyl groups to reactive amino groups may be 5:1 to 1:4.5, 5:1 to 1:4, 5:1 to 1:3.5, 5:1 to 1:3, 5:1 to 1:2.5, 5:1 to 1:2, 5:1 to 1:1.8, 5:1 to 1:1.5, 5:1 to 1:1.2, 5:1 to 1:1, 5:1 to 1:0.8, and 5:1 to 1:0.5.
  • ratios such as 4:1 to 1:5, 3.5:1 to 1:5, 3:1 to 1:5, 2.5:1 to 1:5, 2:1 to 1:5, 1.5:1 to 1:5, 1:1 to 1:5, 0.8:1 to 1:5 and 0.5:1 to 1:5.
  • the upper and lower borders of the above-mentioned ratios may be freely combined.
  • reactive amino group is not particularly restricted and includes any amino group in the polyamino acid component which is capable of reacting with the carbohydrate component.
  • reactive amino groups include primary and secondary amino groups, imine (or imino) groups, as well as guanido (or guanidino) groups.
  • carbohydrate component is not specifically restricted and generally includes any carbohydrate compound which is capable of reacting with a polyamino acid component.
  • the at least one carbohydrate component is selected from the group consisting of monosaccharides, disaccharides, polysaccharides, and a reaction product thereof.
  • the carbohydrate component is or comprises a reducing sugar and/or a component which yields a reducing sugar in situ.
  • reducing sugar indicates one or more sugars that contain aldehyde or keto groups, or that can isomerize, i.e., tautomerize, to contain aldehyde or keto groups, which groups may be oxidized with, for example, Cu-ions to afford carboxylic acids.
  • any such carbohydrate component may be optionally substituted, such as with hydroxy, halo, alkyl, cycloalkyl, heteroalkyl, cycloheteroalkyl, alkoxy, and the like.
  • any such carbohydrate component one or more chiral centers may be present, and both possible optical isomers at each chiral center are within the scope of the invention described herein. Further, it is also to be understood that various mixtures, including racemic mixtures, or other diastereomeric mixtures of the various optical isomers of any such carbohydrate component, as well as various geometric isomers thereof, may be used in one or more embodiments described herein.
  • Non-reducing sugars for instance sucrose
  • sucrose may be used as the carbohydrate component or as a part thereof, especially when capable of and/or subjected to in situ conversion to a reducing sugar.
  • a monosaccharide, a disaccharide, or a polysaccharide may be partially reacted with a precursor to form a carbohydrate reaction product.
  • the carbohydrate reaction product is derived from a monosaccharide, a disaccharide, or a polysaccharide, and maintains similar reactivity with a polyamino acid component to form reaction products similar to those of a monosaccharide, a disaccharide, or a polysaccharide with a polyamino acid component
  • the carbohydrate reaction product is within the scope of term “carbohydrate component” as used herein.
  • any carbohydrate component should be sufficiently nonvolatile to maximize its ability to remain available for reaction with the polyamino acid component.
  • the carbohydrate component may be a monosaccharide in its aldose or ketose form, including a triose, a tetrose, a pentose, a hexose, or a heptose; or a polysaccharide; or combinations thereof.
  • a triose serves as the carbohydrate component, or is used in combination with other reducing sugars and/or a polysaccharide
  • an aldotriose sugar or a ketotriose sugar may be utilized, such as glyceraldehyde and dihydroxyacetone, respectively.
  • aldotetrose sugars such as erythrose and threose
  • ketotetrose sugars such as erythrulose
  • aldopentose sugars such as ribose, arabinose, xylose, and lyxose
  • ketopentose sugars such as ribulose, arabulose, xylulose, and lyxulose
  • aldohexose sugars such as glucose (i.e., dextrose), mannose, galactose, allose, altrose, talose, gulose, and idose may be utilized; and ketohexose sugars, such as fructose, psicose, sorbose and tagatose, may be utilized.
  • a heptose serves as the carbohydrate component, or is used in combination with other reducing sugars and/or a polysaccharide, a ketoheptose sugar such as sedoheptulose may be utilized.
  • a ketoheptose sugar such as sedoheptulose
  • Other stereoisomers of such carbohydrate components not known to occur naturally are also contemplated to be useful in preparing the binder compositions as described herein.
  • the carbohydrate component is high fructose corn syrup (HFCS).
  • the carbohydrate component may be a polysaccharide.
  • the carbohydrate component may be a polysaccharide with a low degree of polymerization, including, for example, molasses, starch, cellulose hydrolysates, or mixtures thereof.
  • the carbohydrate component is a starch hydrolysate, a maltodextrin, or a mixture thereof. While carbohydrates of higher degrees of polymerization may not be preferable, they may nonetheless be useful within the scope of the present invention when they are treated to achieve in situ depolymerization.
  • the carbohydrate component may be used in combination with a non-carbohydrate polyhydroxy reactant.
  • non-carbohydrate polyhydroxy reactants which can be used in combination with the carbohydrate component include, but are not limited to, trimethylolpropane, glycerol, triethanolamine, pentaerythritol, polyvinyl alcohol, partially hydrolyzed polyvinyl acetate, fully hydrolyzed polyvinyl acetate, and mixtures thereof.
  • a non-carbohydrate polyhydroxy reactant is sufficiently nonvolatile to maximize its ability to remain available for reaction with a polyamino acid and/or with a monomeric or polymeric cross-linker.
  • the hydrophobicity of the non-carbohydrate polyhydroxy reactant may be a factor in determining the physical properties of a binder prepared as described herein.
  • Other co-reacting compounds for example, carbonyl-containing compounds—aldehydes, ketones, carboxylic acids and anhydrides, and the like, may be used.
  • the at least one carbohydrate component is selected from the group consisting of ribose, arabinose, xylose, lyxose, glucose (i.e., dextrose), mannose, galactose, allose, altrose, talose, gulose, idose, fructose, psicose, sorbose, dihydroxyacetone, sucrose and tagatose, as well as mixtures thereof.
  • polyamino acid component is not particularly limited and includes any amino acid, either alone or in a mixture of amino acids (e.g., from hydrolyzed protein and/or amino acid-containing waste sludge), which contains at least two amino groups that are capable of reacting and/or react with the at least one carbohydrate component.
  • any such polyamino acid component may be optionally substituted, such as with hydroxy, halo, alkyl, cycloalkyl, heteroalkyl, cycloheteroalkyl, alkoxy, and the like.
  • the at least one polyamino acid component is lysine, which may be substituted or unsubstituted, as well as salts thereof.
  • lysine may be used as such (e.g., in the form of an aqueous solution), or lysine may be used in the form of an inorganic or organic salt, as long as these salts do not interfere with reaction between lysine and the carbohydrate component defined above.
  • inorganic salts include chloride, sulfate, phosphate, and nitrate salts.
  • organic salts include citrate, succinate, and tartrate salts.
  • the polyamino acid component in the pre-reacted binder composition may be a polyamino acid such as lysine, which may be described as ⁇ , ⁇ -diaminohexanoic acid or, more generally, as an ⁇ , ⁇ -diaminoalkyl carboxylic acid.
  • ⁇ , ⁇ -diaminoalkyl carboxylic acids which may be substituted or unsubstituted, including but not limited to ⁇ , ⁇ -diaminopropionic acid, ⁇ , ⁇ -diaminobutyric acid, ⁇ , ⁇ -diaminopentanoic acid (i.e., ornithine), and ⁇ , ⁇ -diaminoheptanoic acid (i.e., homolysine).
  • the polyamino acid component according to the present invention may be a polyamino acid such as ⁇ , ⁇ ′-diaminoisobutyric acid, which may be substituted or unsubstituted.
  • the polyamino acid component according to the present invention may be a polyamino acid such as ⁇ , ⁇ ′-diaminoisohexanoic acid, ⁇ , ⁇ ′-diaminosiooctanoic acid, and like polyamino acids, which may be substituted or unsubstituted.
  • the polyamino acid component according to the present invention may be a polyamino acid such as ⁇ , ⁇ -diaminopentanoic acid, ⁇ , ⁇ -diaminopentanoic acid, ⁇ , ⁇ -diaminopentanoic acid, ⁇ , ⁇ -diaminohexanoic acid, ⁇ , ⁇ -diaminohexanoic acid, ⁇ , ⁇ -diaminohexanoic acid, ⁇ , ⁇ -diaminohexanoic acid, ⁇ , ⁇ -diaminohexanoic acid, ⁇ , ⁇ -diaminohexanoic acid, ⁇ , ⁇ -diaminoheptanoic acid, and like polyamino acids, which may be substituted or unsubstituted.
  • a polyamino acid such as ⁇ , ⁇ -diaminopentanoic acid, ⁇ , ⁇ -diaminopentanoic acid,
  • a further embodiment of a pre-reacted binder composition exemplifies in situ generation of a polyamino acid as an alternative to its overt use in a binder composition.
  • Asparagine and glutamine which are monoamino acids each possessing an alpha amino group and a side-chain carboxamide group, are both expected to react with a carbohydrate component, as described herein.
  • reaction conditions may be adjusted to promote the Hoffmann degradation of primary amides, which reaction conditions include a basic pH, NaOH, and bromine.
  • Hoffmann degradation conditions are known to convert the side-chain carboxamide group of asparagine and glutamine into an amino group through an intermediate isocyanate (i.e., R—N ⁇ C ⁇ O) thereby resulting in ⁇ , ⁇ -diaminopropionic acid and ⁇ , ⁇ -diaminobutyric acid, respectively.
  • the resulting diaminopropionic acid ⁇ -amino group and diaminobutyric acid ⁇ -amino group would be expected to react with a carbohydrdate component, as described herein.
  • the aforementioned intermediate isocyanate would also be expected to react with dextrose in non-Maillard chemistry.
  • polyamino acid includes any amino acid having two or more amino groups, which are capable of reacting and/or react with the at least one carbohydrate component.
  • a polyamine may be used as a cross-linker to further cross-link the pre-reacted binder composition as defined above to yield a polymeric binder suitable for binding loosely-assembled matter, such as wood or mineral fibres.
  • polyamine includes polyamino acids as well as other organic compounds having two or more amino groups, which may independently be substituted.
  • a polyamine that is a polyamino acid may be used to prepare/cross-link a polymeric binder as described herein, and a polyamine (e.g., hexamethylenediamine) may be used in combination with a polyamino acid (e.g., lysine) to prepare/cross-link a polymeric binder as described herein.
  • a “primary polyamine” is an organic compound having two or more primary amino groups (—NH 2 ). Within the scope of the term primary polyamine are those compounds which can be modified in situ or isomerize to generate a compound having two or more primary amino groups (—NH 2 ).
  • a polyamine when used as a cross-linker, may be a primary polyamine.
  • the primary polyamine may be a molecule having the formula H 2 N-Q—NH 2 , wherein Q is an alkyl, cycloalkyl, heteroalkyl, or cycloheteroalkyl, each of which may be optionally substituted.
  • Q may be an alkyl group selected from a group consisting of C 2 -C 24 , an alkyl selected from a group consisting of C 2 -C 9 , and an alkyl selected from a group consisting of C 3 -C 7 .
  • Q is a C 6 alkyl.
  • Q may be a cyclohexyl, cyclopentyl or cyclobutyl, or a benzyl group.
  • alkyl includes a chain of carbon atoms, which may optionally be branched.
  • alkenyl and alkynyl independently include a chain of carbon atoms, which may optionally be branched, and include at least one double bond or triple bond, respectively. It is to be understood that alkynyl may also include one or more double bonds. It is to be further understood that alkyl is advantageously of limited length, including C 1 -C 24 , C 1 -C 12 , C 1 -C 8 , C 1 -C 6 , and C 1 -C 4 .
  • alkenyl and/or alkynyl may each be advantageously of limited length, including C 2 -C 24 , C 2 -C 12 , C 2 -C 8 , C 2 -C 6 , and C 2 -C 4 .
  • shorter alkyl, alkenyl, and/or alkynyl groups may add less hydrophilicity to the compound and accordingly will have different reactivity towards the carbohydrate component and solubility in a binder solution.
  • cycloalkyl includes a chain of carbon atoms, which may optionally be branched, where at least a portion of the chain is cyclic. Moreover, according to the present invention it is to be noted that the term “cycloalkylalkyl” is regarded as a subset of cycloalkyl, and that the term “cycloalkyl” also includes polycyclic structures. For example, such cycloalkyls include, but are not limited to, cyclopropyl, cyclopentyl, cyclohexyl, 2-methylcyclopropyl, cyclopentyleth-2-yl, adamantyl, and the like.
  • cycloalkenyl includes a chain of carbon atoms, which may optionally be branched, and includes at least one double bond, where at least a portion of the chain is cyclic. According to the present invention, said at least one double bond may be in the cyclic portion of cycloalkenyl and/or the non-cyclic portion of cycloalkenyl. Moreover, it is to be understood that cycloalkenylalkyl and cycloalkylalkenyl are each regarded as subsets of cycloalkenyl. Moreover, according to the present invention “cycloalkyl” may be polycyclic.
  • cycloalkenyls include, but are not limited to, cyclopentenyl, cyclohexylethen-2-yl, cycloheptenylpropenyl, and the like.
  • the chain forming cycloalkyl and/or cycloalkenyl is advantageously of limited length, including C 3 -C 24 , C 3 -C 12 , C 3 -C 8 , C 3 -C 6 , and C 5 -C 6 .
  • shorter alkyl and/or alkenyl chains forming cycloalkyl and/or cycloalkenyl, respectively may add less lipophilicity to the compound and accordingly will have different behavior.
  • heteroalkyl includes a chain of atoms that includes both carbon and at least one heteroatom, and is optionally branched. Examples of such heteroatoms include nitrogen, oxygen, and sulfur. In certain variations, said hetero-atoms also include phosphorus, and selenium. In one embodiment, a heteroalkyl is a polyether.
  • cycloheteroalkyl including heterocyclyl and heterocycle, includes a chain of atoms that includes both carbon and at least one heteroatom, such as heteroalkyl, and may optionally be branched, where at least a portion of the chain is cyclic.
  • cycloheteroalkyl examples include, but are not limited to, tetrahydrofuryl, pyrrolidinyl, tetrahydropyranyl, piperidinyl, morpholinyl, piperazinyl, homopiperazinyl, quinuclidinyl, and the like.
  • the term “optionally substituted” includes the replacement of hydrogen atoms with other functional groups on the radical that is optionally substituted.
  • Such other functional groups illustratively include, but are not limited to, amino, hydroxyl, halo, thiol, alkyl, haloalkyl, heteroalkyl, aryl, arylalkyl, arylheteroalkyl, nitro, sulfonic acids and derivatives thereof, carboxylic acids and derivatives thereof, and the like.
  • any of amino, hydroxyl, thiol, alkyl, haloalkyl, heteroalkyl, aryl, arylalkyl, arylheteroalkyl, and/or sulfonic acid is optionally substituted.
  • a primary polyamine used as a cross-linker to further cross-link the pre-reacted binder composition may be a diamine, triamine, tetraamine, or pentamine.
  • the polyamine is a triamine selected from a diethylenetriamine, 1-piperazineethaneamine, or bis(hexamethylene)triamine.
  • the polyamine is a tetramine, for example triethylenetetramine.
  • the polyamine is a pentamine, for example tetraethylenepentamine.
  • One aspect of the primary polyamine is that it may possess low steric hindrance.
  • 1,2-diaminoethane, 1,4-diaminobutane, 1,5-diaminopentane, 1,6-diaminohexane, 1,12-diaminododecane, 1,4-diaminocyclohexane, 1,4-diaminoben-zene diethylenetriamine, triethylenetetramine, tetraethylenepentamine, 1-piperazine-ethaneamine, 2-methyl-pentamethylenediamine, 1,3-pentanediamine, and bis(hexamethylene)triamine, as well as 1,8-diaminooctane have low steric hindrance and are within the scope of the present invention as are other polyamines (e.g.
  • polyethylene imines polyvinylamines, polyetheramines.
  • the polyamino acid lysine is combined with 1,6-diaminohexane (hexamethylenediamine, HMDA) and/or triethanolamine and/or glycerol to form a pre-reacted binder composition as defined above.
  • 1,6-diaminohexane hexamethylenediamine, HMDA
  • triethanolamine and/or glycerol triethanolamine and/or glycerol
  • the term “solvent” is not particularly restricted and includes any solvent which may be used to carry out a reaction between the carbohydrate component and the polyamino acid component.
  • the solvent may be water, an organic solvent or mixtures thereof.
  • organic solvents include alcohols, ethers, esters, ketones, aldehydes, alkanes and cycloalkanes.
  • the solvent consists of or consists essentially of water.
  • the above-defined pre-reacted binder composition has an average molecular weight in the range of 200 Daltons to 5000 Daltons.
  • the average molecular weight of the pre-reacted binder composition may range from 300 Daltons to 4500 Daltons, from 400 Daltons to 4000 Daltons, from 450 Daltons to 3500 Daltons, from 500 Daltons to 300 Daltons or from 600 Daltons to 1500 Daltons.
  • the average molecular weight of the pre-reacted binder composition is not limited to the aformentioned ranges and the upper and lower values thereof may be freely combined.
  • a further embodiment of the present invention relates to the above-defined pre-reacted binder composition, wherein the weight ratio between the carbohydrate component and the polyamino acid component is 0.5:1 to 30:1.
  • weight ratio between the carbohydrate component and the polyamino acid component is 0.5:1 to 30:1.
  • further inclusive molar ratios include ratios of 0.7:1 to 25:1, 1:1 to 22:1, 1.5:1 to 20:1, 2:1 to 15:1, 2.5:1 to 10:1 or 3:1 to 8:1.
  • the molar ratio of carbohydrate component to polyamino acid component is not limited to the aforementioned ranges and the above upper and lower borders may be freely combined.
  • a further embodiment of the present invention relates to the pre-reacted binder composition as defined above comprising at least 10% of the initial carbonyl groups provided by the carbohydrate component.
  • some of the initial carbonyl groups of the carbohydrate component have not reacted with the polyamino acid component and are still present therein.
  • Further examples of the number of unreacted carbonyl groups in the pre-reacted binder composition include at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 50%, at least 60% or at least 75% of the carbonyl groups present in the carbohydrate component before reaction with the polyamino acid component.
  • the initial carbonyl groups are present in the form of unreacted carbohydrate.
  • the expression “unreacted carbohydrate” component relates to any compound of the (i) at least one carbohydrate component which is still present in its initial form, i.e., which has not undergone any reaction.
  • the pre-reacted binder composition comprises, based on the total weight of the binder composition, up to 80 wt.-% of unreacted carbohydrate, e.g., up to 75 wt.-%, up to 70 wt.-%, up to 65 wt.-%, up to 60 wt.-%, up to 55 wt.-% or up to 50 wt.-%.
  • the pre-reacted binder composition of the present invention may be used as such, i.e., by applying it to loosely-assembled matter and curing it, for example through application of heat and/or radiation to arrive at a polymeric binder.
  • the pre-reacted binder composition may be used by subsequently adding a cross-linker, applying the mixture onto the loosely-assembled matter and curing the mixture, thus forming a highly cross-linked polymeric binder having similar or even improved properties over known carbohydrate-based binders.
  • the pre-reacted binder composition of the present application may advantageously be prepared, stored and/or shipped, and used later and/or at a different location by adding a cross-linker, to complete the final binder composition.
  • a further aspect of the present invention relates to a method of manufacturing the pre-reacted binder composition as defined above, comprising the steps:
  • the method of manufacturing the pre-reacted binder composition may be carried out under the same conditions (i.e., components and ratios) as defined above with respect to the pre-reacted binder composition.
  • the preparation of the pre-reacted binder composition is carried out in a solvent, such as water, to directly yield a binder solution usable for storage, shipping or as a basis for preparing the final binder composition.
  • a solvent such as water
  • the pre-reacted binder composition may be prepared in a concentrated aqueous solution of the carbohydrate component and polyamino acid component.
  • the thus obtained concentrated pre-reacted binder solution may then be used, for example, at a later time and/or a different place, e.g., by dilution and addition of a cross-linker, as an effective binder for consolidating loosely assembled matter.
  • the above steps (i) to (iv) are carried out while the carbohydrate component(s) and polyamino acid component(s) are not in contact with a collection of matter which is to be bound by a polymeric binder.
  • the temperature in step (iv) of the above method of manufacturing the pre-reacted binder composition of the present invention is not specifically restricted and includes temperatures in the range of 10° C. to 120° C., 15° C. to 110° C., 20° C. to 100° C. or 25° C. to 90° C.
  • the reaction temperature may range from 25° C. to 85° C., 30° C. to 80° C., 35° C. to 75° C. or 40° C. to 70° C.
  • Specific examples of the temperature range include 40° C. to 90° C., 45° C. to 85° C. and 50° C. to 75° C.
  • the temperature at which the pre-reacted binder composition is prepared is not limited to the above ranges, and the upper and lower values of the aforementioned ranges may be freely combined.
  • reaction step (iv) of the above method is carried out by reacting the carbohydrate component(s) and polyamino acid component(s) at a temperature of at most 120° C., e.g., of at most 115° C., at most 110° C., at most 105° C., at most 100° C., at most 95° C., at most 90° C., at most 85° C. or at most 80° C.
  • pre-reaction of a carbohydrate-polyamino acid binder system exemplified by glucose-lysine formulations highlighted an improvement in cure rate as a result of pre-reaction that apparently coincided with the production of carbon dioxide (CO 2 ).
  • the improvement in cure rate (i.e., increasing the rate of cure) of such a carbohydrate-polyamino acid-based pre-reacted binder composition may be the result of decarboxylation of the polyamino acid component to afford the corresponding polyamine (i.e., lysine to cadaverine in a glucose-lysine binder formulation) with a concomitant doubling of amino groups available for reaction with the carbohydrate component.
  • decarboxylation would be expected to diminish, if not prevent, protonation of an ⁇ -, ⁇ -, ⁇ -, ⁇ -, ⁇ -, ⁇ -, and/or ⁇ -amino group within a diaminoalkyl carboxylic acid (i.e., polyamino acid) that would otherwise be accomplished by an ⁇ -carboxyl group.
  • a diaminoalkyl carboxylic acid i.e., polyamino acid
  • reagents e.g., transition metal-containing compounds
  • capable of accelerating (i.e., catalyzing) and/or that accelerate decarboxylation of the polyamino acid component to afford the corresponding polyamine should further improve (i.e., increase) the cure rate of carbohydrate-polyamino acid-based pre-reacted binder compositions.
  • the duration of reacting the carbohydrate component(s) and polyamino acid component(s) in reaction step (iv) in the above method is not specifically restricted and includes durations of 5 minutes to 240 minutes, 5 minutes to 210 minutes, 5 minutes to 180 minutes, 5 minutes to 150 minutes, 5 minutes to 120 minutes, 5 minutes to 90 minutes, 5 minutes to 75 minutes 5 minutes to 60 minutes, 5 minutes to 40 minutes, 5 minutes to 30 minutes and 5 minutes to 25 minutes.
  • durations of up to one, two, three, four, five and six days, as well as durations of one, two or three weeks may also be reasonable within the scope of the present invention.
  • the duration for preparing the pre-reacted binder composition as defined above is not limited to the above examples and the upper and lower values of the aforementioned ranges may be freely combined herein.
  • reaction step (iv) is carried out by reacting the carbohydrate component(s) and polyamino acid components for a period of at most 96 hours, e.g. of at most 90 hours, at most 85 hours, at most 80 hours, at most 75 hours, at most 70 hours, at most 65 hours, at most 60 hours, at most 55 hours, at most 50 hours, at most 45 hours, at most 40 hours, at most 35 hours, at most 30 hours, at most 25 hours, at most 20 hours, at most 15 hours, at most 10 hours, at most 5 hours or at most 3 hours.
  • at most 96 hours e.g. of at most 90 hours, at most 85 hours, at most 80 hours, at most 75 hours, at most 70 hours, at most 65 hours, at most 60 hours, at most 55 hours, at most 50 hours, at most 45 hours, at most 40 hours, at most 35 hours, at most 30 hours, at most 25 hours, at most 20 hours, at most 15 hours, at most 10 hours, at most 5 hours or at most 3 hours.
  • Reaction step (iv) may be carried out by reacting the carbohydrate component(s) and polyamino acid component(s) for a period of at least 5 minutes, 10 minutes, 15 minutes, 20 minutes, 25 minutes, 30 minutes, 40 minutes, 60 minutes, 120 minutes or 180 minutes.
  • reaction step (iv) is carried out by reacting the carbohydrate component(s) and polyamino acid component(s) at a temperature range of 40° C. to 120° C. for a period of 5 minutes to 180 minutes.
  • reaction step (iv) is carried out by reacting the carbohydrate component(s) and polyamino acid component(s) at a temperature range of 20° C. to 30° C. for a period of 1 hour to 96 hours.
  • the duration and temperature for carrying out reaction step (iv) in the above method is not limited to the above examples and the upper and lower values of the aforementioned ranges may be freely combined herein.
  • the viscosity of the solution or dispersion during step (iv) of reacting the carbohydrate component(s) and the polyamino acid component(s) does not increase by more than 300 cP, when determined at 20° C. and a starting concentration of 70 wt.-% total carbohydrate and polyamino acid components present before step (iv).
  • the viscosity does not increase by more than 275 cP, more than 250 cP, more than 225 cP, more than 200 cP, more than 175 cP, more than 150 cP, more than 100 cP, more than 75 cP, or more than 50 cP.
  • the reaction step (iv) may be carried out at or substantially at atmospheric pressure, for example in an open reaction vessel.
  • the reaction step (iv) may be carried out in a closed reaction vessel; it may be carried out at a pressure above atmospheric pressure.
  • the present invention relates to a water-soluble pre-reacted binder composition obtainable by the method as defined above.
  • one embodiment of the present invention relates to the pre-reacted binder composition as defined above, wherein the binder-composition is obtainable by reacting in a solvent the at least one carbohydrate component with the at least one polyamino acid component at a temperature of at least 10° C. for a period of at least 5 minutes.
  • the present invention relates to a use of the water-soluble pre-reacted binder composition as defined above in the manufacture of a product comprising a collection of matter bound by a polymeric binder.
  • the term “collection of matter” is not particularly restricted and includes any collection of matter which comprises fibres selected from the group consisting of mineral fibres (including slag wool fibres, stone wool fibres, glass fibres), aramid fibres, ceramic fibres, metal fibres, carbon fibres, polyimide fibres, polyester fibres, rayon fibres, and cellulosic fibres.
  • a collection of matter include: particulates such as coal, sand; cellulosic fibres; wood shavings, sawdust, wood pulp, ground wood, wood chips, wood strands, wood layers; other natural fibres such as jute, flax, hemp, and straw; wood veneers; facings; wood facings, particles, woven or non-woven materials (e.g., comprising fibres, notably of the type(s) referred to above).
  • particulates such as coal, sand; cellulosic fibres; wood shavings, sawdust, wood pulp, ground wood, wood chips, wood strands, wood layers; other natural fibres such as jute, flax, hemp, and straw; wood veneers; facings; wood facings, particles, woven or non-woven materials (e.g., comprising fibres, notably of the type(s) referred to above).
  • a further aspect of the present invention relates to a method of manufacturing a collection of matter bound by a polymeric binder comprising the steps:
  • the step (iv) of applying energy to the collection of matter as defined in the above method is not particularly restricted and includes, for example, heating in an oven at a temperature of 100° C. to 350° C., depending on the type of matter, the amount of binder and other conditions.
  • step (ii) a cross-linker is added to the pre-reacted binder composition as defined above or the pre-reacted binder composition obtained by the method as defined above, or the solution or dispersion thereof.
  • the pre-reacted binder composition as defined above or the pre-reacted binder composition obtained by the method as defined above has been aged for at least 24 hours before the cross-linker is added in step (ii). Further examples include ageing periods of at least 48 hours, at least 72 hours, at least 96 hours, at least one week, two weeks or three weeks, or at least one month or two months.
  • the pre-reacted binder composition may change over time in its chemical composition by continuing the reaction between the carbohydrate component and the polyamino acid component.
  • the pre-reacted binder composition may change over time in its chemical composition by continuing the reaction between the carbohydrate component and the polyamino acid component.
  • Maillard-type reactions may continue between the carbohydrate component and the polyamino acid component towards the formation of melanoidins.
  • aging of the pre-reacted binder composition may lead to an accelerated final curing process of the binder and/or to improved bond strength.
  • the collection of matter prior to the step of applying the solution or dispersion obtained in step (ii) to the collection of matter, the collection of matter is substantially free of binder.
  • a further aspect of the present invention relates to a binder solution or dispersion comprising in a solvent the pre-reacted binder composition as defined above and a cross-linker.
  • the pre-reacted binder composition solution or dispersion, particularly in the state applied to the material to be bound, may comprise:
  • the present invention relates to a fibre- or particle-containing product comprising one or more types of fibres and/or particles and the pre-reacted binder composition as defined above in a cured state.
  • Binders in accordance with the present invention may be used as binders, e.g., in articles selected from the group consisting of: thermal insulation materials; mineral wool insulation (including glass wool insulation and stone wool insulation); wood boards; fibreboards; wood particle boards; chip boards; orientated strand board; medium density fibreboards; plywood; and high pressure laminates.
  • the quantity of binder in the finished product may be:
  • the quantity of binder for mineral wool insulation is typically measured by loss on ignition (LOI).
  • the products may have one or more of the following parting strengths:
  • the parting strength is expressed in grams/gram being the total breaking load of six test specimens divided by their total weight.
  • the test is carried out on mineral fibre mats as received for testing (Ordinary Parting Strength) and after an accelerated weathering test as explained below (Weathered Parting Strength).
  • a first set of six samples of the form and dimensions shown in FIG. 14 are cut from the mineral fibre mat to be tested.
  • the dimensions are:
  • the long axis of the samples should be parallel to the conveyor direction and the samples should be taken across the full width of the mineral mat. A second set of six samples is then taken in the same way.
  • the total weight of the first group of six samples W1 in grams is recorded.
  • the total weight of the second group of six samples W2 in grams is recorded; these samples are then placed in a preheated autoclave and conditioned on a wire mesh shelf away from the bottom of the chamber under wet steam at 35 kN/m 2 for one hour. They are then removed, dried in an oven at 100° C. for five minutes and tested immediately for parting strength.
  • each sample is mounted in turn on the jaws of a 5500 Instron tensile strength machine and the maximum breaking load in grams or Newtons is recorded. If the breaking load is measured in Newtons it is converted to grams by multiplying it by 101.9. Six results in grams are obtained for each set of samples: G1 G2 G3 G4 G5 and G6 for the first set of samples and G7 G8 G9 G10 G11 and G12 for the second set of samples.
  • product is wood board product, it may have one or more of the following characteristics:
  • the binder may include a silicon-containing coupling agent.
  • silicon-containing coupling agents are commercially available from the Dow-Corning Corporation, Evonik Industries, and Momentive Performance Materials.
  • the silicon-containing coupling agent includes compounds such as silylethers and alkylsilyl ethers, each of which may be optionally substituted, such as with halogen, alkoxy, amino, and the like.
  • the silicon-containing compound is an amino-substituted silane, such as, gamma-aminopropyltriethoxy silane (SILQUEST A-1101; Momentive Performance Materials, Corporate Headquarters: 22 Corporate Woods Boulevard, Albany, N.Y. 12211 USA).
  • the silicon-containing compound is an amino-substituted silane, for example, aminoethylaminopropyltrimethoxy silane (Dow Z-6020; Dow Chemical, Midland, Mich.; USA).
  • the silicon-containing compound is gamma-glycidoxypropyltrimethoxysilane (SILQUEST A-187; Momentive).
  • the silicon-containing compound is an aminofunctional oligomeric siloxane (HYDROSIL 2627, Evonik Industries, 379 Interpace Pkwy, Parsippany, N.J. 07054).
  • the silicon-containing coupling agents are typically present in the binder in the range from about 0.1 percent to about 1 percent by weight based upon the dissolved binder solids (i.e., about 0.05% to about 3% based upon the weight of the solids added to the aqueous solution).
  • These silicone containing compounds enhance the ability of the binder to adhere to the matter the binder is disposed on, such as glass fibres Enhancing the binder's ability to adhere to the matter improves, for example, its ability to produce or promote cohesion in non- or loosely-assembled substance(s).
  • a binder of the present invention may include one or more corrosion inhibitors. These corrosion inhibitors prevent or inhibit the eating or wearing away of a substance, such as, metal caused by chemical decomposition brought about by an acid.
  • a corrosion inhibitor is included in a binder of the present invention, the binder's corrosivity is decreased as compared to the corrosivity of the binder without the inhibitor present.
  • these corrosion inhibitors can be utilized to decrease the corrosivity of the mineral fibre-containing compositions described herein.
  • corrosion inhibitors include one or more of the following, a dedusting oil, or a monoammonium phosphate, sodium metasilicate pentahydrate, melamine, tin(II) oxalate, and/or methylhydrogen silicone fluid emulsion.
  • corrosion inhibitors are typically present in the binder in the range from about 0.5 percent to about 2 percent by weight based upon the dissolved binder solids.
  • a binder of the present invention may include de-dusting oils for mineral wool and waxes (as a water repellent) for wood board.
  • a fibre or particle-containing product as defined above is obtainable by the method of manufacturing a collection of matter as defined above.
  • the fibre or particle-containing product contains one or more fructosazines.
  • said one or more frutosazines are present in an amount of from 0.001 to 5 wt.-%, e.g.
  • Further examples include ranges of from 0.01 to 4.5 wt.-%, from 0.01 to 4 wt.-%, from 0.01 to 3.5 wt.-%, from 0.01 to 3 wt.-%, from 0.01 to 2.5 wt.-%, from 0.01 to 2 wt.-%, from 0.01 to 1.5 wt.-%, from 0.01 to 1 wt.-% or from 0.01 to 0.75 wt.-%.
  • the amount at which the one or more fructosazines are contained in the fibre or particle-containing product of the present invention is not limited to the above ranges, and the upper and lower values of said ranges may be freely combined.
  • FIG. 1 shows: Cure rates of Glucose/Lysine/Polyol formulations vs. Glucose/HMDA binder formulations at 110° C.
  • FIG. 2 shows: Cure rates of pre-reacted Glucose-Fructose/Lysine ⁇ triethanolamine binder formulations vs. Glucose/HMDA formulations at 120° C.
  • FIG. 3 shows: Cure rates of pre-reacted Glucose-Fructose/Lysine ⁇ triethanolamine binder formulations vs. Glucose/HMDA formulations at 140° C.
  • FIG. 4 shows: Bond strengths (dry strength and wet strength) of various Glucose-Fructose/Amino acid-based binders (determined via shell bone test).
  • FIG. 5 shows: Comparison of cure rates at 130° C. for pre-reacted 70/30 Glucose/Lysine binders: Change in cure rate as a function of pre-reaction (reflux) time.
  • FIG. 6 shows: Comparison of cure rates at 130° C. for pre-reacted 70/30 Glucose/Lysine binders: Effect of pre-reaction on bond strength (determined via glass veil test).
  • FIG. 7 shows: Confirmation of CO 2 evolution, determination of rate of CO 2 production, and measurement of viscosity increase during pre-reaction of 70/30 Glucose/Lysine binder.
  • FIG. 8 shows: Comparison of cure rates at 130° C. for pre-reacted 65/35 Xylose/Lysine binders as a function of time.
  • FIG. 9 shows: Comparison of cure rates at 160° C. for pre-reacted pure lysine-based binders versus pre-reacted impure (crude) lysine-based binders.
  • FIG. 10 shows: Comparison of cure rates for pre-reacted lysine-based binders containing 30% glycerol as a function of lysine concentration.
  • FIG. 11 shows: Comparison of cure rates for pre-reacted lysine-based binders containing 30% polyol as a glycerol alternative (several glycerol alternatives were screened that formed azeotropes)
  • FIG. 12 shows: Comparison of bond strength improvements for pre-reacted lysine-based binders containing glycerol alternatives: ethylene glycol (EG), polyethylene glycol (PEG-400), trimethylolpropane (TMP), tris(hydroxymethyl)aminomethane (Tris), and pentaerythritol (determined via glass veil test).
  • EG ethylene glycol
  • PEG-400 polyethylene glycol
  • TMP trimethylolpropane
  • Tris tris(hydroxymethyl)aminomethane
  • pentaerythritol determined via glass veil test.
  • FIG. 13 shows: Comparison of bond strength improvements for pre-reacted lysine-based binders containing glycerol alternatives: glycine (Gly), propane-1,2-diol (propan1-2OL), propane-1,3-diol (propan1-3OL), diethyleneglycol (DEG), and triethylene glycol (TEG) (determined via glass veil test).
  • Gly glycine
  • propane-1,2-diol propane-1,2-diol
  • propane-1,3-diol propane-1,3-diol
  • DEG diethyleneglycol
  • TOG triethylene glycol
  • FIG. 14 shows: Internal bond strength as a function of density for particle board prepared with pre-reacted 65/35 Xylose/Lysine binder formulation.
  • FIG. 15 shows: Internal bond strength as a function of density for particle board prepared with pre-reacted 32.5/32.5/35 Glucose/Fructose/Lysine binder formulation.
  • the pre-reacted binder composition of the present invention advantageously overcomes a variety of drawbacks known from common carbohydrate-based binders.
  • preferred embodiments of the pre-reacted binder composition may be stored or shipped for a prolonged time without recrystallization of the carbohydrate component or gelling which would render the binder composition unusable.
  • preferred embodiments of the pre-reacted binder composition of the present invention result in improved cure times, improved bond strength and reduced fading, e.g., of resulting fibre products.
  • fibre- or particle-containing products can be obtained which have a reduced content of unreacted carbohydrate components, so that they are more stable against microbial degradation.
  • the Maillard reaction takes place in three major steps:
  • the cross linking step of the Maillard reaction makes the binder less and less soluble, therefore absorbance decreases.
  • Fifty (50) ul samples of binders to be compared are spotted onto a strip of GFA filter paper and placed in an oven at a set temperature (generally, 140° C.) for 2 minutes and then removed; this heating process is repeated for 3 minutes, 4 minutes, 5 minutes and so on.
  • the spotted samples are then cut out and each sample is left to leach out into a 50-g beaker of water in an ultrasound bath for 15 minutes.
  • the 50 g of leached water is then analysed in a photometer by measuring absorbance at 470 nm (A 470 ), which is recorded as shown in FIG. 1 .
  • lysine is the most similar in structure to HMDA in that lysine is a diamine, i.e., a polyamino acid, with a chain length of 5 carbons separating the two amino groups, while HMDA is a polyamine having a chain length of 6 carbons separating the two amino groups.
  • the lysine molecule requires a high pH environment to achieve the same level of amine reactivity presumably due to protonation of the lysine ⁇ -amino group and/or ⁇ -amino group by the ⁇ -carboxyl group (thereby creating a Zwitterion).
  • a pH environment can be accomplished, for example, by adding HMDA as a cross-linker to a pre-reacted lysine/dextrose binder composition, as described above, in order to buffer the composition to a suitably high pH.
  • the presence of an ⁇ -carboxyl group in a polyamino acid component may be beneficial to (i.e., promote) and participate in esterification processes that occur downstream in the Maillard reaction.
  • esterification processes would also be expected to liberate the lysine ⁇ -amino group and/or ⁇ -amino group thereby enabling both amino groups to participate in Maillard chemistry with a concomitant increase in cure rate, wet bond strength and/or dry bond strength.
  • metal hydroxides such as sodium hydroxide, potassium hydroxide and calcium hydroxide were added to the binder formulation to increase pH. Although the resulting formulations browned much faster than the corresponding lower pH starting formulations, thereby indicating a faster initial Maillard reaction, upon curing in the oven at 140° C. no polymerisation took place.
  • TSA triethanolamine
  • lysine-containing binder formulations were prepared by making up to 70% solids and pre-reacting at 60° C. for 30 minutes; this was done to ensure the early stages of the Maillard reaction were carried out prior to curing. The formulations were then diluted to 35% binder solids, which formulations were then used for subsequent curing and bond strength testing. HMDA-containing formulations were made up to 35% solids at the start and pre-reacted for 30 minutes to prevent any gelling which typically occurs at 70% solids. No gelling was observed under any conditions using any lysine-containing binders.
  • Lysine binder was made up at a 70/30 (w/w) ratio of Glucose/Lysine at 70% starting solids in a 2 litre round bottom flask with attached water condenser and water trap and placed inside an isomantle set to 110° C. The mixture was heated under agitation and a starting sample was taken once binder components were fully dissolved and mixed at 60° C. Upon further heating at ⁇ 80° C. the binder exo-thermed to 105° C. and produced large quantities of gas, the experiment was continually heated and stayed at a steady 105° C. throughout. Samples were taken at 1, 2 and 3 hours into the pre-reaction which was continued under reflux conditions, the binder eventually became too viscous to continue the reaction after 200 minutes.
  • FIG. 5 demonstrates a change in cure rate over pre-reaction time.
  • FIG. 5 demonstrates a clear improvement in binder cure rate as the pre-reaction progresses (i.e., as a function of pre-reaction time, or in this instance, reflux time).
  • Lysine binder was made up at a 70/30 (w/w) ratio of Glucose/Lysine at 70% starting solids in a 2 litre round bottom flask with an attached water condenser and water trap filled with lime water and channelled into a gas flow meter; the round bottom flask was placed inside an isomantle set to 110° C. The mixture was heated under agitation and a starting sample was taken once binder components were fully dissolved and mixed at 60° C. Upon further heating at ⁇ 80° C. the binder exo-thermed to 105° C. and produced large quantities of gas; the experiment was continually heated and stayed at a steady 105° C. throughout. Samples were taken at regular intervals up to 210 minutes; the binder eventually became too viscous to continue the reaction after 220 minutes.
  • FIG. 7 shows that a large volume of gas was produced throughout the pre-reaction experiment; the water trap filled with limewater turned milky during throughput of gas thereby confirming CO 2 as the gas being produced. In total 4.6 litres of CO 2 were produced.
  • Binder formulations of 65/35 Xylose/Lysine were subjected to pre-reaction conditions, which included initial heating of the formulations at 70% solids to 80° C., at which point the formulations (mixtures) were observed to exotherm to ⁇ 105° C. as the majority of the carbon dioxide (CO 2 ) bubbled off. Analysis of such mixtures before heating and 5 minutes after the exotherm indicated that all of the xylose had reacted within the first 5 minutes. After 5 minutes, the loss of water/CO 2 afforded a formulation (mixture) at ⁇ 90% starting solids (based on weight) at which point the binder formulations were cooled to 40° C.
  • the cure curve in FIG. 8 indicates that the lysine standard, i.e., the 65/35 Xylose/Lysine binder formulation before pre-reaction, appears to cure faster than the pre-reacted formulations.
  • the lysine standard did not cure properly and is therefore unusable as a binder thereby pointing to an advantage imparted by the preparation and use of a pre-reacted binder composition as described herein.
  • Glucose/Lysine binder per se fails to provide good bond strength and cure rate
  • addition, i.e., inclusion, of one or more polyol compounds in such a binder formulation results in both greatly improved bond strength and cure rate (see FIG. 10 , FIG. 11 , FIG. 12 , and FIG. 13 ).
  • Lysine binder was made up at a 65/35 (w/w) ratio of Xylose/Lysine at 70% starting solids (as per excel sheet below) in a 2 litre open top beaker and placed on a hot plate set to 300° C.
  • the binder was heated continually for approximately 10 minutes whilst under agitation to reduce foaming of the emitted CO2 gas, contents were weighed until the binder reached 90% of its starting solids then was left to cool to room temperature before being sealed in a bottle and left in a water bath set to 40° C. for 24 hours.
  • Lysine binder was made up at a 32.5/32.5/35 (w/w) ratio of Glucose/Fructose/Lysine at 70% starting solids (as per excel sheet below) in a 2 litre open top beaker and placed on a hot plate set to 300° C.
  • the binder was heated continually for approximately 10 minutes whilst under agitation to reduce foaming of the emitted CO 2 gas, contents were weighed until the binder reached 90% of its starting solids then was left to cool to room temperature before being sealed in a bottle and left in a water bath set to 60° C. for 48 hours.
  • FIG. 14 shows the xylose/lysine binder to have an average IB of 0.23.
  • FIG. 15 shows the Glucose/Fructose/lysine binder to have an average IB of 0.29.
  • Binder baked out solids at Projected desired curing temperature Veil LOI 0.5% ⁇ 3% 1.0% ⁇ 6% 1.5% ⁇ 9% 2.0% ⁇ 12% 2.5% ⁇ 15%
  • the Mathis oven steel frame must be at 200° C. prior to the veil being placed into it; this is to prevent cooling of the oven.

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US20190119446A1 (en) 2019-04-25

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