WO2010132641A1

WO2010132641A1 - Bio-based aqueous binder for fiberglass insulation materials and non-woven mats

Info

Publication number: WO2010132641A1
Application number: PCT/US2010/034670
Authority: WO
Inventors: Liang Chen; William E. Downey; Jesus M. Hernandez-Torres
Original assignee: Owens Corning Intellectual Capital, Llc
Priority date: 2009-05-15
Filing date: 2010-05-13
Publication date: 2010-11-18
Also published as: US20110003522A1

Abstract

An aqueous binder composition is provided that includes a protein-containing biomass and a pH adjuster. Optionally, a crosslinking agent and/or a moisture resistant agent may be included in the binder composition. The protein-containing biomass is natural in origin and may be derived from plant or animal sources. The pH adjuster is used to adjust the pH of the binder to a desired pH and lower the viscosity of the protein-based biomass. In addition, the pH adjuster may act as a crosslinking agent. The crosslinking agent may be any compound suitable for crosslinking the protein-containing biomass and reacting with the moisture resistant agent, when the moisture resistant agent is present in the binder. In addition, the binder has a light color after it has been cured. The environmentally friendly, formaldehyde-free binder may be used in the formation of insulation materials and non-woven chopped strand mats.

Description

BtO-BASEP AQl EOUS BEXPKR FOR FIBERGLASS INSULATION MATERIALS AND NOX-WQVEΛ' MAFS

This application is, related to and claims domestic priority benefits ftom U. S. Provisional Patent Application Serial No. 6 ! ■" ! 78.745 entitled "Bio-based Aqueous Binder For Fiberglass Insulation Materials And Non-Woven Mats^"' filed May 15, 2009, and Utility Patent Application Serial No. 12/776.703 entitled "Bio-based Aqueous Binder For Fiberglass Insulation Materials And Non-Woven Mats" filed May 10, 2O U), the entire content of which is expressly incorporated herein by reference in its entirety.

TECHNICAL FIELD AKD INDUSTRIAL APPLiCABlUTV OF TIiE INVENTION

The present im emion relates yenerally to rotary fiber insulation and non-woven mats, and more particularly, to a binder fot use in manufacturing both fiberglass insulation and non-woven mats that is protein-based, free of formaldehyde, and environmentally friendly

BACKGROUND OF THE SN VENTION

Conventional fibers are useful in a variety of applications including reinforcements, textiles, and acoustical and thermal insulation materials. Although mineral fibers (for example, glass, fibers) are typically used m insulation products and non- en mats, depending on the particular application, organic fibers such as polypropylene, poh ester, and multi-component fibers may be used alone or m combination w ith mineral fibers ro forming the insulation product or nou- woven mat.

-Fibrous, insulation is typically manufactured by fibenzing a molten composition of polymer, glass, or other mineral and spinning fine fibers from a ftberi/irsg apparatus, such as a rotating spinner. To form an insulation product, fibers produced by the rotating spmner are drawn downwardly from the spinner towards a conveyor by a blower As the fibers move downward, a binder material is sprayed onto the fibers and the libers are collected into a high loft, continuous blanket on the conveyor. The binder material giv es the insulation product resiliency for recovery alter packaging and provides stiffness and handleabifity so Ui at the insulation product can be handled and applied as needed in the insulation

ities of buildings. The bindei composition also provides protection io the flbeis fiom mterfilameni abiasion and piomotes compatibility between the indiv idual fibeis

The blanket containing the bindci -coated fibers ^ then passed thiough a tiding Q\ en and tlie bmdei is cuied to ^et the blanket tυ a desired thickness Λtlei the binder has cured {he fiber

ma) be cut into lengths to foim indiv idual insulation piøducte, and the insulation pioducts ma> be packaged Ib i shipping to eustoniei locations One typical insulation product pioduced is an insuiauun bolt oi blanket, which is suitable for us»e as_* wall insulation in i evidential duellings or as insulation in the atUc <ind fioot insulation ca\ mes in buildmgs Λnothei common msubtion pioduct is an -blow n Oi loose- Bl! insulation wluch is suitable for use as sidew all and attic insulation m rewdennal and conuneicial buildings as well as m άα\ haid-to-teatb locations Loose-illl insulation is formed of small cubes that are cut from insulation blankets, compressed, and packaged in bagN.

Non-woven mats may be fanned b> conventional wet-iaid piocesses tot example wet chopped fibers- <«e dispeised m a vvatet ^hnty ihat contamii sin factanfe \ iscos>ih raodifieis detbaiuuig agents and ot othei chemical agents The slum contasmng the chopped fiheis is then agitated so that the fibers become dispersed throughout the i.luu v The slum containing the fibers is deposited onto a

ing scieeti w here a substantial portion of the \\ ater is ιemo\ ed to form a w eb A bmdei is then apphed and the resulting mat is dned to remove am temaming w ater and cure the binder l he fonϊied non-wo\ en mat is an assenibh of dispersed, individual glass filaments

V'aπous attempts have been made to iediice undesπabie fojmaldeln de emissions fϊorø fonnaldehvde-based iesins for e\amp!e v auous formaldehvde scavengets such as ammonia and urea have been, added to the fomiaϊdehv de-based I CMΏ m an attempt So reduce losmaldelude emission lroni the insulatton product Because of ib Uw cost, urea is added directK to Ui e uii cured resni s> stem to act at> a foimaldehv de &cav enget The addition of urea to the iesin s>stem pioduces urea-extended plienol-formaldehvdc resole iesins These iesole resins can be iuither treated ot apphed as> a coαUng oi binder and then cured I'nfoπunatch the us ea-ex tended

of this mstabihiv. the

mus»t be prepaied OR s.ue IR addition, the Kndet nn enton must be caret ulK raunuoied to

ptocessmg problems, caused bv undesπed crystalline preαpitaics ot dinict species ihal t^a^ form diirsns storage Ammonia is not a particuhulv desirable alternative to urea as a tαimaidebyde scavenger because anrmonsa generates an unpleasant oJoi and ma> cause tin oat and nose irritation to workets Furthet. the use of a fotmaSdehxde scavengei in general is iindcsuabie due So us potential adverse aiieUs to the ptoperties of the insulation ptoducL such as iowei recσveiy and iowci stiffness

Sn addiuon,

focused on the use of polyaeryhc acid with a poiyhydroxj cross lmking agent or caibohj drate-based ciiemisιr> that is linked to the Maii lard reaction Po!) acrylic acid mhciemly has problems doe to its auditv and associated eouosion uf machine parts ϊn addition, poiyam he acid bmdei s

high \ ΪSCONHV, high curing temperatures, and high associated curing costs b orther the Mαillaid-based piυducts hav e an undesirable daik htown colot aflei cunng Also, the use of large amounts of ammonia needed to make the hinder ptesents a safetx risk and possible emission pioblems

Λkeuiatn e poKmeπe binder systems to those descubed abtne lbs fibiuus glass products h'ά\ c also been proposed How e\ er, these altematπ e binder wsϊeras tema m piobleiuauc For εκaπφ!e. low moJecubt weight, lovs

bmdets w hich allow maximum s eitϊcal expansion of the insulation pack m the transfer /one generalK cure to foim a non-iigid pksUc matrix in the finished product, thereb> reducing the attainable vertical height recover} of the finished insulation product when imulted Com erselv, high viscositv bmdeis, xvhich geneial!> cute to foim a ugid matrix m the finished product, do not allow tine desired maximum Λeiticai expansion of the coated, uncuied pack in \ iew of the existing ptoblems with cmrent hinders there remains a need m the ait foi a bmdet system that does not coirode machine paits, does not emit fotmaldehvde, and which is en\ ironmentalty

SUMMARY OF TI iC 1N\ ENTlON

It is an obfeet of the piesent invention to piovidc a binder composition for use in the knmauon of fibei glass insulation and non-w o\ en chopped sti and inah that mci udes a protein based biomass dersv ed from natural sources and a pH adjusting agent in exemplary embodiments the piotem-based bioraass mm be derived fiαm soy, peanuts, siinfloweis, &ϊdne> beans, walnuts, eggs, blood, meat, and or fish Additionally , the piotein-contaπiing biomass max contain up to about *>5⁰<J prυtem The pϊl adjuster is utih/ed to adjust ihe pH of the binder composition to a desned acidic t/or example, about 1 to about 6), basic (foi example, about H to about 14). or neutral pH (for example, about 7j The piϊ adiustci ma> be selected from cituc acid, acetic acid, sulfuric acid, sodmm bisulfite, sodmm h> dioxide, potassium

dioxide, ammonium hydtoxide, and the like The binder composition may also include a crosshnking agent and or a moisntie

agent The imeiune bmdci composition cures at a tempeiatuie tiiat is lower than a cuπng temperature of a corn entional

theiebj ieducmg manufaetuung co^ts and gaseous emissions it is anolbej object of the ptesent indention to

ide a fibious msulauoπ product that includes a plurality of randomly oriented fibers and a hinder composition applied io at least a portion oi the iibeis and intet connecting the fibeis The bindei mchιd«s> a pioι«tn- based biortias.. dem ed from natural sources and a pH ad]iistiπg agent that is itsed to adjust the pTl of said binder composition to a pH Aom I to 14 The pf l of the bmdet composition, when m an acidic state, may range fiom about 1 to about «\ and when in a basic state, mav tange from about K to about 14 In exempian embodiments, the protein- contajmng biornass inaj contain up to about V5°ό piotem The piotem-based bsomass mav he demed from so> , peanuts, suniloxsets,

beans, walnuts, eggs, blood, meat arid Oi fish The bsndei composition mav also include a cto^shnking agent atid ot a moisture reststatn agent I he binder composition cures at a temperature that is low er than a curing temperature of a comentional foi maided de-based hinder, there b\ reducing niamtlactuϊing costs In addition, the binder corøposiuon has a light color upon curing, unlike com entional foimaldelij de binder compositions

U is vet anothei object of the piesenl tmcnlion to p

to\ ide a chopped strand mat formed of a piuialitv of randomly oriented glass fibers

a discrete length enmeshed in the iorm of a mat

ing a first maior surface and a second major surface and a bnuiet composition at least partially coating said first major smtace of said mai The hinder includes a protesn-based biomass deitved from natural sources and a pH adjusting agent The pioiem-based biomass is oatuiai HI origin and demed ft am lenewable iesoυrce^, such as from plants and animals In exemplar) embodiments, the protcm-hased biomass ma> be

cd flora so> . peanuh, suntlow ers. ksdnev beans walnuts, eggs blood, meat, and oi fish Λddmo«a!l> , the piotein-contamuig biomass may contain up so about ⁽⁾^% prøicm The bmdci composition may also include a eiosvhnksng agent and oi a moisiuie iesistanl agerit The bindei composition has a light eoiot after euung and roav be cured at a temperatme (hat is lowei than a curing tempeiatuie uf a cum entional foπnaldeh\ de-based bmdei

It is an adv antage of the piesenl invention thai the pioiem-based biomass is a protein-containing biomasN that is natural JΠ ougtn and

cd fiom tenevv able res?oιoees

H ι_. anoihet adv antage of the piesent inv ention that formaldehyde emission fiom insulation products can be i educed and vvorkes safctv can be rnipun ed at a low cost to ihc niautifaetuiet due to the Sow prsce of the pιotem-bas»ed compounds

Jt is, a further adv antage of the present jn%entton that the bindct can be cured at terøperakues

εr ιhan conventional bmd«i5>« thercbv reducing maiiti factoring costs and gaseous emissions

It is set anothei adv antage of the piesent

that the piotein-based biomass is of oatuial oπym and is tow in cost

U is also an adv antage of the present inv ention that insula! ton products and non- v* mats utilϊ/mg the nnentn-e buider compos.mon can be manufactured using cuuent nianiifacmnng lines theicln sav ing time and mone\

H is a ieatisie of the piesent im ention that ^

o> flour, a protem-ha^ed can be modified lυ ⁽oim an aqueous ΪMKUUC thai cati be appiiυd b> comenπonai bfπdei applicators, mcludmg spray apphcatoss

It is a Suidiei feature of the pieseiu imetuion that the binder can be acidic, aeutiai or basic

It is also a featuie of the presem iπ\en«on that the binder has a light coloi upon curing

It is another feature ol the present invention that the ιn\entπ c insulation ptoduets and en mats

no added foimaldeinde fhc foiegooig and other objects features and ads anfages of the inv ention \uli appear more full> hereinafter fiom a consideiation of the detailed dcscnption that follow s It is to be

puiposc^ and are not to be const! ued as detlninα the hmus of the invention BRIFt- DhSCRiP HOX OF I Hh DRAW LNGb fbe advantages of this imennon « ill be apparem upon consideration of the follow ing detailed disclosure of ihc inx erUion, εspecuilh when taken HI conjunction w ttn the accompanvim. drawings wherein

MG 1 is a schematic illustration of the fosmauøϊi of a faced insulation product with a posi-αsse application of uiea onto the insulation blanket pπor to the application of a facing la> er,

FIG 2 is a is an elex attøriaϊ \ icw of a rrsartυfactutmg line foi producing a fϊbeig Ia^s- insulation product that dues not contain a facing mateπai accoidmg to at least one excmplaπ embodiment of the present m\ entton,

FICJ 3 is a schematic itiυstiatiou ofa v- et-iasd ptoeessmg line foi foπnmg a chopped stiand mat utils/mg the

e binder composition according to at ieast one exc-mplarv embodiment ol the piesent in\ entton, and

FlCi 4 IS a tnapiueal illustration ol the Dy namic Nfechanital Analysis of a cuπiig test of a binder composition accoidmg to at least one

embodiment of the piesent invention

DETAILED DESCRIPTION AND PREFERRED CMBOPiMEXTS OP THE INVEXTiOX

Unless defined otherw ise, all technical and scientific terms used herein Im e the same meaning as couimonh uudet stood bj one of otdmarv skill m the ait to which the

methods and materials similar oi equivalent to those described hesein can be used m the practice or testing of the present sm cntson the preferred methods and mateuals are desciibed heiein Ml references cued herein, including published or corresponding I' S or foreign patent applications, issued L S or ibieigϊi patents, and am othei iefereπces, aie each incorporated b\ tefetence in tbeir entireties, including all data, tables. Figures, and text presented m the cited references

In the diawsiigit, the thickness of the hnes, layers, and regions may be exaggerated foi clautv It v.

as a ia>ej, legion, subsuate, oi panel LS referred to a» being "on" anotbct eieinent Jt can be directlv on the othci element oi intervening element*_* mav also be pteseni Also, when an element is seieued to as being "adiacent" to another element, the element ma\ be direct! v adjaceni to the other elenieo. ot itnen enniy elements may be piesem The teπut. "tup" ''bottom" "side", and the like are used herein fos the puspo&e of explanation onK Like numbers found throughout the llgioes denote like element* It is to be noted that the phrase ' bindei composition", "bmdet mixtute", and "binder^' n

ta\ be itsed interibangeablv herein

The present imentiυn ieiates to an aqueous binder composition that is piotein- based and em jronmentallv fnendK 1» addition, the bmdei ts fice of added forma Idchj de The bmdei includes a protein-con tamniu bioma»s and a pll adjubte? and optionally, a αosshnkmg agent and 01 a moisture resistant agent Additional!} , the bindei has a light color after it has been cuied The bindci iiκn be used m the formation of insulation niateuals and non-v. o\ en chopped stiand mats in

at least one pnuctn-contammy bionusi. that is natutal in origin and

ftom tenewabie tesources Tot instance, the piotem be dem ed from plaiit soυices such as so> (foi example, a soj flooi piotesn) peanuts, sunflowei*_*,

beans

or from othcj plants that hase a high ptotcm content -Vlteuiatn elv, the piotein may come from αmmal suuices siϋh as, but not hmned to eggs, blood, meat and fish in some exemplary embodiments the protein-coniaming bjouiass contains up to about ^5'O ptotein and in other exemplaiv embodiments, up to 50, 1*> or 90*. i protein The piotem-cnntaimng biorøass ma> he pjesem m the bmdei composition in an amount ltoni about 25° o to about vv°o b\ w eight of the binder composition or ftom about M⁾% to about 95° o bv weight

Λdditiotiallj the bindei composition contains a pH adjustei m an amount sufficient to adjust the pH to a desired level the pH mas be adjusted depending on the intended application or to facilitate the compatibility of the mgiedients of the si/e composition In exempbrv embodiments the pT J adjuster is utih/ed to adjust the pll of the bmdei composition to an acidic pH hvampJes of siutahic acidic pH adμisteit. include mono- or poh catbox\ hc acids such as, but not hmucd to citric acid, acetic acid, and sulfuric acid, anh> dπdes thereof, and inorganic salts that can be actd ptecutsos* The acid adjusts the pll, and in some instances acts as a

agent The pϊl of the binder composition, w hen in an acidic state, may range horn about ϊ to about 6, and in some exemplary embodiments, from about I to about ^ In at least one exemplar} embodiment, the pi 1 oi the bindei composition is about ! The pi 1 adjuster m aτi acidic binder composition ma\ be present in the bmdei composition m an amount ftom about 3 0"« to about 20% bj xs eight of the binder composition, 01 from abont 5 0% to about 1 ^ς% b\ % eight

Iu another embodiment of the m\ enuon the pif adiustei has a basic pi I and ts added to the proteni-hased biomass in an amount sufficient to produce a bmdei that has a desired basic pH

examples, cf suitable basic pH adjuster include sod turn bisulfite, sodium hydroxide potassium hsdiovsde aπd os amnion aim hv dioxide The pϊl of the binder composition, when in a basic state, niaj iange from about 8 to about 14, oi fiom about H to about 12 ϊn <u least one cxempUitv embodiment, the pil of the bmdei composition is about 10 The basic pH assists m opening the pioiein snuetuie and improves the adhesion of the protein The pH admstet in a hasic bϊndei composition ma\ be piesent m the binder composition m an amount ftom about I 0% to about 20% b\ weight of the hinder composition, oi from about 2 0% to about 10% bv weight hi a further embodiment of the invention, the hindet composition has <i ncatral pi! In an exemplars embodiment wheie the binder has a neutiai pH sodium bisulfite and os urea may be used to break the pioicm {polvmerj bonds present withm the protein-based bsomass and lowet the \ tscøsit} of the protein-based biomass Sodium bisulfite and oi urea also be added to an acidic bmcSei composition to break the protesn bonds, such as is show n below in Example 1 The pϊϊ adjustet in a neuttaS binder composition ma\ be present m the binder composition in an amount from about 0 1 to about 5 0% bv weight of the binder composition, or Aom about 0 5 to about i 0% b\ weight

In addition, the binder composition ma> contain a crossliniing agent 1 he crosslmkmg agent ma} be am compound suitable foi ciossimknig the piotem-cørit&mmg biosnass and ieacting with the moisture iesibtatu agent, w hen it is ptesent in the bmdet composition Kon-himting examples of suitable crαsslinking agenib include phenols (.foi example tannic acid), resorcmol, poϊvammes poK immcs,

ghitardwldchjde, nialose,

acid, esleis oi dicaiboxj hc acid,

acid and

he present in the bmdci composition m an amount up to about 2f⁾ 0^!i <> b\ weight of the bmdei composition ϊn everapϊaiy embodiments, the crosshnkin« agent ma) be present m the binder composition m an amount fiom about ^ 0 to about 20 0% b\ weight of the bindei tυmposition of nom about 7 0 to about 15 ⁽>°o b\ w emht ϊ lie binder composition røa\ also contain a moisture resistant agent, such as a latex, a silicon emulsion, a h\ diophobic pulsmer emulsion (hi example pohetSn iene emulsion or polvesTci emulsion), and mixtures tbeteof In at least one exeπnplat) embodiment, the latex sWem is an aqueous latex emulsion The latex emulsion includes latex particles thai are tj picalh produced b> emulsion pøtjmen/ation hi addition to the latex

raa\ mclude w atef A siabih/ei such as auvnmma, and a surfactant ϊhe moisture resistant agent nuv be present in the binder composition m an amount fioni about O to about SO⁰Ii In weight of the boidei composition, 01 from about s n°« to about 20% b> w eight

I here tire numetous πpcs of ϊatex that ma\ be used in the latex emalsion Nf on- SirøUmg examples of suitable latexes include natuiaS aud sviuhetic rubbei testns. and mixtures theieoC including thernioseftabϊe atbbeis thermoplastic πibbeis and elastomeis mcludjng tor example nttπle ruhbcts ( tor example actv lofutjile-bittadiene), polx isoptenc lubbers, poHehloiOprene lubbers, polv butadiene jubbejs butyl lubbers, etiniene- prop>lene~diene monomer rubbes s (FPDMi

lene-FPDM ciastomcts etrvv lene- piop> lene tubbets, stvrene-buudiene copo!vmeιs»

copolvmets, sι> i ene- rubbers, shrene-isopreoe-sureπe lubbers,

!ene-

jubbets, sivrene-eUivlene-prop> ien«-stMene mbbeis. pols isobutv ieue iubbeis eth\ Iene Λ UI> 1 acetate rubbeis, silicone rubbers- including for example, polvsjloxanes, niethacn'late rubbers, pol\ act> Sale rubbei s including, foi example, copolymers of isooct\l acr> late and acr> IΪC aαd poh esters, polvefhei esteis p

oly\ S chloπde

in> hdene chloπde, po!> \ my! ethers, poh urethanes and blends, acrvSates such as methj 1 aα\ Sates aud ! aeivlates, and combioatjons thet«of

I he btndcr mav optional \y contain conventional additn e^ such as bin not limited to ds es pigments, oils filleis, colorants LA btabih/ers thetma! stabth/ets, anti-toaming agents antι-oκidains, emulsifϊers, and mixiuies thereof Othei additn es may be added to the binder composition for the irnprcn erncnl of process and product performance Such additne* include coupling agents (fos example silane aminosikne and the like), dust sitppiessϊon agents, lubricants, wetting agents, surfactarøs antisuiiϊc agents and ot x\ater tepelleut agents

bc ptesent m the binder coτπpoi»iifoπ from ttαce amounts (such as about 0 ! " <>

weight the bindei composition) up to about 10 0% In w eight o⁽ the bmdei composition In some exeroptat} embodiments the addnnes ase psesenϊ m an amount fiom about O 1 % to about 5 0% b> weight of the binder composition

The bmdei further includes watei to dfasohe or dispeisc the actn e solids fot application onto the reinforcement fιbet&> Watei mav be added m an amount sufficient to dilute the aqueous binder composition to a % iscosϊtΛ that is suitable for Us application to llie reinfori-emciU flheij. and to aehiex c a d^sπed solids content on {he Hbeis In paiiiculai. the binder composition ma\ contain watei in an amount from about ⁷H 0 to about 98 if, a by weight of the total binder composition

The bmdei composition ma> be made b> dispersing the protem-based lnomasb m w afer to foim a piotein stock The proieirt stock maj then be mixed with the pH adjustei (foi example, acid or ba.se t and the crosslinking agent to tbim the bsudet The bmdei composition ma} be fiitihei diluted

watei to obtain a desired amount of solids If necessary., the pH of the mixture ma\ be adjusted to the desired pif

e! hi the bioadest aspect of the invention the binder compositiun is foimed of a protein-based biomass {foi example soj flour ptotein) and a pH adjuster (for cxampie an acid such as citπc acid or a base such as sodium hvdtoxtde) The iange of conipotients used m the im entn e bmdei composition according to other embodiments of the im enuon is set forth jn Table 1

TABLE I

Λqueoub bmdei coiuposiUons accoidirig to ftuthei

eiftbodmients of the piesem uneauon aie set fuilh m Table 2

IABLE 2

In one exemplary embodiment the bincJei composition is υvd to fosm an insulation pioduci Hbrons insulation pioducts ΆΪ C generalh formed of malted inorganic fibers bonded together bj a ciued theimoset pol> met ic maiei ml Examples of suitable inorganic fibeis include glass fibcts wool glass fibers -mά eetamie fibeib Optionally otiiei ieinfoiung fibeis such as natural fibers and ot

fibers such as pohestet, pαh ethy lene polvcSSnlcne tetephthalate,

!cnε, poHamidc aramid, <ind oi polvaiamjd fibeis ina> be piεsent m the insuiaiion ptoduct m addition k> die ala^^ fibeis The teiro ~ natural fibej" as used m conjunction w tth the piesent un ention sefeis to plant Obeis extracted from any pait of a plant uu ludtrig but no* hrancd to she stem, seeds, leax es looiv oi phloem Examples of natωal fibeis suitable for use as the ieinfoicing fibci mates sal include basalt cotton, jute, bamboo, lamie, bagasse hemp con linen, keuaf sisal

henequen and combinations theieof Insulation pioducts nu> be fυmied entneh of one t> pe of fiber, oi tliej ma\ be formed of a combination of iλpes of fibeis For example the insulation ptoduct niav be foi mcd of combinations of \ <ΪI IOUS types- of glass hbeib ot vauous combϊoaiions of different snot game hbeis and oi nauiral libers depending on the desiied application foi the msulatsoo The embodiments described keiein ate with tefeience to insulation products totmed entnel> of glass fibers

The mamifactute of glass iϊbei insulation ma> he earned out in a continuous piocess bv fibeu/my molten glass umnediateh totnung a fibious glass batt on a

tng con\ e\or, and curing the hinder on the fibrous glass insulation bat! io form an insulation blanket as depicted in MO 1 Glass mav be melted in a tank (not shown) and supplied to a fibei foiming

such as a fibeπ/mg spinnei 15 I he spmneis 15 are rotated at high speeds Ceutiifugal foice causes the molten glass- to pass through holes in the circiunfetential sidewalb of the fιbeπ/mg spmαeis 15 to foira g.ϊαs»s Hbeis Glass fibers 30 of iandotn lengths mav be attenuated from the fihen/mg spinners I ^ and blown geneialiy

I ^ b> bloncιs 20 positioned \\ itliin a foimmg chamber 25 it ΪS to be appi eciated that the glass fibeis 30 mav be the same tvpe of glass oi thes mav be formed of different types of glass It is also wnhm the pumew ofthe piesem m\ anion that at least one of the fibers M⁾ foimed from the fibeπ/ing spinners i *> is a dual glass fiber wheie each uidrudual fibei is formed of two different glass compositions

The blow efs 20 mm the lϊbeis M) downw atd to tbim a fibrous bait 40 The glass fibers 30 mav kπ c a diameter from about 2 to about 9 mtcroπs, or from about * io about f> microns The small diameter of the glass fibers 30 helps to gne the final insulation product a soft feel and flexibiLu>

The glass fibcis while »i transu m the forming chambei 25 and whilu still hot fiom the draw j«g αpeiation, aie sprayed wnh the πnentne aqueous binder composition b> an annular spray πng ^ *» so as to result m a distribution of the binder composition throughout the foimed insulation pack 40 of fibious glass W atei mav also he applied to the glass ftbeis 30 in the formmg chamber 25, such as

spiaymg. pπor to the application of the {ormaldeh\ de-based bindei composition to at least paiualK cool the glass tlhcis 30 The biiider ma> be pi esent in an amount ftoro less than OΪ equal to 4 0% by w eight of the total product The low amount of binder contributes to the flexibility of the final insulation pioduct

I he glass fibers 30

ing the xmcured resinous bmdei adhered theieto ma> be gatlieied and foinied into an uncured insulation pack 40 on an endless fomung

es ot the lbmnng chamber 25 with the aid of a vacuum (not shown) drawn through the fibrous pack 40 from below the forming com eyot 45 1 he residual heat from the glass libers 3⁽J and the flow of an thiough the ftbrous pack 40 duπng the formmg operation aie geneιal!> sufficient to xolatili/e a majorit} of the walei from the bindei before the glass Ilbeis 30 es.it the foiimng chambei 25, theietn leav ing the remaining components of the binder on the fibers M) as a uscous or semi-Λ ΪSCOIΪS high-sol tds liquid

The coated fibrous pack 40 which is m a compressed state due to the flow of air through the pack 40 »i Ui e foimmg chamber 2^, is then transfeired out of the foinung eliambct 25 undei

rolici 50 to a tiansfci /one 55 %hcie the pack 4(J

expands due to the lesihencv of the glass fibeis The expanded insolation pack 40 IN then heated, such as b> com eying the pack 40 through a curing ov en 60 W JUM C healed atr ts blow n iliiυugh the insulation pack 40 to εwpoiate aiiv iemainnig watef in the birtdei. cure the binder, and πgidh bond the fibers togethet Heated an is foiced though α fan 75 through the knsei os en. COΠΛ esof 70, ihc insulation pack 40 the upper

en convex oi 6\ and out

M of the curing o\en 60 through an exhaust appasatus M) The cored bradcr impaus strength and resiliency to the insulation blanket W it is to be appreciated that the

mg and cuung of the binder may be earned out in either one ot two different steps The two stage ( tw o-step t piocuss is commoπh known as R-staging

Also, m the cυi mg o\en 60, the insulation pack 40 ma> he compressed by upper and kme? foi aminims oven com C\ QΓS 65, ⁷O to form a fsbious insulation blanket IU It is to be appreciated that the insulation blanket 10 has an upper surface and a ϊowei surface Tn paiUcular the msuSauon blanket H) has two majoi surfaces, tx picalh a top and bottom surface and two minoi or side sui faces v. ith fiber blanket St.) ouented so that the maior surfaces have a substantially hon/ontai orientation The upper and low er o\ en com e} ors 65, ⁷O ma> be used to compress Use uisuiauon pack 40 to gn e ihe msislatton blanket U> a piedeteπiuned thickness U is to be appreciated £hat although HG 1 depicts the coiB Csofs 65, 7(J a» being in a substantially parallel oiientatitm, the% mav ahemam elv be positioned at an angle

to each oihei (not illustiated)

I he cunrtg oven 60 m_ry be operated at a temperature from about HK) ^"( to about 325 °(\ oi from about 250 ^' C to about 300 °C The insulation paci 40 ouv remain withm the ox en foi a penod of time sufficient fo crosslink (cine) the binder and form the insulation blanket 10 The imenm e binder composition cures at a ternpeuiute that is Sower than the curing temperature of com enπoml formaldehyde binders This low er cm ing temperature requires less energv to heat the insolation pack, and non-woven chopped strand mat described in detail be km . which results m iowei røanufacαiπng costs

A f acing material ⁽>3 is then placed on the insulation blanket IO to foim a facing Saver 95 \on-l muting examples of suitable facing materials W include Kraft paper, a foil-scϋm-Kraft paper laminate recycled paper, and calendared paper The facing maieual 93 nia\ be adlieted to the surface of the insulation blanket 10 b> a bonding agent (not show n) to form a faced msuiauon pioduet 97 Suitable bonding agents include adhesrxes. poHmeπe lesins, asphalt and bituminous mateπais that can be canted or otherwise applied to the facing materia 1 91 The faced fibrous trisulmton 97 nun subscquenfH be tolled foi storage and'υi shipment oτ cut into ptedeteππmed lengths

a cutting dev ice uioi illusUated) Such feced insulation products ma> be used, for example, as panels in basement finishing s\stenis as Juetwrap, duetboard, as faced residential insulation, and as pipe insulation. It is to be appreciated that, in some exemplary embodiments, the insulation blanket 10 that emerges from the oven 60 is roiled onto a take-up roll or cut into sections having a desired length and is not faced with a facing material 94,

A significant portion of the insulation placed in the insulation cavities of buildings is i« the form of . insulation blankets rolled from insulation products such as is described above. Faced insulation products are installed with the facing placed flat on the edge of the insulation cavity, typically on the interior side of the insulation cavity. Insulation products where the facing is a vapor retarder are commonly used to insulate wall, floor, or ceiling cavities that separate a warm interior space from a cold exterior space. The vapor retarder is placed on one side of the insulation product to retard or prohibit the movement of water vapor through the insulation product

The presence of water, dust, and/or other microbial nutrients in the insolation product 10 may support the growth and proliferation of microbial organisms. Bacterial and/or mold growth in the insulation product may cause odor, discoloration, and deterioration of the insulation product 10, such as, for example, deterioration of the vapor barrier properties of the Kraft paper facing. To inhibit the growth of unwanted microorganisms such as bacteria, fungi, and/or mold in the insulation product 10, the insulation pack 40 may be treated with one or more aeti-roicrobkl agents, fungicides, and/or hiocides. The anti-mierobial agents, fungicides, and/or biocides may be added during manufacture or in a post manufacture process of the insulation product 10.

In a second embodiment of the present invention, the binder composition may be used to form a non-woven chopped strand mat. In particular, binder is added during the formation of the chopped strand mat in a wet-laid mat processing line. One exemplary process of separately adding the coupling agent to the chopped strand mat is depicted in FlG. 3. It is to be appreciated that reference is made herein to glass fibers, although the chopped strand mat could be formed of or include, non-glass fibers. Chopped glass fibers 1 10 may be provided to a conveying apparatus such as a conveyor 1 12 by a storage container i i 4 for conveyance to a mixing tank 1 16 that contains various surfactants, viscosity modifiers, defoaniing agents, and/or other chemical agents with, agitation to disperse the fibers and form a chopped glass fiber slurry (not shown). The glass fiber slurry may be transferred to a head box 118 where the slurry is deposited onto a conveying appaiams such as a mov ing sαeen or foiammous conveyor ! 20 and a substantial poiuon of (lie v atei from the slum is remoΛed tu form a w eb ⁽mm⁾ 122 of enmeshed fibers The w ater may be terncned ftom the

122 bj a conventional vacuum oi au suction

(not shown i

The invent

a suitable binder applicator, such as the spιa\ appheatoi 126 or a ciutain coalei (not illustrated) Once the binder 124 has been applied to the mai 122. the binder coated mat 128 is passed through at least one div ing m en UO to

any remaining water and cure the binder composition 124 The formed

chopped sπ and mat 132 that emerges twin the

UO is an assembly ofrandomly oriented, dispersed, mdnidua! glass fibers The chopped strand mat 132 ma> be rolled onto a take-up toll 134 foτ stoiage for later use as dlustiaied

There are numerous

e binder formulation For example, unlike conv entional urca-lormaldchvdε bmdcrs. the bmdci fouiuihmoπ has a hght color aftei cuung Io addition, the piotem-based biomass ss a piotein-cuntammg biomass thai is natural m ongm and deriv ed ftom tenewable resources Also, the binder composition can be cured at lempeialuies lower than conv entional formaldehvde-based hinders,

B\ lowering or ehnuuaung formaldehyde emission, the ov eraii \ oktile otgantc conipouαdi ( VOCs t emitted in the workplace are reduced, and the workplace becomes a safer env ironment Additionally , because protem-baved biomass compounds are relatn eh mcxpensπ e. the insulation pioduct or chopped fiber mat can be manufactured at a iowei cost generally described this indention, a ftulhei understanding can be obtained b\ jefeience to ceiiain specific examples ilhistiated below which ate ptos ided lot purposes of iilustiation only and are not intended to be all mchisne or limning unless otheivuse specified

EXAMPLES

Cxample 1

A 20"_'O ^{ock dispei sioii of soy fiooi ptotein in w ater was prepaied vv ith the addition of a small amount of sodium bisulfite to aid m ihe dispersion A portion of the pjotem stock dispei sum w as mixed

citiic acid and tanmc acid and fuithei diluted WJSh water io achiev e a 22⁰O solids bmdei mixtuie containing 7I⁰O piotem, 23⁽'i> citric acid, and 6% tannic acid The bmdci coniposiiion w as subjected to a cuttnu test performed

Dynamic Mechanical Analysis (DMA), As illustrated in. FiG. 4. {he modulus eun. e demonstrated curing similar to that of standard phenol-formaldehyde binder. Fiberglass handsheets were prepared utilizing the binder composition. Good tensile strength and integrity was observed in the handsheets contaimng the inventh e binder, as can be seen in Table 3.

TABLE 3

Example 2:

IM

6⁽Hi g of deionked water, 7⁽>.6 g of 20% soy flour ( Pro ha ^f ^ 200 ^CX⁾. commercially available from Cargill), 23.5 g of citric acid solid, and 0.3 g of 2% amino silanc (,A-1 100, commercially available from General F.lecuic) were mixed in a 2000 mL beaker. Additional deionized water was added to the beaker to prepare a total of 800 g of hinder mixture A fiber glass hand sheet was prepared following, standard lab procedure The hand sheet was then coated with the binder and cured in a convection o\ en for 3 minutes at 450 "F. A statistically significant sample si/e was determined and the samples were measured using an Insiron* machine. The av erage tensile strength was recorded.

Additional binders were prepared in a manner similar to that described above with respect to Example 2. The ratio of components was adjusted to achieve desired LOIs. As used in conjunction with this application, LOl ma> be defined as the reduction in weight experienced by the fibeis after heating them to a temperature sufficient Jo burn or pyroly/e the organic si/e from the fibers, LOI may be defined as the percentage of organic solid matter deposited on the reinforcement fiber surfaces, The tensile strengths of handsheets formed and coated with the binders were measured and recorded. The measured tensile strengths were compared using a "normalized tensile" (that is, tensile strength κ!ed by LOT). These normalized tensile strengths for the handsheets containing the mvenih e binder are set forth in Table 4. Control samples are set forth in Table 5. TABLE 4

It can be seen from Tables 4 and 5 that the addition of a latex to the binder composition significantly improves the tensile strengths of the handsheets in both ambient and steamed conditions.

The invention of tins application has been described above both genetically and with regard to specific embodiments. Although the invention has been set forth in what is believed to be the preferred embodiments, a wide variety of alternatives known to those of skill in the art can be selected within the generic disclosure. The invention is not otherwise limited, except for the recitation of the claims set forth below.

Claims

1. An aqueous binder composition foi ose in the formation of fiberglass insulation and non-woven mats comprising: al least one protein-based biomass derived from natural sources; and ai least one pH adjusting agent.

2. The aqueous binder composition of claim i . wherein: said protein-based biomass is derived from at least one member selected from soy, peanuts, sunflowers, kidney beans, walnuts, eggs, blood, meat and fish; and said pH adjuster is selected from citπc acid, acetic acid, sulfuric acid, sodium bisulfite, sodium hy droxide, potassium hydroxide, ammonium hydroxide and combinations thereof.

3. The aqueous binder composition of claim 2. wherein said pH adjusting agent adjusts the pM of the binder composition to a range from 1 io 6.

4. The aqueous binder composition of claim 2, wherein said pH adjusting agent adjusts the pl-1 of the binder composition to a range from 8 to 14.

5. The aqueous binder composition of claim 1 , wherein said protein-costaiaiag biomass contains up to V5% protein.

⁽>. The aqueous binder composition of claim 1 , further comprising at least one member selected from a crossl inking agent and a moisture resistant agent.

7. The aqueous binder composition of claim 6, wherein said erosstmking agent is selected from phenols, tesorcinol, polyamines, poiyiniines. glyoxaL glutardϊaidehyde. malose, dicarbαxylic acid, esters of dicarbαxylie acid, poly carhoxy lie acid and combinations thereof, and wherein said moisture resistant agent is selected from latex, a silicon emulsion, a hydrophobic polymer emulsion and mixtures thereof.

I S 8 fbe aqueous binder composition of claim 1. w herein said bindei cuies at a sempetatuic {hat ss lower than a cuung temperature of a corπcntiυrωl foπiiaϊdebΛ de-based

⁽⁾ Λ iibious insulation puxiuct comprising a plurality of randomh oπented fibers, and a bmdct composition apphed io at least a poitson of said fibcts and interconnecting said fibeis, said bmdei composition including at least one protein-based biomass dern ed from πattnaϊ sources, and at least one pH adjustuig agent said pH adjusting agent adiustmg lite pH of said bmdei composition to a pH from i to U

Ut ϊhe fibious msulatioα product of claim ^l> t herein said pjoteui-contajaing luomass con tarns up Lo 9S% pjtoteui

) \ I he fibi ous insulation product of claim O w herein said pioiein-based biomass JS deined from at least one membet selected from sov peantns suαflow ers, kidney beans, walnuts, eggs, blood meat and fish; and said pH adjuster is selected ftom αtπc acid, acetic acid, sulfuric actd, sodium bisulfite, sodium Sn dt oxide, potassium

ammonium inJruxide and combinations theieof

12 ϊhe fibrous insulation product of claim 9 fimhct compnsnig at least one member selected from a crosslink ma aacnt and a moistute iesistant agent

i 3 The fibrous insulation pioduct of claim 12. w herein said etosshnkmg agent LS selected from pliunols lehoicinol, poK amines, pυS\miines, gKoxal, glutaidialdelnde malose, dicarboxj hc acid, esters of dicarbox> lic acid,

acsd and eombmauons iheieol^', and wheiein sasd

resistant agent is selecieU from latex, a silicon emulsion, a hvdtophobic polvmci emulsion and mixtutcs thereof 14 fbe fibrous insulation pioduct of claim 9, wheiem

binder cures at a rcnφctatuic {hat JS lower ihan a cuung temperature of a comentϊoπaϊ Ibtnwldehv de-ba&ed

15 Λ non~vx m en chopped sir and roat comprising a of randomh ouemed glass fibeis

ing a discrete length enmeshed in the iorm of a mat

me a first majot surface and a second raajoi outface, and a bindet compositsun at least paUialK coatsng ^aid fit it raasw suϊ face of said m<u, said Hinder compoMUon including at least one protem-based

desn ecl honi natoia! ^>jouic«s>, and at least one pH adjusting agent

16 ϊ HK non-w o% en chopped stiand mat of claim 1 ^ f unites compi ismg ai leasi one mernbei selected fiom a crosiahrtkiπg agent and a moisture resisLint agent

) ⁷ I he iiøn-w o\ en chopped stt and mat of elai m 16 w herein said binder cm es at a terøperakue that is lowet than a cuπuy iempeiatuie of a convetuional formaldehvde-based bmdei

IK ϊhe non-woΛβn chopped sttand mai of claim i ~i wherein said bindei compθ->ιtion has a Sight color aftei cuπng

19 ϊhe non-\\o\ en chopped sUand mat of claim 16 w herein said pιotein-cont<iming biomasa contains up to ¹^¹O protein

20. The non-woven chopped strand mat of claim I ^KK wherein: said protein-based bioraass is derived from a member selected from soy, peanuts, sunflowers, kidney beans, walnuts, eggs, blood, meat and fish; said pH adjuster is selected from citric acid, acetic acid, sulfuric acid, sodium bisulfite, sodium hydroxide, potassium hydroxide, ammonium hydroxide, and combinations thereof, said crosslinkiog agent is selected from phenols, resorcinoL polyamines. polyimincs, glyoxal. gfutardialdehyde, malosc. dicarboxylic acid, esters of dϊcarboxyiic acid, polycarboλylic acid and combinations thereof; and said moisture resistant agent is selected from latex, a silicon emulsion, a hydrophobic polymer emulsion and mixtures thereof.