Curable biopolymer nanoparticle latex binder for mineral, natural organic, or synthetic fiber products and non-woven mats

Abstract

A curable aqueous binder composition includes a dispersion of biopolymer particles, optionally with and an inter-particle crosslinking agent, for use in the formation of composite materials such as mineral, natural organic, or synthetic fiber products, including mineral fiber insulation, non-woven mats, fiberglass insulation and related glass fiber products, and wood based products, and construction materials. In an application of the curable aqueous composition to making fiberglass insulation, the composition may be blended with a second resin which may be a non-formaldehyde resin. In an application of the composition to making fiberglass roofing shingles, the biopolymer particles may be mixed into a formaldehyde based resin during or after the polymerization of the resin.

1 . A curable composition, the composition comprising:
 a latex including particles comprising crosslinked biopolymer molecules; and   a crosslinking agent in solution with the latex.   
     
     
         2 . The curable composition of  claim 1  wherein:
 the biopolymer molecules comprise amylose or amylopectin. 
 
     
     
         3 . The curable composition of  claim 1  wherein:
 the particles have an average particle size in the range from 1 to 1000 nanometers. 
 
     
     
         4 . The curable composition of  claim 1  in combination with a plurality of fibers or wood in a form other than pulp. 
     
     
         5 . The curable composition of  claim 1  in combination with a plurality of mineral fibers. 
     
     
         6 . The curable composition of  claim 1  further comprising a non-biopolymer binder or a non-biopolymer latex. 
     
     
         7 . The curable composition of  claim 1  further comprising a polycarboxylic acid binder or a polyester binder. 
     
     
         8 . The curable composition of  claim 1  wherein the crosslinking agent is a silicate crosslinking agent. 
     
     
         9 . The curable composition of  claim 1  wherein the particles are formed by reactive extrusion processing. 
     
     
         10 . The curable composition of  claim 1  wherein:
 the particles are present in the curable composition at a concentration of between 4% and 20% by weight of the curable composition. 
 
     
     
         11 . A composition comprising,
 a) an aqueous binder;   b) dispersion of particles in the aqueous binder; and,   c) a crosslinker in solution with the aqueous binder adapted to bond to the particles and to mineral fibers.   
     
     
         12 . The composition of  claim 11  wherein the particles comprise crosslinked starch. 
     
     
         13 . The composition of  claim 11  wherein the particles form a colloidal dispersion in the aqueous binder. 
     
     
         14 . The composition of  claim 11  wherein the curable binder is substantially formaldehyde free of has less than 1 ppm of formaldehyde based on the weight of the composition. 
     
     
         15 . The composition of  claim 11  wherein the crosslinker is a silicate crosslinker. 
     
     
         16 . The composition of  claim 11  in combination with a non-woven mat of glass fibers. 
     
     
         17 . A composition comprising,
 a) an aqueous formaldehyde binder;   b) a dispersion of particles in the aqueous binder, the particles comprising crosslinked biopolymers.   
     
     
         18 . The composition of  claim 17  wherein the particles are added during the polymerization of urea and formaldehyde. 
     
     
         19 . The composition of  claim 17  in combination with a mat of glass fibers and asphalt. 
     
     
         20 . A composite material comprising:
 a binder comprising particles selected from the group consisting of a) particles made of crosslinked biopolymers, b) particles having an average size of less than 400 nm, c) particles having a volume swell ratio of 6 or more and d) particles comprising starch; and,   a material comprising mineral fibers or non-pulped wood.