Binder compositions with polyvalent phosphorus crosslinking agents

Abstract

An fibrous insulation product is provided that includes a binder comprising a polyol and a phosphorus crosslinking agent derived from a phosphonic or phosphoric acid, salt, ester or anhydride to form crosslinked phosphodiester linkages. The polyol is polyvalent, but may be monomeric or preferably polymeric; and may be synthetic or natural in origin. Carbohydrate polysaccharides are exemplary polyols, including water-soluble polysaccharides such as dextrin, maltodextrin, starch, modified starch, etc. Additionally, the carbohydrate polymer may have a dextrose equivalent (DE) number from 2 to 20. In exemplary embodiments, the binder may also include a catalyst, a coupling agent, a process aid, and other additives. The environmentally friendly, formaldehyde-free binder may be used in the formation of residential and commercial insulation materials and non-woven chopped strand mats. A method of making fibrous products is also provided.

What is claimed is: 
     
         1 . A method of making a fibrous product comprising:
 applying a binder to a pack of randomly oriented fibers, said binder composition comprising:
 at least one polyol having multiple hydroxyl groups; and 
 at least one polyvalent phosphorus crosslinking agent; and 
   heating the pack to which the binder composition is applied to at least partially cure the binder, wherein the cured binder comprises hydroxyl groups of the polyol crosslinked by phosphodiester linkages.   
     
     
         2 . The method of  claim 1 , further comprising forming the phosphodiester linkages with a crosslinking agent of formula I 
       
         
           
           
               
               
           
         
         wherein ˜Y represents either a double bonded oxygen or a lone pair of electrons; R 1  and R 2  are independently selected from OH, OR 4 , O(CO)R 4 , or O − M + ; and R 3  is selected from H, OH, R 4 , OR 4 , O(CO)R 4 , O − M +  or OR 5 ; 
         wherein R 4  is (C 1 -C 5 )alkyl, (C 1 -C 5 )alkenyl, (C 1 -C 5 )alkynyl, or aryl; M +  is a cation representing an ionizable salt; and R 5  represents 1 to 5 additional phosphonate moieties or a polymeric backbone of 1-20 carbons connected to additional phosphonate moieties. 
       
     
     
         3 . The method of  claim 2 , wherein the crosslinking agent is selected from acids or ammonium salts of phosphonic acid, phosphorous acid, phosphoric acid, or polyphosphoric acid. 
     
     
         4 . The method of  claim 3 , wherein the crosslinking agent is an ammonium salt of phosphoric acid, or a polyphosphoric acid. 
     
     
         5 . The method of  claim 1 , further comprising forming the phosphodiester linkages with a polymeric polyol. 
     
     
         6 . The method of  claim 5 , wherein said polymeric polyol is selected from polyvinyl alcohol, polyether polyols, polyester polyols, polyacrylic polyols and polysaccharides. 
     
     
         7 . The method of  claim 6 , wherein said polyol is a water-dispersible polysaccharide selected from the group consisting of pectin, dextrin, maltodextrin, starch, modified starch, starch derivatives and combinations thereof. 
     
     
         8 . The method of  claim 7 , wherein said polysaccharide is a carbohydrate having a dextrose equivalent number from 2 to 20. 
     
     
         9 . The method of  claim 8 , wherein the binder further comprises from about 20% to about 99% by weight of the total solids in the binder composition of the at least one carbohydrate polyol; and from about 1% to about 40% by weight of the total solids of the at least one crosslinking agent.