Binder Compositions and Uses Thereof

Abstract

The present invention relates to a new aqueous curable binder composition comprising a polyphenolic macromolecular compound which bears a multitude of catechol radicals (dihydroxybenzene), preferably lignosulfonate salts and condensed tannins and mixtures thereof, and a polyamine functional compound comprising primary and/or secondary and/or tertiary and/or quaternary amine functional groups, suitable for bonding particulate matter, such as fibers, more particularly mineral wool fibers, or particles, such as wood particles.

1 . An aqueous curable binder composition comprising (i) a polyphenolic macromolecular compound which bears a multitude of phenol or polyhydroxybenzene radicals, such as catechol radicals (dihydroxybenzene), preferably lignosulfonate salts and condensed tannins and mixtures thereof, and (ii) a polyamine functional compound comprising primary and/or secondary and/or tertiary and/or quaternary amine functional groups, and/or reaction product of (i) and (ii), the ratio of polyphenolic macromolecular compound to polyamine functional compound ranging from 98:2 to 50:50, preferably from 98:2 to 70:30 w %, more preferably from 95:5 to 80:20 w %. 
     
     
         2 . The aqueous curable binder composition of  claim 1  wherein the lignosulfonate salt is selected from calcium lignosulfonate, sodium lignosulfonate, ammonium lignosulfonate, magnesium lignosulfonate and mixtures thereof. 
     
     
         3 . The aqueous curable binder composition of  claim 1  wherein the polyamine functional compound is selected from diamines, triamines, tetramines, pentamines and polymeric polyamines or polyimines, such as hexamethylenediamine, diethylenetetramine, diethylenetriamine, polyethyleneimine (PEI), polyvinyl amine, polyether amine, polylysine, ethylene diamine, 1,3-diaminopropane, cadaverine, spermidine, spermine, putrescine, tetraethylmethylenediamine, and triethylenetetramine, different types of polyethylenimines, such as linear polyethylenimines, branched polyethylenimines and dendrimer type polyethylenimine, and polyetheramines in linear and branched form. 
     
     
         4 . The aqueous curable binder composition of  claim 2  comprising a lignosulfonate salt, preferably ammonium lignosulfonate or calcium lignosulfonate or magnesium, and a diamine, such as hexamethylenediamine (HMDA). 
     
     
         5 . The aqueous curable binder composition of  claim 1  further comprising a matrix polymer selected from naturally derived polymers, such as polysaccharides, such as cellulose, starch, alginate, hyaluronic acid, and their derivatives, carboxymethyl cellulose (CMC), sodium carboxymethyl cellulose (NaCMC), hydroxypropyl cellulose (HPC), 2-hydroxyethyl cellulose (HEC), oligosaccharides, synthetically derived polymers, such as polyvinyls (PVA, PVAc, PAN), polyacrylics, polyacrylate, polymethacrylate, polyacrylamide, polymethacrylamides, polyurethanes, polyesters, aliphatic isocyanate oligomers, azetidinium containing polymer, chitosan and its derivatives, copolymers thereof and mixtures thereof. 
     
     
         6 . The aqueous curable binder composition of  claim 5  wherein the polyphenolic macromolecular compound makes from 50 up to 98 w % based on the total of the three components; the polyamine functional compound makes from 1 up to 40 w % based on the total of the three components; and the polymer content ranges from 1 to 20 w % based upon the total of the three components. 
     
     
         7 . The aqueous curable binder composition of  claim 1  further comprising dyes, antifungal agents, antibacterial agents, hydrophobes, silicone containing coupling agents and/or other additives such as silane, dedust oil, hydrophobic polymers, and/or combinations thereof. 
     
     
         8 . An assembly of fibers or particles bonded with an aqueous binder composition according to  claim 1  or with a binder resulting from the curing of a binder composition according to  claim 1 . 
     
     
         9 . The assembly of fibers according to  claim 8  being an insulation product, such as a mineral wool mat. 
     
     
         10 . The assembly of particles according to  claim 8  being a composite wood board, such as a wood fiber board, wood particle board, plywood or similar board. 
     
     
         11 . A process for the manufacturing an assembly of fibers or particles characterized in that a combination of (i) an aqueous composition of a polyphenolic macromolecular compound which bears a multitude of phenol or polyhydroxybenzene radicals, such as catechol radicals (dihydroxybenzene), preferably lignosulfonate salts and condensed tannins and mixtures thereof, and (ii) an aqueous composition of a polyamine functional compound comprising primary and/or secondary and/or tertiary and/or quaternary amine functional groups, is applied sequentially or simultaneously onto a collection of fibers or particles such that the ratio of polyphenolic macromolecular compound to polyamine functional compound ranges from 98:2 to 50:50, preferably 98:2 to 70:30 w %, more preferably from 95:5 to 80:20 w %, or an aqueous binder composition according to  claim 1  is applied onto a collection of fibers or particles, in that the coated fibers or particles are gathered in an assembly and subjected to curing conditions whereby the polyphenolic macromolecular compound and the polyamine functional compound are caused to react to form a macromolecular binder and water is evaporated. 
     
     
         12 . The process according to  claim 11  wherein the polyamine functional compound is selected from diamines, triamines, tetramines, pentamines and polymeric plolyamines or polyimines, such as hexamethylenediamine, diethylenetetramine, diethylenetriamine, polyethyleneimine (PEI), polyvinyl amine, polyether amine, polylysine, ethylene diamine, 1,3-diaminopropane, cadaverine, spermidine, spermine, putrescine, tetraethylmethylenediamine, and triethylenetetramine, different types of polyethylenimines, such as linear polyethylenimines, branched polyethylenimines and dendrimer type polyethylenimine, and polyetheramines in linear and branched form. 
     
     
         13 . The process according to  claim 11  characterized in that curing is performed at a temperature ranging from 90° C.-200° C., preferably higher than 140° C., more preferably lower than 190° C., typically between 160 and 180° C. 
     
     
         14 . The process of  claim 11  wherein the aqueous binder composition is applied by spraying onto the collection of fibers or particles. 
     
     
         15 . The process of  claim 11  wherein the assembly is a wood fiber board or wood particle board or similar wood board, subjected to pressing during curing.