Binder system

Abstract

An environmentally friendly, aqueous binder composition that includes a metal salt and a polyol is provided. The metal salt may be a water soluble salt, including salts of boron, aluminum, gallium, indium, tin, zirconium, thallium, lead, and bismuth. The polyol may include water miscible or water soluble polymeric alcohols including polyvinyl alcohol. The binder composition may be used in the formation of insulation materials and non-woven mats, among other products.

1 . A binder composition for use in the formation of fibrous insulation and non-woven mats, the binder composition comprising:
 water;   a metal salt;   and a polyol;   wherein the metal salt and the polyol are present in a weight ratio of 1:99 to 1:1.   
     
     
         2 . The aqueous binder composition of  claim 1 , wherein the weight ratio of the metal salt to the polyol is in the range of 1:9 to 1:1. 
     
     
         3 . The aqueous binder composition of  claim 1 , wherein the metal salt comprises a metal selected from the group consisting of boron, aluminum, gallium, indium, tin, iron, zinc, titanium, bismuth, zirconium, and combinations thereof. 
     
     
         4 . The aqueous binder composition of  claim 3 , wherein the metal salt is a salt of aluminum. 
     
     
         5 . The aqueous binder composition of  claim 4 , wherein the metal salt is selected from the group consisting of aluminum chloride, aluminum nitrate, aluminum sulfate, aluminum phosphate monobasic, sodium aluminate, and combinations thereof. 
     
     
         6 . The aqueous binder composition of  claim 1 , wherein the polyol is selected from the group consisting of aromatic alcohols, glycerol, polyglycerol, ethylene glycol, propylene glycol, polyethylene glycol, aliphatic alcohols, unmodified polyvinyl alcohol, modified polyvinyl alcohol, polyvinyl alcohol copolymer, polyvinyl acetate, polyacrylic acid, and combinations thereof. 
     
     
         7 . The aqueous binder composition of  claim 6 , wherein the polyol is polyvinyl alcohol. 
     
     
         8 . The aqueous binder composition of  claim 7 , wherein the polyvinyl alcohol has a viscosity of 3-5 centipoise. 
     
     
         9 . The aqueous binder composition of  claim 8 , wherein the polyvinyl alcohol is at least 50% hydrolyzed. 
     
     
         10 . A fibrous insulation product comprising:
 a plurality of fibers; and   a binder composition applied to at least a portion of the fibers, the binder composition comprising:   water;   a metal salt;   and a polyol;   wherein a weight ratio of the metal salt to the polyol is in the range of 1:99 to 1:1; and   wherein the binder composition is present in the fibrous insulation product in an amount of 1% to 25% loss on ignition.   
     
     
         11 . The fibrous insulation product of  claim 10 , wherein the weight ratio of the metal salt to the polyol is in the range of 1:9 to 1:1. 
     
     
         12 . The fibrous insulation product of  claim 10 , wherein the metal salt comprises a metal selected from the group consisting of boron, aluminum, gallium, indium, tin, iron, zinc, titanium, bismuth, zirconium, and combinations thereof. 
     
     
         13 . The fibrous insulation product of  claim 12 , wherein the metal salt is a salt of aluminum. 
     
     
         14 . The fibrous insulation product of  claim 13 , wherein the metal salt is selected from the group consisting of aluminum chloride, aluminum nitrate, aluminum sulfate aluminum phosphate monobasic, sodium aluminate, and combinations thereof. 
     
     
         15 . The fibrous insulation product of  claim 10 , wherein the polyol is selected from the group consisting of aromatic alcohols, glycerol, polyglycerol, sorbitol, ethylene glycol, propylene glycol, polyethylene glycol, pentaerythritol, aliphatic alcohols, unmodified polyvinyl alcohol, modified polyvinyl alcohol, polyvinyl alcohol copolymer, polyvinyl acetate, polyacrylic acid, and combinations thereof. 
     
     
         16 . The fibrous insulation product of  claim 15 , wherein the polyol is polyvinyl alcohol. 
     
     
         17 . The fibrous insulation product of  claim 16 , wherein the polyvinyl alcohol has a viscosity of 3-5 centipoise. 
     
     
         18 . The aqueous binder composition of  claim 17 , wherein the polyvinyl alcohol is at least 50% hydrolyzed. 
     
     
         19 . The fibrous insulation product of  claim 10 , wherein the insulation product is free of added formaldehyde. 
     
     
         20 . The fibrous insulation product of  claim 10 , wherein the fibers are glass fibers. 
     
     
         21 - 24 . (canceled)