US 11,939,460 B2
Binder compositions and uses thereof
Carl Hampson, Liverpool (GB); Oliver Callaghan, Manchester (GB); and Kenneth Snyder, Mauldin, SC (US)
Assigned to Knauf Insulation, Inc., Shelbyville, IN (US); Knauf Insulation SPRL, Vise (BE); and McTron Technologies, Inc, Greenville, SC (US)
Appl. No. 17/041,892
Filed by KNAUF INSULATION SPRL, Vise (BE); and MCTRON TECHNOLOGIES, INC., Greenville, SC (US)
PCT Filed Mar. 27, 2019, PCT No. PCT/EP2019/057803
§ 371(c)(1), (2) Date Sep. 25, 2020,
PCT Pub. No. WO2019/185762, PCT Pub. Date Oct. 3, 2019.
Claims priority of provisional application 62/662,494, filed on Apr. 25, 2018.
Claims priority of application No. 1804908 (GB), filed on Mar. 27, 2018.
Prior Publication US 2021/0130560 A1, May 6, 2021
Int. Cl. C08J 5/24 (2006.01); C08G 12/06 (2006.01); C08L 3/02 (2006.01); C08L 21/02 (2006.01); C08L 61/22 (2006.01); C08L 79/00 (2006.01)
CPC C08L 3/02 (2013.01) [C08G 12/06 (2013.01); C08J 5/246 (2021.05); C08L 21/02 (2013.01); C08L 61/22 (2013.01)] 12 Claims
 
1. A method of manufacturing a composite product comprising:
preparing a binder composition in the form of an aqueous solution, which comprises combining: i) Maillard reactants; ii) a component selected from a resin, reactants of the resin, and a combination thereof; and water; wherein the i) Maillard reactants are: a combination of one or more reducing sugar reactants and one or more nitrogen-containing reactants; a curable reaction product of the one or more reducing sugar reactants and the one or more nitrogen-containing reactants; or a combination of the one or more reducing sugar reactants, the one or more nitrogen-containing reactants, and the curable reaction product; and
stabilizing the i) Maillard reactants before, during or after said combining by introducing carbon dioxide; wherein the carbon dioxide reacts with the one or more nitrogen-containing reactants and/or the curable reaction product to form one or more carbamate compounds;
applying the binder composition to non-assembled or loosely-assembled matter to provide resinated matter;
arranging the resinated matter to provide loosely arranged resinated matter; and
subjecting the loosely arranged resinated matter to heat and/or pressure to cure the binder composition and to form the composite product.
 
10. A method in accordance with claim 1, wherein the i) Maillard reactants are: the curable reaction product of the one or more reducing sugar reactants and the one or more nitrogen-containing reactants.