US 12,297,342 B2
Fiberglass insulation product
Gert Mueller, New Albany, OH (US); Andrew Broderick, Newark, OH (US); Xiujuan Zhang, New Albany, OH (US); Liang Chen, New Albany, OH (US); Kendel Smith, Westerville, OH (US); Larry J. Grant, Westerville, OH (US); Ronald A. Houpt, Newark, OH (US); Teno Boone, Columbus, OH (US); and Toni Elwell Newsome, Pataskala, OH (US)
Assigned to Owens Corning Intellectual Capital, LLC, Toledo, OH (US)
Filed by Owens Corning Intellectual Capital, LLC, Toledo, OH (US)
Filed on Dec. 8, 2020, as Appl. No. 17/114,820.
Claims priority of provisional application 62/945,318, filed on Dec. 9, 2019.
Claims priority of provisional application 62/945,328, filed on Dec. 9, 2019.
Claims priority of provisional application 62/945,323, filed on Dec. 9, 2019.
Claims priority of provisional application 62/945,334, filed on Dec. 9, 2019.
Claims priority of provisional application 62/945,313, filed on Dec. 9, 2019.
Prior Publication US 2021/0171757 A1, Jun. 10, 2021
This patent is subject to a terminal disclaimer.
Int. Cl. C08L 33/02 (2006.01); C08F 20/06 (2006.01); C08K 3/40 (2006.01); C08K 7/14 (2006.01); C08L 29/04 (2006.01); C08L 29/14 (2006.01); E04B 1/76 (2006.01)
CPC C08L 33/02 (2013.01) [C08F 20/06 (2013.01); C08K 3/40 (2013.01); C08K 7/14 (2013.01); C08L 29/04 (2013.01); C08L 29/14 (2013.01); E04B 1/7662 (2013.01); C08F 2810/20 (2013.01); C08L 2312/00 (2013.01)] 30 Claims
 
1. A fibrous insulation product comprising:
a plurality of randomly oriented glass fibers; and
a cross-linked formaldehyde-free binder composition at least partially coating the fibers, wherein the cross-linked formaldehyde-free binder composition is formed from an aqueous binder composition comprising:
5.0% by weight to 37.0% by weight of at least one monomeric polyol having at least four hydroxyl groups, based on the total solids content of the aqueous binder composition; and
at least 55% by weight of a cross-linking agent comprising a polymeric polycarboxylic acid having at least two carboxylic acid groups, based on the total solids content of the aqueous binder composition, wherein said binder composition has a ratio of molar equivalents of carboxylic acid groups to hydroxyl groups is between 0.60/1.0 and 1.0/0.6,
wherein the quantity of cross-linked formaldehyde-free binder is in the range of 2% to 10% by weight of the fibrous insulation product;
wherein an R-value of the fibrous insulation product is in the range of 10 to 54;
wherein the glass fibers have an average fiber diameter in the range of 8 HT to 12 HT;
wherein the fibrous insulation product, after curing, has a density, when uncompressed, in the range of 0.30 pcf to 2.7 pcf, and a stiffness of 45 degrees of less.