	US 12,325,790 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)
Filed by KNAUF INSULATION SPRL, Vise (BE); and MCTRON TECHNOLOGIES, INC., Greenville, SC (US)
Filed on Jan. 15, 2024, as Appl. No. 18/412,735.
Application 18/412,735 is a continuation of application No. 17/041,892, granted, now 11,939,460, previously published as PCT/EP2019/057803, filed on Mar. 27, 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 2024/0150558 A1, May 9, 2024
This patent is subject to a terminal disclaimer.
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 3/00 (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 composition selected from a resin, reactants of the resin, and combinations thereof; and water; wherein the i) Maillard reactants are selected from: one or more reducing sugar reactants and one or more nitrogen-containing reactants; one or more curable reaction products of the one or more reducing sugar reactants and the one or more nitrogen-containing reactants; and combinations thereof; wherein the one or more nitrogen-containing reactants are polyprimary polyamines which are organic compounds having two or more primary amines;

wherein the binder composition comprises at least 50 wt % by dry weight of ii) the composition selected from a resin, reactants of a resin, and combinations thereof;

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.

9. The method in accordance with claim 1, wherein the preparation of the binder composition prior to the application of the binder composition further comprises stabilising the Maillard reactants.

10. The method in accordance with claim 9, wherein stabilising the Maillard reactants comprises reacting the Maillard reactant(s) with carbon dioxide (CO₂).

11. The method in accordance with claim 10, wherein stabilising the Maillard reactants comprises treating the one or more curable reaction products of the one or more reducing sugar reactants and the one or more nitrogen-containing reactants with carbon dioxide (CO₂).