	US 12,351,738 B2
	Binder compositions and uses thereof
Carl Hampson, Liverpool (GB); and Ferdous Khan, St. Helens (GB)
Assigned to Knauf Insulation, Inc., Shelbyville, IN (US); and Knauf Insulation SPRL, Vise (BE)
Filed by KNAUF INSULATION SPRL, Visé (BE); and KNAUF INSULATION, INC., Shelbyville, IN (US)
Filed on Oct. 11, 2021, as Appl. No. 17/498,146.
Application 17/498,146 is a continuation of application No. 17/386,445, filed on Jul. 27, 2021, abandoned.
Application 17/386,445 is a continuation of application No. 17/323,991, filed on May 18, 2021, abandoned.
Application 17/323,991 is a continuation of application No. 17/194,269, filed on Mar. 7, 2021, abandoned.
Application 17/194,269 is a continuation of application No. 17/129,787, filed on Dec. 21, 2020, abandoned.
Application 17/129,787 is a continuation of application No. 17/063,630, filed on Oct. 5, 2020, abandoned.
Application 17/063,630 is a continuation of application No. 16/941,474, filed on Jul. 28, 2020, abandoned.
Application 16/941,474 is a continuation of application No. 15/931,565, filed on May 13, 2020, abandoned.
Application 15/931,565 is a continuation of application No. 15/326,532, abandoned, previously published as PCT/EP2015/066455, filed on Jul. 17, 2015.
Claims priority of application No. 1412709 (GB), filed on Jul. 17, 2014.
Prior Publication US 2022/0098452 A1, Mar. 31, 2022
Int. Cl. C09J 103/02 (2006.01); B27K 3/02 (2006.01); B27N 3/00 (2006.01); C08L 3/02 (2006.01); C09J 101/26 (2006.01); C09J 101/28 (2006.01); C09J 105/08 (2006.01); C09J 131/04 (2006.01); C09J 179/02 (2006.01)

CPC C09J 101/286 (2013.01) [B27K 3/02 (2013.01); B27N 3/002 (2013.01); C08L 3/02 (2013.01); C09J 101/26 (2013.01); C09J 103/02 (2013.01); C09J 105/08 (2013.01); C09J 131/04 (2013.01); C09J 179/02 (2013.01)]

18 Claims

1. An aqueous curable binder composition consisting of water, starting materials required for forming a thermoset resin upon curing and a matrix polymer, optionally one or more dyes, antifungal agents, antibacterial agents, hydrophobes, and silicone-containing coupling agents, and optionally a component selected from microparticles, nano-particles, or combinations thereof derived from one or more of MgO, CaO, Al₂O₃, CaCO₄, nanoclays, montmorillonite, bentonite, kaolinite, hectorite, and halloysite, wherein the starting materials required for forming a thermoset resin upon curing consist of a carbohydrate component selected from the group consisting of reducing sugars and a carbohydrate component capable of producing one or more reducing sugars in situ under thermal curing conditions, and a nitrogen-containing component and/or a reaction product thereof, and wherein the matrix polymer comprises 5-15% of the dry weight of the binder composition, and is selected from the group consisting of carboxymethyl cellulose (CMC), sodium carboxymethyl cellulose (NaCMC), hydroxypropyl cellulose (HPC), 2-hydroxyethyl cellulose (HEC), chitosan, polyurethanes, aliphatic isocyanate oligomers, azetidinium polymer, copolymers thereof and mixtures thereof.