Owens Corning Fiberglas Technology, Inc.

Owens Corning Intellectual Capital, LLC

William E Downey

Liang Chen

Harry B Cline

Michael Eugene Evans

Michael T Pellegrin

Yadollah Delaviz

William R Cooper

Kathleen M Bullock

Kevin Guigley

David Michael Cook

Patrick M Gavin

Steven G Schmitt

James Justin Evans

Justin Depenhart

Tim Newell

Kenneth J Wiechert

Frank Charles O'Brien-Bernini

Fatemeh Nassreen Olang

Yadi Delaviz

Michael P Lewis

Bobby R Gibson

Michael V Mager

Frank C O'brien-Bernini

Steven Schmitt

The general inventive concepts relate to unbonded loose-fill fiberglass compositions useful for insulation. The compositions demonstrate high hydrolytic stability. In certain instances, this is accomplished by application of a surface modifier. In certain embodiments, the modifying agent is prepared by dilution and hydrolysis of a silane at a high solid content (i.e., hydrolysis at 25% to 60% solid).

Highly hydrolytically stable loose-fill insulation

A loosefill insulation installation includes a loosefill insulation material made from fiberglass fibers. The loosefill insulation material unexpectedly has improved thermal performance, even though the amount of mineral oil applied to the fiberglass fibers is reduced. For example, the fiberglass fibers can be coated with a mineral oil in an amount that is between 0.1% and 0.6% of the weight of the fiberglass fibers, such as about 0.375%.

Unbonded loosefill insulation

A loosefill insulation installation includes a loosefill insulation material made from fiberglass fibers. The loosefill insulation material unexpectedly has improved thermal performance, even through the amount of mineral oil applied to the fiberglass fibers is reduce. For example, the fiberglass fibers can be coated with a mineral oil in an amount that is between 0.1% and 0.6% of the weight of the fiberglass fibers, such as about 0.375%.

A recovery system recycles the washwater used to clean excess binder and debris from the production components, including a forming hoodwall constructed of non-corrosive materials, for manufacturing fiberglass insulation. A separate closed-loop recovery system is provided for the forming hoodwall in which the binder-containing washwater is screened and then recycled back to the forming hoodwall without further chemical treatment to change the pH level. A binder reclamation system is coupled to the hoodwall washwater recovery system to divert the low pH washwater when the supply of binder needs replenished at the forming hoodwall. The binder reclamation system introduces an acid solution to the cleaned washwater to lower the pH from about 2.5 to about 3.5. The other production components share a bulk washwater recovery system in which a base solution is introduced to raise the pH to approximately 8 or above to reduce corrosion in the other production components.

Process water reuse system for low pH binders

A neutralization system for controlling the pH of the washwater used to clean and maintain polyacrylic bound glass forming equipment is provided. The neutralization system introduces a base solution to a washwater solution when the pH of the washwater solution contained in a closed loop washwater recovery system and in a washwater tank holding the washwater solution is determined to be below approximately 8.0. Maintaining the pH of the washwater solution reduces the corrosion rate of the glass fiber forming equipment that is typically associated with acidic binders. In a second embodiment of the invention, a closed-loop hoodwall reclaim washwater recovery system utilized in addition to the washwater neutralization system that allows for the recovery and reuse of a polycarboxylic acid binder with a minimal amount of base solution. The closed-loop hoodwall reclaim washwater system is not connected to the closed-loop washwater neutralization system.

Control of the pH in washwater recovery system for a glass forming line

A neutralization system for controlling the pH of the washwater used to clean and maintain polyacrylic bound glass forming equipment. The neutralization system introduces a base solution to a washwater solution when the pH of the washwater solution contained in a closed loop washwater recovery system falls below about 8.5, thereby substantially reducing the corrosion rate of the components of the equipment associated with acidic polyacrylic acid binder, maleic acid cobinder or maleic anhydride cobinder and washwater solution. A closed-loop hoodwall washwater recovery system may also be introduced in addition to the neutralization system that allows for the recovery and reuse of polyacrylic acid binder and maleic acid cobinder or maleic anhydride cobinder with a minimal amount of base solution, thereby minimizing degradation of insulation properties of polyacylic acid bound glass fiber products.

Washwater neutralization system for glass forming line

A neutralization system for controlling the pH of the washwater used to clean and maintain polyacrylic bound glass forming equipment. The neutralization system introduces a base solution to a washwater solution when the pH of the washwater solution contained in a closed loop washwater recovery system falls below approximately 8.0, thereby substantially reducing the corrosion rate of the components of the equipment associated with acidic polyacrylic acid binder and washwater solution. A closed-loop hoodwall washwater recovery system may also be introduced in addition to the neutralization system that allows for the recovery and reuse of polyacrylic acid binder with a minimal amount of base solution, thereby minimizing degradation of insulation properties of polyacylic acid bound glass fiber products.

The present invention provides a variety of extended polyacrylic acid based binder compositions comprising a low molecular weight polyacrylic acid (typically hypophosphite or sulfite terminated), a crosslinking agent (such as triethanolamine or glycerol) and one or more water soluble materials, such as lignin, low molecular weight starch and soybean protein. The extended binder composition of the present invention provides a lower cost binder composition without degrading the performance and may be selected to alter one or more characteristics of the basic binder composition such binder wetting, emulsion compatibility, dust suppression and wash water flow properties.

Extended binder compositions

A binder composition, obtained by polymerizing acrylic acid monomer in water in the presence of a cure accelerator comprising an alkali metal salt of a phosphorous-containing inorganic acid to form a low molecular weight polyacrylic acid and subsequently reacting said low molecular weight polyacrylic acid with a polyhydroxy crosslinking agent in a crosslinking step to make a composition suitable for use as a component in a binder for fiberglass. A significant improvement involves conducting the crosslinking step in the absence of added catalyst. Moreover, satisfactory results are obtained in the absence of conventional undesirable sulfur odors.

Low odor insulation binder from phosphite terminated polyacrylic acid

The present invention provides a binder composition comprising a low molecular weight polycarboxylic acid, such as maleic anhydride, and a low molecular weight poly alcohol, such as polyvinyl alcohol, that exhibits improved cure performance with reduced emissions without sacrificing the performance of the final product or complication the manufacturing process. The binder composition may also incorporate a cure catalyst or accelerant such as sodium hypophosphite.

Poly alcohol-based binder composition

A formaldehyde free co-binder solution formed by using a polyol to crosslink polycarboxylic acid and a polyacid monomer is provided. In forming the co-binder solution, the polyacid monomer and the polyol are mixed in any conventional device with heat and agitation for a period of time sufficient for the chemicals to react and form a reaction product. The resultant product is then admixed with polycarboxylic acid to form a co-binder solution. In a preferred embodiment, the polyacid is maleic anhydride and the polyol is triethanolamine.

Polycarboxylic acid based co-binder

The present invention relates to a pourable or blowable loose-fill insulation, and in particular to a loose-fill insulation comprising glass fibers which are compressed and packaged in relatively small containers for easier installation by consumers. Agents capable of chemically interacting with the glass fibers are used in order to increase recoverability of the compressed glass fibers when they are removed from their packaging.

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Granville, OH, United States of America

William E Downey