US 20090324.915A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2009/0324915 A1 Swift et al. (43) Pub. Date: Dec. 31, 2009

(54) BINDERS AND MATERIALS MADE (21) Appl. No.: 12/524,539 THEREWITH (22) PCT Filed: Jan. 25, 2007 (75) Inventors: Brian Lee Swift, Morristown, IN (US); Ronald E. Kissell, (86). PCT No.: PCT/US07/O1892 Shelbyville, IN (US); Ruljian Xu, Indianapolis, IN (US); Ronald A. S371 (c)(1), Houpt, Shelbyville, IN (US); (2), (4) Date: Jul. 24, 2009 Charles Fitch Appley, O O Cumberland, IN (US); Patrick M. Publication Classification Noonan, Columbus, IN (US) (51) Int. Cl. B32B (7/04 (2006.01) Correspondence Address: CO3C I4/00 (2006.01) BARNES & THORNBURG LLP 11 SOUTH MERIDAN (52)52 U.S.Oa - Cl------428/219; 501/32 INDIANAPOLIS, IN 46204 (US) (57) ABSTRACT (73) Assignee: KNAUF INSULATION GMBH, Binders to produce or promote cohesion in non-assembled or Shelbyville (US) loosely assembled matter.

AMINE REACTANT REDUCING or Non- Corbonyl reactant

Proteins/Peptides (e.g., cologen, casein, gelatin, gluten) /Monnose/ Amino acids (e.g., Cly, Asp, Clu, homoClu, y-carboxyClu) // ( "NH, polymeric polycarboxylate // "NH.R. polymeric polycarboxylate /Arabulose/ "NHR'R'', polymeric polycarboxylate // *NH, monomeric polycarboxylole Pyruvoldehyde/Acetoldehyde *NH.R. monomeric polycarboxylate Furfurol/Crotonaldehyde NHRR), monomeric polycarboxylate AsCorbic acid/Quinone

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*amino Compound Sugar N-substituted glycosylamine "20 Amadori-rearrangement Amadori rearrangement product (ARP) 1-amino-1-deoxy-2-

Fission products Schiff's base of (acetol, diocetyl, pyruvaldehyde, etc.) hydroxymethylfurfural

-2H +2H s (HMF) or furfural

Dehydroreductones +H,0

-C0 + amino - amino +a, amino acid Strecker degradation Compound Compound

- Aldehydes HMF or furfural Aldols and 4 dmino N-free polymers + Omino compound Compound Aldimines and Ketimines

Melanoidins (brown nitrogenous polymers)

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BNDERS AND MATERALS MADE 0007. One potential feature of the present binders is that THEREWITH they are formaldehyde free. Accordingly, the materials the binders are disposed upon may also be formaldehyde free BACKGROUND (e.g., fiberglass). In addition, the present binders may have a reduced trimethylamine content as compared to other known 0001 Binders are useful in fabricating materials from binders. non-assembled or loosely-assembled matter. For example, 0008. With respect to the present binder's chemical con binders enable two or more surfaces to become united. Bind stituents, they may include ester and/or polyester compounds. ers may be broadly classified into two main groups: organic The binders may include ester and/or polyester compounds in and inorganic, with the organic materials being Subdivided combination with a vegetable oil. Such as Soybean oil. into those of animal, vegetable, and synthetic origin. Another 0009 Furthermore, the binders may include ester and/or way of classifying binders is based upon the chemical nature polyester compounds in combination with sodium salts of of these compounds: (1) protein or protein derivatives; (2) organic acids. The binders may include Sodium salts of inor starch, , or gums and their derivatives; (3) thermo ganic acids. The binders may also include potassium salts of plastic synthetic resins; (4) thermosetting synthetic resins; (5) organic acids. Moreover, the binders may include potassium natural resins and bitumens; (6) natural and synthetic rubbers; salts of inorganic acids. The described binders may include and (7) inorganic binders. Binders also may be classified ester and/or polyester compounds in combination with a clay according to the purpose for which they are used: (1) bonding additive, Such as montmorillonite. rigid Surfaces, such as rigid plastics, and metals; and (2) 0010 Furthermore, the binders of the present invention bonding flexible surfaces, such as flexible plastics, and thin may include a product of a Maillard reaction. For example, metallic sheets. see FIG. 2. As shown in FIG. 2, Maillard reactions produce 0002 Thermoplastic binders comprise a variety of poly melanoidins, i.e., high molecular weight, furan ring- and merized materials such as polyvinyl acetate, polyvinyl nitrogen-containing polymers that vary in structure depend butyral, polyvinyl alcohol, and other polyvinyl resins; poly ing on the reactants and conditions of their preparation. Mel styrene resins; acrylic and methacrylic acid ester resins; anoidins display a CN ratio, degree of unsaturation, and cyanoacrylates; and various other synthetic resins such as chemical aromaticity that increase with temperature and time polyisobutylene polyamides, courmarone-idene products, of heating. (See, Ames, J. M. in “The Maillard Browning and silicones. Such thermoplastic binders may have perma Reaction—an update.” Chemistry and Industry (Great Brit nent solubility and fusibility so that they creep under stress ain), 1988, 7, 558-561, the disclosure of which is hereby and soften when heated. They are used for manufacturing incorporated herein by reference). Accordingly, the Subject various products, for example, tapes. binders may be made via a Maillard reaction and thus contain 0003. Thermosetting binders comprise a variety of phe melanoidins. It should be appreciated that the subject binders nol-aldehyde, urea-aldehyde, melamine-aldehyde, and other may contain melanoidins, or other Maillard reaction prod condensation-polymerization materials like the furane and ucts, which products are generated by a separate process and polyurethane resins. Thermosetting binders may be charac then simply added to the composition that makes up the terized by being transformed into insoluble and infusible binder. The melanoidins in the binder may be water-in materials by means of either heat or catalytic action. Binder soluble. Moreover, the binders may be thermoset binders. compositions containing phenol-, resorcinol-, urea-, 0011. The Maillard reactants to produce a melanoidin may melamine-formaldehyde, phenol-furfuraldehyde, and the include an amine reactant reacted with a reducing-Sugar car like are used for the bonding of textiles, plastics, rubbers, and bohydrate reactant. For example, an ammonium salt of a many other materials. monomeric polycarboxylic acid may be reacted with (i) a 0004 As indicated above, binders are useful in fabricating in its aldose or ketose form or (ii) a polysac materials from non-assembled or loosely-assembled matter. charide or (iii) with combinations thereof. In another varia Accordingly, compositions capable of functioning as a binder tion, an ammonium salt of a polymeric polycarboxylic acid are desirable. may be contacted with (i) a monosaccharide in its aldose or ketose form or (ii) a , or (iii) with combina SUMMARY tions thereof. In yet another variation, an amino acid may be contacted with (i) a monosaccharide in its aldose or ketose 0005. Cured or uncured binders in accordance with an form, or (ii) with a polysaccharide or (iii) with combinations illustrative embodiment of the present invention may com thereof. Furthermore, a peptide may be contacted with (i) a prise one or more of the following features or combinations monosaccharide in its aldose or ketose form or (ii) with a thereof. In addition, materials in accordance with the present polysaccharide or (iii) with combinations thereof. Moreover, invention may comprise one or more of the following features a protein may be contacted with (i) a monosaccharide in its or combinations thereof: aldose or ketose form or (ii) with a polysaccharide or (iii) with 0006 Initially it should be appreciated that the binders of combinations thereof. the present invention may be utilized in a variety of fabrica 0012. It should also be appreciated that the binders of the tion applications to produce or promote cohesion in a collec present invention may include melanoidins produced in non tion of non-assembled or loosely-assembled matter. A collec Sugar variants of Maillard reactions. In these reactions an tion includes two or more components. The binders produce amine reactant is contacted with a non-carbohydrate carbonyl or promote cohesion in at least two of the components of the reactant. In one illustrative variation, an ammonium salt of a collection. For example, subject binders are capable of hold monomeric polycarboxylic acid is contacted with a non-car ing a collection of matter together such that the matter adheres bohydrate carbonyl reactant such as pyruvaldehyde, acetal in a manner to resist separation. The binders described herein dehyde, crotonaldehyde, 2-furaldehyde, quinone, ascorbic can be utilized in the fabrication of any material. acid, or the like, or with combinations thereof. In another US 2009/03249 15 A1 Dec. 31, 2009

variation, an ammonium salt of a polymeric polycarboxylic pounds (i.e., these reactants produce melanoidins when acid may be contacted with a non-carbohydrate carbonyl reacted under conditions to initiate a Maillard reaction). The reactant such as pyruvaldehyde, acetaldehyde, crotonalde method can further include removing water from the binder in hyde, 2-furaldehyde, quinone, ascorbic acid, or the like, or contact with the fibers (i.e., the binder is dehydrated). The with combinations thereof. In yet another illustrative varia method can also include curing the binder in contact with the tion, an amino acid may be contacted with a non-carbohy glass fibers (e.g., thermally curing the binder). drate carbonyl reactant Such as pyruvaldehyde, acetaldehyde, 0018. Another example of utilizing this method is in the crotonaldehyde, 2-furaldehyde, quinone, ascorbic acid, or the fabrication of cellulosic materials. The method may include like, or with combinations thereof. In another illustrative contacting the cellulosic material (e.g., cellulose fibers) with variation, a peptide may be contacted with a non-carbohy a thermally-curable, aqueous binder. The binder may include drate carbonyl reactant Such as pyruvaldehyde, acetaldehyde, (i) an ammonium salt of a polycarboxylic acid reactant and crotonaldehyde, 2-furaldehyde, quinone, ascorbic acid, or the (ii) a reducing-Sugar carbohydrate reactant. As indicated like, or with combinations thereof. In still another illustrative above, these two reactants are melanoidin reactant com variation, a protein may be contacted with a non-carbohy pounds. The method can also include removing water from drate carbonyl reactant Such as pyruvaldehyde, acetaldehyde, the binder in contact with the cellulosic material (i.e., the crotonaldehyde, 2-furaldehyde, quinone, ascorbic acid, and binder is dehydrated). As before, the method can also include the like, or with combinations thereof. curing the binder (e.g., thermal curing). 0013 The melanoidins discussed herein may be generated 0019. One way of using the binders is to bind glass fibers from melanoidin reactant compounds (e.g., Maillard reac together Such that they become organized into a fiberglass tants). These reactant compounds are disposed in an aqueous mat. The mat of fiberglass may be processed to form one of Solution at an alkaline pH and therefore are not corrosive. several types of fiberglass materials, such as fiberglass insu That is, the alkaline solution prevents or inhibits the eating or lation. In one example, the fiberglass material may have glass wearing away of a Substance, such as metal, caused by chemi fibers present in the range from about 75% to about 99% by cal decomposition brought about by, for example, an acid. weight. The uncured binder may function to hold the glass The reactant compounds may include a reducing-Sugar car fibers together. Alternatively, the cured binder may function bohydrate reactant and an amine reactant. In addition, the to hold the glass fibers together. reactant compounds may include a non-carbohydrate carbo 0020. In addition, a fibrous product is described that nyl reactant and an amine reactant. includes a binder in contact with cellulose fibers, such as 0014. It should also be understood that the binders those in a mat of wood shavings or sawdust. The mat may be described herein may be made from melanoidin reactant processed to form one of several types of wood fiber board compounds themselves. That is, once the Maillard reactants products. In one variation, the binder is uncured. In this varia are mixed, this mixture can function as a binder of the present tion, the uncured binder may function to hold the cellulosic invention. These binders may be utilized to fabricate uncured, fibers together. In the alternative, the cured binder may func formaldehyde-free matter, such as fibrous materials. tion to hold the cellulosic fibers together. 0.015. In the alternative, a binder made from the reactants 0021. Also described herein are illustrative embodiments of a Milliard reaction may be cured. These binders may be of uncured and cured binders of the present invention used as used to fabricate cured formaldehyde-free matter, such as, glass fiber binders in a variety of uncured and cured fiberglass fibrous compositions. These compositions may be water-re insulation products, respectively. sistant and, as indicated above, may include water-insoluble 0022. Additional features of the present invention will melanoidins. become apparent to those skilled in the art upon consideration 0016. It should be appreciated that the binders described of the following detailed description of illustrative embodi herein may be used in manufacturing products from a collec ments exemplifying the best mode of carrying out the inven tion of non-assembled or loosely-assembled matter. For tion as presently perceived. example, these binders may be employed to fabricate fiber products. These products may be made from woven or non BRIEF DESCRIPTION OF THE DRAWINGS woven fibers. The fibers can be heat-resistant or non heat resistant fibers or combinations thereof. In one illustrative 0023 FIG. 1 shows a number of illustrative reactants for embodiment, the binders are used to bind glass fibers to make producing melanoidins; fiberglass. In another illustrative embodiment, the binders are 0024 FIG. 2 illustrates a Maillard reaction schematic used to make cellulosic compositions. With respect to cellu when reacting a with an amino compound; losic compositions, the binders may be used to bind cellulosic matter to fabricate, for example, wood fiber board which has (0025 FIG. 3 shows the FT-IR spectrum of an illustrative desirable physical properties (e.g., mechanical strength). embodiment of a dried binder of the present disclosure; 0017. One embodiment of the invention is directed to a (0026 FIG. 4 shows the FT-IR spectrum of an illustrative method for manufacturing products from a collection of non embodiment of a cured binder of the present disclosure; assembled or loosely-assembled matter. One example of (0027 FIG.5 shows the 650°F, hot surface performance of using this method is in the fabrication of fiberglass. However, a fiberglass pipe insulation material fabricated with an illus as indicated above this method can be utilized in the fabrica trative embodiment of a binder of the present disclosure; tion of any material, as long as the method produces or pro (0028 FIG. 6 shows the 1000°F. hot surface performance motes cohesion when utilized. The method may include con of a fiberglass pipe insulation material fabricated with an tacting the fibers with a thermally-curable, aqueous binder. illustrative embodiment of a binder of the present disclosure; The binder may include (i) an ammonium salt of a polycar and boxylic acid reactant and (ii) a reducing-Sugar carbohydrate 0029 FIG. 7 shows an exemplary schematic that depicts reactant. These two reactants are melanoidin reactant com one way of disposing a binder onto fibers. US 2009/03249 15 A1 Dec. 31, 2009

DETAILED DESCRIPTION term "heteroaryl” refers to an aromatic mono or polycyclic ring of carbon atoms and at least one heteroatom selected 0030. While the invention is susceptible to various modi from nitrogen, oxygen, and Sulfur, Such as pyridinyl, pyrim fications and alternative forms, specific embodiments will idinyl, indolyl, benzoxazolyl, and the like. It is to be under herein be described in detail. It should be understood, how stood that each of alkyl, cycloalkyl, alkenyl, cycloalkenyl, ever, that there is no intent to limit the invention to the par ticular forms described, but on the contrary, the intention is to and heterocyclyl may be optionally substituted with indepen cover all modifications, equivalents, and alternatives falling dently selected groups such as alkyl, haloalkyl, hydroxyalkyl, within the spirit and scope of the invention. aminoalkyl, carboxylic acid and derivatives thereof, includ 0031. As used herein, the phrase “formaldehyde-free' ing esters, amides, and nitrites, hydroxy, alkoxy, acyloxy, means that a binder or a material that incorporates a binder amino, alkyl and dialkylamino, acylamino, thio, and the like, liberates less than about 1 ppm formaldehyde as a result of and combinations thereof. It is further to be understood that drying and/or curing. The 1 ppm is based on the weight of each of aryland heteroaryl may be optionally substituted with sample being measured for formaldehyde release. one or more independently selected Substituents, such as 0032 Cured indicates that the binder has been exposed to halo, hydroxy, amino, alkyl or dialkylamino, alkoxy, alkyl conditions so as to initiate a chemical change. Examples of Sulfonyl, cyano, nitro, and the like. these chemical changes include, but are not limited to, (i) 0038. As used herein, the term “polycarboxylic acid indi covalent bonding, (ii) hydrogen bonding of binder compo cates a dicarboxylic, tricarboxylic, tetracarboxylic, pentacar nents, and (iii) chemically cross-linking the polymers and/or boxylic, and like monomeric polycarboxylic acids, and anhy oligomers in the binder. These changes may increase the drides, and combinations thereof, as well as polymeric binder's durability and solvent resistance as compared to the polycarboxylic acids, anhydrides, copolymers, and combina uncured binder. Curing a binder may result in the formation of tions thereof. In one aspect, the polycarboxylic acid ammo a thermoset material. Furthermore, curing may include the nium salt reactant is sufficiently non-volatile to maximize its generation of melanoidins. These melanoidins may be gen ability to remain available for reaction with the carbohydrate erated from a Maillard reaction from melanoidin reactant reactant of a Maillard reaction (discussed below). In another compounds. In addition, a cured binder may result in an aspect, the polycarboxylic acid ammonium salt reactant may increase in adhesion between the matter in a collection as be substituted with other chemical functional groups. compared to an uncured binder. Curing can be initiated by, for 0039 Illustratively, a monomeric polycarboxylic acid example, heat, microwave radiation, and/or conditions that may be a dicarboxylic acid, including, but not limited to, initiate one or more of the chemical changes mentioned unsaturated aliphatic dicarboxylic acids, saturated aliphatic above. dicarboxylic acids, aromatic dicarboxylic acids, unsaturated 0033. In a situation where the chemical change in the cyclic dicarboxylic acids, Saturated cyclic dicarboxylic acids, binder results in the release of water, e.g., polymerization and hydroxy-substituted derivatives thereof, and the like. Or, cross-linking, a cure can be determined by the amount of illustratively, the polycarboxylic acid itself may be a tricar water released above that which would occur from drying boxylic acid, including, but not limited to, unsaturated ali alone. The techniques used to measure the amount of water phatic tricarboxylic acids, Saturated aliphatic tricarboxylic released during drying as compared to when a binder is cured, acids, aromatic tricarboxylic acids, unsaturated cyclic tricar are well known in the art. boxylic acids, Saturated cyclic tricarboxylic acids, hydroxy 0034. In accordance with the above paragraph, an uncured substituted derivatives thereof, and the like. It is appreciated binder is one that has not been cured. that any such polycarboxylic acids may be optionally Substi 0035. As used herein, the term "alkaline' indicates a solu tuted. Such as with hydroxy, halo, alkyl, alkoxy, and the like. tion having a pH that is greater than or equal to about 7. For In one variation, the polycarboxylic acid is the Saturated example, the pH of the Solution can be less than or equal to aliphatic tricarboxylic acid, citric acid. Other suitable poly about 10. In addition, the solution may have a pH from about carboxylic acids are contemplated to include, but are not 7 to about 10, or from about 8 to about 10, or from about 9 to limited to, aconitic acid, adipic acid, azelaic acid, butane about 10. tetracarboxylic acid dihydride, butane tricarboxylic acid, 0036. As used herein, the term “ammonium” includes, but chlorendic acid, citraconic acid, dicyclopentadiene-maleic is not limited to, “NH “NHR', and "NHR'R', where R' acid adducts, diethylenetriamine pentaacetic acid, adducts of and R are each independently selected in "NHR'R', and dipentene and maleic acid, ethylenediamine tetraacetic acid where R' and Rare selected from alkyl, cycloalkyl, alkenyl, (EDTA), fully maleated rosin, maleated tall-oil fatty acids, cycloalkenyl, heterocyclyl, aryl, and heteroaryl. fumaric acid, glutaric acid, isophthalic acid, itaconic acid, 0037. The term “alkyl” refers to a saturated monovalent maleated rosin oxidized with potassium peroxide to alcohol chain of carbon atoms, which may be optionally branched; then carboxylic acid, maleic acid, malic acid, mesaconic acid, the term “cycloalkyl refers to a monovalent chain of carbon biphenol A or bisphenol F reacted via the KOLBE-Schmidt atoms, a portion of which forms a ring; the term “alkenyl reaction with carbon dioxide to introduce 3-4 carboxyl refers to an unsaturated monovalent chain of carbon atoms groups, oxalic acid, phthalic acid, sebacic acid, Succinic acid, including at least one double bond, which may be optionally tartaric acid, terephthalic acid, tetrabromophthalic acid, tet branched; the term “cycloalkenyl refers to an unsaturated rachlorophthalic acid, tetrahydrophthalic acid, trimellitic monovalent chain of carbon atoms, a portion of which forms acid, trimesic acid, and the like, and anhydrides, and combi a ring; the term "heterocyclyl refers to a monovalent chain of nations thereof. carbon and heteroatoms, wherein the heteroatoms are 004.0 Illustratively, a polymeric polycarboxylic acid may selected from nitrogen, oxygen, and Sulfur, a portion of be an acid, including, but not limited to, polyacrylic acid, which, including at least one heteroatom, form a ring; the polymethacrylic acid, polymaleic acid, and like polymeric term “aryl” refers to an aromatic mono or polycyclic ring of polycarboxylic acids, anhydrides thereof, and mixtures carbon atoms, such as phenyl, naphthyl, and the like; and the thereof, as well as copolymers of acrylic acid, methacrylic US 2009/03249 15 A1 Dec. 31, 2009

acid, maleic acid, and like carboxylic acids, anhydrides molecular weight less than about 1000 bearing at least two thereof, and mixtures thereof. Examples of commercially hydroxyl groups such as, ethylene glycol, glycerol, pen available polyacrylic acids include AQUASET-529 (Rohm & taerythritol, trimethylol propane, Sorbitol. Sucrose, glucose, Haas, Philadelphia, Pa., USA), CRITERION 2000 (Kemira, resorcinol, catechol, pyrogallol, glycollated ureas, 1,4-cyclo Helsinki, Finland, Europe), NF1 (H. B. Fuller, St. Paul, hexane diol, diethanolamine, triethanolamine, and certain Minn., USA), and SOKALAN (BASF, Ludwigshafen, Ger reactive polyols, for example, B-hydroxyalkylamides such as, many, Europe). With respect to SOKALAN, this is a water for example, bisN,N-di(B-hydroxyethyl)adipamide, or it soluble polyacrylic copolymer of acrylic acid and maleic may be an addition polymer containing at least two hydroxyl acid, having a molecular weight of approximately 4000. groups such as, polyvinyl alcohol, partially hydrolyzed poly AQUASET-529 is a composition containing polyacrylic acid vinyl acetate, and homopolymers or copolymers of hydroxy cross-linked with glycerol, also containing sodium hypo ethyl(meth)acrylate, hydroxypropyl(meth)acrylate, and the phosphite as a catalyst. CRITERION 2000 is an acidic solu like. tion of a partial salt of polyacrylic acid, having a molecular 0044 As described in U.S. Pat. Nos. 5,318,990 and 6,331, weight of approximately 2000. With respect to NF1, this is a 350, the catalyst (in a composition including a polymeric copolymer containing carboxylic acid functionality and polycarboxylic acid) is a phosphorous-containing accelerator hydroxy functionality, as well as units with neither function which may be a compound with a molecular weight less than ality, NF1 also contains chain transfer agents, such as sodium about 1000 such as, an alkali metal polyphosphate, an alkali hypophosphite or organophosphate catalysts. metal dihydrogen phosphate, a polyphosphoric acid, and an 0041 Further, compositions including polymeric polycar alkyl phosphinic acid or it may be an oligomer or polymer boxylic acids are also contemplated to be useful in preparing bearing phosphorous-containing groups, for example, addi the binders described herein, such as those compositions tion polymers of acrylic and/or maleic acids formed in the described in U.S. Pat. Nos. 5,318,990, 5,661,213, 6,136,916, presence of Sodium hypophosphite, addition polymers pre and 6.331,350, the disclosures of which are hereby incorpo pared from ethylenically unsaturated monomers in the pres rated herein by reference. Described in U.S. Pat. Nos. 5,318, ence of phosphorous salt chain transfer agents or terminators, 990 and 6.331,350 are compositions comprising an aqueous and addition polymers containing acid-functional monomer Solution of a polymeric polycarboxylic acid, a polyol, and a residues, for example, copolymerized phosphoethyl meth catalyst. acrylate, and like phosphonic acid esters, and copolymerized 0042. As described in U.S. Pat. Nos. 5,318,990 and 6,331, vinyl Sulfonic acid monomers, and their salts. The phospho 350, the polymeric polycarboxylic acid comprises an organic rous-containing accelerator may be used at a level of from polymer or oligomer containing more than one pendant car about 1% to about 40%, by weight based on the combined boxy group. The polymeric polycarboxylic acid may be a weight of the polymeric polycarboxylic acid and the polyol. A homopolymer or copolymer prepared from unsaturated car level of phosphorous-containing accelerator of from about boxylic acids including, but not necessarily limited to, acrylic 2.5% to about 10%, by weight based on the combined weight acid, methacrylic acid, crotonic acid, isocrotonic acid, maleic of the polymeric polycarboxylic acid and the polyol may be acid, cinnamic acid, 2-methylmaleic acid, itaconic acid, used. Examples of Such catalysts include, but are not limited 2-methylitaconic acid, C.B-methyleneglutaric acid, and the to, sodium hypophosphite, sodium phosphite, potassium like. Alternatively, the polymeric polycarboxylic acid may be phosphite, disodium pyrophosphate, tetrasodium pyrophos prepared from unsaturated anhydrides including, but not nec phate, sodium tripolyphosphate, sodium hexametaphosphate, essarily limited to, maleic anhydride, itaconic anhydride, potassium phosphate, potassium polymetaphosphate, potas acrylic anhydride, methacrylic anhydride, and the like, as sium polyphosphate, potassium tripolyphosphate, sodium tri well as mixtures thereof. Methods for polymerizing these metaphosphate, and sodium tetrametaphosphate, as well as acids and anhydrides are well-known in the chemical art. The mixtures thereof. polymeric polycarboxylic acid may additionally comprise a 0045 Compositions including polymeric polycarboxylic copolymer of one or more of the aforementioned unsaturated acids described in U.S. Pat. Nos. 5,661,213 and 6,136,916 carboxylic acids or anhydrides and one or more vinyl com that are contemplated to be useful in preparing the binders pounds including, but not necessarily limited to, styrene, described hereincomprise anaqueous solution of a polymeric C.-methylstyrene, acrylonitrile, methacrylonitrile, methyl polycarboxylic acid, a polyol containing at least two hydroxyl acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate, groups, and a phosphorous-containing accelerator, wherein methyl methacrylate, n-butyl methacrylate, isobutyl meth the ratio of the number of equivalents of carboxylic acid acrylate, glycidyl methacrylate, vinyl methyl ether, vinyl groups to the number of equivalents of hydroxyl groups is acetate, and the like. Methods for preparing these copolymers from about 1:0.01 to about 1:3 are well-known in the art. The polymeric polycarboxylic 0046. As described in U.S. Pat. Nos. 5,661.213 and 6,136, acids may comprise homopolymers and copolymers of poly 916, the polymeric polycarboxylic acid may be a polyester acrylic acid. The molecular weight of the polymeric polycar containing at least two carboxylic acid groups or an addition boxylic acid, and in particular polyacrylic acid polymer, may polymer or oligomer containing at least two copolymerized be is less than 10000, less than 5000, or about 3000 or less. carboxylic acid-functional monomers. The polymeric poly For example, the molecular weight may be 2000. carboxylic acid is preferably an addition polymer formed 0043. As described in U.S. Pat. Nos. 5,318,990 and 6,331, from at least one ethylenically unsaturated monomer. The 350, the polyol (in a composition including a polymeric poly addition polymer may be in the form of a solution of the carboxylic acid) contains at least two hydroxyl groups. The addition polymer in an aqueous medium Such as, an alkali polyol should be sufficiently nonvolatile such that it will soluble resin which has been solubilized in a basic medium; in substantially remain available for reaction with the polymeric the form of an aqueous dispersion, for example, an emulsion polycarboxylic acid in the composition during heating and polymerized dispersion; or in the form of an aqueous Suspen curing operations. The polyol may be a compound with a Sion. The addition polymer must contain at least two carboxy US 2009/03249 15 A1 Dec. 31, 2009

lic acid groups, anhydride groups, or salts thereof. mers containing acid-functional monomer residues such as, Ethylenically unsaturated carboxylic acids such as, meth copolymerized phosphoethyl methacrylate, and like phos acrylic acid, acrylic acid, crotonic acid, fumaric acid, maleic phonic acid esters, and copolymerized vinyl sulfonic acid acid, 2-methyl maleic acid, itaconic acid, 2-methyl itaconic monomers, and their salts. The phosphorous-containing acid, C.B-methylene glutaric acid, monoalkyl maleates, and accelerator may be used at a level of from about 1% to about monoalkyl fumarates; ethylenically unsaturated anhydrides, 40%, by weight based on the combined weight of the polyacid for example, maleic anhydride, itaconic anhydride, acrylic and the polyol. A level of phosphorous-containing accelerator anhydride, and methacrylic anhydride; and salts thereof, at a of from about 2.5% to about 10%, by weight based on the level of from about 1% to 100%, by weight, based on the combined weight of the polyacid and the polyol, may be weight of the addition polymer, may be used. Additional utilized. ethylenically unsaturated monomers may include acrylic 0049. As used herein, the term “amine base' includes, but ester monomers including methyl acrylate, ethyl acrylate, is not limited to, ammonia, a primary amine, i.e., NHR', and butyl acrylate, 2-ethylhexyl acrylate, decyl acrylate, methyl a secondary amine, i.e., NHR'R'', where R' and Rare each methacrylate, butyl methacrylate, isodecyl methacrylate, independently selected in NHR'R', and where R' and Rare hydroxyethyl acrylate, hydroxyethyl methacrylate, and selected from alkyl, cycloalkyl, alkenyl, cycloalkenyl, het hydroxypropyl methacrylate; acrylamide or Substituted acry erocyclyl, aryl, and heteroaryl, as defined herein. Illustra lamides; styrene or Substituted styrenes; butadiene; vinyl tively, the amine base may be substantially volatile or sub acetate or other vinyl esters; acrylonitrile or methacryloni stantially non-volatile under conditions sufficient to promote trile; and the like. The addition polymer containing at least formation of the thermoset binder during thermal curing. two carboxylic acid groups, anhydride groups, or salts thereof Illustratively, the amine base may be a substantially volatile may have a molecular weight from about 300 to about 10,000, base. Such as ammonia, ethylamine, diethylamine, dimethy 000. A molecular weight from about 1000 to about 250,000 lamine, ethylpropylamine, and the like. Alternatively, the may be used. When the addition polymer is an alkali-soluble amine base may be a Substantially non-volatile base. Such as resin having a carboxylic acid, anhydride, or salt thereof, aniline, 1-naphthylamine, 2-naphthylamine, para-aminophe content of from about 5% to about 30%, by weight based on nol, and the like. the total weight of the addition polymer, a molecular weight 0050. As used herein, “reducing sugar indicates one or from about 10,000 to about 100,000 may be utilized Methods more that contain aldehyde groups, or that can isomer for preparing these additional polymers are well-known in the ize, i.e., tautomerize, to contain aldehyde groups, which art. groups are reactive with an amino group under Maillard reac 0047. As described in U.S. Pat. Nos. 5,661.213 and 6,136, tion conditions and which groups may be oxidized with, for 916, the polyol (in a composition including a polymeric poly example, Cu" to afford carboxylic acids. It is also appreci carboxylic acid) contains at least two hydroxyl groups and ated that any Such carbohydrate reactant may be optionally should be sufficiently nonvolatile that it remains substantially Substituted, such as with hydroxy, halo, alkyl, alkoxy, and the available for reaction with the polymeric polycarboxylic acid like. It is further appreciated that in any such carbohydrate in the composition during heating and curing operations. The reactant, one or more chiral centers are present, and that both polyol may be a compound with a molecular weight less than possible optical isomers at each chiral center are contem about 1000 bearing at least two hydroxyl groups, for example, plated to be included in the invention described herein. Fur ethylene glycol, glycerol, pentaerythritol, trimethylol pro ther, it is also to be understood that various mixtures, includ pane, Sorbitol. Sucrose, glucose, resorcinol, catechol, pyro ing racemic mixtures, or other diastereomeric mixtures of the gallol, glycollated ureas, 1,4-cyclohexane diol, diethanola various optical isomers of any Such carbohydrate reactant, as mine, triethanolamine, and certain reactive polyols, for well as various geometric isomers thereof, may be used in one example, 3-hydroxyalkylamides, for example, bis-N,N-di or more embodiments described herein. (B-hydroxyethyl)adipamide, bisN,N-di(B-hydroxypropyl) 0051. As used herein, the term “fiberglass' indicates heat azelamide, bisN N-di(B-hydroxypropyl)adipamide, bis resistant fibers suitable for withstanding elevated tempera N N-di(3-hydroxypropyl)glutaramide, bisN N-di(B- tures. Examples of such fibers include, but are not limited to, hydroxypropyl)succinamide, and bisN-methyl-N-(B- mineral fibers (e.g., rock fibers), aramidfibers, ceramic fibers, hydroxyethyl)oxamide, or it may be an addition polymer metal fibers, carbon fibers, polyimide fibers, certain polyester containing at least two hydroxyl groups such as, polyvinyl fibers, rayon fibers, mineral wool (e.g., glass wool or rock alcohol, partially hydrolyzed polyvinyl acetate, and wool), and glass fibers. Illustratively, such fibers are substan homopolymers or copolymers of hydroxyethyl (meth)acry tially unaffected by exposure to temperatures above about late, hydroxypropyl (meth)acrylate, and the like. 120° C. 0048. As described in U.S. Pat. Nos. 5,661.213 and 6,136, 0.052 FIG. 1 shows examples of reactants for a Maillard 916, the phosphorous-containing accelerator (in a composi reaction. Examples of amine reactants include proteins, pep tion including a polymeric polycarboxylic acid) may be a tides, amino acids, ammonium salts of polymeric polycar compound with a molecular weight less than about 1000, boxylic acids, and ammonium salts of monomeric polycar Such as an alkali metal hypophosphite salt, an alkali metal boxylic acids. As illustrated, “ammonium can be 'NH), phosphite, an alkali metal polyphosphate, an alkali metal "NHR', and "NHR'R'', where x is at least about 1. dihydrogen phosphate, a polyphosphoric acid, and an alkyl With respect to “NHR'R, R and Rare each independently phosphinic acid, or it may be an oligomer or polymer bearing selected. Moreover, R' and R are selected from alkyl, phosphorous-containing groups such as addition polymers of cycloalkyl, alkenyl, cycloalkenyl, heterocyclyl, aryl, and het acrylic and/or maleic acids formed in the presence of sodium eroaryl, as described above. FIG. 1 also illustrates examples hypophosphite, addition polymers prepared from ethyleni of reducing-Sugar reactants for producing melanoidins, cally unsaturated monomers in the presence of phosphorous including , in their aldose or ketose form, salt chain transfer agents or terminators, and addition poly , or combinations thereof. Illustrative non US 2009/03249 15 A1 Dec. 31, 2009 carbohydrate carbonyl reactants for producing melanoidins Sugar carbohydrate reactant to afford N-Substituted glycosy are also shown in FIG. 1, and include various aldehydes, e.g., lamine, as shown in FIG. 2. Consumption of ammonia in Such pyruvaldehyde and furfural, as well as compounds Such as a way, with ammonia and a reducing-Sugar carbohydrate ascorbic acid and quinone. reactant combination functioning as a latent acid catalyst, 0053 FIG. 2 shows a schematic of a Maillard reaction, would be expected to result in a decrease in pH, which which culminates in the production of melanoidins. In its decrease is believed to promote esterification processes and/ initial phase, a Maillard reaction involves a carbohydrate or dehydration of the polycarboxylic acid to afford its corre reactant, for example, a reducing oraldose Sugar (note that the sponding anhydride derivative. At pHs7, the Amadori rear carbohydrate reactant may come from a Substance capable of rangement product of N-Substituted glycosylamine, i.e., producing a reducing Sugar under Maillard reaction condi 1-amino-1-deoxy-2-ketose, would be expected to undergo tions). The reaction also involves condensing the carbohy mainly 1.2-enolization with the formation of furfural when, drate reactant (e.g., a reducing or aldose Sugar) with an amine for example, are involved, or hydroxymethylfur reactant, e.g., an amino compound possessing an amino fural when, for example, are involved, as a prelude to group. In other words, the carbohydrate reactant and the melanoidin production. Concurrently, contemporaneously, or amine reactant for a Maillard reaction are the melanoidin sequentially with the production of melanoidins, esterifica reactant compounds. The condensation of these two reactants tion processes may occur involving melanoidins, polycar produces an N-Substituted glycosylamine. For a more boxylic acid and/or its corresponding anhydride derivative, detailed description of the Maillard reaction see, Hodge, J. E. and residual carbohydrate, which processes lead to extensive Chemistry of Browning Reactions in Model Systems.J. Agric. cross-linking. Accompanied by Sugar dehydration reactions, Food Chem. 1953, 1928-943, the disclosure of which is whereupon conjugated double bonds are produced that may hereby incorporated herein by reference. The compound pos undergo polymerization, a water-resistant thermoset binder is sessing a free amino group in a Maillard reaction, which produced consisting of polyester adducts interconnected by a compound serves as the amine reactant, may be present in the network of carbon-carbon single bonds. Consistent with the form of an amino acid. The free amino group can also come above reaction scenario is a strong absorbance near 1734 from a protein, where the free amino groups are available in cm in the FT-IR spectrum of a cured binder described the form of for example, the e-amino group of lysine resi herein, which absorbance is within the 1750-1730 cm range dues, and/or the C-amino group of the terminal amino acid. expected forester carbonyl C O vibrations. The afore-men Alternatively, as described herein, an ammonium salt of a tioned spectrum is shown in FIG. 4. polycarboxylic acid may serve as the amine reactant in a 0057 FIG. 7 is an exemplary schematic showing one Maillard reaction. embodiment of a process for disposing a binder of the present 0054 Another aspect of conducting a Maillard reaction as invention onto a substrate Such as glass fibers. In particular, as described herein is that, initially, the aqueous Maillard reac shown in FIG. 7, silica (sand) particles 10 are placed in the tant solution (which also is a binder), as described above, has interior 12 of a vat 14, where the particles 10 are moltenized an alkaline pH. However, once the Solution is disposed on a to produce molten glass 16. Molten glass 16 is then advanced collection of non-assembled or loosely-assembled matter, through a fiberizer 18 so as to fiberize molten glass 16 into and curing is initiated, the pH decreases (i.e., the binder glass fibers 20. A container 22 that contains a liquid uncured becomes acidic). It should be understood that when fabricat binder 24 of the present invention is in fluid communication ing a material, the amount of contact between the binder and with fiberizer 18 and disposes the liquid uncured binder 24 components of machinery used in the fabrication is greater onto glass fibers 20 so as to bind the fibers together. Glass prior to curing, (i.e., when the binder Solution is alkaline) as fibers 20 are placed onto a forming chain 26 so as to form a compared to after the binder is cured (i.e., when the binder is collection 38 of glass fibers 20. The collection 38 is then acidic). An alkaline composition is less corrosive than an advanced in the direction indicated by arrow 28 so as to enter acidic composition. Accordingly, corrosively of the fabrica oven 30 where the collection is heated and curing occurs. tion process is decreased. While positioned in oven 30, collection 38 is positioned 0055. It should be appreciated that by using the aqueous between flights 32 and 34. Flight 32 can be moved relative to Maillard reactant solution described herein, the machinery flight 34 in the direction indicated by arrow 36, i.e., flight 32 used to fabricate fiberglass is not exposed to an acidic Solution can be positioned closer to flight 34 or moved away from because, as described above, the pH of the Maillard reactant flight 34 thereby adjusting the distance between flights 32 and Solution is alkaline. Furthermore, during the fabrication pro 34. As shown in FIG. 7, flight 32 has been moved relative to cess, the only time an acidic condition develops is after the flight 34 so as to exert a compressive force on collection 38 as binder has been applied to glass fibers. Once the binder is it moves through the oven 30. Subjecting the collection 38 to applied to the glass fibers, the binder and the material that a compressive force decreases the thickness of collection 38 incorporates the binder have relatively infrequent contact as compared to its thickness prior to encountering flights 32 with the components of the machinery, as compared to the and 34. Accordingly, the density of the collection 38 is time prior to applying the binder to the glass fibers. Accord increased as compared to its density prior to encountering ingly, corrosively of fiberglass fabrication (and the fabrica flights 32 and 34. As mentioned above, the collection 38 is tion of other materials) is decreased. heated in the oven 30 and curing occurs so as to produce a 0056. Without being bound to theory, covalent reaction of cured binder 40 being disposed on glass fibers 20. The curing the polycarboxylic acid ammonium salt and reducing Sugar may result in a thermoset binder material being disposed reactants of a Maillard reaction, which as described herein upon glass fibers 22. The collection 38 then exits oven 30 occurs substantially during thermal curing to produce brown where it can be utilized in various products, e.g., products colored nitrogenous polymeric and co-polymeric melanoi described herein, such as, acoustical board, pipe insulation, dins of varying structure, is thought to involve initial Maillard batt residential insulation, and elevated panel insulation to reaction of ammonia with the aldehyde moiety of a reducing name a few. US 2009/03249 15 A1 Dec. 31, 2009

0058. The above description sets forth one example of tant, or is used in combination with other reducing Sugars how to adjust a process parameter to obtain one or more and/or a polysaccharide, an aldotriose Sugar or a ketotriose desirable physical/chemical characteristics of a collection Sugar may be utilized, such as and dihydroxy bound together by a binder of the present invention, e.g., the acetone, respectively. When a serves as the carbohy thickness and density of the collection is altered as it passes drate reactant, or is used in combination with other reducing through the oven. However, it should be appreciated that a Sugars and/or a polysaccharide, aldotetrose Sugars, such as number of other parameters (one or more) can also be and ; and ketotetrose Sugars, such as eryth adjusted to obtain desirable characteristics. These include the rulose, may be utilized. When a serves as the carbo amount of binder applied onto the glass fibers, the type of hydrate reactant, or is used in combination with other reduc silica utilized to make the glass fibers, the size of the glass ing Sugars and/or a polysaccharide, aldopentose Sugars, such fibers (e.g., fiber diameter, fiber length and fiber thickness) as ribose, arabinose, Xylose, and ; and ketopentose that make up a collection. What the desirable characteristic Sugars, such as ribulose, arabulose, Xylulose, and lyXulose, are will depend upon the type of product being manufactured, may be utilized. When a serves as the carbohydrate e.g., acoustical board, pipe insulation, batt residential insula reactant, or is used in combination with other reducing Sugars tion, and elevated panel insulation to name a few. The desir and/or a polysaccharide, aldohexose Sugars, such as glucose able characteristics associated with any particular product are (i.e., dextrose), , galactose, , , , well known in the art. With respect to what process param gulose, and ; and ketohexose Sugars, such as fructose, eters to manipulate and how they are manipulated to obtain , Sorbose and , may be utilized. When a hep the desirable physical/chemical characteristics, e.g., thermal tose serves as the carbohydrate reactant, or is used in combi properties and acoustical characteristics, these can be deter nation with other reducing Sugars and/or a polysaccharide, a mined by routine experimentation. For example, a collection ketoheptose Sugar Such as Sedoheptulose may be utilized. having a greater density is desirable when fabricating acous Other stereoisomers of such carbohydrate reactants not tical board as compared with the density required when fab known to occur naturally are also contemplated to be useful in ricating residential insulation. preparing the binder compositions as described herein. When 0059. The following discussion is directed to (i) examples a polysaccharide serves as the carbohydrate, or is used in of carbohydrate and amine reactants, which reactants can be combination with monosaccharides, sucrose, , mal used in a Maillard reaction, (ii) how these reactants can be tose, starch, and cellulose may be utilized. combined with each other and with various additives to pre 0062. Furthermore, the carbohydrate reactant in the Mail pare binders of the present invention, and iii) illustrative lard reaction may be used in combination with a non-carbo embodiments of the binders described herein used as glass hydrate polyhydroxy reactant. Examples of non-carbohy fiber binders in fiberglass insulation products and as cellulo drate polyhydroxy reactants which can be used in sic fiber binders in wood fiber board products. First, it should combination with the carbohydrate reactant include, but are be understood that any carbohydrate and any compound pos not limited to, trimethylolpropane, glycerol, pentaerythritol, sessing a primary or secondary amino group, which will act as sorbitol. 1.5-pentanediol, 1.6-hexanediol, polyTHF so, poly a reactant in a Maillard reaction, can be utilized in the binders THF-so, textrion whey, polyvinyl alcohol, partially hydro of the present invention. Such compounds can be identified lyzed polyvinyl acetate, fully hydrolyzed polyvinyl acetate, and utilized by one of ordinary skill in the art with the guide and mixtures thereof. In one aspect, the non-carbohydrate lines disclosed herein. polyhydroxy reactant is sufficiently nonvolatile to maximize 0060. With respect to exemplary reactants, it should also its ability to remain available for reaction with a monomeric be appreciated that using an ammonium salt of a polycar or polymeric polycarboxylic acid reactant. It is appreciated boxylic acid as an amine reactant is an effective reactant in a that the hydrophobicity of the non-carbohydrate polyhydroxy Maillard reaction. Ammonium salts of polycarboxylic acids reactant may be a factor in determining the physical proper can be generated by neutralizing the acid groups with an ties of a binder prepared as described herein. amine base, thereby producing polycarboxylic acid ammo 0063. When a partially hydrolyzed polyvinyl acetate nium salt groups. Complete neutralization, i.e., about 100% serves as a non-carbohydrate polyhydroxy reactant, a com calculated on an equivalents basis, may eliminate any need to mercially available compound such as an 87-89% hydrolyzed titrate or partially neutralize acid groups in the polycarboxy polyvinyl acetate may be utilized, such as, DuPont lic acid prior to binder formation. However, it is expected that ELVANOL 51-05. DuPont ELVANOL 51-05 has a molecular less-than-complete neutralization would not inhibit forma weight of about 22,000-26,000 Da and a viscosity of about tion of the binder. Note that neutralization of the acid groups 5.0-6.0 centipoises. Other partially hydrolyzed polyvinyl of the polycarboxylic acid may be carried out either before or acetates contemplated to be useful in preparing binder com after the polycarboxylic acid is mixed with the carbohydrate. positions as described herein include, but are not limited to, 0061. With respect to the carbohydrate reactant, it may 87-89% hydrolyzed polyvinyl acetates differing in molecular include one or more reactants having one or more reducing weight and viscosity from ELVANOL 51-05, such as, for Sugars. In one aspect, any carbohydrate reactant should be example, DuPont ELVANOL 51-04, ELVANOL 51-08, sufficiently nonvolatile to maximize its ability to remain ELVANOL 50-14, ELVANOL 52-22, ELVANOL 50-26, available for reaction with the polycarboxylic acid ammo ELVANOL 50-42; and partially hydrolyzed polyvinyl nium salt reactant. The carbohydrate reactant may be a acetates differing in molecular weight, viscosity, and/or monosaccharide in its aldose or ketose form, including a degree of hydrolysis from ELVANOL 51-05, such as, DuPont , a tetrose, a pentose, a hexose, or a ; or a ELVANOL 51-03 (86-89% hydrolyzed), ELVANOL 70-14 polysaccharide; or combinations thereof. A carbohydrate (95.0-97.0% hydrolyzed), ELVANOL 70-27 (95.5-96.5% reactant may be a reducing Sugar, or one that yields one or hydrolyzed), ELVANOL 60-30 (90-93% hydrolyzed). Other more reducing Sugars in situ underthermal curing conditions. partially hydrolyzed polyvinyl acetates contemplated to be For example, when a triose serves as the carbohydrate reac useful in preparing binder compositions as described herein US 2009/03249 15 A1 Dec. 31, 2009

include, but are not limited to, Clariant MOWIOL 15-79, ing Sugar. It should be appreciated that when an ammonium MOWIOL3-83, MOWIOL 4-88, MOWIOL5-88, MOWIOL salt of a monomeric or a polymeric polycarboxylic acid is 8-88, MOWIOL 18-88, MOWIOL 23-88, MOWIOL 26-88, used as an amine reactant, the molar equivalents of ammo MOWIOL 40-88, MOWIOL 47-88, and MOWIOL 30-92, as nium ion may or may not be equal to the molar equivalents of well as Celanese CELVOL. 203, CELVOL. 205, CELVOL acid groups present on the polycarboxylic acid. In one illus 502, CELVOL 504, CELVOL 513, CELVOL 523, CELVOL trative example, an ammonium salt may be monobasic, diba 523TV, CELVOL 530, CELVOL 540, CELVOL 540TV, sic, or tribasic when a tricarboxylic acid is used as a polycar CELVOL 418, CELVOL 425, and CELVOL 443. Also con boxylic acid reactant. Thus, the molar equivalents of the templated to be useful are similar or analogous partially ammonium ion may be present in an amount less than or hydrolyzed polyvinyl acetates available from other commer about equal to the molar equivalents of acid groups present in cial Suppliers. a polycarboxylic acid. Accordingly, the ammonium salt can 0064. When a fully hydrolyzed polyvinyl acetate serves as a non-carbohydrate polyhydroxy reactant, Clariant be monobasic or dibasic when the polycarboxylic acid reac MOWIOL 4-98, having a molecular weight of about 27,000 tant is a dicarboxylic acid. Further, the molar equivalents of Da, may be utilized. Other fully hydrolyzed polyvinyl ammonium ion may be present in an amount less than, or acetates contemplated to be useful include, but are not limited about equal to, the molar equivalents of acid groups present in to, DuPont ELVANOL 70-03 (98.0-98.8% hydrolyzed), a polymeric polycarboxylic acid, and so on and so forth. ELVANOL 70-04 (98.0-98.8% hydrolyzed), ELVANOL When a monobasic salt of a dicarboxylic acid is used, or when 70-06 (98.5-99.2% hydrolyzed), ELVANOL 90-50 (99.0-99. a dibasic salt of a tricarboxylic acid is used, or when the molar 8% hydrolyzed), ELVANOL 70-20 (98.5-99.2% hydro equivalents of ammonium ions are present in an amount less lyzed), ELVANOL 70-30 (98.5-99.2% hydrolyzed), than the molar equivalents of acid groups present in a poly ELVANOL 71-30 (99.0-99.8% hydrolyzed), ELVANOL meric polycarboxylic acid, the pH of the binder composition 70-62 (98.4-99.8% hydrolyzed), ELVANOL 70-63 (98.5-99. may require adjustment to achieve alkalinity. 2% hydrolyzed), ELVANOL 70-75 (98.5-99.2% hydro 0068. The uncured, formaldehyde-free, thermally-cur lyzed), Clariant MOWIOL 3-98, MOWIOL 6-98, MOWIOL able, alkaline, aqueous binder composition can be used to 10-98, MOWIOL 20-98, MOWIOL56-98, MOWIOL 28-99, fabricate a number of different materials. In particular, these and Celanese CELVOL. 103, CELVOL. 107, CELVOL 305, binders can be used to produce or promote cohesion in non CELVOL 310, CELVOL 325, CELVOL 325LA, and CEL assembled or loosely-assembled matter by placing the binder VOL. 350, as well as similar or analogous fully hydrolyzed in contact with the matter to be bound. Any number of well polyvinyl acetates from other commercial Suppliers. known techniques can be employed to place the aqueous 0065. The aforementioned Maillard reactants may be binder in contact with the material to be bound. For example, combined to make an aqueous composition that includes a the aqueous binder can be sprayed on (e.g., during the binding carbohydrate reactant and an amine reactant. These aqueous binders represent examples of uncured binders. As discussed glass fibers) or applied via a roll-coat apparatus. below, these aqueous compositions can be used as binders of 0069. The aqueous binders described herein can be the present invention. These binders are formaldehyde-free, applied to a mat of glass fibers (e.g., sprayed onto the mat) curable, alkaline, aqueous binder compositions. Further during production of fiberglass insulation products. Once the more, as indicated above, the carbohydrate reactant of the aqueous binder is in contact with the glass fibers, the residual Maillard reactants may be used in combination with a non heat from the glass fibers (note that the glass fibers are made carbohydrate polyhydroxy reactant Accordingly, any time the from molten glass and thus contain residual heat) and the flow carbohydrate reactant is mentioned, it should be understood of air through the fibrous mat will evaporate (i.e., remove) that it can be used in combination with a non-carbohydrate water from the binder. Removing the water leaves the remain polyhydroxy reactant. ing components of the binder on the fibers as a coating of 0066. In one illustrative embodiment, the aqueous solu Viscous or semi-Viscous high-solids liquid. This coating of tion of Maillard reactants may include (i) an ammonium salt Viscous or semi-Viscous high-solids liquid functions as a of a polycarboxylic acid reactant and (ii) a carbohydrate binder. At this point, the mat has not been cured. In other reactant having a reducing Sugar. The pH of this solution prior words, the uncured binder functions to bind the glass fibers in to placing it in contact with the material to be bound can be the mat. greater than or equal to about 7. In addition, this solution can 0070. In one illustrative embodiment, the uncured binders have a pH of less than or equal to about 10. The ratio of the described herein can be used as glass fiber binders in uncured number of moles of the polycarboxylic acid reactant to the fiberglass insulation products exemplified by “ship out number of moles of the carbohydrate reactant can be in the uncured. “Ship out uncured insulation is manufactured as a range from about 1:4 to about 1:15. In one illustrative varia rolled-up blanket including glass fibers that are loosely tion, the ratio of the number of moles of the polycarboxylic bonded together with a thermosetting binder. This insulation acid reactant to the number of moles of the carbohydrate is typically an in-process material, which is shipped in a wet reactant in the binder composition is about 1:5. In another and uncured State to be further processed, usually by com variation, the ratio of the number of moles of the polycar pression molding or match metal die molding, and heat curing boxylic acid reactant to the number of moles of the carbohy into components of a desired shape and density for use in drate reactant is about 1:6. In another variation, the ratio of the transportation, office, appliance, architectural, acoustical, number of moles of the polycarboxylic acid reactant to the and industrial applications. Thermal and acoustical perfor number of moles of the carbohydrate reactant is about 1:7. mance of a molded part depend on part design, thickness, and 0067. As described above, the aqueous binder composi density. Thickness and/or density of “ship out uncured are tion may include (i) an ammonium salt of a polycarboxylic determined in accordance with ASTM C 167. “Ship out” acid reactant and (ii) a carbohydrate reactant having a reduc uncured insulation typically requires a nominal moisture con US 2009/03249 15 A1 Dec. 31, 2009

tent of about 4-tabout 3.0/-about 2.0%, a nominal binder lbs/ft, e.g., in some embodiments the nominal density can be content of about 16-tabout 2.0%, and a nominal fiber diameter about 1.89 lbs/ft and the nominal weight can be about 0.1572 of about 31 tabout 4 ht. lbs/ft. In another variation, “ship out” uncured has a nominal 0071. In one illustrative variation, “ship out” uncured has density of about 1.9 lbs/ft and a nominal weight of about 0.2 a nominal density of about 0.8 lbs/ft and a nominal weight of lbs/ft, e.g., in some embodiments the nominal density can be about 0.07 lbs/ft, e.g., in some embodiments the nominal about 1.94 lbs/ft and the nominal weight can be about 0.1615 weight can be about 0.0669 lbs/ft. In another variation, “ship lbs/ft. In another variation, “ship out” uncured has a nominal out” uncured has a nominal density of about 0.9 lbs/ft and a density of about 2.0 lbs/ft and a nominal weight of about 0.2 nominal weight of about 0.07 lbs/ft, e.g., in some embodi lbs/ft, e.g., in some embodiments the nominal density can be ments the nominal density can be about 0.89 lbs/ft and the about 2.04 lbs/ft and the nominal weight can be about 0.1700 nominal weight can be about 0.0744 lbs/ft. In another varia lbs/ft. In another variation, “ship out” uncured has a nominal tion, “ship out uncured has a nominal density of about 0.9 density of about 2.1 lbs/ft and a nominal weight of about 0.2 lbs/ft and a nominal weight of about 0.08 lbs/ft, e.g., in lbs/ft, e.g., in some embodiments the nominal density can be some embodiments the nominal weight can be about 0.0750 about 2.14 lbs/ft and the nominal weight can be about 0.1780 lbs/ft. In another variation, “ship out” uncured has a nominal lbs/ft. In another variation, “ship out” uncured has a nominal density of about 1.1 lbs/ft and a nominal weight of about 0.09 density of about 2.2 lbs/ft and a nominal weight of about 0.2 lbs/ft, e.g., in some embodiments the nominal density can be lbs/ft, e.g., in some embodiments the nominal density can be about 1.15 lbs/ft and the nominal weight can be about 0.0954 about 2.24 lbs/ft and the nominal weight can be about 0.1870 lbs/ft. In another variation, “ship out” uncured has a nominal density of about 1.3 lbs/ft and a nominal weight of about 0.1 lbs/ft. In another variation, “ship out” uncured has a nominal lbs/ft, e.g., in some embodiments the nominal density can be density of about 2.3 lbs/ft and a nominal weight of about 0.2 about 1.29 lbs/ft and thenominal weight can be about 0.1075 lbs/ft, e.g., in some embodiments the nominal density can be lbs/ft. In another variation, “ship out” uncured has a nominal about 2.25 lbs/ft and the nominal weight can be about 0.1875 density of about 1.3 lbs/ft and a nominal weight of about 0.1 lbs/ft. In another variation, “ship out” uncured has a nominal lbs/ft, e.g., in Some embodiments the nominal density can be density of about 2.5 lbs/ft and a nominal weight of about 0.2 about 1.34 lbs/ft and thenominal weight can be about 0.1117 lbs/ft, e.g., in some embodiments the nominal density can be lbs/ft. In another variation, “ship out” uncured has a nominal about 2.50 lbs/ft and the nominal weight can be about 0.2083 density of about 1.4 lbs/ft and a nominal weight of about 0.1 lbs/ft. In another variation, “ship out” uncured has a nominal lbs/ft, e.g., in some embodiments the nominal density can be density of about 2.6 lbs/ft and a nominal weight of about 0.2 about 1.38 lbs/ft and the nominal weight can be about 0.1153 lbs/ft, e.g., in some embodiments the nominal density can be lbs/ft. In another variation, “ship out” uncured has a nominal about 2.65 lbs/ft and the nominal weight can be about 0.2208 density of about 1.4 lbs/ft and a nominal weight of about 0.1 lbs/ft. In another variation, “ship out” uncured has a nominal lbs/ft, e.g., in some embodiments the nominal density can be density of about 2.8 lbs/ft and a nominal weight of about 0.2 about 1.41 lbs/ft and thenominal weight can be about 0.1175 lbs/ft, e.g., in some embodiments the nominal density can be lbs/ft. In another variation, “ship out” uncured has a nominal about 2.75 lbs/ft and the nominal weight can be about 0.2292 density of about 1.4 lbs/ft and a nominal weight of about 0.1 lbs/ft. In another variation, “ship out” uncured has a nominal lbs/ft, e.g., in Some embodiments the nominal density can be density of about 3.0 lbs/ft and a nominal weight of about 0.3 about 1.44 lbs/ft and thenominal weight can be about 0.1200 lbs/ft, e.g., in Some embodiments the nominal weight can be lbs/ft. In another variation, “ship out” uncured has a nominal about 0.2500 lbs/ft. density of about 1.5 lbs/ft and a nominal weight of about 0.1 0072. In another illustrative embodiment, the uncured lbs/ft, e.g., in some embodiments the nominal density can be binders described herein can be used as glass fiber binders in about 1.53 lbs/ft and the nominal weight can be about 0.1275 uncured fiberglass insulation products exemplified by pipe lbs/ft. In another variation, “ship out” uncured has a nominal insulation-uncured. Pipe insulation-uncured is manufactured density of about 1.6 lbs/ft and a nominal weight of about 0.1 as a rolled-up blanket including glass fibers that are loosely lbs/ft, e.g., in some embodiments the nominal density can be bonded together with a thermosetting binder. This insulation about 1.57lbs/ft and the nominal weight can be about 0.1311 is typically an in-process material, which is shipped in a wet lbs/ft. In another variation, “ship out” uncured has a nominal and uncured State to be further processed by heat curing into density of about 1.6lbs/ft and a nominal weight of about 0.1 varying densities and dimensions of cured pipe insulation, lbs/ft, e.g., in Some embodiments the nominal density can be which insulation has specific thermal performance require about 1.63 lbs/ft and thenominal weight can be about 0.1360 ments (see cured pipe insulation embodiment below). Thick lbs/ft. In another variation, “ship out” uncured has a nominal ness and/or density are determined in accordance with ASTM density of about 1.7 lbs/ft and a nominal weight of about 0.1 C 167. Pipe insulation-uncured typically requires a nominal lbs/ft, e.g., in Some embodiments the nominal density can be moisture content of about 3+about 2.0%f-about 1.0%, a about 1.73 lbs/ft and thenominal weight can be about 0.1444 nominal bindercontent of about 7-tabout 2.0%, and a nominal lbs/ft. In another variation, “ship out” uncured has a nominal fiber diameter of about 30-about 4 ht. density of about 1.8 lbs/ft and a nominal weight of about 0.1 0073. In one illustrative variation, pipe insulation-uncured lbs/ft, e.g., in some embodiments the nominal density can be has a nominal density of about 0.8 lbs/ft and a nominal about 1.78 lbs/ft and the nominal weight can be about 0.1487 weight of about 0.07 lbs/ft, e.g., in some embodiments the lbs/ft. In another variation, “ship out” uncured has a nominal nominal density can be about 0.85 lbs/ft and the nominal density of about 1.8 lbs/ft and a nominal weight of about 0.1 weight can be about 0.0708 lbs/ft. In another variation, pipe lbs/ft, e.g., in some embodiments the nominal density can be insulation-uncured has a nominal density of about 0.8 lbs/ft about 1.84 lbs/ft and thenominal weight can be about 0.1530 and a nominal weight of about 0.07 lbs/ft, e.g., in some lbs/ft. In another variation, “ship out” uncured has a nominal embodiments the nominal density can be about 0.85 lbs/ft density of about 1.9 lbs/ft and a nominal weight of about 0.1 and the nominal weight can be about 0.0736 lbs/ft. US 2009/03249 15 A1 Dec. 31, 2009

0.074. In another illustrative embodiment, the uncured tions where thermal and/or acoustical efficiency is required. binders described herein can be used as glass fiber binders in Thermal conductivity and acoustical properties for acoustical uncured fiberglass insulation products exemplified by filter board insulation are determined in accordance with ASTM tube insulation-uncured. Filter tube insulation-uncured is C177 and ASTM C423 (Type A Mounting), respectively. manufactured as a rolled-up blanket including glass fibers Thickness and/or density are determined in accordance with that are loosely bonded together with a thermosetting binder. ASTMC 167. Acoustical board insulation typically requires This insulation is typically an in-process material, which is a nominal fiber diameter of about 20-about 3 ht for less than shipped in a wet and uncured state to be further processed by about 3 lb/ft density board, and about 27tabout 3 ht for heat curing into varying densities and dimensions of cured greater than or equal to 3 lbs/ft density board, and nominal filter tube insulation, which insulation has specific thermal loss on ignition of about 11+about 2%. performance requirements (see cured pipe insulation embodi 0079. In one illustrative variation, acoustical board insu ment below). Thickness and/or density are determined in lation has a density of about 2 lbs/ft, a nominal thickness of accordance with ASTMC 167. Filter tube insulation-uncured about 1 in, 1.5 in, 2 in, 2.5 in, 3 in, 3.5 in, and 4 in, and a insulation typically requires a nominal moisture content of thermal conductivity of about 0.24 BTU in/hr ft F. at 75° F., about 3+about 2.0/-about 1.0%, a nominal binder content of about 0.25 BTU in/hr ft F. at 100°F., about 0.33 BTU in/hr about 10-about 1.0%, and a nominal fiber diameter of about ft. F. at 2009 F., and about 0.42 BTU in/hr ft F. at 300° F., 27-about 4 ht. e.g., in such embodiments the density can be about 1.6 lbs/ft. 0075. In one illustrative variation, filter tube insulation In another variation, acoustical board insulation has a density uncured has a nominal density of about 0.8 lbs/ft and a of about 2 lbs/ft, a nominal thickness of about 1 in, 1.5 in, 2 nominal weight of about 0.07 lbs/ft, e.g., in some embodi in, 2.5 in, 3 in, 3.5 in, and 4 in, and a noise reduction coeffi ments the nominal density can be about 0.85 lbs/ft and the cient of about 0.65 at 1-in thickness, about 0.85 at 1.5-in nominal weight can be about 0.0708 lbs/ft. In another varia thickness, and about 0.95 at 2-in thickness, e.g., in Such tion, filter tube insulation-uncured has a nominal density of embodiments the density can be about 2.25 lbs/ft. In another about 0.8 lbs/ft and a nominal weight of about 0.07 lbs/ft, variation, acoustical board insulation has a density of about 3 e.g., in some embodiments the nominal density can be about lbs/ft, a nominal thickness of about 1 in, 1.5 in, 2 in, 2.5 in, 0.85 lbs/ft and the nominal weight can be about 0.0736 3 in, 3.5 in, and 4 in, a thermal conductivity of about 0.23 1bs/ft. BTU in/hr ft F. at 75° F., about 0.24 BTU in/hrift F. at 100° 0076. It should be understood that the aqueous binders F., about 0.29 BTU in/hr ft F. at 2009 F., about 0.37 BTU described herein can be cured, and that drying and curing may in/hr ft F. at 300° F., and a noise reduction coefficient of occur either sequentially, contemporaneously, or concur about 0.65 at 1-in thickness, about 0.85 at 1.5-in thickness, rently. For example, any of the above-described aqueous and about 1.00 at 2-in thickness. In another variation, acous binders can be disposed (e.g., sprayed) on the material to be tical board insulation has a density of about 4 lbs/ft, a nomi bound, and then heated. Illustratively, in the case of making nal thickness of about 1 in, 1.5 in, 2 in, and 2.5 in, and a noise fiberglass insulation products, after the aqueous binder has reduction coefficient of about 0.75 at 1-in thickness, e.g., in been applied to the mat, the binder-coated mat is immediately such embodiments the density can be about 4.25 lbs/ft. In or eventually transferred to a curing oven (eventual transfer is another variation, acoustical board insulation has a density of typical when additional components, such as various types of about 6 lbs/ft, a nominal thickness of about 1 in, 1.5 in, and oversprays and porous glass fiber facings, for example, are 2 in, a thermal conductivity of about 0.22 BTU in/hr ft F. at added to the binder-coated mat prior to curing). In the curing 75°F., about 0.23 BTU in/hr ft F. at 100°F., about 0.27 BTU oven the mat is heated (e.g., from about 300°F. to about 600° in/hr ft F. at 2009 F., about 0.34 BTU in/hr ft F. at 300°F. F.) and the binder is cured. The cured binder is a formalde and a noise reduction coefficient of about 0.80 at 1-in thick hyde-free, water-resistant thermoset binder that attaches the ness, about 0.90 at 1.5-in thickness, and about 1.00 at 2-in glass fibers of the mat together. The mat of fiberglass may be thickness. processed to form one of several types offiberglass materials, 0080. In another illustrative embodiment, the cured bind Such as fiberglass insulation products. ers described herein can be used as glass fiber binders in a 0077. It should be appreciated that materials including a cured fiberglass insulation product exemplified by acoustical collection of glass fibers bonded with the binders of the board-black. Acoustical board-black is an acoustical insula present invention may have a density in the range from about tion product including glass fibers that are preformed into 0.4 lbs/ft to about 6 lbs/ft. It should also be appreciated that boards and bonded with a thermoset binder. This product has Such materials may have an R-value in the range from about a black overspray applied to provide a tough finish with a dark 2 to about 60. Further, it should be appreciated that such Surface. Acoustical board-black may be used on walls and materials may have a noise reduction coefficient in the range ceilings when reduction of airborne sound transmission is from about 0.45 to about 1.10. desired, where system design requires a rigid product, and 0078. In one illustrative embodiment, the cured binders where additional strength and abuse resistance are required. described herein can be used as glass fiber binders in a cured Acoustical properties for acoustical board-black are deter fiberglass insulation product exemplified by acoustical board mined in accordance with ASTM C423 (Type A Mounting). insulation. Acoustical board insulation is a thermal and Thickness and/or density are determined in accordance with acoustical insulation product including glass fibers that are ASTM C 167. Acoustical board-black typically requires a preformed into boards and bonded with a thermoset binder. nominal fiber diameter of about 33+about 2 ht, and an over This product may be manufactured plain, or faced with white spray of black dye applied to the top of the product. mat, factory-applied foil-scrim-kraft (FSK), white poly 0081. In one illustrative variation, acoustical board-black scim-kraft (PSK), or all-service-jacket (ASJ) facings. Acous has a density of about 2 lbs/ft, a nominal thickness of about tical board insulation may be used in ceiling panels, wall 1.5 in and 2 in, and a noise reduction coefficient of about 0.95 treatments, Sound baffles, office dividers, and other applica at 2-in thickness, e.g., in Such embodiments the density can be US 2009/03249 15 A1 Dec. 31, 2009 about 2.25 lbs/ft. In another variation, acoustical board Thermal conductivity and acoustical properties for cured black has a density of about 3 lbs/ft, a nominal thickness of blanket insulation are determined in accordance with ASTM about 1 in, 1.5 in, 2 in, and 3 in, and a noise reduction C518 (75° F. mean temperature) and ASTM C423 (Type A coefficient of about 0.65 at 1-inthickness, about 0.85 at 1.5-in Mounting), respectively. Thickness and/or density are deter thickness, and about 0.95 at 2-in thickness. In another varia mined in accordance with ASTMC 167. Cured blanket insu tion, acoustical board-black has a density of about 4 lbs/ft, a lation typically requires a nominal fiber diameter of about nominal thickness of about 1 in, 1.5 in, 2 in, and 3 in, and a 20-tabout 2 ht or about 22-tabout 2 ht, and nominal loss on square foot weight of about 0.3 lbs/ft, about 0.5 lbs/ft, about ignition of about 10-about 1%. 0.7 lbs/ft, and about 1.0 lbs/ft, respectively, e.g., in such 0085. In one illustrative variation, cured blanket insulation embodiments the density can be about 4.25 lbs/ft and the has a density of about 0.8 lbs/ft, a nominal thickness of about square foot weight can be 0.3542 lbs/ft, 0.5313 lbs/ft, 1 in, 1.5 in, and 2 in, a thermal conductivity of about 0.30 0.7083 lbs/ft, and 1.0625 lbs/ft, respectively. BTU in/hrft F. at 75° F., and a noise reduction coefficient of 0082 In another illustrative embodiment, the cured bind about 0.70 at 1.5-in thickness, e.g., in such embodiments the ers described herein can be used as glass fiber binders in a density can be about 0.75 lbs/ft. In another variation, cured cured fiberglass insulation product exemplified by acoustical blanket insulation has a density of about 1 lbs/ft, a nominal board-Smooth. Acoustical board-Smooth is a thermal and thickness of about 1 in, 1.5 in, and 2 in, athermal conductivity acoustical insulation product including glass fibers that are of about 0.28 BTU in/hrift F. at 75° F., and a noise reduction preformed into boards and bonded with a thermoset binder. coefficient of about 0.65 at 1-in thickness. In another varia Acoustical board-Smooth is Smooth on one side with preci tion, cured blanket insulation has a density of about 1 lbs/ft. Sion-cut tolerances. Products with a density ranging from a nominal thickness of about 0.5 in, 0.75 in, 1 in, and 1.5 in, about 3 lbs/ft to about 6 lbs/ft, and a thickness of about 1 in a thermal conductivity of about 0.26 BTU in/hr ft F. at 75° or greater have a smooth Surface made from the manufactur F., and a noise reduction coefficient of about 0.60 at 0.5-in ing process. Products less than about 1-in thick are bisected. thickness, e.g., in Such embodiments the density can be about Acoustical board-Smooth may be used in thermal and acous 1.5 lbs/ft. In another variation, cured blanket insulation has a tical applications such as office partitions, interior panels, and density of about 2 lbs/ft, a nominal thickness of about 0.5 in, Sound baffles. Thermal conductivity and acoustical properties 0.75 in, and 1 in, a thermal conductivity of about 0.24 BTU for acoustical board-Smooth are determined in accordance in/hrift F. at 75° F., and anoise reduction coefficient of about with ASTM C518 (75° F. mean temperature) and ASTM 0.65 at 0.75-in thickness. In another variation, cured blanket C423 (Type A Mounting), respectively. Thickness and/or insulation has a density of about 2.5 lbs/ft, a nominal thick density are determined in accordance with ASTM C 167. ness of about 0.5 in, a thermal conductivity of about 0.23 BTU Acoustical board-Smooth typically requires a nominal fiber in/hrift F. at 75° F., and a noise reduction coefficient of about diameter of about 34tabout 3 ht, and nominal loss on ignition 0.60 at 0.5-in thickness. of about 17-about 2%. 0086. In another illustrative embodiment, the cured bind 0083. In one illustrative variation, acoustical board ers described herein can be used as glass fiber binders in a smooth has a density of about 3 lbs/ft, a nominal thickness of cured fiberglass insulation product exemplified by black dif about 1 in, 1.5 in, 2 in, and 3 in, a thermal conductivity of fuserboard. Black diffuserboard is a thermal and acoustical about 0.23 BTU in/hr ft F. at 75° F., and a noise reduction insulation product including glass fibers that are preformed coefficient of about 0.65 at 1-inthickness, about 0.85 at 1.5-in into heavy density boards and bonded with a thermoset thickness, about 1.00 at 2-in thickness, and about 1.10 at 3-in binder. The product can be bottom-faced with foil-scrim-kraft thickness. In another variation, acoustical board-Smooth has a (FSK) facing, and it has a black overspray applied to the air density of about 4 lbs/ft, a nominal thickness of about 0.5 in, stream surface to provide a tough finish with a dark Surface. 1 in, 1.5 in, and 2 in, a thermal conductivity of about 0.23 Black diffuser board may be used as an interior insulation BTU in/hrft F. at 75° F., and a noise reduction coefficient of material for heating, ventilating, and air conditioning diffus about 0.75 at 1-in thickness, e.g., in such embodiments the ers as well as other air distribution components. It offers a density can be about 4.25 lbs/ft. In another variation, acous combination of Sound absorption, low thermal conductivity, tical board-smooth has a density of about 6 lbs/ft, a nominal and minimal air Surface friction for systems operating at thickness of about 0.5 in, 1 in, 1.5 in, and 2 in, a thermal temperatures up to about 250 F. and velocities up to about conductivity of about 0.22 BTU in/hr ft F. at 75° F., and a 5,000 fpm. Thermal properties and acoustical properties for noise reduction coefficient of about 0.80 at 1-in thickness, black diffuser board are determined in accordance with about 0.90 at 1.5-in thickness, and about 1.00 at 2-in thick ASTM C177 (75° F mean temperature) and ASTM C423 CSS. (Type A Mounting), respectively. Thickness and/or density 0084. In another illustrative embodiment, the cured bind are determined in accordance with ASTMC 167. Black dif ers described herein can be used as glass fiber binders in a fuser board typically requires a nominal fiber diameter of cured fiberglass insulation product exemplified by cured about 33+about 2 ht, a nominal loss on ignition of about blanket insulation, which product may be referred to as 13+about 2%, and an overspray of black dye applied to the top “amber blanket' when binders other than those of the present of the product. invention are used. Cured blanket insulation is a uniformly 0087. In one illustrative variation, black diffuserboard has textured, resilient, thermal insulating and sound absorbing a density of about 3 lbs/ft, a nominal thickness of about 1 in, material including glass fibers bonded with a thermoset 1.4 in, 1.9 in, and 2 in, a thermal conductivity of about 0.23 binder. This product has sufficient tensile strength to allow for BTU in/hr ft F. at 1-in thickness, about 0.15 BTU in/hr ft die-cutting, fabrication, lamination, and installation in OEM F. at 1.5-in thickness, about 0.11 BTU in/hr ft F. at 2-in applications. Cured blanket insulation may be used as thermal thickness, and a noise reduction coefficient of about 0.65 at and/or acoustical insulation for appliance, equipment, indus 1-in thickness, about 0.85 at 1.5-in thickness, and about 0.95 trial, commercial, and marine applications up to about 650°F. at 2-in thickness. In another variation, black diffuser board US 2009/03249 15 A1 Dec. 31, 2009

has a density of about 4 lbs/ft, a nominal thickness of about 0090. In another illustrative embodiment, the cured bind 1 in and 1.4 in, and a square foot weight of about 0.3 lbs/ft ers described herein can be used as glass fiber binders in a and 0.4 lbs/ft, respectively, e.g., in such embodiments the cured fiberglass insulation product exemplified by JET square foot weight can be about 0.3333 lbs/ft and 0.4583 STREAM loose-fill blowing insulation. JET STREAM lbs/ft, respectively. loose-fill blowing insulation typically includes unbonded 0088. In another illustrative embodiment, the cured bind fiberglass with a nominal fiber diameter and nominal fiber ers described herein can be used as glass fiber binders in a length, however, such fiberglass may be bonded with the cured fiberglass insulation product exemplified by SUMMIT cured thermoset binders described herein and subsequently loose-fill blowing insulation. SUMMIT loose-fill blowing cut apart (shredded) in, for example, a hammer mill, to be used in loose-fill blowing insulation.JET STREAM loose-fill insulation typically includes unbonded fiberglass with a blowing insulation may be used for loose-fill thermal insula nominal fiber diameter and nominal fiber length, however, tion applications in attics, sidewalls, and floors, and is applied such fiberglass may be bonded with the cured thermoset with a pneumatic blowing machine. The product is typically binders described herein and subsequently cut apart (shred sprayed with silicone, dedusting oil, and anti-static agents in ded) in, for example, a hammer mill, to be used in loose-fill order to improve blowing properties and performance. Ther blowing insulation. SUMMIT loose-fill blowing insulation mal resistance properties for JET STREAM loose-fill blow may be used for loose-fill thermal insulation applications in ing insulation are determined in accordance with ASTM attics, sidewalls, and floors, and is applied with a pneumatic C687 using ASTM C518. JET STREAM loose-fill blowing blowing machine. The product is typically sprayed with sili insulation typically requires a nominal average fiber diameter cone, dedusting oil, and anti-static agents in order to improve of about 7.5+about 1.5 ht, a nominal fiber length of about blowing properties and performance. Thermal resistance 0.75+about 0.25 in, nominal loss on ignition of about properties for SUMMIT loose-fill blowing insulation are 1.25tabout 0.4%, and a nominal density of about 0.5 lbs/ft. determined in accordance with ASTM C687 using ASTM 0091. In one illustrative variation, JET STREAM loose C518. SUMMIT loose-fill blowing insulation typically fill blowing insulation with an R-value of about 60 requires an requires a nominal average fiber diameter of about 9-tabout installed minimum square foot weight of about 1 lbs/ft and 1.5 ht, a nominal fiber length of about 0.75+about 0.25 in, an installed minimum thickness of about 19.7 in. In another nominal loss on ignition of about 1.5+about 0.5%, and a variation, JET STREAM loose-fill blowing insulation with an nominal density of about 0.5 lbs/ft. R-value of about 49 requires an installed minimum square 0089. In one illustrative variation, SUMMIT loose-fill foot weight of about 0.8 lbs/ft and an installed minimum blowing insulation with an R-value of about 60 requires an thickness of about 16.5 in. In another variation, JET installed minimum square foot weight of about 1 lbs/ft and STREAM loose-fill blowing insulation with an R-value of an installed minimum thickness of about 23.5 in. In another about 44 requires an installed minimum square foot weight of variation, SUMMIT loose-fill blowing insulation with an about 0.7 lbs/ft and an installed minimum thickness of about R-value of about 49 requires an installed minimum square 14.8 in. In another variation, JET STREAM loose-fill blow foot weight of about 0.8 lbs/ft and an installed minimum ing insulation with an R-value of about 38 requires an thickness of about 19.5 in. In another variation, SUMMIT installed minimum square foot weight of about 0.6 lbs/ft and loose-fill blowing insulation with an R-value of about 44 an installed minimum thickness of about 13 in. In another requires an installed minimum square foot weight of about variation, JET STREAM loose-fill blowing insulation with an 0.7 lbs/ft and an installed minimum thickness of about 17.7 R-value of about 30 requires an installed minimum square in. In another variation, SUMMIT loose-fill blowing insula foot weight of about 0.4 lbs/ft and an installed minimum tion with an R-value of about 38 requires an installed mini thickness of about 10.2 in. In another variation, JET mum square foot weight of about 0.6 lbs/ft and an installed STREAM loose-fill blowing insulation with an R-value of minimum thickness of about 15.5 in. In another variation, about 26 requires an installed minimum square foot weight of SUMMIT loose-fill blowing insulation with an R-value of about 0.4 lbs/ft and an installed minimum thickness of about about 30 requires an installed minimum square foot weight of 9 in. In another variation, JET STREAM loose-fill blowing about 0.5 lbs/ft and an installed minimum thickness of about insulation with an R-value of about 22 requires an installed 12.5 in. In another variation, SUMMIT loose-fill blowing minimum square foot weight of about 0.3 lbs/ft and an insulation with an R-value of about 26 requires an installed installed minimum thickness of about 7.8 in. In another varia minimum square foot weight of about 0.4 lbs/ft and an tion, JET STREAM loose-fill blowing insulation with an installed minimum thickness of about 11 in. In another varia R-value of about 19 requires an installed minimum square tion, SUMMIT loose-fill blowing insulation with an R-value foot weight of about 0.3 lbs/ft and an installed minimum of about 22 requires an installed minimum square foot weight thickness of about 6.8 in. In another variation, JET STREAM of about 0.3 lbs/ft and an installed minimum thickness of loose-fill blowing insulation with an R-value of about 13 about 9.3 in. In another variation, SUMMIT loose-fill blow requires an installed minimum square foot weight of about ing insulation with an R-value of about 19 requires an 0.2 lbs/ft and an installed minimum thickness of about 4.8 in. installed minimum square foot weight of about 0.3 lbs/ft and In another variation, JET STREAM loose-fill blowing insu an installed minimum thickness of about 8 in. In another lation with an R-value of about 11 requires an installed mini variation, SUMMIT loose-fill blowing insulation with an mum square foot weight of about 0.1 lbs/ft and an installed R-value of about 13 requires an installed minimum square minimum thickness of about 4 in. foot weight of about 0.2 lbs/ft and an installed minimum 0092. In another illustrative embodiment, the cured bind thickness of about 5.8 in. In another variation, SUMMIT ers described herein can be used as glass fiber binders in a loose-fill blowing insulation with an R-value of about 11 cured fiberglass insulation product exemplified by Medium requires an installed minimum square foot weight of about density loose-fill blowing (blue-label) insulation. Medium 0.21bs/ft and an installed minimum thickness of about 4.8 in. density loose-fill blowing insulation includes off-grade fiber US 2009/03249 15 A1 Dec. 31, 2009

glass batts and rolls that have been shredded (e.g., in a an installed minimum thickness of about 5.2 in, e.g., in Such hammer mill) into Small nodules. It is not composed of embodiments the installed minimum square foot weight can uncured, undercured, or overcured material, or material with be about 0.240 lbs/ft. density greater than about 1 lb/ft. Medium-density loose-fill 0094. In another illustrative embodiment, the cured bind blowing insulation may be used for loose-fill thermal insula ers described herein can be used as glass fiber binders in a tion applications in attics, sidewalls, and floors, and is applied cured fiberglass insulation product exemplified by Low-den with a pneumatic blowing machine. Thermal resistance prop sity loose-fill blowing (orange-label) insulation. Low-density erties for Medium-density loose-fill blowing insulation are loose-fill blowing insulation includes off-grade fiberglass determined in accordance with ASTM C687 using ASTM batts and rolls of residential insulation that have been shred C518. Medium-density loose-fill blowing insulation typi ded (e.g., in a hammer mill) into Small nodules. It is not cally requires golfball-size nodules and a nominal density of composed of uncured, undercured, or overcured material, or about 0.6 lbs/ft. material with density greater than about 1 lb/ft. Low-density 0093. In one illustrative variation, Medium-density loose loose-fill blowing insulation may be used for loose-fill ther mal insulation applications in attics, sidewalls, and floors, and fill blowing insulation with an R-value of about 60 requires an is applied with a pneumatic blowing machine. Thermal resis installed minimum square foot weight of about 1.4 lbs/ft and tance properties for Low-density loose-fill blowing insulation an installed minimum thickness of about 23.5 in, e.g., in Such are determined in accordance with ASTMC687 using ASTM embodiments the installed minimum square foot weight can C518. Low-density loose-fill blowing insulation typically be about 1.447 lbs/ft. In another variation, Medium-density requires golfball-size nodules and a nominal density of about loose-fill blowing insulation with an R-value of about 49 0.5 lbs/ft. requires an installed minimum square foot weight of about 0095. In one illustrative variation, Low-density loose-fill 1.2 lbs/ft and an installed minimum thickness of about 20.2 blowing insulation with an R-value of about 60 requires an in, e.g., in Such embodiments the installed minimum square installed minimum square foot weight of about 1.3 lbs/ft and foot weight can be about 1.190 lbs/ft. In another variation, an installed minimum thickness of about 27.5 in, e.g., in Such Medium-density loose-fill blowing insulation with an embodiments the installed minimum square foot weight can R-value of about 44 requires an installed minimum square be about 1.311 lbs/ft. In another variation, Low-density foot weight of about 1.0 lbs/ft and an installed minimum loose-fill blowing insulation with an R-value of about 49 thickness of about 18 in, e.g., in Such embodiments the requires an installed minimum square foot weight of about installed minimum square foot weight can be about 1.022 1.0 lbs/ft and an installed minimum thickness of about 23 in, lbs/ft. In another variation, Medium-density loose-fill blow e.g., in Such embodiments the installed minimum square foot ing insulation with an R-value of about 38 requires an weight can be about 1.046 lbs/ft. In another variation, Low installed minimum square foot weight of about 0.9 lbs/ft and density loose-fill blowing insulation with an R-value of about an installed minimum thickness of about 16 in, e.g., in Such 44 requires an installed minimum square foot weight of about embodiments the installed minimum square foot weight can 0.91bs/ft and an installed minimum thickness of about 21 in, be about 0.881 lbs/ft. In another variation, Medium-density e.g., in Such embodiments the installed minimum square foot loose-fill blowing insulation with an R-value of about 30 weight can be about 0.935 lbs/ft. In another variation, Low requires an installed minimum square foot weight of about density loose-fill blowing insulation with an R-value of about 0.7 lbs/ft and an installed minimum thickness of about 13 in, 38 requires an installed minimum square foot weight of about e.g., in Such embodiments the installed minimum square foot 0.8 lbs/ft and an installed minimum thickness of about 18.5 weight can be about 0.682 lbs/ft. In another variation, in, e.g., in Such embodiments the installed minimum square Medium-density loose-fill blowing insulation with an foot weight can be about 0.801 lbs/ft. In another variation, R-value of about 26 requires an installed minimum square Low-density loose-fill blowing insulation with an R-value of foot weight of about 0.6 lbs/ft and an installed minimum about 30 requires an installed minimum square foot weight of thickness of about 11.2 in, e.g., in Such embodiments the about 0.6 lbs/ft and an installed minimum thickness of about installed minimum square foot weight can be about 0.573 15 in, e.g., in Such embodiments the installed minimum lbs/ft. In another variation, Medium-density loose-fill blow square foot weight can be about 0.624 lbs/ft. In another ing insulation with an R-value of about 22 requires an variation, Low-density loose-fill blowing insulation with an installed minimum square foot weight of about 0.5 lbs/ft and R-value of about 26 requires an installed minimum square an installed minimum thickness of about 9.7 in, e.g., in Such foot weight of about 0.5 lbs/ft and an installed minimum embodiments the installed minimum square foot weight can thickness of about 13 in, e.g., in Such embodiments the be about 0.484 lbs/ft. In another variation, Medium-density installed minimum square foot weight can be about 0.528 loose-fill blowing insulation with an R-value of about 19 lbs/ft. In another variation, Low-density loose-fill blowing requires an installed minimum square foot weight of about insulation with an R-value of about 22 requires an installed 0.4 lbs/ft and an installed minimum thickness of about 8.5 in, minimum square foot weight of about 0.4 lbs/ft and an e.g., in Such embodiments the installed minimum square foot installed minimum thickness of about 11.2 in, e.g., in Such weight can be about 0.413 lbs/ft. In another variation, embodiments the installed minimum square foot weight can Medium-density loose-fill blowing insulation with an be about 0.447 lbs/ft. In another variation, Low-density R-value of about 13 requires an installed minimum square loose-fill blowing insulation with an R-value of about 19 foot weight of about 0.3 lbs/ft and an installed minimum requires an installed minimum square foot weight of about thickness of about 6 in, e.g., in Such embodiments the 0.4 lbs/ft and an installed minimum thickness of about 10 in, installed minimum square foot weight can be about 0.279 e.g., in Such embodiments the installed minimum square foot lbs/ft. In another variation, Medium-density loose-fill blow weight can be about 0.392 lbs/ft. In another variation, Low ing insulation with an R-value of about 11 requires an density loose-fill blowing insulation with an R-value of about installed minimum square foot weight of about 0.2 lbs/ft and 13 requires an installed minimum square foot weight of about US 2009/03249 15 A1 Dec. 31, 2009

0.3 lbs/ft and an installed minimum thickness of about 7 in, 0.5 lbs/ft and an installed minimum thickness of about 8.2in, e.g., in Such embodiments the installed minimum square foot e.g., in Such embodiments the installed minimum square foot weight can be about 0.264 lbs/ft. In another variation, Low weight can be about 0.484 lbs/ft. In another variation, High density loose-fill blowing insulation with an R-value of about density loose-fill blowing insulation with an R-value of about 11 requires an installed minimum square foot weight of about 13 requires an installed minimum square foot weight of about 0.2 lbs/ft and an installed minimum thickness of about 6 in, 0.3 lbs/ft and an installed minimum thickness of about 5.7 in, e.g., in Such embodiments the installed minimum square foot e.g., in Such embodiments the installed minimum square foot weight can be about 0.223 lbs/ft. weight can be about 0.328 lbs/ft. In another variation, High 0096. In another illustrative embodiment, the cured bind density loose-fill blowing insulation with an R-value of about ers described herein can be used as glass fiber binders in a 11 requires an installed minimum square foot weight of about cured fiberglass insulation product exemplified by High-den 0.3 lbs/ft and an installed minimum thickness of about 5 in, sity loose-fill blowing (purple-label) insulation. High-density e.g., in Such embodiments the installed minimum square foot loose-fill blowing insulation includes off-grade fiberglass weight can be about 0.283 lbs/ft. batts, blankets, and rolls (produced from large, high-strength 0098. In another illustrative embodiment, the cured bind fibers) that have been shredded (e.g., in a hammer mill) into ers described herein can be used as glass fiber binders in a Small nodules. It is not composed of uncured, undercured, or cured fiberglass insulation product exemplified by PERIM overcured material, or material with density greater than ETER PLUS loose-fill blowing insulation. PERIMETER about 1 lb/ft. High-density loose-fill blowing insulation may PLUS loose-fill blowing insulation typically includes be used for loose-fill thermal insulation applications in attics, unbonded fiberglass with a nominal fiber diameter and nomi sidewalls, and floors, and is applied with a pneumatic blowing nal fiber length, however, such fiberglass may be bonded with machine. Thermal resistance properties for High-density the cured thermoset binders described herein and subse loose-fill blowing insulation are determined in accordance quently cut apart (shredded) in, for example, a hammer mill, with ASTMC687 using ASTM C518. High-density loose-fill to be used in loose-fill blowing insulation. PERIMETER blowing insulation typically requires golf ball-size nodules PLUS loose-fill blowing insulation may be used for loose-fill and a nominal density of about 0.7 lbs/ft. thermal insulation applications in the sidewalls and/or other 0097. In one illustrative variation, High-density loose-fill closed cavities of framed buildings where ventilation is not blowing insulation with an R-value of about 60 requires an required, and is applied with a pneumatic blowing machine. installed minimum square foot weight of about 1.6lbs/ft and The product is typically sprayed with silicone, dedusting oil, an installed minimum thickness of about 24 in, e.g., in such and anti-static agents in order to improve blowing properties embodiments the installed minimum square foot weight can and performance, and is installed behind approved netting. be about 1.647 lbs/ft. In another variation, High-density Thermal resistance properties for PERIMETER PLUS loose loose-fill blowing insulation with an R-value of about 49 fill blowing insulation are determined in accordance with requires an installed minimum square foot weight of about ASTMC687 using ASTM C518. PERIMETER PLUS loose 1.3 lbs/ft and an installed minimum thickness of about 20 in, fill blowing insulation typically requires a nominal average e.g., in Such embodiments the installed minimum square foot fiber diameter of about 7.5+about 1.5 ht, a nominal fiber weight can be about 1.322 lbs/ft. In another variation, High length of about 0.5+about 0.5 in/-0 in, nominal loss on igni density loose-fill blowing insulation with an R-value of about tion of about 1.25+about 0.4%, and a nominal density of 44 requires an installed minimum square foot weight of about about 0.5 lbs/ft. 1.2 lbs/ft and an installed minimum thickness of about 18.2 0099. In one illustrative variation, PERIMETER PLUS in, e.g., in Such embodiments the installed minimum square loose-fill blowing insulation installed in a cavity depth of foot weight can be about 1.186 lbs/ft. In another variation, about 3.5 in (2x4 framing) at a density of about 2 lbs/ft, and High-density loose-fill blowing insulation with an R-value of a minimum weight per square foot of about 0.5 lbs/ft, about 38 requires an installed minimum square foot weight of achieves an R-value of about 15. In another variation, about 1.0 lbs/ft and an installed minimum thickness of about PERIMETER PLUS loose-fill blowing insulation installed in 16 in, e.g., in Such embodiments the installed minimum a cavity depth of about 5.5 in (2x6 framing) at a density of square foot weight can be about 1.017 lbs/ft. In another about 2 lbs/ft, and a minimum weight per square foot of variation, High-density loose-fill blowing insulation with an about 0.8 lbs/ft, achieves an R-value of about 23. In another R-value of about 30 requires an installed minimum square variation, PERIMETER PLUS loose-fill blowing insulation foot weight of about 0.8 lbs/ft and an installed minimum installed in a cavity depth of about 7.2 in (2x8 framing) at a thickness of about 12.7 in, e.g., in Such embodiments the density of about 2 lbs/ft, and a minimum weight per square installed minimum square foot weight can be about 0.784 foot of about 1.1 lbs/ft, achieves an R-value of about 31. In lbs/ft. In another variation, High-density loose-fill blowing another variation, PERIMETER PLUS loose-fill blowing insulation with an R-value of about 26 requires an installed insulation installed in a cavity depth of about 9.2 in (2x10 minimum square foot weight of about 0.7 lbs/ft and an framing) at a density of about 2 lbs/ft, and a minimumweight installed minimum thickness of about 11.2 in, e.g., in Such per square foot of about 1.4 lbs/ft achieves an R-value of embodiments the installed minimum square foot weight can about 39. be about 0.681 lbs/ft. In another variation, High-density 0100. In another illustrative embodiment, the cured bind loose-fill blowing insulation with an R-value of about 22 ers described herein can be used as glass fiber binders in a requires an installed minimum square foot weight of about cured fiberglass insulation product exemplified by air duct 0.6lbs/ft and an installed minimum thickness of about 9.5 in, board. Air duct board is a thermal and acoustical insulation e.g., in Such embodiments the installed minimum square foot product including glass fibers preformed into rigid, rectangu weight can be about 0.565 lbs/ft. In another variation, High lar boards bonded with a thermoset binder. Air duct board is density loose-fill blowing insulation with an R-value of about faced on the bottom with a foil-scrim-kraft (FSK) facing, and 19 requires an installed minimum square foot weight of about the air stream Surface is faced with a lightweight black mat. US 2009/03249 15 A1 Dec. 31, 2009

The mat facing is intended to improve the abuse resistance of R-value of about 6.5, a density of about 4 lbs/ft, a thermal the airstream Surface, lower the resistance to air flow, and conductivity of about 0.23 BTU in/hr ft F., and a noise improve the aesthetic appearance. Air duct board may be used reduction coefficient of about 0.95, e.g., in such embodiments in commercial and residential air handling installations, for the density can be about 3.75 lbs/ft. In another variation, air cooling, heating, or dual-temperature service at operating duct board (all glass mat) has a nominal thickness of about 2 temperatures ranging up to about 250 F., maximum air in, a flexural rigidity of about 800, and R-value of about 8.7, velocities of about 5000 fpm and about 2-in static pressure. a density of about 4 lbs/ft, a thermal conductivity of about Thermal resistance and acoustical properties for air duct 0.23 BTU in/hr ft F., and a noise reduction coefficient of board are determined in accordance with ASTM C518/ about 1.00, e.g., in Such embodiments the density can be ASTMC177 (at 75°F) and ASTM E477, respectively. Thick about 3.75 lbs/ft. ness and/or density are determined in accordance with ASTM C 167. Air duct board typically requires a nominal fiber 0104. In another illustrative embodiment, the cured bind diameter of about 32-tabout 2 ht, nominal loss on ignition of ers described herein can be used as glass fiber binders in a about 15+about 2%, and application of a black overspray cured fiberglass insulation product exemplified by housing air prior to thermal curing to adhere the non-woven mat to the duct board. Housing air duct board is a thermal insulation board. product including glass fibers preformed into rigid, rectangu 0101. In one illustrative variation, air duct board has a lar boards bonded with a thermoset binder. Housing air duct nominal thickness of about 1 in, a flexural rigidity of about board is faced on the bottom with a foil-scrim-kraft (FSK) 475, and R-value of about 4.3, a density of about 4.5 lbs/ft, a facing, and the air stream Surface is coated with an overspray thermal conductivity of about 0.23 BTU in/hr ft F., and a prior to thermal curing to increase the abuse resistance of the noise reduction coefficient of about 0.70. In another illustra airstream Surface. Housing air duct board may be used in tive variation, air duct board has a nominal thickness of about manufactured housing systems for dual-temperature service 1.5 in, a flexural rigidity of about 800, and R-value of about at operating temperatures ranging up to about 250 F. maxi 6.5, a density of about 3.8 lbs/ft, a thermal conductivity of mum air velocities of about 2400 fpm and about 2-in static about 0.23 BTU in?hrift F., and a noise reduction coefficient pressure. Thermal properties for housing air duct board are of about 0.95, e.g., in such embodiments the density can be determined in accordance with ASTM C518 and ASTMC177 about 3.75 lbs/ft. In another illustrative variation, air duct (at 75°F). Thickness and/or density are determined in accor board has a nominal thickness of about 2 in, a flexural rigidity dance with ASTM C 167. Housing air duct board typically of about 800, and R-value of about 8.7, a density of about 3.8 lbs/ft, and a thermal conductivity of about 0.23 BTU in/hr requires a nominal fiber diameter of about 35+about 2 ht, and ft F., e.g., in such embodiments the density can be about a nominal loss on ignition of about 15-about 2%. 3.75 lbs/ft. 0105. In one illustrative variation, housing air duct board 0102. In another illustrative embodiment, the cured bind has a nominal thickness of about 0.8 in, an R-value of about ers described herein can be used as glass fiber binders in a 3.5, a density of about 4.2 lbs/ft, a square foot weight of cured fiberglass insulation product exemplified by air duct about 0.3 lbs/ft, and a thermal conductivity of about 0.23 board (all glass mat). Air duct board (all glass mat) is a BTU in/hr ft F., e.g., in such embodiments the square foot thermal and acoustical insulation product including glass weight can be about 0.2846 lbs/ft. In another variation, hous fibers preformed into rigid, rectangular boards bonded with a ing air duct board has a nominal thickness of about 1 in, an thermoset binder. Air duct board (all glass mat) is faced on the R-value of about 4.0, a density of about 4.2 lbs/ft, a square bottom with a foil-scrim-kraft (FSK) facing, and the air foot weight of about 0.3 lbs/ft, and a thermal conductivity of stream Surface is faced with a lightweight white glass mat. about 0.23 BTU in/hr ft F., e.g., in such embodiments the The mat facing is intended to improve the abuse resistance of square foot weight can be about 0.3281 lbs/ft. the airstream Surface, lower the resistance to air flow, and 0106. In another illustrative embodiment, the cured bind improve the aesthetic appearance. Air duct board (all glass ers described herein can be used as glass fiber binders in a mat) may be used in commercial and residential air handling cured fiberglass insulation product exemplified by duct liner. installations, for cooling, heating, or dual-temperature ser Duct liner is a flexible edge-coated, mat-faced, thermal and Vice at operating temperatures ranging up to about 250 F., acoustical insulation product including glass fibers bonded maximum air velocities of about 5000 fpm and about 2-in with a thermoset binder. Duct liner is faced with a non-woven static pressure. Thermal resistance and acoustical properties black mat, providing the air stream side with a smooth, abuse for air duct board (all glass mat) are determined in accordance resistant Surface during installation and operation. The side with ASTM C518/ASTM C177 (at 750 F) and ASTM E477, edges are coated to reduce the need for “buttering of trans respectively. Thickness and/or density are determined in verse joints during fabrication. Duct liner may be used as an accordance with ASTMC 167. Air duct board (all glass mat) interior insulation material for sheet metal ducts in heating, typically requires a nominal fiber diameter of about 32=about ventilating, and air conditioning applications. It offers a com 2 ht, nominal loss on ignition of about 15-about 2%, and bination of Sound absorption, low thermal conductivity, and application of a yellow overspray prior to thermal curing to minimal air Surface friction characteristics for systems oper adhere the non-woven mat to the board. ating attemperatures up to about 250°F. and velocities up to 0103) In one illustrative variation, air duct board (all glass about 6000 fpm. Thermal resistance and acoustical properties mat) has a nominal thickness of about 1 in, a flexural rigidity for duct liner are determined in accordance with ASTM of about 475, and R-value of about 4.3, a density of about 4.4 C518/ASTMC177 as per ASTMC653 (at 75°F) and ASTM lbs/ft, athermal conductivity of about 0.23 BTU in/hr ft F., C423, respectively. Thickness and/or density are determined and a noise reduction coefficient of about 0.70. In another in accordance with ASTM C 167. Duct liner typically variation, air duct board (all glass mat) has a nominal thick requires a nominal fiber diameter of about 22-tabout 2 ht, and ness of about 1.5 in, a flexural rigidity of about 800, and nominal loss on ignition of about 17-tabout 2%. US 2009/03249 15 A1 Dec. 31, 2009

0107. In one illustrative variation, duct liner has a nominal equipment liner has a nominal thickness of about 1 in, a thickness of about 1 in, a nominal density of about 1.5 lbs/ft. nominal density of about 2 lbs/ft, a thermal conductivity of an R-value of about 4.2, a thermal conductivity of about 0.24 about 0.24 BTU in?hrift F., and a noise reduction coefficient BTU in/hr ft F., and a noise reduction coefficient of about of about 0.70. In another variation, equipment liner has a 0.70. In another variation, duct liner has a nominal thickness nominal thickness of about 1.5 in, a nominal density of about of about 1.5 in, a nominal density of about 1.5 lbs/ft, an 2 lbs/ft, a thermal conductivity of about 0.24 BTU in/hr ft R-value of about 6, athermal conductivity of about 0.16 BTU F., and a noise reduction coefficient of about 0.85. in/hr ft F., and a noise reduction coefficient of about 0.80. In 0110. In another illustrative embodiment, the cured bind another variation, duct liner has a nominal thickness of about ers described herein can be used as glass fiber binders in a 2 in, a nominal density of about 1.5 lbs/ft, an R-value of cured fiberglass insulation product exemplified by duct wrap about 8, a thermal conductivity of about 0.13 BTU in/hr ft insulation. Duct wrap insulation is a uniformly textured, resil F., and a noise reduction coefficient of about 0.90. In another ient, thermal insulating and Sound absorbing material includ variation, duct liner has a nominal thickness of about 0.5 in, a ing glass fibers that are bonded with a thermoset binder. Duct nominal density of about 2 lbs/ft, an R-value of about 2.1, a wrap insulation may be used to externally insulate air han thermal conductivity of about 0.48 BTU in/hr ft F., and a dling ducts for energy conservation and condensation control. noise reduction coefficient of about 0.45. In another variation, Duct wrap insulation may or may not have a facing. If faced, duct liner has a nominal thickness of about 1 in, a nominal facings may be foil-scrim-kraft (FSK), white or black poly density of about 2 lbs/ft, an R-value of about 4.2, a thermal scrim-kraft (PSK), or white or grey vinyl. Duct wrap insula conductivity of about 0.24 BTU in/hr ft F., and a noise tion may be used as external insulation on commercial or reduction coefficient of about 0.70. In another variation, duct residential heating or air conditioning ducts with an operating liner has a nominal thickness of about 1.5 in, a nominal temperature of about 45° F. to about 250 F. for faced prod density of about 2 lbs/ft, an R-value of about 6.3, a thermal ucts, and on commercial or residential heating ducts with a conductivity of about 0.16 BTU in/hr ft F., and a noise maximum operating temperature of about 350°F. for unfaced reduction coefficient of about 0.85. products. Thermal resistance properties for duct wrap insula 0108. In another illustrative embodiment, the cured bind tion are determined in accordance with ASTMC 177 (at 75° ers described herein can be used as glass fiber binders in a F.) and ASTM C518. Thickness and/or density are deter cured fiberglass insulation product exemplified by equipment mined in accordance with ASTM C 167. Faced duct wrap liner. Equipment liner is a flexible mat-faced, thermal and insulation typically requires a nominal fiber diameter of about acoustical insulation product including glass fibers bonded 18tabout 2ht; unfaced duct wrap typically requires a nominal with a thermoset binder. Equipment liner is faced with a fiber diameter of about 20-about 2 ht (nominal loss on igni non-woven black mat, providing the air stream side with a tion for both is about 7-about 1%). Smooth, abuse resistant Surface during installation and opera 0111 Illustratively, duct wrap insulation at a nominal den tion. Equipment liner may be used for OEM applications in sity of about 0.75 lbs/ft displays thermal conductivity (in heating, ventilating, and air conditioning applications. It BTU in/hr ft F.) as a function of mean temperature as offers a combination of Sound absorption, low thermal con follows: 50°F, 0.28; 75° F., 0.29; 100°F, 0.31: 125° F., 0.33; ductivity, and minimal air Surface friction characteristics for 150°F, 0.36; 175° F., 0.39; and 2009 F., 0.43. Illustratively, systems operating at temperatures up to about 250 F. and duct wrap insulation at a nominal density of about 1 lbs/ft velocities up to about 6000 fpm. Thermal resistance and displays thermal conductivity (in BTU in/hr ft F.) as a acoustical properties for equipment liner are determined in function of mean temperature as follows: 50°F, 0.26; 75° F., accordance with ASTM C177 (at 75° F.) and ASTM C423 0.27; 100°F, 0.29; 125° F., 0.31: 150°F, 0.34; 1759 F., 0.37; (Mounting A), respectively. Thickness and/or density are and 200° F., 0.40. Illustratively, duct wrap insulation at a determined in accordance with ASTM C 167. Equipment nominal density of about 1.5 lbs/ft displays thermal conduc liner typically requires a nominal fiber diameter of about tivity (in BTU in/hr ft F.) as a function of mean temperature 22-tabout 2 ht, and nominal loss on ignition of about as follows: 50° F., 0.23, 75° F., 0.24; 100° F., 0.26; 125° F., 17-about 2%. 028: 150°F, 0.31: 1759 F., 0.33; and 2009 F., 0.36. 0109. In one illustrative variation, equipment liner has a 0112. In one illustrative variation, duct wrap has a nominal nominal thickness of about 0.5 in, a nominal density of about thickness of about 1 in, a nominal density of about 0.75 1.5 lbs/ft, a thermal conductivity of about 0.25 BTU in/hr lbs/ft, an out-of-package R-value of about 3.4, and an ft F., and a noise reduction coefficient of about 0.45. In installed R-value (at 25% compression) of about 2.8. In another variation, equipment liner has a nominal thickness of another variation, duct wrap has a nominal thickness of about about 1 in, a nominal density of about 1.5 lbs/ft, a thermal 1.5 in, a nominal density of about 0.75 lbs/ft, an out-of conductivity of about 0.25 BTU in/hr ft F., and a noise package R-value of about 5.1, and an installed R-value (at reduction coefficient of about 0.70. In another variation, 25% compression) of about 4.2. In another/variation, duct equipment liner has a nominal thickness of about 1.5 in, a wrap has a nominal thickness of about 2 in, a nominal density nominal density of about 1.5 lbs/ft, athermal conductivity of of about 0.75 lbs/ft, an out-of-package R-value of about 6.8, about 0.25 BTU in/hrft F., and a noise reduction coefficient and an installed R-value (at 25% compression) of about 5.6. of about 0.80. In another variation, equipment liner has a In another variation, duct wrap has a nominal thickness of nominal thickness of about 2 in, a nominal density of about about 2.2 in, a nominal density of about 0.75 lbs/ft, an 1.5 lbs/ft, a thermal conductivity of about 0.25 BTU in/hr out-of-package R-value of about 7.4, and an installed R-value ft F., and a noise reduction coefficient of about 0.90. In (at 25% compression) of about 6. In another variation, duct another variation, equipment liner has a nominal thickness of wrap has a nominal thickness of about 2.5 in, a nominal about 0.5 in, a nominal density of about 2 lbs/ft, a thermal density of about 0.75 lbs/ft, an out-of-package R-value of conductivity of about 0.24 BTU in/hr ft F., and a noise about 8.5, and an installed R-value (at 25% compression) of reduction coefficient of about 0.45. In another variation, about 7. In another variation, duct wrap has a nominal thick US 2009/03249 15 A1 Dec. 31, 2009 ness of about 3 in, a nominal density of about 0.75 lbs/ft, an In another variation, elevated temperature board (850°F) out-of-package R-value of about 10.2, and an installed insulation has a nominal density of 2.8 lbs/ft, a nominal R-value (at 25% compression) of about 8.4. thickness of about 1.5 in, and a nominal weight of about 0.3 0113. In another variation, duct wrap has a nominal thick lbs/ft, e.g., in such embodiments the nominal weight can be ness of about 1 in, a nominal density of about 1 lbs/ft, an about 0.3500 lbs/ft. In another variation, elevated tempera out-of-package R-value of about 3.7, and an installed R-value ture board (850 F) insulation has a nominal density of 2.8 (at 25% compression) of about 3. In another variation, duct lbs/ft, a nominal thickness of about 1.7 in, and a nominal wrap has a nominal thickness of about 1.5 in, a nominal weight of about 0.4 lbs/ft, e.g., in such embodiments the density of about 1 lbs/ft, an out-of-package R-value of about nominal weight can be about 0.4083 lbs/ft. In another varia 5.6, and an installed R-value (at 25% compression) of about tion, elevated temperature board (850 F.) insulation has a 4.5. In another variation, duct wrap has a nominal thickness of nominal density of 2.8 lbs/ft, a nominal thickness of about 2 about 2 in, a nominal density of about 1 lbs/ft, an out-of in, and a nominal weight of about 0.5 lbs/ft, e.g., in such package R-value of about 7.4, and an installed R-value (at embodiments the nominal weight can be about 0.4667 lbs/ft. 25% compression) of about 6. In another variation, elevated temperature board (850°F) 0114. In another variation, duct wrap has a nominal thick insulation has a nominal density of 2.8 lbs/ft, a nominal ness of about 1 in, a nominal density of about 1.5 lbs/ft, an thickness of about 2.5 in, and a nominal weight of about 0.6 out-of-package R-value of about 4.1, and an installed R-value lbs/ft, e.g., in such embodiments the nominal weight can be (at 25% compression) of about 3.2. In another variation, duct about 0.5833 lbs/ft. In another variation, elevated tempera wrap has a nominal thickness of about 1.5 in, a nominal ture board (850 F) insulation has a nominal density of 2.8 density of about 1.5 lbs/ft, an out-of-package R-value of lbs/ft, a nominal thickness of about 3 in, and a nominal about 6.1, and an installed R-value (at 25% compression) of weight of about 0.7 lbs/ft, e.g., in such embodiments the about 4.8. In another variation, duct wrap has a nominal nominal weight can be about 0.7000 lbs/ft. In another varia thickness of about 2 in, a nominal density of about 1.5 lbs/ft, tion, elevated temperature board (850 F.) insulation has a an out-of-package R-value of about 8.2, and an installed nominal density of 2.8 lbs/ft, a nominal thickness of about 4 R-value (at 25% compression) of about 6.4. in, and a nominal weight of about 0.9 lbs/ft, e.g., in such 0115. In another illustrative embodiment, the cured bind embodiments the nominal weight can be about 0.9333 lbs/ft. ers described herein can be used as glass fiber binders in a 0119. In another illustrative embodiment, the cured bind cured fiberglass insulation product exemplified by elevated ers described herein can be used as glass fiber binders in a temperature board (850°F) insulation. Elevated temperature cured fiberglass insulation product exemplified by elevated board (850°F) insulation is a uniformly textured, resilient, temperature batt (1000°F) and blanket (1000°F) insulation. high temperature thermal insulating and Sound absorbing Elevated temperature batt (1000 F) and blanket (1000°F) material including glass fibers that are bonded with a high insulation is a uniformly textured, resilient, high temperature temperature thermoset binder. The thermoset binder mini thermal insulating and Sound absorbing material including mizes exothemmic temperature rise and protects against glass fibers that are bonded with a high-temperature thermo punking and fusing of the product when applied at maximum set binder. The thermoset binder minimizes exothermic tem operating temperature. The binder content of this product is perature rise and protects against punking and fusing of the related to maintaining the product’s rated temperature resis product when applied at maximum operating temperature. tance and reducing the Smoke and off-gassing generated dur The binder content of this product is related to maintaining ing the decomposition of the binder during product heat-up. the product's rated temperature resistance and reducing the 0116. This product may be used for high temperature Smoke and off-gassing generated during the decomposition applications for hot surface temperatures up to about 850°F. of the binder during product heat-up. This product may be at a maximum of about 6-in thickness with no heat-up cycle used for high temperature applications for hot surface tem required. Thermal properties for elevated temperature board peratures up to about 1000 F. at a maximum of about 6-in (850°F) insulation are determined in accordance with ASTM thickness with no heat-up cycle required. Thermal properties C 177. Thickness and/or density are determined in accor for elevated temperature batt (1000 F) and blanket (1000° dance with ASTM C 167. Elevated temperature board (850° F.) insulation are determined in accordance with ASTM F.) insulation typically requires a nominal fiber diameter of C177. Thickness and/or density are determined in accordance about 27tabout 3 ht, and a nominal loss on ignition of about with ASTMC 167. Elevated temperature batt (1000°F) and 6-about 1%. blanket (1000 F) insulation typically requires a nominal 0117 Illustratively, elevated temperature board (850°F) fiber diameter of about 22=about 2 ht, and a nominal loss on insulation at a nominal density of about 3 lbs/ft displays ignition of about 3-about 0.5%/+about 2%. thermal conductivity (in BTU in/hr ft F.) as a function of I0120 Illustratively, elevated temperature batt (1000°F) mean temperature as follows: 100° F., 0.25: 200° F., 0.33: and blanket (1000°F) insulationata nominal density of about 300° F., 0.40; 400° F., 0.49; and 500° F., 0.57, e.g., in such 2 lbs/ft displays thermal conductivity (in BTU in/hr ft F.) embodiments the nominal density can be about 2.8 lbs/ft. as a function of mean temperature as follows: 100°F., 0.24: 0118. In one illustrative variation, elevated temperature 2009 F., 0.33; 300°F, 0.44; 400° F., 0.57; and 500°F., 0.72, board (850°F) insulation has a nominal density of about 2.8 e.g., in Such embodiments the nominal density can be about lbs/ft, a nominal thickness of about 1 in, and a nominal 1.6 lbs/ft. weight of about 0.2 lbs/ft, e.g., in such embodiments the I0121. In one illustrative variation, elevated temperature nominal weight can be about 0.2333 lbs/ft. In another varia batt (1000°F.) and blanket (1000°F.) insulation has a nominal tion, elevated temperature board (850 F) insulation has a density of 1.6lbs/ft, a nominal thickness of about 1.5 in, and nominal density of 2.8 lbs/ft, a nominal thickness of about a nominal weight of about 0.2 lbs/ft, e.g., in such embodi 1.2 in, and a nominal weight of about 0.3 lbs/ft, e.g., in such ments the nominal weight can be about 0.2000 lbs/ft. In embodiments the nominal weight can be about 0.2917 lbs/ft. another variation, elevated temperature batt (1000 F) and US 2009/03249 15 A1 Dec. 31, 2009 blanket (1000 F) insulation has a nominal density of 1.6 about 0.4000 lbs/ft. In another variation, elevated tempera lbs/ft, a nominal thickness of about 2 in, and a nominal ture panel (1000 F) insulation has a nominal density of 2.4 weight of about 0.3 lbs/ft, e.g., in such embodiments the lbs/ft, a nominal thickness of about 2.25 in, and a nominal nominal weight can be about 0.2667 lbs/ft. In another varia weight of about 0.4 lbs/ft, e.g., in such embodiments the tion, elevated temperature batt (1000°F) and blanket (1000° nominal weight can be about 0.4500 lbs/ft. In another varia F.) insulation has a nominal density of 1.6 lbs/ft, a nominal tion, elevated temperature panel (1000 F) insulation has a thickness of about 2.5 in, and a nominal weight of about 0.3 nominal density of 2.4 lbs/ft, a nominal thickness of about lbs/ft, e.g., in such embodiments the nominal weight can be 2.5 in, and a nominal weight of about 0.5 lbs/ft, e.g., in such about 0.3333 lbs/ft. In another variation, elevated tempera embodiments the nominal weight can be about 0.5000 lbs/ft. ture batt (1000 F) and blanket (1000°F) insulation has a In another variation, elevated temperature panel (1000 F) nominal density of 1.6 lbs/ft, a nominal thickness of about 3 insulation has a nominal density of 2.4 lbs/ft, a nominal in, and a nominal weight of about 0.4 lbs/ft, e.g., in such thickness of about 3 in, and a nominal weight of about 0.6 embodiments the nominal weight can be about 0.4000 lbs/ft. lbs/ft, e.g., in such embodiments the nominal weight can be In another variation, elevated temperature batt (1000°F) and about 0.6000 lbs/ft. In another variation, elevated tempera blanket (1000 F) insulation has a nominal density of 1.6 ture panel (1000 F) insulation has a nominal density of 2.4 lbs/ft, a nominal thickness of about 3.5 in, and a nominal lbs/ft, a nominal thickness of about 3.5 in, and a nominal weight of about 0.5 lbs/ft, e.g., in such embodiments the weight of about 0.7 lbs/ft, e.g., in such embodiments the nominal weight can be about 0.4667 lbs/ft. In another varia nominal weight can be about 0.7000 lbs/ft. In another varia tion, elevated temperature batt (1000°F) and blanket (1000° tion, elevated temperature panel (1000 F) insulation has a F.) insulation has a nominal density of 1.6 lbs/ft, a nominal nominal density of 2.4 lbs/ft, a nominal thickness of about 4 thickness of about 4 in, and a nominal weight of about 0.5 in, and a nominal weight of about 0.8 lbs/ft, e.g., in such lbs/ft, e.g., in such embodiments the nominal weight can be embodiments the nominal weight can be about 0.8000 lbs/ft. about 0.5333 lbs/ft. In another variation, elevated temperature panel (1000 F) 0122. In another illustrative embodiment, the cured bind insulation has a nominal density of 2.4 lbs/ft, a nominal ers described herein can be used as glass fiber binders in a thickness of about 4.5 in, and a nominal weight of about 0.9 cured fiberglass insulation product exemplified by elevated lbs/ft, e.g., in such embodiments the nominal weight can be temperature panel (1000 F) insulation. Elevated tempera about 0.9000 lbs/ft. ture panel (1000 F) insulation is a uniformly textured, resil ient, high temperature thermal insulating and Sound absorb 0.125. In another illustrative embodiment, the cured bind ing material including glass fibers that are bonded with a ers described herein can be used as glass fiber binders in a high-temperature thermoset binder. The thermoset binder cured fiberglass insulation product exemplified by elevated minimizes exothermic temperature rise and protects against temperature fabrication board (850°F) insulation. Elevated punking and fusing of the product when applied at maximum temperature fabrication board (850°F) insulation is a uni operating temperature. The binder content of this product is formly textured, resilient, high temperature thermal insulat related to maintaining the product’s rated temperature resis ing and sound absorbing material including glass fibers that tance and reducing the Smoke and off-gassing generated dur are bonded with a high-temperature thermoset binder. The ing the decomposition of the binder during product heat-up. thermoset binder minimizes exothermic temperature rise and This product may be used for high temperature applications protects against punking and fusing of the product when for hot surface temperatures up to about 1000°F. at a maxi applied at maximum operating temperature. The binder con mum of about 6-in thickness with no heat-up cycle required. tent of this product is related to maintaining the product’s Thermal properties for elevated temperature panel (1000F.) rated temperature resistance and reducing the Smoke and insulation are determined in accordance with ASTM C 177. off-gassing generated during the decomposition of the binder Thickness and/or density are determined in accordance with during product heat-up. This product may be used for high ASTMC 167. Elevated temperature panel (1000°F) insula temperature applications (e.g., use by fabricators for the tion typically requires a nominal fiber diameter of about manufacture of pipe and tank insulation) for hot surface tem 22-tabout 2 ht, and a nominal loss on ignition of about peratures up to about 850 F. at a maximum of about 6-in 3-about 0.57+about 2%. thickness with no heat-up cycle required. Thermal properties (0123 Illustratively, elevated temperature panel (1000°F) insulation at a nominal density of about 2 lbs/ft displays for elevated temperature fabrication board (850°F) insula thermal conductivity (in BTU in/hr ft F.) as a function of tion are determined in accordance with ASTM C177. Thick mean temperature as follows: 100° F., 0.25: 200° F., 0.32: ness and/or density are determined in accordance with ASTM 300° F., 0.40; 400° F., 0.52; and 500° F., 0.68, e.g., in such C 167. Elevated temperature board (850°F) insulation typi embodiments the nominal density can be about 2.4 lbs/ft. cally requires a nominal fiber diameter of about 27-tabout 3 0.124. In one illustrative variation, elevated temperature ht, and a nominal loss on ignition of about 6-tabout 1%. panel (1000 F) insulation has a nominal density of 2.4 lbs/ 0.126 Illustratively, elevated temperature fabrication ft, a nominal thickness of about 1 in, and a nominal weight of board (850 F) insulation at a nominal density of about 3 about 0.2 lbs/ft, e.g., in such embodiments the nominal lbs/ft displays thermal conductivity (in BTU in/hr ft F.) as weight can be about 0.2000 lbs/ft. In another variation, a function of mean temperature as follows: 100°F., 0.25:200 elevated temperature panel (1000 F) insulation has a nomi F., 0.33:300°F., 0.40; 400°F., 0.49; and 500°F., 0.57, e.g., in nal density of 2.4 lbs/ft, a nominal thickness of about 1.5 in, such embodiments the nominal density can be about 2.8 and a nominal weight of about 0.3 lbs/ft, e.g., in such 1bs/ft. embodiments the nominal weight can be about 0.3000 lbs/ft. I0127. In one illustrative variation, elevated temperature In another variation, elevated temperature panel (1000 F) fabrication board (850°F) insulation has a nominal density of insulation has a nominal density of 2.4 lbs/ft, a nominal about 2.8 lbs/ft, a nominal thickness of about 4 in, and a thickness of about 2 in, and a nominal weight of about 0.4 nominal weight of about 0.9 lbs/ft, e.g., in such embodi lbs/ft, e.g., in such embodiments the nominal weight can be ments the nominal weight can be about 0.9333 lbs/ft. US 2009/03249 15 A1 Dec. 31, 2009

0128. In another illustrative embodiment, the cured bind 0.131. In another illustrative embodiment, the cured bind ers described herein can be used as glass fiber binders in a ers described herein can be used as glass fiber binders in a cured fiberglass insulation product exemplified by elevated cured fiberglass insulation product exemplified by flexible temperature blanket (1000°F.) insulation. Elevated tempera duct media. Flexible duct media is a uniformly textured, ture blanket (1000 F) insulation is a uniformly textured, resilient, thermal insulating and Sound absorbing material resilient, high temperature thermal insulating and sound including glass fibers that are bonded with a thermoset binder. absorbing material including glass fibers that are bonded with This product may be used in the manufacture of flexible duct a high-temperature thermoset binder. The thermoset binder insulation for air handling systems. Thermal properties for minimizes exothermic temperature rise and protects against flexible duct media are determined inaccordance with ASTM C177 and ASTM C653. Thickness and/or density are deter punking and fusing of the product when applied at maximum mined in accordance with ASTMC 167. Flexible duct media operating temperature. The binder content of this product is typically requires a nominal fiber diameter of about 20-about related to maintaining the product’s rated temperature resis 2 ht, and a nominal loss on ignition of about 6-tabout 1%. tance and reducing the Smoke and off-gassing generated dur I0132 Illustratively, flexible duct media displays Type I ing the decomposition of the binder during product heat-up. thermal conductivity (in BTU in/hr ft F.) as a function of This product may be used for high temperature applications mean temperature as follows: 75° F., 0.36:100°F., 0.39; 200° for operating temperatures up to about 1000 F. with no F., 0.55; and 300°F., 0.76. Further, flexible duct media dis heat-up cycle required (e.g., for industrial furnaces, panel plays Type II thermal conductivity (in BTU in/hr ft F.) as a systems, marine applications, and irregular surfaces). Ther function of meantemperature as follows: 75° F., 0.31; 100°F. mal properties for elevated temperature blanket (1000 F) 0.33: 2009 F., 0.44; and 300° F., 0.60. insulation are determined in accordance with ASTM C177. 0133. In one illustrative variation, flexible duct media has Thickness and/or density are determined in accordance with a nominal thickness of about 1.2 in, an R-value of about 4.2, ASTMC 167. Elevated temperature blanket (1000 F) insu and a nominal weight of about 0.08 lbs/ft, e.g., in such lation typically requires a nominal fiber diameter of about embodiments the nominal weight can be about 0.0825 lbs/ft. 22-tabout 2 ht, and a nominal loss on ignition of about In another variation, flexible duct media has a nominal thick 3-about 0.51+about 2%. ness of about 2 in, an R-value of about 6, and a nominal 0129. Illustratively, elevated temperature blanket (1000° weight of about 0.1 lbs/ft, e.g., in such embodiments the F.) insulation at a nominal density of about 1 lbs/ft displays nominal weight can be about 0.1150 lbs/ft. In another varia thermal conductivity (in BTU in/hr ft F.) as a function of tion, flexible duct media has a nominal thickness of about 2.6 mean temperature as follows: 100° F., 0.28; 200° F., 0.38: in, an R-value of about 8, and a nominal weight of about 0.2 300° F., 0.52; 400° F., 0.70; and 500° F., 0.90, e.g., in such lbs/ft, e.g., in such embodiments the nominal weight can be embodiments the nominal density can be about 1.1 lbs/ft. about 0.1500 lbs/ft. 0.134. In another illustrative embodiment, the cured bind 0130. In one illustrative variation, elevated temperature ers described herein can be used as glass fiber binders in a blanket (1000 F) insulation has a nominal density of 1.1 cured fiberglass insulation product exemplified by insulation lbs/ft, a nominal thickness of about 1 in, and a nominal board. Insulation board is a thermal and acoustical insulation weight of about 0.09 lbs/ft, e.g., in such embodiments the product including glass fibers that are preformed into boards nominal weight can be about 0.0917 lbs/ft. In another varia and bonded with a thermoset binder. This product may be tion, elevated temperature blanket (1000°F.) insulation has a manufactured plain, or faced with factory-applied foil-scrim nominal density of 1.1 lbs/ft, a nominal thickness of about kraft (FSK), white poly-scim-kraft (PSK), or all-service 1.5 in, and a nominal weight of about 0.1 lbs/ft, e.g., in such jacket (ASJ) facings. Insulation board may be used in heating embodiments the nominal weight can be about 0.1375 lbs/ft. and air conditioning ducts, power and process equipment, In another variation, elevated temperature blanket (1000F.) boiler and stack installations, metal and masonry walls, wall insulation has a nominal density of 1.1 lbs/ft, a nominal and roof panel systems, curtain wall assemblies and cavity thickness of about 2 in, and a nominal weight of about 0.2 walls. Thermal conductivity and acoustical properties for lbs/ft, e.g., in such embodiments the nominal weight can be insulation board are determined in accordance with ASTM about 0.1833 lbs/ft. In another variation, elevated tempera C177 and ASTM C423 (Type A Mounting), respectively. ture blanket (1000 F) insulation has a nominal density of 1.1 Thickness and/or density are determined in accordance with lbs/ft, a nominal thickness of about 2.5 in, and a nominal ASTMC 167. Insulation board insulation typically requires a weight of about 0.2 lbs/ft, e.g., in such embodiments the nominal fiber diameter of about 20-about 3 ht for less than nominal weight can be about 0.2292 lbs/ft. In another varia about 3 lb/ft board density, and about 27tabout 3 ht for tion, elevated temperature blanket (1000°F.) insulation has a greater than or equal to 3 lbs/ft board density, and nominal nominal density of 1.1 lbs/ft, a nominal thickness of about 3 loss on ignition of about 11+about 2%. in, and a nominal weight of about 0.3 lbs/ft, e.g., in such 0.135 Illustratively, insulation board at a nominal density embodiments the nominal weight can be about 0.2750 lbs/ft. of about 2 lbs/ft displays noise reduction coefficients in the In another variation, elevated temperature blanket (1000F.) range from about 0.80 to about 1.05, and thermal conductivity insulation has a nominal density of 1.1 lbs/ft, a nominal (in BTU in/hr ft F.) as a function of mean temperature as thickness of about 3.5 in, and a nominal weight of about 0.3 follows: 75° F., 0.24; 100°F, 0.25; 2009 F., 0.33; and 300°F., lbs/ft, e.g., in such embodiments the nominal weight can be 0.42, e.g., in Such embodiments the nominal density can be about 0.3208 lbs/ft. In another variation, elevated tempera about 1.6 lbs/ft. Further, insulation board at a nominal den ture blanket (1000 F) insulation has a nominal density of 1.1 sity of about 3 lbs/ft displays noise reduction coefficients in lbs/ft, a nominal thickness of about 4 in, and a nominal the range from about 0.65 to about 1.10, and thermal conduc weight of about 0.4 lbs/ft, e.g., in such embodiments the tivity (in BTU in/hr ft F.) as a function of mean temperature nominal weight can be about 0.3667 lbs/ft. as follows: 75° F., 0.23; 100°F., 0.24; 200°F., 0.29; and 300° US 2009/03249 15 A1 Dec. 31, 2009 20

F., 0.37. Further, insulation board at a nominal density of 0.138. In another variation, insulation board has a nominal about 6 lbs/ft displays noise reduction coefficients in the density of about 3 lbs/ft, a nominal thickness of about 1 in, range from about 0.5 to about 1.00, and thermal conductivity and a nominal weight of about 0.3 lbs/ft, e.g., in such (in BTU in/hr ft F.) as a function of mean temperature as embodiments the nominal weight can be about 0.2500 lbs/ft. follows: 75° F., 0.22; 100°F, 0.23; 2009 F., 0.27; and 300°F., In another variation, insulation board has a nominal density of O34. about 3 lbs/ft, a nominal thickness of about 1.5 in, and a nominal weight of about 0.4 lbs/ft, e.g., in such embodi 0136. In one illustrative variation, insulation board has a ments the nominal weight can be about 0.3750 lbs/if. In nominal density of about 1.6 lbs/ft, a nominal thickness of another variation, insulation board has a nominal density of about 1 in, and a nominal weight of about 0.1 lbs/ft, e.g., in about 3 lbs/ft, a nominal thickness of about 2 in, and a such embodiments the nominal weight can be about 0.1375 nominal weight of about 0.5 lbs/ft, e.g., in such embodi lbs/ft. In another variation, insulation board has a nominal ments the nominal weight can be about 0.5000 lbs/ft. In density of about 1.6 lbs/ft, a nominal thickness of about 1.5 another variation, insulation board has a nominal density of in, and a nominal weight of about 0.2 lbs/ft, e.g., in such about 3 lbs/ft, a nominal thickness of about 2.5 in, and a embodiments the nominal weight can be about 0.2063 lbs/ft. nominal weight of about 0.6 lbs/ft, e.g., in such embodi In another variation, insulation board has a nominal density of ments the nominal weight can be about 0.6250 lbs/ft. In about 1.6 lbs/ft, a nominal thickness of about 2 in, and a another variation, insulation board has a nominal density of nominal weight of about 0.3 lbs/ft, e.g., in such embodi about 3 lbs/ft, a nominal thickness of about 3 in, and a ments the nominal weight can be about 0.2750 lbs/ft. In nominal weight of about 0.8 lbs/ft, e.g., in such embodi another variation, insulation board has a nominal density of ments the nominal weight can be about 0.7500 lbs/ft. In about 1.6 lbs/ft, a nominal thickness of about 2.5 in, and a another variation, insulation board has a nominal density of nominal weight of about 0.3 lbs/ft, e.g., in such embodi about 3 lbs/ft, a nominal thickness of about 3.5 in, and a ments the nominal weight can be about 0.3438 lbs/ft. In nominal weight of about 0.9 lbs/ft, e.g., in such embodi another variation, insulation board has a nominal density of ments the nominal weight can be about 0.8750 lbs/ft. In about 1.6 lbs/ft, a nominal thickness of about 3 in, and a another variation, insulation board has a nominal density of nominal weight of about 0.4 lbs/ft, e.g., in such embodi about 3 lbs/ft, a nominal thickness of about 4 in, and a ments the nominal weight can be about 0.4125 lbs/ft. In nominal weight of about 1.0 lbs/ft, e.g., in such embodi another variation, insulation board has a nominal density of ments the nominal weight can be about 0.1.0000 lbs/ft. 0.139. In another variation, insulation board has a nominal about 1.6 lbs/ft, a nominal thickness of about 3.5 in, and a density of about 4.25 lbs/ft, a nominal thickness of about 1 nominal weight of about 0.5 lbs/ft, e.g., in such embodi in, and a nominal weight of about 0.4 lbs/ft, e.g., in such ments the nominal weight can be about 0.4813 lbs/ft. In embodiments the nominal weight can be about 0.3542 lbs/ft. another variation, insulation board has a nominal density of In another variation, insulation board has a nominal density of about 1.6 lbs/ft, a nominal thickness of about 4 in, and a about 4.25 lbs/ft, a nominal thickness of about 1.5 in, and a nominal weight of about 0.6 lbs/ft, e.g., in such embodi nominal weight of about 0.5 lbs/ft, e.g., in such embodi ments the nominal weight can be about 0.5500 lbs/ft. ments the nominal weight can be about 0.5313 lbs/ft. In 0137 In another variation, insulation board has a nominal another variation, insulation board has a nominal density of density of about 2.2 lbs/ft, a nominal thickness of about 1 in, about 4.25 lbs/ft, a nominal thickness of about 2 in, and a and a nominal weight of about 0.2 lbs/ft, e.g., in such nominal weight of about 0.7 lbs/ft, e.g., in such embodi embodiments the nominal weight can be about 0.1875 lbs/ft. ments the nominal weight can be about 0.7083 lbs/ft. In In another variation, insulation board has a nominal density of another variation, insulation board has a nominal density of about 2.2 lbs/ft, a nominal thickness of about 1.5 in, and a about 4.25 lbs/ft, a nominal thickness of about 2.5 in, and a nominal weight of about 0.3 lbs/ft, e.g., in such embodi nominal weight of about 0.9 lbs/ft, e.g., in. Such embodi ments the nominal weight can be about 0.2813 lbs/ft. In ments the nominal weight can be about 0.8854 lbs/ft. another variation, insulation board has a nominal density of 0140. In another variation, insulation board has a nominal about 2.2 lbs/ft, a nominal thickness of about 2 in, and a density of about 6 lbs/ft, a nominal thickness of about 1 in, nominal weight of about 0.4 lbs/ft, e.g., in such embodi and a nominal weight of about 0.5 lbs/ft, e.g., in such ments the nominal weight can be about 0.3750 lbs/ft. In embodiments the nominal weight can be about 0.5000 lbs/ft. another variation, insulation board has a nominal density of In another variation, insulation board has a nominal density of about 2.2 lbs/ft, a nominal thickness of about 2.5 in, and a about 6 lbs/ft, a nominal thickness of about 1.5 in, and a nominal weight of about 0.5 lbs/ft', e.g., in such embodi nominal weight of about 0.7 lbs/ft, e.g., in such embodi ments the nominal weight can be about 0.4688 lbs/ft. In ments the nominal weight can be about 0.7500 lbs/ft. In another variation, insulation board has a nominal density of another variation, insulation board has a nominal density of about 2.2 lbs/ft, a nominal thickness of about 3 in, and a about 6 lbs/ft, a nominal thickness of about 2 in, and a nominal weight of about 0.6 lbs/ft, e.g., in Such embodi nominal weight of about 1.0 lbs/ft, e.g., in such embodi ments the nominal weight can be about 0.5625 lbs/ft. In ments the nominal weight can be about 1.0000 lbs/ft. another variation, insulation board has a nominal density of 0.141. In another illustrative embodiment, the cured bind about 2.2 lbs/ft, a nominal thickness of about 3.5 in, and a ers described herein can be used as glass fiber binders in a nominal weight of about 0.7 lbs/ft, e.g., in such embodi cured fiberglass insulation product exemplified by self-clean ments the nominal weight can be about 0.6563 lbs/ft. In ing range insulation. Self-cleaning range insulation is a uni another variation, insulation board has a nominal density of formly textured, resilient, high temperature thermal and about 2.2 lbs/ft, a nominal thickness of about 4 in, and a acoustical insulation material including glass fibers that are nominal weight of about 0.8 lbs/ft, e.g., in such embodi bonded with a high temperature thermoset binder. The ther ments the nominal weight can be about 0.7500 lbs/ft. moset binder minimizes exothermic temperature rise and pro US 2009/03249 15 A1 Dec. 31, 2009 tects against punking and fusing of the product when applied has a nominal density of about 1.5 lbs/ft, a nominal thickness at maximum operating temperature. The binder content of of about 3 in, and a nominal weight of about 0.4 lbs/ft, e.g., this product is related to maintaining the product’s rated tem in such embodiments the nominal weight can be about 0.3750 perature resistance and reducing the Smoke and off-gassing 1bs/ft?. generated during the decomposition of the binder during 0146 In another variation, self-cleaning range insulation product heat-up. This product may be used for high tempera has a nominal density of about 2 lbs/ft, a nominal thickness ture range applications for self-cleaning ovens and is Suitable of about 1 in, and a nominal weight of about 0.2 lbs/ft, e.g., for operating temperatures up to about 1000 F. with no in such embodiments the nominal weight can be about 0.1667 heat-up cycle required. Self-cleaning range insulation may be lbs/ft. In another variation, self-cleaning range insulation used by OEM range manufacturers as thermal insulation for has a nominal density of about 2 lbs/ft, a nominal thickness energy conservation and reduced surface temperatures of of about 1.5 in, and a nominal weight of about 0.3 lbs/ft, e.g., self-cleaning ranges. This product is associated with minimal in such embodiments the nominal weight can be about 0.2500 Smoke and odor on the initial start-up of the range. Thermal lbs/ft. In another variation, self-cleaning range insulation conductivity properties for self-cleaning range insulation are has a nominal density of about 2 lbs/ft, a nominal thickness determined in accordance with ASTM C177 and ASTM of about 2 in, and a nominal weight of about 0.3 lbs/ft, e.g., C518. Thickness and/or density are determined in accordance in such embodiments the nominal weight can be about 0.3333 with ASTM C 167. Self-cleaning range insulation typically 1bs/ft. requires a nominal fiber diameter of about 22-tabout 2 ht, and 0.147. In another illustrative embodiment, the cured bind a nominal loss on ignition of about 2.0+about 2.0/-about ers described herein can be used as glass fiber binders in a O.5%. cured fiberglass insulation product exemplified by standard 0142 Illustratively, self-cleaning range insulation at a range insulation. Standard range insulation is a uniformly nominal density of about 1 lbs/ft displays athermal conduc textured, resilient, high temperature thermal and acoustical tivity of 0.26 BTU in/hrift F. at 75° F., e.g., in such embodi insulation material including glass fibers that are bonded with ments the nominal density can be about 1.1 lbs/ft. Illustra a high temperature thermoset binder. The thermoset binder tively, self-cleaning range insulation at a nominal density of minimizes exothermic temperature rise and protects against about 1.5 lbs/ft displays a thermal conductivity of 0.24 BTU punking and fusing of the product when applied at maximum in/hr ft F. at 75° F. Illustratively, self-cleaning range insu operating temperature. The binder content of this product is lationata nominal density of about 2 lbs/ft displays athermal related to maintaining the product’s rated temperature resis conductivity of 0.23 BTU in/hr ft F. at 75° F. tance and reducing the Smoke and off-gassing generated dur 0143. In one illustrative variation, self-cleaning range ing the decomposition of the binder during product heat-up. insulation has a nominal density of about 1.1 lbs/ft, a nomi This product may be used for high temperature range appli nal thickness of about 1 in, and a nominal weight of about cations for non-self-cleaning ovens and is suitable for oper 0.09 lbs/ft, e.g., in such embodiments the nominal weight ating temperatures up to about 1000°F. with no heat-up cycle can be about 0.0917 lbs/ft. In another variation, self-cleaning required. Standard range insulation is used by OEM range range insulation has a nominal density of about 1.1 lbs/ft, a manufacturers as thermal insulation for energy conservation nominal thickness of about 1.5 in, and a nominal weight of and reduced surface temperatures of standard ranges. This about 0.1 lbs/ft, e.g., in such embodiments the nominal product is associated with minimal Smoke and odor on the weight can be about 0.1375 lbs/ft. In another variation, self initial start-up of the range. Thermal conductivity properties cleaning range insulation has a nominal density of about 1.1 for standard range insulation are determined in accordance lbs/ft, a nominal thickness of about 2 in, and a nominal with ASTMC177 and ASTMC518. Thickness and/or density weight of about 0.2 lbs/ft, e.g., in such embodiments the are determined in accordance with ASTM C 167. Standard nominal weight can be about 0.1833 lbs/ft. In another varia range insulation typically requires a nominal fiber diameter of tion, self-cleaning range insulation has a nominal density of about 22+about 2 ht, and a nominal loss on ignition of about about 1.1 lbs/ft, a nominal thickness of about 3 in, and a 3.0+about 2.0/-about 0.5%. nominal weight of about 0.3 lbs/ft, e.g., in such embodi 0148 Illustratively, standard insulation at a nominal den ments the nominal weight can be about 0.2750 lbs/ft. In sity of about 1 lbs/ft displays a thermal conductivity of 0.26 another variation, self-cleaning range insulation has a nomi BTU in/hr ft F. at 75° F., e.g., in such embodiments the nal density of about 1.1 lbs/ft, a nominal thickness of about nominal density can be about 1.1 lbs/ft. Illustratively, stan 4 in, and a nominal weight of about 0.4 lbs/ft, e.g., in such dard range insulation at a nominal density of about 1.5 lbs/ft embodiments the nominal weight can be about 0.3667 lbs/ft. displays a thermal conductivity of 0.24 BTU in/hr ft F. at 0144. In another variation, self-cleaning range insulation 75° F. Illustratively, standard range insulation at a nominal has a nominal density of about 1.5 lbs/ft, anominal thickness density of about 2 lbs/ft displays a thermal conductivity of of about 1 in, and a nominal weight of about 0.1 lbs/ft, e.g., 0.23 BTU in/hr ft2 F. at 75° F. in such embodiments the nominal weight can be about 0.1250 0149. In one illustrative variation, standard range insula lbs/ft. In another variation, self-cleaning range insulation tion has a nominal density of about 1.1 lbs/ft, a nominal has a nominal density of about 1.5 lbs/ft, anominal thickness thickness of about 1 in, and a nominal weight of about 0.09 of about 1.5 in, and a nominal weight of about 0.2 lbs/ft, e.g., lbs/ft, e.g., in such embodiments the nominal weight can be in such embodiments the nominal weight can be about 0.1875 about 0.0917 lbs/ft. In another variation, standard range 1bs/ft. insulation has a nominal density of about 1.1 lbs/ft, a nomi 0145. In another variation, self-cleaning range insulation nal thickness of about 1.5 in, and a nominal weight of about has a nominal density of about 1.5 lbs/ft, anominal thickness 0.1 lbs/ft, e.g., in such embodiments the nominal weight can of about 2 in, and a nominal weight of about 0.3 lbs/ft, e.g., be about 0.1375 lbs/ft. In another variation, standard range in such embodiments the nominal weight can be about 0.2500 insulation has a nominal density of about 1.1 lbs/ft, a nomi lbs/ft. In another variation, self-cleaning range insulation nal thickness of about 2 in, and a nominal weight of about 0.2 US 2009/03249 15 A1 Dec. 31, 2009 22 lbs/ft, e.g., in such embodiments the nominal weight can be function of mean temperature as follows: 5 F., 0.26; 75° F., about 0.1833 lbs/ft. In another variation, standard range 0.27; 100°F, 0.29; 125° F., 0.31: 150°F, 0.34; 1759 F., 0.37; insulation has a nominal density of about 1.1 lbs/ft, a nomi and 200° F., 0.40. Illustratively, KN series insulation at a nal thickness of about 3 in, and a nominal weight of about 0.3 nominal density of about 1.5 lbs/ft displays thermal conduc lbs/ft, e.g., in such embodiments the nominal weight can be tivity (in BTU in/hr ft F.) as a function of mean temperature about 0.2750 lbs/ft. In another variation, standard range as follows: 50°F, 0.23; 75° F., 0.24; 100° F., 0.26; 125° F., insulation has a nominal density of about 1.1 lbs/ft, a nomi 028: 150°F, 0.31: 1759 F., 0.33; and 2009 F., 0.36. nal thickness of about 4 in, and a nominal weight of about 0.4 lbs/ft, e.g., in such embodiments the nominal weight can be 0154. In one illustrative variation, KN series insulation about 0.3667 lbs/ft. has a nominal density of about 0.75 lbs/ft, a nominal thick 0150. In another variation, standard range insulation has a ness of about 1 in, 1.5 in, 2 in, 2.5 in, and 3 in, and a noise nominal density of about 1.5 lbs/ft, a nominal thickness of reduction coefficient of about 0.75 at 1.5-in thickness. In about 1 in, and a nominal weight of about 0.1 lbs/ft, e.g., in another variation, KN Series insulation has a nominal density such embodiments the nominal weight can be about 0.1250 of about 1 lbs/ft, a nominal thickness of about 0.75 in, 1 in, lbs/ft'. In another variation, standard range insulation has a 1.5 in, 2 in, 2.5 in, and 3 in, and a noise reduction coefficient nominal density of about 1.5 lbs/ft, a nominal thickness of of about 0.65 at 1-in thickness, and about 0.85 at 1.5-in about 1.5 in, and a nominal weight of about 0.2 lbs/ft, e.g., in thickness. In another variation, KN Series insulation has a such embodiments the nominal weight can be about 0.1875 nominal density of about 1.5 lbs/ft, a nominal thickness of lbs/ft. In another variation, standard range insulation has a about 0.75 in, 1 in, 1.5 in, and 2 in, and a noise reduction nominal density of about 1.5 lbs/ft, a nominal thickness of coefficient of about 0.65 at 1-inthickness, about 0.90 at 1.5-in about 2 in, and a nominal weight of about 0.3 lbs/ft, e.g., in thickness, and about 1.05 at 2-in thickness. In another varia such embodiments the nominal weight can be about 0.2500 tion, KN series insulation has a nominal density of about 2 lbs/ft. In another variation, standard range insulation has a lbs/ft, a nominal thickness of about 0.75 in, 1 in, 1.5 in, and nominal density of about 1.5 lbs/ft, a nominal thickness of 2 in, and a noise reduction coefficient of about 0.70 at 1-in about 3 in, and a nominal weight of about 0.4 lbs/ft, e.g., in thickness, about 0.90 at 1.5-in thickness, and about 1.05 at such embodiments the nominal weight can be about 0.3750 2-in thickness. In another variation, KN Series insulation has 1bs/ft. a nominal density of about 2.5 lbs/ft, and a nominal thickness 0151. In another variation, standard range insulation has a of about 0.75 in, 1 in, and 1.5 in. nominal density of about 2 lbs/ft, a nominal thickness of about 1 in, and a nominal weight of about 0.2 lbs/ft, e.g., in 0.155. In another illustrative embodiment, the cured bind such embodiments the nominal weight can be about 0.1667 ers described herein can be used as glass fiber binders in a lbs/ft. In another variation, standard range insulation has a cured fiberglass insulation product exemplified by metal nominal density of about 2 lbs/ft, a nominal thickness of building insulation. Metal building insulation is a uniformly about 1.5 in, and a nominal weight of about 0.3 lbs/ft, e.g., in textured, resilient, thermal insulating and sound absorbing such embodiments the nominal weight can be about 0.2500 material including glass fibers bonded with a thermoset lbs/ft. In another variation, standard range insulation has a binder. This product has a facing (bottom) surface suitable for nominal density of about 2 lbs/ft, a nominal thickness of facing adherence and Sufficient tensile strength to allow for about 2 in, and a nominal weight of about 0.3 lbs/ft", e.g., in fabrication, lamination, and installation. Metal building insu such embodiments the nominal weight can be about 0.3333 lation may be used forthermal and acoustical insulation in the 1bs/ft?. walls and ceilings of pre-engineered metal buildings for 0152. In another illustrative embodiment, the cured bind energy conservation and condensation control. Thermal con ers described herein can be used as glass fiber binders in a ductivity and acoustical properties for metal building insula cured fiberglass insulation product exemplified by KN series tion are determined in accordance with ASTM C518/C 653 insulation. KN series insulation is a uniformly textured, resil and ASTMC423 (Type A Mounting), respectively. Thickness ient, thermal insulating and Sound absorbing material includ and/or density are determined in accordance with ASTMC ing glass fibers bonded with a thermoset binder. This product 167. Metal building insulation typically requires a nominal has sufficient tensile strength to allow for die-cutting, fabri fiber diameter of about 18-tabout 2 ht, and nominal loss on cation, lamination, and installation in OEM applications. KN ignition of about 8-tabout 1%. series insulation may be used as thermal and/or acoustical 0156. In one illustrative variation, metal building insula insulation for appliance, equipment, industrial, commercial, tion has a nominal thickness of about 3.25 in, and an R-value and marine applications. Thermal conductivity and acoustical of about 10. In another variation, metal building insulation properties for KN series insulation are determined in accor has a nominal thickness of about 3.5 in, an R-value of about dance with ASTM C177 and ASTM C423 (Type A Mount 11, and a noise reduction coefficient of about 0.95. In another ing), respectively. Thickness and/or density are determined in variation, metal building insulation has a nominal thickness accordance with ASTMC 167. KN series insulation typically of about 4.25 in, an R-value of about 13, and a noise reduction requires a nominal fiber diameter of about 18-tabout 2 ht, and coefficient of about 1.00. In another variation, metal building nominal loss on ignition of about 5% or about 8%tabout 1%. insulation has a nominal thickness of about 5 in, and an 0153 Illustratively, KN series insulation at a nominal den R-value of about 16. In another variation, metal building sity of about 0.75 lbs/ft displays thermal conductivity (in insulation has a nominal thickness of about 6 in, an R-value of BTU in/hr ft F.) as a function of mean temperature as about 19, and a noise reduction coefficient of about 1.15. In follows: 50°F, 0.28; 75° F., 0.29; 100°F, 0.31: 125° F., 0.33; another variation, metal building insulation has a nominal 150°F, 0.36; 175° F., 0.39; and 2009 F., 0.43. Illustratively, thickness of about 8 in, and an R-value of about 25. In another KN series insulation at a nominal density of about 1.0 lbs/ft variation, metal building insulation has a nominal thickness displays thermal conductivity (in BTU in/hr ft F.) as a of about 9.5 in, and an R-value of about 30. US 2009/03249 15 A1 Dec. 31, 2009

O157. In another illustrative embodiment, the cured bind and institutional buildings where fire safety, resistance to ers described herein can be used as glass fiber binders in a physical abuse, and a finished building appearance is desired. cured fiberglass insulation product exemplified by manufac This product is intended for use on systems with operating tured housing insulation rolls. Manufactured housing insula temperatures from about 0° F to about 1000° F. Thermal tion rolls are a uniformly textured, resilient, thermal insulat conductivity for pipe insulation-1000 F. is determined in ing and sound absorbing material including glass fibers that accordance with ASTM C 335. are bonded with a thermoset binder. This product may be 0160 Illustratively, pipe insulation-1000°F. displays ther manufactured either with or without a vapor retarding facing mal conductivity (in BTU in/hr ft F.) as a function of mean on one face of the product. Manufactured housing insulation temperature as follows: 75° F., 0.23; 100° F., 0.24; 200° F., rolls may be used in manufactured houses as a thermal insu 0.28; 300° F., 0.34; 400° F., 0.42; 500°F, 0.51, and 600°F., lation and Sound absorbing material in the walls, floors, and O62. ceilings. Thermal properties for manufactured housing insu 0.161. In another illustrative embodiment, the cured bind lation rolls are determined in accordance with ASTMC 653 ers described herein can be used as glass fiber binders in a as per ASTM C665. Thickness and/or density are determined cured fiberglass insulation product exemplified by KWIK in accordance with ASTM C167. Manufactured housing FLEX pipe and tank insulation. KWIK FLEX pipe and tank insulation rolls typically require a nominal fiber index of insulation is a thermal insulation product including glass about 19-tabout 2 units or a nominal fiber diameter of about fibers preformed into a semi-rigid blanket bonded by a ther 18-tabout 2 ht, and nominal loss on ignition of about moset resin and packaged in a roll form. It is available faced 4.5-about 0.5%. with a factory-applied all-service jacket (ASJ), foil-scrim 0158. In one illustrative variation, a manufactured housing kraft (FSK), or white poly-scrim (PSK) vapor retarderjacket. insulation roll has an R-value of about 5, a nominal thickness This product is typically used on tanks, vessels, and large of about 1.5 in, and a nominal weight of about 0.09 lbs/ft, diameter (greater than about 10-in) pipes. It can also be used e.g., in Such embodiments the nominal weight can be about for curved or irregular Surfaces that require finished charac 0.0894 lbs/ft. In another variation, a manufactured housing teristics of rigid fiberglass insulation. Thermal conductivity insulation roll has an R-value of about 7, a nominal thickness for KWIK FLEX pipe and tank insulation is determined in of about 2.25 in, and a nominal weight of about 0.1 lbs/ft, accordance with ASTMC 177. Thickness and/or density are e.g., in Such embodiments the nominal weight can be about determined in accordance with ASTM C 167. KWIK FLEX 0.1200 lbs/ft. In another variation, a manufactured housing pipe and tank insulation typically requires a nominal fiber insulation roll has an R-value of about 11, a nominal thickness diameter of about 22-tabout 2 ht, and a nominal loss on of about 3.5 in, and a nominal weight of about 0.2 lbs/ft, e.g., ignition of about 6+about 2%. in such embodiments the nominal weight can be about 0.1580 0162 Illustratively, KWIK FLEX pipe and tank insulation lbs/ft. In another variation, a manufactured housing insula displays thermal conductivity (in BTU in/hr ft F.) as a tion roll has an R-value of about 13, a nominal thickness of function of mean temperature as follows: 75° F., 0.24; 100°F. about 3.5 in, and a nominal weight of about 0.3 lbs/ft, e.g., in 0.25; 2009 F., 0.32: 300° F., 0.39; 400° F., 0.49; and 500° F., such embodiments the nominal weight can be about 0.2600 O61. lbs/ft. In another variation, a manufactured housing insula (0163. In one illustrative variation, KWIK FLEX pipe and tion roll has an R-value of about 14, a nominal thickness of tank insulation has a nominal density of about 2.5 lbs/ft, a about 3.5 in, and a nominal weight of about 0.4 lbs/ft, e.g., in nominal thickness of about 1 in, and a nominal weight of such embodiments the nominal weight can be about 0.3600 about 0.2 lbs/ft, e.g., in such embodiments the nominal lbs/ft. In another variation, a manufactured housing insula weight can be about 0.2344 lbs/ft. In another variation, tion roll has an R-value of about 19, a nominal thickness of KWIK FLEX pipe and tank insulation has a nominal density about 6.25 in, and a nominal weight of about 0.3 lbs/ft, e.g., of about 2.5 lbs/ft, a nominal thickness of about 1.5 in, and a in such embodiments the nominal weight can be about 0.2600 nominal weight of about 0.3 lbs/ft, e.g., in such embodi lbs/ft. In another variation, a manufactured housing insula ments the nominal weight can be about 0.3215 lbs/ft. In tion roll has an R-value of about 25, a nominal thickness of another variation, KWIK FLEX pipe and tank insulation has about 8.25 in, and a nominal weight of about 0.3 lbs/ft, e.g., a nominal density of about 2.5 lbs/ft, a nominal thickness of in such embodiments the nominal weight can be about 0.3285 about 2 in, and a nominal weight of about 0.4 lbs/ft, e.g., in lbs/ft. In another variation, a manufactured housing insula such embodiments the nominal weight can be about 0.4167 tion roll has an R-value of about 30, a nominal thickness of lbs/ft. In another variation, KWIK FLEX pipe and tank about 9.5 in, and a nominal weight of about 0.4 lbs/ft, e.g., in insulation has a nominal density of about 2.5 lbs/ft, a nomi such embodiments the nominal weight can be about 0.3762 nal thickness of about 3 in, and a nominal weight of about 0.6 1bs/ft. lbs/ft, e.g., in such embodiments the nominal weight can be 0159. In another illustrative embodiment, the cured bind about 0.6250 lbs/ft. In another variation, KWIK FLEX pipe ers described herein can be used as glass fiber binders in a and tank insulation has a nominal density of about 2.5 lbs/ft, cured fiberglass insulation product exemplified by pipe insu a nominal thickness of about 3.5 in, and a nominal weight of lation-1000°F. Pipe insulation-1000 F. is a slit, one-piece, about 0.7 lbs/ft, e.g., in such embodiments the nominal hollow cylindrical-molded, heavy-density insulation includ weight can be about 0.7290 lbs/ft. In another variation, ing glass fibers that are bonded with a thermoset binder typi KWIK FLEX pipe and tank insulation has a nominal density cally produced in about 3-in lengths with or without a factory of about 2.5 lbs/ft, a nominal thickness of about 4 in, and a applied jacket. The jacket is a white-kraft paper bonded to nominal weight of about 0.9 lbs/ft, e.g., in such embodi aluminum foil and reinforced with glass fibers, and the lon ments the nominal weight can be about 0.9380 lbs/ft. gitudinal flap of the jacket is available with or without a (0164. In another illustrative embodiment, the cured bind self-sealing adhesive. Pipe insulation-1000°F. may be used in ers described herein can be used as glass fiber binders in a power, process, and industrial applications and commercial cured fiberglass insulation product exemplified by residential US 2009/03249 15 A1 Dec. 31, 2009 24 building insulation in the form of batts. Residential building Rolls of residential building insulation are precision-cut insulation is a uniformly textured, resilient, thermal insulat pieces ready to be cut-to-length to fit in variously sized stud ing and sound absorbing material including glass fibers that cavities. This insulation product is initially compressed in are bonded with a thermoset binder. This product may be roll-up equipment and then further compressed using second manufactured either with or without a vapor retarding facing ary compression by means of vacuum packaging or a roll-in on one principle face of the product. Unfaced residential bag unit. The resulting roll in then placed in a protective building insulation may befriction fit between framing mem sleeve of a preformed bag. Such rolls typically require a bers of walls, ceilings, and floor of buildings. Batts of resi nominal fiber index of about 16.5+about 2 units or a nominal dential building insulation are precision-cut pieces, ready to fiber diameter of about 18-tabout 2 ht, and nominal loss on install in framing cavities, packaged in preformed bags and ignition of about 4.5+about 0.5%; alternatively, when a larger unitized to a particular number of bags per unit depending on fiber diameter is required for increased mechanical strength, R-value, i.e., thermal resistance (determined in accordance Such rolls may require a nominal fiber index of about with ASTM C 653 as per ASTM C665), and product width. 19tabout 2 units or a nominal fiber diameter of about Thickness and/or density are determined in accordance with 20-tabout 2 ht, and nominal loss on ignition of about ASTM C 167. Such batts typically require a nominal fiber 4.5-about 0.5%. index of about 16.5+about 2 units or a nominal fiber diameter (0168. In one illustrative variation, a roll of residential of about 18-tabout 2 ht, and nominal loss on ignition of about building insulation has an R-value of about 11, a nominal 4.5-about 0.5%. thickness of about 3.5 in, and a nominal weight of about 0.1 0165. In one illustrative variation, a batt of residential lbs/ft, e.g., in such embodiments the nominal weight can be building insulation has an R-value of about 3, a nominal about 0.1420 lbs/ft. In another variation, a roll of residential thickness of about 0.75 in, and a nominal weight of about 0.09 building insulation has an R-value of about 19, a nominal lbs/ft, e.g., in such embodiments the nominal weight can be thickness of about 6.25 in, and a nominal weight of about 0.2 about 0.0938 lbs/ft. In another variation, a batt of residential lbs/ft, e.g., in such embodiments the nominal weight can be building insulation has an R-value of about 5, a nominal about 0.2340 lbs/ft. In another variation, a roll of residential thickness of about 1.5 in, and a nominal weight of about 0.09 building insulation has an R-value of about 26, a nominal lbs/ft, e.g., in such embodiments the nominal weight can be thickness of about 8.5 in, and a nominal weight of about 0.3 about 0.0894 lbs/ft. lbs/ft, e.g., in such embodiments the nominal weight can be 0166 In another variation, a batt of residential building about 0.3004 lbs/ft. In another variation, a roll of residential insulation has an R-value of about 11, a nominal thickness of building insulation with a nominal fiber diameter of 20+2 ht about 3.5 in, and a nominal weight of about 0.1 lbs/ft, e.g., in has an R-value of about 11, a nominal thickness of about 3.5 such embodiments the nominal weight can be about 0.1420 in, and a nominal weight of about 0.2 lbs/ft, e.g., in such lbs/ft. In another variation, a batt of residential building embodiments the nominal weight can be about 0.1580 lbs/i. insulation has an R-value of about 13, a nominal thickness of In another variation, a roll of residential building insulation about 3.5 in, and a nominal weight of about 0.2 lbs/ft, e.g., in with a nominal fiber diameter of 20+2 ht has an R-value of such embodiments the nominal weight can be about 0.2316 about 13, a nominal thickness of about 3.5 in, and a nominal lbs/ft. In another variation, a batt of residential building weight of about 0.3 lbs/ft, e.g., in such embodiments the insulation has an R-value of about 19, a nominal thickness of nominal weight can be about 0.2600 lbs/ft. In another varia about 6.25 in, and a nominal weight of about 0.2 lbs/ft, e.g., tion, a roll of residential building insulation with a nominal in such embodiments the nominal weight can be about 0.2340 fiber diameter of 20+2 ht has an R-value of about 19, a lbs/ft. In another variation, a batt of residential building nominal thickness of about 6.25 in, and a nominal weight of insulation has an R-value of about 22, a nominal thickness of about 0.3 lbs/ft, e.g., in such embodiments the nominal about 6.5 in, and a nominal weight of about 0.3 lbs/ft, e.g., in weight can be about 0.2600 lbs/ft. In another variation, a roll such embodiments the nominal weight can be about 0.3202 of residential building insulation with a nominal fiber diam lbs/ft. In another variation, a batt of residential building eter of 20+2 ht has an R-value of about 26, a nominal thick insulation has an R-value of about 26, a nominal thickness of ness of about 8.5 in, and a nominal weight of about 0.3 lbs/ft, about 9 in, and a nominal weight of about 0.3 lbs/ft, e.g., in e.g., in Such embodiments the nominal weight can be about such embodiments the nominal weight can be about 0.3004 0.3285 lbs/ft2. lbs/ft. In another variation, a batt of residential building (0169. In another illustrative embodiment, the cured bind insulation has an R-value of about 30, a nominal thickness of ers described herein can be used as glass fiber binders in a about 9.5 in, and a nominal weight of about 0.4 lbs/ft, e.g., in cured fiberglass insulation product exemplified by residential such embodiments the nominal weight can be about 0.3897 building insulation (as described above) in the form of retail lbs/ft. In another variation, a batt of residential building rolls. Retail rolls of residential building insulation achieve insulation has an R-value of about 30, a nominal thickness of their finished roll diameter in roll-up equipment. Secondary about 10 in, and a nominal weight of about 0.4 lbs/ft, e.g., in packaging involves form-fill-seal equipment to allow product such embodiments the nominal weight can be about 0.3631 identification and protection. Such rolls typically require a lbs/ft. In another variation, a batt of residential building nominal fiber index of about 19-tabout 2 units or a nominal insulation has an R-value of about 38, a nominal thickness of fiber diameter of about 20-about 2 ht, and nominal loss on about 12 in, and a nominal weight of about 0.5 lbs/ft, e.g., in ignition of about 4.5+about 0.5%. such embodiments the nominal weight can be about 0.4957 (0170. In one illustrative variation, a retail roll of residen 1bs/ft?. tial building insulation has an R-value of about 11, a nominal 0167. In another illustrative embodiment, the cured bind thickness of about 3.5 in, and a nominal weight of about 0.1 ers described herein can be used as glass fiber binders in a lbs/ft, e.g., in such embodiments the nominal weight can be cured fiberglass insulation product exemplified by residential about 0.1580 lbs/ft. In another variation, a retail roll of building insulation (as described above) in the form of rolls. residential building insulation has an R-value of about 13, a US 2009/03249 15 A1 Dec. 31, 2009

nominal thickness of about 3.5 in, and a nominal weight of R-value of about 15, a nominal thickness of about 3.5 in, and about 0.3 lbs/ft, e.g., in such embodiments the nominal a nominal weight of about 0.4 lbs/ft, e.g., in such embodi weight can be about 0.2600 lbs/ft. In another variation, a ments the nominal weight can be about 0.3938 lbs/ft. In retail roll of residential building insulation has an R-value of another variation, a staple-free batt of residential building about 19, a nominal thickness of about 6.25 in, and a nominal insulation has an R-value of about 21, a nominal thickness of weight of about 0.3 lbs/ft, e.g., in such embodiments the about 5.5 in, and a nominal weight of about 0.4 lbs/f, e.g., in nominal weight can be about 0.2600 lbs/ft. In another varia such embodiments the nominal weight can be about 0.4043 tion, a retail roll of residential building insulation has an 1bs/ft. R-value of about 25, a nominal thickness of about 8.5 in, and 0.175. In another illustrative embodiment, the cured bind a nominal weight of about 0.3 lbs/ft, e.g., in such embodi ers described herein can be used as glass fiber binders in a ments the nominal weight can be about 0.3285 lbs/ft. cured fiberglass insulation product exemplified by residential 0171 In another illustrative embodiment, the cured bind building insulation (as described above) in the form of zip ers described herein can be used as glass fiber binders in a strip batts. Zip-strip batts of residential building insulation are cured fiberglass insulation product exemplified by residential precision-cut pieces, which are perforated to allow for non building insulation (as described above) in the form of heavy standard frame sizes by tearing (instead of cutting with a density batts, including cathedral ceiling heavy density batts. knife) length-wise down the product. Zip-strip batts are Heavy density batts of residential building insulation are pre manufactured with three slits lengthwise in, but not cut com cision-cut pieces, ready to install in framing cavities, pack pletely through, the batt. Such batts typically require a nomi aged in preformed bags and unitized to a particular number of nal fiber index of about 16.5+about 2 units or a nominal fiber bags per unit. This insulation product includes high-resistiv diameter of about 18-tabout 2 ht, a nominal loss on ignition of ity blankets with a thermal conductivity lower than about about 4.5-about 0.5%, a nominal un-slit depth of about 0.275 BTU in/hr ft F. Cathedral ceiling heavy density batts 0.375+about 0.125/- about 0.25 in, and a nominal slit dis may be used to maximize thermal performance of cathedral tance of about 2.50+about 0.25 in. ceilings while still allowing an unrestricted airspace under the 0176). In one illustrative variation, a zip-strip batt of resi roof deck for proper ventilation and natural convection. dential building insulation has an R-value of about 13, a Heavy density batts typically require a nominal fiber index of nominal thickness of about 3.5 in, and a nominal weight of about 16.5+about 2 units or a nominal fiber diameter of about about 0.2 lbs/ft, e.g., in such embodiments the nominal 18-tabout 2 ht., and nominal loss on ignition of about weight can be about 0.2316 lbs/ft. In another variation, a 4.5-about 0.5%. zip-strip batt of residential building insulation has an R-value 0172. In one illustrative variation, a heavy density batt of of about 15, a nominal thickness of about 3.5 in, and a nomi residential building insulation has an R-value of about 15, a nal weight of about 0.4 lbs/ft, e.g., in such embodiments the nominal thickness of about 3.5 in, and a nominal weight of nominal weight can be about 0.3938 lbs/ft. In another varia about 0.4 lbs/ft, e.g., in such embodiments the nominal tion, a Zip-strip batt of residential building insulation has an weight can be about 0.3985 lbs/ft. In another variation, a R-value of about 21, a nominal thickness of about 5.5 in, and heavy density batt of residential building insulation has an a nominal weight of about 0.4 lbs/ft, e.g., in such embodi R-value of about 21, a nominal thickness of about 5.5 in, and ments the nominal weight can be about 0.4043 lbs/ft. a nominal weight of about 0.4 lbs/ft, e.g., in such embodi 0177. In another illustrative embodiment, the cured bind ments the nominal weight can be about 0.4043 lbs/ft. In ers described herein can be used as glass fiber binders in a another variation, a heavy density batt of residential building cured fiberglass insulation product exemplified by commer insulation has an R-value of about 30, a nominal thickness of cial building insulation in the form of faced and unfaced batts. about 8.25 in, and a nominal weight of about 0.5 lbs/ft, e.g., Commercial building insulation is a uniformly textured, resil in such embodiments the nominal weight can be about 0.5069 ient, thermal insulating and Sound absorbing material includ lbs/ft. In another variation, aheavy density batt of residential ing glass fibers bonded with a thermoset binder. This product building insulation has an R-value of about 38, a nominal may be manufactured either with or without a vapor retarding thickness of about 10.25 in, and a nominal weight of about 0.7 facing on one principle face of the product. Unfaced commer lbs/ft, e.g., in such embodiments the nominal weight can be cial building insulation may be friction fit between framing about 0.6738 lbs/ft. members of walls, ceilings, and floor of buildings. Batts of 0173. In another illustrative embodiment, the cured bind commercial building insulation are precision-cut pieces, ers described herein can be used as glass fiber binders in a ready to install in framing cavities, packaged in preformed cured fiberglass insulation product exemplified by residential bags and unitized to a particular number of bags per unit building insulation (as described above) in the form of staple depending on R-value, i.e., thermal resistance (determined in free batts. Staple-free batts of residential building insulation accordance with ASTM C 653 as per ASTM C 665), and are precision-cut pieces, faced to provide a vapor retarder, to product width. Thickness and/or density are determined in befriction fit into framing cavities without stapling in order to accordance with ASTMC 167. Such batts typically require a reduce labor and time required for installation. Such batts nominal fiber index of about 16.5+about 2 units or a nominal typically require a nominal fiber index of about 16.5+about 2 fiber diameter of about 18+about 2 ht, and nominal loss on units or a nominal fiber diameter of about 18-tabout 2 ht, and ignition of about 4.5+about 0.5%. nominal loss on ignition of about 4.5+about 0.5%. 0.178 In one illustrative variation, a batt of commercial 0.174. In one illustrative variation, a staple-free batt of building insulation (faced and unfaced) has an R-value of residential building insulation has an R-value of about 13, a about 8, a nominal thickness of about 2.5 in, and a nominal nominal thickness of about 3.5 in, and a nominal weight of weight of about 0.1 lbs/ft, e.g., in such embodiments the about 0.2 lbs/ft, e.g., in such embodiments the nominal nominal weight can be about 0.1095 lbs/ft. In another varia weight can be about 0.2316 lbs/ft. In another variation, a tion, a batt of commercial building insulation (faced and staple-free batt of residential building insulation has an unfaced) has an R-value of about 11, a nominal thickness of US 2009/03249 15 A1 Dec. 31, 2009 26 about 3.5 in, and a nominal weight of about 0.1 lbs/ft, e.g., in conditioning plenums and sheet metal ducts. It offers a com such embodiments the nominal weight can be about 0.1420 bination of Sound absorption, low thermal conductivity, and lbs/ft. In another variation, a batt of commercial building minimal air Surface friction for systems operating attempera insulation (faced and unfaced) has an R-value of about 13, a tures up to about 250°F. and velocities up to about 5000 fpm. nominal thickness of about 3.5 in, and a nominal weight of Thermal conductivity and acoustical properties for rigid ple about 0.2 lbs/ft, e.g., in such embodiments the nominal num liner are determined in accordance with ASTM C 177 weight can be about 0.2316 lbs/ft. In another variation, a batt and C423 (Type A Mounting), respectively. Thickness and/or of commercial building insulation (faced and unfaced) has an density are determined in accordance with ASTM C 167. R-value of about 19, a nominal thickness of about 6.25 in, and Rigid plenum liner typically requires a nominal fiber diam a nominal weight of about 0.2 lbs/ft, e.g., in such embodi eter of about 33+about 2 ht, and a nominal loss on ignition of ments the nominal weight can be about 0.2340 lbs/ft. about 15-about 2%. 0179. In another illustrative embodiment, the cured bind 0183 In one illustrative variation, rigid plenum liner has a ers described herein can be used as glass fiber binders in a nominal density of about 3 lbs/ft, a nominal thickness of cured fiberglass insulation product exemplified by commer about 1 in, a thermal conductance of about 0.23, a thermal cial building insulation (as described above) in the form of resistance of about 4.3, and a noise reduction coefficient of standard foil-faced batts and fire- and smoke-resistant (FSK) about 0.65. foil-faced batts. Standard foil-faced batts are specified for a 0184. In another variation, rigid plenum liner has a nomi low-emittance Surface and/or reduced vapor permeance prop nal density of about 3 lbs/ft, a nominal thickness of about 1.5 erty, and are not rated for fire propagation resistance. Fire in, a thermal conductance of about 0.15, a thermal resistance and smoke-resistant (FSK) foil-faced batts use a facing that of about 6.5, and a noise reduction coefficient of about 0.85. affords a fire propagation resistance index of 25 or less, and a In another variation, rigid plenum liner has a nominal density smoke developed index of 50 or less when tested in accor of about 3 lbs/ft, a nominal thickness of about 2 in, athermal dance with ASTM E84. Such batts typically require a nominal conductance of about 0.11, athermal resistance of about 8.7, fiber index of about 16.5+about 2 units or a nominal fiber and a noise reduction coefficient of about 0.95. diameter of about 18-tabout 2 ht, and nominal loss on ignition 0185. In another illustrative embodiment, the cured bind of 4.5-0.5%. ers described herein can be used as glass fiber binders in a 0180. In one illustrative variation, a standard foil-faced cured fiberglass insulation product exemplified by textile duct batt and a fire- and smoke-resistant (FSK) foil-faced batt of liner insulation. Textile duct liner insulation is a flexible edge commercial building insulation has an R-value of about 11, a coated, mat-faced insulation including glass fibers bonded nominal thickness of about 3.5 in, and a nominal weight of with a thermoset binder. This product is faced with a tightly about 0.1 lbs/ft, e.g., in such embodiments the nominal bonded mat, providing the air stream side with a smooth, weight can be about 0.1420 lbs/ft. tough Surface that resists damage during installation and 0181. In another variation, a standard foil-faced batt and a operation. Textile duct liner may be used as an interior insu fire- and smoke-resistant (FSK) foil-faced batt of commercial lation material for sheet metal ducts in heating, ventilating, building insulation has an R-value of about 13, a nominal and air conditioning applications. It offers a combination of thickness of about 3.5 in, and a nominal weight of about 0.2 Sound absorption, low thermal conductivity, and minimal air lbs/ft, e.g., in such embodiments the nominal weight can be Surface friction for systems operating at temperatures up to about 0.2316 lbs/ft. In another variation, a standard foil about 250°F. and velocities up to about 6000 fpm. Thermal faced batt and a fire- and smoke-resistant (FSK) foil-faced and acoustical properties for textile duct liner are determined batt of commercial building insulation has an R-value of in accordance with ASTM C 177 and C423 (Type A Mount about 19, a nominal thickness of about 6.25 in, and a nominal ing), respectively. Thickness and/or density are determined in weight of about 0.2 lbs/ft, e.g., in such embodiments the accordance with ASTM C 167. nominal weight can be about 0.2340 lbs/ft. In another varia 0186. In one illustrative variation, textile duct liner has a tion, a standard foil-faced batt and a fire- and Smoke-resistant nominal density of about 1.5 lbs/ft, a nominal thickness of (FSK) foil-faced batt of commercial building insulation has about 1 in, a thermal conductance of about 0.25, a thermal an R-value of about 30, a nominal thickness of about 10 in, resistance of about 4.0, and a noise reduction coefficient of and a nominal weight of about 0.4 lbs/ft, e.g., in such about 0.70. embodiments the nominal weight can be about 0.3631 lbs/ft. 0187. In another variation, textile duct liner has a nominal In another variation, a standard foil-faced batt and a fire- and density of about 1.5 lbs/ft, a nominal thickness of about 1.5 smoke-resistant (PSK) foil-faced batt of commercial building in, a thermal conductance of about 0.17, a thermal resistance insulation has an R-value of about 38, a nominal thickness of of about 6.0, and a noise reduction coefficient of about 0.80. abut 12 in, and a nominal weight of about 0.5 lbs/ft, e.g., in In another variation, textile duct liner has a nominal density of such embodiments the nominal weight can be about 0.4957 about 1.5 lbs/ft, a nominal thickness of about 2 in, a thermal lbs/ft. conductance of about 0.13, athermal resistance of about 8.0, 0182. In another illustrative embodiment, the cured bind and a noise reduction coefficient of about 0.90. ers described herein can be used as glass fiber binders in a 0188 Inanother illustrative variation, textile duct liner has cured fiberglass insulation product exemplified by rigid ple a nominal density of about 2 lbs/ft, a nominal thickness of num liner. Rigid plenum liner is a thermal and acoustical about 0.5 in, a thermal conductance of about 0.48, a thermal insulation product including glass fibers preformed into resistance of about 2.1, and a noise reduction coefficient of heavy density boards bonded with a thermoset binder. This about 0.45. product has a black top layer of fiberglass, and a black over (0189 In another variation, textile duct liner has a nominal spray applied to the airstream surface to provide a tough finish density of about 2 lbs/ft, a nominal thickness of about 1 in, a with a dark Surface. Rigid plenum liner may be used as an thermal conductance of about 0.24, a thermal resistance of interior insulation material for heating, ventilating, and air about 4.2, and a noise reduction coefficient of about 0.70. In US 2009/03249 15 A1 Dec. 31, 2009 27 another variation, textile duct liner has a nominal density of another variation, marine hull board insulation has a nominal about 2 lbs/ft, a nominal thickness of about 1.5 in, a thermal density of about 3 lbs/ft, a nominal thickness of about 3 in, conductance of about 0.16, athermal resistance of about 6.3, and a nominal weight of about 0.7 lbs/ft, e.g., in such and a noise reduction coefficient of about 0.85. embodiments the nominal density can be about 2.8 lbs/ft and 0190. In another illustrative embodiment, the cured bind the nominal weight can be about 0.7000 lbs/ft. In another ers described herein can be used as glass fiber binders in a variation, marine hull board insulation has a nominal density cured fiberglass insulation product exemplified by exterior of about 3 lbs/ft, a nominal thickness of about 4 in, and a foundation insulation board. Exterior foundation insulation nominal weight of about 0.9 lbs/ft, e.g., in such embodi board is a uniformly textured, thermal insulating and Sound ments the nominal density can be about 2.8 lbs/ft and the absorbing material including glass fibers preformed into nominal weight can be about 0.9333 lbs/ft. boards that are bonded with a thermoset binder. This product 0.194. In another illustrative embodiment, the cured bind may have drainage capability parallel to the thickness of the ers described herein can be used as glass fiber binders in a board and Sufficient compressive strength to maintain the cured fiberglass insulation product exemplified by Canadian drainage capability after backloading with soil. Thermal commercial building insulation batts. Canadian commercial properties for exterior foundation insulation board are deter building insulation is an unfaced, semi-rigid batt insulation mined in accordance with ASTM C 653 in accordance with prepared for the Canadian market. This product is a uniformly ASTM C 665. Thickness and/or density are determined in textured, resilient, thermal insulating and sound absorbing accordance with ASTM C 167. Exterior foundation insula material including glass fibers that are bonded with a high tion board typically requires a nominal fiber diameter of temperature thermoset binder. Canadian commercial build about 37tabout 2 ht, and a nominal loss on ignition of about ing insulation may be used in wall panels, roof cavities, and 17-about 2%. between metal studs in pre-engineered metal buildings, and 0191 In one illustrative variation, exterior foundation other types of commercial building applications. This product insulation board has an R-value of about 3, a nominal thick has sufficient tensile strength, bond strength, and rigidity for ness of about 0.75 in, and a nominal weight of about 0.3 normal handling by a fabricator or contractor. Thermal prop lbs/ft, e.g., in some embodiments the nominal weight can be erties for Canadian commercial building insulation are deter about 0.2500 lbs/ft. In another variation, exterior foundation mined in accordance with ASTMC 653 in accordance with insulation board has an R-value of about 5, a nominal thick ASTM C 665. Thickness and/or density are determined in ness of about 1.2in, and a nominal weight of about 0.4 lbs/ft, accordance with ASTMC 167. Canadian commercial build e.g., in some embodiments the nominal weight can be about ing insulation typically requires a nominal fiber diameter of 0.3958 lbs/ft. In another variation, exterior foundation insu about 18-tabout 2 ht, and a nominal loss on ignition of about lation board has an R-value of about 10, a nominal thickness 4.5-about 0.5%. of about 2.4 in, and a nominal weight of about 0.8 lbs/ft, e.g., 0.195. In one illustrative variation, a batt of Canadian com in Some embodiments the nominal weight can be about mercial building insulation has an R-value of about 8, a nomi 0.7917 lbs/ft’. nal thickness of about 2 in, and a nominal weight of about 0.2 0192 In another illustrative embodiment, the cured bind lbs/ft, e.g., in such embodiments the nominal weight can be ers described herein can be used as glass fiber binders in a about 0.1833 lbs/ft. In another variation, a batt of Canadian cured fiberglass insulation product exemplified by marine commercial building insulation has an R-value of about 10, a hull insulation board. Marine hull insulation board is a skid nominal thickness of about 2.5 in, and a nominal weight of ded Smooth, resilient, high temperature thermal insulating about 0.2 lbs/ft, e.g., in such embodiments the nominal and Sound absorbing material including glass fibers that are weight can be about 0.2292 lbs/ft. In another variation, a batt bonded with a high temperature thermoset binder. The ther of Canadian commercial building insulation has an R-value moset binder minimizes exothermic temperature rise and pro of about 12, a nominal thickness of about 3 in, and a nominal tects against punking and fusing of the product when applied weight of about 0.3 lbs/ft, e.g., in such embodiments the at maximum operating temperature. The binder content of nominal weight can be about 0.2750 lbs/ft. In another varia this product is related to maintaining the product’s rated tem tion, a batt of Canadian commercial building insulation has an perature resistance and reducing the Smoke and off-gassing R-value of about 14, a nominal thickness of about 3.5 in, and generated during the decomposition of the binder during a nominal weight of about 0.3 lbs/ft, e.g., in such embodi product heat-up. This product may be used for high tempera ments the nominal weight can be about 0.3208 lbs/ft. In ture applications for hot surface temperatures up to about another variation, a batt of Canadian commercial building 850 F. with no heat-up cycle required. Thickness and/or insulation has an R-value of about 16, a nominal thickness of density are determined in accordance with ASTM C 167. about 4 in, and a nominal weight of about 0.4 lbs/ft, e.g., in Marine hull insulation board typically requires a nominal such embodiments the nominal weight can be about 0.3667 fiber diameter of about 27-tabout 3 ht, and a nominal loss on lbs/ft. In another variation, a batt of Canadian commercial ignition of about 7-about 1%. building insulation has an R-value of about 18, a nominal 0193 In one illustrative variation, marine hull board insu thickness of about 4.5 in, and a nominal weight of about 0.4 lation has a nominal density of about 3 lbs/ft, a nominal lbs/ft, e.g., in such embodiments the nominal weight can be thickness of about 1 in, and a nominal weight of about 0.2 about 0.4125 lbs/ft. In another variation, a batt of Canadian lbs/ft, e.g., in such embodiments the nominal density can be commercial building insulation has an R-value of about 20, a about 2.8 lbs/ft and the nominal weight can be about 0.2312 nominal thickness of about 5 in, and a nominal weight of lbs/ft. In another variation, marine hull board insulation has about 0.4 lbs/ft, e.g., in such embodiments the nominal a nominal density of about 3 lbs/ft, a nominal thickness of weight can be about 0.4583 lbs/ft. In another variation, a batt about 2 in, and a nominal weight of about 0.5 lbs/ft, e.g., in of Canadian commercial building insulation has an R-value such embodiments the nominal density can be about 2.8 of about 22, a nominal thickness of about 5.5 in, and a nomi lbs/ft and the nominal weight can be about 0.4625 lbs/ft. In nal weight of about 0.5 lbs/ft, e.g., in such embodiments the US 2009/03249 15 A1 Dec. 31, 2009 28 nominal weight can be about 0.5042 lbs/ft. In another varia matter the binder is disposed on, Such as glass fibers. Enhanc tion, a batt of Canadian commercial building insulation has an ing the binder's ability to adhere to the matter improves, for R-value of about 24, a nominal thickness of about 6 in, and a example, its ability to produce or promote cohesion in non nominal weight of about 0.6 lbs/ft, e.g., in such embodi assembled or loosely-assembled Substances. ments the nominal weight can be about 0.5500 lbs/ft. 0200. A binder that includes a silicon-containing coupling 0196. With respect to making binders that are water-resis agent can be prepared from a polycarboxylic acid reactant tant thermoset binders when cured, it should be appreciated and a carbohydrate reactant, the latter having reducing Sugar, that the ratio of the number of molar equivalents of acid salt groups present on the polycarboxylic acid reactant to the which reactants are added as Solids, mixed into and dissolved number of molar equivalents of hydroxyl groups present on in water, and then treated with aqueous amine base (to neu the carbohydrate reactant may be in the range from about tralize the polycarboxylic acid reactant) and a silicon-con 0.04:1 to about 0.15:1. After curing, these formulations result taining coupling agent to generate an aqueous solution about in a water-resistant thermoset binder. In one illustrative varia 3-50 weight percent in each of a polycarboxylic acid reactant tion, the number of molar equivalents of hydroxyl groups and a carbohydrate reactant. In one illustrative variation, a present on the carbohydrate reactant is about twenty five-fold binder that includes a silicon-containing coupling agent can greater than the number of molar equivalents of acid salt be prepared by admixing about 3 weight percent to about 50 groups present on the polycarboxylic acid reactant. In another weight percent aqueous solution of a polycarboxylic acid variation, the number of molar equivalents of hydroxyl reactant, already neutralized with an amine base or neutral groups present on the carbohydrate reactant is about ten-fold ized in situ, with about 3-50 weight percent aqueous solution greater than the number of molar equivalents of acid salt of a carbohydrate reactant having reducing Sugar, and an groups present on the polycarboxylic acid reactant. In yet effective amount of a silicon-containing coupling agent. another variation, the number of molar equivalents of 0201 In another illustrative embodiment, a binder of the hydroxyl groups present on the carbohydrate reactant is about present invention may include one or more corrosion inhibi six-fold greater than the number of molar equivalents of acid tors. These corrosion inhibitors may prevent or inhibit the salt groups present on the polycarboxylic acid reactant. eating or wearing away of a substance, such as metal, caused 0197) In other illustrative embodiments of the present by chemical decomposition brought about by an acid. When invention, a binder that is already cured can be disposed on a a corrosion inhibitor is included in a binder of the present material to be bound. As indicated above, most cured binders invention, the binder's corrosivity is decreased as compared of the present invention will typically contain water-insoluble to the corrosivity of the binder without the inhibitor present. melanoidins. Accordingly, these binders will also be water In another embodiment, these corrosion inhibitors can be resistant thermoset binders. utilized to decrease the corrosivity of the glass fiber-contain 0198 As discussed below, various additives can be incor ing compositions described herein. Illustratively, corrosion porated into the binder composition. These additives may inhibitors may include one or more of the following, a dedust give the binders of the present invention additional desirable ing oil, a monoammonium phosphate, sodium metasilicate characteristics. For example, the binder may include a sili pentahydrate, melamine, tin(II) oxalate, and/or methylhydro con-containing coupling agent. Many silicon-containing cou gen silicone fluid emulsion. When included in a binder of the pling agents are commercially available from the Dow-Corn present invention, corrosion inhibitors are typically present in ing Corporation, Petrarch Systems, and from the General the binder in the range from about 0.5 percent to about 2 Electric Company. Illustratively, the silicon-containing cou percent by weight based upon the dissolved binder solids. pling agent includes compounds such as silylethers and alkyl 0202 By following the disclosed guidelines, one of ordi silyl ethers, each of which may be optionally substituted, such nary skill in the art will be able to vary the concentrations of as with halogen, alkoxy, amino, and the like. In one variation, the reactants of the aqueous binder to produce a wide range of the silicon-containing compound is an amino-Substituted binder compositions. In particular, aqueous binder composi silane, Such as, gamma-aminopropyltriethoxy silane (Gen tions can be formulated to have an alkaline pH. For example, eral Electric Silicones, SILOUESTA-1101: Wilton, Conn.; a pH in the range from greater than or equal to about 7 to less USA). In another variation, the silicon-containing compound than or equal to about 10. Examples of the binder reactants is an amino-Substituted silane, for example, aminoethylami that can be manipulated include (i) the polycarboxylic acid nopropyltrimethoxy silane (Dow Z-6020: Dow Chemical, reactant, (ii) the amine base, (iii) the carbohydrate reactant, Midland, Mich.: USA). In another variation, the silicon-con (iv) the non-carbohydrate polyhydroxy reactant, (v) the sili taining compound is gamma-glycidoxypropyltrimethoxysi con-containing coupling agent, and (vi) the corrosion inhibi lane (General Electric Silicones, SILOUESTA-187). In yet tor compounds. Having the pH of the aqueous binders (e.g., another variation, the silicon-containing compound is an uncured binders) of the present invention in the alkaline range n-propylamine silane (Creanova (formerly Huls America) inhibits the corrosion of materials the binder comes in contact HYDROSIL 2627; Creanova: Somerset, N.J.; U.S.A.). with, such as machines used in the manufacturing process 0199 The silicon-containing coupling agents are typically (e.g., in manufacturing fiberglass). Note this is especially true present in the binder in the range from about 0.1 percent to when the corrosivity of acidic binders is compared to binders about 1 percent by weight based upon the dissolved binder of the present invention. Accordingly, the “life span of the Solids (i.e., about 0.1 percent to about 1 percent based upon machinery increases while the cost of maintaining these the weight of the Solids added to the aqueous Solution). In one machines decreases. Furthermore, standard equipment can be application, one or more of these silicon-containing com used with the binders of the present invention, rather than pounds can be added to the aqueous uncured binder. The having to utilize relatively corrosive resistant machine com binder is then applied to the material to be bound. Thereafter, ponents that come into contact with acidic binders, such as the binder may be cured if desired. These silicon-containing stainless steel components. Therefore, the binders disclosed compounds enhance the ability of the binder to adhere to the herein decrease the cost of manufacturing bound materials. US 2009/03249 15 A1 Dec. 31, 2009 29

0203 The following examples illustrate specific embodi addition of water to the aluminum bake-out pan and Subse ments in further detail. These examples are provided for quent standing at room temperature. Wet strength was noted illustrative purposes only and should not be construed as as Dissolved (for no wet strength), Partially Dissolved (for limiting the invention or the inventive concept to any particu minimal wet strength), Softened (for intermediate wet lar physical configuration in any way. For instance, separate strength), or Impervious (for high wet strength, water-in aqueous solutions of the polycarboxylic acid ammonium salt soluble). The color of the water resulting from its contact with reactant and the reducing-Sugar carbohydrate reactant the cured ammonium citrate-dextrose binder samples was also weight percents of each of which fall within the range from determined. Table 1 below shows illustrative examples of about 3-50 weight percent can be admixed to prepare the triammonium citrate-dextrose binders prepared according to binders and the bonded materials of the present invention. Example 1, curing conditions therefor according to Example Further, aqueous solutions including the polycarboxylic acid 2, and testing and evaluation results according to Example 3. ammonium salt reactant and the reducing-Sugar carbohydrate reactant the weight percents of each of which fall outside the Example 4 range of about 3-50 weight percent can be used to prepare the binders and the bonded materials of the present invention. In Elemental Analysis of Cured Triammonium Citrate addition, a primary amine Salt or a secondary amine Salt of a polycarboxylic acid may be used as the polycarboxylic acid Dextrose (1:6) Binder Samples ammonium salt reactant to prepare the binders and the 0207 Elemental analyses for carbon, hydrogen, and nitro bonded materials of the present invention. gen (i.e., C, H, N) were conducted on 5-g samples of 15% Example 1 triammonium citrate-dextrose (1:6) binder, prepared as described in Example 1 and cured as described below, which Preparation of Aqueous Triammonium Citrate-Dex 0.75-g cured samples included a molar ratio of triammonium trose Binders citrate to dextrose monohydrate of about 1:6. Binder samples 0204 Aqueous triammonium citrate-dextrose binders were cured as a function of temperature and time as follows: were prepared according to the following procedure: Aque 300°F. for 1 hour; 350° F. for 0.5 hour; and 400°F. for 0.33 ous solutions (25%) of triammonium citrate (81.9 g citric hour. Elemental analyses were conducted at Galbraith Labo acid, 203.7g water, and 114.4 g of a 19% percent solution of ratories, Inc. in Knoxyille, Tenn. As shown in Table 2, ammonia) and dextrose monohydrate (50.0 g of dextrose elemental analysis revealed an increase in the CN ratio as a monohydrate in 150.0 g water) were combined at room tem function of increasing temperature over the range from 300° perature in the following proportions by volume: 1:24, 1:12, F. to 350° F., which results are consistent with a melanoidin 1:8, 1:6, 1:5, 1:4, and 1:3, where the relative volume of containing binder having been prepared. Further, an increase triammonium citrate is listed as “1” For example, 10 mL of in the CH ratio as a function of increasing temperature is also aqueous triammonium citrate mixed with 50 mL of aqueous shown in Table 2, which results are consistent with dehydra dextrose monohydrate afforded a “1:5” solution, wherein the tion, a process known to occur during formation of melanoi mass ratio of triammonium citrate to dextrose monohydrate is dins, occurring during binder cure. about 1:5, the molar ratio of triammonium citrate to dextrose monohydrate is about 1:6, and the ratio of the number of molar equivalents of acid salt groups, present on triammo Example 5 nium citrate, to the number of molar equivalents of hydroxyl groups, present on dextrose monohydrate, is about 0.10:1. Preparation of Ammonium Polycarboxylate-Sugar The resulting solutions were stirred at room temperature for Binders Used to Construct Glass Bead Shell Bones, several minutes, at which time 2-gsamples were removed and Glass Fiber-Containing Mats, and Wood Fiber Board thermally cured as described in Example 2. Compositions Example 2 0208 Aqueous triammonium citrate-dextrose (1:6) bind ers, which binders were used to construct glass bead shell Preparation of Cured Triammonium Citrate-Dextrose bones and glass fiber-containing mats, were prepared by the Binder Samples from Aqueous Triammonium Cit following general procedure: Powdered dextrose monohy rate-Dextrose Binders drate (91.5 g) and powdered anhydrous citric acid (152.5 g) 0205 2-g samples of each binder, as prepared in Example were combined in a 1-gallon reaction vessel to which 880 g of 1, were placed onto each of three individual 1-galuminum distilled water was added. To this mixture were added 265g bake-out pans. Each binder was then subjected to the follow of 19% aqueous ammonia with agitation, and agitation was ing three conventional bake-out/cure conditions in pre continued for several minutes to achieve complete dissolution heated, thermostatted convection ovens in order to produce of solids. To the resulting solution were added 3.3 g of the corresponding cured binder sample: 15 minutes at 400°F. SILOUESTA-1101 silane to produce a pH 8-9 solution (us 30 minutes at 350° F., and 30 minutes at 300°F. ing pH paper), which Solution contained approximately 50% dissolved dextrose monohydrate and dissolved ammonium Example 3 citrate Solids (as a percentage of total weight of Solution); a 2-g sample of this solution, upon thermal curing at 400°F. for Testing/Evaluation of Cured Triammonium Citrate 30 minutes, would yield 30% solids (the weight loss being Dextrose Binder Samples Produced from Aqueous attributed to dehydration during thermoset binder formation). Triammonium Citrate-Dextrose Binders Where a silane other than SILOUESTA-1101 was included 0206 Wet strength was determined for each cured triam in the triammonium citrate-dextrose (1:6) binder, substitu monium citrate-dextrose binder sample, as prepared in tions were made with SILOUESTA-187 Silane, HYDROSIL Example 2, by the extent to which a cured binder sample 2627 Silane, or Z-6020 Silane. When additives were included appeared to remain intact and resist dissolution, following in the triammonium citrate-dextrose (1:6) binder to produce US 2009/03249 15 A1 Dec. 31, 2009 30 binder variants, the standard solution was distributed among while also scraping the edges wherein the glass beads lay in bottles in 300-galiquots to which individual additives were the bottom of the bowl. The mixer was then turned back on for then Supplied. an additional minute, and then the whisk (mixer) was 0209. The FT-IR spectrum of a dried (uncured) triammo removed from the unit, followed by removal of the mixing nium citrate-dextrose (1:6) binder, which spectrum was bowl containing the glass beads/ammonium polycarboxy obtained as a microscopic thin film from a 10-g sample of a late-sugar binder mixture. Using a large spatula, as much of 30% (dissolved binder solids) binder dried in vacuo, is shown the binder and glass beads attached to the whisk (mixer) as in FIG. 3. The FT-IR spectrum of a cured triammonium cit possible were removed and then stirred into the glass beads/ rate-dextrose (1:6) Maillard binder, which spectrum was ammonium polycarboxylate-Sugar binder mixture in the mix obtained as a microscopic thin film from a 10-g sample of a ing bowl. The sides of the bowl were then scraped to mix in 30% binder (dissolved binder solids) after curing, is shown in any excess binder that might have accumulated on the sides. FIG. 4. At this point, the glass beads/ammonium polycarboxylate 0210. When polycarboxylic acids other than citric acid, Sugar binder mixture was ready for molding in a shell bone Sugars other than dextrose, and/or additives were used to mold. prepare aqueous ammonium polycarboxylate-Sugar binder 0214. The slides of the shell bone mold were confirmed to variants, the same general procedure was used as that be aligned within the bottom mold platen. Using a large described above for preparation of an aqueous triammonium spatula, a glass beads/ammonium polycarboxylate-Sugar citrate-dextrose (1:6) binder. For ammonium polycarboxy binder mixture was then quickly added into the three mold late-Sugar binder variants, adjustments were made as neces cavities within the shell bone mold. The surface of the mix sary to accommodate the inclusion of for example, a dicar ture in each cavity was flattened out, while scraping off the boxylic acid or a polymeric polycarboxylic acid instead of excess mixture to give a uniform Surface area to the shell citric acid, or to accommodate the inclusion of for example, bone. Any inconsistencies or gaps that existed in any of the a triose instead of dextrose, or to accommodate the inclusion cavities were filled in with additional glass beads/ammonium of for example, one or more additives. Such adjustments polycarboxylate-Sugar binder mixture and then flattened out. included, for example, adjusting the Volume of aqueous Once a glass beads/ammonium polycarboxylate-sugar binder ammonia necessary to generate the ammonium salt, adjusting mixture was placed into the shell bone cavities, and the mix the gram amounts of reactants necessary to achieve a desired ture was exposed to heat, curing began. As manipulation time molar ratio of ammonium polycarboxylate to Sugar, and/or can affect test results, e.g., shell bones with two differentially including an additive in a desired weight percent. cured layers can be produced, shell bones were prepared consistently and rapidly. With the shell bone mold filled, the Example 6 top platen was quickly placed onto the bottom platen. At the same time, or quickly thereafter, measurement of curing time Preparation/Weathering/Testing of Glass Bead Shell was initiated by means of a stopwatch, during which curing Bone Compositions Prepared with Ammonium Poly the temperature of the bottom platen ranged from about 400° carboxylate-Sugar Binders F. to about 430 F., while the temperature of the top platen 0211 When evaluated for their dry and “weathered” ten ranged from about 440°F. to about 470°F. At seven minutes sile strength, glass bead-containing shell bone compositions elapsed time, the top platen was removed and the slides pulled prepared with a given binder provide an indication of the out so that all three shell bones could be removed. The freshly likely tensile strength and the likely durability, respectively, made shell bones were then placed on a wire rack, adjacent to of fiberglass insulation prepared with that particular binder. the shell bone mold platen, and allowed to cool to room Predicted durability is based on a shell bone's weathered temperature. Thereafter, each shell bone was labeled and tensile strength: dry tensile strength ratio. Shell bones were placed individually in a plastic storage bag labeled appropri prepared, weathered, and tested as follows: ately. If shell bones could not be tested on the day they were prepared, the shell bone-containing plastic bags were placed Preparation Procedure for Shell Bones: in a desiccator unit. 0212. A shell bone mold (Dietert Foundry Testing Equip ment; Heated Shell Curing Accessory, Model 366, and Shell Conditioning (Weathering) Procedure for Shell Bones: Mold Accessory) was set to a desired temperature, generally 0215. A Blue Mhumidity chamber was turned on and then 425° F., and allowed to heat up for at least one hour. While the set to provide weathering conditions of 90°F. and 90% rela shell bone mold was heating, approximately 100 g of an tive humidity (i.e.,90°F./90% rH). The water tank on the side aqueous ammonium polycarboxylate-Sugar binder (generally of the humidity chamber was checked and filled regularly, 30% in binder solids) was prepared as described in Example usually each time it was turned on. The humidity chamber 5. Using a large glass beaker, 727.5g of glass beads (Quality was allowed to reach the specified weathering conditions over Ballotini Impact Beads, Spec. AD, US Sieve 70-140, 106-212 a period of at least 4 hours, with a day-long equilibration Micron-if7, from Potters Industries, Inc.) were weighed by period being typical. Shell bones to be weathered were loaded difference. The glass beads were poured into a clean and dry quickly (since while the doors are open both the humidity and mixing bowl, which bowl was mounted onto an electric mixer the temperature decrease), one at a time through the open stand. Approximately 75 g of aqueous ammonium polycar humidity chamber doors, onto the upper, slotted shelf of the boxylate-sugar binder were obtained, and the binder then humidity chamber. The time that the shell bones were placed poured slowly into the glass beads in the mixing bowl. in the humidity chamber was noted, and weathering con 0213. The electric mixer was then turned on and the glass ducted for a period of 24 hours. Thereafter, the humidity beads/ammonium polycarboxylate-Sugar binder mixture was chamber doors were opened and one set of shell bones at a agitated for one minute. Using a large spatula, the sides of the time were quickly removed and placed individually into whisk (mixer) were scraped to remove any clumps of binder, respective plastic storage bags, being sealed completely. Gen US 2009/03249 15 A1 Dec. 31, 2009

erally, one to four sets of shell bones at a time were weathered screen-covered frame, already in place under the wire, facili as described above. Weathered shell bones were immediately tated the transfer of the glass fiber sample. The sample was taken to the Instron room and tested. dewatered by passing over an extractor slot with 2540 inches of water-column Suction. One pass was used for an 11-g Test Procedure for Breaking Shell Bones: sample, two passes were used for a 22-g sample, and three 0216. In the Instron room, the shell bone test method was passes were used for a 33-g sample. The sample was trans loaded on the 5500 RInstron machine while ensuring that the ferred to a second screen-covered frame and the forming wire proper load cell was installed (i.e., Static Load Cell 5 kN), and removed. The sample was then dried and separated from the the machine allowed to warm up for fifteen minutes. During screen. Subsequently, the sample was passed over a 3-inch this period of time, shell bone testing grips were verified as diameter applicator roll rotating in a bath containing an aque being installed on the machine. The load cell was Zeroed and ous ammonium polycarboxylate-Sugar binder (containing balanced, and then one set of shell bones was tested at a time 15% dissolved binder solids, prepared as described in as follows: A shell bone was removed from its plastic storage Example 5), wherein the glass fibers were saturated with bag and then weighed. The weight (in grams) was then binder. The excess binder was extracted by passing over the entered into the computer associated with the Instron extractor slot again to produce glass fiber-containing mats, machine. The measured thickness of the shell bone (in inches) which mats were cured at 375° F. for 30 minutes in an oven was then entered, as specimen thickness, three times into the having up-flow forced convection air. computer associated with the Instron machine. A shell bone specimen was then placed into the grips on the Instron Conditioning (Weathering) Procedure for Glass Fiber Mats: machine, and testing initiated via the keypad on the Instron 0220 Glass fiber-containing mat samples to be condi machine. After removing a shell bone specimen, the mea tioned were placed on TEFLON-coated course-weave belt Sured breaking point was entered into the computer associ and weighted down to prevent floating. A pair of sample mats ated with the Instron machine, and testing continued until all was prepared for each ammonium polycarboxylate-sugar shell bones in a set were tested. binder under evaluation. The mats were conditioned at ambi 0217 Test results are shown in Tables 3-6, which results ent temperature and humidity in an air-conditioned, but not are mean dry tensile strength (psi), mean weathered tensile humidity-controlled room for at least one day. Seven test strength (psi), and weathered:dry tensile strength ratio. specimens were cut from each mat using a die with the proper profile; six specimens were cut in one direction and one Example 7 specimen was cut in a perpendicular direction, with each specimen kept separate. Each specimen was 2 inches wide Preparation/Weathering/Testing of Glass Fiber-Con and narrowed, down to 1 inch wide in the mid-section, while taining Mats Prepared with Ammonium polycar being approximately 12 inches long. Three specimens from boxylate-Sugar (1:6) Binders each mat were placed in a “weathering chamber at 37-38°C. 0218. When evaluated for their dry and “weathered” ten and 90% relative humidity for 24 hours. The weathered speci sile strength, glass fiber-containing mats prepared with a mens were removed from the chamber and stored in sealable given binder-provide an indication of the likely tensile plastic bags, each bag containing a moist paper towel, until strength and the likely durability, respectively, of fiberglass immediately before testing. insulation prepared with that particular binder. Predicted durability is based on a glass fiber mat’s “weathered tensile Test Procedure for Breaking Glass Fiber Mats: strength: dry tensile strength ratio. Glass fiber mats were 0221) A tensile tester was set up with a crosshead speed of prepared, weathered, and tested as follows: 0.5 inches perminute. The clamp jaws were 2 inches wide and had approximately 1.5-inch grips. Three dry specimens and Preparation Procedure for Glass Fiber-Containing Mats: three weathered specimens were tested from each mat. The 0219. A “Deckel box,” 13 inches highx13 inches widex 14 dry specimens were used for binder content measurement, as inches deep, was constructed of clear acrylic sheet and determined by loss on ignition (LOI). attached to a hinged metal frame. Under the Deckel box, as a 0222 Test results are shown in Table 7, which results are transition from the box to a 3-inch drain pipe, was installed a mean % LOI, mean dry tensile strength (1b force), mean system of a perforated plate and coarse metal screen. A woven weathered tensile strength (1b force), and weathered:dry ten plastic belt (called a “wire') was clamped under the Deckel sile strength ratio. box. For mixing purposes, a 5-gallon bucket equipped with an internal, vertical rib and a high-shear air motor mixer were Example 8 used. Typically, 4 gallons of water and E-glass (i.e., high Preparation of Triammonium Citrate-Dextrose (1:6) temperature glass) fibers (11 g, 22 g, or 33 g) were mixed for Binder/Glass Fiber Compositions: Uncured Blanket two minutes. A typical E-glass had the following weight and Cured Blanket percent composition: SiO, 52.5%; NaO, 0.3%; CaO. 22.5%: MgO, 1.2%; Al-O, 14.5%: Fe0/FeO, 0.2%; KO, 0223 Powdered dextrose monohydrate (300 lbs) and pow 0.2%; and BO, 8.6%. The drain pipe and transition under dered anhydrous citric acid (50 lbs) were combined in a the wire had previously been filled with water such that the 260-gallon tote. Soft water was then added to achieve a vol bottom of the Deckel box was wetted. The aqueous, glass ume of 235 gallons. To this mixture were added 9.5 gallons of fiber mixture was poured into the Deckel box and agitated 19% aqueous ammonia, and the resulting mixture was stirred Vertically with a plate containing forty nine (49) one-inch to achieve complete dissolution of solids. To the resulting holes. The slide valve at the bottom of the drain line was solution were added 0.56 lbs of SILOUESTA-1101 silane to opened quickly and the glass fibers collected on the wire. A produce a solution 15.5% in dissolved dextrose monohydrate US 2009/03249 15 A1 Dec. 31, 2009 32 and dissolved ammonium citrate Solids (as a percentage of Further, binder content can be adjusted by increasing or total weight of solution); a 2-g sample of this solution, upon decreasing the concentration (i.e., the percent solids) of liquid thermal curing at 400°F. for 30 minutes, would yield 9.3% binder, and/or by increasing or decreasing the Volume of Solids (the weight loss being attributed to dehydration during binder that is sprayed onto glass fibers. Density, fiber size, thermoset binder formation). The solution was stirred for and/or binder content may be varied to produce a particular several minutes before being transported to a binder pump insulation product with desired thermal and acoustical prop where it was used in the manufacture of glass fiberinsulation, erties. specifically, in the formation of material referred to as “wet 0227 Typically, the curing oven was operated at a tem blanket,” or “ship out uncured, and “amber blanket,” or perature over a range from about 350° F. to about 600°F. cured blanket. Generally, the mat resided within the oven for a period of time 0224 Uncured blanket and cured blanket were prepared from about 0.5 minute to about 3 minutes. For the manufac using conventional fiberglass manufacturing procedures; ture of conventional thermal or acoustical insulation prod ucts, the time ranges from about 0.75 minute to about 1.5 such procedures are depicted in FIG. 7 and are described minutes. The fibrous glass having a cured, rigid binder matrix generally below and in U.S. Pat. No.5,318,990, the disclosure emerged from the oven in the form of a bat which may be of which is hereby incorporated herein by reference. Typi compressed for packaging and shipping and which will there cally, a binder is applied to glass fibers as they are being after Substantially recover its as-made Vertical dimension produced and formed into a mat, water is volatilized from the when unconstrained. By way of example, a fibrous glass mat binder, and the high-solids binder-coated fibrous glass mat is which is about 1.25 inches thick as it exits from the forming heated to cure the binder and thereby produce a finished chamber, will expand to a vertical thickness of about 9 inches fibrous glass bat which may be used, for example, as athermal in the transfer Zone, and will be slightly compressed to a or acoustical insulation product, a reinforcement for a Subse Vertical thickness of about 6 inches in the curing oven. quently produced composite, etc. 0228 Nominal specifications of the cured blanket product 0225. A porous mat of fibrous glass was produced by prepared as described above were about 0.09 pounds per fiberizing molten glass and immediately forming a fibrous square foot weight, about 0.7 pounds per cubic foot density, glass mat on a moving conveyor. Glass was melted in a tank about 1.5 inch thick, fiber diameter of about 22 hundred and Supplied to a fiber forming device Such as a spinner or a thousandths of an inch (5.6 microns), about 11% binder con tent after curing, and about 0.7% mineral oil content for bushing. Fibers of glass were attenuated from the device and dedusting (dedusting oil). Curing oven temperature was set at then blown generally downwardly within a forming chamber. about 460° F. Uncured blanket exited the forming chamber The glass fibers typically have a diameter from about 2 to white to off-white in apparent color, whereas cured blanket about 9 microns and have a length from about 0.25 inch to exited the oven dark brown in apparent color and well about 3 inches. Typically, the glass fibers range in diameter bonded. from about 3 to about 6 microns, and have a length from about 0.5 inch to about 1.5 inches. The glass fibers were deposited Example 9 onto a perforated, endless forming conveyor. A binder was applied to the glass fibers, as they were being formed, by Preparation of Triammonium Citrate-Dextrose (1:6) means of Suitable spray applicators so as to result in a distri Binder/Glass Fiber Composition: Air Duct Board bution of the binder throughout the formed mat of fibrous 0229 Powdered dextrose monohydrate (1800 lbs) and glass. The glass fibers, having the uncured binder adhered powdered anhydrous citric acid (300 lbs) were combined in a thereto, were gathered and formed into a mat on the endless 2000-gallon mixing tank that contained 743.2 gallons of soft conveyor within the forming chamber with the aid of a water. To this mixture were added 52.9 gallons of 19% aque vacuum drawn through the mat from below the forming con ous ammonia under agitation, and agitation was continued for veyor. The residual beat contained in the glass fibers as well as approximately 30 minutes to achieve complete dissolution of the airflow through the mat caused a majority of the water to solids. To the resulting solution were added 9 lbs of volatilize from the mat before it exited the forming chamber. SILOUEST A-1 101 silane to produce a pH-8 solution (using (Water was removed to the extent the uncured binder func pH paper), which solution contained approximately 25% dis tioned as a binder; the amount of water to be removed for any Solved dextrose monohydrate and dissolved ammonium cit particular application can be determined buy one of ordinary rate Solids (as a percentage of total weight of Solution); a 2-g skill in the art with routine experimentation) sample of this solution, upon thermal curing at 400°F. for 30 0226. As the high-solids binder-coated fibrous glass mat minutes, would yield 15% solids (the weight loss being attrib emerged from the forming chamber, it expanded vertically uted to dehydration during thermoset binder formation). The due to the resiliency of the glass fibers. The expanded mat was solution was stirred for several minutes before being trans then conveyed to and through a curing oven wherein heated ferred to a binder hold tank from which it was used in the air is passed through the mat to cure the binder. Flights above manufacture of glass fiber insulation, specifically, in the for and below the mat slightly compressed the mat to give the mation of a product called “air duct board.” finished product a predetermined thickness and Surface fin 0230 Air duct board was prepared using conventional ish. As mentioned above, one exemplary way of obtaining a fiberglass manufacturing procedures; Such procedures are desired thickness is to compress the mat by utilizing the described generally in Example 8. Nominal specifications of afore-mentioned flights. Since thickness is related to density, the air duct board product were about 0.4 pounds per square a desired density may be achieved by compressing the mat foot density, about 4.5 pounds per cubic foot density, at 1 inch utilizing the afore-mentioned flights. Another exemplary way thick, with a fiber diameter of about 32 hundred thousandths of obtaining a desired density is by altering the amount of ofan inch (8.1 microns), and a binder content of about 14.3%, glass fibers per unit volume. Fiber size can be manipulated by with 0.7% mineral oil for dedusting (dedusting oil). Curing adjusting the fiber forming device (e.g., a spinner or a bush oven temperature was set at about 550°F. Product exited the ing) in a well-known manner to obtain a desired fiber size. oven dark brown in apparent color and well bonded. US 2009/03249 15 A1 Dec. 31, 2009 33

Example 10 end of the line, with a fiber diameter of 18 hundred thou sandths of an inch (4.6 microns), 3.8% binder content, and Preparation of Triammonium Citrate-Dextrose (1:6) 0.7% mineral oil content (for dedusting). Curing oven tem Binder/Glass Fiber Composition: R30 Residential perature was set at about 570 F. Product exited the oven Blanket brown in apparent color and well bonded. 0231 Powdered dextrose monohydrate (1200 lbs) and powdered anhydrous citric acid (200 lbs) were combined in a Batch A-2: 2000-gallon mixing tank that contained 1104 gallons of soft water. To this mixture were added 42.3 gallons of 19% aque 0235 Powdered dextrose monohydrate (1200 lbs) and ous ammonia under agitation, and agitation was continued for powdered anhydrous citric acid (200 lbs) were combined in a approximately 30 minutes to achieve complete dissolution of 2000 gallon mixing tank that contained 558 gallons of soft solids. To the resulting solution were added 6 lbs of water. To this mixture were added 35.3 gallons of 19% ammo SILOUESTA-1101 silane to produce a pH-8 solution (using nia under agitation, and agitation was continued for approxi pH paper), which Solution contained approximately 13.4% mately 30 minutes to achieve complete dissolution of solids. dissolved dextrose monohydrate and dissolved ammonium To the resulting solution were added 5 lbs of SILOUEST citrate solids (as a percentage of total weight of Solution); a A-1 101 silane to produce a pH~8 solution (using pH paper), 2-g sample of this solution, upon thermal curing at 400°F. for which solution contained about 20.5% dissolved dextrose 30 minutes, would yield 8% solids (the weight loss being monohydrate and ammonium citrate solids (as a percentage attributed to dehydration during thermoset binder formation). of total weight of Solution); a 2-g sample of this solution, The solution was stirred for several minutes before being upon thermal curing at 400°F. for 30 minutes, would yield transferred to a binder hold tank from which it was used in the 12% solids (the weight loss being attributed to dehydration manufacture of residential glass fiber insulation, specifically, during thermoset binder formation). The solution was stirred in the formation of a product called “R30 residential blanket.” for several minutes before being transferred to a binder hold 0232 R30 residential blanket was prepared using conven tank from which it was used in the manufacture of residential tional fiberglass manufacturing procedures; Such procedures glass fiber insulation, specifically, in the formation of a prod are described generally in Example 8. Nominal specifications uct called “R19 Residential Blanket.’ of the R30 residential blanket product were about 0.4 pound 0236 R19 Residential Blanket, Batch A-2, was prepared per square foot weight, a target recovery of 10 inches thick at using conventional fiberglass manufacturing procedures; the end of the line, with a fiber diameter of 18 hundred such procedures are described generally in Example 8. Nomi thousandths of an inch (4.6 microns), 3.8% binder content, nal specifications of the R19 Residential Blanket product and 0.7% mineral oil content for dedusting (dedusting oil). were about 0.2 pound per square foot weight, about 0.4 pound Curing oven temperature was set at about 570 F. Product per cubic foot density, a target recovery of 6.5 inches thick at exited the oven brown in apparent color and well bonded. the end of the line, with a fiber diameter of 18 hundred thousandths of an inch (4.6 microns), 3.8% binder content, Example 11 and 0.7% mineral oil content (for dedusting). Curing oven temperature was set at about 570 F. Product exited the oven Preparation of Triammonium Citrate-Dextrose (1:6) brown in apparent color and well bonded. Binder/Glass Fiber Composition: R19 Residential Blanket Batch B: Batch A-1: 0237 Powdered dextrose monohydrate (300 lbs) and pow 0233 Powdered dextrose monohydrate (1200 lbs) and dered anhydrous citric acid (50 lbs) were combined in a 260 powdered anhydrous citric acid (200 lbs) were combined in a gallon International Bulk Container (IBC) that already con 2000 gallon mixing tank that contained 1104 gallons of soft tained 167 gallons of distilled water. To this mixture were water. To this mixture were added 35.3 gallons of 19% ammo added 10.6 gallons of 19% ammonia under agitation, and nia under agitation, and agitation was continued for approxi agitation was continued for approximately 30 minutes to mately 30 minutes to achieve complete dissolution of solids. achieve complete dissolution of Solids. To the resulting solu To the resulting solution were added 6 lbs of SILOUEST tion were added 1.5 lbs of SILOUEST A-1 101 silane to A-1 101 silane to produce a pH~8 solution (using pH paper), produce a pH ~8 solution (using pH paper), which solution which solution contained about 13.3% dissolved dextrose contained approximately 20.1% dissolved dextrose monohy monohydrate and ammonium citrate solids (as a percentage drate and ammonium citrate solids (as a percentage of total of total weight of Solution); a 2-g sample of this solution, weight of Solution); a 2-g sample of this solution, upon ther upon thermal curing at 400°F. for 30 minutes, would yield mal curing at 400°F. for 30 minutes, would yield 12% solids 8% solids (the weight loss being attributed to dehydration (the weight loss being attributed to dehydration during ther during thermoset binder formation). The solution was stirred moset binder formation). The IBC containing the aqueous for several minutes before being transferred to a binder hold binder was transferred to an area at which location the binder tank from which it was used in the manufacture of residential was pumped into the binder spray rings in the forming hood, glass fiber insulation, specifically, in the formation of a prod diluted thereinto with distilled water, and then used in the uct called “R19 Residential Blanket.’ manufacture of residential glass fiber insulation, specifically, 0234 R19 Residential Blanket, Batch A-1, was prepared in the formation of a product called “R19 Residential Blan using conventional fiberglass manufacturing procedures; ket. such procedures are described generally in Example 8. Nomi 0238. R19 Residential Blanket, Batch B, was prepared nal specifications of the R19 Residential Blanket product using conventional fiberglass manufacturing procedures; were about 0.2 pound per square foot weight, 0.2 pound per such procedures are described generally in Example 8. Nomi cubic foot density, a target recovery of 6.5 inches thick at the nal specifications of the R19 Residential Blanket product US 2009/03249 15 A1 Dec. 31, 2009 34 made were about 0.2 pound per square foot weight, and about spray rings in the forming hood, diluted thereinto with dis 0.4 pound per cubic foot density, a target recovery of 6.5 tilled water, and then used in the manufacture of residential inches thick at the end of the line, with a fiber diameter of 18 glass fiber insulation, specifically, in the formation of a prod hundred thousandths of an inch (4.6 microns), 3.8% binder uct called “R119 Residential Blanket. content, and 0.7% mineral oil content (for dedusting). Curing 0242 R19 Residential Blanket, Batch D, was prepared oven temperature was set at about 570 F. Product exited the using conventional fiberglass manufacturing procedures; oven brown in apparent color and well bonded. such procedures are described generally in Example 8 Nomi nal specifications of the R19 Residential Blanket product Batch C: made that day were about 0.2 pound per square foot weight, about 0.4 pound per cubic foot density, a target recovery of 6.5 0239 Powdered dextrose monohydrate (300 lbs) and pow inches thick at the end of the line, with a fiber diameter of 18 dered anhydrous citric acid (50 lbs) were combined in a 260 hundred thousandths of an inch (4.6 microns), 3.8% binder gallon International Bulk Container (IBC) that already con content, and 0.7% mineral oil content (for dedusting). Curing tained 167 gallons of distilled water. To this mixture were oven temperature was set at about 570 F. Product exited the added 10.6 gallons of 19% ammonia under agitation, and oven brown in apparent color and well bonded. agitation was continued for about 30 minutes to achieve com plete dissolution of solids. To the resulting solution were Example 12 added 1.5 lbs of SILOUESTA-1101 silane followed by 1.80 Preparation of Triammonium Citrate-Dextrose (1:6) gallons of the methylhydrogen emulsion BS1040 (manufac Binder/Glass Fiber Composition: Pipe Insulation tured by the Wacker Chemical Corporation) to produce a pH Uncured ~8 Solution (using pH paper), which Solution contained approximately 20.2% dissolved dextrose monohydrate and 0243 Powdered dextrose monohydrate (1200 lbs) and ammonium citrate solids (as a percentage of total weight of powdered anhydrous citric acid (200 lbs) were combined in a Solution); a 2-g sample of this solution, upon thermal curing 2000-gallon mixing tank that contained 215 gallons of soft water. To this mixture were added 42.3 gallons of 19% aque at 400°F. for 30 minutes, would yield 12% solids (the weight ous ammonia under agitation, and agitation was continued for loss being attributed to dehydration during thermoset binder approximately 30 minutes to achieve complete dissolution of formation). The IBC containing the aqueous binder was solids. To the resulting solution were added 6 lbs of transferred to an area at which location the binder was SILOUEST A-1 101 silane to produce a pH-8 solution (using pumped into the binder spray rings in the forming hood, pH paper), which solution contained approximately 41.7% diluted thereinto with distilled water, and then used in the dissolved dextrose monohydrate and dissolved ammonium manufacture of residential glass fiber insulation, specifically, citrate Solids (as a percentage of total weight of Solution); a in the formation of a product called “R19 Residential Blan 2-g sample of this solution, upon thermal curing at 400°F. for ket. 30 minutes, would yield 25% solids (the weight loss being 0240 R19 Residential Blanket, Batch C, was prepared attributed to dehydration during thermoset binder formation). using conventional fiberglass manufacturing procedures; The solution was stirred for several minutes before being such procedures are described generally in Example 8. Nomi transferred to a binder hold tank from which it was used in the nal specifications of the R19 Residential Blanket product manufacture of glass fiber insulation, specifically, in the for made was about 0.2 pound per square foot density, about 0.4 mation of a product called "pipe insulation-uncured.” 0244 Pipe insulation-uncured was prepared using con pound per cubic foot weight, a target recovery of 6.5 inches ventional fiberglass manufacturing procedures; Such proce thick at the end of the line, with a fiber diameter of 18 hundred dures are described generally in Example 8. Nominal speci thousandths of an inch (4.6 microns), 3.8% binder content, fications of the pipe insulation uncured product were about and 0.7% mineral oil content (for dedusting). Curing oven 0.07 pound per square foot weight, about 0.85 pound per temperature was set at about 570 F. Product exited the oven cubic foot density, an estimated thickness of 1 inch, a fiber brown in apparent color and well bonded diameter of 30 hundred thousandths of an inch (7.6 microns), and a binder content of 7% when cured. Pipe insulation Batch D: uncured was transported to a pipe insulation-forming area, where it was cast into cylindrical shells, with 6-inch walls and 0241 Powdered dextrose monohydrate (300 lbs) and pow a 3-inch diameter hole and 4-pound per cubic foot density, to dered anhydrous citric acid (50 lbs) were combined in a 260 be used as pipe insulation. These shells were cured with the gallon International Bulk Container (IBC) that already con curing oven set at approximately 450° F. to produce dark tained 167 gallons of distilled water. To this mixture were brown, well-bonded pipe insulation product. Shells cured at added 10.6 gallons of 19% ammonia under agitation, and higher temperatures exhibited punking and could not be used agitation was continued for approximately 30 minutes to further for testing. achieve complete dissolution of Solids. To the resulting solu tion were added 1.5 lbs of SILOUEST A-1 101 silane fol Example 13 lowed by 22 lbs of the clay product Bentalite L10 (manufac tured by Southern Clay Products) to produce a pH-8 solution Preparation of Triammonium Citrate-Dextrose (1:6) (using pH paper), which solution contained about 21.0% Binder/Glass Fiber Composition: ET Blanket (Range dissolved dextrose monohydrate and ammonium citrate Sol Insulation) ids (as a percentage of total weight of solution); a 2-g sample 0245 Powdered dextrose monohydrate (74 lbs) and pow of this solution, upon thermal curing at 400°F. for 30 minutes, dered anhydrous citric acid (12 lbs) were combined in a would yield 12.6% solids (the weight loss being attributed to 2000-gallon mixing tank that contained 390 gallons of soft dehydration during thermoset binder formation). The IBC water. To this mixture were added 2.6 gallons of 19% aqueous containing the aqueous Maillard binder was transferred to an ammonia under agitation, and agitation was continued for area at which location the binder was pumped into the binder approximately 30 minutes to achieve complete dissolution of US 2009/03249 15 A1 Dec. 31, 2009

solids. To the resulting solution were added 0.37 lbs of tial blanket, and pipe insulation-uncured, were tested versus a SILOUESTA-1101 silane to produce a pH-8 solution (using corresponding phenol-formaldehyde (PF) binder/glass fiber pH paper), which solution contained approximately 2.65% composition for one or more of the following: product emis dissolved dextrose monohydrate and dissolved ammonium sions, density, loss on ignition, thickness recovery, dust, ten citrate solids (as a percentage of total weight of Solution); a sile strength, parting strength, durability of parting strength, 2-g sample of this solution, upon thermal curing at 400°F. for bond strength, water absorption, hot surface performance, 30 minutes, would yield 1.6% solids (the weight loss being corrosivity on Steel, flexural rigidity, stiffness-rigidity, com attributed to dehydration during thermoset binder formation). pressive resistance, conditioned compressive resistance, The solution was stirred for several minutes before being compressive modulus, conditioned compressive modulus, transferred to a binder hold tank from which it was used in the and Smoke development on ignition. The results of these tests manufacture of glass fiber insulation, specifically, in the for are shown in Tables 8-13. Also determined were the gaseous mation of a product called “ET Blanket (range insulation).” compounds produced during pyrolysis of cured blanket from 0246 ET Blanket (range insulation) was prepared using Example 8, and the gaseous compounds produced during conventional fiberglass manufacturing procedures; Such pro thermal curing of pipe insulation uncured from Example 12; cedures are described generally in Example 8. Nominal speci these testing results are shown in Tables 14-15. Hot surface fications of the ET Blanket (range insulation) product were performance for cured pipe insulation is shown in FIG.5 and about 0.298 pound per square foot weight, about 1.10 pound FIG. 6. Specific tests conducted and conditions for perform per cubic foot density, a target recovery of 3.25 inches thick ing these tests are as follows: after packaging, with a fiber diameter of 22 hundred thou sandths of an inch (5.6 microns), two set points of 1.5% and Product Emissions Testing 3.0% binder content, respectively. Curing oven temperature was set at about 450° F. Product exited the oven light brown 0250 Product emissions for cured blanket from Example in apparent color and reasonably bonded. 8 and air duct board from Example 9 were determined in accordance with AQS Greenguard Testing procedures. The Example 14 insulation products were monitored for emissions of total volatile organic compounds (TVOCs), formaldehyde, total Preparation of Triammonium Citrate-Dextrose (1:6) selected aldehydes in accordance with ASTM D5116 ("Stan Binder/Glass Fiber Composition: Flexible Duct dard Guide for Small-Scale Environmental Chamber Deter Media minations of Organic Emissions from Indoor Materials/Prod 0247 Powdered dextrose monohydrate 3000 lbs) and ucts”), the United States Environmental Protection Agency powdered anhydrous citric acid (500 lbs) were combined in a (USEPA), and the State of Washington IAQ Specification of 2000-gallon mixing tank that contained 390 gallons of soft January, 1994. The emission data were collected over a one water. To this mixture were added 106.6 gallons of 19% week exposure period and the resultant air concentrations aqueous ammonia under agitation, and agitation was contin were determined for each of the aforementioned substances. ued for approximately 30 minutes to achieve complete disso Air concentration predictions were computer monitored lution of solids. To the resulting solution were added 15 lbs of based on the State of Washington requirements, which SILOUEST A-1 101 silane. This produced a solution that include a standard room loading and ASHRAE Standard contained approximately 39.3% dissolved dextrose monohy 62-1999 ventilation conditions. Product loading is based on drate and dissolved ammonium citrate solids (as a percentage of total weight of Solution); a 2-g sample of this solution, standard wall usage of 28.1 m in a 32 m room. upon thermal curing at 400°F. for 30 minutes, would yield 23.6% solids (the weight loss being attributed to dehydration Emissions Testing Selected Aldehydes during thermoset binder formation). The solution was stirred 0251. The insulation products were tested in a small-sized for several hours before being transferred to a binder hold environmental chamber 0.0855 m involume with the chemi tank from which it was used in the manufacture of glass fiber insulation, specifically, in the formation of a product called cal emissions analytically measured. Emission of selected “flexible duct media. aldehydes, including formaldehyde, were measured follow 0248 Flexible duct media was prepared using conven ing ASTM D5197 (“Standard Test Method for Determination tional fiberglass manufacturing procedures; Such procedures of Formaldehyde and Other Carbonyl Compounds in Air are described generally in Example 8. Nominal specifications (Active Sampler Methodology)) using high performance liq of the flexible duct media product were about 0.115 pound per uid chromatography (HPLC). Solid sorbent cartridges with square foot weight, about 0.690 pound per cubic foot density, 2,4-dinitrophenylhydrazine (DNPH) were used to collect a target recovery of 2 inches thick after packaging, with a fiber formaldehyde and other low-molecular weight carbonyl diameter of 18 hundred thousandths of an inch (4.6 microns), compounds in the chamber air. The DNPH reagent in the with set points of 5.45%, 11.4%, and 14.25% binder content cartridge reacted with collected carbonyl compounds to form respectively, and 0.7% mineral oil content for dedusting (de the stable hydrazone derivatives retained by the cartridge. The dusting oil). Curing oven temperature was set at about 450°F. hydrazone derivatives were eluted from a cartridge with Product exited the oven brown in apparent color and well HPLC-grade acetonitrile. An aliquot of the sample was ana bonded. lyzed for low-molecular weight aldehyde hydrazone deriva tives using reverse-phase high-performance liquid chroma Example 15 tography (HPLC) with UV detection. The absorbances of the derivatives were measured at 360 nm. The mass responses of Testing/Evaluation of Triammonium Citrate-Dex the resulting peaks were determined using multi-point cali trose (1:6) Binder/Glass Fiber Compositions bration curves prepared from standard solutions of the hydra 0249. The triammonium citrate-dextrose (1:6) binder/ Zone derivatives. Measurements are reported to a quantifiable glass fiber compositions from Examples 8-12, i.e., cured level of 0.2 g based on a standard air volume collection of 45 blanket, air duct board, R30 residential blanket, R19 residen L. US 2009/03249 15 A1 Dec. 31, 2009 36

Emissions Testing Volatile Organic Compounds (VOC) Durability of Parting Strength 0252 VOC measurements were made using gas chroma 0257 The durability of parting strength for R30 residen tography with mass spectrometric detection (GC/MS). tial blanket from Example 10 and R19 residential blanket Chamber air was collected onto a solid sorbent which was from Example 11 were determined in accordance with ASTM then thermally desorbed into the GC/MS. The sorbent collec C 686, “Parting Strength of Mineral Fiber Batt and Blanket tion technique, separation, and detection analysis methodol ogy has been adapted from techniques presented by the Type Insulation.” following one-week conditioning at 90°F. USEPA and other researchers. The technique follows USEPA and 950% relative humidity. Method 1P-1B and is generally applicable to Cs-C organic chemicals with a boiling point ranging from 35° C. to 250° C. Tensile Strength Measurements are reported to a quantifiable level of 0.4 ug based on a standard air volume collection of 18 L. Individual 0258. The tensile strength of cured blanket from Example VOCs were separated and detected by GC/MS. The totalVOC 8 and R19 residential blanket from Example 11 was deter measurements were made by adding all individual VOC mined in accordance with an internal test method KRD-161, responses obtained by the mass spectrometer and calibrating “Tensile Strength Test Procedure.” The test was performed on the total mass relative to toluene. samples die cut in both the machine direction and the cross cut machine direction. Samples were conditioned for 24 Emissions Testing Air Concentration Determinations hours at 75° F. and 50% relative humidity. Ten samples in 0253 Emission rates of formaldehyde, total aldehydes, each machine direction were tested in a test environment of and TVOC were used in a computer exposure model to deter 75° F., 50% relative humidity. The dogbone specimen was as mine the potential air concentrations of the Substances. The specified in ASTM D638, “Standard Test Method for Tensile computer model used the measured emission rate changes Properties of Plastics.” A cross-head speed of 2 inches/minute over the one-week time period to determine the change in air was used for all tests. concentrations that would accordingly occur. The model measurements were made with the following assumptions: Bond Strength air with open office areas in the building is well-mixed at the breathing level Zone of the occupied space; environmental 0259. The inter-laminar bond strength of cured blanket conditions are maintained at 50% relative humidity and 73°F. from Example 8, R30 residential blanket from Example 10, (23°C.); there are no additional sources of these substances: and R19 residential blanket from Example 11 was determined and there are no sinks or potential re-emitting sources within using an internal test method KRD-159, “Bond Strength of the space for these substances. The USEPA's Indoor Air Fiberglass Board and Blanket Products.” Molded specimens Exposure Model, Version 2.0, was specifically modified to accommodate this product and chemicals of interest. Venti with a cross sectional area of 6 inches by 6 inches were glued lation and occupancy parameters were provided in ASHRAE to 6 inch by 7 inch specimen mounting plates and placed in a Standard 62-1999. fixture that applied the force perpendicular to the surface of the specimen. A cross-head speed of 12 inches perminute was Density used for all tests. 0254 The density of cured blanket from Example 8 was Thickness Recovery determined in accordance with internal test method PTL-1, “Test Method for Density and Thickness of Blanket or Batt 0260 Out-of-package and rollover thickness tests were Thermal Insulation, which test method is virtually identical performed on cured blanket from Example 8 using internal to ASTMC 167. The density of air duct board from Example test methods K-123, "Recovered Thickness—End of Line 9 was determined in accordance with internal test method Dead Pin Method Roll Products, and K-109, “Test Proce PTL-3, “Test Procedure for Density Preformed Block-Type dure for Recovered Thickness of Roll Products—Rollover Thermal Insulation, which test method is virtually identical Method.” Recovered thickness was measured by forcing a pin to ASTM C 303. gauge through a sample of cured blanket from a roll product, either 15 minutes after packaging or at a later point in time, Loss on Ignition (LOI) until the pin contacts a flat, hard Surface underlying the 0255. The loss on ignition for cured blanket from Example sample, and then measuring the recovered thickness with a 8 and air duct board from Example 9 was determined in steel rule. Thickness tests were performed on R30 residential accordance with internal test method K-157. “Ignition Loss blanket from Example 10 and R19 residential blanket from of Cured Blanket (LOI). The test was performed on a sample Example 11 using internal test methods K-120. “Test Proce in a wiretray placed in a furnace at 1000°F., +/-50°F., for 15 dure for Determining End-of-Line Dead-Pin Thickness— to 20 minutes to ensure complete oxidation, after which treat Batts, and K-128, “Test Procedure for Recovered Thickness ment the resulting sample was weighed. of Batt Products—Drop Method, both of which test methods are similar to ASTM C 167, “Standard Test Methods for Parting Strength Thickness and Density of Blanket or Batt Thermal Insula tions.” 0256 The parting strength of cured blanket from Example 8, R30 residential blanket from Example 10, and R19 resi Dust Testing dential blanket from Example 11 were determined in accor dance with internal test method KRD-161, which test method 0261 Dust testing was performed on cured blanket from is virtually identical to ASTM C 686, “Parting Strength of Example 8, R30 residential blanket from Example 10, and Mineral Fiber Batt and Blanket-Type Insulation.” R19 residential blanket from Example 111 using internal test US 2009/03249 15 A1 Dec. 31, 2009 37 procedure K-102, “Packaged Fiber Glass Dust Test, Batt using ASTM C 411, “Test Method for Hot Surface Perfor Method.” Dust liberated from randomly selected samples mance of High Temperature Thermal Insulation.” Hot surface (batts) of cured blanket, R30 residential blanket, and R19 performance tests were conducted on 3x6-inch sections of residential blanket dropped into a dust collection box was cured pipe insulation product from Example 12 at 650°F. and collected on a filter and the amount of dust determined by 1000°F. using ASTM C411, “Test Method for Hot Surface difference weighing. Performance of High Temperature Thermal Insulation.” There was no measurable internal temperature rise in the Water Absorption insulation above the pipe hot surface temperature. 0262 Water absorption (% by weight) tests were per formed on cured blanket from Example 8 and R19 residential Corrosivity on Steel blanket from Example 11 using ASTMC 1104, “Test Method for Determining the WaterVapor Absorption of Unfaced Min 0270. Corrosivity testing was performed on R30 residen eral Fiber Insulation.” tial blanket from Example 10 and R19 residential blanket from Example 11 versus steel coupons using internal test Flexural Rigidity (EI) procedure Knauf PTL-14, which is virtually identical to 0263. The flexural rigidity of air duct board from Example ASTM C 665. 9, which is the force couple required to bend the rigid air duct board, i.e., the product of E, the modulus of elasticity, and I, Smoke Development on Ignition the bending moment of inertia, was determined in accordance with NAIMA AHS100-74, “Test Method for Flexural Rigid 0271 Smoke development on ignition for cured blanket ity of Rectangular Rigid Duct Materials.” from Example 8, with calculation of specific extinction area (SEA), was determined by cone calorimetry using ASTM E Stiffness-Rigidity 1354, “Test Method for Heat and Visible Smoke Release 0264. Stiffness-rigidity testing was performed on R19 Rates for Materials and Products Using an Oxygen Consump residential blanket from Example 11 using internal test pro tion Calorimeter.” cedure K-117. “Test Procedure for Rigidity of Building Insu lation.” A sample of R19 residential blanket, approximately Gaseous Compounds Produced During Pyrolysis 47.5 inches in length (+0.5 inch), was placed on the center Support bar of a stiffness test apparatus, which apparatus 0272 Gaseous compounds producing during pyrolysis of included a protractor scale directly behind the center support cured blanket from Example 8 were determined as follows: bar. With the ends of the sample hanging free, the angle (in Approximately 10g of cured blanket was placed in a test tube, degrees) at each end of the sample was recorded by sighting which tube was then heated to 1000 F. for 2.5 minutes at along the bottom edge of the sample while reading the pro which time the headspace was sampled and analyzed by gas tractor scale. chromatography/mass spectrometry (GC/MS) under the fol lowing conditions: Oven, 50° C. for one minute—10° Compressive Resistance C./minute to 300° C. for 10 minutes; Inlet, 280° C. splitless; Column, HP-530 mmx0.32 mmx0.25um; Column flow, 1.11 0265. The compressive resistance of air duct board from mL/minute Helium; Detector, MSD 280° C.; Injection vol Example 9 was determined in accordance with ASTMC 165, ume, 1 mL. Detector mode, scan 34-7.00amu; Threshold, 50: “Standard Test Method for Measuring Compressive Proper and Sampling Rate, 22 scans/second. A computer search of ties of Thermal Insulations.” the mass spectrum of a chromatographic peak in the sample was made against the Wiley library of mass spectra. The best Conditioned Compressive Resistance match was reported. A quality index (closeness of match to 0266 The conditioned compressive resistance of air duct the library spectra) ranging from 0 to 99 was generated. Only board from Example 9, after one week at 90° F. and 95% the identity of peaks with a quality index of greater than or relative humidity, was determined in accordance with ASTM equal to 90 were reported. C 165, "Standard Test Method for Measuring Compressive Properties of Thermal Insulations.” Gaseous Compounds Produced During Thermal Curing Compressive Modulus 0273 Gaseous compounds producing during thermal cur ing of pipe insulation uncured from Example 12 were deter 0267. The compressive modulus of air duct board from mined as follows: Approximately 0.6 g of pipe insulation Example 9 was determined in accordance with ASTMC 165, uncured was placed in a test tube, which tube was then heated “Standard Test Method for Measuring Compressive Proper to 540° F. for 2.5 minutes at which time the headspace was ties of Thermal Insulations.” sampled and analyzed by gas chromatography/mass spec Conditioned Compressive Modulus trometry under the following conditions: Oven, 50° C. for one minute 10°C/minute to 300° C. for 10 minutes; Inlet, 280° 0268. The conditioned compressive modulus of air duct C. splitless; Column, HP-530 mmx0.32 mmx0.25um: Col board from Example 9, after one week at 90° F. and 95% umn flow, 1.11 mL/minute Helium; Detector, MSD 280° C.; relative humidity, was determined in accordance with ASTM Injection volume, 1 mL. Detector mode, scan 34-700 amu: C 165, "Standard Test Method for Measuring Compressive Threshold, 50, and Sampling Rate, 22 scans/second. A com Properties of Thermal Insulations.” puter search of the mass spectrum of a chromatographic peak in the sample was made against the Wiley library of mass Hot Surface Performance spectra. The best match was reported. A quality index (close 0269 Hot surface performance tests were performed on ness of match to the library spectra) ranging from 0 to 99 was cured blanket from Example 8, R30 residential blanket from generated. Only the identity of peaks with a quality index of Example 10, and R19 residential blanket from Example 11 greater than or equal to 90 were reported. US 2009/03249 15 A1 Dec. 31, 2009 38

Example 16 Preparation of Triammonium Citrate-Dextrose (1:6) TABLE 2 Binder/Cellulose Fiber Composition: Wood Fiber Board Elemental Analysis Results for Cured Triammonium Citrate-Dextrose 0274 Several methods were used to produce wood fiber (1:6) BinderOle S8)I{SSamples 8Sas 8a FunctionCOil Oof TemperatureCl(38C and T le. boards/sheets bonded with triammonium citrate-dextrose Elemental Elemental Analysis Results (1:6) binder. A representative method, which method pro- EICICIll All SSIS RCSUIS duced strong, uniform samples, is as follows: Wood in the form of assorted pine wood shavings and sawdust was pur- Cure Temp Cure Time Analysis C:H C:N chased from a local farm supply store. Wood fiber board 300°F. 1 hour Carbon 48.75% samples were made with the as received” wood and also Hydrogen 5.60% 8.7O 11.89 material segregated into the shavings and sawdust compo- Nitrogen 4.10% nents. Wood was first dried in an oven at approximately 200° 300°F. 1 hour Carbon 49.47% F. over night, which drying resulted in moisture removal of Hydrogen 5.55% 8.91 12.00 14-15% for the wood shavings and about 11% for the saw- Nitrogen 4.12% dust. Thereafter, dried wood was placed in an 8 inch highx12 300°F. 1 hour Carbon 50.35% inch widex10.5 inch deep plastic container (approximate Hydrogen 5.41% 9.31 12.04 dimensions). Triammonium citrate-dextrose (1:6) binder was Nitrogen 4.18% Avg: -- 8.97 11.98 prepared (36% in binder solids) as described in Example 5, 350 F. 0.5 hour Carbon 52.55% and then 160 g of binder was sprayed via anhydraulic nozzle Hydrogen 5.20% O. 10 12.36 onto a 400-g sample of wood in the plastic container while the Nitrogen 4.25% container was inclined 3040 degrees from the vertical and 350 F. 0.5 hour Carbon S4.19% rotated slowly (approximately 5-15 rpm). During this treat- Hydrogen 5.08% 0.67 12.31 ment, the wood was gently tumbled while becoming uni- Nitrogen 4.40% formly coated. 350 F. O.S C 52.86% 0275 Samples of resinated wood were placed in a collaps- Ol Hydrogen80 5.17% O.22 12.47 ible frame and compressed in between heated platens under N 4.24% Avg. -- 10.33 12.38 the following conditions: resinated wood shavings, 300 psi; 400°F O.33 s so Vg. resinated sawdust, 600 psi. For each resinated sample, the ... Oli 80 o cure conditions were 350°F. for 25 to 30 minutes. The result- ydrogen 59 O.68 12.21 ing sample boards were approximately 10 inches longx10 Nitrogen 4.45% inches wide, and about 0.4 inches thick before trimming, 400°F. 0.33 hour Carbon SS.63% well-bonded internally, Smooth Surfaced and made a clean cut Hydrogen 5.06% O.99 12.15 when trimmed on the band saw. Trimmed sample density and Nitrogen 4.58% the size of each trimmed sample board produced were as 400°F. 0.33 hour Carbon 56.10% follows: sample board from wood shavings, density ~54pcf. Hydrogen 4.89% 1.47 12.06 size -8.3 inches longx9 inches widex0.36 inches thick; Nitrogen 4.65% Avg. -- 11.05 12.14 sample board from sawdust, density ~44pcf, size -8.7inches longx8.8 inches widex0.41 inches thick. The estimated From Example 4 binder content of each sample board was ~12.6%.

TABLE 1. Testing Evaluation Results for Cured Triannonium citrate-Dextrose Binder Samples

BINDER COMPOSITION Wet Water Wet Water Wet Water Triammonium citrate:Dextrose.H.O. Strength Color Strength Color Strength Color Mass Ratio Mole Ratio COOH:OH Ratio (400°F.) (400°F.) (350° F.) (350° F.) (300° F.) (300°F) :24 (1:30) O.O2: Dissolved Light Dissolved Light Dissolved Light caramel- caramel- caramel colored colored colored :12 (1:15) O.04: mpervious Clear and Dissolved Caramel- Dissolved Caramel colorless colored colored :8 (1:10) O.06: mpervious Clear and Partially Caramel- Dissolved Caramel colorless Dissolved colored colored :6 (1:7) O.08: mpervious Clear and Softened Clear Dissolved Caramel colorless yellow colored :5 (1:6) O.10: mpervious Clear and Softened Clear Dissolved Caramel colorless yellow colored 4e (1:5) 0.12:1e mpervious Clear and Softened Clear Dissolved Caramel colorless yellow colored :3e (1:4) 0.15:1e mpervious Clear and Softened Clear Dissolved Caramel colorless Orange colored From Example 1 MW = 243 g/mol; 25% (weight percent) solution MW = 198 g/mol; 25% (weight percent) solution Approximate Associated with distinct ammonia Smell US 2009/03249 15 A1 Dec. 31, 2009 39

TABLE 3 TABLE 3-continued Measured Tensile Strength for Glass Bead Shell Bone Compositions Measured Tensile Strength for Glass Bead Shell Bone Compositions Prepared With Triammonium Citrate-Dextrose (1:6) Binder vs. Prepared With Triammonium Citrate-Dextrose (1:6) Binder vs. Standard PF Binder Standard PF Binder

Mean Mean Mean Mean Dry Weathered Dry Weathered Weathered:Dry Tensile Tensile Weathered:Dry Tensile Tensile Tensile Strength Strength Strength Tensile Strength Strength Strength Binder Description Ratio (psi) (psi) Binder Description Ratio (psi) (psi) Triammonium Citrate-Dextrose O.71 286 2O2 SILQUESTA-187 silane O.71 351 250 Triammonium Citrate-Dextrose O.76 368 281 Substituted 2:1 by weight for Triammonium Citrate-Dextrose 0.79 345 271 SILQUESTA-110 Triammonium Citrate-Dextrose O.77 333 2S6 HYDROSIL 2627 silane O.87 337 293 Triammonium Citrate-Dextrose O.82 345 284 Substituted 1:1 by weight for Triammonium Citrate-Dextrose 0.75 379 286 SILQUESTA-110 Triammonium Citrate-Dextrose O.74 447 330 HYDROSIL 2627 silane O.99 316 312 Triammonium Citrate-Dextrosef O.76e 358e 273e Substituted 2:1 by weight for Triammonium Citrate-Dextrose: SILQUEST A-110 o Z-6020 silane Substituted 1:1 by O.78 357 279 weight for SILQUESTA-1101 Day Binder Made 0.79 345 271 Z-6020 silane Substituted 2:1 by O.78 373 291 a B.A.R. N. E weightStandard for PF SIQUESTA-101 (Ductliner) Binder 0.79 637 505 Week. After Binder Made O.88 361 316 2 Weeks After Binder Made O.82 342 28O From Example 6 rammonium citrate-Dextrose From Example 5 with Silane Substitution: Mean of nine shell bone samples SILQUESTA-187 silane O.69 324 222 One of seven different batches of triammonium citrate-dextrose (1:6) binder made over a five-month period Substituted 1:1 by weight for Average of seven different batches of triammonium citrate-dextrose (1:6) SILQUESTA-1101 binder made over a five-month period

TABLE 4

Measured Tensile Strength for Glass Bead Shell Bone Compositions Prepared With Triammonium Citrate-Dextrose (1:6) Binder Variants' vs. Standard PF Binder

Quantity of Mean Mean Additive in Weathered:Dry Dry Weathered 300 g of Tensile Tensile Tensile binder Strength Strength Strength Binder Description (grams) Ratio (psi) (psi) Triammonium citrate-Dextrose O.76 358 273d Triammonium citrate-Dextrose with Additive:

Sires BS 1042 1.6 O.84 381 325 Sires BS 1042 3.2 O.94 388 363 Sires BS 1042 4.8 1.01 358 362 Sodium Carbonate O.45 O.88 281 248 Sodium Carbonate O.9 O.71 339 242 Sodium Carbonate 1.35 O.89 282 251 Sires BS 1042 + Sodium Carbonate 1.6 - 1.35 O.84 335 28O Sires BS 1042 + Sodium Carbonate 3.2 - 0.9 O.93 299 277 Sires BS 1042 + Sodium Carbonate 4.8 + 0.48 0.73 368 270 Sodium Carbonate? O.9 O.83 211 175 Sodium Carbonate? O.9 O.69 387 266 Sodium Carbonate 1.8 O.81 222 18O Sodium Carbonate 1.8 O.66 394 259 LE 46 6.4 O.80 309 248 LE 46 12.9 O.98 261 256 TPX5688/AQUA-TRETE BSM40 S.6 O.78 320 250 Sires BS 1042 6.4 O.91 3O8 28O Trimethylmethoxysilane O.9 O.78 262 205 US 2009/03249 15 A1 Dec. 31, 2009 40

TABLE 4-continued

Measured Tensile Strength for Glass Bead Shell Bone Compositions Prepared With Triammonium Citrate-Dextrose (1:6) Binder Variants' vs. Standard PF Binder

Quantity of Mean Mean Additive in Weathered:Dry Dry Weathered 300 g of Tensile Tensile Tensile binder Strength Strength Strength Binder Description (grams) Ratio (psi) (psi)

Potassium Permanganate O.2 O.69 3O2 2O7 PGN 9 O.82 246 2O1 Cloisite NA+ 9 O.71 28O 199 Blown Soya Emulsion (25%)' 18 1.04 239 248 Flaxseed Oil Emulsion (25%) 18 O.90 362 326 Bentolite L-10' 9 1.00 288 288 Michem 45745 PE Emulsion (50%) 9 O.81 335 270 Bone Glue Solution 15 O.82 435 358 Tannic Acid 4.5 0.79 474 375 Glycine 4.5 O.80 346 277 Glycerol S.28 O.69 361 249 Sodium Tetraborate Decahydrate + O.9 - 4.5 O.74 378 28O Glycerol Sodium Tetraborate Decahydrate 1% O.9 O.86 387 331 Sodium Tetraborate Decahydrate 2% 1.8 O.80 335 267 Sodium Tetraborate Decahydrate 3% 2.5 O.84 334 282 Axel INT-26-LF9SA O.9 O.70 374 263 ISO Chill Wheya 1% O.9 O.74 444 328 ISO Chill Whey 2% 1.8 1.01 4O7 412 ISO Chill Whey 5% 4.5 NC 473 NM Resorcinol 5% 4.5 O.76 331 251 Maltitol 3.23 O.82 311 256 1.5-Pentanediol 4.5 O.74 451 333 1.5-Pentanediol 9 0.67 488 327 1.5-Pentanediol 13.5 O.85 459 389 1,6-Hexanediol 4.5 O.84 462 387 1,6-Hexanediol 9 0.67 529 353 1,6-Hexanediol 13.5 O.78 547 427 poly THF-so 4.5 0.75 475 357 polyTHF-so 9 O.69 485 337 polyTHF-so 13.5 O.69 463 321 Textrion whey O.9 1.13 42O 475 Textrion whey 1.8 O.96 469 445 polyTHFso 4.5 O.9S 399 379 poly THF-so 9 O.94 397 372 polyTHFso 13.5 O.9S 371 353 Glycero 4.5 0.75 326 245 Glycero 9 O.63 370 233 Glycero 13.5 O.S9 372 220 Glycero 18 O.65 339 221 Sorbitol 4.5 O.85 352 3OO Sorbitol 9 0.75 402 301 Sorbitol 13.5 0.73 374 272 TMP 4.5 O.78 496 386 TMP 9 O.85 466 395 TMP 13.5 O.84 489 412 PETo 4.5 O.81 431 349 US 2009/03249 15 A1 Dec. 31, 2009 41

TABLE 4-continued Measured Tensile Strength for Glass Bead Shell Bone Compositions Prepared With Triammonium Citrate-Dextrose (1:6) Binder Variants' vs. Standard PF Binder

Quantity of Mean Mean Additive in Weathered:Dry Dry Weathered 300 g of Tensile Tensile Tensile binder Strength Strength Strength Binder Description (grams) Ratio (psi) (psi)

PETol 9 O.90 370 334 PETol 13.5 O.64 445 286 Standard PF (Ductliner) Binder 0.79 637 505 From Example 6 From Example 5 Mean of nine shell bone samples Average of seven different batches of triammonium citrate-dextrose (1:6) binder made over a five-month period Silres BS 1042 to be 50% solids emulsion of methylhydrogen polysiloxane VReplicate samples 8 Replicate sample "LE 46 to be 35% solids emulsion of polydimethylsiloxane TPX5688/AQUA-TRETE BSM40 to be 40% emulsion of alkylsilane JPGN, a grade of clay, montmorillonite, from Nanocor *Cloisite NA+, the sodium salt of a clay from Southern Clay Products Blown Soya Emulsion (25%), a 25% solids emulsion of soybean oil with PEG 400 dioleate (4% on solids) and guar gum (1% on Solids) "Bentolite L-10, a clay from Southern Clay Products "Michem 45745 PE Emulsion (50%), a 25% solids emulsion of low molecular weight polyeth ylene Bone Glue Solution, a 30% solids solution Axel INT-26-LF95, a fat-based, mold-release agent emulsion aISO Chill Whey 9010 Not calculated Not measured poly Tetrahydrofuran (OH-(CH2—CH2—CH2—CH2—O—), H) with molecular weight = 250 "poly Tetrahydrofuran (OH-(CH2—CH2—CH2—CH2—O-), H) with molecular weight = 6SO Trimethylol propane "Pentaerythritol

TABLE 5 Measured Tensile Strength for Glass Bead Shell Bone Compositions Prepared With Ammonium Polycarboxylate-Dextrose Binder Variants' vs. Polycarboxylic Acid-based Binders vs. Standard PF Binder Mean Dry Weathered: Dry Tensile Mean Weathered Tensile Strength Strength Tensile Strength Binder Description Ratio (psi) (psi) Triammonium citrate-dextrose (1:6) O.76 358 273d Triammonium citrate-dextrose (1:5) O.68 377 257 +Sodium carbonate (0.9 g) O.71 341 243 +Sodium carbonate (1.8 g) O.78 313 243 AQUASET-529 + Dex + Ammonia O41 499 205 AQUASET-529 + Dex + Silane? 0.57 541 306 AQUASET-529 + Ammonia + Silanes O.11 314 33 AQUASET-529 + Silane" O48 60S 293 PETol + Maleic Acid + Silane' 0.73 654 477 PETol + Maleic Acid + TSA + Silane O.64 614 390 Binder + Ammonia + Dex + Silane O.S8 420 245 PETol + Citric Acid + Silane' O.S6 539 303 CRITERION 2000+ Glycerol" O.26 532 136 CRITERION 2000 + Glycerol O.20 472 95 US 2009/03249 15 A1 Dec. 31, 2009 42

TABLE 5-continued Measured Tensile Strength for Glass Bead Shell Bone Compositions Prepared With Ammonium Polycarboxylate-Dextrose Binder Variants' vs. Polycarboxylic Acid-based Binders vs. Standard PF Binder

Mean Dry Weathered: Dry Tensile Mean Weathered Tensile Strength Strength Tensile Strength Binder Description Ratio (psi) (psi)

SOKALAN + Dex + Ammonia O.66 664 437 NF1 + Dex + Ammonia O.SO 877 443 Standard PF (Ductliner) Binder 0.79 637 505 From Example 6 From Example 5 Mean of nine shell bone samples Average of seven different batches of triammonium citrate-dextrose (1:6) binder made over a five-month period 200 g AQUASET-529 + 87 g 19% ammonia + 301 g Dextrose + 301 g water to be a 30% Solution V300 mL of solution from binder + 0.32 g of SILQUESTA-1101 $200 g AQUASET-529 + 87 g 19% ammonia + 101 g water + 0.6 g SILOUESTA-1101 AQUASET-529 + SILQUESTA-1101 (at 0.5% binder solids), diluted to 30% solids 136 gpentaerythritol +98g maleic anhydride +130 g water, refluxed for 30 minutes; 232g of resulting solution mixed with 170 g water and 0.6 g of SILOUESTA-1101 136 g pentaerythritol + 98 g maleic anhydride + 130 g water + 1.5 mL of 66% p-toluene Sulfonic acid, refluxed for 30 minutes; 232 g of resulting solution mixed with 170 g water and 0.6 g of SILQUESTA-1101 220g of binder' + 39 g of 19% ammonia + 135 g Dextrose +97g water + 0.65g SILQUESTA-1101 '128g of citric acid + 45g of pentaerythritol + 125 g of water, refluxed for 20 minutes; resulting mixture diluted to 30% solids and SILQUESTA-1101 added at 0.5% on solids "200 g of Kemira CRITERION 2000 + 23g glycerol + 123 g water + 0.5g SILQUEST A-1101 "200 g of Kemira CRITERION 2000 + 30 g glycerol + 164 g water + 0.6 g SILOUEST A-1101 100 g of BASF SOKALANCP 10 S + 57 g 19% ammonia + 198g Dextrose + 180g water + 0.8 g. SILOUESTA-1101 P211 g of H.B. Fuller NF1 + 93 g 19% ammonia + 321 g Dextrose + 222 gwater + 1.33 g SILQUESTA-1101

TABLE 6 Measured Tensile Strength for Glass Bead Shell Bone Compositions Prepared With Ammonium Polycarboxylate-Sugar Binder Variants' vs. Standard PF Binder Mean Mean Weathered:Dry Dry Weathered Tensile Tensile Tensile Strength Strength Strength Binder Description Molar Ratio Ratio (psi) (psi) Triammonium citrate-Dextrose Dextrose = 2xCOOH O.76 358 273d Triammonium citrate-DHAf DHA = 2xCOOH 1.02 130 132 Triammonium citrate-Xylose Xylose = 2xCOOH 0.75 322 241 Triammonium citrate-Fructose Fructose = 2xCOOH 0.79 363 286 Diammonium tartarate-Dextrose Dextrose = 2xCOOH O.76 314 239 Diammonium maleate-Dextrose Dextrose = 2xCOOH O.78 393 3O8 Diammonium maliate-Dextrose Dextrose = 2xCOOH O.67 49 28O Diammonium succinate-Dextrose Dextrose = 2xCOOH O.70 400 281 Ammonium lactate?-Dextrose Dextrose = 2xCOOH O.68 257 175 Ammonia + tannic acid-Dextrose Dextrose = 2x NH" OSO 395 199 Standard PF (Ductliner) Binder 0.79 637 505 From Example 6 From Example 5 Mean of nine shell bone samples Average of seven batches DHA = dihydroxyacetone /Monocarboxylate *Non-carboxylic acid US 2009/03249 15 A1 Dec. 31, 2009 43

TABLE 7 Measured Tensile Strength and Loss on Ignition for Glass Fiber Mats' Prepared With Ammonium Polycarboxylate-Sugar (1:6) Binder Variants vs. Standard PF Binder

Mean Weathered:Dry Weathered Tensile Mean Dry Tensile Mean 96 Strength Tensile Strength Strength Binder Composition LOI Ratio (Ib force) (Ib force) Triammonium citrate-Dex S.90 O.63 11.4 7.2 Triammonium citrate-Dex 6.69 0.72 14.6 1O.S Diammonium maliate-Dex S.O2 O.86 102 8.8 Diammonium maliate-Dex 6.36 O.78 10.6 8.3 Diammonium Succinate-Dex S.12 O.61 8.0 4.9 Diammonium Succinate-Dex 4.97 O.76 7.5 5.7 Triammonium citrate-Fruc 5.8O 0.57 11.9 6.8 Triammonium citrate-Fruc S.96 O.6O 11.4 6.8 Diammonium maliate-Fruc 6.O1 O.6O 9.0 5.4 Diammonium maliate-Fruc 5.74 O.71 7.9 S.6 Diammonium Succinate-Fruc 4.60 1.OS 3.7 3.9 Diammonium Succinate-Fruc 4.13 0.79 4.4 3.5 Triammonium citrate-DHA 4.45 O.96 4.7 4.5 Triammonium citrate-DHA 4.28 O.74 5.4 4.0 Triammonium citrate-DHA- 3.75 O.S2 8.5 4.4 Glycerols Triammonium citrate-DHA- 3.38 O.S9 8.0 4.7 Glycerols Triammonium citrate-DHA- 4.96 O.61 10.7 6.5 PETo Triammonium citrate-DHA- 5.23 O.65 9.4 6.1 PETo Triammonium citrate-DHA- S.11 O.74 15.7 11.6 PVOH Triammonium citrate-DHA- 5.23 O.85 14.9 12.6 PVOH Standard PF Binder 7.22 0.75 15.9 12.0 Standard PF Binder 8.OS 0.75 18.8 14.2 From Example 7 From Example 5 Mean of three glass fiber mats Dex = Dextrose Fruc = Fructose JDHA = Dihydroxyacetone & Glycerol substituted for 25% of DHA by weight "PETol = Pentaerythritol substituted for 25% of DHA by weight PVOH = Polyvinyl alcohol (86-89% hydrolyzed polyvinyl acetate, MW ~22K-26K), sub stituted for 20% of DHA by weight Ductiner binder

TABLE 8 TABLE 8-continued Testing Results for Cured Blanket from Example 8: Triammonium Testing Results for Cured Blanket from Example 8: Triammonium citrate-Dextrose (1:6) Binder vs. Standard PF Binder citrate-Dextrose (1:6) Binder vs. Standard PF Binder PF Binder PF Binder- Melanoidin- Fiberglass Fiberglass Cured BINDER Melanoidin- Fiberglass Cured Blanket Blanket % of Fiberglass Cured BINDER TEST BINDER STANDARD STANDARD Cured Blanket Blanket % of TEST BINDER STANDARD STANDARD Tensile Strength (Ib?in. width) Density O.65 O.67 97% Machine Direction 2.77 3.81 7396 Loss on Ignition (%) 13.24% 10.32% 128% Cross Machine Dir. 1.93 2.33 83% Avg. 2.35 3.07 76% Thickness Recovery 1.46 1.59 92%0. Parting Strength (g/g) (dead, in.) Thickness Recovery 1.55 1.64 94% Machine Direction 439.22 511.92 86% (drop, in.) Cross Machine 315.95 468.99 67% Direction Dust (mg) 8.93 8.8O 1.02% Avg. 377.59 490.46 779, US 2009/03249 15 A1 Dec. 31, 2009 44

TABLE 8-continued Testing Results for Cured Blanket from Example 8: Triammonium citrate-Dextrose (1:6) Binder vs. Standard PF Binder

PF Binder Melanoidin- Fiberglass Fiberglass Cured BINDER Cured Blanket Blanket % of TEST BINDER STANDARD STANDARD Bond Strength (1b/ft) 11.58 1423 81% Water Absorption 1.24% 1.06% 11.6% (% by weight) Hot Surface Pass Pass Performance Product Emissions (at 96 Hours) TotalVOCs (ig/m) O 6 Total HCHO (ppm) O 56 Total Aldehydes (ppm) 6 56

TABLE 9 Smoke Development on Ignition for Cured Blanket from Example 8: Triammonium citrate-Dextrose (1:6) Binder vs. Standard PF Binder Average SEA External Heat Melanoidin-Fiberglass PF Binder-Fiberglass Flux Cured Blanket Cured Blanket 35 kW/m2 2,396 m/kg 4.923 m. kg 35 kW/m2 1.496 m/kg 11,488 m. kg 35 kW/m2 3,738 m/kg 6,848 m /kg Overall Avg. = 2,543 m/kg Overall Avg. = 7,756 m/kg 50 kW/m2 2,079 m/kg 7,305 m/kg 50 kW/m2 3,336 ml/kg 6.476 m /kg 50 kW/m2 1467 m/kg 1,156 m/kg Overall Avg. = 2.294 m/kg Overall Avg. = 4.979 m/kg SEA = specific extinction area

TABLE 10 TABLE 10-continued Testing Results for Air Duct Board from Example 9: Triammonium Testing Results for Air Duct Board from Example 9: Triammonium citrate-Dextrose (1:6) Binder vs. Standard PF Binder citrate-Dextrose (1:6) Binder vs. Standard PF Binder Melanoidin- PF Binder Fiberglass Fiberglass Melanoidin- PF Binder Air Duct Board Air Duct Board BINDER 90 of Fiberglass Fiberglass TEST BINDER STANDARD STANDARD Air Duct Board Air Duct Board BINDER 96 of TEST BINDER STANDARD STANDARD Density 4.72 4.66 1.01% Loss on Ignition (%) 18.5% 16.8% 1.10% Compressive (psi) Flexural Rigidity Resistance at 20% (Ib in in width) Compressive Modulus 6.85 7.02 97% Machine Direction 724 837 86% (psi) Cross Machine Dir. 550 544 1.01% Conditioned 6.57 6.44 1.02% Avg. 637 691 92% Compressive Compressive (psi) 0.67 0.73 92% Modulus (psi) Resistance at 10% Compressive (psi) 1.34 1.34 100% Product Emissions Resistance at 20% (at 96 Hours) Conditioned O.719 O661 109% Compressive (psi) Total VOCs (ig/m) 40 39 1.02% Resistance at 10% Total HCHO (ppm) O.OO7 O.043 16% Conditioned 1.31 1.24 106% Total Aldehydes (ppm) O.OO7 O.043 16% US 2009/03249 15 A1 Dec. 31, 2009 45

TABLE 11 Testing Results for R30 Residential Blanket from Example 10: Triammonium citrate-Dextrose (1:6) Binder vs. Standard PF Binder

PF Binder Binder Binder Binder Test (% of Std) (% of Std) (% of Std) Std Thickness recovery (dead, in.): week 10.05 (97%) 10.36 (99%) 9.75 (94%) 10.38 6 week 7.17 (91%) 7.45 (94%) 7.28 (92%) 7.90 Thickness recovery (drop, in.): week 11.06 (10.1%) 4.23 (1.02%) 11.01 (100%) 11.00 6 week 9.07 (1.01%) 9.06 (101%) 9.31 (1.03%) 8.99 Parting Strength (gg) Machine Direction 214.62 (78%) 186.80 (68%) 228.22 (83%) 275.65 Cross Machine 219.23 (75%) 202.80 (70%) 210.62 (72%) 29O.12 Direction Average 216.93 (77%) 194.80 (69%) 219.42 (77%) 282.89 Durability of Parting Strength (gg) Machine Direction 214.62 (84%) 209.54 (82%) 259.58 (1.02%) 254.11 Cross Machine 219.23 (87%) 204.12 (81%) 221.44 (88%) 252.14 Direction Average 216.93 (86%) 206.83 (82%) 240.5195%) 2S3.13 Bond Strength (Ib/ft2) 1.86 (84%) NM NM 2.20 Dust (mg) 0.0113 (79%) 0.0137 (96%) 0.01.01 (71%) O.O142 Hot Surface Performance Pass Pass Pass Pass (pass/fail) Corrosivity (steel) Pass Pass Pass NM (pass/fail) Melanoidin binder; nominal machine condition to produce loss on ignition of 5% Melanoidin binder; machine adjustment to increase loss on ignition to 6.3% Melanoidin binder; machine adjustment to increase loss on ignition to 6.6% Not measured

TABLE 12 TABLE 12-continued Testing Results for R19 Residential Blanket from Example 11 (Batch Testing Results for R19 Residential Blanket from Example 11 (Batch A-1): Triammonium citrate-Dextrose (1:6) Binder vs. Standard PF Binder A-1): Triammonium citrate-Dextrose (1:6) Binder vs. Standard PF Binder

Melanoidin- PF Binder- Melanoidin- PF Binder Fiberglass R19 Fiberglass R19 BINDER 9% Fiberglass R19 Fiberglass R19 BINDER 9% Residential Residential of Residential Residential of TEST BINDER STANDARD STANDARD TEST BINDER STANDARD STANDARD Thickness Recovery Parting Strength (g/g) (dead, in.): Machine Direction 28.18 173.98 74% week 6.02 6.OS 99% Cross Machine 18.75 159.42 74% 5 week 6.15 6.67 92% Direction 6 week 4.97 5.14 97% Average 23.47 166.70 74% 3 month 6.63 6.20 1.07% Durability of Parting Thickness Recovery Strength (gg) (drop, in.): k 6.79 6.69 1.01% Machine Direction 43.69 161.73 89% Wee 0. C Mach 27.30 149.20 859 4 week 6.92 7.11 97% nine 0. 6 k 5.83 6.07 96% Wee Average 35.50 155.47 87% 3 month 7.27 6.79 1.07% d b/ft2 0. Dust (mg) 2.88. 8.03 36% Bon Strength ( ) 1.97 2.37 83% Tensile Strength Water Absorption (%) 7.1 7.21 98% (Ib?in. width) Hot Surface Pass Pass o Performance Machine Direction 2.42 3.47 70% Corrosion Pass Pass Cross Machine Dir. 2.OO 3.03 66% Stiffness-Rigidity 49.31 44.94 1.10% Average 2.21 3.25 68% US 2009/03249 15 A1 Dec. 31, 2009 46

TABLE 13 Testing Results for R19 Residential Blanket from Example 11: Triammonium citrate-Dextrose (1:6) Binder Variants vs. Standard PF Binder

Binder Batch Binder Batch Binder Batch Binder Batch A-2 Ba Ca Da Test (% of Std) (% of Std) (% of Std) (% of Std) PF Binder Std. Thickness recovery (dead, in.): 1 week 5.94 (99%) 5.86 (98%) 6.09 (1.01%) 6.25 (104%) 6.O1 6 week 4.86 (91%) 5.29 (99%) 5.0 (93%) 5.10 (95%) Thickness recovery (drop, in.): 1 week 6.83 (105%) 6.7025 (1.03%) 6.81 (104%) 6.88 (105%) 6.OO 6 week 5.76 (96%) 6.02 (100%) 5.89 (98%) 6.00 (100%) Tensile Strength (Ib?in) Machine Direction 1.28 (36%) 1.40 (39%) 1.71 (48%) 1.55 (43%) 3.58 Cross Machine Direction 1.65 (71%) 1.21 (52%) 1.12 (48%) 1.12 (48%) 2.31 Average 1.47 (50%) 1.31 (44%) 1.42 (48%) 1.34 (45%) 2.95 Parting Strength (gg) Machine Direction 111.82 (42%) 164.73 (62%) 136.00 (51%) 164.56 (62%) 264.81 Cross Machine Direction 140.11 (85%) 127.93 (78%) 126.46 (77%) 108.44 (66%) 164.60 Average 125.97 (59%) 146.33 (68%) 131.23 (61%) 136.50 (64%) 214.71 Durability of Parting Strength (gg) Machine Direction 138.55 (72%) 745.62 (76%) 113.37 (59%) 176.63 (92%) 1912O Cross Machine Direction 158.17 (104%) 116.44 (77%) 97.10 (64%) 162.81 (107%) 151.49 Average 148.36 (86%) 131.03 (76%) 105.24 (61%) 169.72 (99%) 171.35 Bond Strength (Ib/ft2) 1.30 (52%) 1.50 (60%) 1.60 (64%) 1.60 (64%) 2.50 Dust (mg) 0.0038 (86%) 0.0079 (179%) 0.0053 (120%) 0.0056 (126%) O.OO44 Stiffness-Rigidity (degrees) 57.50 (N/A) 55.50 (NIA) 61.44 (NIA) 59.06 (NA) 39.38 Melanoidin binder

TABLE 1.4 TABLE 15-continued GC/MS Analysis of Gaseous Compounds Produced During Pyrolysis of GC/MS Analysis of Gaseous Compounds Produced During Thermal Cured Blanket (from Example 8) Prepared With Ammonium Curing of Pipe Insulation Uncured (from Example 12) Prepared With Citrate-Dextrose (1:6) Binder Ammonium Citrate-Dextrose (1:6) Binder Retention Time (min) Tentative Identification 0.% Peak Area Retention Time (min) Identification % Peak Area 1.15 2-cyclopenten-1-one 10.67 1.34 2,5-dimethyl-furan 5.84 3.13 1-(2-furanyl)-ethanone O.S2 3.54 furan 2.15 3.55 furan 4.92 3.60 3-methyl-2,5-furandione 3.93 3.62 2-pyridinecarboxyaldehyde O.47 4.07 phenol O.38 3.81 5-methylfurfural 3.01 4.89 2,3-dimethyl-2-cyclopenten-1-one 1.24 3.99 furancarboxylic acid, methyl ester O.34 S.11 2-methyl phenol 1.19 4.88 3,4-dimethyl-2,5-furandione O.S3 E. IES R 541 2-furancarboxylic acid 1.01 4-dimenyl-pheno 6.37 2-amino-6-hydroxymethylpyridine 1.08 10.57 dimethylphthalate 0.97 6.67 6-methyl-3 idinol O.49 17.89 octadecanoic acid 1.00 R y1- R. d 22.75 erucylamide 9.72 7.59 2-?urancarboxaldehyde O.47 7.98 picolinamide O.24 10.34 2H-1-benzopyran-2-one O.23 TABLE 1.5 16.03 hexadecanoic acid O.21 17.90 octadecanoic acid 2.97 GC/MS Analysis of Gaseous Compounds Produced During Thermal 22.74 erucylamide 10.02 Curing of Pipe Insulation Uncured (from Example 12) Prepared With Ammonium Citrate-Dextrose (1:6) Binder 0276 While certain embodiments of the present invention Retentionetention TimeTi (min)in) IdentificationIdentificati %O Peak(8KA8 Air have been described and/or exemplified above, it is contem 1.33 2,5-dimethylfuran 1.02 plated that considerable variation and modification thereof 2.25 furfural OR 3-furaldehyde 2.61 2.48 2-furanmethanol OR3- 1.08 a possible. Accordingly, the present 1nVent1On 1S not limited furanmethanol to the particular embodiments described and/or exemplified herein. US 2009/03249 15 A1 Dec. 31, 2009 47

What is claimed is: 175. The fiberglass material of claim 161, wherein the 1.-160. (canceled) fiberglass material has a noise reduction coefficient of from 161. A fiberglass material comprising: about 0.7 to about 1.00. (a) a collection of glass fibers; and 176. The fiberglass material of claim 161, wherein the (b) a binder disposed on the collection of glass fibers, fiberglass material has a noise reduction coefficient of from wherein, the binder includes at least one reaction prod about 0.95 to about 1.15. uct of a carbohydrate reactant and an amine reactant, and 177. A fiberglass material comprising: the fiberglass material has a density of from about 0.4 (a) a collection of glass fibers; and lbs/ft to about 6 lbs/ft. (b) a binder disposed on the collection of glass fibers, the 162. The fiberglass material of claim 161, wherein the binder comprising a mixture of Maillard reactants, carbohydrate reactant is a reducing Sugar. wherein the fiberglass material has a predetermined den 163. The fiberglass material of claim 161, wherein the sity, a predetermined R-value, and a predetermined amine reactant is an ammonium salt of a polycarboxylic acid. noise reduction coefficient. 164. The fiberglass material of claim 161, wherein the 178. The fiberglass material of claim 177, wherein the amine reactant is an ammonium salt of a monomeric polycar predetermined density is in the range from about 0.4 lbs/ft to boxylic acid. about 6 lbs/ft. 179. The fiberglass material of claim 177, wherein the 165. The fiberglass material of claim 161, wherein the predetermined noise reduction coefficient is in the range from density is from about 0.75 lbs/ft to about 2.5 lbs/ft. about 0.5 to about 1.10. 166. The fiberglass material of claim 161, wherein the 180. The fiberglass material of claim 177, wherein the density is from about 2.25 lbs/ft to about 4.25 lbs/ft. predetermined R-value is in the range from about 2 to about 167. The fiberglass material of claim 161, wherein the 60. density is from about 0.4 lbs/ft to about 1.5 lbs/ft. 181. A fiberglass material comprising: 168. The fiberglass material of claim 161, wherein the (a) a collection of glass fibers; and density is from about 3.75 lbs/ft to about 5.2 lbs/ft, (b) a binder disposed on the collection of glass fibers, 169. The fiberglass material of claim 161, wherein the wherein i) the binder includes at least one product of a fiberglass material has an R-value of from about 11 to about carbohydrate reactant and a polycarboxylic acid ammo 6O. nium salt reactant and ii) the fiberglass material has a 170. The fiberglass material of claim 161, wherein the predetermined density, a predetermined R-value, and a fiberglass material has an R-value of from about 2 to about 8. predetermined noise reduction coefficient. 171. The fiberglass material of claim 161, wherein the 182. The fiberglass material of claim 181, wherein the fiberglass material has an R-value of from about 3.4 to about predetermined density is in the range from about 0.4 lbs/ft to 102. about 6 lbs/ft. 172. The fiberglass material of claim 161, wherein the 183. The fiberglass material of claim 181, wherein the fiberglass material has an R-value of from about 8 to about 38. predetermined noise reduction coefficient is in the range from 173. The fiberglass material of claim 161, wherein the about 0.5 to about 1.10. fiberglass material has a noise reduction coefficient of from 184. The fiberglass material of claim 181, wherein the about 0.5 to about 1.10. predetermined R-value is in the range from about 2 to about 174. The fiberglass material of claim 161, wherein the 60. fiberglass material has a noise reduction coefficient of from about 0.6 to about 0.70.