Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Cellular products or processes of preparing a cellular...
Reexamination Certificate
2000-04-05
2001-11-13
Seidlack, James J. (Department: 1711)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Cellular products or processes of preparing a cellular...
C521S093000, C521S134000, C521S141000, C524S416000
Reexamination Certificate
active
06316510
ABSTRACT:
FIELD OF THE INVENTION
The present invention is related to a foamable binder composition and methods for producing the same.
BACKGROUND OF THE INVENTION
Methods for supplying fibrous insulating materials by injection under air pressure provide a generally economical method of insulating a desired space. Such methods are economical at least partly because relatively inexpensive fibrous materials such as cellulose, or mineral fibers, fiberglass and the like can be used, as described, for example, in U.S. Pat. Nos. 4,487,365, 4,530,468, and 4,768,710, all of which are issued to Sperber and are incorporated herein by reference in their entirety, and also because of the relative speed with which the insulation can be blown in compared with the installation of batt-type insulation.
In order to avoid or reduce the problem of nonhomogeneous density from such methods, the insulating fibrous material is typically admixed with a binder composition as described in the Sperber patents above. Unfortunately, most binder compositions used in the process of blowing-in fibrous insulation are generally water-based materials, and therefore may cause corrosion of any metals that may be present in the building structure that receives and holds the insulation material. Corrosion of metals in walls, floors, and/or ceilings of a building reduces their strength, and therefore is undesirable. In addition, adhesive property of most binder systems is derived from organic compounds, e.g., polymers. These organic compounds are flammable and create fire hazards.
Therefore, there is a need for a binder system which contains corrosion preventing and fire retardant properties.
SUMMARY OF THE INVENTION
The present invention provides a foamable binder composition and methods for producing the same. In one embodiment of the present invention, the foamable binder composition comprises a corrosion preventing agent, a main adhesion material, a surfactant capable of inducing formation of foams, and water.
Preferably, the corrosion preventing agent also has flame retardant properties to reduce the flammability of the foamable binder composition. In one aspect of the present invention, the corrosion preventing agent comprises an inorganic material, preferably an inorganic salt. More preferably, the corrosion preventing agent is an inorganic phosphate salt. And most preferably, the corrosion preventing agent is monoammonium phosphate. Since ammonium ion itself has fungicide properties, use of monoammonium phosphate as the corrosion preventing agent is particularly useful where the surfactant (e.g., foaming agent) does not have a fungicide property. Preferably, the corrosion preventing agent comprises at least about 10% by weight of the main adhesion material.
The amount of main adhesion material present in the foamable binder composition of the present invention is, preferably from about 12% to about 48% by weight of the water. Preferably, the main adhesion material comprises polyvinyl alcohol.
The foamable binder composition of the present invention can also include a fast wet tack material, i.e., a special adhering component that is especially beneficial when the combination of binder composition and insulation particles are applied overhead or to a ceiling for preventing falloffs during drying of the foamed binder system. Any fast wet tack material known to one skill in the art may be used including vinyl acetate copolymers. When the fast wet tack material is present in the binder composition, it is generally present in the amount ranging from about 10% to about 25% by weight of the main adhesion material.
The amount of surfactant present in the foamable binder composition of the present invention is preferably at least about 2% by weight of the foamable binder composition, preferably about 2.3% by weight. Preferred surfactants are those which are capable of forming foams. Any surfactant which is capable of generating a foamable binder composition can be used. Such surfactants are well known to one of ordinary skill in the art. Preferably, the surfactant has a fungicide property to prevent growth of fungus. Exemplary surfactants which are capable of producing (i.e., inducing formation of) foam and have fungicide properties include lauryl sulfate.
Another embodiment of the present invention provides a method for producing the foamable binding composition described above. The method generally involves admixing in water a corrosion preventing agent, a main adhesion material, and a surfactant capable of inducing formation of foam. The method can also include admixing the fast wet tack material.
REFERENCES:
patent: 4148781 (1979-04-01), Narukawa et al.
patent: 4613627 (1986-09-01), Sherman et al.
Bagwell Melanie
Seidlack James J.
Sheridan & Ross P.C.
LandOfFree
Foamable binder composition and methods for producing the same does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Foamable binder composition and methods for producing the same, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Foamable binder composition and methods for producing the same will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-2577536