Patents Assigned to Knauf Insulation, Inc.
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Patent number: 11945979Abstract: A method of manufacturing a composite product, comprising: —applying a binder composition, notably in the form of an aqueous solution, to non or loosely assembled matter to provide resinated matter, wherein the binder composition consists of a binder composition prepared by combining reactants comprising at least 50% by dry weight reducing sugar reactant(s) and at least 5% by dry weight nitrogen-containing reactant(s); and—arranging the resinated matter to provide loosely arranged resinated matter; and—subjecting the loosely arranged resinated matter to heat and/or pressure to cure the binder composition and to form the composite product; —wherein the nitrogen-containing reactant(s) comprise TPTA triprimary triamine(s), notably wherein the nitrogen-containing reactant(s) comprise at least 5% by dry weight of TPTA triprimary triamine(s).Type: GrantFiled: March 27, 2019Date of Patent: April 2, 2024Assignees: Knauf Insulation, Inc., Knauf Insulation SPRLInventors: Carl Hampson, Oliver Callaghan
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Patent number: 11946582Abstract: An un-reacted substantially formaldehyde free curable binder solution for binding loose matter consists essentially of a solution obtainable by dissolving a reducing sugar, an ammonium salt acid precursor, optionally a carboxylic acid or a precursor thereof and optionally ammonia in water.Type: GrantFiled: May 7, 2019Date of Patent: April 2, 2024Assignees: Knauf Insulation, Inc., Knauf Insulation SPRLInventor: Carl Hampson
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Patent number: 11939460Abstract: A binder used for manufacturing a composite product is prepared by combining i) Maillard reactants selected from: reducing sugar reactant(s) and nitrogen-containing reactant(s); curable reaction product(s) of reducing sugar reactant(s) and nitrogen-containing reactant(s); and combinations thereof; and ii) a resin; reactants of a resin; and combinations thereof.Type: GrantFiled: March 27, 2019Date of Patent: March 26, 2024Assignees: Knauf Insulation, Inc., Knauf Insulation SPRL, McTron Technologies, IncInventors: Carl Hampson, Oliver Callaghan, Kenneth Snyder
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Patent number: 11905206Abstract: Binders to produce or promote cohesion in non-assembled or loosely assembled matter.Type: GrantFiled: August 1, 2022Date of Patent: February 20, 2024Assignees: Knauf Insulation, Inc., Knauf Insulation SPRLInventors: Brian Lee Swift, Ronald E. Kissell, Ruijian Xu
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Publication number: 20240052966Abstract: A method of manufacturing a mineral fibre thermal insulation product comprises the sequential steps of: Forming mineral fibres from a molten mineral mixture; Spraying a substantially formaldehyde free binder solution on to the mineral fibres, the binder solution comprising: a reducing sugar, an acid precursor derivable from an inorganic salt and a source of nitrogen; Collecting the mineral fibres to which the binder solution has been applied to form a batt of mineral fibres; and Curing the batt comprising the mineral fibres and the binder which is in contact with the mineral fibres by passing the batt through a curing oven so as to provide a batt of mineral fibres held together by a substantially water insoluble cured binder.Type: ApplicationFiled: October 22, 2023Publication date: February 15, 2024Applicant: KNAUF INSULATION, INC.Inventors: Carl Hampson, Gert Mueller, Charles Appley
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Patent number: 11846097Abstract: A fiber product is described which includes fibers, a binder and a temperature control additive. The fiber product has properties that make it useful for a variety of applications. The fibers may be glass fibers and the product may be a fiberglass insulation product for use in buildings, vehicles, or other structures for acoustic and/or thermal insulation. The fibers may be cellulosic fibers and the product may be a wood board product. The temperature control additive is incorporated into the uncured fiber product to prevent deleterious self-heating during or after binder curing. The temperature control additive undergoes an endothermic process that consumes at least a portion of the energy generated during the exothermic curing reaction.Type: GrantFiled: April 20, 2018Date of Patent: December 19, 2023Assignees: Knauf Insulation, Inc., Knauf Insulation SPRLInventors: Gert Mueller, Charles Fitch Appley
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Patent number: 11814481Abstract: A binder comprising the products of a carbohydrate reactant and polyamine is disclosed. The binder is useful for consolidating loosely assembled matter, such as fibers. Uncured fibrous products comprising fibers in contact with a carbohydrate reactant and a polyamine are also disclosed. The binder composition may be cured to yield a fibrous product comprising fibers bound by a cross-linked polymer. Further disclosed are methods for binding fibers with the carbohydrate reactant and polyamine based binder.Type: GrantFiled: July 2, 2021Date of Patent: November 14, 2023Assignees: Knauf Insulation, Inc., Knauf Insulation SPRLInventors: Charles Fitch Appley, Carl Hampson, Gert R. Mueller, Benedicte Pacorel
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Patent number: 11725124Abstract: The present invention relates to a water-soluble pre-reacted binder composition, a method of its manufacture, a use of said pre-reacted binder composition, a method of manufacturing a collection of matter bound by a polymeric binder, a binder solution or dispersion comprising said pre-reacted binder composition, as well as products comprising the pre-reacted binder composition in a cured state.Type: GrantFiled: August 22, 2022Date of Patent: August 15, 2023Assignees: Knauf Insulation, Inc., Knauf Insulation SPRLInventors: Carl Hampson, Benedicte Pacorel, Roger Jackson
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Patent number: 11649562Abstract: An apparatus for producing fibers from molten material includes a drive shaft rotatable about an axis, a slinger basket including a base, a side wall, and an interior void. The side wall extends axially upward from the base and includes a plurality of distribution holes. The interior void extends radially from the drive shaft to the side wall and extends axially from the base to an upper opening which extends radially outward from the drive shaft toward the upper flange. A spinner body is coupled with the slinger basket and includes a roof contacting and extending radially outward from the upper flange such that the upper opening is substantially unobstructed by the spinner body. A spinner side wall extends axially downward from the roof and includes a fiberizing region including a plurality of fiberizing holes provided therein.Type: GrantFiled: February 25, 2021Date of Patent: May 16, 2023Assignees: Knauf Insulation Inc., Knauf Insulation SPRLInventors: Robert W. Zembrodt, Matthew W. Revercomb, Roberto O. Pellizzari
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Publication number: 20220389286Abstract: The present invention relates to a water-soluble pre-reacted binder composition, a method of its manufacture, a use of said pre-reacted binder composition, a method of manufacturing a collection of matter bound by a polymeric binder, a binder solution or dispersion comprising said pre-reacted binder composition, as well as products comprising the pre-reacted binder composition in a cured state.Type: ApplicationFiled: August 22, 2022Publication date: December 8, 2022Applicant: KNAUF INSULATION, INC.Inventors: Carl Hampson, Benedicte PACOREL, Roger JACKSON
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Patent number: 11459754Abstract: A method of manufacturing a mineral fiber insulating board comprising i) spraying a formaldehyde-free aqueous binder solution onto a plurality of mineral fibers to provide uncured binder disposed on the plurality of mineral fibers, ii) passing the plurality of mineral fibers having uncured binder disposed thereon through a curing oven to cure the uncured binder and provide the mineral fiber insulating board with a cured binder disposed on the plurality of mineral fibers in about 0.5%-15% by weight as determined by loss on ignition, wherein the binder is based on reducing sugar(s) and the cured binder includes at least one reaction product of the reducing sugar(s) and an amine reactant.Type: GrantFiled: August 28, 2020Date of Patent: October 4, 2022Assignees: Knauf Insulation, Inc., Knauf Insulation SPRLInventors: Roger Jackson, Tony Aindow, George Baybutt
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Patent number: 11453807Abstract: The present invention relates to a water-soluble pre-reacted binder composition, a method of its manufacture, a use of said pre-reacted binder composition, a method of manufacturing a collection of matter bound by a polymeric binder, a binder solution or dispersion comprising said pre-reacted binder composition, as well as products comprising the pre-reacted binder composition in a cured state.Type: GrantFiled: March 18, 2019Date of Patent: September 27, 2022Assignees: Knauf Insulation, Inc., Knauf Insulation SPRLInventors: Carl Hampson, Benedicte Pacorel, Roger Jackson
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Patent number: 11453780Abstract: In a stack of composite wood boards, the wood boards comprise wood particles and an organic binder.Type: GrantFiled: July 18, 2019Date of Patent: September 27, 2022Assignees: Knauf Insulation, Inc., Knauf Insulation SPRLInventors: Roger Jackson, Tony Aindow, George Baybutt
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Patent number: 11401209Abstract: Binders to produce or promote cohesion in non-assembled or loosely assembled matter.Type: GrantFiled: June 10, 2020Date of Patent: August 2, 2022Assignees: Knauf Insulation, Inc., Knauf Insulation SPRLInventors: Brian Lee Swift, Ronald E. Kissell
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Patent number: 11401204Abstract: Disclosed are formaldehyde-free, thermally-curable, alkaline, aqueous binder compositions. Also disclosed are compositions comprising formaldehyde-free, thermally-curable binder compositions, as described herein, applied to non-woven fibers. Uses of the disclosed binder compositions as binders for non-woven fibers are also disclosed.Type: GrantFiled: February 6, 2015Date of Patent: August 2, 2022Assignees: Knauf Insulation, Inc., Knauf Insulation SPRLInventors: Charles Fitch Appley, Gert Mueller
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Patent number: 11384203Abstract: The present disclosure provides for improved binder compositions comprising an amine component, as well as methods for manufacturing articles and collections of matter comprising the disclosed binder compositions.Type: GrantFiled: June 6, 2019Date of Patent: July 12, 2022Assignees: Knauf Insulation, Inc., Knauf Insulation SPRLInventor: Benedicte Pacorel
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Patent number: 11332577Abstract: The present invention relates to a water-soluble carbohydrate-polyamino acid-based pre-reacted binder composition, a method of its manufacture, use of the pre-reacted binder composition, a method of manufacturing a collection of matter bound by a polymeric binder, a binder solution or dispersion comprising the pre-reacted binder composition, as well as products comprising the pre-reacted binder composition in a cured state.Type: GrantFiled: December 18, 2018Date of Patent: May 17, 2022Assignees: Knauf Insulation SPRL, Knauf Insulation, Inc.Inventors: Carl Hampson, Richard Hand, James Robinson
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Patent number: 11318639Abstract: A molding process includes the operation of placing insulation material comprising fibers and binder on the fibers in a mold cavity. The molding process further includes the step of transferring heat to the insulation material to cause the binder to cure.Type: GrantFiled: August 21, 2020Date of Patent: May 3, 2022Assignee: Knauf Insulation, Inc.Inventors: Gert R. Mueller, Robert W. Zembrodt, Charles Fitch Appley, Walter A. Johnson, Steven Lee Collings
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Patent number: 11078332Abstract: A binder comprising the products of a carbohydrate reactant and polyamine is disclosed. The binder is useful for consolidating loosely assembled matter, such as fibers. Uncured fibrous products comprising fibers in contact with a carbohydrate reactant and a polyamine are also disclosed. The binder composition may be cured to yield a fibrous product comprising fibers bound by a cross-linked polymer. Further disclosed are methods for binding fibers with the carbohydrate reactant and polyamine based binder.Type: GrantFiled: May 5, 2020Date of Patent: August 3, 2021Assignees: Knauf Insulation, Inc., Knauf Insulation SPRLInventors: Charles Fitch Appley, Carl Hampson, Gert R. Mueller, Benedicte Pacorel
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Patent number: 10968629Abstract: A method of manufacturing a mineral fiber insulating board comprising i) spraying a formaldehyde free aqueous binder solution onto a plurality of mineral fibers, the aqueous binder solution comprising binder reactants comprising a) a reducing sugar reactant and b) an amine reactant, wherein the reducing sugar reactant is selected from the group consisting of: a reducing sugar; a reducing sugar yielded by a carbohydrate in situ under thermal curing conditions; and combinations thereof, wherein the percent by dry weight of the reducing sugar reactant with respect to the total weight of the binder reactants in the binder solution ranges from about 73% to about 96%, and wherein the percent by dry weight of the amine reactant with respect to the total weight of the binder reactants in the binder solution ranges from about 4% to about 27%, ii) dehydrating the aqueous binder solution such that a dehydrated binder is disposed on the plurality of mineral fibers, and iii) curing the dehydrated binder on the plurality oType: GrantFiled: August 30, 2017Date of Patent: April 6, 2021Assignees: Knauf Insulation, Inc., Knauf Insulation SPRLInventors: Roger Jackson, Tony Aindow, George Baybutt