AU2015200550A1 - Carbohydrate polyamine binders and materials made therewith - Google Patents

Abstract

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.

Description

CARBOJYHDRATE POLYAMINE BiNDERS AN M TRIALS MADEWTERE TH CROSS- REFESRENC TORLTDAP ITONS Thi apiOatin claim the benefit of Unied States nrsional appiatibon A34 , d i 7 May 2010 which is incorpratd by rferene herein. ECHNICAL FELD 10011 This diseosure reltes to a ider finlaton and mateias made thcdwith comprising a car bohydrate-ased bhia and a thod for preparing the sawe t In partiula, a binde amrising he reaction podu of a cabohydrate reactant and a olyamine and material made thee 'iEis dscrbed. BACKGROUND |0121 Binders are useful in fabricating icles because they are capable of consoldaig non- or looey- assembled matter. For examle, binders enbil two or more surfaces to become united. In partiula hinders may be used to Produce products comprising consolidated fibers Thernoseting binders may be characterized by hei nsformed into insoluble and infusible material! by means of either heat or catalytic action. Examp o f a thermosering hinder include variety of phonol-aldehyde, urca-alddchyde, meclamtnc-aidchydc, and other co ndcns at'on-polymerization materials Eke uran and polyurethane resins Binder compositions containing pheno.aldchyde, resorcino aldehyde, phenol/aldehydc/urea, pheno!/mnelamineaidehyde, and the lke are used for the bonding of fibers, tex tiles, p1lastice, rubbers, andi many other materia ls. [003 'rho in nerat] wool and fiber board industics have historically used a phenol formaldehyde binder to bind fibers. Pheol formaldehyde type binders provide suitable properties to the final products; however, environmental considerations have motivated the development of alternative hinders. One such alemnaTive binder is a carbohydrate based binder derivd ron reacting a carbohydrate and mNuliprotic acki, for exanp, U.S. Published Application No. 2007/0027283 and P Wublished PO Application W200019235 Another atrnative binder is the esterification products of acting a polycarbuxylic acid and a polY for example, U.S. Published Application No, 2005/0r202224. Because these indes do no utilize formaldehyde as a reagent, they have been collect ively referred to as formalidehyde-Prcc binders. [0041 One area of current dclopment is to find a rthsement for the phenol formaldehyde ype binders across the enie range of product: in the building and automotive sector (e.g. fiberglass insulation, particle boards, ofice panels. and acoustical sound insulation). In partic m ar, ;:e previously developed formaldehyde- e binders may nor posses all of the desired properties for all the products in this sector. For example, acr'ylic acid and poiy(vinylaicohol) based bin ders have shown promising performance characteristics. However, these are relatively more expensive than phenol formaldehyde binders, are derived essential from petroleum-based resources, and have a tendency to exhibit lower reaction rates compared to the phenol formaldehyde based binder composidns (requiring either prolonged cure tieGricesdenetmeaue) arbohydrate-based binder compositions are made of relatively inlxpensive preaursors and are derived mainly from renewable resources; howmeen these inders may also require region cottions for curing that are substantially dtiferet from those condions uer which the tradiioral Phenol fbnnahiehyde hinder system cured, As such, facile replacement of phAol formaldehyde tvpa binders with an existing alternative has not been readily achievale. [0054 According to the present disclosure, a crbohydrate based binder is described, Yhe binder composition has properties that make it useM for a variety of applications; particularly, the binder may be used to bind loosely assembled matter such as ibers. 10061 l illstrative enmbodimentN the present isclosure relates to a binder comprising a polymeric product of a carbohydrate reactant and a polyamne. In one enodimen, the carbohydrate reactant is a polysaccharidc. in one embodiment the carbohydate reactant is a monosaccharide or a disaccharide. In another embodiment, the carbohydrate as a monosaccharide in its alduse or ketUse fornm In another etnbodiment the carbohy'drate reactant is selectd from a group consisting of dextrose, xylose, fructose, dihydruxyacetone, and mixtures thiof. in another embodiment, the polymeric product is a thermnoset polymeric product [007] in illustrative~ embodiments, the pulyamine is a primary polyatnine, in one embodin"t, the polyamine may be a molecule having the formula of H2N-Q-N1Hr wherein Q i an alkyl, cycloalkyl hetcruoIkyl or cyclohcteroaikyi each of' which may be optionallysubstitutd. In one embodiment, Q is an alkyl selected from a group consisting of CC In another embodiment, Q is an alkyl selected f rm a group consisting of Cr-Gg In another embodiment, Q 4 is an alky'l selected from a group consisring of 6-C. ln yet another embodiment, Q is a CA Alky L In one embodiment, Q is selected from the group consisting of a cyciohexyl, cyclopentyl or cclobutyl, i another embodiment, Q is a benz/L [0081 In illustrative embodiments, the polyamine is selected from a group consisting of a diamine, triamine, tetraaminc, and penamine. In one embodiment, the polyamine is a diamine selected from a group Consisting o~f I 6-diamninuhexane and l 5-diamnino-2-i ethylpentaue. in one embodimmt, the diamnine is b6-diaminhexane. In One embodiment, the poy 'amine is atriamine selected rm a group consisting of dieihylenetriamine, .l-pinerazineethaneamine, and bis(hexamethylenerimine, in another e-bodiment, the polyamine is a tetranmin such as tniethylenetetramine. In another embodiment, the pulyamnine is a pentaminl~e, such as tetraethylenepentamine, [0091 In illustrative embodimets, the primary polyanu e is a polyether-polyamine, in one embodiment, the polyCeher-polvamin is a diamine or a triamine.

in iloutraive emlbodiments the weight ratio of the carbohydrate reactant to the polyamineis in the range of about 1:1 to about 301 In another embodimetr, the weight ratio of the earbohydae reactant to the polyamine is in the range of about 2:1 to about 10: 1 IN another embodiment, an aqueous extract of the polymeric product has a pH in the range of about 5 to about 9, In another eNb odment, an aqueous extract of the polytne product is essentially colorless. In yet another embodiment, the poly merC pro duet is phenokfre and/or formaldehvde-free, in another embodimnt, an lqueou, extract othe polymeric product is capable of reducing Benedict'a reagem. in another embodiment, the poymeric product absorbs lighM between 400 and 500 nm, for example, at 420 nm [0111| In :-n illustrative embodiment, a method of making a collection of matter bound with a polymeric binder comrpries preparing a solution conaining reactants for producing the polymeric binder and a solvent, wherein the eactants include aarhohydrate reactat and a polyamine: disposing the sohtion onto the cehlecrion of matter; volatilizing the solvera to form an uncored product, and subjecting the uncured product to conditions that cause the carbohydrate reactant and the polyamine to polynetire to form the polymeric binder, in one embodiment, ihe colicetion of matter comaprises fibers selected front a group consisting of mineral fibers (slag wool fbers rock wool fibers or glas fibers). arnid fibers, cm ibers, metl fibers, carbon fibers, polyinmide fibers, polyester fibers, ryon fibers andcellulosic fibers In another embodiment, the collection oftnattercomprises particulate such as coal or sand, it mother embodiment, the collection of mater is glass ibers. in yet another embstodintemi, the glass fibers are present 'n the range from about 70% to about 99% by weight In another embodiment the collection of mtter comprises cellulosic fibers, For example, the cellulosic fiber ay be wood shavings, sawdus wood pulp, or gmund wood. h yet another mbodinmant, the cllulosi tbers mav be other natural bears such as jute, nax hemp, and straw 10121 In ilusrative embodiments, the method of taking a collection of matter bound with 'i polymeric bider fue her includes preparing a solution by adding an amount of a carbohydrate reactant and an amount of a polvamine so that the weight ratio is in the range of about 2:1 to about 10:1, iuespetivelyI-. fIn one embodntmem, preparing th~e solution includes adding, the carbohydrate reactant tand the polyamine to an aqueous solution. In another eatbodient, preparing the solution includes adjusting the p1H of the solution to within the rnge of about S to about 13. for example, the range of about 8 to about 12 [033; in illustrative ebodiments, the present disclosure relates to . composition comprising a collection of'natter and a binde; the binder comprising the polymeric products ofa reaction between a carbohydrate reacant and a poiyamine, the polymeric products being substantially water insolble, in one embodinment thcollecion of matter includes nineral fibers (lag wool fibers, rock wvool fibrs. or gilss fibers), aamid ibers. ceramic fibers, tmetl fibers, carbon tiers, polyimide fibers polyst fibers, rayon fibers and celluiuoiebers. For example, celluosic fbers include wood shaving', sa wdost w ood pulp, and/or ground wood. in one embodiment the earbohy'drawe reactant is selected rom a group consisting of dextrose xylose fructose. dihydroxyacetone. and mixtures thereof. In another embodimcl ibe polyanen: is Wctd from a group consistinA of a diamino, triamine, tetranine, and penta Ine, In one embodiment, the polyamine is N-QNfg, wherein Q is Ayl, cycloalkyL heteroikyl or cycloheteralky, each of whichis optionally substitLed. In another enbodimen, the composition iurther comprise a silicon-containing compon. i one embodiment the siicon-containing ctmpounid is a funettonaized silylether or a funetionalized alkyisilylether, suchx as tor example, an amine-tunctionalizedc alysilylether. For example, in on' embodiment, the silicon containing compotmd may be gamma-aminopropyjriethoxysilane, gamna-glycidoxVpropy tameho vo-h" - mehmsihmne, or aminoethyhlnininopropvltrmethoxy'silane, or t mtinre thereof' Tn another ibodiment, the siicon-contnmng compound may ho an aminofunotional oigomerio siloxane, in anot her embodiment, iihe c'mposiOtin comprises a corrosion inhibitor selected from 'a group consisting of deducting oil, monoamimonium phosphate, sodium mectasilicate pentahydratc, melanme. tin (llJox'alate, and a mtdhylhydrogen silicone fluid emulsion, BRIE OESCRIPT NOF THE DPAWINGS JO 14 Fg.1 hos a shematic P Matillardreaoo, hich culninates i.the Iroducdin ofmielanoidins. j1l15| Fig. 2 shows a schematic of a representative Amadori rearrangemnt (01 6j Fig 3 shows the cure temperature profile (Y-axis in "C) of thee ceter of a fiberglass mat sample for different b inders during a heat mnoldingb cycle 9X-axis in mninutes of mold tiime ustng a mold press with a temperature controlled platen at 204 "C. Binder I (+) is a phenol formal dchyde binder (Comnparative Example 2); Binder 2 (in) is a carbohydrate - inorganic acid binder (Comparative Examp le 3): and Binder 3 (X) is a dextrose -ammonia.- hexamthylene diamnine rD) d r ample 5) DETAILED D)ESCR IPTION f017 While the invention is Museptibic to various modifcations and alternative forms, specific embodiment: wvill herein be described in detaiL it should be understood, however, that there is no imfeurt to limit the invention .o th p articular formts desc ribed, but on the contrary, the intention is to cover all tmodifteati ons, equivalents, and alternatie' falling within the spirit and scope of the invention. (01]84 The present disclosure relates to a binder composition having unexpected utility in consolidating non- or ioosely- assembled matter. The binder composition represents an uine.pexted adv ancement in the current state of technmology in the area ofbindcr compositions. Specifically, the binder offers imnprovemnents ini performance and provides for m)ote simnpi~fed and advantageous menufa ring methodologies, while maintaining the enviro nmeatally sound advantages that are charaeri"stic of a Ccrbohydrate based hinder system- -5 (019% As ued herein, the ter binder solmion is the solution of chemicals which can be sutbstantily dehydrated to form an uncured binder As used herein the binder or binder composition may be cured, unured, or partially cured The coposition of the uncured binder is referred t as an uncured binder composition. An uncured binder is a substaintialy dehydrated mixmre of chemicals which can be cared to form a cured binder. Subtially dehydrted roenas that the solvent (ypicaly water ctr a mv<ure tereof) used to make the binder solution is vaporized to the exter that the viscosity of the remaining o [uutrial (comprising the binder reactans and solvent is sufficiently high to create cohesion between the loosely assembled naner: thus, the remlainng material is an uncured binder. In one emnbodimuenit. the solvent is less han 65% of the tot' weight of the remaining material In another embodin, a subtantialy dehydrated binder h'as a moisture content between about 5% and about 6% water by weight of total binder, in another embodimem, the siveni may be less than 50% of the otal weight of the remaining rmerial In yt another embodiment, the solvent tray be less than 35% of the total weight tf the remaining material, In another embodiment, a substantially dehydrated binder has between about 10% and about 35% water by weight of total binder. In another embodiment, the solvent nmay comprise Is than about 20% of the toa weight of the remaining material, 10201 In ilustLtiveembodiments atn encoed binder may be colorless, white, off white, ochre or yellow to brownish MickY substance that is at least partialy, water soluble. As used herein, the lern cured binder describe the polmernac product of curing the uncured binder composition. The cured binder may have a characterstic brown to bck color. Whie described as brown or black, another charactrstic is that the binder tends to absorb eight over a broad range of wavelengths. In particular, the'c may be higher absorbanc a approxtmatdly 420 nmt As the polymer is ext 'sively cross-linked, the cured binder is substantialy insoluble. For examrpie, the binder is p~redomtinautly insoluble in water. As described herein, the un~cured hinder provides sufficient binding capacity to consolidate fnbers; however, the cured binder impars the robust long-I sting durability and physical propenties conrnonly associated with cross- linked po lymners. [0121 in illustrative embhodiments. the binder reactnt descrtbed het'ein are soluble in water and the binder solution is a solution of the bitnder reactants in an aqueous solution, in one embhodimet,. a surflctanit R include d in the aqueous solu'ti to increase the solubility or disperse bilry of' one or more binder reactants or additives, Foe exampic, a surfatetant rity be added to the aqueous hinder solution to enhance the dispersibility of a particulate additive. In one embodiment, a surfiactant is usedit create an emulsion wthb a non-polar additive or btnder reactant, In another embodiment, the bindecr solut ion comuptises about 0.01%/ to about 5% surfiat by w eight based on the w eight of the binder so ution [022j In iluttstrative embodimens, the binder solutions described herein can be applied to funeral fibers (eg, sprayed onto the mat or sproed tio the fibers as they emer the forming region), during pduetion of mineral fiber insuluion ptoducts. Once the binder solution is in contact with the mineral fibers the residual heat from the mineral fibers (note that glas, fibers for example arenmade fironm molten glass and thus coain reidual heat) and the flow of air through and/or around the product will caue a porton of the water to evaporate from the hinde solution. Removing the water leaves the remaining components of toe binder on the fiber s a coating of viscous or Sem-viscous high-solds moisture. This coating of viscous or semi-viscous high-solid mixture functions as a blinder. At this point the mat has not been cured In oher words, the uncured binder functions to bind the mineral fibers in the mat, 10231 Furthermore, it should he understood that the above described uncured hinders car be cured, For example, the process of manufacuIring a cured imution product tay include a subsequent step in which heat is applied as to cause a chemical reaction in the uncured binder composition. For example,, in the ease of aking fbirglass insuh:ion produce or other mineral fiber inating p otducts, fat the bnder solution has been applied to the fibers and dehydrated, the uncu-ed insulation product may be transferred to a curing oven. In thecurig oven the uncured insulation product is heated g., frm about 300 F to about 600 0 F 'from about W50 MC to about 320 'C0. causing the binder to cure, The cared binder is a f'rmaichyde-free, waer-reistant binder that binds the bers of' the insulation product together. Note ft- t he drying and thermal en ing may occur either sequemitally, simuit neously. contempoiranceously, or concurrently, 10241 li iluOstrative embodiments, an uncored fiber product comprises about 3% o about 40% of dry binder solids (total uncured solids by weight) In one embodiment, the uncured fiber product comprises about 5% to abom 2% of dry binder solids In another embodimem, the uncured tier product comprises about 50%/to about 97?% fib -rs by weight. [0251 As mentioned herein with respect to a inder on mineral fibers, a cured binder is the product of curing binder reactants. The term cured indicates that the binder has been exposed to conditions so as to initiate a chemical change. Examples of these chemical changes include, but are not limited to, (i) covalent bonding, (ii) hydrogen bonding of binder components, and (iii) chemically cross linking the polymers and/or oligomers in the binde,. These changes may increase the binder's durabilitv and solvest resistance as compared to the uncured binder. Curing a bindeR may result in the formanon of a thermOSe material In addition, a cured binder may resulbin increase in adhesion between the matter in a collection as compared to an uncured bider. Curing can be initiated b.y, for example, beat, microwave radiaWon, atndor conditions that initiate one or nore of the chemical chngs mentioned above While not limited to a particular thoryuringmincle e reactio o hecarbdrae at the polyammne to formnmolanoidina 10261 In a simation whue the chemical change in the binder resultss in the release of water, e.g., polymerization and cross-linin, a cure can be ocetmined by the amount of water released above that which vould occur from drying alone. The techniques used to measure the amount of water released during drying as compared to when a binder is cured, are 'ell known in the art.

[02'7] One aspect of the present disclosure is that the cured binder composit ion omresa nitrogenous polymer. The nitrogenous polym er is brown to black in color. W hile not limited to a particular theory, the cured binder composition comprises meianoidins. Melaoidins are identifiable as being brown, high molecular weight, complex, Puran ring-containing and nimogen contining polmers. High molecular ' weight, as used herein, includes those pymers having a molcular weight in excess of 100,000 Dahons. D ing cmr ised of highly cross-linked polymeric chains, the molecular weight of the melanoidinis described herein approaches infinity. Accordingly, the molcula~r weight of a melamoidin may be afnmein of the mass anid physical dimensions of the polymier being analyzed. For examp, a uniry sample of melanoidins bavnb; a mass of 3 grams may be presumed to onmp ise a single pa ymeric molecule due to the extensive cross-linking. Accordingly, the molecular weight of the polymer would be opproximatei L8 x grams per mole (being the product of the sample mass and A vogadro's numberr. As used herein, a high molecular weight polymer includes polymers with a molecular weight in the ordet of between about x 10 and aboW I x i024 gran pe 1028] While not be limited to a particular theory. it is known that melanoidins vary in structure according to the reactants and conditions of pre'parartion, it is also known that melameidine possess a carbon to nitrogen ratio which increases with temperature and tme of heating. Furthermore, melanoidins posses. saturated, unsaturated and aromatic character. For mclancidins, the degt'ce of un15atumitsion and aromnanity incases w~xith tem-perauref(cure temperature) and tin-e of heating (cure time), Melanooidinr also contain the C-1 of those sugars incorporated as reactants in a vaeey of structure wthin the melanodin. Mekancidns may also coanu earbonyl, carboxyl, amne, mide, pyrUle, indole, azomethine estr anhydride, ether, tmethy and"/r hy'droyl groups. Depending on the complex ity of the structure, infrared spectroscopy may be usefl in the identifications of one or more of these functional group:. While dyscribed as a omelanoidin-type polymer herein cne of ordinary skil would appreciate that thei binder may also be classifiable according to the existence of a particular bond present suc it a epolycster, poiyether, polyamnide, etc. [029] Another manner in which thei binder is characterizable is through analysis of the gaseous compounds produced during pyroly sis of the cured binder. Gas pyr'oil of a cured bindem within the scope of the present disclosure may yield approximately 0.5 to about 15% (by relative peak area) of one or omoe ol'the folowing compound:: 2-cyclopenten- I-one, 2,5,dhueth yl-ffan, furan, 3 methyl-2,5-trandione,. phenol, 2.3-di methyl-2-cycloperten-1-cne, 2-methyl phenol, 4-miethyl phenol, 2A dimnethyl-phenol. dhne-thylphtahalate, octadecanoic acid. or erucyltamide. Fingerprinting in pyrolvsis gas chromatograph; mass spectrometry (Py 'C-MO) catrried out at 770 CC of a hinder sample prepared using hexanmethylenedia mine as the polyamine component shows pyridine and a number of components which are pyr'roie or pyridine derivatives (a methyl pyridine, ia methyl p yrrole, dimethyl pyr'idines, a dimethyl pyrrole, atn ethyl methyI pyrrole, andl other pyrtrole related N- containi tg componentss. Another manner i vhich the binder may be identified is whether a solution containing the hinder (or an extract s lution) is capable of reducing Benedicts reagent in one embodimcm, a solution in contact wihi the binder or an aqiueous extract thereof reduces Benedict's reage nt 1030] One aspect oft te pr esent disclosure is that the hirders described herein are environmentally friendly. ParalielI to atdvancing gov'ermunent regulation, the present disclosure describes a binder that may be made formaldhvyde-free, Additiona liy, the chemistry described herein is essentially free of firmaldehyde and phenol in this ense, neither formnadehyde nor phenol is used as a agent within the scope of the present disclosure, While both may be added to otain a binder with putemialy useul properties, one a:peet of the present disclosure is a binder that can be made free flom both of these reactants. In another aspect, the present binder compostion may b e manufactured without the use of voAtile ractas. In one embodiment the primary amine and the carbohydrate are both no n volatile reactants. As used herein, a volatile reactant is one that has a vapo pressure greater than 10 kPa at 20 *C, Similarly, a' used herein a non-volatile reactant has a vapor pressure of less than about 10 kPia at 20 C. Specifically and as an example, the present inder may be manufactured without the addition of ammonia or an anonnia rel a sing compound. In 0e embodiment, the polyamine has a vapor pr-essure of less than about 0,5.kPa at 60 *C, [lB3If Another environmentally friendly aspect of the pre'sent disclosure is that dhe primary react'ants of the binder arc carbohydrates, Carbohydrates aire considered a renewable rcs'xurcc, Ht xwever, the current state of the art primarily uses petroleum-dei ved reactants for the manufacture of binder compositions, in another aspect, the binder is made through chemical reactions which can occur at iower temperatnres than thos comparabe sysens described I ihe prior art As such the ctiring ovens and manufacturing equipment can be operated at lower temperature, saving valutabe resources. in the alemative and ii a reinedi herein cares more quickly than comparable binders currently used when rujected to similar curing tmperaturcs. Accordingly, through either approach, one alSpect of the present disclosure is that the carbon foe print oe a formed product using the pre'sendfy disclosed binder may be stubstanuially reduced cornpared to a comparable binder madeording to the curn stt.fteat o example a pheniol :formaldehyde based producm. 1032] in addition to the environmental benefits, the present hinder compnsition and matertis made therewith can be made having performance characteristic: equ ivalent or exceeding those of comparable hinde'r system:, for example phenol for maldehyde hinders, In one aspect, a binder according to the present disciosurr provides artices made therewith sufficient tensile strengthb to allow for die-cutting, fabrication, lamrifon, and installations in OEM applications, In one aspiec, I binder according to the present disclosure has water hold-up (wveatherability) comparable to that of a phenol foumaldehyde binder. Other performance characteristic that may be relev'anit for 0. particular application. include product emissions, density loss on ignition. thickness recovery, dust, tensile strength. pamring strength, do ability of parting strength, bond strength, water absorption, hot surtface peformance, -9.

corrosivty on steel fexural rigidity, stiffness-rigidity, comnpressive resistance, condiioned compressive resistane, compressive mnodulus, conditioned conpresive modulus. and smnokc dc lomicnt on ignitiont One aspect of the present disclosure is that the exranct of the cured binder is essentially pH neutral, for example betw'een a pH oft6 and 8. Another aspect of the present disclosure is that the present binder enables the manufacture of products aving comparable relevant performance characteristics to phenol formaldehy ie binder compositions, 1033 lilustratively, in one emnbodimrent a binder according to the present disclosure invention has the advantage of yielding essentially colorless aqueous ex tracts. This feature of the present disclosure makes the binder deiable in applications such as ceiling tiles, furniture, or office panels, wherein the fMnished product may come into contact wih water. A cured manufactured good made with the present binder shows a'n excellent resistance to discoloration or bleeding a after coming in contact with moisture or water. Furthermore, in such an embodiment, the water that contacts the binder does not leave a residual color on other articles or parts which it muy compact subsequem to contact the hinder. For example, in one embodiment, the binder may be used to bind glass fibers in an office Panel application. Covering the bound fiberglass composition may be a light colored fabric. Advatageously, in one embodiment, water contacting the fiberglass composition does not leave a colored residue upon the fabric after the office pane] has dried, [0341 in addition to the performance characteristics, the nmamufacturing processes and methods involving the presently disclosed binder have a numliber ofutnexpected advantages over previously described binders. in one aspet, as previously described with respect to the environmental bcnefits, the present bin der inny be artu lioturd without the use of highly volatile reactants. Accordingly, manufacturing emission controls are under a reduced burden. Furthermore, the reaction efficiency is higher because reaciant loss due to vap.riation is reduced. Accordingly, ote aspect of the present dscosure is that th compounds used herein are substantially non-volatile, thus the tops one munst take to multigrte untdesirable emissions 'are redouced. [0351 According to another aspect, the reactants that react to form a binder are sufcienly slow to react such thai a on' step/one pot binder ssem can be used. Accordino this aspect the reactt compounds are suficienty low to react that they can be added to a single reactan solution atd stored for a reasonable amount of time during which they can be applied to a product using one distrbblion systein. Thi contr ats with hose binder systems whihi react at low tempemures resultinghingn insolublc action products Within binder souion delivery systems. As used here, a reasonable atn t of titme for storage without substantial (>5%) polyerio precipitation is two weeks !036} Another aspect oft'h present disclosure is that although the bitder is sunffciently unreactive at room temperature conditions to tacilitate a one-pot approach, it is sufficient reaciv 'at elevated temperatures to ;ute at very low temperatures and'or very short curing residency tire. in on e respect the leered curing temperatr credues the risk of' A n insulation product undergoing nameless eonmbusion and/or causing line fres. As used here, very low temperatures are eharacerize. as !ess than or equal to abou0 120 *C. As used here, very short eurc times are less than or equal to about 4 min, [037, In illustratiu emnbodiments, thbinde composition includes an acid or an acid salt to increase the shelf life of the uncured hinder or hinder solution. While this acid is not a reactant or a catalyst, t may be included to slow or inhibit the binder reactants fron forming the binder while the binder solution or uncured tinder is being manined under storage conditions, For example, a volatile acid or acid salt ray be included in the binde solution or uncured binder that slows or inhibits the curing reaction at ambient conditions, Hw the acid may be removed by heating the binder souion oncured binder so that the acid is voluilzed arid the pH of the binder solution or uneured binder increases, In one mbodimen, the ind composition includes a shelf-ife extending acid. In another ertnbodimnent, the binder comnposition inchudes a mole ratio of shelIf-life extending acid to polyamine of about 1:20 to about 1:. 6381 Another aspect of the present disclosure is a binder having a euro rate, cycle time, and cure temperature which meets or exceeds those cure rates that a comparable phenol and formaidchyde type binder may exhibit within the scope of a comparable use, in thiinder can be used as a direct replacement to phenol formaldehyde resins in applications without modification to the equipment. Furthermore the present binder nabies the modification of the curing temperature and tites so that both the reac ion temperature and cure Onies maybe reduced. This reduction has the effect of reducing the encirg cnnumtion of the process overall and reduces the environmental imact of manufacturing the product. Furthemor, the lower cure temperatures have the further effect of increasing the safety of muanufactrin pmecensk Aodher dieoct of the tower cure t emperatures is a reduction in the risk of fiameless combustion or nie. [039] In the manufacture of insulation products, the heat released by the exothermic curing reaction may resub in self-heating of the product. Self-heating is typically not problematic so long as the heal dissipates front th product However, if the heat increases the temperature of the product to the point where oxidarive processes commence, the self-heating nay cause significant damage to ;he produtc For example, ihaneless combustion or oxidation may occur when the temperature of the insulation product exceeds about &2 TF (20 t.% Atthese temperatures, the exotbermiac combustuon or oxidation press promote further self-heating and the binder may be destroyed, Putthennore, the tempe:rature may increase to a &evel in which fNsiw or dA caon of glass kiers is possible. N only does this damage the struclure aid value of the insulation product. it may also create a fire hasar. 0401Another aspect of the present disclosure is that the binder svstcm is essentially non-corrosve with r wit hout the addition of corrosion inibirors, Furthermor, the bitider sysem does not require the addition of any organic or inorganic acid or salts thereof as catalyst or active ingredient Accordngly, une aspect of the present bindr is that it niy be made essentially acid-ree. Furthermore the binder tnay e manufactured tnder entirely alkaline conditions. A used hero, the term acid includes those compounds whic'hare characte.rizabic primarily for their acidic character such muhiprotic inorganic and organic acids (eg sulfuric acid and citric acid). This aspect reduces the ear and maintenance requirements of the manufacturing equipment and enhances worker afety. 1041] In ilutative embodiments, a binde comprises a polymeric produce of a carbohydrate reactnt and a polyanmne. As uIed herein, di term carbohydrate reactant rcers to a monosaceharwie, a disaccharide, a polysaccharid, or a reacion product thereof. in one embodiment the carbchydrate reactant may be a redocing sugar, As tued hxemren educing intgnr indicates one or more sugars that contain aldehyde groups, or that can isomerie e tautomerize. to contain aldehyde groups, which groups may be oxidied with, for eunple. Cuj to afford carboxylic acids, i is alo appreciated that any such carbohydrate reactant may be optionally substitute, such as with hydroxy, halo, alkyi, alkoxy, and the ike It is fiurher appreciated that in any such carbohydrate reactant, one or 1 re chhal centers are present, and that both possible optical isomers as each chiral center are cointemplned to be included in the invention descubed herein Futher, it is also to be uderstood that varous mtxturcs, including acelic mixtures, or other diastercomeric mixtures of the various optica kamrers of any such carbohydrate reactan1t, as well as various geometric isomers thereof, may he used in one or more embodiments described herein. While non-reducing sugars, for instance sucrose, may not be preferable, they tmay nonc-the-lcss be useful within the scope of the present disclosure by in-situ conversion to a reducing sugar i.e. coiversion of sucrose to invert sugar is a method known in the ar Further, it is als o understood that at moosaccharide, a disaccharide, or polysaccharido may be partialy reacted with a precursor to tormn a carbohydrate reaction pomduct. To the extent that the carbohydrate reaction product is derived from a monosaccharide, a disaccharide, or a polysaccharide and maintains similar activity witi the polyane to form reaction produce simnilr to those of a monosaccharide, a disaccharide, or a polysaccharide with a polyamine. the carbohydrate reaction product is within the scope of ter m cbhyrt rea ctant. 10421 in me aspect any carbohydrate reactant should be sufficiently nonvolaile to maximize its ability to remain available for reaction with the polyamnm. The carbohydrate retant may be a monosaccharide in its aldose or keios2 form, incuding a triose. a tetrose, a pentose. a hexose, or a hetose; or C polysaccharide; or combinations thereof For example, when a triose serve s Athe carbohydrate recant or is used combination with other reducing sugars and/or a polysaccharide, an aidotriose sugar or a .kerotiose sugar may be uiized, such as giyceraidchyde and dihydroxyactone, respectively. When a teirose serves as the carbohydrate reactant, or is used in combination with other reducing sugars and/or a pelsaccharide, aidotetrose sugars, 'uch as erythres and threose; and ketoteirose sugars. such as erythruiose, nmy be utilized. When a pentose serves as the carbohydrate reactant, or is used in combination with other reducing sugars and/or apolysacciarde, adopentose sugar;, such as ribose, arabinose, xylose. and lyxose; and ketopetose sugars, such as ribulose, arabulo.e, zylulose, and lyxulose, ay be utilized. When a hexose serves as the carbohydrate reactant, or is used in combrtion with other reducing sogars and/or a pnlysaccharide. aldohexose sugars, such a: glucose c (Ec. dextrose), manner. galaciose, allose. altrose, talose, gulose, and idose: and kotohexose sugars, such as fructose, psicos.e, sorhose and tagatose, mray he utiied. When a heptose serves as the carbohydrate reactant, or is used in combination it h other reducing sugars arnd/or a polysa ccharide. a Iretoheptose sugar such as sedoheptulose may be utilized Other sterenisomers of such carbohydrate reactats nul known to occur naturally are also contemplated to be useful in preparing the binder COmp)osition as described herein. In one embodiment th carbohydrate reactant i high fructose corn JOB, in illusIrative m 3birents the carbohydrate reactanl is a poiysacciAde, iI one embodiment the carbon yr te reactant is a poiyaccharide with a low degree of poly erization in one embodiment. the pouysacharide is molasses.starch, clulose hydrlysates or mixtures thereof In one embodiment, the carbohydrate reactant is a starch hyd olysare, a mtaltodextrin, or a mixture thereof. While carbohydrates of higher degrees of polymerization nay ot be preferable, they may noneohe-less beusefu withinthe sope of the present disclosure by in-situ dcpolymeriz aion (ie. lepolynmerization through ammoniation at elevated temperatures is a method known in the art) 10441 Furthermore, the carbohydrate reactat may be used in combination with a non. carbohydrare polvhvdroxy reacta, Examples of non-carbohydrate polyhydroxy reactants which can be used in combnaiion with the carbohydrate reactant include. but ore not limited to, trimethyloipropanc, glcerol, penltirythritol, polyviyl alcohol parnily hydroly'zed polyviny acetate, flly hydrolyzed polyvinyl acetate. and mixtures thereof. In one aspect, the non--carbohydrate polyhydroxy reactant is suffliintly nunv olatile to mximize its ability to remain available for reaction ith a mn iomoric or polymeric polyamine, Tt is appreciated that the hydrophobicit} of the non-carbohydrate polyhydroxy reactant may be a factor in determining the physical properties of a binder prepared as described herein. [05 As used herein, a polyamine is an organic compound having tw or more anine group. As used herei, , a primary polyamnitne is an organic compound having two a more primary attune groups NI~. Within the scope of the term primary polyine are those compounds which can b modified in siu or isomerze to generate a compound having two or more primary mine groups ( N EUj In illustrative embodiments, the potyamine is a primary polyarndti In one embodiment, the pt 'mary polyanme mtay be a molecule having the formiuia H2 N 2 , wherein Q is an alkyl, cycloalkyt hetI ~eroalkyl, or cvcioheter oakyl, each of which may he optionally substit fed. Itt one embodiment, Q is an alkyl selected from a group consisting of C C in another embodimnct, Q is an alkyl selected from a group consisting of C 2 -Cs, In another embodiment Q is an aikyl selected frans group consisting of Cs-C-, In yet another embodiment, Q is a C6 alkvl In one embodiment, Q is selected from the group consisting of a cyclohexyl, cyciopentyl or cyclobutyl. it another embodiment Q is a bev.'y [046] As used herein the term "alkyl" includes a chain of carbon atoms, which is opitonallv branched. As used herein, the term "aikenyl" end "alkynyl" inludes a chain of carbon atoms. which is optionally branched, and includes at leas: one double. bond or triple bond, respectively. It is to be understood that alkyny may also iriLu one or more double bonds. It is to be further understood tha is advatageously of imted length, including CPQ> CCX C&, C& mi td -C, It is to 1)0 further understood that alkcny and/or alkynyl may each be advantagously of limited length, including CrCs. Cr~, C 2 ., 0..C. and CrQC It is appreciated heroin hat shorter ulkyl, aikeny. and/or akyyl groups may add Onss hydrophilicity to the compound and accordingly will have diffrent reactiiy towardis the carbohydrate reactant arnd solubilty in a binder solution, [047j As used herein, the ternS-cycloalkyr includes a chain of carbon atoms, which is optionally branched, where at least a potion of the chain in cyclic. It is to he understood that cycloalkyiikyi is a subset of cycoalkyLt is to be understood that cyctoaikyl may be polycycie. 1Ilustrative cyclakyyis include, hm are not limited to, cyclopropyl cyclopentyl, cyclohexyl, 2 tmethy'levelopropyi yclopcmyleth-2-y adamamyl, and the ike. As used herein, the term "eycloalkeny!" includes a chain of carbon ats, wbieh is optiontliy branched, and includes at st one duubl bonds where at least a portion of the chain n cyclic. i is to be understood that the one ormore double bonds may be in the cyclc portion of cycloalkeny! nd/or the non-cyclic portion of eycloalkenyl. It is to be understood that cycloalkenylaiky and cycloalkylaikenyl are each ubsets of eycloalkenyi. I is to be tmderstood that cycloalkyl may be polycyclic Tlustrative cycloaikenyl include, hut are not limited to, eyclopentenyl, eyclohexylethcn-yv, cycloheptenylpropeny, and the like,. is to be further understood ta chain forming cycoatkyl and/or cycloalknyl is adanageously of limned length, including C-24 C-C, C 0 Cs, CV-s and C , i is appreciated herein that shiorte alkyl and/or anyi chains fonning cycloalky and/or cycloalkenyL respeciely, may add less hipopihcty to the compound and acec)t'dingty will have different behavior, [048) As used herein, Te tern "heeroalkyF' includes a chain of atom that includes both carbon and at least one heteroatonm. and is optionally branched.i lilustraitive bet roatomin include nitrogen, oxygen, antd sulfur. in certain variations illustrative heteroatotms also include phosphorus, and selenium. in one embodiment, a heteroalkyi is a polyether. As used herein, the tern"CcloheSeroalkyI" inehuding heterecyclyl and heterocycle, includes a chain of atoms that includes both arbon and at least one heteroatom, such as hetcroalkyl, and is optionaly branched, where at least a portion of the chain is cyclic. Ulustative heteroatoms include nitrogen, oxygen. and sulfur. In ctain variations, illustrative heteroarons aso include phosphorus, and seeNt i Illustrative eycioheteaalkyi include, but are not limited to, etravdroibryl, pyrroldinyi, tetrahvdropya -y piperidinyl, torpholwiy piper azinyl, hoopiperazioyi, quinuelidinyl, and the hike, [049] T ie term 'opt ictuly substituted" as used hereint itncludes the retlacetment of hydrogen atoms with other functional groups on the radical that is optionaly substitured. Such other 4 functiona group. illustratively include, but are no limited to, amino, hydroxyl, halo, thin], alkyl, ha]oaiky, hetoroalkyl aryl. arylkyl aryheteroalky intro sulfonic acids and derivatives theretf, carboxylic acids and derivatives theveon and the like Illurtratively, any of amino, hydxy, thiol, alkyl, haloalkyl, heterorkyl, arvl, arylalky , rylhevtoalkl and/or sulfonti acd is optionally substituted, 10501 In illustative embodiments, the primry polyamine is a dianine, triatne, tetraamine, or pentanne, in o-ne enmbodment, the polyamine isa t iamne selected d a diethyl enetrinmine, 1-'piperazineethaneamnine, or his (hexamet hylene)triamaine, in another embodiment the polyamine is atetramine, for example triethyienezetrarnine, Tn another embodiment, the polyamine is a pentami ne, for example t etraethyl enep entamnine. 1051] One aspect of the priuary polyamine is that i may posess low steric hindrance. For example, I 2-diaminoethane, 1 ,4,diaminobutane, 1 S-diaminopentane, I 6-diaminehexane, 1,12 diamitnododecanc, 1,4-diaminoeccohexanc, I ,4-diamin-obenzene. dicthylencvriamine, trieth yl enetetr amine, etraerhyl enep entami n e. Ipiper-azi neethanieamine, 2-methyL pentamethyloncrdiatminc, I ,3-pcntanedia mince, and bis(hexamnethylene itrianmine, as wel as 1-dianminooctane hae low steric hindrance Within the scope of the p sent disclosure. One emnbodnent i\ L 6-diaminohene (hexamethy lenediamine). Another embodiment is 1,5-diumino~ 2- methylpcetae (2-tmethy-pentamethy lenediaine),f in another embo dimnent, the primary pmoiyamnine is a plyether-poiyaimine, In another embodrimnt, he polyether-polyamini is a diamine or a triomine, In ne embodiment, the polyether-polyamine is a trifbucttonal primary amine having an average molecular weight of 440 known as Jeffamuine T- 403 Polyetherawmine (H-untsman COrporation). {052] In one etnbodime, the polyamine may include a pCymeric polyamine, For exatnpIe, po lymeric po lya mines within the scope ox the p~resentt disclosure include ehitosan, polylysine, polye thylenimine, pol(N-vinyl~N-mnethyj amine), polyaminostyrene and p olyvinyianmines. In one embodiment, the polyamine comp sties a polyvinyl amine. As used herein, the pohvinyl amine can be a homnopolymer or a copoly met 10531 While nio limited to a particolar theory, one- ast of the present dIs cosure Is tit ie primary polyam ine and the carbohydrate reactant are Mailiard reactaml that react to form a tmeanoidia product Fig. I shows a schematic of a Molard reaction, which culminates i the prodoctiot of melanoidins. In its initial phase a Mailhard re action involWes carbohydrate reactant, for example, a reducing sugar (note hat the carbohd ate reactan may come from a substance capable of producing a reducing sugar under Mailard reaction conditions), The reaction also involves condensing the carbohydrate reactanM (e3g, reducing sugar) with an amine eacltam, i.e., a compound pos ssing an amino grtoup. In oiher wordz, .he carbohydrate react and the amine reactant are the melanoidin r etant-s lot a Maillard reaetior. The condensation of thWse two constitutes produces an N-substituted glycosyiannne. For a more detailed description of the Mailiard reaction see, Hodge, jL. Chemistry of Browning R'actions in ModeA Systems .J Agric, Fod (C 1953, C, 9-, the disclosure of which is hereby incorporated hrein by erence, The literPaure on Mailard reactions focuses on a melanoidins produced from amino acids, The present disclosure can be distingushed from these references in that not all amino acids are polyaminnes. Common amino acids which are considered polyamnes within the scope of the present disclosure Wl aparaine, glutamin, histidine, lysine and arinine. 10541 Without being bound to theory, the covaenm reaction between the polyamine and theecarbohydrate reactant will be described in greater specinicity, As described herein, the pathway of' he present reaction is dinct fron those taught ir the prior art for the following reasons: J0) the present reaction tany occur completely at basic pH, (2) the polyarnine is di-fmnciomal in its teactivity towards the carbohydrate reactant, (3) the polyamnine, through irs di-funeiional reactivity or another unrecognized phenomena, xhibts a lower actution energy within the scope of the reaction which results in an unexpected increase in reaction rate and/or a decrease in the temperature at which the reaction will proceed. 1055] The firstt step in the Formation of melanoidns from a polyamiune and a carbohydrate reactant is the cotndensation of the carbohydrate reactant and the polyamine. Evidence indices that the conditim described heroin ares pecially suitable for driving this reaction to completion. F irs, it is believe ed that the alkalinity of the binder solution drives the condensation. For examnple, it has been shown t-hat sugars and a-mines undergo browning in aqucouts solution in proportion to the basic Arength ofthe amines emIployed or the pH of the solutin. It is believed that the N substituted glycoslamines remain: undissociated in aqueous solouions to appreciable extent. Thus, the irreversible tra-nsrmiations that. the undissociated molecules undergo must be con sidered While it is known that the condensation reaction is reversible, we discov-red that this reaction can be further driven o comnpletion, in accordance wih Le Chateliets principle by the concurrent dehydraion of the binder solution, As such, it was estabbshed that iniially a primary constituent of the uncured binder composition was the N-glycosyl derivaives of the primary -poyaines [0561 Rcferring again to Fig. l, the second step in the conversion of the binder reactants to melanoidin products is the so-caled Anadori rearranement A schematic of a represent ative Anm di rearra-ngeet is shown in Pie. 2. Referring to Fig. 2. the N-giycosyl derivanves of th- rinary polyamines are in equilibrium with the cation of a Schiff base. While this equilibrium favors the Ng Yycosv6ammine, further t-catrangemie of the cation of a Schiff base to the eno or keto form is known to proceed spontaneously. It was discovered that this spontaneous reaction is fur ther faciltated by dehydration,- as the .ate was increased in dehydrated sample-s. One aspect of the present disclosure is that the structure oF a primaty-polyamine specifically accelerates this rearrangement by stabilizing the posiive charge, th t is acquNire while the colmound is in the form of a cation of a SOiff base. it is believed that this stabiizaiion effect has not been discussed in the prior art or the literature as the enhanced effect ofusing a primary polyamine has not previously been disclosed.

-16 Accordingly, one aspect of the present disclosure is that the primary polyamiae is of a type that provides stability to a cation of a Schiff base during an Amadori rearrmgement in another aspect, the primary polyamine is of a type that provides stability to a cation of a Schiff base during an Amadori rearrangemecnt while in a substantially dry state, v [0571 Another aspect of the present disclosure is that the earbohydrae structure is also believed to influence the kinetics of the Amadori rearrangement. Specifically it is known when the C-2 hydroxylI of a crystal line N-substituted giycosylamine was unsubstitated, the compound was slowly trarformed (luring storage to the Amadori rearrangement product. However, if the C-2 hydroxyl was substituted, then the rearrngement was substantially inhibited. Accordingly, one aspect of the present disclosure is that a carbohydrate of the present disclosure is unsubsntuted as the C-2 hydroxyl One aspect of the present diosure is that the uncured binder composition comprises a mixture of Nglycosylambn, -aminoI-deox-ctoses in their col- and kero- form. Referring again to Fig, 1 after the formation ofthe mixture of N-giycosyhanines !-amino-deoxy-2-ketoses in their n]- and keto- form the mimre will also include a noii-negligibic concentration of both the un-reacted primary polyamine and the carbohydrate. From then, a number of reacions my occur which lead to what car be broadly described asnekdins. Deendingvo the int bohcabhyate reactn nd polymeric polyamine and the reaction conditions (pH, temperature, oxygen levels, humidity, and presence of additives) one or more of the shown reaction pathways shown in Fig. 1 may be favored. Furthermore, the favored reaction pathway for a given melanoidin product may not be classifiable as any of those shown specifically in Fig. K l0581 In illustrative embodiments, the weight ratio ofthe carbohydrate reactant to the primary polyamine is in the range of about 1:1 to about 30:1L in another embodiment, the weight ratio of the carbohydrate reactant to the primary polyamnine is in the range ofabout 2:1 to about 10:. in yet another embodimenh the weight ratto of the carbohydrate reactant to the primary polyamine is in the range of about 3.: to about 6: 1. According to one aspect, the cure rate is a fRnetion of the weight ratio of the carbohydrate reactant to the primary polyamine. According to this function, it was established that as the rato decreased, the cure rate increased; thus the cute te decreased. Accordinely. the oti aspect of the present disclosure is that the cure time is directly related to the weight ratio of the carbohydrate reactant to the polyamine provided tha other parameters are held equivalent. In another aspect, the binder cure time is reduced to the cure time of a comparable phetol formaldehyde binder composition when the weight ratio of the carbohydrate reactant to the primary polyamine is equal to about 6: 1 Aeordingly, in one embodiment, a binder according to the present disclosure has a cure rate exceeding a comparable phenol formaldehyde binder system when the carbohydrate reactant to primary polyamine weight ratio is in the range of about 2:1 to about 6.1. [059j Another aspect of the reaction as described herein is that, initially, the aqueous reactant solution (which may be dehydrated and used as a binder), as described above, has an alkaline -*17pH. One aspect of the present disclosure is that the almaline hinde-r onionn is less corrosive towards metal than acidic solution, Accordingly, cue feature of the present disclosure which overcomes a asubsantiai barrier to the industry is that the hinder described herein has low corrosivity towards the manufacturing equipment which may be used to produce materials which include the present binder bcanse of the alkaline binder composition. One distinguishing feature ofthe ureaent disclosure over other recently describedc carbohydrate binder systemnsieg. U.S. Published Application No. 2007/0027283), is that the reaction does nol necessarily proceed though an acidic pathway. Rather one aspect of the present disclosure that the uncured binder may haven alkaline pH throughout the course of the chemical reaction which leads to the formation of the cured binder. As such. the uncured binder, throughout its use and 'orage doer not present a coiosion risk in illustrative embodiments, an aqueous extract of the cutred binder has a pH in the range of about 5 to about 9. Furthermore, an aqueous extract of the polymnric Product is essentially colorless. 0601 In iustrative emrbodiments, a. method of making a colleton of matter bound 'Th a polymers binder comprise preparing a solution containing reactants or producing the polymeric binder and a solvent. whetein the reactants include a carbohydrate reactnot and a polyamine; disposing the solution onto the collect of marcr; volatilizing the solvent to form an uncured product, and subjecting the uncured product to conditions that cause the carbohydrate reactant and the polyamine to polymiierize to form the polymeric binder. 10611 In illustrattve embodiments, the collection of matte includes insulating fibers. in one embodiment, a fiber insulatio product is described which includes inating fibers and a binder. As uisod here the term "isuahing fiber, indicaites hearcaistant fibers suitable 'for wvshsanding elevated temperatures, Examples of such fbers include, but are not hmited to, mineral fibers (glass bers sltag wool fiber, and rock wool fibers), aramid fibers, ceramic fibers, metal fibers, carbon fbers, polyimide fibers, certain polyester fibers, and rayon fibers, ilustratively, such bers are substantially unaffected by exposure to temperanuresmabove about 120 *C. In one embodiment, the insulating fibers are glass fibers, In yet another embodiment, the mineral fhers arc present in the range fom about 70% to ahot 99% by weight. 1062a ilustraliac enmbodimnents, the colt ion ofmiatter includes celluiosic fibers. For example, the cello Sic fibers may be woodlshavings, sawdust wood pulp, or ground wood. In yet another embodhnent, the cellulosic fbers may be other natural fbers such as jute, flax, hemp, and sv. Tihe binder disclosed herei may be used as in the place of the binder descrbed in Published PCT apphcation WO 200S/18984, which is incorporated herein by reference i its entirety. In one embodiment, a composite wood board comprising 'ood particles and a binder is disclosed. In another embodiment, the composite wood board is furmaidehvde free. In one embodinent, the composite weed hoard has a nomni ml thickness range of greater than 6 to 13 mrn and has a modulus of elasticity (MOE of at east about 1050 n 2 . a bend srength n(1OR) of at least about 7 Nm 2 and an intenal bond strength (TB) of' at least 0.20 Nrmm 2 in another embodiment the composite Wood board hs a nominal thickness range of greater than 6 mm to 13 mm. and has a bending strength (MOR) of at least about 12.5 Non min and an internal bond strength (IB) of at least 0.28 N/nmm!. In another embodiment, the composite wood board hmas nominal thickness range of greater than 6 imm to 13 nm, nd has a modubus of elastiity (MOE) of at least about 18 NO nnm 2 , a bending strength (MOR) of at lead about 1 in-n 2 , and an internal bond strength HB) of a ieasO 0 40 N/mnm. n another enbodimet. the composite wood board ha s a modulus of casticity (MOE) of at least about 1800 N/mm 2 . In another etnoodimnent the composite wood board ha, a maodulus of elasticity (MOE) of at ear about 2500 NI/mu 2 in another embodiment, the composite wood board has a bending strength PMOR) of at est about 14 N/mm 1 in yet another emnbodnem, the composite wood board has a bending strength (MsORW is at least about 18 N/mii in one embodiment, the composite wood board has an mirnal bond strength (.IB) of at least 6l2 N/mm in yet another embodiment, the coposite wood board has an interim bond strength (1) is at least 0.4 N/mn in yet another embodiment, die composite wood board swels less than or equal to about 12%, us measured by a change in thickness, after 24 hours in water at 20 C in another emibodinient the composite wood hoard has a water absorption aftir 24 hours in water at 20 "C of less than or equal to about 40%. I0631 in ithusrative etmbodiments the composite wood board is a wood panricleboard, an orientated stramdboard, or a medium density fiberboard In one embodinment, the Intder cmnprises from about 8% to about 18% by weight (weight of dry resin to weight of dry wood particles) of the composit e wood board, In another enmbodliment the conmposhe wood board further comprises a wax. In yet another embodiment, the composite wood board conprise from about 0. 1% to about 2% Ka by weight of the composite wood board In illustrative embodimnts, the method of making a collection of matter borod with a polymeric binder may further include preparing a soltion by adding an amount of a carbohyd-ate reactaait and an amount of a primary polyamtine so a weight ratio is in Tbe range of about: 20 to about 10:1. in one embodinut, preparing the solution includes adding the ca bohydrare reactant and the notyamine to an aqueus sohuion. In another etnbodiment. preparing the solution includes adjustng the pH of the solution to Wthin the rang of about S to about 12. In yet another embodimem, the method of mni g a collection of matter bound with a polymeric bidder may fmtiher comprise packaging the uncured product in a packaging material suitable for storage . [064] In illustrative embodiments, the present disclosure relates to a composition comnprising a coleetiou of mat and a. binder, the bitndet comprising polymterie products of a reacetion between a carbohydrate reactant and a polyamine, the polymeric proucts being substantial wate inoubl In one embodimnent the collection of tmater includes minral fibers, aranid fibers, ceramic ttibers melail fibers. carbon fibers, polyimide fibers, polycszer fibers, rayon fibers, glass offers cellulosic ftbers or other particub tes. For example, cellulosic fibers mayv include wood shavings, sawdust wood pulp and.'rground wod. in one embodimentr, the collection of mat er includes sand or othe inorganie p~articulate matter. in ne embodiment the collection of matter is cod particulate, tn one embodiment, the carbohydraic reactant is selected fon a group consisting of dextrose. xyoe, frucose, dihydroxyaertone, and mixtures thereof in one embodiment the potyamrrne is elect ed from any of the polyanines described hereinabove. Ia another embudirnt, the polyamin Is alectd arn a goup consisting of a diamine, triantine, tettamine, and pentmine. In one embodiment the polyamine is h~NQN He wherein Q is alky l cyciou kyl, heteroalkyl, or cycloheseroaIkyl. each ol which is uptionally substituted. in another embodinme the composition further comprises a sihcon-containing compound. none embodinment. the silicon-containimg comnpound is a functionalized silylesher ora finmctional ied altkystileterr such as for example. an amino-functionalize~d alkylsilyiether. For example,. in one embodiment, the sili~ec-onining compound may be gamma amiopmpy Itr ihoxysi lane, g~arnmna-gycidoxcvpropylrimethox yst 1me, 0r amninoethyiaminopropyhbrim ethoxysilano, or a mixture thereof. In another crmbodbmenxthie silicon containing compound may be an aminofunecional oligomeric siloxane. i another embhodiment~ the composition comprise:, a corrosion inhibitor selected trom a group consisting of dedusting oil, monoamniumn phosphate, sodium metasilIicas e penrahydrate, mehamiine, tin (Tf)oxalate, and a methylhydrocnlicneid naulsn 1065 In farther illustrative embodiments, the binder may be disposed upo a collecti on of fiber, substantially dehydrated, packaged, and then stored or sold to another party. An uncured product sold to ancther party hr u6e in further manufacturing process may be referred to as "ship-out uncured" An uncured product stored for use in other manufacturing pr ocesses may be referred to as plant uneured." In setinig or storing this type of product, it is packaged in suitable containers or bags, [0661 In ilustrative embodiments, a packaged Uncured taor product comprises an uncored binder composition and a clectina of inbrs, wherein (i) the uncured binder cornmaion is i contact with the collection of fibers consolidating the collection otfibers and (ii0 the uncured binder composition in cotct with the collection of fibers is packaged in a suitable package to material In oneo embodiment. the aooutir of moisture in tile uncored binder composition may be in a rangc ronm about 1% to about 15% by weight based on a total weight of the product In yet another embodiment the suitable packaging material may be capable of maintaining the amount of moisture in the uncured binder composition to within about% of an original moisture love] for a pered of oe week at an ambient temperatu-e and an ambient pressure. hI on embodiment, the packaged uncored fiber product comrprises from about 3%/ to ab~ont 30% by weight of theouneured binder compoosiiion based on weight of the packaged uneorod hboer prodc t without considermg the weight of trh suitable packaging material hn one emibodiment, the packaged urncure'd fiber product comprises from about 60 to ahout 97% by weight fbers based on weight of the packaged uncured fiber insulation product without considering the weight of the suitable packaging maeral.

-20 1067j One 'aspect ofhe present disclosure is that the binder described herein is unexpectedly usend in applications ship-out uncurcd and plant uncured applications. Specifically, ship OuT uncured produce and plant uncured products are provided with ' uncured binder so that the curing can xour at a later ime ani in a later place. In the case of ship-out uncured, the curing temperatures ad time are properties of the product which are of greai importance to the customers Specificaly, the cun temperatures must he suffciently low such that the product can be cured using their existing equipment. Furthermore, the cure time must be sufficiently short ch that the cycle time for curing the products remain low. Within this industry, the manufacturing equipment and acceptable cycle times have been established for uncured produce comprising phenol formaldehyde type resin. Th erefore, uficiemrly low cure temperatures are those cure tempe-ratures suitable for curing a comparable phenol formaldehyde type product. Similarly, suffcienly lnv cyce tnes are those cycle times which would b' mttne for curing a comparable phenol formaidehyde typ product, One of rdinar' skill in the art will appreciate that neither cure time no cure teInperature can be set forth as definite quanittes because the speci fic aippiications~ may have dramatically dfifyrent paramerers. However, it is well understood that the cure time and cure temperatures of a model system provide sufcient representative iriormation regarding the kinetics of the underlying chemical curng reaction so that reliable predictions of binder performance in th various applications can be made. [68 In illustrative embodiment, the cure ume and the cure temperature of the bnder is equal to or less than a comparable phenol foarmaldehyde hinder composition. In one embodiment, the cure time of the binder is less than the 'ure time of a comparable phenol formaldehyde binder composition. In another embodiment the ce temperature of the binder is lees than tho c-rc tem perature of comparable phenol foi'maldchyde binder composition. A2 used herein, a comparable phenol founaldehyd e binder comrposirion is like that described according to 11.. Patent No. 6,638.82. which patent is hereby i ncorporated by reference herein in its entirety. [069j As discussed below, various additives can be incorporated into the binder composition. These additives give the binders of he resent invention additional desirable characteristics, For example, the hinder mayinclode a silicon-conaining coupling agent. Many silicon containing coupling agent are commercially available form the Dow-Corning CDorporatrion. Evon ik Industries, and Moimentive PerfOrmance Matei'ia Is. illustratively, the silicon-containing coupling agent includes compounds :uch as sily'lether; and aikysily! ethers, each of which may be optionally substituted, such as with halogen, alkoxy, amino, and the lke. in one variation, the silicon-containing *compisound is an amino-substised silane, such as, gamma-aniinopropyitrierhoxy silane (St QIUEST A i 301; Momeative Performance Matei'ials, Corporate Headquarters: 22 Corpora Woods Blouleatd, Albany. NY I2211 USA). In another variation, the silicon-containing compound is an ano substituted -i ane, for example, aminoethylaminopropyltimethoxy silane (Dow Z-6020; Dow Chemical Midland, Mi; USL in another variation, the silicen-conaining compound i nn glycidoxy ropyltrimethoxysiiane (S L.QUEST A-i 7; Momenive). In vet another variation, the silicon contaiing cOmpjOUnd is an ainofunctional oligonmeric siloxane H YDR.OSIL> 2627. Evonik Industries, 379ine-pce Pkwv. Parsppanv, NJ0754) 1070] The silicon-conaining coupling agents are typically present in the binder in the rang from aot 0. I percent to about ] percent by weight based upon the dissolved bindUr Solts Ne.. about 0.0% to about 3% based upon the weight of the solids added to the aqueous solution. in one application, one or more of these isiicon-containing compounds can be added to the aqueous binder solution The binder is then applied to the material to he beimd. Thereafter, the binder may be cured if desired. These silicone containing compounds enhance dhe ability of th binder to adhere to the mater the binder is disposed on, such as glass fibers. Enhancing the binder's ability to adhere to the nauer improves for extipl, its ability to produce or promote cohesion in non- or loosely- assembled substancess. 10711 In another illustrative embodiment a indler of the present invention may include one or more corrosion itnhibliors. These corrosion inhibitrr prevent or inhibit thc cating, or wearing away of a substance, such as metal caused by chemical decotmpositioni brought about by an acid, When o corrosion inhibitor is included in a binder of the proot inventon, the binder's corrosivity is decreased as compared to the corrostvty of the binder without the inhibitor present In one embodiment, these corrosion inhibitors can be utiied to decrease the cur'osiity of the mineral tiher-containing compositions described hereim Ilustratively corrosin inhibitors include one or lmnre of the following, a dedusting oil, or a monamnmonium thosphase. sodium meUasilicate petahydrate, melanmine, titn( i) oxalae, and/or eththyvdrogen sdone fhind fmusison When included in a bindr of the present invemttion, co rrosion inhibitors are typically preent in the binder in the range from about 05 percent to about 2 pierce by weight based upon the dissolved binder solids. One aspect of the present disclosure is that the need for corrosion inhibiting additives is greatly reduced by the alkalinity of the binder solution and the substantially dehydrated uncured bitnder. In one embodiment the binder is hre Uromn corrosion inhibitors and the corrosivity of the hinder solution is within the acceptabic range. 10721 in iustrative embodnes, the binder may further include a non-aqueous moistnuzer. The non-aqueous moisturizer may include one or rore polyethers. For example, rt non. aqueous moisturizer may include an ethylene oxide vt propylenc oxide condensates having snright and/or branched chain alkyl and alkaryi groups o one embodiment the non-aqueous mroisturier includes a polyethylene glycol, a polypropylene glycol ether, a thioether, a polyoxyaikylene glycol (eg., Jeffox TP400:. a dipropylene gyol, and/or a poypropylete glyco!(eg., Pluniol P425 or Piuriol 20006 [n one embodiment, the non-aqueous tnoistrizer comprises a polyoxyalkylene gyeo or a polypropylene gycoi. 3n another embodiment the notn-aqueous moisturizer includes a cotmound based embnodiemenr, the non-aqueous moisturizer includes a polyhydroxy based on a glycerine, a propylene glycol, an ethylene glycoL a glyeirnc acetate, a sorbiroL a INtol or a maltirol 10731 n another embodiment, the non-aqueous moisturizer includes other compounds ihagving muliple hydroxyl groups based on ietrahydrofuran, a eaprolactone, and/or a alky lphenoxypoly(ethyleeoyethanos having alkyl groups containing from about 7 to about 1S carbon atoms and having from about 4 to about 240 ethyleneoxy units. For example, the non-aqueous moisturizer may include a heptysphenoxypolvfethyleneoxyqohanol and/or a nonylphenxypoly(erhyleneoxy)erhanol, In another embodiment, the non-aqueous moisturizer includes a polyaxyalkylene derivative of hexitt l uch as a srbitan, sorbide, m Initan, arId/or a mannide. In yet another embodiment, the non~aqueous misorizer may include a partial iong-chain faty acids ester, such as a polyoxyaiky lone derivai ve of sorbium innonoluurate, sorbitan monopalmnitate, sorbitan monostearate, sorbitan rtrisrearate, sorbitan monooleae, anti/or sorbitan trioleate, j074f In illustrative embodiments, the non-aqueous moisturizer tracludes a condensate of ethylene oxide with a hydrophobic base, the base being formed by condensing propylene oxide with propylene glycol. In one embodiment, the onn-aqueous moisturizer includes a sulfur containing condensate, such as those prepared by condensing ethylene oxide with a higher alky mercaptan (e.g. nonyl, dodecyl, tetradecy nmercaptan, or alkylhiophenols having about 6 to aut t 15 carbon atoms in the alkyl gr oup). in another embodiment, the non-aqucous moisturtzer includes an ethylene oxide derivative of a long-chain carboxylic acid, uch as lauric, myristc pahitic, or oleic acids. h yel another embodiment, the non-aqueous moisturizer includes an erhylene oxide derivative of a long-chain alcohol such as otyl, doocy, laury], or oct51 alcohoE, In another embodnment, tile nonc-queous moisturize iludes an ethylene oxide/tetrahydrofuran copolymer or an erhylen oxide/propylene oxide copeolytmer 10751 The folloing exapes illustrate specific cinbodients infonther dtiln These examples are p . illustratie pu eoad shou Knot be consumed s imig the inention o he inventve concept to) ay parinulr physicalnfiyaion in tiy y. EXAMPi ES 10761 Example I: A solution of 50 g dextrose (0,278 mol) 50 g hexamethylenediamine (0.431 mo a dissolved m 566. g deionized water (15% sols solution, pH 11.9) was heated to the boiling poi, of the solution, A brownish wart insoluble polymer was observed as a precipitate in the reaction vessel, 10771 Eal om the above solutn of 50 g dextrose(07nol50 2 pofth bndr olutiwasaidn Mo a filte pad whOich is plaedin a Mitr.Balance ~andhae -23 for 15 min at 120 0 C A brownish water insolble polymer formed on the filter pad. An extraction of the curd filter pad usin 100 g of deionized war is essentially colorcess and has a pH of 6.8. t078] Examole' 3:X solution of 85 g dextrose (0.472 mol), 15 g hexamethylenediamnine (0129 ml) dissolved in 566 g deionized water (15% solids solution, pH 10.8) was prepardW 2 g of the binder solution was apphid on a titer pad which is placed in a Moisture Balance and heated for 15 main at 140 CC. A brownsh water insohuble polymer fomed on the ilter pad. An extraction of the cured filter Md using 100 g of deionized w 0ter is essentially colorless ind has a pH of 6.8. [079] Examole 4:A solution of 95 g dextrose (0.528 mol), 5 g.hexametlwlenediamine (0.043 mnol dissolved in 566A 0 deionized water (15% solids solution) was prepared. 2 g of the binder solution was applied on a filter pad which is placed in a Moisture Balance and heated for 1 5 mmin t 180 *C, A brownish water in-souble polymrn formed on the filter pad, An extraction of the aured filter pad using 100 g of deionized water is essentially colorless and has a pH of 6.8. [080 ComaratveFxampoe_1: A solution of 180 g dextrose (1 moD dissolved in 1020 g deionized water (15% solds solution) was prepared, 2 g of the binder solution was applied oi a filter pad which is placed in a Moisture Balane and heated for 15 win at 80 *C. A water insoluble polyner was not formed on the fier pad, The resulting heat treated binder was essentially fully water soluble. [ost Cure Rare and C'ue Time: Square Fiberglass mats (13 x 13) ithl a weight of 44 g (corresponding to 34.5 gA 2 ) wre impregnated with a kinder containing 15% solids, Excess of binde is removed by vacuum suction, and the nOist mat is dried for at last 12 hours at90 0 F in an oven (recirculation). [082] The dried mat is cut in four squares of the saetn dimension. The squares are stacked on top of ecl other, and at least one hneriocouple connected to a recorder (i.e. oven mole) is placed in the middle of the stack between the 2 and 34 layer, [083] A mnol~d press with temperature controlled platen is heated to 400 tP (204 "C). The sample with the prepared thermocouple is placed in the middle of the platen, and pressed to a thickness of 5/8" for a predefined time (ie. 3.5 nmn, 4.0 min, 5,0 min, 60 Ain, 15 min), [084) Each melded samli was evaluated for the degree of cwre by testing evenness of the surtces, water hold-up, and extract. A sample was deem to be cured when the surfaces are smooth without any "bumps", the sample does not noticeably weaken when immersed in water. and no significant ex tract color is formed when immersing the sample in water, The temperature profile of the center of the sample is measured during the molding cycle and is shown in Fig, 3. 1085] Comnparative Example 2: Phol Formaldehyde Binder, Composion2based ndry solids - 2.41 pari Anmtoniumn Sulfat - T3 phenol fo[aulehyde Re r r i 0 Comartiv xamle efe to as ind 1t Fi3 10861 m~ a ivern Exatnole 3:Carbohydrateenrgai Aci Binder. om stin bedon d Q pan of o nmunia 0.3p Silen i l dd 10871 EaMo I 8094 pars Dext e and Aunonias l ( ameous so o ontaining 2 rMolte Dextrose and 2 Moliiter Ammoni) 19.06 parts Hdexamethyleediamne Example 5 ise edt as Binder 4 hinFig 3 [88! It was detertn tha the t rqnd to achie fU Ce of erwithn the Scope of the presendsclure less tan that of comparatie example bdersstems having derse chernslies. hisnode ysem llustrae tatnne cair ten providing that other variables are kept condanti dependenm on the lhemsisrry of he binder system. The ch enxisu'yf an illstrt i binder mposion i in he cope ofhe a n I disc lore ahieves ipro ed cu e times in eotnptrison hsethue n empary sstems. h eut are showfollowing Comaatve Mix 2 -. Bder I Minum of 240 seonds Coearatifix. 3 Binder 2 Mnim um of' 300econds 5- Bide4 Ct edat 20sonds [*891 Rferir n v to Fig. 3s is the empeature profile characterii for each of binder1, and 4. s enacd ta hetmpcrac profit is caeeritic funach bider. wa not estabishedthat her cur to te ad curimae no characteristic of te cure tempratre groe. Ho Wcver the cutemperatre p e hep tonderstand and predict cre re and curei Specicaly Conaratve Example retired the geesteu time; and sim rly the cure emperaturepieeird the greatest amounted to asymptotcal aime Snlariy, Exmple 5 e d the east anu of Atime t asyptoticaly maximze and demonstrated shortest o1 carbokwer Reactan o valmne Raio E on Cre C Tne, wetia:id Mats (WL.Mi werc made with varying ratio., of dexurose tmonoh'ydrate (DMH1) to Hlexamethylenedianine (H MDA). The weigh] ratios tested include 75/25. 85/15, and 92/8 respectively, (0911 A 1 5% Dxrose-HMvDA IBindlr was appliedeto 5 INN Thg e foggo dwn bn compositions warea prepared: Example 6 Ixample 7 amplee 8 DMH/HMDA 75/25 DN I M[A 1, '5 DM I iHHMDA 92.8 Water 1677.45 g 6I745 g 167745 g DMH 246,78 g 2798 g 302 g HMDA 74.77 g 44.86 g 23.3 g Silano .~ LOt) t1092' The mats are prepared in 13"x1 3" pieces, with a thickness of 3/R", The press used to mold the mats is set at 400 0 F. Once the sample is molded it is approximately 5/8" thick, A temperature profile was rst determined in a 15 minute interval The next sanIple was pressed for 4 minutes this is the time it takes to curea comparable phenol formadehyd binder composition (results not showni. The experiments were repeated with v:aryingv cure times until the minimum time required to cure each composition was determined. The extent to which each binder had cured was determined based on weight. The following results were determined: Cure Cycle Time Example 6 2:30 mit. Example 7 4 in, Eamp le S 8 n n [093] As described airove, comparable phenol formaldehyde based product (e.g, Comparative Example- 2) cures with a4 minute cycale t ime. Furthermore, a comparable car bohydrate based binder (e g. Comparative Exam 1 e 3) cures with a 5 minute Ac timn. These results indicate that a binder within the scope of the present disclosure with a carbohydrate reactant to primary plyamine of 8515 or lower cures at a comparable or faster rare tha the phenol formaldehyde based product. Further experiment showed that the cure temperauro can be lowered in products having a shorter cure time to achieve equivalent cure times at lower t emperaates. The results obtained agreed in principle to our expectations based on the Arrhenius equation. (094] In addition to those examples described in detail, the following examples were made to ensure that the carbohydrae reactan and polyamine may comrnprise a wid range of aernatives Fx Polyamine Carbohydrate Reactant Binder Formed 9. hcxamecthylencdiaminc dextrose Yes Sethlnediamine dteYes iidiethylenetriamxine dextroseYe 12 hexamethylenedianine high fructose'onsyuYe hexamehylnediamine scrose 1s 1 cta methvlene diamine dexrs e 15 tetramethyl anediamine detre Furt Dextrose -Polyamine. Examples: [095 Eamniej[6: As suspension of 56,08 g deionized water, 7 .15 g dextrose monohydrate, and 3.5 g 11 2-diaminodecane was acidified with 11 N HCI to p H 1.0, and heated to 70 *C under citation resulting into a clear, colorless solution. The solution forms a thermoset, water insoluble polymer at 160 *C. (rest condition: 2 g binder solution is applied on a tiler pad which is placed in a Moisture Balane. The 5er pad is heated for 15 nn at 160 "CJ An extract of the cured filter pad with 100 g of deionized water is essentially colorless [096i example 17: A solution of825 g dextrose tonuhydrate, and 2.50 g 1.5-diamino2-methlpenme (Dytek A, lnvista) dislved in 5608 g deionized water forms a thermoset, ater insoluble polymer at 160 "C, (Test condlion: 2 g binder solution is applied on a filter pad which is placed in Moisture BaIancc. The filter pad is heated for 15 min at 160K"C) An extract of the cured lfter pad with 100 g of dionized 'wter is essentially colorless, |097J .Example 18: A solution of 8&03 g dextrose mnonohydrate, and 2.70 g N43-amintopropyi'KL3-propanediamine dissolvedI in 56.08 g deionized water forms a thermoset, water insoluble polymer at 200 "C. (Test condition: 2 g binder solution is applied on a filter pad which is placed in a Moisure Balance The hie pad is heated for 15 min at 200 "C.) An extract of the cared filter pad with 100 g of dioAWed water has a slight yellowish color. 10981 Examtploj9; A solution of 1.0 g dextros (5,55 mmnol), 10 g (approx. 2,27 amrol) Jeffanine T-403 Poyetherasmine dissolved in 8.5 g deojnized wner (l9% solids solution) was prepared. 2 g of the binder solution was applied an a filter pad viL'h is place in a Moiste Balance nd heated fSor min at 180 *C. A brownish walker insoluble polymer formed on the filter pad. A n extrac'tion. of the cured filter p'd usinug 100 g of deionized water is essentially colorless and has a pH- of [099) JeRffarulm P403 Polvethm eramint a frfncra imar am- ine having, an averaa moleAcular weawcf40 t iegop- r oae t eodr ab n os at the ends of al iphat ic poytechl]as. Its strur may be represened as follws Wi wit1 Wl'te enum of. y and z is g of a cured product having the binder thereon is placed in a rest tube. which rube is then heated to 1000 *E for 2.5 minutes at which time the headspace is sampled and analyzed by gas ehromatography/mass spectrometry (OC/MS) under the following condii ons: Oven, 50 "C for one mluue - 10 *C/inute to 300 *C for 10 minutes; Ilet, 20 "C spless; Column, HP-5 30mm x 0.32 mm x 0.25 u: Column flow, L1 I m/mxnute 1eiuim; Detector, MSD 280 *C: Injection olume, I mL; Detector mode, scan 34-700 amu; Threshold, 50; and Sampling Rate, 22 ccas/seond. A computer search of the nmss spectrum of a chromatographic peak in the sample is made against the Wiley library of mass spectra. The best match is reported. A. quality indcx (closeness of match to the library spectra) ranging oin 0 to 99 is generated. Only the identity of peaks wih a quality index of greater than or equal to 90 is reponed. [0101) The follo wing table provides representative pyrolysis date 'that one expects from the ciMS analysis of ascous compounds produced dring pyrolysis of a melanoidin based binder composition. Retention Time (mi ) Temaiv'e dentification % Peak Area 1S 2-cyciopenten-1-one 10.6~ 1 34 2,5-dimethy!-iran 5,84 3,54 tua 2.15 3.60 3-methyb-2,5 -furandione 3.93 407 henoi 0.38 4.89 2,3-dimethyl-2-cyclopenen-v [one 1.24 5. I 2-methyl phenol 1.19 5.42 4-methyl ph enol 2.17 6.46 2,4-dimethyI-phenol L13 1,57 dimethylphthalate 0,97 17.89 octadecanoic acid 1000 22.75 eneylamide 9.72 [01021 Following is a listing of the species observed in the pyrolysis gas chromatography mass spectometry (Py CC-MS) of a hind sample prepared usin .hexamethylenediaine as te poiyamine component. The pyrolysis was carried out at 200 "C, 300 "C, and 770 *C, Fingerprinting shows a 'ety significant peak which corresponds to acetic aci in the mass cluomatogram at both 200 "C and 300 "C, which was not seen in a sample made using d e and ammonium sulfate (see Comparative Example 3), in which the significam volatile was S02 particularly -2s at 300 " At 770 %C, the peaks observed, in order of increasing retention time were assigned as fEllows: A: Co-coting CN10, 0 5

"

12 , aetone possI low mw ace acid ster; : C58 diene: C: CC AM diene; D: likey a pentanol; E: C 6 H12 -ca mdhyl pente F: hexane; : methylclopenane H: a cyclOhexadiene; 1: C6H 1' - prohbabJly a methyleyclopentane I: be.nzene; K: acetic acd L cyciohexene: M: probably nonanol; N: 2-mety1pentanone: 0: 2,-dimethylfuatan P: C7 ; 1 o+ unassigned co-ecate; Q: pyridine + unaisignoed co-elute; R:. oluene; S: possibly decenal+± unassigned co-eate; T: 2-mshyl-5-methylfuran; U: a methyl pyridine; V:a methyl pyrrole; W: a xylene; X: unassigned - with alcohol funotionality; Y: unassigned; Z: a xylene + unassigned co-eltt; AA: onassgned; AB: a dimethyl pyrrole; AC: a dimethyl pyridine; AD: a dimethy pyridiri; AE: unassigned; AF?: unassigned; AG: an ethyl methyl pyrrole + unassigned cocut A : an unassigned but distinci mass spectrum (N-containing. pyrrole related; As: an unassigned but distinct mass spectrum (N-containing), possibly an acetamide; AK: an unassigned but distinct mass spectrum (Neontainng) pyr-role related; AL: an assigned but distinct mass spectrum (N-containing), pyrrole elaAd AM; an unassigned but distinct mass spectrum (N-conltaing) pyrrole related. The distinct mass spectra seen fm peaks Al to AM are not seen in the data ofpior binders not having the po ly arnin component. Ir their -y and "w thered" tensile strength, 5lass bead-containing shel bonc Compositions prepared ith a given binder provide an indication of the likely tensile strength and the likely duability, respectively. ofCa fiberglass product prepared with that particular binder. Predicted durability is based en a shell hone's weathered tensle strength : dry tensie strength ratio, Shel bones are prepared, weathered, and tested as follow's, for example, for a hexamethyienediamnine-dextrose binder mixture, {01041 A shell bone mold (Dierert Foundry Testing Equipment; Heated ShelI Curing Accessory, Model 366, and Shel Mold Accessory) is set to a desired temperaure, generally 425 "F. and allowed to heat up fr at leas one hour. While the shell bone mold is heating approximately 100 g of an acqueou binder generaly 15% in binder solids) s prepped (e.g. as described in Example 7). Usiag a large glass beaker, 7?7.5 g of glass beads (Quakiy Baiini impact Beads, Spec. Al), US Sieve 70 1 40, 106212 micron!7, from Potter Indutries. ic. re weighed by difference. The glass beads are poured into a clean and dry mixing bowl, which bowl was mounted onto an electric mixer stand. Appro-imNately 75 g of aqueous binder is poured lowly into the glass beacs in the mixing bowl. The Electric mixer is then turned on and ihe gls edst binder mixte is agit ne large spatula, lie sides of the whsk (m ixef are scraped to remove anyclunps of binder, while thu scapmng the edges wherein the glass heads lay in the boom of the bowl Thoe mixr is then tumA back on fB! an additional iRote, and then the whisk (mii'r) is removed nom tho un allowed by removal of the miing bow! containing the glass beadsybinder mixmue. Using a large spatula, as much of h binder and glass bands attached to tAc whsk (mixer) as possible are removed and then ied into the glass beadsbinder mixure in h m ixing howh The sides of the bowl are then scraped to mix in any excess hinder that might have aeumauhted or the sides, At this point, the glas beads? hex amethylenedianme-dextrose binder mixture is ready for mtoling in a shell bone mold. [0O51 The slides or the shell bone mold arc confirmed to be aligned within the botnm mold platen. Ising a large spatula, a glass hads/hexamerhylenediaminc-dexttose binder mixtre is thenf quickly added into the tree mold cavaies within The shell bone id. The surface of the mixiure in each caviNy is flattened oat while scraping off the excess mixture to gve a uniform stice area to the shell bone Any inconsisencies or gaps at existed in any ofthe cavities are filed in with additional glass beads/hexamethyncda m IS -dexrose binder mixture and then flatened oM. (the a glass bdshexamnethyienediarntie-es binder mixture is placed into the shell bone cavies, and the mixture is exposed to heat, rriing begins. As manipuhaion time can affect test results. e -g.. shel hones wit h I wo dKirenstaly cured ers can be reduced; shell bones arc prepared consistently and rapidly. Withhe shell boue m old tilled the t op platen is qtnicklyplced onto the boAtm platen. At the same time, or quickly thereafter, measurement of curing thne is initiated by meams of a stopwath during which curing the terperaure of the bottom platen ranged from abou G 400 F to about 430 while the temperature of the top platen ranged from about 440 "F to about 470 0 F At seven minutes clapsed tine, the top platen is rem ved and the slides pulled out so that all three shel bones can be removed The freshly made shell bones are then placed en a wire rack. adiacm to the shel bone mold platen and allowed to cool to room temperamre. Theeafter, each shell bone is labeled and psced incividually in a plast ic storage bag labeledc appropriately. :If shel bones can nor he tested on the day they were prepared, the shell bonecntaining plastic bags were placed in a desiccator un [01 06| tndi,+ioningjyir;d ; pn otdr h hl OONABu thmti chambr tumNed on and then set to provide weatherin condition, of 90, F and 90% relative humidity (t , 90 1 90% r H . The w'ter tanic on the ASd of the hunidity chamber is checked and lled regularly, usually each , time it s turned on. The humidity chamber is allowed to tc h the specfied weathering conditions over a period of at least 4 hours, with a daylong equilibration period being typica!. Shell ones to be weathered are loaded quickly (since whilethe doots are open both the humidly and the temperature decrease), one at a ine through the open humidity chamber door., onto the upper, slotted shelf of the huit'ty chamber, The time that the shel bones are placed in the humidity chamber is noted, and weathering is conducted for a period of24 hour:. Thereafer, the humidity chamber dotrs are opened and one set of shell bes a't ainim are quickly removed and placed individual ito respective plastic storage bags, being sealed completely. Generally, one to four sets of shell bones at a time are w~eahered as described above. Weathered shell bones re immediately taken to the Itrstroni room timd tested.

[0107J T P drfor Breakn&.SheillBones: In the instron room, the bell bone test tmethod is loaded on the 55009 R Ionston machine while ensudamg that. the proper load cell is installed (i e., Static Load Cell 5 kNh and the machine is allowed to warm up for fifteen mimoes. During this period of ime, shell bone t'sng grips are verified as being instalod on the machine. The load cell is zeroed and balanced, and ben one sot of shell bones is tested at a time as flows: A she bone is removed from its plastic storag" bag and then weighed. The weight (in grams) js then entered into the computer associated witth he Instron machine. The insured thickness of the shel bone (in inches) is then entered, as specimn thickness, three times into the copter associated with the hnsron machine, A shell hone specimen is then placed into the grips on thelnstron machine, and testing itiated vi' the keypad on the instron machine. After remvng a shell hone speimn the measured poit is entered into the computer associated with the Watron machine and testing coMinued until all shel bones in a et are tested 10108] Crbnhydr ate Reactant. Plvamine Ratio E fcz on Shell Bone Poyerties, Shell Bones were made with varying ratios of dextrose monohydrate (DMH ) to Hexamethylenediamine (HMDA) with silane additive (110200) were examined a described above, at a et speed of 25 mm/mn. The weight ratios tested include 90/10, 85/15, 80/20 and 75/25, respectively, Strength Stress at peak / MNnr 2 Ls Dry Weathered 90% DMH+ 10% NMDA- 03% R510200, Q1 I S06 2.954 L929 3.9 bS% DMHt 15% -MDA 0.% STO200, ph-i 119 2.573 2.17 2 k I 80% DMH 20% H MDA- 0.3% S0200, pi I .54 2.747 2.344 21 75% DMH+ 25% HMDA- 0.3%1510200, pH 11.71 2,735 2.073 24,21 Exanile: Glass Wool Fier Glass) Trials 10109| Comparisons of the qualiis of two glucose -hexamethylenediamine hinders with a stdard binder in termS of cOring and rigidity on a glass wool product (Ac!032 100 mm 1200 im wdth; 32 kg/m 3 - 15 m/min) were carried ot by measuring the parting strength and density, Binder 1: 85% glucose - 15% heam ethylenedianmine. B~inder 2: 90% gluceose - 10% hexanmethylenediamine. 191101 Ordinary Partig Strength (Before Autoclave) and Weathered Parting Strength (After' Autocave) may be measured as described in International Patent Application, Publication Number WO 2008/089851 or W02009/019235 1 ~ ~~~~~ -l 90- l9I \ TAl V M~c.v P S~~~-----

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R--------------AF E R-3 4 S g o w LOS 6 6 gfgws oI 18~~ -0 ... .. 18 ~N\ LOS. L3 . y t '12 I~ U A. ?0i2 1 FM~ 7 ..9...\..... LLN N' .o I_ E-) 6 =as .V

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jk 3,$0.89 4g SY12 g PS, t FOR E : 3 S gf/gwt PS. AFTER: L42iL11 gflg LOSS 781 gflgwt isl tOhservations during the trial: The product was browner on the line with the two glucose hexamethytenediamine binders, 01 11 Conclusions: With the two glucose -hexamethyienediamine binders ,the parttrtg strength (whiich is a longitudinal tensile strength) results showed a significant implrovement; and a significant improvement was Olbser-ved in three other rigidity tests ("604" test - sagging measured when leaned at 6O" against a chutc; "table" test -sagging measured against a horizontal plane: and Accenmi test sagging measured 35 cm from the edge of a table). Exmpe Pht1icle~ Boatd Trial 10112] Conparisons of the qualities o:f particle boards made using a urea-tbrmldehyde hinder ( UF EO) and using a carbohydrate polyamine (hexamethylenediamnine) binder were catrried out under the following conditions. Board. ize: 350 x 333 mm and main 10 mm thick (2x2mm) Platen temperature: 1950(C mainly but also. 175 and ~215 "C. Pressure: 3-5 Mpa (35 bar) Quoted - Actual 3. Kg.em 2 ., 56 bar to achieve. Density target: 650 kg/m 3 Ptre-form prepared prtor to preting. Results: IIoder J PressTirne [ I11 Strengt ure(secs) i _pa Carbo~hydrate0 6 poix'amin (00 6.93 ____130__0,61 90--- .. ,15 . ------- _ _ _ _ -t - -- -. ... .. ---------- -_ _ _ 01-- ..I---------- .

A I boards prepaid appeared ofhigh quality: no sp1its or degasing were observed. The bords made with this carbohydrate polyaminc formulation match urea formaichyde board when they arc cured fbr

Claims (26)

1. 5. The binder of claim 1, 'herein the carbohydrte reactant is selected from a group consisting of dextrose, xylose, fructose, dihydroxyacetone, and mixtures thereof,
2. 6. The binder of any one of claims 1-5, wherein the polyamine is a pnary polyamine selected from a group consisting of a diamin, tdamine, telxaamine, and pentmie.
3. 7. The binder of claim 6, wherein the polyamine is H 2 N-Q-NHi 2 , wherein Q is alkyl, cycloalkyl, heteroalkyl, or cy'cloheteroaalkyL. each of which is optionally substituted.
4. 8. The binder of claim 7, wherein Q is an aLkyl selected from a group consisting of C2-C24. 9, The binder of claim 7, wherein Q is an alky! selected from a group consisting of C4Cg.
5. 10. The binder oain 7. 'herin Q i an alk Yseleed from a group consing Of 1L The binder of claim 7, wherein Q is a C6 aikyl
6. 12. The binder of claim 7, wherein Q is selected fIrm the group consisting of a cyclohexyl, c vlopenmyl and cyclobuvtyL
7. 13. The binder ofclaim .7, wherein Q is a henzyh
8. 14. The binder of claim 6, wherein the polyamine is a diamine selected from the group consisting of 1,6-dtiminohexane and I ,5-dicanino--mthlpentanc,
9. 15. The binder ofeclaim 14, 'herein the diamiine is 1.6-diaminohexane,
10. 16. 1The binder of claim6, wherein ihe trianmine is selected from the group consisting of diethylenetriaine.1 -piperazincethaneamine, and bis(hexamtethylenetrianme, 17 The bide of lan , wherein the fesramnine is triethyieneternsnine, S.The binder of claim n wheremn the ptentanmint is retraethylenepemtamine. T1he inder of clai 6, wherein the primary polyanine is a polyether-poyamne. 2a The binder of'claim 19, wherein the polyether-polyamne is dianine or a fliamine, 21, The binde-r of any one of claims 1-20, wherein a weight raio of the carbohydrate reactant to the primary polyamine is in the tange of about 1:1 to about 30:1,
11. 22. The hinder of any one of cam 1-20, wherein a weight ratio of the carbohydrate reactant to the prilmry poly'amine is tn the range of about 2:1 to about 10:1L
12. 23. The binder of any one of claims 1-22, whern an aqueom extract of the polymeric product has a pH in the range of about 5 to about 9.
13. 24. The binder of any one of claims 1-23, wherein an aqueous extrat of the polymeric product is essentially colon ess.
14. 25. 'The binder of any one of claims 1 -24, wherein an aqueous extract of the polymeric product is a capable of reducing Benedict's reagent.
15. 26. The hinder of nv one of claims 1-25, wherein the polymeric product is phenol free and formaldehyde-free.
16. 27. The binder of any one of cam 1-26, wherein the carbohydrate reactant and te primary polyamine are non-volatile. 23, The binder oFny one ofclaimS 1-27, wherein the polymeric product reduces Benedicr's reagent,
17. 29. The binder of any one of claims 1-28, wherein the polymeric product strongly absorbs light at 420 no.
18. 30. A method of making a collection of aunr bound with a polymeric binder comsprising: preparing a solution containtn rerants for producing the polymeric binder and a solvent, wherein the react ts include a carbohydrate reactant and a polyanine; disposing the solution onto the collection of mater; volamihzing the solvent to forim an uncured product and subjectin the neured product to conditions that cause the carbohydrate reactant and the polyamie 10 polymerize to form thepolymeic binder. 31 The mehod of claim 30 wherein the collection of matter comprises fibers selected from a group consisting of miural ibers, aranid fibers, ceramic fibers, metal fibers, carbon fibers, polyiminde fibers, pole ster fibers, rayon fibers andi cellulosic fibers. .t2. The method of clain 30, wherein the collection omatter is coat or sand particls.
19. 33. The method o claim 30 wherein the gass fibers are present in the range from about 80% to about 99% by weight
20. 34. The method of' claim 31, wherein the collection of moater comprises cellulosic fibers, 35 T e ol Khra the c losic fibers are present in a subsrate selected from the group cOnsisting of wood shavings, sawdust, wood pulp, ground wood, jute, flax, hemp. and straw.
21. 36. The method of claim 30, further comprising packaging the uncured product in a packaging material suitablec for storage.
22. 37. The method of any one of claims 30-36, wherein preparing the solution includes adding an amount of the carbohydrate reactant and an amount of the primary polyamine so a weight ratio is in the range of about 21 to about 10:L 38 The method of any one of claim 30-3.7, wherein prepare ta sootion includes adding the carbohydrate reactant and the poilyamine to an aqueou s solution.
23. 39. The method of claim 38, wherein prering rho solution includes adjusting the pH ofthe solution w within the range of about 8 to about 12,
24. 40. A composition compising a collection of matter and a binder, the hinder comprising polmric products of a racdon between a carbohydrate reactant and a polyamine, the polymeric pr oducets being substa ntially ater insoluble. 41L The composition or chim 40, wherein the collection of matter comprises fibers selected from te group consisting of mineral fibers aramnid fibers, ceramic fibers, metal fibers, cabon fibers, polvimide fibers, polyester fibers, rayon fibers, and cellulosic fibers. 42, T b composition of claim 4] wherein the collection of matter comprises glass fibers. 4. Thea copsto ofclim41,iheein the collection'mattericldes ceilulicifibers,
25. 44. The composition of chtim 43, wherein the cellulosic fbers are present in a cllulosic substrate selected from th group consisting of wood shavings, sawdust, wood pulp, and Around wood. 45, The composition of claim 40, 'herein the carbohydra reactant is selected. from a. group consisting of dextrose, xylose, fructose, dihvdroxyacetone, and mixtures thereof.
26. 46. 'The compositions of any 'one of claims 40-45, wheboein The polyamnine is selected fon a group consisting of a diamine riamine, feamin md pentamine. 41, Th cmposiion ofclam46xercithe polyanne i eren The compositon of any one olas 4047 fuecom sing aslic containing compound 4'9. The eonposition of claim 48, wherein the silicon-contaitning compound is selected from the gro0up consisting of g'amma-aminopropyitriethoxysilane, gamma- gaceidoxypropyh'iethx ysane. anmetlyb.triopropyltrinetoxysilane, an am-nofnctional oligoaeric silane and mixtures thereof. 5.0 The composition of claim49. wherein te|siticocadaining compound is gama-aminopropyhethoxysiha Si. The composition of any one of claims 40-50, further comprising a corrosion inhibitor selected from the group consisting of dedusting oil, monioarnmonium phosphate, sodium metasilimct pentahydrate. melanmine, tin. (Il)oxalate, and a metihyihydrogen silicone fluid emulsion.