U.S. patent application number 16/844998 was filed with the patent office on 2020-07-23 for mineral fibre board.
The applicant listed for this patent is Knauf Insulation SPRL Knauf Insulation, Inc.. Invention is credited to Tony AINDOW, George BAYBUTT, Roger JACKSON.
Application Number | 20200232217 16/844998 |
Document ID | / |
Family ID | 38606712 |
Filed Date | 2020-07-23 |
United States Patent
Application |
20200232217 |
Kind Code |
A1 |
JACKSON; Roger ; et
al. |
July 23, 2020 |
MINERAL FIBRE BOARD
Abstract
A high density mineral fibre board having a formaldehyde free
binder has acceptable strength and good dimensional stability.
Inventors: |
JACKSON; Roger; (St. Helens,
GB) ; AINDOW; Tony; (St. Helens, GB) ;
BAYBUTT; George; (St. Helens, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Knauf Insulation SPRL
Knauf Insulation, Inc. |
Vise
Shelbyville |
IN |
BE
US |
|
|
Family ID: |
38606712 |
Appl. No.: |
16/844998 |
Filed: |
April 9, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15690623 |
Aug 30, 2017 |
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16844998 |
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12524512 |
Nov 12, 2009 |
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PCT/EP2007/050749 |
Jan 25, 2007 |
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15690623 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y10T 428/24 20150115;
E04B 1/80 20130101; E04C 2/16 20130101; C03C 25/321 20130101 |
International
Class: |
E04C 2/16 20060101
E04C002/16; C03C 25/321 20060101 C03C025/321; E04B 1/80 20060101
E04B001/80 |
Claims
1.-12. (canceled)
13. A mineral fiber insulating board having a density in a range
from about 100 to about 200 kg/m.sup.3 comprising mineral fibers
and an organic, formaldehyde free binder, wherein the mineral fiber
insulating board has: a) an ordinary compression strength of at
least about 60 kPa; and b) a weathered compression strength of at
least about 25 kPa; and c) a change in thickness of less than about
6% after autoclave.
14. The mineral fiber insulating board of claim 13, wherein the
ordinary compression strength is at least about 70 kPa.
15. The mineral fiber insulating board of claim 13, wherein the
weathered compression strength is at least about 30 kPa.
16. The mineral fiber insulating board of claim 13, wherein the
change in thickness after autoclave is less than about 5%.
17. The mineral fiber insulating board of claim 13, wherein the
fibers are rock wool mineral fibers.
18. The mineral fiber insulating board of claim 13, wherein the
mineral fiber insulating board comprises from about 0.5% to about
5% of organic, formaldehyde free binder by weight.
19. The mineral fiber insulating board of claim 13, wherein the
organic, formaldehyde free binder comprises a product of a reaction
including a reducing sugar.
20. The mineral fiber insulating board of claim 13, wherein the
organic, formaldehyde free binder comprises at least one Maillard
reaction product.
21. The mineral fiber insulating board of claim 13, wherein the
organic, formaldehyde fee binder comprises a product of curing an
aqueous solution comprising citric acid, ammonia and dextrose.
22. The mineral fiber insulating board of claim 13, wherein the
density is from about 130 to about 190 kg/m.sup.3.
23. The mineral fiber insulating board of claim 13, wherein the
mineral fiber insulating board is adapted for a use selected from a
group consisting of a fire barrier, fire protection, cladding for
buildings, ceiling tiles, a roof board, thermal insulation for high
temperature machinery, and foundation walls for basements.
24. A method of manufacturing a mineral fiber insulating board
comprising applying an aqueous binder solution to a plurality of
mineral fibers, dehydrating the aqueous binder solution such that a
substantially dehydrated binder is disposed on the plurality of
mineral fibers and curing the substantially dehydrated binder,
wherein a) the mineral fiber insulating board has a density from
about 100 to about 200 kg/m.sup.3, b) the mineral fiber insulating
board has an ordinary compression strength of at least about 60
kPa, c) the mineral fiber insulating board has a weathered
compression strength of at least about 25 kPa, and d) the mineral
fiber insulating board a change in thickness of less than 6% after
autoclave, and e) the aqueous binder solution is formaldehyde free.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 12/524,512, filed Jul. 24, 2009, which is a U.S. national
counterpart application of international application serial no.
PCT/EP2007/050749, filed Jan. 25, 2007.
FIELD OF THE INVENTION
[0002] This invention relates to a mineral fibre insulating product
having a low formaldehyde or formaldehyde free binder.
BACKGROUND
[0003] Industry standard binders used for fibre insulation, for
example glass wool and rock wool insulation are based on phenol
formaldehyde. Whilst such binders can provide suitable properties
to the insulating products there has for some time been a desire to
move away from the use of phenol formaldehyde, particularly due to
environmental considerations.
[0004] Traditional polyester based binder systems have previously
been proposed but have not gained acceptance in the insulation
industry, particularly as their strength in holding the mineral
fibres together, especially when exposed to moisture or weathering,
has been perceived as insufficient.
[0005] To date, only one low formaldehyde based mineral insulation
binder system has been used on an industrial scale on glass wool
insulation; this is based on polyacrylic acid and supplied by Rohm
& Haas. Unfortunately, the highly acid nature of these types of
binders can cause excessive corrosion of manufacturing plant unless
significant investment is made in acid resistant equipment. U.S.
Pat. No. 5,977,232 discloses a formaldehyde free binder for glass
wool insulation based on a polycarboxylic acid. European patent
application EP1698598A discloses use of a corrosion meter to try to
mitigate problems associated with polycarboxylic acid-based
fibreglass binder resins. In addition, whilst the strength of these
binders is acceptable for some applications it is not as good as
the commonly used phenol formaldehyde based binders.
[0006] It has not been thought possible to provide a formaldehyde
free binder system useable on an industrial scale that will confer
characteristics to mineral wool insulating products that could
match or even exceed those obtained with formaldehyde binders.
SUMMARY
[0007] According to one aspect, the present invention provides a
mineral fibre insulating board as defined in claim 1. Other aspects
are defined in other independent claims. Preferred and/or
alternative features are defined in the dependent claims.
DETAILED DESCRIPTION
[0008] As used herein, the term formaldehyde free means that the
composition is substantially free from formaldehyde, preferably
does not liberate substantial formaldehyde as a result of drying or
curing and/or preferably comprises less than one part per million
by weight of formaldehyde.
[0009] Desired characteristics of the mineral fibre insulation
board can be assessed by measuring Ordinary Compression Strength
and/or Weathered Compression Strength and/or change in thickness
after autoclave.
[0010] The invention may be particularly useful in applications
where dimensional stability of the insulation board is important.
It is surprising that a formaldehyde free binder can confer the
strength and/or dimensional stability that has been found.
[0011] The insulating board may be: a fire barrier; a fire
protection; cladding for a building; a ceiling tile; a roof board;
thermal insulation for high temperature machinery for example,
generators, ovens and industrial plant; foundation wall insulation,
for example for use in basements or in a wall or partition between
a room and a layer of earth and/or rock. The insulating board may
be used to provide thermal and/or acoustic insulation.
[0012] The cured binder content may be in the range 0.5%-15% by
weight determined for example by loss on ignition. A cured binder
content of 0.5-5% by weight, particularly 1.5-3.5% by weight may
provide suitable characteristics, particularly with respect to one
or more of the products mentioned above.
[0013] The binder may: [0014] be based on a reducing sugar; and/or
[0015] be based on reductosis; and/or [0016] be based on an
aldehyde containing sugars/and/or [0017] include at least one
reaction product of a carbohydrate reactant and an amine reactant;
and/or [0018] include at least one reaction product of a reducing
sugar and an amine reactant; and/or [0019] include at least one
reaction product of a carbohydrate reactant and a polycarboxylic
acid ammonium salt reactant; and/or [0020] include at least one
reaction product from a Maillard reaction.
[0021] The binder may be based on a combination of a polycarboxylic
acid, for example citric acid, a sugar, for example dextrose, and a
source of ammonia, for example ammonia solution. It may be based on
a combination of ammonium citrate and dextrose. Where the binder is
based on sugars and/or citric acid and/or comprises significant
--OH groups, it is particularly surprising that such levels of
performance can be achieved. It would have been thought that the
--OH groups for example in the sugars and/or citric acid would be
readily subject to hydrolysis and that this would be detrimental to
strength, particularly weathered strength, and/or dimensional
stability.
[0022] The binder may comprise a silicon containing compound,
particularly a silane; this may be an amino-substituted compound;
it may be a silyl ether; it may facilitate adherence of the binder
to the mineral fibres.
[0023] The binder may comprise melanoidins; it may be a thermoset
binder; it may be thermally curable.
[0024] The binder may be one of those disclosed in International
patent application n.degree. PCT/US2006/028929, the contents of
which is hereby incorporated by reference.
[0025] The insulating board may have [0026] a nominal thickness in
the range 20 to 200 mm; and/or [0027] a thermal resistance R of
R.gtoreq.1.7 m.sup.2K/W, preferably R.gtoreq.2 m.sup.2K/W at a
thickness or 100 mm; and/or [0028] a density in the range 100 to
200 kg/m.sup.3, particularly 130 to 190 kg/m.sup.3.
[0029] The density may be in the order of 110 kg/m.sup.3, for
example in the range 100 to 120 kg/m.sup.3; it may be in the order
of 140 kg/m.sup.3, for example in the range 130 to 150 kg/m.sup.3;
in the order of 180 kg/m.sup.3, for example in the range 170 to 190
kg/m.sup.3. Such density can provide products with desirable
characteristics.
[0030] The mineral fibres may be glass wool or rock wool; the
fibres may have an average diameter between 2 and 9 microns or be
microfibres of smaller diameter; they may have an average length
between 8 and 80 mm.
[0031] The mineral fibres may be crimped.
[0032] The insulating board preferably has good stability in a High
Temperature Shrinkage test. The performance in such a test
generally depends upon the thickness and density of the board.
Table 1 shows desired performance for a 80 mm thick board with a
density of 150 kg/m.sup.3. The low level of High Density Shrinkage
is particularly surprising as it was assumed that shrinkage is
primarily determined by fibre composition and little influenced by
the binder.
EXAMPLE
[0033] A non-limiting example of the invention is described
below.
[0034] An aqueous binder was prepared by mixing together:
TABLE-US-00001 Approximate % by weight Powdered dextrose
monohydrate 19.1% Powdered anhydrous citric acid 3.4% 28% aqueous
ammonia 2.6% Silane A-1100 0.07% Water 73.5%
[0035] This binder was used in the manufacture of a rock wool roof
board on a standard manufacturing line, the binder being sprayed
onto the fibres just after fiberising and the coated fibres being
collected, assembled in to a mat, compressed and cured in the usual
way.
[0036] The cured roof board had: [0037] a binder content of about
3% by weight as determined by loss on ignition [0038] a thickness
of about 80 mm [0039] a density of about 150 kg/m.sup.3
[0040] Desired characteristics and results achieved are set out in
Table 1:
TABLE-US-00002 TABLE 1 Acceptance More Most Result Equivalent
phenol Units limit Preferred Preferred preferred archieved
formaldehyde product Ordinary kPa .gtoreq.60 .gtoreq.70 .gtoreq.80
.gtoreq.90 72.3 86.5 Compression Strength Weathered kPa .gtoreq.25
.gtoreq.30 .gtoreq.40 .gtoreq.50 54.6 32.5 Compression Strength
Change in % .ltoreq.6 .ltoreq.5 .ltoreq.2 .ltoreq.0.5 0.2 4.4
thickness after autoclave High Density % .ltoreq.60 <50
.ltoreq.40 .ltoreq.30 21.1 44.9 Shrinage (80 mm thick)
[0041] The comparison in the table with a product that is
equivalent other than containing a phenol formaldehyde binder shows
that, surprisingly, the invention can provide improved dimensional
stability, i.e. less change in thickness after autoclave and
improved High Density Shrinkage.
[0042] Testing of Ordinary Compression Strength and Weathered
Compression Strength:
[0043] Ordinary Compression Strength is determined according to
British Standard BS EN 826: 1996 (incorporated herein by
reference).
[0044] Weathered Compression Strength is determined according to
British Standard BS EN 826: 1996 on samples that have been
subjected to the following accelerated weathering procedure:
samples are cut to size and then placed in a preheated autoclave
and conditioned on a wire mesh shelf away from the bottom of the
chamber under wet steam at 35 kN/m.sup.2 for one hour. They are
then removed, dried in an oven at 100.degree. C. for five minutes
and tested immediately for compression strength.
[0045] In both cases, compression strength is determined in the
direction of the thickness of the product; the dimensions of face
of the samples in contact with the compression test apparatus are
preferably 200 mm.times.200 mm.
[0046] Testing of Change in thickness after autoclave:
[0047] The thickness of the samples is determined, for example in
accordance with British Standard BS EN 823: 1995 and recorded. The
samples are then placed in a preheated autoclave and conditioned on
a wire mesh shelf away from the bottom of the chamber under wet
steam at 35 kN/m.sup.2 for one hour. They are then removed, dried
in an oven at 100.degree. C. for five minutes and their thickness
is immediately measured again. The change in thickness after
autoclave is calculated as (((thickness after autoclave)-(thickness
before autoclave))/(thickness before autoclave)).times.100.
[0048] Testing of High Density Shrinkage:
[0049] Four samples 100 mm.times.75 mm are cut at random from an
insulating board to be tested using a band saw or equivalent to
ensure square and straight edges. The width and length at the
centre position of the top and bottom face is measured, for example
using a metal rule in mm. The mean average length l1 and mean
average width w1 is calculated from these measurements for each
sample. For each sample, the thickness at the centre position of
each edge of the sample is measured and the mean average thickness
t1 calculated from these measurements.
[0050] Each sample is placed individually in the centre of a muffle
furnace maintained at a temperature of 800.degree. C. The sample is
removed from the furnace after 30 minutes and allowed to cool to
room temperature on a wire tray. When cool, the width, length and
thickness of the sample is measured in the same way as before and
the mean average width w2, length l2 and thickness t2 calculated in
the same way.
[0051] The shrinkage for the sample is calculated using the
formula:
Shrinkage=(((l1.times.w1.times.t1)-(l2.times.w2.times.t2))/(l1.times.w1.-
times.t1)).times.100
[0052] The High Density Shrinkage is calculated as the mean average
of the % shrinkage of the four samples.
* * * * *