Formaldehyde-free mineral fibre insulation product

• US 7,854,980 B2
• Filed: 01/25/2007
• Issued: 12/21/2010
• Est. Priority Date: 01/25/2007
• Status: Active Grant

• Current Assignee: Knauf Insulation LLC (GEBR Knauf Verwaltungsgesellschaft KG), Knauf Insulation Sprl (GEBR Knauf Verwaltungsgesellschaft KG)
• Original Assignee: Knauf Insulation Limited (GEBR Knauf Verwaltungsgesellschaft KG)
• Inventors: Jackson, Roger, Aindow, Tony, Baybutt, George
• Primary Examiner(s): EDWARDS, NEWTON O
• Application Number:
  US12/524,491
• Publication Number:
  US 20100080976A1
• Time in Patent Office: 1,426 Days
• Field of Search: 428/44, 428/45, 428/47, 428/292.1, 524/487, 527/312
• US Class Current: 428/45
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 2111/1006 Absence of well-defined organic compounds
• CPC Class Codes: C04B 24/287 Polyamides
• CPC Class Codes: C04B 30/02 containing fibrous materials
• CPC Class Codes: D04H 1/4209 Inorganic fibres
• CPC Class Codes: D04H 1/64 the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• CPC Class Codes: E04B 1/7658 comprising fiber insulation, e.g. as panels or loose filled fibres
• CPC Class Codes: Y10T 428/161 with frame, casing, or perimeter structure
• CPC Class Codes: Y10T 428/163 Next to unitary web or sheet of equal or greater extent
• CPC Class Codes: Y10T 428/249924 Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity

Abstract

A packaged mineral fibre insulating material has: a) a Recovered Thickness of at least 95% nominal thickness; and b) an Ordinary Parting Strength of at least 95 g/g; and c) a Weathered Parting Strength of at least 75 g/g the material comprising mineral fibres and an organic, formaldehyde free binder in a quantity of less than 15% by weight, preferably less than 10% by weight, said binder having been applied to the fibres of the insulating material in liquid form at pH of greater than 5.

Claims

1. A mineral fiber insulating material comprising mineral fibers and less than about 15% by weight of an organic binder, wherein

a) the organic binder is a formaldehyde free product of curing an aqueous solution having a pH of greater than 5 when applied to the mineral fibers,

b) the mineral fiber insulating material has a recovered thickness of at least about 95% as determined according to Annex A of British standard BS EN 823:

1995,

c) the mineral fiber insulating material having an ordinary parting strength of at least about 95 g/g,

d) the mineral fiber insulating material having a weathered parting strength of at least about 75 g/g, and

e) the mineral fiber insulating material is packaged.

2. The mineral fiber insulating material of claim 1, wherein the recovered thickness is at least about 100%.

3. The mineral fiber insulating material of claim 1, wherein the ordinary parting strength is at least about 100 g/g.

4. The mineral fiber insulating material of claim 1, wherein the weathered parting strength is at least about 80 g/g.

5. The mineral fiber insulating material of claim 1, wherein the mineral fiber insulating material is a rolled product having a density between about 5 and about 40 kg/m³ and the mineral fiber insulating material is packaged under compression.

6. The mineral fiber insulating material of claim 1, wherein the organic, formaldehyde free binder is the product of drying and curing the aqueous solution with the pH being less than about 11 when applied to the mineral fibers.

7. The mineral fiber insulating material of claim 6, wherein the organic, formaldehyde free binder is the product of drying and curing the aqueous solution with the pH being between about 6 and about 10 when applied to the mineral fibers.

8. The mineral fiber insulating material of claim 1, wherein the organic, formaldehyde free binder is between about 2% and about 8% of the mineral fiber insulating material by weight.

9. The mineral fiber insulating material of claim 1, wherein the organic, formaldehyde free binder comprises a product of a reaction including a reducing sugar.

10. The mineral fiber insulating material of claim 1, wherein the organic, formaldehyde free binder comprises at least one Maillard reaction product.

11. A mineral fiber insulating material having a density in a range of 100 to 200 kg/m³ comprising mineral fibers and less than 15% by weight an organic, formaldehyde free binder, wherein

a) the mineral fiber insulating material has an ordinary compression strength of at least about 60 kPa,

b) the mineral fiber insulating material has a weathered compression strength of at least about 25 kPa,

c) the organic, formaldehyde free binder is a product of drying and curing an aqueous solution with a pH of greater than about 5 when applied to the mineral fibers, and

d) the mineral fiber insulating material is packaged.

12. The mineral fiber insulating material of claim 11, wherein the ordinary compression strength is at least about 70 kPa.

13. The mineral fiber insulating material of claim 11, wherein the weathered compression strength is at least about 30 kPa.

14. The mineral fiber insulating material of claim 11, wherein the organic, formaldehyde free binder is the product of drying and curing the aqueous solution with the pH being less than about 11 when applied to the mineral fibers.

15. The mineral fiber insulating material of claim 11, wherein the organic, formaldehyde free binder is the product of drying and curing the aqueous solution with the pH being between about 6 and about 10 when applied to the mineral fibers.

16. The mineral fiber insulating material of claim 11, wherein the organic, formaldehyde free binder is between about 2% and about 8% of the mineral fiber insulating material by weight.

17. The mineral fiber insulating material of claim 11, wherein the organic, formaldehyde free binder comprises a product of a reaction including a reducing sugar.

18. The mineral fiber insulating material of claim 11, wherein the organic, formaldehyde free binder comprises at least one Maillard reaction product.

19. The mineral fiber insulating material of claim 11, wherein the aqueous solution further comprises citric acid, ammonia and dextrose.

20. A method of manufacturing a packaged mineral fibre insulating material selected from the group consisting of:

(i) material having

a) a Recovered Thickness of at least 95%; and

b) an Ordinary Parting Strength of at least 95 g/g; and

c) a Weathered Parting Strength of at least 75 g/g; and

(ii) material having

a) an Ordinary Compression Strength of at least 60 kPa; and

b) a Weathered Compression Strength of at least 25 kPa;

comprising the steps of

i) applying an organic, formaldehyde free binder in aqueous solution to the mineral fibres at a pH of greater than 5 and

ii) curing the product so that it contains a quantity of less than 15% by weight of binder and

iii) packaging the insulating material.