Mineral fibre board

Patent metadata

Field	Value
Publication number	US-11459754-B2
Application number	US-202017006735-A
Country	US
Kind code	B2
Filing date	Aug 28, 2020
Priority date	Jan 25, 2007
Publication date	Oct 4, 2022
Grant date	Oct 4, 2022

Abstract

A method of manufacturing a mineral fiber insulating board comprising i) spraying a formaldehyde-free aqueous binder solution onto a plurality of mineral fibers to provide uncured binder disposed on the plurality of mineral fibers, ii) passing the plurality of mineral fibers having uncured binder disposed thereon through a curing oven to cure the uncured binder and provide the mineral fiber insulating board with a cured binder disposed on the plurality of mineral fibers in about 0.5%-15% by weight as determined by loss on ignition, wherein the binder is based on reducing sugar(s) and the cured binder includes at least one reaction product of the reducing sugar(s) and an amine reactant.

First claim

What is claimed is:

1. A method of manufacturing a mineral fiber insulating board comprising
i) spraying a formaldehyde-free aqueous binder solution onto a plurality of mineral fibers to provide uncured binder disposed on the plurality of mineral fibers,
ii) passing the plurality of mineral fibers having uncured binder disposed thereon through a curing oven to cure the uncured binder and provide the mineral fiber insulating board with a cured binder disposed on the plurality of mineral fibers in about 0.5%-15% by weight as determined by loss on ignition, wherein the uncured binder is based on reducing sugar(s) and the cured binder includes at least one reaction product of the reducing sugar(s) and an amine reactant, and wherein
a) the mineral fiber insulating board has a density from about 100 kg/m 3 to about 200 kg/m 3 ,
b) the mineral fiber insulating board has an ordinary compression strength of at least 60 kPa,
c) the mineral fiber insulating board has a weathered compression strength of at least 40 kPa, and
d) the mineral fiber insulating board has a change in thickness of less than 2% after autoclave;
and wherein the mineral fibers are rock mineral wool fibers.

2. The method of claim 1 , wherein the ordinary compression strength is at least 70 kPa.

3. The method of claim 1 , wherein the weathered compression strength is at least 50 kPa.

4. The method of claim 1 , wherein the change in thickness after autoclave is less than about 0.5%.

5. The method of claim 1 , wherein the mineral fiber insulating board comprises from about 0.5% to about 5% of cured binder by weight.

6. The method of claim 1 , wherein the density is from about 130 kg/m 3 to about 190 kg/m 3 .

7. The method of claim 1 , 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.

8. The method of claim 1 , wherein the uncured binder comprises a silicon-containing compound.

9. The method of claim 1 , wherein the mineral fiber insulating board has a High Density Shrinkage of not more than 30%.

10. The method of claim 1 , wherein the mineral fiber insulating board has a High Density Shrinkage of not more than 40%.

11. The method of claim 1 , wherein the amine reactant comprises a polycarboxylic acid ammonium salt reactant.

12. The method of claim 1 , wherein the aqueous binder solution comprises citric acid, ammonia and dextrose.

13. The method of claim 1 , wherein the reducing sugar(s) comprise(s) dextrose.

14. The method of claim 1 , wherein the amine reactant comprises ammonia.

15. The method of claim 1 , wherein the amine reactant comprises ammonium citrate.

16. The method of claim 1 , wherein the mineral fiber insulating board has mineral fibers present in the range from about 85% to about 99% by weight.

17. The method of claim 1 , wherein the aqueous binder solution comprises binder reactants which consist essentially of Maillard reactants.

18. The method of claim 1 , wherein curing of the binder consists essentially of a Maillard reaction.

Assignees

• Knauf Insulation Sprl
• Knauf Insulation Inc

Inventors

• Jackson Roger
• Aindow Tony
• Baybutt George

Classifications

• C03C25/321

  Starch; Starch derivatives · CPC title

• Y10T428/24

  Structurally defined web or sheet [e.g., overall dimension, etc.] · CPC title

• E04B1/80

  slab-shaped · CPC title

• E04C2/16 Primary

  of fibres, chips, vegetable stems, or the like · CPC title

• D06M13/207

  Substituted carboxylic acids, e.g. by hydroxy or keto groups; Anhydrides, halides or salts thereof · CPC title