Silicone-coated mineral wool insulation materials and methods for making and using them

Patent metadata

Field	Value
Publication number	US-11746192-B2
Application number	US-201916386086-A
Country	US
Kind code	B2
Filing date	Apr 16, 2019
Priority date	Apr 16, 2018
Publication date	Sep 5, 2023
Grant date	Sep 5, 2023

Abstract

The present disclosure relates to silicone-coated mineral wool insulation materials, methods for making them using specific coating methods, and methods for using them. One aspect of the disclosure is a method for making a silicone-coated mineral wool, the method comprising: providing a mineral wool comprising a collection of mineral wool fibers; applying to the mineral wool a solvent-borne coating composition comprising a silicone, the silicone of the coating composition having a number-average molecular weight of at least 25 kDa; and allowing the solvent to evaporate to provide silicone-coated mineral wool.

First claim

What is claimed is:

1. A method for making an unbound loose-fill silicone-coated mineral wool, the method comprising:
providing a loose-fill mineral wool comprising a collection of loose mineral wool fibers;
applying to the loose-fill mineral wool a solvent-borne coating composition comprising a silicone, the silicone of the coating composition having a number-average molecular weight in the range of 40 kDa to 83 kDa; and
allowing the solvent to evaporate to provide silicone-coated mineral wool,
wherein the rate of application of the coating composition to the mineral wool is in the range of 0.1-2 mg silicone per gram mineral wool,

wherein the mineral wool is at a temperature in range of 200-500° C. when it is coated with the solvent-borne coating composition.

2. The method according to claim 1 , wherein the mineral wool is a glass wool.

3. The method according to claim 1 , wherein the mineral wool is at a temperature in range of 285-500° C. when it is coated with the solvent-borne coating composition.

4. The method according to claim 3 , wherein the application of the solvent-borne coating composition to the mineral wool lowers the temperature of the mineral wool to in the range of 50° C. to 250° C.

5. The method according to claim 1 , wherein the mineral wool has a soak test pH in the range of 8 to 11 just before it is coated.

6. The method according to claim 1 , wherein the silicone of the coating composition has a number-average molecular weight of at least 60 kDa.

7. The method according to claim 1 , wherein the silicone is a poly(dimethylsiloxane).

8. The method according to claim 1 , wherein the silicone is a polymer or copolymer of one or more of an alkylsiloxane; and arylsiloxane; and a functionalized siloxane.

9. The method according to claim 8 , wherein the polymer or copolymer includes a functionalized siloxane.

10. The method according to claim 9 , wherein the functionalized siloxane is 3-aminopropylmethylsiloxane.

11. The method according to claim 8 , wherein the alkylsiloxane is selected from dimethylsiloxane and methylsiloxane.

12. The method according to claim 8 , wherein the arylsiloxane is selected from phenylmethylsiloxane, 2-phenylpropylmethylsiloxane, and phenylsiloxane.

13. The method according to claim 1 , wherein the concentration of the silicone in the coating composition is in the range of 0.01-5% by weight.

14. The method according to claim 1 , wherein the amount of silicone on the fibers after application is in the range of 0.1-1 mg silicone per gram mineral wool.

15. The method according to claim 1 , further comprising applying an effective amount of an antistatic additive to the mineral wool, and/or a dedusting oil to the mineral wool in an amount in the range of 0.4-4% by weight of the mineral wool.

16. The method according to claim 1 , wherein the rate of application of the coating composition to the mineral wool is in the range of 0.2-2 mg silicone per gram mineral wool.

17. The method according to claim 1 , wherein the amount of silicone on the fibers after application is in the range of 0.2-1 mg silicone per gram mineral wool.

Assignees

• Certainteed Llc

Inventors

• Saxena Pawan
• Gallagher Kevin J
• Bozek John J
• Saylor Kathleen H

Classifications

• C08G77/26 Primary

  nitrogen-containing groups · CPC title

• B05D1/02

  performed by spraying · CPC title

• B05D7/24

  for applying particular liquids or other fluent materials · CPC title

• C03C25/40 Primary

  Organo-silicon compounds · CPC title

• C09D183/04

  Polysiloxanes · CPC title