Mineral wool insulation

Patent metadata

Field	Value
Publication number	US-12012489-B2
Application number	US-202318308750-A
Country	US
Kind code	B2
Filing date	Apr 28, 2023
Priority date	Sep 19, 2018
Publication date	Jun 18, 2024
Grant date	Jun 18, 2024

Abstract

Mineral wool insulation products are provided. The mineral wool insulation includes a plurality of mineral wool fibers and a wax emulsion applied to the mineral wool fibers. The wax emulsion imparts excellent water resistance and thermal performance properties to the mineral wool insulation.

First claim

What is claimed is:

1. A mineral wool insulation comprising:
a plurality of mineral wool fibers; and
a binder and a wax emulsion applied to the mineral wool fibers,
wherein the wax emulsion comprises 0.001% to 0.4% by weight of the total weight of the mineral wool insulation,
wherein the binder and the wax emulsion collectively comprise 1% to 10% by weight of the total weight of the mineral wool insulation, and
wherein an R-value per inch of thickness of the mineral wool insulation decreases by less than 10%, after a water absorption test conducted in accordance with ASTM C209.

2. The mineral wool insulation of claim 1 , wherein the plurality of mineral wool fibers comprise 90% to 99% by weight of the total weight of the mineral wool insulation.

3. The mineral wool insulation of claim 1 , wherein the binder is a carbohydrate-based, formaldehyde free binder.

4. The mineral wool insulation of claim 1 , wherein the wax emulsion comprises at least one of an anionic polyethylene/paraffin wax emulsion and an anionic paraffin/hydrocarbon wax emulsion.

5. The mineral wool insulation of claim 1 , wherein the plurality of mineral wool fibers comprise at least one of basalt, bauxite, dolomite, peridotite, diabase, gabbro, limestone, nepheline syenite, silica sand, granite, clay, feldspar, phosphate-smelter slag, copper slag, and blast furnace slag.

6. The mineral wool insulation of claim 1 , wherein the water absorption of the mineral wool insulation is less than 1% by volume based on the volume of the mineral wool insulation, as tested according to ASTM C209.

7. The mineral wool insulation of claim 1 , the R-value per inch of thickness of the mineral wool insulation is unchanged after a water absorption test conducted in accordance with ASTM C209.

8. A thermal and acoustic insulation material comprising the mineral wool insulation of claim 1 .

9. A safing insulation material comprising the mineral wool insulation of claim 1 .

10. A curtain wall insulation material comprising the mineral wool insulation of claim 1 .

11. A pipe insulation material comprising the mineral wool insulation of claim 1 .

12. A mineral wool insulation comprising:
a plurality of mineral wool fibers; and
a binder, a wax emulsion, and a dedusting oil applied to the mineral wool fibers,
wherein the wax emulsion comprises 0.001% to 0.4% by weight of the total weight of the mineral wool insulation, and the dedusting oil comprises 0.0005% to 0.27% by weight of the total weight of the mineral wool insulation.

13. The mineral wool insulation of claim 12 , wherein the plurality of mineral wool fibers comprise 90% to 99% by weight of the total weight of the mineral wool insulation.

14. The mineral wool insulation of claim 12 , wherein the binder, the wax emulsion, and the dedusting oil comprise 1% to 10% by weight of the total weight of the mineral wool insulation.

15. The mineral wool insulation of claim 12 , wherein the wax emulsion comprises at least one of an anionic polyethylene/paraffin wax emulsion and an anionic paraffin/hydrocarbon wax emulsion, and the dedusting oil comprises at least one of mineral oil and a mixture of water, petrolatum, and emulsifiers.

16. The mineral wool insulation of claim 12 , wherein the plurality of mineral wool fibers comprise at least one of basalt, bauxite, dolomite, peridotite, diabase, gabbro, limestone, nepheline syenite, silica sand, granite, clay, feldspar, phosphate-smelter slag, copper slag, and blast furnace slag.

17. The mineral wool insulation of claim 12 , wherein the water absorption of the mineral wool insulation is from 1.5% to 2% by volume based on the volume of the mineral wool insulation, as tested according to ASTM C209.

18. The mineral wool insulation of claim 12 , wherein the binder is a carbohydrate-based, formaldehyde free binder.

19. A mineral wool insulation comprising:
a plurality of mineral wool fibers; and
a binder and a wax emulsion applied to the mineral wool fibers,
wherein the binder is a carbohydrate-based, formaldehyde free binder,
wherein the binder and the wax emulsion comprise 1% to 10% by weight of the total weight of the mineral wool insulation, and
wherein an R-value per inch of thickness of the mineral wool insulation decreases by less than 10%, after a water absorption test conducted in accordance with ASTM C209.

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Schweiger Scott W
• Stoneburg Christopher A

Classifications

• E04B1/88

  Insulating elements for both heat and sound · CPC title

• C03C25/255

  Oils, waxes, fats or derivatives thereof · CPC title

• C08J2391/06

  Waxes · CPC title

• C08J2433/02

  Homopolymers or copolymers of acids; Metal or ammonium salts thereof · CPC title

• C08J2333/02

  Homopolymers or copolymers of acids; Metal or ammonium salts thereof · CPC title