Fire-protecting insulation product and use of such product

Patent metadata

Field	Value
Publication number	US-12397537-B2
Application number	US-201716611321-A
Country	US
Kind code	B2
Filing date	Nov 13, 2017
Priority date	May 13, 2016
Publication date	Aug 26, 2025
Grant date	Aug 26, 2025

Abstract

A fire-protecting insulation product has air-laid mineral wool fibres and a binder. The binder is the result of curing a binder composition comprising at least one hydrocolloid. The product further comprises a particulate endothermic material.

First claim

The invention claimed is:

1. A fire-protecting insulation product comprising:
air-laid mineral wool fibres;
a binder, said binder being the result of curing a binder composition comprising:
at least one hydrocolloid comprising gelatin; and
a tannin, an enzyme, or both a tannin and an enzyme, wherein:
the tannin is selected from the group consisting of tannic acid, condensed tannins (proanthocyanidins), hydrolysable tannins, gallotannins, ellagitannins, complex tannins, and tannin originating from one or more of oak, chestnut, staghorn sumac, fringe cups, and combinations thereof; and
the enzyme is selected from the group consisting of transglutaminase (EC 2.3.2.13), protein disulfide isomerase (EC 5.3.4.1), thiol oxidase (EC 1.8.3.2), polyphenol oxidase (EC 1.14.18.1), lysyl oxidase (EC 1.4.3.13), and peroxidase (EC 1.11.1.7); and
a particulate endothermic material selected from the group consisting of gypsum, magnesium hydroxide, hydromagnesite, aluminium hydroxide, and aluminium trihydroxide;
wherein the binder composition is cured at a curing temperature of from 5 to 95° C.;
wherein the binder composition has a pH of 7 to 10;
wherein the binder has a 3-point bending strength of at least 0.18 kN, measured in accordance with a Mechanical Strength Bar Test, unaged condition; and
wherein the fire-protecting insulation product comprises the mineral wool fibres wherein the fibers are blown into a forming chamber and, while airborne and while still hot, are sprayed with the binder composition and randomly deposited as a mat or web onto a traveling conveyor, the randomly deposited mineral wool fibres then being transferred to a curing oven where the binder composition is cured into the binder by air blown through the randomly deposited mineral wool fibres, thereby binding the mineral wool fibres together.

2. The product according to claim 1 , wherein the binder further comprises at least one fatty acid ester of glycerol.

3. The product according to claim 1 , wherein the particulate endothermic material is distributed evenly within the fire-protecting insulation product.

4. The product according to claim 1 , wherein the product has a first and a second face section of a mineral wool fibre portion with a core section of the mineral wool fibre portion therebetween, and wherein the particulate endothermic material is distributed such that there is a higher concentration of endothermic material in the core section of the mineral fibre wool product than in the first and second face sections.

5. The product according to claim 1 , further comprising at least a second hydrocolloid selected from the group consisting of pectin, starch, alginate, agar agar, carrageenan, gellan gum, guar gum, gum arabic, locust bean gum, xanthan gum, and cellulose derivatives.

6. The product according to claim 5 , wherein the gelatin is present in the binder composition by an amount of 10 to 95 wt. % based on a combined weight of the at least one hydrocolloid and the at least the second hydrocolloid.

7. The product according to claim 5 , wherein the at least one hydrocolloid and the at least the second hydrocolloid have complementary charges.

8. The product according to claim 2 , wherein the at least one fatty acid ester of glycerol is soured from a plant oil and/or animal oil.

9. The product according to claim 2 , wherein the at least one fatty acid ester of glycerol is sourced from a plant-based oil.

10. The product according to claim 2 , wherein the at least one fatty acid ester of glycerol is sourced from one or more components selected from the group consisting of linseed oil, olive oil, tung oil, coconut oil, hemp oil, rapeseed oil, and sunflower oil.

11. The product according to claim 2 , wherein the at least one fatty acid ester of glycerol is sourced from an animal oil, or fish oil.

12. The product according to claim 2 , wherein the at least one fatty acid ester of glycerol is sourced from a plant oil and/or animal oil having a iodine number of ≥75.

13. The product according to claim 2 , wherein the at least one fatty acid ester of glycerol is sourced from a plant oil and/or animal oil having a iodine number of ≤100.

14. The product according to claim 2 , wherein the content of the fatty acid ester of glycerol is 0.5 to 40, based on dry hydrocolloid basis.

15. The product according to claim 1 , wherein a loss on ignition (LOI) is within the range of 0.1 to 25.0% by weight.

16. The mineral wool product according to claim 1 , wherein the binder results from the curing of the binder composition at a temperature of less than 95° C.

17. The product according to claim 1 , wherein the binder composition is not a thermoset binder composition.

18. The product according to claim 1 , wherein the binder composition does not contain a poly(meth)acrylic acid, a salt of a poly(meth)acrylic acid or an ester of a poly(meth)acrylic acid.

19. The product according to claim 1 , wherein the binder is formaldehyde-free.

20. The product according to claim 1 , wherein the binder composition consists essentially of:
the at least one hydrocolloid;
the tannin, the enzyme, or both the tannin and the enzyme
at least one fatty acid ester of glycerol;
optionally at least one pH-adjuster;
optionally at least one anti-fouling agent;
optionally at least one anti-swelling agent; and
water.

21. The product according to claim 1 , wherein the binder is crosslinked.

22. The product according to claim 1 , wherein curing the binder composition further comprises increasing the temperature of the binder composition.

23. The product according to claim 1 , wherein the density of the fire-protecting insulation product is in the range of 10-1200 kg/m 3 .

24. The product according to claim 1 , wherein the binder composition comprises the enzyme, and wherein the enzyme is catechol oxidase, tyrosine oxidase, or phenoloxidas.

25. The product according to claim 1 , wherein the at least one hydrocolloid further comprises a cellulose derivative selected from the group consisting of carboxymethylcellulose, arabinoxylan, cellulose, curdlan, and β-glucan.

26. The product according to claim 1 , wherein the air blown through the web is heated air.

27. A method of making the fire-protecting insulation product of claim 1 , the method comprising:
blowing mineral wool fibres into a forming chamber and, while airborne and while still hot, spraying the mineral wool fibres with the binder composition;
randomly depositing the mineral wool fibres as the mat or web onto the traveling conveyor;
adding, to the mat or web of randomly deposited mineral wool fibres, the particulate endothermic material;
transferring the mat or web of randomly deposited mineral wool fibres to the curing oven;
curing the binder composition at the curing temperature of from 5 to 95° C. by blowing air through the mat or web of randomly deposited mineral wool fibres, thereby binding the mineral wool fibres together.

Assignees

• Rockwool As

Inventors

• Hjelmgaard Thomas
• Tielemann Thomas

Classifications

• E04F13/0866

  composed of several layers, e.g. sandwich panels or layered panels (layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence) · CPC title

• E04D3/352

  at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets · CPC title

• E04C2/284

  at least one of the materials being insulating · CPC title

• E04B1/80

  slab-shaped · CPC title

• D10B2505/20

  for civil engineering, e.g. geotextiles · CPC title