Process for the manufacture of an insulating product based on mineral fibres

Patent metadata

Field	Value
Publication number	US-12559423-B2
Application number	US-202318171048-A
Country	US
Kind code	B2
Filing date	Feb 17, 2023
Priority date	Jun 23, 2017
Publication date	Feb 24, 2026
Grant date	Feb 24, 2026

Abstract

An insulating product includes mineral fibers of aluminosilicate glass including aluminum oxide, Al 2 O 3 , in a fraction by weight of between 14% and 28%, that are sized with a sizing composition including the following constituents within the limits defined below, expressed as fractions by weight with respect to the total weight of the composition: from 80% to 98% of water, from 2% to 20% of water-soluble poly(furfuryl alcohol), which is obtained by polycondensation of furfuryl alcohol, and less than 0.5% of furfuryl alcohol, wherein a sum of the fractions by weight of the poly(furfuryl alcohol) and of the water is at least 95%, and wherein the sizing composition applied to the mineral fibres has a pH in a range from 5 to 8.

First claim

The invention claimed is:

1 . An insulating product comprising mineral fibers of aluminosilicate glass including aluminum oxide, Al 2 O 3 , in a fraction by weight of between 14% and 28%, that are sized with a sizing composition comprising the following constituents within the limits defined below, expressed as fractions by weight with respect to the total weight of the composition:
from 80% to 98% of water, from 2% to 20% of water-soluble poly(furfuryl alcohol), which is obtained by polycondensation of furfuryl alcohol, and less than 0.5% of furfuryl alcohol, wherein a sum of the fractions by weight of the poly(furfuryl alcohol) and of the water is at least 95%, and wherein the sizing composition applied to the mineral fibres has a pH in a range from 5 to 8.

2 . The insulating product according to claim 1 , wherein the mineral fibres have a fraction by weight of SiO 2 of between 32% and 50%.

3 . The insulating product according to claim 1 , wherein a sum of the Al 2 O 3 and SiO 2 fractions by weight of the mineral fibres is between 46% and 78%.

4 . The insulating product according to claim 1 , wherein the mineral fibres have an Al 3+ /(Al 3+ +Si 4+ ) molar ratio of greater than 0.25.

5 . The insulating product according to claim 4 , wherein the mineral fibres have an Al 3+ /(Al 3+ +Si 4+ ) molar ratio of greater than 0.35.

6 . The insulating product according to claim 1 , wherein the mineral fibres additionally comprise the oxides CaO and MgO, a sum of the fractions by weight of the oxides being between 7% and 32%.

7 . The insulating product according to claim 1 , wherein the mineral fibres additionally comprise the oxides Na 2 O and K 2 O, a sum of the fractions by weight of the oxides being between 1% and 15%.

8 . The insulating product according to claim 1 , wherein the mineral fibres have a dissolution coefficient of greater than 100 ng·cm −2 ·h −1 , the dissolution coefficient being calculated from the amount of SiO 2 of the mineral fibres which is dissolved in a synthetic pulmonary fluid of pH 4.5, thermally regulated at 37° C., after 14 days.

9 . The insulating product according to claim 8 , wherein
the dissolution coefficient is greater than 400 ng·cm −2 ·h −1 .

10 . The insulating product according to claim 1 , wherein a content of furfuryl alcohol of the sizing composition is less than 0.1%.

11 . The insulating product according to claim 1 , wherein said sizing composition additionally comprises one or more adjuvants chosen from coupling agents, dust-preventing agents, hydrophobic agents, retardants, antistatic agents, softening agents, conditioning agents, colouring agents or opacifying agents.

12 . The insulating product according to claim 11 , wherein a fraction by weight of adjuvants and additives of the solid part of the sizing composition does not exceed 25%.

13 . The insulating product according to claim 11 , wherein a fraction by weight of adjuvants and additives of the solid part of the sizing composition does not exceed 20%.

14 . The insulating product according to claim 1 , wherein a sum of the fractions by weight of the poly(furfuryl alcohol) and of the water is at least 98%.

15 . The insulating product according to claim 1 , the pH is from 5.5 to 8.0.

16 . The insulating product according to claim 1 , the pH is from 6.0 to 8.0.

17 . An insulating product comprising mineral fibers of aluminosilicate glass including aluminum oxide, Al 2 O 3 , in a fraction by weight of between 14% and 28%, and an organic binder that binds the mineral fibers, wherein said organic binder is obtained by crosslinking a sizing composition applied to the mineral fibers, said sizing composition comprising the following constituents within the limits defined below, expressed as fractions by weight with respect to the total weight of the composition:
from 80% to 98% of water, from 2% to 20% of water-soluble poly(furfuryl alcohol), which is obtained by polycondensation of furfuryl alcohol, and less than 0.5% of furfuryl alcohol, wherein a sum of the fractions by weight of the poly(furfuryl alcohol) and of the water is at least 95%, and wherein the sizing composition applied to the mineral fibres has a pH in a range from 5 to 8.

18 . The insulating product according to claim 17 , wherein the mineral fibres have a fraction by weight of SiO 2 of between 32% and 50%.

19 . The insulating product according to claim 17 , wherein a sum of the Al 2 O 3 and SiO 2 fractions by weight of the mineral fibres is between 46% and 78%.

20 . The insulating product according to claim 17 , wherein the mineral fibres have an Al 3+ /(Al 3+ +Si 4+ ) molar ratio of greater than 0.25.

Assignees

• Saint Gobain Isover

Inventors

• Salomon Pierre
• Azevedo Joël
• Jaffrennou Boris

Classifications

• E04B2001/742

  Use of special materials; Materials having special structures or shape · CPC title

• E04B1/74

  Heat, sound or noise insulation, absorption, or reflection (forms of, or arrangements in, rooms for influencing or directing sound E04B1/99); Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls (fire protection E04B1/94; elements chiefly adapted for structural purposes E04C1/00 - E04C3/00; chiefly adapted for surface coverings E04F13/00; as underlayers for floor coverings E04F15/18; closures for wall or like openings E06B) · CPC title

• C03C2218/112

  by spraying · CPC title

• C03C2217/445

  Organic continuous phases · CPC title

• C03C2213/00

  Glass fibres or filaments · CPC title