Fiber products having temperature control additives

Patent metadata

Field	Value
Publication number	US-2016333573-A1
Application number	US-201615222122-A
Country	US
Kind code	A1
Filing date	Jul 28, 2016
Priority date	Jun 7, 2010
Publication date	Nov 17, 2016
Grant date	—

Abstract

A fiber product is described which includes fibers, a binder and a temperature control additive. The fiber product has properties that make it useful for a variety of applications. The fibers may be glass fibers and the product may be a fiberglass insulation product for use in buildings, vehicles, or other structures for acoustic and/or thermal insulation. The fibers may be cellulosic fibers and the product may be a wood board product. The temperature control additive is incorporated into the uncured fiber product to prevent deleterious self-heating during or after binder curing. The temperature control additive undergoes an endothermic process that consumes at least a portion of the energy generated during the exothermic curing reaction.

First claim

1 . A mineral fiber insulation product comprising
a binder, a collection of mineral fibers, and a particulate selected from a group consisting of magnesia, alumina, and calcined gypsum, wherein the binder is disposed upon the collection of mineral fibers and the particulate is distributed within the mineral fiber insulation product, wherein the binder comprises a reaction product of a carbohydrate and an amine.

2 . The fiber product of claim 1 , wherein the particulate has a number weighted average particle size of less than about 200 micrometers.

3 . The fiber product of claim 1 , wherein the particulate has a number weighted average particle size of less than about 50 micrometers.

4 . The fiber product of claim 1 , wherein the particulate has a number weighted average particle size of less than about 20 micrometers.

5 . The fiber product of claim 1 , wherein the wherein the fiber product comprises from about 0.25% to about 15% by weight of the particulate.

6 . The fiber product of claim 1 , wherein the wherein the fiber product comprises from about 3% to about 30% by weight of the binder.

7 . The fiber product of claim 1 , wherein the carbohydrate comprises a monosaccharide and the amine comprises a primary amine.

8 . The fiber product of claim 1 , wherein the carbohydrate comprises dextrose, fructose, or mixtures thereof.

9 . The fiber product of claim 1 , wherein the particulate is dispersed within the binder.

10 . The mineral fiber insulation product of claim 1 , wherein the mineral fiber insulation product comprises about 61% to about 96% mineral fibers and about 1% to about 15% of the particulate.

11 . The mineral fiber insulation product of claim 1 , wherein the particulate has a number weighted average particle size of less than about 200 micrometers.

12 . The mineral fiber insulation product of claim 1 , wherein the particulate has a number weighted average particle size of less than about 50 micrometers.

13 . The mineral fiber insulation product of claim 1 , further comprising an organosilane in contact with the particulate.

14 . An uncured mineral fiber insulation product comprising
an uncured binder, a collection of fibers, and a temperature control additive, wherein the uncured binder is disposed upon the collection of fibers and the temperature control additive is a particulate in contact with the collection of fibers, in contact with the binder, or dispersed throughout the uncured fiber product, wherein the uncured binder comprises a carbohydrate and an amine.

15 . The uncured fiber product of claim 14 , wherein
the temperature control additive is selected from a group consisting of aluminum hydroxide, magnesium hydroxide, calcium silicate hydrates, and calcium sulfate dihydrate.

16 . The uncured fiber product of claim 14 , wherein
the carbohydrate is selected from a group consisting of dextrose, xylose, fructose, dihydroxyacetone, and mixtures thereof.

17 . The uncured fiber product of claim 14 , wherein
the amine is an ammonium salt or a primary amine.

18 . The uncured fiber product of claim 14 comprising about 61% to about 96% fibers, about 1% to about 15% of the temperature control additive, and 3% to about 30% of the uncured binder.

19 . The uncured fiber product of claim 14 , further comprising a silicon containing compound, wherein the silicon containing compound is concentrated at a first interface between the uncured binder and the fibers and at a second interface between the uncured binder and the temperature control additive.

20 .- 26 . (canceled)

27 . A method of manufacturing an insulation product comprising
contacting a collection of fibers with a binder to form an uncured insulation product, contacting the collection of fibers with a temperature control additive, shaping the uncured insulation product into a configuration adapted for an insulating purpose, applying an amount of energy to the uncured insulation product subsequent to contacting the collection of fibers with the temperature control additive, the amount of energy sufficient to initiate an exothermic process curing of the binder from an uncured state to a cured state, and maintaining the temperature of the binder within a predetermined range.

28 . The method of manufacturing an insulation product of claim 27 further comprising
forming a dispersion comprising the binder and the temperature control additive, wherein contacting the collection of fibers with the binder and contacting the collection of fibers with the temperature control additive occur concurrently through contacting the collection of fibers with the dispersion including the binder and the temperature control additive.

29 . The method of manufacturing an insulation product of claim 28 , wherein
forming the dispersion includes adding a surfactant.

30 . The method of manufacturing an insulation product of claim 27 further comprising
forming an aqueous dispersion of the temperature control additive and a surfactant, wherein contacting the collection of fibers with the temperature control additive occurs subsequently to contacting the collection of fibers with the binder.

31 . The method of manufacturing an insulation product of claim 27 , wherein contacting the collection of fibers with the temperature control additive includes
sprinkling the temperature control additive onto the uncured insulation product, the temperature control additive being in the form of a dry powder or concentrated slurry.

32 . The method of manufacturing an insulation product of claim 27 , wherein
shaping the uncured insulation product includes shaping the uncured insulation product into a configuration adapted for insulating walls.

33 . The method of manufacturing an insulation product of claim 27 , wherein
shaping the uncured insulation product includes shaping the uncured insulation product into a configuration adapted for insulating pipes.

34 . (canceled)

Assignees

• Knauf Insulation Inc
• Knauf Insulation Sprl

Inventors

• Mueller Gert
• Appley Charles Fitch

Classifications

• D04H1/587 Primary

  characterised by the bonding agents used · CPC title

• D04H1/64

  the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions · CPC title

• B29K2105/12

  of short lengths, e.g. chopped filaments, staple fibres or bristles · CPC title

• E04B2001/7683

  Fibrous blankets or panels characterised by the orientation of the fibres · CPC title

• E04B1/78 Primary

  Heat insulating elements {(E04B1/7662 takes precedence)} · CPC title