Sizing composition for fibers, in particular mineral fibers, comprising a non-reducing sugar and an inorganic acid ammonium salt, and resulting products

Patent metadata

Field	Value
Publication number	US-9938184-B2
Application number	US-201615016857-A
Country	US
Kind code	B2
Filing date	Feb 5, 2016
Priority date	Nov 30, 2010
Publication date	Apr 10, 2018
Grant date	Apr 10, 2018

Abstract

A formaldehyde-free sizing composition for products based on fibers, in particular mineral fibers, such as fibers of glass or of rock, includes at least one non-reducing sugar, and at least one inorganic acid ammonium salt, preferably chosen from ammonium sulfates, phosphates, nitrates and carbonates. Another subject matter of the present invention is the products thus obtained, in particular thermal and/or acoustic insulators based on mineral wool and veils of nonwoven mineral fibers, and their process of manufacture.

First claim

What is claimed is:

1. An aqueous formaldehyde-free sizing composition comprising:
sucrose; and
ammonium sulfate;
wherein the ammonium sulfate is present in a range from 3% to 20% by weight of sucrose and ammonium sulfate; and
further comprising one or more additives in an amount from
0 to 2 parts of silane,
4 to 15 parts of mineral oil,
0 to 20 parts of glycerol,
0 to 5 parts of a silicone, and
0 to 30 parts of an extender,
wherein the amount of each of the one or more additives is calculated on the basis of 100 parts by weight of sucrose and ammonium sulfate.

2. The composition of claimed 1 , wherein the ammononium sulfate is present in a range from 5 to 15% by weight of sucrose and ammonium sulfate.

3. The composition of claim 1 , wherein the one or more additives comprise from 0 to 10 parts of glycerol.

4. The composition of claim 1 , wherein the sizing composition is devoid of organic polycarboxylic acid.

5. A product based on mineral fibers and/or organic fibers, the mineral fibers and/or organic fibers being sized using an aqueous formaldehyde-free sizing composition comprising:
sucrose; and
ammonium sulfate;
wherein the ammonium sulfate is present in a range from 3% to 20% by weight of sucrose and ammonium sulfate.

6. The product of claim 5 , wherein the product is a veil that includes mineral fibers.

7. The product of claim 5 , wherein the product is an acoustic and/or thermal insulating product.

8. The product of claim 5 , wherein the mineral fibers comprise glass wool or rock wool.

9. The product of claim 8 , wherein the glass wool is made of E, C, R or AR (alkali-resistant) glass, and the rock wool is made from basalt, or the mineral fibers comprise more than 96% by weight of silica, or the mineral fibers are ceramic fibers based on at least one oxide, nitride, or carbide of a metal or a semimetal.

10. The product of claim 5 , wherein the organic fibers are synthetic or natural fibers.

11. The product of claim 10 , wherein the synthetic fibers are based on polyethylene or polypropylene.

12. The product of claim 5 , wherein the sizing composition further comprises one or more additives in an amount from
0 to 2 parts of silane,
4 to 15 parts of mineral oil,
0 to 20 parts of glycerol,
0 to 5 parts of a silicone, and
0 to 30 parts of an extender,
wherein the amount of each of the one or more additives is calculated on the basis of 100 parts by weight of sucrose and ammonium sulfate.

13. The product of claim 12 , wherein the one or more additives comprise from 0 to 10 parts of glycerol.

14. The product of claim 5 , wherein the ammonium sulfate is present in a range from 5 to 15% by weight of sucrose and ammonium sulfate.

15. The product of claim 5 , wherein the sizing composition is devoid of organic polycarboxylic acid.

16. A process for the manufacture of a product, according to which mineral fibers and/or organic fibers is manufactured, the process comprising
applying a sizing composition to said mineral fibers and/or organic fibers; and
treating said mineral fibers and/or organic fibers at a temperature which makes possible the crosslinking of the size and the formation of an infusible binder, wherein the sizing composition comprises an aqueous formaldehyde-free sizing comprising:
sucrose; and
ammonium sulfate;
wherein the ammonium sulfate is present in a range from 3% to 20% by weight of sucrose and ammonium sulfate.

17. The process of claim 16 , wherein the sizing composition further comprises one or more additives in an amount from
0 to 2 parts of silane,
4 to 15 parts of mineral oil,
0 to 20 parts of glycerol,
0 to 5 parts of a silicone, and
0 to 30 parts of an extender,
wherein the amount of each of the one or more additives is calculated on the basis of 100 parts by weight of sucrose and ammonium sulfate.

18. The process of claim 17 , wherein the one or more additives comprise from 0 to 10 parts of glycerol.

19. The process of claim 16 , wherein the mineral fibers comprise glass wool or rock wool.

20. The process of claim 19 , wherein the glass wool is made of E, C, R or AR (alkali-resistant) glass, and the rock wool is made of basalt fibers including more than 96% by weight of silica.

21. The process of claim 16 , wherein the ammonium sulfate is present in a range from 5 to 15% by weight of sucrose and ammonium sulfate.

22. The process of claim 16 , wherein the sizing composition is devoid of organic polycarboxylic acid.

23. The process of claim 16 , wherein the product is an acoustic and/or thermal insulating product.

24. The process of claim 6 , wherein the product is a veil that includes mineral fibers.

Assignees

• Saint Gobain Isover

Inventors

• Jaffrennou Boris
• Obert Edouard

Classifications

• C08K3/24

  Acids; Salts thereof {(C08K3/16 takes precedence)} · CPC title

• D04H1/4218

  Glass fibres · CPC title

• D04H1/4282

  Addition polymers · CPC title

• D04H1/435

  Polyesters · CPC title

• E04B1/7662

  comprising fiber blankets or batts · CPC title