Method of reducing the formaldehyde emission of a mineral fiber product, and mineral fiber product with reduced formaldehyde emission

a technology of mineral fiber and formaldehyde, which is applied in the field of reducing the formaldehyde the reduction of formaldehyde emission of mineral fiber products, can solve the problems of undesirable formaldehyde emission, and achieve the effect of reducing the formaldehyde emission

Inactive Publication Date: 2013-11-07
ROCKWOOL INT AS
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0014]Accordingly, in one aspect, the present invention relates to a method of reducing the formaldehyde emission of a mineral fibre product bonded with a urea-modified phenol-formaldehyde resol resin-type binder, said method comprising the step of adding dextrose to the binder composition during and / or after preparation of the binder composition but before curing of the binder composition applied to the mineral fibres. Preferably, the dextrose is added to the binder composition after the preparation of the binder composition but before curing of the binder composition applied to the mineral fibres.

Problems solved by technology

Such formaldehyde emission is undesirable, particularly in enclosed spaces, because it is hazardous to human health and to the environment.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0074]A phenol-formaldehyde resin is prepared by reacting formaldehyde and phenol in a molar ratio of 3.7 to 1 in the presence of a catalyst (6 wt % KOH, relative to the amount of phenol) at a reaction temperature of 84° C. The reaction is continued until the acid tolerance of the resin is 4 and most of the phenol is converted. Urea is then added in an amount corresponding to 52 parts by weight of phenol-formaldehyde resin and 48 parts by weight of urea.

[0075]Using the urea-modified phenol-formaldehyde resin obtained, a binder is made by addition of ammonium sulphate in equimolar amounts to the catalyst so as to inactivate the catalyst. The final PUF resin has a free formaldehyde content of <0.5%, relative to the solids.

[0076]The thus obtained PUF binder is mixed with a dextrose preparation, Sirodex® 431 from Syral (DE value 95), in the amounts indicated in Table 1 below.

[0077]Further, the binder is diluted with water to a solids content equal to 22%, and a commercial prehydrolysed ...

example 2

[0079]A commercial resin PF-0415M from Hexion is used for the test. The resin is a phenol-formaldehyde resin modified with urea and ammonia. Free formaldehyde is <0.3% based on the liquid resin. The amount of urea is 28% in relation to the solids content.

[0080]The resin is mixed with a dextrose preparation, Sirodex® 431 (DE value 95) from Syral, in the amounts indicated in Table 2 below. For comparison, a glucose syrup, i.e. C Sweet® 01403 (DE value 30) from Cargill, is used in the amount indicated in Table 2 (Sample H).

[0081]The composition is diluted to 15% with water to provide a binder composition and further added with 0.5% of a commercial silane of the type pre-hydrolysed amino silane.

[0082]The binder composition obtained is used for production of monolayer roof boards (DP-GF). Further details are given in the following table.

TABLE 2Binder contentProductof product*densityPUF Binder %Dextrose %(%)(kg / m3)D10003.431553.20150E72283.63146F54463.59151G50503.66155H80203.12141The PUF ...

example 3

[0083]The formaldehyde emission is measured for the products A-H of Examples 1 and 2 and stated in Table 3 below as formaldehyde emission in μg / m3. The emissions were measured in the climate chamber at the Danish Technological Institute (TI) according to standard EN 717-1.

[0084]The actually determined values are compared with the expected values (assuming a pure dilution effect of dextrose). The value of 80 for 100 parts of PUF is used as a reference and the expected values are calculated with reference to the value. For instance, the 50 / 50 PUF / dextrose expected value is (50 PUF / 100 PUF)×80=40.

TABLE 3ExpectedMeasuredA100 / 0 PUF / Dextrose8083B80 / 20 PUF / Dextrose6436C43 / 57 PUF / Dextrose4013D100 / 0 PUF / Dextrose8083 (77)E72 / 28 PUF / Dextrose5836F54 / 46 PUF / Dextrose43 7G50 / 50 PUF / Dextrose4016H80 / 20 PUF / DE 30 syrup6465

[0085]As can be seen from Table 3, the use of dextrose results in a significant reduction of the formaldehyde emission of the bonded mineral fibre products which cannot be explained...

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Abstract

A method of reducing the formaldehyde emission of a mineral fibre product bonded with a urea-modified phenol-formaldehyde resol resin-type binder comprises the step of adding dextrose to the binder composition during and/or after preparation of the binder composition but before curing of the binder composition applied to the mineral fibres.

Description

FIELD OF THE INVENTION [0001]The present invention relates to a method of reducing formaldehyde emission of a mineral fibre product, and to bonded mineral fibre products having low formaldehyde emission.BACKGROUND OF THE INVENTION[0002]Mineral fibre products generally comprise man-made vitreous fibres (MMVF) such as, e.g., glass fibres, ceramic fibres, basalt fibres, slag wool, mineral wool and stone wool, which are bonded together by a cured thermoset polymeric binder material. For use as thermal and / or acoustical insulation products, bonded mineral fibre mats are generally produced by converting a melt made of suitable raw materials to fibres in conventional manner, for instance by a spinning cup process or by a cascade rotor process. The fibres are blown into a forming chamber and, while airborne and while still hot, are sprayed with a binder solution and randomly deposited as a mat or web onto a travelling conveyor. The fibre mat is then transferred to a curing oven where heated...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): E04B1/74F16L59/00B29D7/01
CPCE04B1/74B29D7/01F16L59/00C03C25/26C03C25/34C08J5/04C08J2361/14C09J161/30C09J161/32E04B1/7658Y10T442/60C08J5/241C08J5/249D04H1/4209D04H3/12D04H1/58
Inventor HANSEN, ERLING LENNARTNAERUM, LARSNISSEN, POVL
Owner ROCKWOOL INT AS
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