Mineral wool binder with reduced moisture permeability

Abstract

A mineral wool insulation product for insulating and / or waterproofing the exterior of a structure (e.g., a roof) includes a mineral wool substrate, a non-woven fibrous finish, and a fluorine-free water resistant adhesive. The adhesive is modified to have reduced permeability and is disposed at the interface between the mineral wool substrate and the nonwoven facing so as to limit water intrusion, otherwise water may intrude into the product.

Description

Technical Field

[0001] The present invention relates to insulating materials for structures including exterior sheathing, and more particularly to systems and methods for avoiding problems associated with moisture intrusion that occurs in, for example, mineral wool insulation systems. Background Art

[0002] Mineral wool is an insulating material used in a wide variety of applications. The unique properties of mineral wool make it an effective choice for use in insulation applications, including exterior building cladding. While mineral wool insulation performs the necessary functions of energy retention and heat retention, other problems may arise due to environmental conditions. For example, when moisture is allowed to penetrate or otherwise migrate between the surface of the insulation and the substrate or structure, the insulation or structure may become compromised, requiring expensive repairs.

[0003] In some applications, mineral wool insulation has a nonwoven fiber facing. The facing can increase the mechanical strength of the insulation, enhance the aesthetic properties of the insulation, and protect it from environmental influences. However, both the mineral wool insulation and the facing are generally porous, thereby allowing moisture penetration, which is disadvantageous in some applications. One method of preventing water intrusion into mineral wool insulation products is to use a water-resistant glue when bonding the facing to the insulation or to coat the facing with a water-repellent coating. Typically, these water-resistant glues / water-resistant coatings are composed of fluorochemicals to provide water-resistant properties. However, recent environmental regulations regarding fluorochemical components make their use in many applications disadvantageous or impermissible. Summary of the invention

[0004] Therefore, there is a need for an insulation product that can provide adequate thermal insulation for structures in a variety of challenging environments, including roofing applications, yet prevent water intrusion while avoiding conventional fluorinated waterproofing materials.

[0005] The overall inventive concept is based in part on the discovery that certain modified cement-like adhesives (also referred to as glues) can deliver good adhesion between fibrous insulation (e.g., mineral wool insulation) and fibrous facings while also providing fluorine-free moisture resistance. Mineral wool and conventional (glass fiber nonwoven) facings are inherently porous and offer little moisture resistance to the underlying structure. As previously mentioned, this problem is typically addressed by applying a water-resistant glue or water-resistant coating to the facing insulation product (typically via application to at least one surface of the nonwoven facing or by impregnation with a fluorine-containing material). Conventional fluorine-containing water-resistant additives have become disadvantageous. Therefore, there is a need for a waterproof (or otherwise moisture-resistant) manufacturing adhesive for insulation applications using mineral wool and nonwoven facings, including those applications exposed to the elements (e.g., on exterior building sheathing).

[0006] In certain exemplary embodiments, the general inventive concept contemplates an insulation product comprising: a single substrate comprising a plurality of interconnected first fibers (e.g., a mineral wool insulation substrate); a nonwoven facing comprising a plurality of interconnected second fibers; and a fluorine-free water-resistant adhesive material that bonds the substrate and the facing together. In certain exemplary embodiments, the fluorine-free water-resistant adhesive material is a modified gypsum cement comprising a solid component and a liquid component. In certain exemplary embodiments, the solid component comprises a gypsum cement matrix, and the liquid component comprises a waterproof component and water. In certain exemplary embodiments, the waterproof component and water are pre-combined to form a liquid component. In certain exemplary embodiments, the solid component and the liquid component are combined in a ratio of about 1:1 to about 3:1, including about 2:1, by weight. In certain exemplary embodiments, the modified gypsum cement comprises a gypsum cement matrix, water, and a waterproof component present in an amount of about 5% by weight to about 40% by weight of the gypsum cement matrix.

[0007] In certain exemplary embodiments, the general inventive concept contemplates a method of manufacturing a faced mineral wool insulation product. The method includes: providing a mineral wool substrate and a nonwoven facing; mixing a gypsum cement matrix, water, and a waterproofing component to form a modified gypsum cement (e.g., a fluorine-free water-resistant binder material), wherein the waterproofing component displaces a portion of the water; applying the modified gypsum cement to at least one of the nonwoven facing and the mineral wool substrate; and bonding the nonwoven facing to a surface of the mineral wool substrate. Unless the context indicates otherwise, the features and optional features of the first aspect (insulation product) are equally applicable to the other aspects discussed herein, including the second aspect (manufacturing method), and vice versa.

[0008] In certain exemplary embodiments, the general inventive concept contemplates a method of insulating a structure. The method includes: mixing a gypsum cement matrix, water, and a waterproofing component to form a modified gypsum cement (e.g., a fluorine-free water-resistant binder material), wherein the waterproofing component displaces a portion of the water; providing a plurality of mineral wool insulation members and providing a plurality of non-woven facings; applying the modified gypsum cement to a surface of each of the mineral wool members; positioning each facing on a surface of a corresponding mineral wool member of the mineral wool members to form a plurality of facing mineral wool products; and positioning the facing mineral wool products around an exterior of the structure.

[0009] Other aspects and features of the general inventive concept will become more apparent to those of ordinary skill in the art upon reviewing the following description of various exemplary embodiments in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The general inventive concept and its embodiments and advantages are described in more detail below by way of example with reference to the accompanying drawings, in which:

[0011] Figure 1 A SEM image of a control gypsum cement without a waterproofing component is shown. The image shows the typical open porosity of the cement resulting in high water vapor permeability.

[0012] Figure 2 is a SEM image of a control cement (ie, modified gypsum cement) formulated with a wax emulsion showing a closed cell structure with the addition of paraffin wax particles.

[0013] Figure 3 is a SEM image of a control gypsum cement without waterproofing component.

[0014] Figure 4 is a SEM image of gypsum cement with a silicone emulsion waterproofing component (ie, modified gypsum cement).

[0015] Figure 5A is a SEM image of the size and shape of paraffin wax emulsions showing average particle sizes between 0.5 microns and 20 microns in diameter.

[0016] Figure 5B is an enlarged view of the paraffin shown in FIG. 9A , showing paraffin particles having an average particle size between 1 micron and 5 microns in diameter. DETAILED DESCRIPTION

[0017] Several exemplary embodiments will be described in detail, it being understood that this disclosure merely illustrates the general inventive concept. Embodiments encompassing the general inventive concept may take various forms, and the general inventive concept is not intended to be limited to the specific embodiments described herein.

[0018] Although various exemplary embodiments are described or suggested herein, other exemplary embodiments utilizing methods and materials similar or equivalent to those described or suggested herein are encompassed by the general inventive concept.

[0019] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs. In this regard, unless otherwise indicated, the concentrations of ingredients given in this document refer to the concentrations of these ingredients in a masterbatch or concentrate, consistent with common practice.

[0020] Mineral wool insulation products (including mineral wool insulation with a fiber facing) are semi-rigid, porous insulation materials that are used in a variety of insulation applications, including those exposed to the elements. However, the porous nature of the products reduces their effectiveness in certain applications or requires the use of undesirable fluorinated glues / coatings to provide waterproofing or water resistance.

[0021] Gypsum cement, made by combining gypsum cement powder with water, is a conventional cement used for certain materials and can provide benefits in terms of fire resistance / fire resistance, but is not generally used in mineral wool applications. That is, conventional gypsum cement used in manufacturing is moisture permeable, which allows for the intrusion of water over time. Therefore, conventional gypsum-based cements do not meet the needs of mineral wool-based insulation systems.

[0022] Applicants have also discovered that due to the porosity of the gypsum cement-based binder material, typical hydrophobic additives (i.e., coatings applied to the exterior of the cement) are not effective in providing water resistance or preventing water penetration in many systems. The overall inventive concepts are based in part on the discovery that certain agents (e.g., water-repellent ingredients) when added as part of a cement mixture perform much better at plugging / sealing the pores of the gypsum cement and displacing a portion of the water that would otherwise be used in the cement mixture. The SEM images shown herein clearly show the high porosity of conventional gypsum binders, in contrast to those gypsum binders made according to the inventive concepts that have additives that are mostly pore-clogging.

[0023] Without wishing to be bound by theory, applicants believe that the porosity of the cement is reduced by occluding the pores of the unmodified gypsum cement microstructure using a waterproofing ingredient in the cement mixture (and replacing / displacing a portion of the water that would otherwise be added). In certain exemplary embodiments, the waterproofing ingredient is one of a wax emulsion and a silicon emulsion, as discussed in more detail herein.

[0024] The general inventive concept therefore contemplates a new cementitious composition for making faced mineral wool insulation products. The new formulation comprises a gypsum cement matrix combined with water and a waterproofing component that displaces a portion of the water that would otherwise constitute a conventional (i.e., unmodified) cementitious mixture.

[0025] As used herein, the term "gypsum cement matrix" refers to the dry ingredients (e.g., solid components) of conventional gypsum cement. For example, commercial products such as those sold by US Gypsum B11.

[0026] As used herein, the term "gypsum cement mixture" refers to a combination of solid components and liquid components (eg, gypsum cement matrix and water).

[0027] As used herein, the term "fluorine-free water-resistant binder material" refers to an adhesive, glue or cement that is substantially free of fluorinated compounds. The fluorine-free water-resistant binder material should provide effective bonding between the mineral wool substrate and the nonwoven fiber facing while also limiting water intrusion. The term means a binder material having less than a functional amount of fluorinated components, but one of ordinary skill in the art will recognize that certain components of the binder may have inherent fluorine byproducts or contaminants and still fall within these concepts. In certain exemplary embodiments, the fluorine-free water-resistant binder material is a modified gypsum cement.

[0028] As used herein, the term "modified gypsum cement" refers to a gypsum cement mixture, optionally water, and a waterproofing component. In certain exemplary embodiments, the solid components (e.g., gypsum cement matrix) and liquid components (e.g., waterproofing components and water) of the modified gypsum cement are combined in a ratio of about 1:1 to about 3:1, including about 2:1 by weight.

[0029] As used herein, the term "waterproofing component" refers to a chemical composition that reduces the permeability and penetration of gypsum cement when added to a gypsum cement mixture. When introduced according to the general inventive concept, the waterproofing component displaces a portion of the water that would otherwise constitute the liquid portion of the gypsum cement mixture.

[0030] As used herein, the term "replacing a portion of water" refers to a modification of a formula for making a gypsum cement mixture or a modified gypsum cement mixture. The modification requires replacing a portion of water (or other liquid portion) that would otherwise be used to make a conventional gypsum cement mixture (e.g., according to the prescription or recommendation of the manufacturer's instructions) with a certain amount of waterproofing ingredients. Therefore, in certain exemplary embodiments, the total amount of water and waterproofing ingredients is about 50% by weight based on the gypsum cement matrix. For example, in a typical mixing procedure: the solid component (100g gypsum matrix) is mixed with the liquid component (50g water). And in the mixing procedure for modified gypsum cement according to the overall inventive concept, 100g gypsum matrix + 25g wax emulsion + 25g water are mixed to form modified gypsum cement. In certain exemplary embodiments, the wax emulsion consists of about 50% wax solids and the remainder of water. In certain exemplary embodiments, the total amount of wax is between 5% and 15% of the modified gypsum cement mixture.

[0031] In any of the exemplary embodiments, the waterproofing component can be one of a wax emulsion, a silicone emulsion, or a mixture thereof. More generally, the waterproofing component is a chemical composition that reduces the porosity of gypsum and thus reduces water vapor permeability according to the ASTM E96 test method.

[0032] In certain exemplary embodiments, the liquid component (e.g., water and waterproofing ingredients) is "premixed". Therefore, the overall inventive concept contemplates a combination of a solid component (i.e., a gypsum matrix) and a liquid component (comprising, for example, a wax emulsion (comprising wax and water) and water). In certain embodiments, the mixing procedure of the modified gypsum cement comprises mixing 100 g of the gypsum matrix with a mixture of 50 g of water and wax emulsion (this is similar to the aforementioned example, but the wax and water components are already in one component). In addition, in certain exemplary embodiments, the modified gypsum cement comprises 100 g of a gypsum cement matrix (solid component) and 50 g of a liquid component comprising a diluted wax emulsion. In any of these exemplary embodiments, the wax itself accounts for about 25% by weight of the liquid component of the binder / cement, and this is equivalent to about 8%-9% of the wax in the total binder solids of the mixture. In these embodiments, the liquid component will contain about 10% to about 40% of wax, including about 20% to about 30% of wax, and including about 25% of wax.

[0033] The general inventive concept contemplates a method of manufacturing a faced mineral wool insulation product. The method includes providing a mineral wool substrate and a nonwoven facing; mixing a gypsum cement matrix, water, and a waterproofing component to form a modified gypsum cement (e.g., a fluorine-free water-resistant binder material). When the modified gypsum cement is mixed, the waterproofing component displaces a portion of the water that would otherwise be required or recommended to form a functional / operational gypsum cement. The insulation material is manufactured by applying the modified gypsum cement to at least one of the nonwoven facing and the mineral wool substrate and bonding the nonwoven facing to a surface of the mineral wool substrate.

[0034] The general inventive concepts also relate to systems and methods for insulating structures having the insulation products described herein. Moisture intrusion into the area or space between the insulation system (e.g., exterior sheathing) and the underlying substrate (e.g., roof or wall) can present serious complications to industrial facilities or buildings. Specifically, water ingress can promote corrosion beneath the insulation material and / or reduce the insulation performance of the system. This problem can be minimized or otherwise improved by using a modified gypsum cement (e.g., a fluorine-free, water-resistant binder material) as a glue on the mineral wool product.

[0035] Specific embodiments of the waterproofing composition include silicone emulsions, wax emulsions, or mixtures thereof. In any exemplary embodiment of the exemplary embodiments, the wax emulsion comprises paraffin particles having an average particle size of about 0.5 microns to about 20 microns in diameter. The waterproofing composition (e.g., emulsified wax in the liquid portion of the mixture) significantly reduces the porosity and pore size in the gypsum cement after solidification (without wishing to be bound by theory, the applicant believes that the emulsified wax particles can effectively fill the pores in the cement, which would otherwise exist in the cement in a manner that cannot be achieved by applying conventional waterproofing aids as a coating to the cement). In addition, the applicant has found that the specific particle size range of the wax component of the waterproofing composition (particles suspended in the emulsion) provides surprising performance in reducing the water vapor permeability of the modified gypsum cement. Thus, in certain aspects, the particle size can be less than 20 microns, including average particle sizes from about 0.1 microns to about 15 microns, from about 0.1 microns to about 10 microns, from about 0.1 microns to about 9 microns, from about 0.1 microns to about 8 microns, from about 0.1 microns to about 7 microns, from about 0.1 microns to about 6 microns, from about 0.5 microns to about 7 microns, from about 1 micron to about 7 microns, from about 1 micron to about 6 microns, from about 1 micron to about 5 microns, and from about 2 microns to about 5 microns.

[0036] The general inventive concept is based in part on the concept of replacing a portion of the water used to mix the gypsum cement matrix with a volume of a waterproofing component (e.g., a wax emulsion) instead of just applying a surface coating to the cement. The cement is then applied to the surface of the nonwoven facing or the surface of the mineral wool, for example, in a substantially conventional manner (such as spraying or directly, for example, with a doctor blade). In certain exemplary embodiments, the general inventive concept contemplates applying the cement to more than one surface of the nonwoven facing, including applying to the entire facing surface. In addition, in certain embodiments, one or more additional waterproofing additives may be added to the cement to provide additional protection.

[0037] In certain exemplary embodiments, the waterproof component is present in the modified gypsum cement (e.g., fluorine-free water-resistant binder material) in an amount of less than 40% by weight based on the gypsum cement matrix. In any exemplary embodiment of the exemplary embodiments, the modified gypsum cement may include a gypsum cement matrix, water, and a waterproof component, the amount of which is from about 5% by weight of the gypsum cement matrix to about 40% by weight of the gypsum cement matrix. In certain exemplary embodiments, the modified gypsum cement includes a gypsum cement matrix, water, and a waterproof component, the amount of which is from about 5% by weight of the gypsum cement matrix to about 35% by weight of the gypsum cement matrix. In certain exemplary embodiments, the modified gypsum cement includes a gypsum cement matrix, water, and a waterproof component, the amount of which is from about 5% by weight of the gypsum cement matrix to about 30% by weight of the gypsum cement matrix. In certain exemplary embodiments, the modified gypsum cement includes a gypsum cement matrix, water, and a waterproof component, the amount of which is from about 5% by weight of the gypsum cement matrix to about 25% by weight of the gypsum cement matrix. In certain exemplary embodiments, the modified gypsum cement comprises a gypsum cement matrix, water, and a waterproofing component, the amount of which is from about 5% by weight of the gypsum cement matrix to about 20% by weight of the gypsum cement matrix. In certain exemplary embodiments, the modified gypsum cement comprises a gypsum cement matrix, water, and a waterproofing component, the amount of which is from about 5% by weight of the gypsum cement matrix to about 15% by weight of the gypsum cement matrix. In certain exemplary embodiments, the modified gypsum cement comprises a gypsum cement matrix, water, and a waterproofing component, the amount of which is from about 5% by weight of the gypsum cement matrix to about 10% by weight of the gypsum cement matrix. In certain exemplary embodiments of the exemplary embodiments, the waterproofing component may be present in the modified gypsum cement in an amount of from about 8% by weight to about 10% by weight of the gypsum cement matrix.

[0038] In certain exemplary embodiments, the total amount of water and waterproofing components is about 40% to about 60% by weight of the gypsum cement matrix. In certain exemplary embodiments, the waterproofing component is present in an amount no greater than that of water. In certain exemplary embodiments, the waterproofing component constitutes almost all of the non-gypsum cement matrix portion (i.e., the liquid portion) of the modified cement, and only a small amount of water is required to formulate the modified gypsum cement.

[0039] In certain aspects, the waterproof component can be present in the modified gypsum cement (e.g., fluorine-free water-resistant binder material) in an amount of about 2.5% to about 20% by weight of the modified gypsum cement. For example, the waterproof component can be present in the modified gypsum cement in an amount of about 5% to about 20% by weight of the modified gypsum cement, including, for example, about 7% to about 20% by weight of the modified gypsum cement, about 8% to about 15% by weight, and about 8% to about 12% by weight.

[0040] The modified gypsum cement (e.g., fluorine-free water-resistant binder material) may have a water vapor permeability of less than about 0.02 perm-inch, including, for example, a water vapor permeability of less than about 0.01 perm-inch, less than about 0.005 perm-inch, less than about 0.002 perm-inch, and less than about 0.001 perm-inch. In certain exemplary embodiments, the modified gypsum cement has a water vapor permeability of about 0.02 perm-inch to about 0.0001 perm-inch. In certain exemplary embodiments, the modified gypsum cement has a water vapor permeability of about 0.02 perm-inch to about 0.0002 perm-inch. In certain exemplary embodiments, the modified gypsum cement has a water vapor permeability of about 0.02 perm-inch to about 0.0005 perm-inch.

[0041] As mentioned, the general inventive concept contemplates a method of insulating a structure. The method includes: mixing a gypsum cement matrix, water, and a waterproofing component to form a modified gypsum cement (e.g., a fluorine-free water-resistant binder material), wherein the waterproofing component displaces a portion of the water; providing a plurality of mineral wool insulation members and providing a plurality of non-woven facings; applying the modified gypsum cement to a surface of each of the mineral wool members; positioning each facing on a surface of a corresponding mineral wool member of the mineral wool members to form a plurality of facing mineral wool products; and positioning the facing mineral wool products around an exterior of the structure.

[0042] Example

[0043] The following examples are provided to better illustrate specific embodiments of the overall inventive concept. They should not be construed as limiting the inventive concept described herein as defined by the claims.

[0044] Example 1: Pore size reduction .

[0045] Example 1 (a) :

[0046] Two gypsum cement formulations were prepared: Conventional cement made from B11 ( Figure 1 , control) and including B11 modified gypsum cement with wax emulsion and water (e.g., a 50% mixture of water and wax) ( Figure 2 ). The modified gypsum cement comprises 30 g gypsum, 12 g wax emulsion and 3 g water. Figure 1 and Figure 2 The SEM images of the cementitious cementitious cements show a difference in porosity, with the latter showing a significant pore reduction / blocking relative to conventional cement, due to the incorporation of the wax emulsion.

[0047] Example 1(b) :

[0048] Two gypsum cement formulations were prepared: Conventional cement made from B11 ( Figure 3 , control) and including B11 and silicon emulsion modified gypsum cement ( Figure 4 ). These images show the difference in porosity, Figure 4 Significant pore reduction / blocking relative to conventional cement is shown due to the incorporation of the wax emulsion.

[0049] Example 2

[0050] A series of modified gypsum cement binders were prepared by using a waterproofing component to replace a portion of the water that would otherwise be used to make gypsum cement. The water vapor permeability of the modified gypsum cement was tested. B11 gypsum cement was used as a control for conventional cement. Table 1 shows the results of the permeability test.

[0051] Table 1

[0052] sample % Waterproof ingredients Perm Inch(body) HydrocalBll (control) 0 6.49 Silicone emulsion (50:50 silicone:water emulsion) 10 3.51 Silicone emulsion (50:50 silicone:water emulsion) 15 2.18 Silicone emulsion (50:50 silicone:water emulsion) 20 1.04 Silicone emulsion (50:50 silicone:water emulsion) 20 0.99 Silicone emulsion (50:50 silicone:water emulsion) + Nuva (fluorinated polymer) 20+15 0.44

[0053] Example 3

[0054] Modified gypsum cement mixes were prepared in the absence of water and their water vapor permeability was measured. B11 gypsum cement and conventional cement made of water as control. Table 2 shows the results of the permeability test.

[0055] Table 2

[0056]

[0057] Example 4

[0058] A series of modified gypsum cement adhesives were prepared using a waterproofing component in an amount of 20 wt % based on the gypsum cement matrix (e.g., solid portion). The water vapor permeability of the modified gypsum cement was tested. B11 gypsum cement was used as a control for conventional cement. Table 3 shows the results of the permeability test.

[0059] Table 3

[0060]

[0061]

[0062] Example 5

[0063] A series of modified gypsum cement adhesives were made using a 50:50 wax emulsion and a 50:50 silicone emulsion waterproofing component with weight % ranging from 10 wt % to 40 wt % of the gypsum cement matrix. The water vapor permeability of the modified gypsum cement was tested. B1 l gypsum cement was used as a control for conventional cement. Table 4 shows the results of the permeability test.

[0064] Table 4

[0065] Cement Additives % Waterproof ingredients Perm Inch (Joint) HydrocalBll (control) 0 0.176 Silicone emulsion 20 0.014 Silicone emulsion 30 0 Silicone emulsion 40 0 Wax Emulsion 10 0 Wax Emulsion 15 0 Wax Emulsion 20 -0.002 Wax Emulsion 30 -0.003 Wax Emulsion 40 0.001

[0066] Example 6

[0067] A series of samples of modified gypsum cement were made according to the general inventive concept. For MIL-DTL-24244D, ASTMC795 and NRC Req.Guide 136. In a 28-day corrosion test, the further modified gypsum cement samples were compared with a control group comprising conventional gypsum cement made according to the manufacturer's instructions. Conventional gypsum cement failed the corrosion test, while the modified gypsum cement of the present invention made with a wax waterproofing component (in an amount of 8% to 9% by weight of the modified gypsum cement) passed the corrosion test as well as MIL-DTL-24244D (SH), ASTM C795 and NRC Req.Guide 136.

[0068] The modified gypsum cement according to the invention is applied as a layer on a single side of a nonwoven facing. After the cement has dried, the nonwoven facing is placed under a vertical water stream at an angle of about 45°, with the coated side facing away from the water stream. Water does not pass through the coated facing. The same nonwoven facing without the cement layer is also placed under the same water stream, and the water stream passes through the nonwoven almost immediately. Thus, the modified gypsum cement directly changes the properties of the facing in terms of water repellency.

[0069] Without wishing to be bound by theory, it is believed that the reduction in porosity of the modified gypsum cement provides a more effective seal (and water-tightness) for the insulation material without sacrificing the overall insulation performance of the system. In addition, the modified gypsum cement does not sacrifice the adhesive properties of conventional gypsum cement (i.e., cement without a waterproofing component).

[0070] All references to singular features or limitations of the present disclosure shall include the corresponding plural features or limitations, and vice versa, unless otherwise specified or clearly implied to the contrary by the context in which the reference is made.

[0071] All combinations of method or process steps as used herein may be performed in any order unless otherwise indicated or clearly implied to the contrary by the context in which the referenced combination is performed.

[0072] All ranges and parameters disclosed herein, including but not limited to percentages, fractions and ratios, should be understood to cover any and all subranges assumed and included therein, and each number between the endpoints. For example, the range "1 to 10" should be considered to include any and all subranges between a minimum value of 1 and a maximum value of 10 (and including the end value); that is, all subranges start with a minimum value of 1 or greater (e.g., 1 to 6.1), and end with a maximum value of 10 or less (e.g., 2.3 to 9.4, 3 to 8, 4 to 7), and ultimately to each number 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10 included in the range.

[0073] The thermal insulation compositions and corresponding methods of the present disclosure may include, consist of, or consist essentially of the basic elements and limitations of the present disclosure as described herein, as well as any additional or optional ingredients, components, or limitations described herein or otherwise useful in mineral wool composition applications.

[0074] The thermal insulation compositions of the present disclosure may also be substantially free of any optional or selected ingredients or features described herein, provided that the remaining composition still contains all the desired elements or features as described herein. In this document, unless otherwise indicated, the term "substantially free" means that the selected composition contains less than a functional amount of the optional ingredient, typically less than 0.1% by weight, and also includes zero weight % of such optional or selected essential ingredients.

[0075] To the extent the terms "include," "comprises," or "contains" are used in the specification or claims, they are intended to be inclusive in a manner similar to the term "comprising," as that term is understood when used as a transitional word in a claim. Furthermore, to the extent the term "or" is used (e.g., A or B), it is intended to mean "A or B or both A and B." When applicants intend to indicate "only A or B but not both," then the term "only A or B but not both" will be used. Thus, the term "or" as used herein is used inclusively, not exclusively. In this disclosure, the words "a" or "an" will be used to include both the singular and the plural. Conversely, any reference to plural items shall include the singular, where appropriate.

[0076] In some embodiments, various inventive concepts can be utilized in combination with each other. In addition, any specific composition described in the specific disclosed embodiment should be understood to be applicable to all disclosed embodiments, unless the introduction of this specific composition will conflict with the expression term of this embodiment. Other advantages and modifications will be apparent to those skilled in the art. Therefore, the present disclosure is not limited to the specific details, representative devices, or the illustrative examples shown and described therein in its broader aspects. Therefore, without departing from the spirit or scope of the overall inventive concept, these details can be deviated from.

[0077] Although the present invention has been illustrated and described in detail in the drawings and the foregoing description, it is considered that these drawings and descriptions are illustrative and not restrictive in nature. It should be understood that only exemplary embodiments have been shown and described, and all changes and modifications within the essence of the present invention are expected to be protected.

Claims

1. A thermal insulation product, comprising: a unitary substrate comprising a plurality of interconnected first fibers; a nonwoven facing comprising a plurality of interconnected second fibers; and a fluorine-free water-resistant adhesive material, which bonds the substrate and the facing together.

2. The thermal insulation product of claim 1, wherein the fluorine-free water-resistant binder material comprises modified gypsum cement.

3. The thermal insulation product of claim 2, wherein the modified gypsum cement comprises a gypsum cement matrix, water, and a waterproofing component, wherein the waterproofing component is present in the gypsum cement in an amount of 5% to 40% by weight of the gypsum cement matrix.

4. The insulation product of claim 3, wherein the water-resistant component is present in the modified gypsum cement in an amount of about 5% to about 30% by weight of the modified gypsum cement.

5. The thermal insulation product according to any one of claims 3 or 4, wherein the waterproof component is one of a wax emulsion and a silicone emulsion.

6. A thermal insulation product according to any preceding claim, wherein the waterproofing component is a wax emulsion.

7. The thermal insulation product of any one of claims 3 to 6, wherein the water resistant component is a wax emulsion having an average particle size of about 0.1 microns to about 10 microns.

8. An insulation product according to any preceding claim, wherein the first fibres are one of glass fibres and mineral wool fibres, and wherein the second fibres are one of glass fibres and mineral wool fibres.

9. An insulation product according to any preceding claim, wherein the first fibres are mineral wool fibres.

10. An insulation product according to any preceding claim, wherein the second fibres are glass fibres.

11. A method of manufacturing a faced mineral wool insulation product, the method comprising: providing a unitary substrate comprising a plurality of interconnected first fibers and a nonwoven facing comprising a plurality of interconnected second fibers, mixing a gypsum cement matrix, water, and a waterproofing component to form a modified gypsum cement, wherein the waterproofing component displaces a portion of the water; The modified gypsum cement is applied to at least one of the facing and the substrate to bond the facing to the substrate.

12. The method of claim 11, wherein the modified gypsum cement comprises a fluorine-free water-resistant binder material.

13. The method of claim 11, wherein the first fibers are one of glass fibers and mineral wool fibers, and wherein the second fibers are one of glass fibers and mineral wool fibers.

14. A method according to any one of claims 11 to 13, wherein the first fibres are mineral wool fibres.

15. The method of any one of claims 11 to 14, wherein the second fiber is a glass fiber.

16. The method of any one of claims 11 to 15, wherein the gypsum cement matrix is ​​combined with the water and waterproofing composition in a ratio of solid components to liquid components of about 1:1 to 3:1 by weight.

17. The method of any one of claims 11 to 16, wherein the waterproofing component is present in an amount of 5% to 40% by weight of the gypsum cement matrix.

18. The method according to any one of claims 11 to 17, wherein the waterproof component is one of a wax emulsion and a silicone emulsion.

19. A method according to any one of claims 11 to 18, wherein the water repellent composition is a wax emulsion.

20. The method according to any one of claims 11 to 18, wherein the water repellent component is a silicone emulsion.

21. The method of any one of claims 11 to 20, wherein the waterproofing component is present in an amount of about 5% to about 30% by weight of the modified gypsum cement.

22. A method of insulating a structure, comprising: mixing a gypsum cement matrix, water, and a waterproofing component to form a modified gypsum cement, wherein the waterproofing component displaces a portion of the water; providing a plurality of fibrous insulation members and providing a plurality of nonwoven facings; applying the modified gypsum cement to the surface of each of the fiber insulation members; positioning each facing on a surface of a corresponding one of the fibrous insulation members to form a multi-faceted mineral wool product; and The facing mineral wool product is positioned around the exterior of the structure.

23. The method of claim 22, wherein the gypsum cement matrix is ​​combined with the water and waterproofing composition in a ratio of solid component to liquid component of about 1:1 to 3:1 by weight.

24. The method of claim 23, wherein the solid component and the liquid component are mixed in a ratio of about 2:1 by weight.

25. The method of any one of claims 22 to 24, wherein the waterproofing component is present in an amount of about 5% to about 40% by weight of the gypsum cement matrix.

26. The method according to any one of claims 22 to 25, wherein the water repellent component is selected from wax emulsions and silicone emulsions.

27. The method according to any one of claims 22 to 26, wherein the modified gypsum cement is fluorine-free.

28. A method according to any one of claims 22 to 27, wherein the fibrous insulation comprises mineral wool insulation.

29. The method of any one of claims 22 to 28, wherein the plurality of nonwoven facings are fiberglass facings.

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