Roofing systems and insulation elements for flat or flat-sloped roofs

Abstract

The present invention relates to a roofing system for flat or flat-sloped roofs of buildings with thermal and / or acoustic insulation, comprising a structural support, a deck, optionally a vapor control layer, a waterproofing membrane and at least one insulation element which is a bonded mineral fibre product made of mineral fibres, preferably asbestos fibres, and a hardened aqueous binder, the aqueous binder composition comprising, before hardening, component (i) in the form of one or more lignosulfonic acid lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, based on the dry weight of the lignosulfonic acid lignin, and component (ii) in the form of one or more crosslinkers, the insulation element having a thermal and / or acoustic insulation material of 70 kg / m 3 ~250kg / m 3 The present invention relates to a roofing system having a bulk density of

Description

[Technical Field]

[0001] The present invention relates to a roofing system for a flat roof or a flat inclined roof of a building having thermal and / or acoustic insulation, comprising a structural support, a deck, optionally a vapor control layer, a waterproofing membrane, and at least one insulation element which is a bonded mineral fiber product made of mineral fibers, preferably asbestos fibers, and a phenol-free, formaldehyde-free, cured aqueous binder composition. Furthermore, the present invention relates to an insulation element for a roofing system made of mineral fibers, preferably asbestos fibers, and a phenol-free, formaldehyde-free, cured aqueous binder composition. [Background technology]

[0002] Flat roofs and flat-sloped roofs are well known in the prior art, for example as membrane roof systems, which are generally divided into the following types depending on the location of the main insulation: insulated roofs, inverted insulated roofs, roof gardens or green roofs, and cool roofs.

[0003] Modern membrane roofing systems are often constructed as single-ply roofing systems used to protect flat or flat-sloped roofs from all weather conditions that may occur during their design life.

[0004] A typical single-ply roofing system includes structural support, a deck to provide continuous support, a vapor control layer (if required), insulation, a waterproofing membrane, and a traffic- or load-bearing finish (if required for functional and / or aesthetic reasons).

[0005] Most modern flat and flat-sloped roofs are designed as so-called insulated roofs. In such insulated roofs, the primary insulation is located directly beneath the roof covering, i.e., the waterproof membrane. This keeps the deck warm in cold weather and prevents condensation even without ventilation. Optionally, a vapor control layer is installed over the deck to control water vapor from penetrating the insulation. Installing a vapor control layer is a very reliable and cost-effective way to insulate membrane roofs to a high level.

[0006] The three main options for installing single-ply roofing systems are mechanical fastening, adhesive / cold glue, and ballasting, which allow the insulation and membrane to be installed in the same or different ways.

[0007] Various systems described in the prior art are useful in roofing systems for flat or flat-sloped roofs on buildings and use bonded mineral fiber product insulation elements. In certain cases, it is also known to use a layer of mineral fibers, e.g., glass fibers, as a nonwoven fleece or tissue over the entire insulation element, thereby sandwiching it between the insulation element and the waterproofing membrane. A panel formed by arranging multiple insulation elements side by side may have a layer of nonwoven fleece or tissue extending over its entire area. The fleece or tissue may be bonded to the elements by an adhesive applied between the contacting surfaces. The fleece or tissue may improve mechanical strength by maintaining the position of the boards within the panel and allowing forces acting on one element to be transmitted to adjacent elements. The fleece or tissue may have small pores, e.g., an average pore size or distance between adjacent fibers of less than 0.5 mm, e.g., only 0.1 mm.

[0008] Modern roofing systems use thin- and woven-faced or bitumen-coated roofing sheets to provide a suitable surface for the insulation element layer for adhesion / bonding of the waterproofing membrane. While these systems are feasible, they have the drawback of potentially dispersing adhesive into the insulation element layer. Such dispersed adhesive significantly reduces the insulating and / or damping properties of the insulation layer. Furthermore, adhesive dispersion increases the cost of the system due to high adhesive consumption and uncontrollable bond strength.

[0009] Finally, such adhesives, which are usually organic adhesives, reduce the fire resistance of the insulation element, especially in the case of the bitumen-coated roofing sheets mentioned above. For example, Patent Document 1 discloses a roofing system comprising a mineral fiber core, a fabric overlying the core and bonded to the core by a resin to form a panel, and a moisture / water-impermeable sheet overlying the fabric, which is joined to the panel by an adhesive that penetrates the mineral fiber core. This composite roofing system is widely used for flat roofs and flat-sloped roofs, but has several drawbacks as mentioned above.

[0010] Another example of a roofing system is disclosed in patent document 2. This roofing system comprises an insulating element for thermal and / or acoustic insulation, which comprises two layers, at least one of which is made of mineral fibers, in particular asbestos fibers, and a second layer made of at least one fabric and fixed to the main surface of the first layer by means of an adhesive, whereby the second layer is provided with a filler, which filler gives the second layer a certain permeability.

[0011] Any load on an insulated roof is transferred to the structure through the insulation, requiring a stiff material. This choice is important because different products have different bearing capacities and require greater or lesser thicknesses to achieve the selected thermal installation value. This must be taken into consideration when designing and planning the roofing system for a building's flat or flat-sloped roof.

[0012] There are two basic classes of insulation products: Porous materials such as, for example, Polyisocyanurate (PIR), Expanded Polystyrene (EPS), and Extruded Polystyrene (XPS); Mineral wool (MW), especially fibrous materials such as asbestos.

[0013] The latter mineral wool products are well known for their excellent thermal and acoustic properties, as well as their mechanical strength and excellent fire resistance. These products are also called bonded mineral fiber products made of mineral fibers and binders, and the respective requirements for such products are specified in Non-Patent Document 1.

[0014] Mineral fiber products typically include man-made vitreous fibers (MMVF), such as glass fiber, ceramic fiber, basalt fiber, slag wool, mineral wool, and asbestos, which are bound together by a cured thermosetting polymeric binder. For use as thermal or acoustic insulation products, bonded mineral fiber mats are typically manufactured by converting a melt made from suitable raw materials into fibers by conventional methods, such as the spinning cup process or the cascade rotor process. The fibers are blown into a molding chamber, sprayed with a binder solution while still hot in air, and randomly deposited as a mat or web on a traveling conveyor. The fiber mat is then transferred to a curing oven, where heated air is blown through the mat to cure the binder and firmly bond the mineral fibers together.

[0015] The best binders are phenol-formaldehyde resins, which can be produced economically and spread with urea before use as a binder. However, existing and proposed legislation aimed at reducing or eliminating formaldehyde emissions has led to the development of formaldehyde-free binders, such as binder compositions based on polycarboxy polymers and polyols or polyamines.

[0016] Another group of non-phenol-formaldehyde binders are the addition / elimination reaction products of aliphatic and / or aromatic anhydrides with alkanolamines. These binder compositions are water-soluble and exhibit excellent bonding properties in terms of cure speed and cure density.

[0017] Because some of the starting materials used in the production of these binders are fairly expensive chemicals, there continues to be a need to provide economically produced formaldehyde-free binders, sometimes also referred to as non-added formaldehyde binders (NAFs).

[0018] A further advantage of known aqueous binder compositions based on mineral fibers is that at least a majority of the starting materials used to produce these binders are derived from fossil fuels. Consumers tend to prefer products made entirely or at least partially from renewable materials, and therefore there is a need to provide binders for mineral wool that are made at least partially from renewable materials.

[0019] A further disadvantage of known aqueous binder compositions for mineral fibers is that they contain corrosive and / or harmful components. This requires protective measures to prevent corrosion in machinery involved in the production of mineral wool products, as well as safety measures for personnel operating the machinery. This leads to increased costs and health issues. Therefore, there is a need to provide mineral fiber products using binder compositions with reduced content of corrosive and / or harmful materials.

[0020] On the other hand, a large number of binders for mineral fiber products are available that are based largely on renewable starting materials, and in many cases, these binders that are based largely on renewable resources are also formaldehyde-free.

[0021] However, many of these binders are still relatively expensive because they are based on relatively expensive base materials, and furthermore, so far these binders have not been able to impart sufficient long-term strength properties to the final mineral fiber product.

[0022] Roofing systems for flat or flat-sloped roofs are constructed with a service life of 30 years or more, and therefore require durable materials. As the load of such roofs is transferred to the structure via the insulation, bonded mineral fibre products must be able to withstand most of the load cases, in particular pressure loads, for example light foot traffic that may occur from time to time during construction, especially for individual inspection purposes during later inspections, and also all weather conditions that are likely to occur over time, in particular wind loads. Mineral fibre products used as insulation in roofing systems therefore require a certain robustness, which is a matter of density, so that the density of such products is generally set at, for example, 70 kg / m 3 ~about 250kg / m 3 and provides specific strength characteristics over time.

[0023] The insulation elements of bonded mineral fiber products using the above-mentioned phenol-formaldehyde resin or urea-extended phenol-formaldehyde resin are known to be superior in terms of strength loss over time, i.e., aging, and have therefore been used for decades. The use of formaldehyde-free or no added formaldehyde binders (NAF) in the prior art has resulted in the production of insulation elements with bulk densities of about 60 kg / m 3 Although this has proven feasible for lightweight products less than 10 ... [Prior art documents] [Patent documents]

[0024] [Patent Document 1] International Publication No. 98 / 31895 [Patent Document 2] International Publication No. 2013 / 034376 [Non-patent literature]

[0025] [Non-Patent Document 1] European Standard EN13162:2015 "Thermal insulation products for buildings - Factory made mineral wool (MW) products" Summary of the Invention [Problem to be solved by the invention]

[0026] It is therefore an object of the present invention to provide a roofing system having a mineral fiber element that is applicable to such roofing systems and that avoids the use of expensive and / or hazardous materials for the binder and / or the expensive and / or hazardous binder itself.A further object of the present invention is to provide a mineral fiber element that is applicable to roofing systems without the use of expensive and / or hazardous materials for the binder and / or without the use of expensive and / or hazardous binder itself. [Means for solving the problem]

[0027] According to the present invention, a roofing system is provided comprising a mineral fiber insulation element having a phenol-free and formaldehyde-free cured aqueous binder composition, the aqueous binder composition comprising, prior to curing, component (i) in the form of one or more lignosulfonic acid lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, based on the dry weight of the lignosulfonic acid lignin, and component (ii) in the form of one or more crosslinkers, the insulation element having a load capacity of 70 kg / m 3 ~250kg / m 3 The insulation element has a bulk density of

[0028] Further according to the present invention, a roofing insulation element is made from mineral fibers, preferably asbestos fibers, and a binder, the aqueous binder composition comprising, before hardening, component (i) in the form of one or more lignosulfonic acid lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, based on the dry weight of the lignosulfonic acid lignin, and component (ii) in the form of one or more crosslinkers, and the insulation element has a viscosity of 70 kg / m 3 ~250kg / m 3 It has a bulk density of

[0029] As mentioned above, it has been found that it is possible to obtain an insulation element made of mineral fibers and a binder, which provides the mechanical stability required for use in roofing systems for flat or flat-pitched roofs, whereby the insulation element does not contain harmful binders, while being phenol- and formaldehyde-free, and the binder has high aging resistance and only a small loss of strength over the service life of the roofing system. Furthermore, the amount of binder can be reduced compared to formaldehyde-free binders used in the prior art, such as existing NAF binders.

[0030] The invention is further described below with reference to the accompanying drawings. [Brief explanation of the drawings]

[0031] [Figure 1] 1 is a cross-sectional view showing a portion of a roofing system for a flat roof according to a first embodiment; [Figure 2] FIG. 2 is a cross-sectional view showing a portion of a roofing system for a flat roof according to a second embodiment. [Figure 3] 1 is a diagram showing a comparison of the delamination strength of insulation elements used in roofing systems with the delamination strength of insulation elements according to the prior art; [Figure 4]1 is a diagram showing a comparison of the aged delamination strength of insulation elements used in roofing systems with the aged delamination strength of prior art insulation elements. [Figure 5] 1 is a diagram showing a comparison of the compressive strength of insulation elements used in roofing systems with the compressive strength of insulation elements according to the prior art; [Figure 6] 1 is a diagram showing a comparison of the aged compressive strength of an insulation element used in a roofing system with the aged compressive strength of an insulation element according to the prior art. [Figure 7] Some of the possible lignosulfonate lignin structures are shown. DETAILED DESCRIPTION OF THE INVENTION

[0032] In one embodiment, the insulation element may have any of the preferred features described for the roofing system. Preferably, the insulation element has a loss on ignition (LOI) in the range of 2 to 8 wt. %, preferably 2 to 5 wt. The binder content is referred to as LOI and is determined in accordance with European Standard EN 13820:2003. The binder includes oils and other binder additives.

[0033] According to a preferred embodiment, the roofing system comprises an insulation element having a compressive strength of 50 to 130 kPa measured in accordance with European Standard EN826:2013.

[0034] According to another embodiment, the roofing system comprises an insulation element having a delamination strength of 20 to 50 kPa measured in accordance with European Standard EN 1607:2013.

[0035] Such insulation elements of bonded mineral fibre products are known for their excellent fire resistance and are generally classified in Euroclass A1 according to European standard EN 13501-1:2018, when not otherwise treated or covered with a coating or facing.

[0036] In one embodiment, the mineral wool product according to the invention comprises mineral fibers in contact with a binder resulting from the curing of a phenol-free and formaldehyde-free aqueous binder composition, Component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin; and component (ii) in the form of one or more cross-linking agents.

[0037] In particular, according to a first aspect of the present invention, there is provided a mineral fiber product comprising mineral fibers in contact with a binder resulting from the curing of a phenol-free and formaldehyde-free aqueous binder composition, Component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin; and component (ii) in the form of one or more crosslinkers; The aqueous binder composition has a molecular weight M of 500 or less. W The mineral fiber product is provided, provided that it does not contain a crosslinking agent selected from epoxy compounds having the formula:

[0038] In particular, according to a first aspect of the present invention, there is provided a mineral fiber product comprising mineral fibers in contact with a binder resulting from the curing of a phenol-free and formaldehyde-free aqueous binder composition, Component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin; and component (ii) in the form of one or more crosslinkers; The aqueous binder composition comprises: Aldehydes, formula R-[C(O)R] x wherein R represents a saturated or unsaturated, linear, branched or cyclic hydrocarbon radical, a radical containing one or more aromatic rings consisting of 5 or 6 carbon atoms, a radical containing one or more aromatic heterocycles containing 4 or 5 carbon atoms and oxygen, nitrogen or sulfur atoms, the R radical may contain other functional groups, and R1 represents a hydrogen atom or a C1-C 10 The carbonyl compound represents an alkyl radical, and x varies from 1 to 10. The mineral fiber product is provided, provided that it does not contain a cross-linking agent selected from:

[0039] In particular, according to a first aspect of the present invention, there is provided a mineral fiber product comprising mineral fibers in contact with a binder resulting from the curing of a phenol-free and formaldehyde-free aqueous binder composition, Component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin; and component (ii) in the form of one or more crosslinkers; A mineral fiber product is provided, provided that the aqueous binder composition does not contain a crosslinking agent selected from polyamines.

[0040] In particular, according to a first aspect of the present invention, there is provided a mineral fiber product comprising mineral fibers in contact with a binder resulting from the curing of a phenol-free and formaldehyde-free aqueous binder composition, Component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin; and component (ii) in the form of one or more crosslinkers; A mineral fiber product is provided, provided that the aqueous binder composition does not contain a cross-linking agent selected from monosaccharides and oligosaccharides.

[0041] In one embodiment, the mineral wool product according to the invention comprises mineral fibers in contact with a binder resulting from the curing of a phenol-free and formaldehyde-free aqueous binder composition, Component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin; β-hydroxyalkylamide crosslinkers, such as N-(2-hydroxyisopropyl)amide crosslinkers, such as N-(2-hydroxyethyl)amide crosslinkers, such as N-(2-hydroxyethyl)adipamide crosslinkers, such as N,N,N',N'-tetrakis(2-hydroxyethyl)adipamide and / or groups consisting of polyfunctional organic amines, such as alkanolamines, diamines, such as hexamethyldiamine, and / or epoxy compounds with a molecular weight greater than 500, containing reactive functional groups such as carbodiimide groups, anhydride groups, oxazoline groups, amino groups, epoxy groups, for example, epoxidized oils based on fatty acid triglycerides, or one or more flexible oligomers or polymers, such as low Tg acrylic polymers, low Tg vinyl polymers, low Tg polyethers, and / or one or more crosslinkers in the form of polyfunctional carbodiimides, for example aliphatic polyfunctional carbodiimides, and / or PrimidXL-552 and component (ii) in the form of one or more crosslinkers selected from The aqueous binder composition comprises: Molecular weight M below 500 W an epoxy compound having the formula Aldehydes, formula R-[C(O)R] x wherein R represents a saturated or unsaturated, linear, branched or cyclic hydrocarbon radical, a radical containing one or more aromatic rings consisting of 5 or 6 carbon atoms, a radical containing one or more aromatic heterocycles containing 4 or 5 carbon atoms and oxygen, nitrogen or sulfur atoms, the R radical may contain other functional groups, and R1 represents a hydrogen atom or a C1-C 10 the carbonyl compound, wherein x is an alkyl radical and varies from 1 to 10; Polyamines The present invention includes mineral fibers, provided that the fibers do not contain a cross-linking agent selected from the group consisting of:

[0042] Optionally, the aqueous binder composition additionally comprises: Component (iii) in the form of one or more plasticizers. In one embodiment, the mineral wool product according to the invention comprises mineral fibers in contact with a binder resulting from the curing of a phenol-free and formaldehyde-free aqueous binder composition, Component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin; Component (ii) in the form of one or more crosslinkers; and component (iii) in the form of one or more plasticizers.

[0043] In particular, according to a first aspect of the present invention, there is provided a mineral fiber product comprising mineral fibers in contact with a binder resulting from the curing of a phenol-free and formaldehyde-free aqueous binder composition, Component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin; Component (ii) in the form of one or more crosslinkers; and component (iii) in the form of one or more plasticizers; The aqueous binder composition has a molecular weight M of 500 or less. W The mineral fiber product is provided, provided that it does not contain a crosslinking agent selected from epoxy compounds having the formula:

[0044] In particular, according to a first aspect of the present invention, there is provided a mineral fiber product comprising mineral fibers in contact with a binder resulting from the curing of a phenol-free and formaldehyde-free aqueous binder composition, Component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin; Component (ii) in the form of one or more crosslinkers; and component (iii) in the form of one or more plasticizers; The aqueous binder composition comprises: Aldehydes, formula R-[C(O)R] x wherein R represents a saturated or unsaturated, linear, branched or cyclic hydrocarbon radical, a radical containing one or more aromatic rings consisting of 5 or 6 carbon atoms, a radical containing one or more aromatic heterocycles containing 4 or 5 carbon atoms and oxygen, nitrogen or sulfur atoms, the R radical may contain other functional groups, and R1 represents a hydrogen atom or a C1-C 10 The carbonyl compound represents an alkyl radical, and x varies from 1 to 10. The mineral fiber product is provided, provided that it does not contain a cross-linking agent selected from:

[0045] In particular, according to a first aspect of the present invention, there is provided a mineral fiber product comprising mineral fibers in contact with a binder resulting from the curing of a phenol-free and formaldehyde-free aqueous binder composition, Component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin; Component (ii) in the form of one or more crosslinkers; and component (iii) in the form of one or more plasticizers; A mineral fiber product is provided, provided that the aqueous binder composition does not contain a crosslinking agent selected from polyamines.

[0046] In particular, according to a first aspect of the present invention, there is provided a mineral fiber product comprising mineral fibers in contact with a binder resulting from the curing of a phenol-free and formaldehyde-free aqueous binder composition, Component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin; Component (ii) in the form of one or more crosslinkers; and component (iii) in the form of one or more plasticizers; A mineral fiber product is provided, provided that the aqueous binder composition does not contain a cross-linking agent selected from monosaccharides and oligosaccharides.

[0047] In one embodiment, the mineral wool product according to the invention comprises mineral fibers in contact with a binder resulting from the curing of a phenol-free and formaldehyde-free aqueous binder composition, the mineral fibers being Component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin; Component (ii) comprising a β-hydroxyalkylamide crosslinker, and / or epoxy compounds with a molecular weight greater than 500, containing reactive functional groups such as carbodiimide groups, anhydride groups, oxazoline groups, amino groups, epoxy groups, for example, epoxidized oils based on fatty acid triglycerides, or one or more flexible oligomers or polymers, such as low Tg acrylic polymers, low Tg vinyl polymers, low Tg polyethers, and / or one or more crosslinkers in the form of polyfunctional carbodiimides, for example aliphatic polyfunctional carbodiimides, and / or PrimidXL-552 component (ii), in the form of one or more crosslinkers selected from and component (iii) in the form of one or more plasticizers; The aqueous binder composition comprises: Molecular weight M below 500 W an epoxy compound having the formula Aldehydes, formula R-[C(O)R] x wherein R represents a saturated or unsaturated, linear, branched or cyclic hydrocarbon radical, a radical containing one or more aromatic rings consisting of 5 or 6 carbon atoms, a radical containing one or more aromatic heterocycles containing 4 or 5 carbon atoms and oxygen, nitrogen or sulfur atoms, the R radical may contain other functional groups, and R1 represents a hydrogen atom or a C1-C 10 the carbonyl compound, wherein x is an alkyl radical and varies from 1 to 10; Polyamines The present invention includes mineral fibers, provided that the fibers do not contain a cross-linking agent selected from the group consisting of:

[0048] In a preferred embodiment, the binder used in the insulation element according to the invention and in the roofing system according to the invention is formaldehyde-free. For the purposes of this application, the term "formaldehyde-free" means that the formaldehyde emission from a mineral wool product is 5 μg / m 2 / hour, preferably less than 3 μg / m 2 This is defined to characterize mineral wool products that have an aldehyde emission rate of less than 1 / hour. Preferably, the test is carried out in accordance with the aldehyde emission test ISO 16000.

[0049] In a preferred embodiment, the binder is phenol-free. For purposes of this application, the term "phenol-free" means that the aqueous binder composition contains phenol in an amount of 0.25 wt. % or less, e.g., 0.1 wt. % or less, e.g., 0.05 wt. % or less, based on the total weight of the aqueous composition having a dry solids binder content of 15 wt. %.

[0050] [ka]

[0051] is defined to contain In one embodiment, the binder composition contains no added formaldehyde. In one embodiment, the binder composition does not contain added phenol.

[0052] For purposes of this invention, the term "mono- and oligosaccharides" is defined to include mono- and oligosaccharides having 10 or fewer saccharide units. For purposes of this invention, the term "sugar" is defined to include monosaccharides and oligosaccharides having 10 or fewer saccharide units.

[0053] Component (i) Component (i) is in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin.

[0054] Lignin, cellulose, and hemicellulose are the three major organic compounds in plant cell walls. Lignin can be thought of as the glue that holds the cellulose fibers together. It contains both hydrophilic and hydrophobic groups. Lignin is the second most abundant natural polymer in the world after cellulose, estimated to account for over 1 billion tons worldwide, accounting for 20-30% of the total carbon content of biomass.

[0055] The lignosulfonate process introduces a large amount of sulfonate groups, making lignin soluble in both water and acidic aqueous solutions. Lignosulfonates contain up to 8% sulfur as sulfonates, whereas kraft lignin contains 1–2% sulfur, mostly bound to the lignin. The molecular weight of lignosulfonates ranges from 15,000 to 50,000 g / mol. The common hydrophobic core of lignin, along with the large number of ionized sulfonate groups, makes it attractive as a surfactant, and it is commonly used to disperse cement and other materials.

[0056] To produce lignin-based value-added products, lignin must first be separated from biomass, and several methods can be used for this separation. Kraft and sulfite pulping processes are known for their effective separation of lignin from wood and are therefore used worldwide. Kraft lignin is separated from wood with the aid of NaOH and Na2S. Lignin obtained from sulfite pulping processes is called lignosulfonate and is produced by using sulfite and / or sulfite salts containing magnesium, calcium, sodium, or ammonium at various pH levels. Currently, lignosulfonate accounts for 90% of the total commercial lignin market, with the total annual global production of lignosulfonate reaching approximately 1.8 million tons. Lignosulfonates generally contain more sulfonic groups and therefore have a higher sulfur content than kraft lignin. Due to the presence of sulfonated groups, lignosulfonates are anionically charged and water-soluble. The molecular weight (Mw) of lignosulfonates can be comparable to or greater than that of kraft lignin. Due to their unique properties, lignosulfonates have a wide range of applications, including animal feed, pesticides, surfactants, additives in oil drilling, stabilizers in colloidal suspensions, and plasticizers in concrete admixtures. However, since the majority of new pulp mills use kraft technology for pulp production, kraft lignin is more readily available for value-added production.

[0057] However, lignosulfonates and kraft lignin have different properties, resulting from the separation process and therefore different functional group distributions. Due to the high level of sulfonic acid groups in lignosulfonates, typically at least one per four C9 units, lignosulfonates are highly charged at all pH levels in water. This abundance of ionizable functional groups explains most of the differences compared to other technical lignins. Their high charge density allows for easier dissolution in water and higher solids content in solution compared to kraft lignin. For the same reason, lignosulfonates can also have lower solution viscosities than kraft lignin at the same solids content, potentially making them easier to handle and process. Model structures of commonly used lignosulfonates are shown in Figure 7.

[0058] In one embodiment, component (i) has a carboxylic acid group content of 0.05 to 0.6 mmol / g, for example 0.1 to 0.4 mmol / g, based on the dry weight of lignosulfonate lignin.

[0059] In one embodiment, component (i) is in the form of one or more lignosulfonic acid lignins having an average carboxylic acid group content per macromolecule taking into account the number average molecular weight of component (i) of less than 1.8, such as less than 1.4, for example less than 1.1, such as less than 0.7, for example less than 0.4.

[0060] In one embodiment, component (i) has a content of phenolic OH groups of 0.3 to 2.5 mmol / g, such as 0.5 to 2.0 mmol / g, for example 0.5 to 1.5 mmol / g, based on the dry weight of lignosulfonate lignin.

[0061] In one embodiment, component (i) has a content of aliphatic OH groups of 1.0 to 8.0 mmol / g, such as 1.5 to 6.0 mmol / g, for example 2.0 to 5.0 mmol / g, based on the dry weight of lignosulfonate lignin.

[0062] In one embodiment, component (i) comprises ammonium lignosulfonate and / or calcium lignosulfonate and / or magnesium lignosulfonate, and any combination thereof.

[0063] In one embodiment, component (i) comprises ammonium lignosulfonate and calcium lignosulfonate, and NH + Against Ca 2+ The molar ratio is in the range of 5:1 to 1:5, particularly 3:1 to 1:3.

[0064] For purposes of the present invention, the term lignosulfonate includes sulfonated kraft lignin. In one embodiment, component (i) is sulfonated kraft lignin.

[0065] In one embodiment, the aqueous binder composition contains added sugar in an amount of 0 to 5 wt %, for example less than 5 wt %, for example 0 to 4.9 wt %, for example 0.1 to 4.9 wt %, based on the weight of lignosulfonate and sugar.

[0066] In one embodiment, the aqueous binder composition comprises component (i), i.e., lignosulfonate, in an amount of 50 to 98 wt.%, such as 65 to 98 wt.%, for example 80 to 98 wt.%, based on the total weight of components (i) and (ii).

[0067] In one embodiment, the aqueous binder composition comprises component (i) in an amount of 50 to 98 wt %, such as 65 to 98 wt %, for example 80 to 98 wt %, based on the dry weight of components (i), (ii), and (iii).

[0068] For purposes of this invention, the content of lignin functional groups is determined using 31P NMR as a characterization method. Sample preparation for P NMR was performed using 2-chloro-4,4,5,5-tetramethyl-1,3,2-dioxaphospholane (TMDP) as the phosphitylation reagent and cholesterol as the internal standard. Integration followed the work of Granata and Argyropoulos (J. Agric. Food Chem. 43:1538-1544).

[0069] Component (ii) Component (ii) is in the form of one or more crosslinkers. In one embodiment, component (ii) comprises one or more crosslinkers selected from β-hydroxyalkylamide crosslinkers and / or oxazoline crosslinkers.

[0070] β-Hydroxyalkylamide crosslinkers are acid-functional macromolecular curing agents. They provide crosslinked polymer networks that are hard, durable, corrosion-resistant, and solvent-resistant. β-Hydroxyalkylamide crosslinkers are believed to cure via an esterification reaction, forming multiple ester bonds. The hydroxy functionality of the β-hydroxyalkylamide crosslinker should average at least 2, preferably greater than 2, and more preferably 2-4, to achieve optimal curing kinetics.

[0071] An oxazoline group-containing crosslinking agent is a polymer containing one or more oxazoline groups in one molecule, and generally, an oxazoline-containing crosslinking agent can be easily obtained by polymerizing an oxazoline derivative. U.S. Patent Application No. 6,818,699 discloses such a process.

[0072] In one embodiment, component (ii) is one or more epoxy compounds having a molecular weight greater than 500, containing reactive functional groups such as carbodiimide groups, for example anhydride groups, for example oxazoline groups, for example amino groups, for example epoxy groups, for example β-hydroxyalkylamide groups, for example epoxidized oils based on fatty acid triglycerides, or one or more flexible oligomers or polymers, for example low Tg acrylic polymers, for example low Tg vinyl polymers, for example low Tg polyethers.

[0073] In one embodiment, component (ii) is one or more crosslinkers selected from the group consisting of fatty amines. In one embodiment, component (ii) is one or more crosslinkers in the form of a fatty amide.

[0074] In one embodiment, component (ii) is one or more crosslinkers selected from polyester polyols such as polycaprolactone. In one embodiment, component (ii) is one or more cross-linking agents selected from the group consisting of starch, modified starch, CMC.

[0075] In one embodiment, component (ii) is one or more crosslinkers in the form of a polyfunctional carbodiimide, such as an aliphatic polyfunctional carbodiimide. In one embodiment, component (ii) is one or more crosslinkers in the form of aziridines such as CX100, NeoAdd-Pax521 / 523, etc.

[0076] In one embodiment, component (ii) is one or more crosslinkers selected from melamine-based crosslinkers, such as hexakis(methylmethoxy)melamine (HMMM)-based crosslinkers.

[0077] Examples of such compounds are Picassian XL 701, 702, 725 (Stahl Polymers), for example ZOLDINE® XL-29SE (Angus Chemical), for example CX300 (DSM), for example Carbodilite V-02-L2 (Nisshinbo Chemical Inc.).

[0078] In one embodiment, component (ii) is PrimidXL552, which has the following structure:

[0079] [ka]

[0080] Component (ii) may be a mixture of any of the compounds mentioned above. In one embodiment, the binder composition according to the present invention comprises component (ii) in an amount of 1 to 50 wt %, such as 4 to 20 wt %, for example 6 to 12 wt %, based on the dry weight of component (i).

[0081] In one embodiment, component (ii) is β-hydroxyalkylamide crosslinkers, such as N-(2-hydroxyisopropyl)amide crosslinkers, such as N-(2-hydroxyethyl)amide crosslinkers, such as N-(2-hydroxyethyl)adipamide crosslinkers, such as N,N,N',N'-tetrakis(2-hydroxyethyl)adipamide and / or groups consisting of polyfunctional organic amines, such as alkanolamines, diamines, such as hexamethyldiamine, and / or epoxy compounds with a molecular weight greater than 500, containing reactive functional groups such as carbodiimide groups, anhydride groups, oxazoline groups, amino groups, epoxy groups, for example, epoxidized oils based on fatty acid triglycerides, or one or more flexible oligomers or polymers, such as low Tg acrylic polymers, low Tg vinyl polymers, low Tg polyethers, and / or In the form of one or more crosslinkers selected from one or more crosslinkers in the form of polyfunctional carbodiimides, for example aliphatic polyfunctional carbodiimides.

[0082] In one embodiment, component (ii) is The crosslinker comprises one or more crosslinkers selected from β-hydroxyalkylamide crosslinkers, such as N-(2-hydroxyisopropyl)amide crosslinkers, such as N-(2-hydroxyethyl)amide crosslinkers, such as N-(2-hydroxyethyl)adipamide crosslinkers, such as N,N,N',N'-tetrakis(2-hydroxyethyl)adipamide.

[0083] In one embodiment, component (ii) comprises component (ii) in an amount of 2 to 90% by weight, such as 6 to 60% by weight, for example 10 to 40% by weight, for example 25 to 40% by weight, based on the dry weight of component (i).

[0084] Component (iii) of the binder composition Optionally, the binder composition may include component (iii), which is in the form of one or more plasticizers.

[0085] In one embodiment, component (iii) is in the form of one or more plasticizers selected from the group consisting of polyols, such as carbohydrates, hydrogenated sugars such as sorbitol, erythritol, glycerol, monoethylene glycol, polyethylene glycol, polyethylene glycol ethers, polyethers, phthalic acids and / or acids such as adipic acid, vanillic acid, lactic acid and / or ferulic acid, acrylic polymers, polyvinyl alcohol, polyurethane dispersions, ethylene carbonate, propylene carbonate, lactones, lactams, lactides, acrylic polymers with free carboxy groups and / or polyurethane dispersions with free carboxy groups, polyamides, amides such as carbamide / urea, or any mixture thereof.

[0086] In one embodiment, component (iii) is in the form of one or more plasticizers selected from the group consisting of carbonates, such as ethylene carbonate, propylene carbonate, lactones, lactams, lactides, compounds having a structure similar to lignin, such as vanillin, acetosyringone, solvents used as coalescing agents, such as alcohol ethers, polyvinyl alcohol.

[0087] In one embodiment, component (iii) is in the form of one or more non-reactive plasticizers selected from the group consisting of polyethylene glycols, polyethylene glycol ethers, polyethers, hydrogenated sugars, phthalates and / or other esters, solvents used as coalescing agents, such as alcohol ethers, acrylic polymers, polyvinyl alcohol.

[0088] In one embodiment, component (iii) is one or more reactive plasticizers selected from the group consisting of carbonates, such as ethylene carbonate, propylene carbonate, lactones, lactams, lactides, di- or tricarboxylic acids, such as adipic acid or lactic acid, and / or vanillic acid and / or ferulic acid, polyurethane dispersions, acrylic polymers with free carboxy groups, compounds with a structure similar to lignin, such as vanillin, acetosyringone.

[0089] In one embodiment, component (iii) is in the form of one or more plasticizers selected from the group consisting of fatty alcohols, monohydroxy alcohols such as pentanol, stearyl alcohol.

[0090] In one embodiment, component (iii) comprises one or more plasticizers in the form of polyethylene glycol, polyethylene glycol ether, and / or polyol, such as one or more plasticizers selected from the group consisting of 1,1,1-tris(hydroxymethyl)propane, and / or triethanolamine.

[0091] Another particularly surprising aspect of the present invention is that the use of plasticizers with boiling points above 100°C, especially between 140 and 250°C, significantly improves the mechanical properties of the mineral fiber products according to the invention, but in view of their boiling points, these plasticizers are likely to at least partially evaporate during curing of the binder in contact with the mineral fibers.

[0092] In one embodiment, component (iii) comprises one or more plasticizers having a boiling point above 100°C, for example, from 110 to 380°C, more preferably from 120 to 300°C, more preferably from 140 to 250°C.

[0093] The effectiveness of these plasticizers in binder compositions according to the present invention is believed to be related to their effect in increasing the mobility of lignin during the curing process, which is believed to facilitate effective cross-linking.

[0094] In one embodiment, component (iii) comprises one or more polyethylene glycols having an average molecular weight of 150 to 50000 g / mol, in particular 150 to 4000 g / mol, more in particular 150 to 1000 g / mol, preferably 150 to 500 g / mol, more preferably 200 to 400 g / mol.

[0095] In one embodiment, component (iii) comprises one or more polyethylene glycols having an average molecular weight of 4000 to 25000 g / mol, in particular 4000 to 15000 g / mol, more in particular 8000 to 12000 g / mol.

[0096] In one embodiment, component (iii) can form a covalent bond with component (i) and / or component (ii) during the curing process. Such components will not evaporate and remain part of the composition, but will be effectively modified so as not to introduce undesirable side effects, such as water absorption, into the cured product. Non-limiting examples of such components are caprolactone and acrylic polymers with free carboxyl groups.

[0097] In one embodiment, component (iii) is selected from the group consisting of fatty alcohols, monohydroxy alcohols such as pentanol, stearyl alcohol. In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of alkoxylates, such as ethoxylates, such as butanol ethoxylates, such as butoxytriglycol.

[0098] In one embodiment, component (iii) is selected from one or more propylene glycols. In one embodiment, component (iii) is selected from one or more glycol esters.

[0099] In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of adipate, acetate, benzoate, cyclobenzoate, citrate, stearate, sorbate, sebacate, azelaate, butyrate, and valerate.

[0100] In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of phenol derivatives, such as alkyl or aryl substituted phenols. In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of silanols, siloxanes.

[0101] In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of sulfates, such as alkyl sulfates; sulfonates, such as alkylaryl sulfonates, such as alkyl sulfonates; phosphates, such as tripolyphosphates; for example, tributyl phosphate.

[0102] In one embodiment, component (iii) is selected from one or more hydroxy acids. In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of monomeric amides, such as acetamide, benzamide, fatty acid amides, such as tall oil amide.

[0103] In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of quaternary ammonium compounds, such as trimethylglycine, distearyldimethylammonium chloride.

[0104] In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of vegetable oils, such as castor oil, palm oil, linseed oil, tall oil, soybean oil. In one embodiment, component (iii) is in the form of tall oil.

[0105] In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of hydrogenated oils, acetylated oils. In one embodiment, component (iii) is selected from one or more fatty acid methyl esters.

[0106] In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of alkyl polyglucosides, gluconamides, aminoglucoseamides, sucrose esters, sorbitan esters.

[0107] In one embodiment, component (iii) is selected from the group consisting of polyethylene glycol, polyethylene glycol ether. In one embodiment, component (iii) is selected from the group consisting of triethanolamine.

[0108] In one embodiment, component (iii) is one or more plasticizers in the form of propylene glycol, phenol derivatives, silanols, siloxanes, hydroxy acids, vegetable oils, polyethylene glycols, polyethylene glycol ethers, and / or polyols, such as 1,1,1-tris(hydroxymethyl)propane, triethanolamine, or any mixture thereof.

[0109] Surprisingly, it has been found that the inclusion of a plasticizer in the binder composition according to the invention strongly improves the mechanical properties of the mineral fiber product according to the invention. The term plasticizer refers to a substance that is added to a material to make it softer, more flexible (by lowering the glass transition temperature, Tg), and easier to process.

[0110] Component (iii) may be a mixture of any of the compounds described above. In one embodiment, component (iii) is present in an amount of 0.5 to 60, preferably 2.5 to 25, more preferably 3 to 15 wt %, based on the dry weight of component (i).

[0111] In one embodiment, component (iii) is present in an amount of 0.5 to 60, preferably 2.5 to 25, more preferably 3 to 15 wt %, based on the dry weight of components (i), (ii) and (iii).

[0112] A mineral fiber product comprising mineral fibers in contact with a binder resulting from the curing of a binder composition comprising components (i) and (iia). In one embodiment, the present invention provides a mineral fiber comprising: Component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin; and component (iia) in the form of one or more modifiers, Preferably, The aqueous binder composition has a molecular weight M of 500 or less. W provided that the crosslinker does not include a crosslinker selected from epoxy compounds having the formula: and / or the aqueous binder composition is Aldehydes, formula R-[C(O)R] x wherein R represents a saturated or unsaturated, linear, branched or cyclic hydrocarbon radical, a radical containing one or more aromatic rings consisting of 5 or 6 carbon atoms, a radical containing one or more aromatic heterocycles containing 4 or 5 carbon atoms and oxygen, nitrogen or sulfur atoms, the R radical may contain other functional groups, and R1 represents a hydrogen atom or a C1-C 10 The carbonyl compound represents an alkyl radical, and x varies from 1 to 10. provided that the compound does not contain a cross-linking agent selected from and / or provided that the aqueous binder composition does not contain a crosslinker selected from polyamines; And / or a mineral fiber product comprising mineral fibers in contact with a binder resulting from the hardening of a binder composition for mineral fibers, provided that the aqueous binder composition does not contain a crosslinking agent selected from monosaccharides and oligosaccharides.

[0113] The inventors have found that excellent binder properties are also achieved by a two-component system comprising component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin, and component (iia) in the form of one or more modifiers, and optionally any of the other components described above and below.

[0114] In one embodiment, component (iia) is a modifier in the form of one or more compounds selected from the group consisting of epoxy compounds having a molecular weight greater than 500, containing reactive functional groups such as carbodiimide groups, for example anhydride groups, for example oxazoline groups, for example amino groups, for example epoxy groups, for example β-hydroxyalkylamide groups, for example epoxidized oils based on fatty acid triglycerides, or one or more flexible oligomers or polymers, for example low Tg acrylic polymers, for example low Tg vinyl polymers, for example low Tg polyethers.

[0115] In one embodiment, component (iia) is one or more modifiers selected from the group consisting of polyethyleneimine, polyvinylamine, fatty amines. In one embodiment, component (iia) is one or more modifiers selected from polyfunctional carbodiimides, such as aliphatic polyfunctional carbodiimides.

[0116] Component (iia) can be a mixture of any of the compounds described above. Without wishing to be bound by any particular theory, the inventors believe that the excellent binder properties achieved by the binder composition for mineral fibers comprising components (i) and (iia), and optionally further components, are at least partly due to the effect that the modifier used as component (iia) at least partly performs the functions of a plasticizer and a crosslinker.

[0117] In one embodiment, the binder composition comprises component (iia) in an amount of 1 to 40 wt %, such as 4 to 20 wt %, for example 6 to 12 wt %, based on the dry weight of component (i).

[0118] Further ingredients In some embodiments, mineral fiber products according to the present invention comprise mineral fibers in contact with a binder composition resulting from the curing of a binder that includes additional ingredients.

[0119] In one embodiment, the binder composition comprises a catalyst selected from inorganic acids such as sulfuric acid, sulfamic acid, nitric acid, boric acid, hypophosphorous acid, and / or phosphoric acid, and / or any salts thereof, such as sodium hypophosphite, and / or ammonium salts, such as ammonium salts of sulfuric acid, sulfamic acid, nitric acid, boric acid, hypophosphorous acid, and / or phosphoric acid, and / or sodium polyphosphate (STTP), and / or sodium metaphosphate (STMP), and / or phosphorus oxychloride. The presence of such a catalyst can improve the curing properties of the binder composition according to the present invention.

[0120] In one embodiment, the binder composition comprises a catalyst selected from Lewis acids capable of accepting an electron pair from a donor compound to form a Lewis adduct, such as a catalyst selected from ZnCl, Mg(ClO), Sn[N(SO-C F) ].

[0121] In one embodiment, the binder composition comprises a catalyst selected from metal chlorides such as KCl, MgCl, ZnCl, FeCl, and SnCl, or adducts thereof such as AlCl adducts, BF adducts, such as BF ethylamine complexes.

[0122] In one embodiment, the binder composition includes an organometallic compound, such as a catalyst selected from titanate-based catalysts and tin-based catalysts. In one embodiment, the binder composition comprises a catalyst selected from chelating agents, such as transition metals, such as iron ions, chromium ions, manganese ions, copper ions, and / or peroxides, such as organic peroxides, such as dicumyl peroxide.

[0123] In one embodiment, the binder composition according to the present invention comprises a catalyst selected from phosphites, such as alkyl phosphites, such as aryl phosphites, such as triphenyl phosphite.

[0124] In one embodiment, the binder composition according to the present invention comprises a catalyst selected from the group of tertiary amines, such as tris-2,4,6-dimethylaminomethylphenol. In one embodiment, the binder composition further comprises a further component (iv) in the form of one or more silanes.

[0125] In one embodiment, the binder composition comprises a further component (iv) in the form of one or more coupling agents, for example organofunctional silanes. In one embodiment, component (iv) is selected from the group consisting of organofunctional silanes, such as primary or secondary amino-functionalized silanes, epoxy-functionalized silanes, such as polymeric or oligomeric epoxy-functionalized silanes, methacrylate-functionalized silanes, alkyl- and aryl-functionalized silanes, urea-functionalized silanes, or vinyl-functionalized silanes.

[0126] In one embodiment, the binder composition further comprises component (v) in the form of one or more components selected from the group of a base, such as ammonia, such as an alkali metal hydroxide, such as KOH, such as an earth alkali metal hydroxide, such as Ca(OH)2, such as Mg(OH)2, such as an amine or any salt thereof.

[0127] In one embodiment, the binder composition further comprises a further component in the form of urea, especially in an amount of 5 to 40% by weight, for example 10 to 30% by weight, 15 to 25% by weight, based on the dry weight of component (i).

[0128] In one embodiment, the binder composition further comprises a further component in the form of one or more carbohydrates selected from the group consisting of sucrose, reducing sugars, in particular dextrose, polycarbohydrates, and mixtures thereof, preferably dextrins and maltodextrins, more preferably glucose syrup, more preferably glucose syrup having a dextrose equivalent value of DE=less than 30-100, such as DE=less than 60-100, for example DE=60-99, such as DE=85-99, for example DE=95-99.

[0129] In one embodiment, the binder composition further comprises a further component in the form of one or more carbohydrates selected from the group consisting of sucrose and reducing sugars in an amount of 5 to 50% by weight, such as 5 to less than 50% by weight, for example 10 to 40% by weight, for example 15 to 30% by weight, based on the dry weight of component (i).

[0130] In one embodiment, the mineral fiber product according to the invention comprises mineral fibers in contact with a binder composition comprising a further component in the form of one or more silicone resins. In one embodiment, the binder composition according to the invention comprises a further component (vi) in the form of one or more reactive or non-reactive silicones.

[0131] In one embodiment, component (vi) is selected from the group consisting of silicones composed of a backbone made up of organosiloxane residues, particularly diphenylsiloxane residues, alkylsiloxane residues, preferably dimethylsiloxane residues, having at least one hydroxyl, carboxyl or anhydride, amine, epoxy or vinyl functional group capable of reacting with at least one of the components of the binder composition, and is preferably present in an amount of 0.025 to 15 wt. %, preferably 0.1 to 10 wt. %, more preferably 0.3 to 8 wt. %, based on binder solids.

[0132] In one embodiment, the mineral fiber product according to the invention comprises mineral fibers in contact with a binder composition comprising a further component in the form of one or more mineral oils. In the context of the present invention, binder compositions having a sugar content of 50% or more by weight, based on the total dry weight of the binder components, are considered to be sugar-based binders. In the context of the present invention, binder compositions having a sugar content of less than 50% by weight, based on the total dry weight of the binder components, are considered to be non-sugar-based binders.

[0133] In one embodiment, the binder composition further comprises additional components in the form of one or more surfactants, such as non-ionic and / or ionic emulsifiers, e.g., polyoxyethylene (4) lauryl ether, e.g., soybean lecithin, e.g., in the form of sodium dodecyl sulfate.

[0134] The use of lignin-based sulfonated products in binders can increase the hydrophilicity of some binders and final products, which means that one or more hydrophobic agents should be added, such as one or more mineral oils, one or more silicone oils, one or more silicone resins.

[0135] In one embodiment, the aqueous binder composition comprises: Component (i) in the form of one or more lignins selected from the group consisting of lignosulfonic acid lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonic acid lignin; and / or component (ii) in the form of one or more crosslinkers; component (iii) in the form of one or more plasticizers; one or more coupling agents, for example, component (iv) in the form of organofunctional silanes; Optionally, a component in the form of one or more compounds selected from the group of a base, such as ammonia, such as an alkali metal hydroxide, such as KOH, such as an earth alkali metal hydroxide, such as Ca(OH)2, such as Mg(OH)2, such as an amine or any salt thereof; Optionally, a component in the form of urea; Optionally, a component in the form of a more reactive or non-reactive silicone; Optionally, a hydrocarbon oil; optionally, one or more surfactants; Consisting essentially of water.

[0136] In one embodiment, the aqueous binder composition comprises: Component (i) in the form of one or more lignins selected from the group consisting of lignosulfonic acid lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonic acid lignin; and / or component (ii) in the form of one or more crosslinkers; one or more coupling agents, for example, component (iv) in the form of organofunctional silanes; Optionally, a component in the form of one or more compounds selected from the group of a base, such as ammonia, such as an alkali metal hydroxide, such as KOH, such as an earth alkali metal hydroxide, such as Ca(OH)2, such as Mg(OH)2, such as an amine or any salt thereof; Optionally, a component in the form of urea; Optionally, a component in the form of a more reactive or non-reactive silicone; Optionally, a hydrocarbon oil; optionally, one or more surfactants; Consisting essentially of water.

[0137] The inventors have surprisingly found that mineral fiber products comprising mineral fibers in contact with a binder that results in the hardening of the aqueous binder composition described above have very high stability both when freshly produced and under aged conditions.

[0138] Additionally, the inventors have found that even greater product stability can be obtained by using cure temperatures above 230°C. Therefore, in one embodiment, the present invention relates to a mineral fiber product comprising mineral fibers in contact with a binder resulting from the curing of the aqueous binder composition described above, wherein a curing temperature above 230°C is used.

[0139] The inventors have further found that the stability of mineral fiber products can be further improved by: Reduced line capacity means longer cure times Addition of silicone resin Adding a large amount of crosslinking agent Addition of a combination of two or more crosslinkers The addition of small amounts of cationic species such as polyvalent metal ions, eg calcium, and / or organic cationic species, eg amines and / or organically modified inorganic compounds, eg amine-modified montmorillonite clay.

[0140] Manufacturing method of mineral fiber products The present invention also provides a method for producing a mineral fiber product by binding mineral fibers with a binder composition.

[0141] The present invention therefore also provides a method for producing a mineral fiber product, comprising the steps of: component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, for example 0.03 to 1.4 mmol / g, for example 0.075 to 2.0 mmol / g, for example 0.075 to 1.4 mmol / g, based on the dry weight of the lignosulfonate lignin; component (ii) in the form of one or more crosslinkers; and optionally component (iii) in the form of one or more plasticizers; Preferably, provided that the aqueous binder composition does not contain a crosslinker selected from epoxy compounds having a molecular weight MW of 500 or less; and / or The aqueous binder composition comprises: Aldehydes, formula R-[C(O)R] x wherein R represents a saturated or unsaturated, linear, branched or cyclic hydrocarbon radical, a radical containing one or more aromatic rings consisting of 5 or 6 carbon atoms, a radical containing one or more aromatic heterocycles containing 4 or 5 carbon atoms and oxygen, nitrogen or sulfur atoms, the R radical may contain other functional groups, and R1 represents a hydrogen atom or a C1-C 10The carbonyl compound represents an alkyl radical, and x varies from 1 to 10. and / or provided that the aqueous binder composition does not contain a crosslinker selected from polyamines; and / or The present invention relates to a method comprising the step of contacting mineral fibers with an aqueous binder composition, provided that the binder composition does not contain a cross-linking agent selected from monosaccharides and oligosaccharides.

[0142] hardening The web hardens due to the chemical and / or physical reaction of the binder components. In one embodiment, the curing occurs in a curing device.

[0143] In one embodiment, the curing is carried out at a temperature of from 100 to 300°C, such as from 170 to 270°C, for example from 180 to 250°C, for example from 190 to 230°C. In one embodiment, the curing is carried out in a conventional curing oven for mineral wool production operating at a temperature of 150-300°C, such as 170-270°C, for example 180-250°C, for example 190-230°C.

[0144] In one embodiment, curing is carried out for a time period of from 30 seconds to 20 minutes, such as from 1 minute to 15 minutes, for example from 2 minutes to 10 minutes. The curing process may begin immediately after the binder is applied to the fibers. Curing is defined as the process by which the binder composition undergoes physical and / or chemical reactions, in the case of chemical reactions, typically increasing the molecular weight of compounds in the binder composition, thereby increasing the viscosity of the binder composition, typically until the binder composition reaches a solid state.

[0145] Mineral fiber products The present invention relates to a mineral fiber product comprising mineral fibers in contact with a hardened binder composition resulting from the hardening of an aqueous binder composition.

[0146] The mineral fibres used may be man-made vitreous fibres (MMVF), glass fibres, ceramic fibres, basalt fibres, slag fibres, rock fibres, stone fibres and others, which may also be present in wool products, e.g. asbestos products, etc.

[0147] Fiber / Melt Composition The man-made vitreous fiber (MMVF) may have any suitable oxide composition. The fibers may be glass fibers, ceramic fibers, basalt fibers, slag fibers, rock or stone fibers. The fibers are preferably of the type commonly known as rock fibers, stone fibers or slag fibers, and most preferably stone fibers.

[0148] Stone fibers generally contain the following oxides (in weight percent): SiO2: 30-51 Al2O3: 12-30 CaO: 8-30 MgO: 2 to 25 FeO (including Fe2O3): 2-15 Na2O+K2O: 10 or less CaO+MgO: 10-30.

[0149] In a preferred embodiment, the MMVF has the following levels of elements (in wt %), calculated as oxides: SiO2: at least 30, 32, 35 or 37; not more than 51, 48, 45 or 43 Al2O3: at least 12, 16, or 17; not more than 30, 27, or 25 CaO: at least 8 or 10; not more than 30, 25 or 20 MgO: at least 2 or 5; not more than 25, 20 or 15 FeO (including Fe2O3): at least 4 or 5; not more than 15, 12, or 10 FeO+MgO: at least 10, 12, or 15; not more than 30, 25, or 20 Na2O+K2O: 0 or at least 1: 10 or less CaO+MgO: at least 10 or 15; not more than 30 or 25 TiO2: 0 or at least 1; 6, 4 or less than 2 TiO2 + FeO: at least 4 or 6; not more than 18 or 12 B2O3: 0 or at least 1; 5 or less than 3 P2O5: 0 or at least 1; 8 or less than 5 Other: 0 or at least 1; 8 or less than 5.

[0150] The MMVF produced by the method of the present invention preferably has the following composition (in weight %): SiO235~50 Al2O312~30 TiO2 max 2 Fe2O33~12 CaO 5-30 MgO max 15 Na2O 0~15 K2O 0~15 P2O5 max 3 MnO max 3 B2O3 max 3.

[0151] Another preferred composition of MMVF is as follows (unit: wt %): SiO2 39-55%, preferably 39-52% Al2O3 16-27%, preferably 16-26% CaO 6-20%, preferably 8-18% MgO 1 to 5%, preferably 1 to 4.9% Na2O 0-15%, preferably 2-12% K2O 0-15%, preferably 2-12% R2O (Na2O+K2O) 10-14.7%, preferably 10-13.5% P2O50-3%, preferably 0-2% Fe2O3 (total iron) 3-15%, preferably 3.2-8% B2O3 0-2%, preferably 0-1% TiO2 0-2%, preferably 0.4-1% Others 0-2.0%.

[0152] Glass fibers typically contain the following oxides (in weight percent): SiO2: 50-70 Al2O3: 10-30 CaO: 27 or less MgO: 12 or less.

[0153] The glass fibers may also contain the following oxides (in wt. %): Na2O+K2O: 8-18, especially Na2O+K2O is more than CaO+MgO B2O3:3~12.

[0154] Some glass fiber compositions may contain less than 2% Al2O3. Suitable fiber-forming methods and subsequent production steps for producing mineral fiber products are conventional in the art. Typically, a binder is sprayed onto the mineral fibers in the air immediately after fibrillation of the mineral melt. The aqueous binder composition is typically applied in an amount of 0.1 to 18%, preferably 0.2 to 8%, by weight of the bound mineral fiber product on a dry basis.

[0155] The spray-coated mineral fiber web is generally cured in a curing oven by a stream of hot air, which can be introduced into the mineral fiber web from below, above, or from alternating directions at specific zones along the length of the oven.

[0156] Typically, the curing oven is operated at a temperature of from about 100° C. to about 300° C., such as from 170° C. to 270° C., for example, from 180° C. to 250° C., for example, from 190° C. to 230° C. Typically, the residence time in the curing oven is from 30 seconds to 20 minutes, for example, from 1 minute to 15 minutes, for example, from 2 minutes to 10 minutes, depending, for example, on the product density.

[0157] If desired, the mineral wool web may be subjected to a forming process prior to curing. Upon exiting the curing oven, the bonded mineral fiber product may be cut into the desired form, for example, in the form of batts, slabs, sheets, plates, or strips.

[0158] According to the present invention, it is also possible to produce composite materials by combining the bonded mineral fiber product with suitable composite or laminate layers, such as glass facing mats and other woven or nonwoven materials.

[0159] The mineral fiber product according to the present invention generally has a density in the range of 70 to 250 kg / m3. The mineral fiber product generally has a loss on ignition (LOI) in the range of 2.0 to 8.0 wt.%, preferably 2.0 to 5.0 wt.%.

[0160] Use of a lignin component for preparing a binder composition The present invention also relates to the use of a lignin component in the form of one or more lignosulfonic acid lignins having the characteristics described above for component (i) for the preparation of a binder composition for mineral wool.

[0161] In one embodiment, the binder composition is phenol-free and formaldehyde-free. In one embodiment, the present invention relates to the use of a lignin component in the form of one or more lignosulfonic acid lignins having the characteristics of component (i) above, for the preparation of a binder composition for mineral wool, which is preferably phenol-free and formaldehyde-free, whereby this binder composition further comprises components (ii) and optionally (iii) as defined above, preferably provided that the aqueous binder composition does not contain a crosslinker selected from epoxy compounds having a molecular weight MW of 500 or less; and / or The aqueous binder composition comprises: Aldehydes, formula R-[C(O)R] x wherein R represents a saturated or unsaturated, linear, branched or cyclic hydrocarbon radical, a radical containing one or more aromatic rings consisting of 5 or 6 carbon atoms, a radical containing one or more aromatic heterocycles containing 4 or 5 carbon atoms and oxygen, nitrogen or sulfur atoms, the R radical may contain other functional groups, and R1 represents a hydrogen atom or a C1-C10 The carbonyl compound represents an alkyl radical, and x varies from 1 to 10. and / or provided that the aqueous binder composition does not contain a crosslinker selected from polyamines; and / or The aqueous binder composition does not contain a cross-linking agent selected from monosaccharides and oligosaccharides.

[0162] In one embodiment, the present invention relates to the use of a lignin component in the form of one or more lignosulfonic acid lignins having the characteristics of component (i) above, for the preparation of a binder composition, which is preferably phenol-free and formaldehyde-free, whereby the binder composition further comprises component (iia) as defined above.

[0163] Example In the following examples, several binders falling within the definition of the present invention were prepared and compared with prior art binders.

[0164] The following properties were determined for the binder according to the invention and for the prior art binder, respectively: Binder component solids content The content of each component in a given binder solution before curing is based on the anhydride amount of the component.

[0165] Lignosulfonates were supplied as liquids with approximately 50% solids by Borregaard (Norway) and Lignotech (Florida, USA). Primid XL552 was supplied by EMS-CHEMIE AG, and silane (Momentive VS-142 40% active) was supplied by Momentive and calculated as 100% for simplicity. Silicone resin BS1052 was supplied by Wacker Chemie AG. NH4OH 24.7% was supplied by Univar and used in the form supplied. PEG200, urea, KOH pellets, and 1,1,1-tris(hydroxymethyl)propane were supplied by Sigma-Aldrich and made anhydrous for simplicity.

[0166] Binder solids The content of the binder after curing is called "binder solids." Asbestos disk samples (5 cm diameter; 1 cm height) were cut from the asbestos and heat-treated at 580 °C for at least 30 minutes to remove all organic matter. The solids content of the binder mixture was measured by dispensing a sample (approximately 2 g) of the binder mixture onto the heat-treated asbestos disk in a tin foil container. The weight of the tin foil container containing the asbestos disk was measured before and immediately after adding the binder mixture. Two such asbestos disks were prepared by filling the tin foil container with the binder mixture and heating them at 200 °C for 1 hour. After cooling and storing at room temperature for 10 minutes, the samples were weighed, and the binder solids content was calculated as the average of the two results. Next, binders with the desired binder solids content could be prepared by diluting the mixture with the required amount of water and 10% aqueous silane (Momentive VS-142).

[0167] Mechanical strength research Bar Test The mechanical strength of the binders was tested in a bar test: for each binder, 16 bars were made from a mixture of binder and asbestos shot from an asbestos spinning factory.

[0168] A sample of this binder solution (16.0 g) with 15% dry solids was thoroughly mixed with 80.0 g of shot. The resulting mixture was then filled into four slots of a heat-resistant silicone form for making small bars (4 x 5 slots per form; slot top dimensions: length = 5.6 cm, width = 2.5 cm; slot bottom dimensions: length = 5.3 cm, width = 2.2 cm; slot height = 1.1 cm). The slotted mixture was then pressed with a flat metal bar of appropriate size to create a flat bar surface. Sixteen bars were produced in this manner from each binder. The resulting bars were then typically cured at 225°C. The curing time was 1 hour. After cooling to room temperature, the bars were carefully removed from the container. Five of these bars were aged in a water bath at 80°C for 3 hours. This method of curing the prepared bars was used, for example, in Tables 1.1, 1.2, 1.4, 1.5, and 1.6. The results in Table 1.3 are based on a slightly different method, which includes a preconditioning step at 90°C for 2 hours, followed by curing at 225°C for 1 hour, but the rest of the procedure is the same.

[0169] After drying for 3 days, the aged bars and five unaged bars were fractured in a three-point bending test on a Bent Tram machine (test speed: 10.0 mm / min; fracture level: 50%; nominal strength: 30 N / mm²; support distance: 40 mm; maximum deflection: 20 mm; nominal e-module: 10,000 N / mm²) to investigate their mechanical strength. The bars were placed in the machine with the "top" side facing up (i.e., with the side measuring length = 5.6 cm and width = 2.5 cm facing up).

[0170] Examples of binders, reference binder (phenol-formaldehyde resin modified with urea, PUF resole) The binder is a PUF resole, a phenol-formaldehyde resin modified with urea.

[0171] Phenol-formaldehyde resin was prepared by reacting 37% aq. formaldehyde (606 g) with phenol (189 g) in the presence of 46% aq. potassium hydroxide (25.5 g) at a reaction temperature of 84°C, followed by heating at a rate of approximately 1°C per minute. The reaction was continued at 84°C until the resin had an acid resistance of 4 and most of the phenol had been converted. Urea (241 g) was then added and the mixture was cooled.

[0172] Acid tolerance (AT) represents the number of times a given amount of binder can be diluted with acid without the mixture becoming cloudy (the binder precipitating). Sulfuric acid is used to determine the termination criterion for binder production, with an acid tolerance of less than 4 indicating the end of the binder reaction.

[0173] To measure the AT, a titrant is prepared by diluting 2.5 mL of concentrated sulfuric acid (>99%) with 1 L of deionized water. 5 mL of the binder to be investigated is then titrated with this titrant at room temperature, shaking the binder manually to keep the binder agitated. If preferred, a magnetic stirrer and magnetic stick can be used. The titration is continued until a slight cloudiness appears in the binder that does not disappear when the binder is shaken.

[0174] Acid resistance (AT) is calculated by dividing the volume of acid (in mL) used in the titration by the volume of sample (in mL): AT = (titration volume used (mL)) / (sample volume (mL)) The resulting urea modified phenol-formaldehyde resin is used to make a binder by adding 25% aq ammonia (90 mL) and ammonium sulfate (13.2 g), followed by water (1.30 kg).

[0175] The binder solids were then determined as above and the mixture was diluted with the amount of water and silane required for the mechanical measurements (15% binder solids solution, 0.5% binder solids silane).

[0176] Examples of binders, reference binder (binder based on alkaline oxidized lignin) 3,267 kg of water is charged to a 6,000 L reactor, followed by 287 kg of aqueous ammonia (24.7%). 1,531 kg of lignin UPM BioPiva 100 is then slowly added over 30 to 45 minutes. The mixture is heated to 40°C and held at that temperature for 1 hour. After 1 hour, the insolubilized lignin is checked. This can be done by checking the solution on a glass plate or Hegman gauge. The insolubilized lignin is visible as small particles in a brown binder. During the dissolution process, the lignin solution changes color from brown to glossy black. After the lignin is completely dissolved, 1 liter of foam dampening agent (Skumdaemper 11-10, NCAA-Verodan) is added. The batch temperature is maintained at 40°C. Next, the addition of 307.5 kg of 35% hydrogen peroxide is initiated. Hydrogen peroxide is added at a rate of 200-300 L / hour. The first half of the hydrogen peroxide is added at a rate of 200 L / hour, then the addition rate is increased to 300 L / hour.

[0177] During the addition of hydrogen peroxide, the temperature of the reaction mixture is controlled by heating or cooling so that the final reaction temperature is 65°C. The final product was analyzed for COOH content, dry solids, pH, viscosity, and residual H2O2. 60 g of this oxidized lignin (18.2% solids) was mixed with 1.4 g of Primid XL552 (100% solids) and 2.8 g of PEG200 (100% solids). 0.6 g of silane (Momentive VS-142 40% active, 10% in water) and 17.4 g of water were added and mixed to obtain a solids content of 15% before being used for mechanical property testing in bar tests.

[0178] Binder composition according to the present invention In the following, the item numbers of the binder examples correspond to the item numbers used in Tables 1-1 to 1-6.

[0179] The carboxylic acid group content of all lignosulfonates used in the binders according to the present invention was measured using 31P NMR and was in the range of 0.05-0.6 mmol / g based on the dry weight of the lignosulfonate lignin in all examples.

[0180] "Example 2" To 30.0 g of the lignosulfonate solution (50% solids), 0.4 g of NH4OH (24.7%) was added and mixed, followed by 1.9 g of Primid XL552 (100% solids) and mixed in. Finally, 0.7 g of silane (Momentive VS-142 40% active, 10% in water) and 64.3 g of water were added and mixed to obtain a solids content of 15% before being used for mechanical property testing in bar tests.

[0181] "Example 11" To 30.0 g of the lignosulfonate solution (50% solids), 0.4 g of NH4OH (24.7%) was added and mixed, followed by 2.1 g of Primid XL552 (100% solids) and 3.4 g of PEG200 (100% solids). Finally, 0.7 g of silane (Momentive VS-142 40% active, 10% in water) and 61.8 g of water were added and mixed to obtain a solids content of 15% before being used for mechanical property testing in bar tests.

[0182] "Example 15" To 30.0 g of the lignosulfonate solution (50% solids), 0.4 g of NH4OH (24.7%) was added and mixed, followed by 2.9 g of Primid XL552 (100% solids) and 3.4 g of PEG200 (100% solids). Finally, 0.8 g of silane (Momentive VS-142 40% active, 10% in water) and 67 g of water were added and mixed to obtain a solids content of 15%. This was then used for mechanical property testing in bar tests.

[0183] "Example 30" To 30.0 g of the lignosulfonate solution (50% solids), 0.4 g of NH4OH (24.7%) was added and mixed, followed by 2.9 g of Primid XL552 (100% solids) and 3.4 g of 1,1,1 tris(hydroxymethyl)propane (100% solids). Finally, 0.8 g of silane (Momentive VS-142 40% active, 10% in water) and 67 g of water were added and mixed to obtain a solids content of 15%. The mixture was then used for mechanical property testing in bar tests.

[0184] "Example 33" To 100.0 g of the lignosulfonate solution (50% solids), 0.3 g of pelleted KOH was added and mixed, followed by 10.8 g of Primid XL552 (100% solids) and 11.3 g of PEG200 (100% solids). Finally, 2.6 g of silane (Momentive VS-142 40% active, 10% in water) and 228 g of water were added and mixed to obtain a solids content of 15% which was then used for mechanical property testing in bar tests.

[0185] "Example 41" To 30.0 g of the lignosulfonate solution (50% solids), 0.4 g of NH4OH (24.7%) was added and mixed, followed by 1.9 g of Primid XL552 (100% solids), 1.7 g of PEG200 (100% solids), and 1.7 g of urea (100% solids). Finally, 0.7 g of silane (Momentive VS-142 40% active, 10% in water) and 60.5 g of water were added and mixed to obtain a solids content of 15% before being used for mechanical property testing in bar tests.

[0186] The mechanical properties are shown in Tables 1.1 to 1.6. For simplicity, the amounts of all other components have been recalculated based on 100 g of dry lignin.

[0187] [Table 1]

[0188] As can be seen from Table 1.1, a combination of crosslinker (PrimidXL552) and plasticizer (PEG200) is required to obtain high mechanical properties (unaged and aged strength in bar tests) at the same level as the reference binder (11 and 15 vs. 2 and 9 for the reference binder).

[0189] [Table 2]

[0190] [Table 3]

[0191] Tables 1.2 and 1.3 show that various plasticizers (13 and 15 vs. 30) or combinations of plasticizers (34 vs. 41) can be used, with PEG200 being the preferred plasticizer.

[0192] [Table 4]

[0193] Table 1.4 shows that the addition of silanes can help achieve the same level of aged strength as the benchmark binder.

[0194] [Table 5]

[0195] Table 1.5 shows that the binder has high strength without a base, but adding a non-permanent base (NH4OH) or a permanent base (KOH) to the formulation can protect manufacturing equipment from corrosion without significantly changing the strength.

[0196] [Table 6]

[0197] Table 1.6 shows the various lignosulfonates that can be used. Overall, this means that it is possible to produce mineral wool products based on phenol-free and formaldehyde-free binder compositions with a high content of lignin-based renewable materials, which have mechanical properties equivalent to those of the reference system, but which can be produced in a simpler and cheaper manner.

[0198] "Examples 47 and 49" Below, the item numbers in the example binders correspond to the item numbers used in Table 2. The carboxylic acid group content of all lignosulfonates used for binders according to the invention was measured using 31P NMR to be in the range of 0.05-0.6 mmol / g based on the dry weight of lignosulfonate lignin, but for this particular batch used for Examples 47, 49 and 54 it was 0.14 mmol / g.

[0199] "Example 47" To 30.0 g of the lignosulfonate solution (50% solids), 0.4 g of NH4OH (24.7%) was added and mixed, followed by 0.7 g of silane (Momentive VS-142 40% active, 10% in water) and 68.9 g of water, which were mixed to give a solids content of 15% before being used for mechanical property testing in bar tests.

[0200] "Example 49" To 30.0 g of the lignosulfonate solution (50% solids), 0.4 g of NH4OH (24.7%) was added and mixed, followed by 6.0 g of Primid XL552 (100% solids) and mixed in. Finally, 1.0 g of silane (Momentive VS-142 40% active, 10% in water) and 102.6 g of water were added and mixed to obtain a solids content of 15% before being used for mechanical property testing in bar tests.

[0201] The mechanical properties are shown in Table 2. For simplicity, the amounts of all other components were recalculated based on 100 g of dry lignin.

[0202] [Table 7]

[0203] As can be seen from Table 2, in the combination of lignosulfonate and cross-linking agent (PrimidXL552), the mechanical properties improve as the amount of cross-linking agent increases. Example: Testing of asbestos products The product properties (meaning relevant mechanical properties as well as other basic properties of asbestos products) were tested in accordance with EN13162:2012+A1:2015, the product standard for factory-manufactured mineral wool (MW) products.

[0204] Tests were carried out on slabs, and specimens were cut according to the dimensional specifications and the number of specimens required to obtain one test result, as specified in EN 13162 for each of the different test methods. Each stated value of the mechanical properties obtained is the average of more results according to EN 13162.

[0205] size The dimensions of the products and test specimens were carried out in accordance with the relevant test methods EN822:2013: "Thermal insulating products for building applications - Determination of length and width" and EN823:2013: "Thermal insulating products for building applications - Determination of thickness".

[0206] Binder content (loss on ignition) Binder content measurements were performed in accordance with EN 13820:2003: "Thermal insulating materials for building applications - Determination of organic content." Binder content is defined as the amount of organic material burned at a specific temperature (500 ± 20°C) specified in the standard. A specific temperature (590 ± 20°C, at least 10 minutes to constant weight) was used to ensure all organic matter was burned off. Loss on ignition determination consisted of at least 10 g of cotton, corresponding to 8 to 20 cuts (minimum 8 cuts), evenly distributed over the test specimen using a cork borer to ensure coverage of the entire thickness of the product. The binder content was determined as the LOI. The binder included oil and other binder additives.

[0207] "Example 54" Asbestos products were produced using the binder of Example 54 and the curing oven temperature was set at 255°C.

[0208] 730.0 kg of ammonium lignosulfonate was placed in a mixing vessel, to which 8.5 L of NH4OH (24.7%) was added and stirred, followed by 151 kg of Primid XL552 solution (pre-made 31 wt% solution in water) and 43 kg of PEG200 (100% solids) and mixing, followed by 13 kg of silane (Momentive VS-142 40% active, 10% in water) and 40 kg of silicone (Wacker BS1052, 12% in water).

[0209] The binder from this example was used to produce a high density asbestos product having a thickness of 100 mm and a density of 145 kg / m³, with an insulation element loss on ignition (LOI) of 3.5% by weight. The curing oven temperature was set at 255°C.

[0210] "Example 55" Asbestos products were produced using the binder of Example 55 and the curing oven temperature was set at 255°C.

[0211] 609.0 kg of ammonium lignosulfonate was placed in a mixing vessel, to which 8 L of NH4OH (24.7%) was added and stirred. 384 kg of Primid XL552 solution (pre-made 31 wt% solution in water) was then added and mixed, followed by 14 kg of silane (Momentive VS-142 40% active, 10% in water).

[0212] The binder from this example was used to produce a high density asbestos product with a thickness of 100 mm, a density of 145 kg / m³ and a loss on ignition (LOI) of 3.5 wt%. The curing oven temperature was set at 255°C.

[0213] Comparative Example Comparative mineral fiber product examples were prepared as controls: Comparative Example A represents an asbestos product containing a conventional phenol-urea-formaldehyde (PUF) binder, and Comparative Example B represents an asbestos product manufactured using a no-additive formaldehyde binder (NAF), one of the assignee's prior art technologies.

[0214] Comparative example A (PUF) The binder is a PUF resole, a phenol-formaldehyde resin modified with urea.

[0215] Phenol-formaldehyde resin was prepared by reacting 37% aq formaldehyde (606 kg) with phenol (189 kg) in the presence of 46% aq potassium hydroxide (25.5 kg) at a reaction temperature of 84°C, followed by heating at a rate of approximately 1°C per minute. The reaction was continued at 84°C until the resin had an acid resistance of 4 and most of the phenol had been converted. Urea (241 kg) was then added and the mixture was cooled.

[0216] Acid resistance (AT) indicates the number of times a given amount of binder can be diluted with acid without the mixture becoming cloudy (the binder precipitating). Sulfuric acid is used to determine the termination criterion for binder production, with an acid resistance of less than 4 indicating the end of the binder reaction.

[0217] To measure the AT, a titrant is prepared by diluting 2.5 mL of concentrated sulfuric acid (>99%) with 1 L of deionized water. 5 mL of the binder to be investigated is then titrated with this titrant at room temperature, shaking the binder manually to keep the binder agitated. If preferred, a magnetic stirrer and magnetic stick can be used. The titration is continued until a slight cloudiness appears in the binder that does not disappear when the binder is shaken.

[0218] Acid resistance (AT) is calculated by dividing the volume of acid (in mL) used in the titration by the volume of sample (in mL): AT = (titration volume used (mL)) / (sample volume (mL)) The resulting urea modified phenol-formaldehyde resin is used to make a binder by adding 25% aq ammonia (90 L) and ammonium sulfate (13.2 kg), followed by water (1300 kg).

[0219] The binder solids were then determined as above and the mixture was diluted with the amount of water and silane required for mechanical testing. A mineral fiber product was prepared by binding 100 mm of mineral wool with this prior art binder composition. The density of the mineral fiber product was 145 kg / m3. The loss on ignition was 3.5 wt%. The proportion of the hardened binder composition in the mineral fiber product was 3.4 wt%, with 0.1 wt% mineral oil.

[0220] Comparative example B (NAF) A mixture of 75.1% aq glucose syrup (19.98 kg; thus effectively 15.0 kg glucose syrup), 50% aq hypophosphorous acid (0.60 kg; thus effectively 0.30 kg, 4.55 mol hypophosphorous acid), and sulfamic acid (0.45 kg, 4.63 mol) in water (30.0 kg) was stirred at room temperature until a clear solution was obtained. Next, 28% aq ammonia (0.80 kg; thus effectively 0.22 kg, 13.15 mol ammonia) was added dropwise until a pH of 7.9 was obtained. The binder solids content was then determined (21.2%). To obtain the appropriate binder composition (15% binder solids solution, 0.5% binder solids silane), the binder mixture was diluted with water (0.403 kg / kg binder mixture) and 10% aq silane (0.011 kg / kg binder mixture, Momentive VS-142). The pH of the final binder mixture was 7.9.

[0221] A mineral fiber product with a thickness of 100 mm, density of 145 kg / m3 and LOI of 3.5 wt% was prepared. The general methods for producing mineral fiber products as described above are used.

[0222] Figure 1 shows a portion of a flat roof 1 of a first embodiment, including a structural support 2, a vapor control layer 3, an insulation element 4, and a covering waterproof membrane 20. The insulation element 4 is a bonded mineral fiber product made of mineral fibers and a binder.

[0223] The covering waterproofing membrane 20 is connected to the insulation element 4 via an adhesive 9, which may be an integral part of the membrane 20. The adhesive 9 may be a bituminous adhesive activated by a burner commonly used in roofing operations, i.e., the membrane 20 is burned to attach it to the insulation element 4. The dotted lines in the insulation element 4 indicate the area 10 where the molten bituminous adhesive 9 spreads before it hardens and connects the membrane 20 to the insulation element 4.

[0224] Figure 2 shows a portion of a flat roof 1 according to a second embodiment of the invention, comprising a structural support 2, a vapor control layer 3, an insulation element 4 and a waterproofing membrane (not shown, but equivalent to Figure 1). The insulation element 4 comprises a first layer 5 comprising asbestos fibres and a binder and a second layer 6 made of a woven glass fleece having an elastic modulus of 573 MPa. The tensile strength of the glass fleece is 71 N.

[0225] The first layer 5 is represented by one or more lamellae with a fiber orientation mainly perpendicular to the main surface 7 of the second layer 6. The lamellae, and therefore the first layer 5, have a fiber strength of 110 kg / m 3 and a typical thickness of 150 mm. The mineral fibers are connected to one another via an adhesive that is cured in a curing oven before the second layer 6 is fixed to the surface 8 of the first layer 5 via the adhesive 9. The adhesive 9 in this particular embodiment may be selected from melamine urea formaldehyde, preferably as a two-component adhesive, a water-based acrylic adhesive, a phenol formaldehyde powder binder, a water-based neoprene foam adhesive, a polyamide-based powder adhesive, a polyurethane adhesive, preferably as a two-component adhesive, a polyurethane moisture-curing adhesive, or a sealing-modified binder, preferably as a one-component moisture-curing adhesive. Preferably, however, the adhesive 9 in this particular embodiment is identical to the binder composition utilized to connect the mineral fibers of the insulation element 4.

[0226] All these adhesives 9 establish a good connection with the mineral fibres and all these adhesives 9 are able to establish an almost closed layer in the area of ​​the lamellae and in the area of ​​the fabric, thereby strengthening the insulation element 4 in the direction parallel to the main surface 7 of the lamellae.

[0227] The adhesive 9 is partially disposed in an area 10 near the main surface 8 of the first layer 5 facing the second layer 6 and in an area 11 near the main surface 7 of the second layer 6 facing the first layer 5. The adhesive 9 connects the first layer 5 and the second layer 6, allowing forces directed perpendicular to the second layer 6 to be compensated for by the tensile strength of the second layer 6 combined with the adhesive 9 and / or the deflection of the fibers of the first layer 5. A force of, for example, 80 kPa directed perpendicular to the second layer 6 causes a limited deformation of less than 5% of the insulation element 4 (first and second layers 5, 6), thus 7.5 mm or less for a 150 mm thickness of the first layer 5. Since the thickness of the second layer 6 is approximately 1 mm or less, it can be ignored in this calculation. A sufficient amount of adhesive 9 is disposed between the fibers of the first layer 5, so that the adhesive 9 surrounds the fibers and forms a layer of adhesive 9 fixed to the first layer 5.

[0228] The adhesive 9 is 80 g / m between the two layers 5 and 6. 2 The adhesive 9 is applied as an acrylic adhesive with a liquid adhesive amount of 9. A sufficient amount of adhesive 9 spreads into the first layer 5 and the second layer 6. Thus, the adhesive 9 forms a layer connecting the first layer 5 and the second layer 6 and is fixed to both layers 5, 6.

[0229] According to the present invention, the binder used in the insulation element 4 comprises a first component in the form of one or more lignosulfonated lignins, for example according to Example 54 above. The diagram according to Figure 3 shows the absolute values ​​of the delamination strength of the insulation element 4 according to the present invention (graph C2) compared with the absolute values ​​of the delamination strength of an insulation element containing a conventional phenol-urea-formaldehyde binder, shown in graph A2 (following Comparative Example A), and with the absolute values ​​of the delamination strength of an insulation element containing an additive-free formaldehyde binder, one of the assignee's prior art, shown in graph B2 (following Comparative Example B).

[0230] The delamination strength is measured according to EN1607:2013, with the first initial measurement being carried out on unaged samples immediately or shortly after the manufacture of the insulation element 4. The average results of this initial test and a representative number of samples are shown at time "0" on the x-axis of the diagram, which corresponds to the start date "0" of the accelerated aging test described below.

[0231] To determine the ageing resistance of mineral fiber products exposed to moisture and heat during the life of a building, such mineral fiber products, with emphasis on mechanical properties, are subjected to accelerated ageing. Ageing resistance is defined as the ability of a product to maintain its original mechanical properties and is calculated as the aged strength as a percentage of the original strength. The test procedure follows the so-called Nord Test Method NT Bild 434:1995.05 and is extended to 28 days.

[0232] The purpose of this method is to subject insulating materials to accelerated aging through increased temperature and heat. This method is applicable to all insulating materials manufactured as insulating boards. The method is not predictive, i.e. it is not intended to assess service life, but a prerequisite for satisfactory performance is that aging by this method does not cause significant changes in the properties of the material under investigation. More than 20 years of experience with the Nord test method has proven that it provides reliable data to ensure satisfactory mechanical performance of mineral fiber products, especially as insulating elements used in roofing systems.

[0233] According to this method, a representative number of test specimens are subjected to heat-moisture action in a climate chamber at 70±2°C and 95±5% relative humidity (RH) for 7, 14, and 28 days. The test specimens are then left to dry for at least 24 hours at 23±2°C and 50±5% RH and prepared for mechanical performance testing. For example, delamination strength is measured according to EN 1607:2013, or compressive strength is measured according to EN 826:2013, as described in more detail below.

[0234] The relative aging resistance is then calculated in % based on the initial absolute value measured at time "0." Results are recorded and illustrated for 7, 14 and 28 days of accelerated aging.

[0235] With respect to Figures 3-6 and the examples shown herein, the insulation element 4 is a bonded mineral fiber roofing product commercially available from the assignee or an affiliated company, manufactured with the different binder types described above and tested for its mechanical properties. The product has a strength of approximately 145 kg / m 3 and a loss on ignition (LOI) of about 3.5 wt.%.

[0236] Table I below shows the interlayer peel strength [kPa] EN1607 according to FIG.

[0237] [Table 8]

[0238] Table I shows the absolute delamination strength of an insulation element 4 (C2) according to the invention compared to an insulation element containing a phenol-formaldehyde binder (A2) and an insulation element containing an unadded formaldehyde binder (B2), initially and after accelerated aging. The corresponding graph is shown in Figure 3.

[0239] Table II below shows the relative delamination strengths according to Table I in % of the initial values ​​according to FIG.

[0240] [Table 9]

[0241] Table II shows the relative delamination strength of an insulation element 4 (C3) according to the invention compared to an insulation element containing a phenol-formaldehyde binder (A3) and an insulation element containing an unadded formaldehyde binder (B3). A corresponding graph is shown in Figure 4.

[0242] In Table I and especially in Table II, it can be seen that the delamination strength of the insulation elements 4 (C2; C3) according to the invention is not significantly different from that of the insulation elements (A2; A3) containing a phenol-formaldehyde binder, and furthermore that the loss in delamination strength of the insulation elements (B2; B3) containing a formaldehyde binder without additives is much greater than that of the insulation elements 4 (C2; C3) according to the invention.

[0243] The relative delamination strength of an insulation element 4 (C3) according to the invention can be seen in comparison with an insulation element containing a phenol-formaldehyde binder (A3) or an insulation element containing an unadded formaldehyde binder (B3) from Table II and Figure 4. All comparative insulation elements 4 were subjected to the aging process as described above.

[0244] In particular, it can be seen from Table II and Figure 4 that the relative values ​​of the delamination strength of the insulation element 4 (C3) according to the invention appear almost equal to the values ​​of the delamination strength of the insulation element (A3) containing a phenol-formaldehyde binder, and even remain slightly higher initially.

[0245] Table III below shows the absolute compressive strength [kPa] EN826 according to FIG.

[0246] [Table 10]

[0247] Table III shows the absolute compressive strength of an insulation element 4 (C4) according to the invention compared with an insulation element containing a phenol-formaldehyde binder (A4) and an insulation element containing an unadded formaldehyde binder (B4). The corresponding graph is shown in Figure 5.

[0248] FIG. 5 shows the compressive strength of an insulation element 4 according to the invention (graph C4) compared with the compressive strength of an insulation element containing mineral fibres and an unadded formaldehyde binder, shown in graph B4, and with the compressive strength of an insulation element containing mineral fibres and a phenol-formaldehyde binder, shown in graph A4.

[0249] The compressive strength is measured according to EN826, it being understood that the compressive strength is measured immediately after the manufacture of the insulation element 4 and after 7 days, 14 days and 28 days after the manufacture of the insulation element 4, including accelerated ageing.

[0250] Table IV below shows the relative compressive strengths according to Table III in % of the initial values ​​according to FIG.

[0251] [Table 11]

[0252] Table IV shows the relative compressive strength of an insulation element 4 (C5) according to the invention compared to an insulation element containing a phenol-formaldehyde binder (A5) and an insulation element containing an unadded formaldehyde binder (B5). A corresponding graph is shown in Figure 6.

[0253] From Figure 6, the relative compressive strength of an insulation element 4 according to the invention (C5) can be derived in comparison with an insulation element containing a phenol-formaldehyde binder (A5) or an insulation element containing an unadded formaldehyde binder (B5). All the insulation elements compared were subjected to an ageing process comprising the steps described above.

[0254] Furthermore, from Figure 6 it can be seen that the relative change in compressive strength of the insulation element 4 according to the invention (C5) is somewhat similar to that of the insulation element containing a phenol-formaldehyde binder (A5), and in particular the residual strength after 28 days is significantly higher than that of the insulation element containing a formaldehyde binder without additives (B5).

[0255] The measurements therefore prove that the binder according to the invention and the respective insulation elements produced with it provide high ageing resistance that is as good as that of state-of-the-art phenol-formaldehyde binders.

Claims

1. 1. A roofing system for a flat roof or flat-sloped roof of a building having thermal and / or acoustic insulation, the roofing system comprising a structural support, a deck, an optional vapor control layer, a waterproofing membrane, and at least one insulation element which is a bonded mineral fiber product made of mineral fibers and a phenol-free, formaldehyde-free, cured aqueous binder composition, the aqueous binder composition, prior to curing, being: Component (i) in the form of one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g based on the dry weight of the lignosulfonate lignin; and component (ii) in the form of one or more crosslinkers; The insulation element has a resistance of 70 kg / m ３ ~250 kg / m ３ and said insulation element has a loss on ignition (LOI) in the range of 2 to 8 wt.%.

2. The roofing system of claim 1, wherein the insulation element has a loss on ignition (LOI) in the range of 2 to 5% by weight.

3. 3. A roofing system according to claim 1 or 2, comprising an insulation element having a compressive strength of 50 to 130 kPa measured according to European Standard EN 826:2013.

4. 4. A roofing system according to any one of claims 1 to 3, comprising an insulation element having a delamination strength of 20 to 50 kPa measured according to European Standard EN 1607:2013.

5. 5. The roofing system of claim 1, wherein component (i) has a carboxylic acid group content of 0.05 to 0.6 mmol / g, based on the dry weight of the lignosulfonate lignin.

6. 6. A roofing system according to any one of claims 1 to 5, wherein component (i) is in the form of one or more lignosulphonic acid lignins having an average carboxylic acid group content per macromolecule taking into account the number average molecular weight of component (i) of less than 1.8, such as less than 1.4, for example less than 1.1, such as less than 0.7, for example less than 0.

4.

7. 7. A roofing system according to any one of claims 1 to 6, wherein component (i) has a content of phenolic OH groups of 0.3 to 2.5 mmol / g, for example 0.5 to 2.0 mmol / g, for example 0.5 to 1.5 mmol / g, based on the dry weight of the lignosulphonic acid lignin.

8. 8. A roofing system according to any one of claims 1 to 7, wherein component (i) has a content of aliphatic OH groups of 1.0 to 8.0 mmol / g, for example 1.5 to 6.0 mmol / g, for example 2.0 to 5.0 mmol / g, based on the dry weight of the lignosulphonic acid lignin.

9. 9. The roofing system of claim 1, wherein component (i) comprises ammonium lignosulfonate and / or calcium lignosulfonate and / or magnesium lignosulfonate, and any combination thereof.

10. Component (i) comprises ammonium lignosulfonate and calcium lignosulfonate, and NH ４ ＋ Against Ca ２＋ 10. A roofing system according to any one of claims 1 to 9, wherein the molar ratio of is in the range of from 5:1 to 1:5, in particular from 3:1 to 1:

3.

11. 11. The roofing system of any one of claims 1 to 10, wherein the aqueous binder composition comprises lignosulfonate and sugar added in an amount of 0 to less than 5% by weight based on the weight of the sugar.

12. 12. A roofing system according to any one of claims 1 to 11, wherein the aqueous binder composition comprises component (i) in an amount of 50 to 98% by weight, such as 65 to 98% by weight, for example 80 to 98% by weight, based on the dry weight of components (i) and (ii).

13. The component (ii) is β-hydroxyalkylamide crosslinkers, and / or an oxazoline crosslinker, and / or groups consisting of polyfunctional organic amines, such as alkanolamines, diamines, such as hexamethyldiamine, and / or an epoxy compound having a molecular weight greater than 500, containing a reactive functional group, such as a carbodiimide group, such as an anhydride group, such as an oxazoline group, such as an amino group, such as an epoxy group, for example an epoxidized oil based on fatty acid triglycerides, or one or more flexible oligomers or polymers, such as a low Tg acrylic polymer, such as a low Tg vinyl polymer, such as a low Tg polyether, and / or one or more crosslinkers selected from the group consisting of fatty amines; and / or one or more cross-linking agents in the form of fatty amides; and / or one or more crosslinkers selected from polyester polyols, such as polycaprolactone; and / or one or more cross-linking agents selected from the group consisting of starch, modified starch, CMC; and / or one or more crosslinkers in the form of polyfunctional carbodiimides, for example aliphatic polyfunctional carbodiimides; and / or one or more crosslinkers selected from melamine-based crosslinkers, such as hexakis(methylmethoxy)melamine (HMMM)-based crosslinkers; 13. The roofing system of any one of claims 1 to 12, in the form of one or more cross-linking agents selected from:

14. 14. The roofing system of any one of claims 1 to 13, wherein component (ii) comprises one or more crosslinkers selected from β-hydroxyalkylamide crosslinkers and / or oxazoline crosslinkers.

15. 15. A roofing system according to any one of the preceding claims, comprising component (ii) in an amount of 1 to 50% by weight, such as 4 to 20% by weight, for example 6 to 12% by weight, based on the dry weight of component (i).

16. The component (ii) is β-hydroxyalkylamide crosslinkers, such as N-(2-hydroxyisopropyl)amide crosslinkers, such as N-(2-hydroxyethyl)amide crosslinkers, such as N-(2-hydroxyethyl)adipamide crosslinkers, such as N,N,N',N'-tetrakis(2-hydroxyethyl)adipamide and / or groups consisting of polyfunctional organic amines, such as alkanolamines, diamines, such as hexamethyldiamine, and / or epoxy compounds with a molecular weight greater than 500, containing reactive functional groups such as carbodiimide groups, anhydride groups, oxazoline groups, amino groups, epoxy groups, for example, epoxidized oils based on fatty acid triglycerides, or one or more flexible oligomers or polymers, such as low Tg acrylic polymers, low Tg vinyl polymers, low Tg polyethers, and / or one or more crosslinkers in the form of polyfunctional carbodiimides, e.g., aliphatic polyfunctional carbodiimides; 16. The roofing system of any one of claims 1 to 15, in the form of one or more cross-linking agents selected from:

17. The component (ii) is 17. A roofing system according to any one of claims 1 to 16, comprising one or more crosslinkers selected from β-hydroxyalkylamide crosslinkers, such as N-(2-hydroxyisopropyl)amide crosslinkers, such as N-(2-hydroxyethyl)amide crosslinkers, such as N-(2-hydroxyethyl)adipamide crosslinkers, such as N,N,N',N'-tetrakis(2-hydroxyethyl)adipamide.

18. 18. A roofing system according to any one of the preceding claims, comprising component (ii) in an amount of 2 to 90% by weight, such as 6 to 60% by weight, for example 10 to 40% by weight, for example 25 to 40% by weight, based on the dry weight of component (i).

19. A roofing system as described in claims 1 to 18, wherein the aqueous binder composition further comprises component (iii) in the form of one or more plasticizers.

20. Component (iii) is one or more plasticizers selected from the group consisting of fatty alcohols, monohydroxy alcohols, such as pentanol, stearyl alcohol; and / or one or more plasticizers selected from the group consisting of alkoxylates, e.g., ethoxylates, e.g., butanol ethoxylates, e.g., butoxytriglycol; and / or one or more plasticizers in the form of propylene glycol; and / or one or more plasticizers in the form of glycol esters; and / or one or more plasticizers selected from the group consisting of adipate, acetate, benzoate, cyclobenzoate, citrate, stearate, sorbate, sebacate, azelaate, butyrate, valerate; and / or one or more plasticizers selected from the group consisting of phenol derivatives, such as alkyl- or aryl-substituted phenols; and / or one or more plasticizers selected from the group consisting of silanols, siloxanes; and / or one or more plasticizers selected from the group consisting of sulfates, e.g., alkyl sulfates, sulfonates, e.g., alkylaryl sulfonates, e.g., alkyl sulfonates, phosphates, e.g., tripolyphosphates; and / or one or more plasticizers in the form of hydroxy acids; and / or one or more plasticizers selected from the group consisting of monomeric amides, such as acetamide, benzamide, fatty acid amides, such as tall oil amide; and / or one or more plasticizers selected from the group consisting of quaternary ammonium compounds, e.g., trimethylglycine, distearyldimethylammonium chloride; and / or one or more plasticizers selected from the group consisting of vegetable oils, such as castor oil, palm oil, linseed oil, soybean oil; and / or tall oil, and / or one or more plasticizers selected from the group consisting of hydrogenated oils, acetylated oils; and / or one or more plasticizers selected from the group consisting of methyl esters of hydroxybenzoates; and / or one or more plasticizers selected from the group consisting of alkyl polyglucosides, gluconamides, aminoglucose amides, sucrose esters, sorbitan esters; and / or one or more plasticizers selected from the group consisting of polyethylene glycol, polyethylene glycol ether; and / or one or more plasticizers in the form of a polyol, e.g., glycerol, e.g., 1,1,1-tris(hydroxymethyl)propane; and / or 20. The roofing system of claim 19 in the form of triethanolamine.

21. 21. The roofing system of claim 19 or 20, wherein component (iii) is in the form of propylene glycol, a phenol derivative, a silanol, a siloxane, a hydroxy acid, a vegetable oil, a polyethylene glycol, a polyethylene glycol ether, triethanolamine, or any mixture thereof.

22. 22. The roofing system of any one of claims 19 to 21, wherein component (iii) comprises one or more plasticizers having a boiling point of from 100 to 380°C.

23. 23. The roofing system of any one of claims 19 to 22, wherein component (iii) comprises one or more polyethylene glycols having an average molecular weight of 150 to 50,000 g / mol.

24. 24. The roofing system of any one of claims 19 to 23, wherein component (iii) is present in an amount of 0.5 to 60% by weight, based on the dry weight of component (i).

25. 25. A roofing system according to any one of claims 1 to 24, wherein the binder composition, prior to curing, comprises a further component (iv) in the form of one or more coupling agents, for example organofunctional silanes.

26. The binder composition may be added with a base such as ammonia, an alkali metal hydroxide such as KOH, an earth alkali metal hydroxide such as Ca(OH) before curing. ２ , for example Mg(OH) ２ 26. A roofing system according to any one of claims 1 to 25, further comprising component (v) in the form of one or more components selected from the group of, for example, amines or any salts thereof.

27. 27. A roofing system according to any one of the preceding claims, wherein the binder composition before curing comprises a further component, in particular in the form of urea, in an amount of 5 to 40% by weight, for example 10 to 30% by weight, for example 15 to 25% by weight, based on the dry weight of component (i).

28. 28. A roofing system according to any one of claims 1 to 27, wherein the binder composition before curing comprises a further component (vi) in the form of one or more more reactive or non-reactive silicones.

29. 29. The roofing system of any one of claims 1 to 28, wherein the insulation element does not contain ammonia-oxidized lignin (AOL).

30. 1. An insulation element made of mineral fibers and a phenol-free and formaldehyde-free cured aqueous binder composition, the aqueous binder composition comprising, before curing, component (i) in the form of one or more lignosulfonic acid lignins having a carboxylic acid group content of 0.03 to 2.0 mmol / g, based on the dry weight of the lignosulfonic acid lignin, and component (ii) in the form of one or more crosslinkers, the insulation element having a tensile strength of 70 kg / m ３ ~250 kg / m ３ 30. An insulation element for a roofing system according to any one of claims 1 to 29, having a bulk density of

31. 31. The insulation element of claim 30, wherein the aqueous binder composition further comprises component (iii) in the form of one or more plasticizers.

32. An insulation element according to claim 30 or 31, further comprising the features of an insulation element according to any one of claims 2 to 29.

33. 33. An insulation element according to claim 30 or 32 for a roofing system according to any one of claims 1 to 29, characterized in that it comprises a first layer comprising asbestos fibers and a binder and a second layer made of glass fleece, whereby the second layer is fixed to the main surface of the first layer by means of an adhesive, whereby the first layer is made of at least one lamella having a fiber orientation mainly perpendicular to the main surface of the second layer, whereby the first layer contains a hardening binder, the adhesive being partially arranged in the areas between the fibers close to the main surface of the first layer directed towards the second layer and in the areas close to the main surface of the second layer directed towards the first layer, the adhesive connecting the first and second layers so that forces directed perpendicular to the second layer can be compensated by the tensile strength of the second layer combined with the adhesive and / or the deflection of the fibers of the first layer, causing a maximum deformation of less than 5% of the thickness of the insulation element.

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