Low-chloride mineral wool products

Abstract

The present invention is directed to mineral fiber products having low water leachable chloride content that are suitable as non-corrosive thermal and / or acoustic insulation materials.

Description

[Technical Field]

[0001] This invention relates to mineral fiber products and the use of mineral fiber products. [Background technology]

[0002] Mineral fiber products (also called mineral wool products) generally include mineral fibers such as glass fibers, ceramic fibers, basalt fibers, slag fibers, and stone fibers (rock fibers), also known as man-made vitreous fibers (MMVF), which are bonded together by a cured thermosetting polymer binder material. For use as thermal insulation or soundproofing products, bonded mineral fiber mats are usually manufactured by converting a molten material made from suitable raw materials into fibers using conventional methods, such as a spinning cup process or a cascade rotor process. The fibers are blown into a molding chamber, and while still hot and in the air, a binder solution is sprayed onto them, and they are randomly deposited on a moving conveyor as mats or webs. The fiber mats are then transferred to a curing oven, where heated air is blown into the mats to cure the binder and firmly bond the mineral fibers.

[0003] In the past, the selected binder resin was phenol-formaldehyde resin, which can be economically manufactured and extended with urea before use as a binder. However, in consideration of existing and proposed laws regarding the reduction or elimination of formaldehyde emissions, formaldehyde-free binders have been developed, such as polycarboxypolymer and polyol or polyamine-based binder compositions disclosed in, for example, European Patent Publication No. 583086, European Patent Publication No. 990727, European Patent Publication No. 1741726, U.S. Patent No. 5,318,990, and U.S. Patent Publication No. 2007 / 0173588.

[0004] Another group of non-phenol-formaldehyde binders are addition / elimination reaction products of aliphatic anhydrides and / or aromatic anhydrides with alkanolamines, as disclosed, for example, in International Publication No. 99 / 36368, International Publication No. 01 / 05725, International Publication No. 01 / 96460, International Publication No. 02 / 06178, International Publication No. 2004 / 007615 and International Publication No. 2006 / 061249. These binder compositions are water-soluble and exhibit excellent binding properties in terms of curing rate and curing density. International Publication No. 2008 / 023032 discloses a urea-modified binder of its type that provides mineral wool products with reduced water absorption.

[0005] Since some of the starting materials used in the manufacture of these binders are fairly expensive chemicals, there is an ongoing need to provide formaldehyde-free binders that can be manufactured economically.

[0006] A further benefit of previously known aqueous binder compositions from mineral fibers is that at least a large portion of the starting materials used in the manufacture of these binders are derived from fossil fuels. The consumer trend towards products made entirely or at least partially from renewable materials continues, and therefore, there is a need to provide binders for mineral wool that are made at least partially from renewable materials.

[0007] The primary problem with the use of mineral fiber products as insulation or soundproofing materials for industrial equipment or piping is corrosion. Therefore, Corrosion Under Insulation (CUI) refers to external corrosion of piping or equipment that occurs beneath the external cladding insulation due to the penetration of water or moisture. The corroded surface is largely hidden by the insulation system and may not be observed until the insulation is removed for inspection or in the event of metal failure and / or leakage that could lead to health and safety accidents. CUI occurs particularly under insulation in steel structures subjected to periodic temperature changes, such as pipelines in the oil and gas industry.

[0008] Corrosion occurs in the presence of water and oxygen. If insulated equipment or piping made of steel or other materials remains dry, there is no corrosion problem. However, keeping insulated parts dry can be difficult. Certain types of corrosion can be caused or aided by water-soluble chlorides. Conventional binder compositions for mineral fibers can contain considerable amounts of water-soluble chlorides. Therefore, mineral fiber products themselves can contribute to the corrosion of insulated components.

[0009] The risk of corrosion in carbon steel under insulation is high in the temperature range of 50 to 175°C and extremely high in periodic (circulating) temperature use from -20 to 320°C. The most frequently occurring types of CUI are general corrosion and pitting corrosion of carbon steel, which can occur when wet insulation comes into contact with carbon steel, and external stress corrosion tracking (ESCT) of austenitic stainless steel, a specific type of corrosion mainly caused by the action of water-soluble chlorides. [Prior art documents] [Patent Documents]

[0010] [Patent Document 1] European Patent Application Publication No. 583086 [Patent Document 2] European Patent Application Publication No. 990727 [Patent Document 3] European Patent Application Publication No. 1741726 Specification [Patent Document 4] U.S. Patent No. 5,318,990 Specification [Patent Document 5] U.S. Patent Application Publication No. 2007 / 0173588 Specification [Patent Document 6] International Publication No. 99 / 36368 Pamphlet [Patent Document 7] International Publication No. 01 / 05725 Pamphlet [Patent Document 8] International Publication No. 01 / 96460 Pamphlet [Patent Document 9] International Publication No. 02 / 06178 Pamphlet [Patent Document 10] International Publication No. 2004 / 007615 Pamphlet [Patent Document 11] International Publication No. 2006 / 061249 Pamphlet [Patent Document 12] International Publication No. 2008 / 023032 Pamphlet [Summary of the Invention] [Problems to be Solved by the Invention]

[0011] Accordingly, an object of the present invention was to provide a mineral fiber product for insulation that has reduced corrosivity to insulating objects, can be produced economically, and uses a renewable material as a starting material for the preparation of an aqueous binder composition used for producing the mineral fiber product.

[0012] A further object of the present invention was to provide use of such a mineral fiber product. [Means for Solving the Problems]

[0013] According to a first aspect of the present invention, a mineral fiber product is provided comprising mineral fibers bound together by a cured binder composition, wherein the uncured binder composition comprises one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignins, and the mineral fiber product has a water-leaching chloride content of less than 10 mg / kg in accordance with EN13468:2001.

[0014] A second aspect of the present invention provides the use of a mineral fiber product comprising mineral fibers bound by a cured binder composition as a thermal insulation and / or soundproofing material, particularly a non-corrosive thermal insulation and / or soundproofing material, wherein the uncured binder composition comprises one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignin, and the mineral fiber product optionally has a water-leaching chloride content of less than 10 mg / kg in accordance with EN13468:2001.

[0015] According to a third aspect of the present invention, a method for producing a mineral fiber product comprising mineral fibers bound by a cured binder composition, wherein the uncured binder composition comprises one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignin, and the mineral fiber product optionally has a water-leaching chloride content of less than 10 mg / kg in accordance with EN13468:2001. This method is a) A step of providing an uncured aqueous binder composition containing one or more lignosulfonates and water, b) A step of bringing mineral fibers into contact with the above-mentioned uncured aqueous binder composition, c) A step of curing the above binder composition in contact with the above mineral fibers. A method is provided in which the uncured aqueous binder composition contains, and at least a portion or all of the water contained in the uncured aqueous binder composition is added unpurified water, which is preferably selected from tap water, rainwater, process water, or a combination thereof.

[0016] Preferably, the lignosulfonate lignin has a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignin.

[0017] According to a fourth aspect of the present invention, a hollow object is provided which is coated with a mineral fiber product as a thermal insulation and / or soundproofing material, wherein the mineral fiber product comprises mineral fibers bound together by a cured binder composition, the uncured binder composition comprising one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignin, and the mineral fiber product optionally has a water-leaching chloride content of less than 10 mg / kg in accordance with EN13468:2001.

[0018] The inventors have found that when a binder composition based on lignosulfonate lignin is used in mineral fiber products, those mineral fiber products can be used as low-corrosion or even non-corrosion thermal and / or soundproofing materials. This binder composition has a remarkably low water-leaching chloride content. [Brief explanation of the drawing]

[0019] [Figure 1] A commonly used model structure for lignosulfonates is shown. [Modes for carrying out the invention]

[0020] The mineral fiber product of the present invention comprises mineral fibers bound together by a cured binder composition, the uncured binder composition comprising one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignin, the mineral fiber product having a water-leaching chloride content of less than 10 mg / kg according to EN13468:2001, and the water-leaching chloride content is preferably less than 6 mg / kg according to EN13468:2001.

[0021] For the purposes of this application, the water-leaching chloride content of mineral fiber products is measured in accordance with EN13468:2001. Standard EN13468:2001 relates, in particular, to the determination of trace amounts of water-soluble chloride in thermal insulation products for building and industrial equipment. This standard specifies apparatus and procedures for determining trace amounts of water-soluble chloride in aqueous extracts of products. See this standard for further details.

[0022] The water-leaching chloride content is given as mg of chloride per kg of mineral fiber product. Referring to Table 1 of the EN standard, leaching at 100°C for 0.5 hours is used. Sample preparation is performed according to EN13468 7.2.1. Analysis is performed according to EN13468 7.2.2.2 (ion chromatography).

[0023] The inventors have found that the mineral fiber products of the present invention have a remarkably low water-leaching chloride content. This is true even when unpurified water, such as tap water or process water, is used to prepare the uncured binder composition. As is known to those skilled in the art, unpurified water can contain a considerable amount of chloride.

[0024] While we do not wish to be bound by any particular theory, the inventors believe that the low water-leaching chloride content of the mineral fiber products of the present invention is at least partially based on the capture of chloride ions within the lignosulfonate-lignin-based binder matrix, even when tap water or process water is used to prepare the binder composition. This capture eliminates chloride leaching, preventing the chloride from being utilized for corrosive activity.

[0025] Generally, the uncured binder composition described above is an aqueous binder composition. The water contained in this aqueous binder composition may be purified water, unpurified water, or a combination of purified and unpurified water added.

[0026] In a preferred embodiment, the uncured binder composition is an aqueous binder composition in which at least some or all of the water contained in this aqueous binder composition is unpurified water, and the rest of the water, if present, is purified water. This is surprising, as in typical prior art binders, purified water is usually used to avoid a substantial chloride content. Examples of purified water include osmotic water, deionized water, or distilled water, which are further mentioned below.

[0027] Purified water is generally water that has been mechanically filtered or treated to remove impurities and make it suitable for use. Distilled water is the most common form of purified water, but in recent years, water has been more frequently purified by other processes including capacitive deionization, reverse osmosis, carbon filtration, microfiltration, ultrafiltration, ultraviolet oxidation, or electrodeionization. Purified water used in uncured binder compositions preferably has a chloride content of less than 10 mg / L, preferably less than 5 mg / L.

[0028] Suitable examples of unpurified water include tap water, rainwater, process water, or a combination thereof. The chloride content of tap water and rainwater is generally in the range of 10 to 200 mg / L. The chloride content of process water is generally in the range of 25 to 200 mg / L. It is preferable that the unpurified water used in the uncured binder composition has a chloride content of at least 10 mg / L, for example, in the range of 10 to 200 mg / L.

[0029] The proportion of unpurified water added can range from 0 to 100% by weight, preferably 30 to 100% by weight, and most preferably 50 to 100% by weight, based on the total weight of water contained in the uncured binder composition, with any other proportion being purified water, if present.

[0030] In the manufacturing plant, the binder composition is typically produced in a concentrated form, i.e., with a low water content. After delivery, the concentrated binder composition is diluted to the appropriate viscosity by adding water at the mineral fiber manufacturing site. The diluted binder composition is then brought into contact with the mineral fibers and cured to produce the mineral fiber product. The advantage of the present invention is that a product with a low water-leaching chloride content is achieved even though unpurified water such as tap water, rainwater, or process water can be used to dilute the concentrated binder composition.

[0031] The mineral wool product according to the present invention is • Component (i) in the form of lignosulfonate trinin 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 trinin, • One or more crosslinking agents as components (ii), • Optionally, one or more components in the form of plasticizers (iii) and It includes mineral fibers that have come into contact with a binder resulting from the curing of an aqueous binder composition that does not contain phenol or formaldehyde.

[0032] In particular, according to the first aspect of the present invention, • Component (i) in the form of lignosulfonate trinin 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 trinin, • One or more crosslinking agents as components (ii), • Optionally, one or more components in the form of plasticizers (iii) and A mineral fiber product containing mineral fibers that have come into contact with a binder resulting from the curing of an aqueous binder composition that does not contain phenol and formaldehyde, provided that the aqueous binder composition is • Molecular weight M of 500 or less W epoxy compounds having Mineral fiber products that do not contain crosslinking agents selected from are provided.

[0033] In particular, according to the first aspect of the present invention, • Component (i) in the form of lignosulfonate trinin 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 trinin, • One or more crosslinking agents as components (ii), • Optionally, one or more components in the form of plasticizers (iii) and A mineral fiber product containing mineral fibers that have come into contact with a binder resulting from the curing of an aqueous binder composition that does not contain phenol and formaldehyde, provided that the aqueous binder composition is ·Formula R-[C(O)R1] x A carbonyl compound selected from the aldehyde and carbonyl compounds, wherein in the above formula, R represents a saturated or unsaturated linear, branched, or cyclic hydrocarbon group, a group containing an aromatic nucleus consisting of one or more 5 or 6 carbon atoms, or a group containing an aromatic heterocycle containing one or more 4 or 5 carbon atoms and an oxygen atom, a nitrogen atom, or a sulfur atom, and this R group may contain other functional groups. R1 is a hydrogen atom or C1~C 10 Represents an alkyl group, x is a carbonyl compound in the range of 1 to 10. Mineral fiber products that do not contain crosslinking agents selected from are provided.

[0034] In particular, according to the first aspect of the present invention, • Component (i) in the form of lignosulfonate trinin 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 trinin, • One or more crosslinking agents as components (ii), • Optionally, one or more components in the form of plasticizers (iii) and A mineral fiber product containing mineral fibers that have come into contact with a binder resulting from the curing of an aqueous binder composition that does not contain phenol and formaldehyde, provided that the aqueous binder composition is • Polyamines Mineral fiber products that do not contain crosslinking agents selected from are provided.

[0035] In particular, according to the first aspect of the present invention, • Component (i) in the form of lignosulfonate trinin 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 trinin, • One or more crosslinking agents as components (ii), • Optionally, one or more components in the form of plasticizers (iii) and A mineral fiber product containing mineral fibers that have come into contact with a binder resulting from the curing of an aqueous binder composition that does not contain phenol and formaldehyde, provided that the aqueous binder composition is • Monosaccharides and oligosaccharides Mineral fiber products that do not contain crosslinking agents selected from are provided.

[0036] In one embodiment, the mineral wool product according to the present invention is • Component (i) in the form of lignosulfonate trinin 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 trinin, (ii) A component in the form of one or more crosslinking agents, • β-hydroxyalkylamide crosslinking agents, and / or • Epoxy compounds having a molecular weight greater than 500, for example, epoxidized oils based on fatty acid triglycerides, or one or more flexible oligomers or polymers containing reactive functional groups, for example, carbodiimide groups, for example, anhydride groups, for example, oxazoline groups, for example, amino groups, for example, epoxy groups, for example, low-Tg acrylic polymers, for example, low-Tg vinyl polymers, for example, low-Tg polyethers, and / or • One or more crosslinking agents in the form of polyfunctional carbodiimides, e.g., aliphatic polyfunctional carbodiimides, and / or Primid XL-552 (ii) a component in the form of one or more crosslinking agents selected from, • Optionally, one or more components in the form of plasticizers (iii) and The aqueous binder composition, which does not contain phenol and formaldehyde, contains mineral fibers that have come into contact with the binder resulting from the curing of the aqueous binder composition, provided that the aqueous binder composition is • Molecular weight M of 500 or less Wepoxy compounds having ·Formula R-[C(O)R1] x A carbonyl compound selected from the aldehyde and carbonyl compounds, wherein in the above formula, R represents a saturated or unsaturated linear, branched, or cyclic hydrocarbon group, a group containing an aromatic nucleus consisting of one or more 5 or 6 carbon atoms, or a group containing an aromatic heterocycle containing one or more 4 or 5 carbon atoms and an oxygen atom, a nitrogen atom, or a sulfur atom, and this R group may contain other functional groups. R1 is a hydrogen atom or C1~C 10 Represents an alkyl group, x is a carbonyl compound in the range of 1 to 10. • Polyamines It does not contain any crosslinking agents selected from the above.

[0037] In a preferred embodiment, the binder according to the present invention does not contain formaldehyde.

[0038] For the purposes of this application, the terms "formaldehyde-free" and "formaldehyde-free" refer to a mineral wool product with an emission level of 5 μg / m². 2 Less than / h, preferably 3 μg / m 2 This is defined to characterize mineral wool products with formaldehyde levels below 1 / h. Preferably, the test is carried out in accordance with ISO 16000 for testing aldehyde emissions.

[0039] In a preferred embodiment, the binder does not contain phenol.

[0040] For the purposes of this application, the terms “phenol-free” and “phenol-free” are defined as an aqueous binder composition containing phenol in an amount of 0.25% by weight or less, for example 0.1% by weight or less, for example 0.05% by weight or less, based on the total weight of the aqueous composition having a dry solids binder content of 15% by weight. [ka]

[0041] In one embodiment, the binder composition does not contain added formaldehyde.

[0042] In one embodiment, the binder composition does not contain added phenol.

[0043] For the purposes of this invention, the term "monosaccharides and oligosaccharides" is defined to include monosaccharides and oligosaccharides having 10 or fewer sugar units.

[0044] For the purposes of this invention, the term "sugar" is defined to include monosaccharides and oligosaccharides having 10 or fewer sugar units.

[0045] The uncured binder composition for preparing mineral fiber products according to the present invention comprises one or more lignosulfonates and lignins as component (i).

[0046] Ingredient (i) Component (i) is one or more lignosulfonate lignins, in the form of 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.

[0047] Lignin, cellulose, and hemicellulose are the three main organic compounds in plant cell walls. Lignin can be thought of as an adhesive that holds cellulose fibers together. Lignin contains both hydrophilic and hydrophobic groups. Lignin is the second most abundant natural polymer in the world, second only to cellulose, and is estimated to account for about 20-30% of the total carbon contained in biomass totaling over 1 billion tons.

[0048] The lignosulfonate process introduces a large number of sulfonate groups to make lignin soluble not only in water but also in acidic aqueous solutions. Lignosulfonates contain up to 8% sulfur as sulfonates, while Kraft lignin contains 1-2% sulfur, most of which is bound to the lignin. The molecular weight of lignosulfonates is 15,000-50,000 g / mol. The typical hydrophobic core of lignin, along with numerous ionized sulfonate groups, makes this lignin attractive as a surfactant, and lignin often finds applications in dispersing cement and other materials.

[0049] To produce value-added lignin-based products, lignin must first be separated from biomass, and several methods can be used for this purpose. Kraft and sulfite pulping processes are well-known for their effective separation of lignin from wood and are therefore used worldwide. Kraft lignin is separated from wood with the help of NaOH and Na2S. Lignin from the sulfite pulping process is expressed as lignosulfonate and is produced by using sulfites containing sulfite and / or magnesium, calcium, sodium, or ammonium at various pH levels. Currently, lignosulfonate accounts for 90% of the entire market for commercially available lignin, and the total annual global production of lignosulfonate is approximately 1.8 million tons. Lignosulfonate generally has abundant sulfonic acid groups and therefore contains more sulfur than kraft lignin. Due to the presence of sulfonating groups, lignosulfonate is anionically charged and water-soluble. The molecular weight (Mw) of lignosulfonate can be similar to or greater than that of kraft lignin. Due to its unique properties, lignosulfonates have a wide range of applications, including animal feed, insecticides, surfactants, additives in oil drilling, stabilizers in colloidal suspensions, and plasticizers in concrete admixtures. However, most new pulp mills employ kraft technology for pulp production, and therefore kraft lignin is more readily available for value-added production.

[0050] However, lignosulfonates and Kraft lignin have different properties due to different isolation processes and therefore different functional group distributions. The high level of sulfonic acid groups in lignosulfonates, generally at least one for every four C9 units, makes lignosulfonates strongly charged at all pH levels in water. This abundance of ionizable functional groups can explain most of the differences compared to other industrial lignins. The higher charge density allows for easier water solubility and a higher solids content in solution compared to Kraft lignin. Also for the same reason, lignosulfonates have a lower solution viscosity compared to Kraft lignin at the same solids content, which can make them easier to handle and process. A commonly used model structure of lignosulfonate is shown in Figure 1.

[0051] 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.

[0052] In one embodiment, component (i) is in the form of one or more lignosulfonate lignins having an average carboxylic acid group content of less than 1.8 groups per polymer, e.g., less than 1.4, e.g., less than 1.1, e.g., less than 0.7, e.g., less than 0.4, considering the M_n weight average of component (i).

[0053] In one embodiment, component (i) has a phenolic OH group content of 0.3 to 2.5 mmol / g, for example 0.5 to 2.0 mmol / g, or for example 0.5 to 1.5 mmol / g, based on the dry weight of lignosulfonate lignin.

[0054] In one embodiment, component (i) has an aliphatic OH group content of 1.0 to 8.0 mmol / g, for example 1.5 to 6.0 mmol / g, or for example 2.0 to 5.0 mmol / g, based on the dry weight of lignosulfonate lignin.

[0055] In one embodiment, component (i) comprises ammonium lignosulfonate (ammonium lignosulphonate) and / or calcium lignosulfonate (calcium lignosulphonate) and / or magnesium lignosulfonate (magnesium lignosulphonate), and any combination of any of these.

[0056] In one embodiment, component (i) comprises ammonium lignosulfonate and calcium lignosulfonate, wherein the molar ratio of NH4 + to Ca 2+ is in the range of 5:1 to 1:5, particularly in the range of 3:1 to 1:3.

[0057] For the purposes of the present invention, the terms lignosulfonate and lignosulfonic acid salt encompass sulfonated kraft lignin.

[0058] In one embodiment, component (i) is sulfonated kraft lignin.

[0059] In one embodiment, the aqueous binder composition contains additional sugar in an amount of 0 to 5% by weight, for example less than 5% by weight, for example 0 to 4.9% by weight, for example 0.1 to 4.9% by weight, based on the weight of lignosulfonate and sugar.

[0060] In one embodiment, the aqueous binder composition comprises component (i), i.e., lignosulfonate, in an amount of 50 to 98% by weight, for example 65 to 98% by weight, for example 80 to 98% by weight, based on the total weight of components (i) and (ii).

[0061] In one embodiment, the aqueous solid binder composition comprises component (i), i.e., lignosulfonate, in an amount of 50 to 88% by weight, for example 50 to 87% by weight, for example 65 to 88% by weight, for example 65 to 87% by weight, for example 80 to 88% by weight, for example 80 to 87% by weight, based on the total weight of components (i) and (ii).

[0062] In one embodiment, the aqueous binder composition contains component (i) in an amount of 50 to 98% by weight, for example 65 to 98% by weight, for example 80 to 98% by weight, based on the dry weight of components (i), (ii), and (iii).

[0063] In one embodiment, the aqueous binder composition contains component (i), i.e., lignosulfonate, in an amount of 50 to 88% by weight, for example 50 to 87% by weight, for example 65 to 88% by weight, for example 65 to 87% by weight, for example 80 to 88% by weight, for example 80 to 87% by weight, based on the total weight of components (i), (ii), and (iii).

[0064] For the purposes of the present invention, the lignin functional group content is used as a characterization method. 31 This is determined by using 1P NMR.

[0065] 31 Sample preparation for 1P NMR is performed using 2-chloro-4,4,5,5-tetramethyl-1,3,2-dioxaphosphoran (TMDP) as the phophytylation reagent and cholesterol as the internal standard. Integration follows the work of Granata and Argyropoulos (J.Agric.Food Chem. 43:1538-1544).

[0066] Ingredients (ii) Component (ii) is in the form of one or more crosslinking agents.

[0067] In one embodiment, component (ii) is, a) β-hydroxyalkylamide crosslinking agents and / or oxazoline crosslinking agents, and / or b) A group consisting of polyfunctional organic amines such as alkanolamines, diamines such as hexamethyldiamine, triamines, and / or c) Epoxy compounds having a molecular weight greater than 500, for example, one or more flexible oligomers or polymers containing reactive functional groups, for example, carbodiimide groups, for example, anhydride groups, for example, oxazoline groups, for example, amino groups, for example, epoxy groups, for example, low Tg acrylic polymers, for example, low Tg vinyl polymers, for example, low Tg polyethers, and / or d) One or more crosslinking agents selected from the group consisting of polyethyleneimine, polyvinylamine, and fatty amine, and / or e) One or more crosslinking agents in the form of fatty amides, and / or f) One or more crosslinking agents selected from the group consisting of aromatic aldehydes, e.g., hydroxybenzaldehyde, e.g., aminobenzaldehyde, e.g., hydroxy-methoxybenzaldehyde, and / or from the group consisting of aliphatic aldehydes, e.g., decanal, and / or g) One or more crosslinking agents selected from polyester polyols such as polycaprolactone, and / or h) One or more crosslinking agents selected from the group consisting of starch, modified starch, and CMC, and / or i) One or more crosslinking agents in the form of aliphatic polyfunctional carbodiimides, and / or j) One or more crosslinking agents selected from melamine-based crosslinking agents such as hexakis(methylmethoxy)melamine (HMMM)-based crosslinking agents. It is in the form of one or more crosslinking agents selected from the following.

[0068] In one embodiment, component (ii) comprises one or more crosslinking agents selected from β-hydroxyalkylamide crosslinking agents and / or oxazoline crosslinking agents.

[0069] β-hydroxyalkylamide crosslinkers are curing agents for acid-functional polymers. These β-hydroxyalkylamide crosslinkers provide a hard, durable, corrosion-resistant, and solvent-resistant crosslinked polymer network. It is believed that the β-hydroxyalkylamide crosslinkers cure through esterification reactions, forming multiple ester bonds. The hydroxyl functionality of the β-hydroxyalkylamide crosslinkers should be at least 2 on average, preferably greater than 2, and more preferably 2-4, to obtain an optimal curing response.

[0070] Oxazoline group-containing crosslinking agents are polymers containing one or more oxazoline groups in each molecule, and generally, oxazoline-containing crosslinking agents can be readily obtained by polymerizing oxazoline derivatives. U.S. Patent No. 6,818,699,B2 provides disclosure of such a process.

[0071] In one embodiment, component (ii) is one or more epoxy compounds having a molecular weight greater than 500, for example, epoxidized oils based on fatty acid triglycerides, or one or more flexible oligomers or polymers containing reactive functional groups, for example, 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, low Tg acrylic polymers, for example, low Tg vinyl polymers, for example, low Tg polyethers.

[0072] In one embodiment, component (ii) is one or more crosslinking agents selected from the group consisting of fatty amines.

[0073] In one embodiment, component (ii) is one or more crosslinking agents in the form of fatty amides.

[0074] In one embodiment, component (ii) is one or more crosslinking agents selected from polyester polyols such as polycaprolactone.

[0075] In one embodiment, component (ii) is one or more crosslinking agents selected from the group consisting of starch, modified starch, and CMC.

[0076] In one embodiment, component (ii) is one or more crosslinking agents in the form of polyfunctional carbodiimides, such as aliphatic polyfunctional carbodiimides.

[0077] In one embodiment, component (ii) is one or more crosslinking agents in the form of aziridines such as CX100 and NeoAdd-Pax 521 / 523.

[0078] In one embodiment, component (ii) is one or more crosslinking agents selected from melamine-based crosslinking agents such as hexakis(methylmethoxy)melamine (HMMM)-based crosslinking agents.

[0079] Examples of such compounds include Picassian XL 701, 702, 725 (Stahl Polymers), ZOLDINE® XL-29SE (Angus Chemical Company), CX300 (DSM), and Carbodilite V-02-L2 (Nisshinbo Chemical Co., Ltd.).

[0080] In one embodiment, component (ii) is Primid XL552 having the following structure: [ka]

[0081] Component (ii) may also be a mixture of any of the above compounds.

[0082] In one embodiment, the binder composition according to the present invention comprises component (ii) in an amount of 1 to 50% by weight, for example, 4 to 20% by weight, for example, 6 to 12% by weight, based on the dry weight of component (i).

[0083] In one embodiment, component (ii) is, • β-hydroxyalkylamide crosslinking agents, e.g., N-(2-hydroxyisopropyl)amide crosslinking agents, e.g., N-(2-hydroxyethyl)amide crosslinking agents, e.g., N-(2-hydroxyethyl)adipoamide crosslinking agents, e.g., N,N,N',N'-tetrakis(2-hydroxyethyl)adipoamide, and / or • A group consisting of polyfunctional organic amines such as alkanolamines, diamines such as hexamethyldiamine, and / or • Epoxy compounds having a molecular weight greater than 500, for example, epoxidized oils based on fatty acid triglycerides, or one or more flexible oligomers or polymers containing reactive functional groups, for example, carbodiimide groups, for example, anhydride groups, for example, oxazoline groups, for example, amino groups, for example, epoxy groups, for example, low Tg acrylic polymers, for example, low Tg vinyl polymers, for example, low Tg polyethers, and / or • One or more crosslinking agents in the form of polyfunctional carbodiimides, e.g., aliphatic polyfunctional carbodiimides. It is in the form of one or more crosslinking agents selected from the following.

[0084] In one embodiment, component (ii) is, • β-hydroxyalkylamide crosslinking agents, such as N-(2-hydroxyisopropyl)amide crosslinking agents, such as N-(2-hydroxyethyl)amide crosslinking agents, such as N-(2-hydroxyethyl)adipoamide crosslinking agents, such as N,N,N',N'-tetrakis(2-hydroxyethyl)adipoamide It contains one or more crosslinking agents selected from the following.

[0085] In one embodiment, component (ii) is in an amount of 2 to 90% by weight, for example 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).

[0086] (iii) Components of the binder composition Optionally, and preferably, the solid binder composition may contain component (iii), which is in the form of one or more plasticizers.

[0087] In one embodiment, component (iii) is in the form of one or more plasticizers selected from the group consisting of polyols, for example carbohydrates, hydrides, for example sorbitol, erythritol, glycerol, monoethylene glycol, polyethylene glycol, polyethylene glycol ether, polyether, hydrides, phthalates 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 having free carboxyl groups and / or polyurethane dispersions having free carboxyl groups, polyamides, amides such as carboamide / urea, or mixtures thereof.

[0088] In one embodiment, component (iii) is in the form of one or more plasticizers selected from the group consisting of carbonates (carbonates), such as ethylene carbonate, propylene carbonate, lactones, lactams, lactides, compounds having a structure similar to lignin, such as vanillin, acetosyringone, and solvents used as binders, such as alcohol ethers and polyvinyl alcohols.

[0089] In one embodiment, component (iii) is in the form of one or more unreactive plasticizers selected from the group consisting of polyethylene glycol, polyethylene glycol ether, polyether, hydride sugar, phthalate and / or other ester, and solvents used as a binder, such as alcohol ether, acrylic polymer, and polyvinyl alcohol.

[0090] In one embodiment, component (iii) is one or more reactive plasticizers selected from the group consisting of carbonate esters, such as ethylene carbonate, propylene carbonate, lactones, lactams, lactides, dicarboxylic acids or tricarboxylic acids, such as adipic acid or lactic acid, and / or vanillic acid and / or ferulic acid, polyurethane dispersions, acrylic polymers having free carboxyl groups, and compounds having a structure similar to lignin, such as vanillin and acetosyringone.

[0091] 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 and stearyl alcohol.

[0092] In one embodiment, component (iii) comprises one or more plasticizers selected from the group consisting of polyethylene glycol and polyethylene glycol ethers, and / or one or more plasticizers in the form of polyols, such as 1,1,1-tris(hydroxymethyl)propane and / or triethanolamine.

[0093] Another particular and surprising aspect of the present invention is that the use of plasticizers having boiling points above 100°C, particularly between 140 and 250°C, strongly improves the mechanical properties of the mineral fiber products according to the present invention, despite the fact that these plasticizers may, given their boiling points, at least partially evaporate during the curing of the binder in contact with the mineral fibers.

[0094] In one embodiment, component (iii) comprises one or more plasticizers having a boiling point greater than 100°C, for example, 110 to 380°C, more preferably 120 to 300°C, and more preferably 140 to 250°C.

[0095] The effectiveness of these plasticizers in the binder composition according to the present invention is thought to be related to their effect of increasing the mobility of lignin during the curing process. The increased mobility of lignin during the curing process is thought to promote effective crosslinking.

[0096] In one embodiment, component (iii) comprises one or more polyethylene glycols having an average molecular weight of 150 to 50,000 g / mol, particularly 150 to 4,000 g / mol, more particularly 150 to 1,000 g / mol, preferably 150 to 500 g / mol, and more preferably 200 to 400 g / mol.

[0097] In one embodiment, component (iii) comprises one or more polyethylene glycols having an average molecular weight of 4,000 to 25,000 g / mol, particularly 4,000 to 15,000 g / mol, and more particularly 8,000 to 12,000 g / mol.

[0098] In one embodiment, component (iii) can form a covalent bond with component (i) and / or component (ii) during the curing process. Such a component will not evaporate and will remain as part of the composition, but will be effectively modified so as not to introduce undesirable side effects to the cured product, such as water absorption. Non-limiting examples of such components are caprolactone and acrylic polymers having free carboxyl groups.

[0099] In one embodiment, component (iii) is selected from the group consisting of fatty alcohols, monohydroxy alcohols, such as pentanol and stearyl alcohol.

[0100] In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of alkoxylates, e.g., ethoxylates, e.g., butanol ethoxylate, e.g., butoxytriglycol.

[0101] In one embodiment, component (iii) is selected from one or more propylene glycols.

[0102] In one embodiment, component (iii) is selected from one or more glycol esters.

[0103] In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of adipate (adipate ester), acetate (acetic acid ester), benzoate (benzoic acid ester), cyclobenzoate (cyclobenzoic acid ester), citrate (citric acid ester), stearate (stearate ester), sorbate (sorbate ester), sebacate (sebacate ester), azelate (azelaic acid ester), butyrate (butyrate ester), and valerate (valeric acid ester).

[0104] 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.

[0105] In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of silanols and siloxanes.

[0106] In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of sulfates (sulfuric acid esters) such as alkyl sulfates, sulfonates (sulfonic acid esters) such as alkylaryl sulfonates and alkyl sulfonates, phosphates (phosphate esters) such as tripolyphosphates (tripolyphosphate esters), for example, tributyl phosphate (tributyl phosphate).

[0107] In one embodiment, component (iii) is selected from one or more hydroxy acids.

[0108] In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of monomer amides such as acetamide and benzamide, and fatty acid amides such as tall oil amide.

[0109] In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of quaternary ammonium compounds such as trimethylglycine and distearyldimethylammonium chloride.

[0110] 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, and soybean oil.

[0111] In one embodiment, component (iii) is in the form of tall oil.

[0112] In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of hardened oils (hydrogenated oils) and acetylated oils.

[0113] In one embodiment, component (iii) is selected from one or more fatty acid methyl esters.

[0114] In one embodiment, component (iii) is selected from one or more plasticizers selected from the group consisting of alkyl polyglucosides, gluconamides, aminoglucoseamides, sucrose esters, and sorbitan esters.

[0115] In one embodiment, component (iii) is selected from the group consisting of polyethylene glycol and polyethylene glycol ether.

[0116] In one embodiment, component (iii) is selected from the group consisting of triethanolamine.

[0117] In one embodiment, component (iii) is in the form of one or more plasticizers, which include propylene glycol, phenol derivatives, silanols, siloxanes, hydroxy acids, vegetable oils, polyethylene glycol, polyethylene glycol ethers, and / or polyols such as 1,1,1-tris(hydroxymethyl)propane, triethanolamine, or any mixture thereof.

[0118] Surprisingly, it was found that including a plasticizer in the solid binder composition according to the present invention significantly improves the mechanical properties of the mineral fiber product according to the present invention.

[0119] The term "plasticizer" refers to a substance added to a material to make it softer, more flexible (by lowering the glass transition temperature Tg), and easier to process.

[0120] Component (iii) may also be a mixture of any of the above compounds.

[0121] In one embodiment, component (iii) is present in an amount of 0.5 to 60% by weight, preferably 2.5 to 25% by weight, and more preferably 3 to 15% by weight, based on the dry weight of component (i).

[0122] In one embodiment, component (iii) is present in an amount of 0.5 to 60% by weight, preferably 2.5 to 25% by weight, and more preferably 3 to 15% by weight, based on the dry weight of components (i), (ii), and (iii).

[0123] Mineral fiber products containing mineral fibers in contact with the binder resulting from the curing of a binder composition containing components (i) and (iia). In one embodiment, the present invention is • Component (i) in the form of lignosulfonate trinin 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 trinin, • One or more modifier components (iia) and A mineral fiber product containing mineral fibers that have come into contact with a binder resulting from the curing of a binder composition for mineral fibers containing, preferably, however, the aqueous binder composition is • Molecular weight M of 500 or less W epoxy compounds having It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is ·Formula R-[C(O)R1] x A carbonyl compound selected from the aldehyde and carbonyl compounds, wherein in the above formula, R represents a saturated or unsaturated linear, branched, or cyclic hydrocarbon group, a group containing an aromatic nucleus consisting of one or more five or six carbon atoms, or a group containing an aromatic heterocycle containing one or more four or five carbon atoms and an oxygen atom, a nitrogen atom, or a sulfur atom. This R group may contain other functional groups. R1 is a hydrogen atom or C1~C 10 Represents an alkyl group, x is a carbonyl compound in the range of 1 to 10. It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is • Polyamines It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is • Monosaccharides and oligosaccharides It is intended for mineral fiber products that do not contain crosslinking agents selected from the available options.

[0124] The present inventors have found that excellent binder properties can also be achieved by a two-component system comprising 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 (i), one or more modifiers (iia), and optionally any of the other components listed above and below.

[0125] In one embodiment, component (iia) is a modifier in the form of one or more compounds selected from the group consisting of an epoxy compound having a molecular weight greater than 500, such as an epoxidized oil based on fatty acid triglycerides, or one or more flexible oligomers or polymers 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, such as a β-hydroxyalkylamide group, such as a low-Tg acrylic polymer, such as a low-Tg vinyl polymer, such as a low-Tg polyether.

[0126] In one embodiment, component (iia) is one or more modifiers selected from the group consisting of polyethyleneimines, polyvinylamines, and fatty amines.

[0127] In one embodiment, component (iia) is one or more modifiers selected from polyfunctional carbodiimides, such as aliphatic polyfunctional carbodiimides.

[0128] Component (iia) may also be a mixture of any of the above compounds.

[0129] While we do not wish to be bound by any particular theory, we believe that the excellent binder properties achieved by the mineral fiber binder composition comprising components (i) and (iia) and any further optional components are at least partially attributable to the effect that the modifier used as component (iia) performs at least partially the functions of a plasticizer and a crosslinking agent.

[0130] In one embodiment, the binder composition contains component (iia) in an amount of 1 to 40% by weight, for example, 4 to 20% by weight, for example, 6 to 12% by weight, based on the dry weight of component (i).

[0131] Further ingredients In some embodiments, the mineral fiber product according to the present invention comprises mineral fibers in contact with a binder composition resulting from the curing of a binder containing further components.

[0132] 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 salt thereof, such as sodium hypophosphite and / or ammonium salts, such as sulfuric acid, sulfamic acid, nitric acid, boric acid, hypophosphorous acid, and / or ammonium salts of 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.

[0133] In one embodiment, the binder composition is a Lewis acid capable of accepting electron pairs from a donor compound to form a Lewis adduct, such as ZnCl2, Mg(ClO4)2, Sn[N(SO2-n-C8F 17 )2]4, comprising a catalyst selected from.

[0134] In one embodiment, the binder composition comprises a catalyst selected from metal chlorides, such as KCl, MgCl2, ZnCl2, FeCl3, and SnCl2, or adducts thereof, such as AlCl3 adducts, such as BF3 adducts, such as BF3 ethylamine complexes.

[0135] In one embodiment, the binder composition includes a catalyst selected from organometallic compounds such as titanate-based catalysts and tin-based catalysts.

[0136] In one embodiment, the binder composition includes a catalyst selected from a chelating agent, such as a transition metal, such as iron ions, chromium ions, manganese ions, or copper ions, and / or a peroxide, such as an organic peroxide, such as a dicumyl peroxide.

[0137] In one embodiment, the binder composition according to the present invention comprises a catalyst selected from phosphites (phosphorous esters), such as alkyl phosphites, such as aryl phosphites, and such as triphenyl phosphites (triphenyl phosphorous esters).

[0138] 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.

[0139] In one embodiment, the binder composition further comprises (iv) a further component in the form of one or more silanes.

[0140] In one embodiment, the binder composition comprises one or more coupling agents, for example, a further component (iv) in the form of an organically functionalized silane.

[0141] In one embodiment, component (iv) is selected from the group consisting of organic functionalized 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.

[0142] In one embodiment, the binder composition further comprises component (v) in the form of one or more components selected from the group consisting of bases, such as ammonia, such as alkali metal hydroxides, such as KOH, such alkali metal hydroxides, such as alkaline earth alkali metal hydroxides, such as Ca(OH)2, such as Mg(OH)2, such as amines, or salts of any of these.

[0143] In one embodiment, the binder composition further comprises a further component in the form of urea in an amount of 5 to 40% by weight, for example, 10 to 30% by weight, or 15 to 25% by weight, based particularly on the dry weight of component (i).

[0144] In one embodiment, the binder composition further comprises one or more carbohydrate components selected from the group consisting of sucrose, reducing sugars, particularly dextrose, polycarbohydrates, and mixtures thereof, preferably dextrin and maltodextrin, more preferably glucose syrup, more preferably glucose syrup having a dextrose equivalent value of DE=30 to less than 100, for example DE=60 to less than 100, for example DE=60 to 99, for example DE=85 to 99, for example DE=95 to 99.

[0145] In one embodiment, the binder composition further comprises an amount of 5 to 50% by weight, for example less than 5 to 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), in the form of one or more carbohydrates selected from the group consisting of sucrose and reducing sugars.

[0146] In one embodiment, the mineral fiber product according to the present invention comprises mineral fibers in contact with a binder composition comprising one or more components in the form of silicone resins.

[0147] In one embodiment, the binder composition according to the present invention comprises a further component (vi) in the form of one or more reactive or non-reactive silicones.

[0148] In one embodiment, component (vi) is selected from the group consisting of silicones comprising a main chain of organosiloxane residues, particularly diphenylsiloxane residues, alkylsiloxane residues, preferably dimethylsiloxane residues, having at least one hydroxyl, carboxyl, anhydride, amine, epoxy, or vinyl functional group that can react with at least one of the components of the binder composition, and is preferably present in an amount of 0.025 to 15% by weight, preferably 0.1 to 10% by weight, and more preferably 0.3 to 8% by weight, based on the binder solids content.

[0149] In one embodiment, the mineral fiber product according to the present invention comprises mineral fibers in contact with a binder composition comprising a further component in the form of one or more mineral oils.

[0150] In the context of the present invention, a binder composition having a sugar content of 50% by weight or more based on the total dry weight of the binder components is considered a sugar-based binder. In the context of the present invention, a binder composition having a sugar content of less than 50% by weight based on the total dry weight of the binder components is considered a non-sugar-based binder.

[0151] In one embodiment, the binder composition further comprises a further component in the form of one or more surfactants, such as nonionic and / or ionic emulsifiers, such as polyoxyethylene (4) lauryl ether, such as soy lecithin, or such as sodium dodecyl sulfate.

[0152] The use of lignin-based sulfonation products in binders can lead to increased hydrophilicity in some binders and final products, which means that one or more hydrophobic agents, such as one or more mineral oils, one or more silicone oils, or one or more silicone resins, should be added.

[0153] In one embodiment, the aqueous binder composition is essentially (i) One or more forms of lignin selected from the group of 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 / or • One or more crosslinking agents as components (ii) • One or more plasticizer components (iii) • One or more coupling agents, for example, components in the form of organically functional silanes (iv) • Optionally, one or more compounds selected from the group of bases, e.g., ammonia, e.g., alkali metal hydroxides, e.g., KOH, e.g., alkaline earth metal hydroxides, e.g., Ca(OH)2, e.g., Mg(OH)2, e.g., amines, or salts of any of these, as components. • Optionally, the component in the form of urea, • Optionally, a component in the form of a more reactive or less reactive silicone. Optional: hydrocarbon oils, • Optionally, one or more surfactants, ·water The aqueous binder composition consists of, but preferably, however, the aqueous binder composition is • Molecular weight M of 500 or less W epoxy compounds having It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is ·Formula R-[C(O)R1] x A carbonyl compound selected from the aldehyde and carbonyl compounds, wherein in the above formula, R represents a saturated or unsaturated linear, branched, or cyclic hydrocarbon group, a group containing an aromatic nucleus consisting of one or more five or six carbon atoms, or a group containing an aromatic heterocycle containing one or more four or five carbon atoms and an oxygen atom, a nitrogen atom, or a sulfur atom. This R group may contain other functional groups. R1 is a hydrogen atom or C1~C 10 Represents an alkyl group, x is a carbonyl compound in the range of 1 to 10. It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is • Polyamines It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is • Monosaccharides and oligosaccharides It does not contain any crosslinking agents selected from the above.

[0154] In one embodiment, the aqueous binder composition is essentially • A component (i) of one or more forms of lignin selected from the group of 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, • One or more crosslinking agents as components (ii), • One or more components in the form of plasticizers (iii), • One or more coupling agents, for example, a component in the form of an organically functional silane (iv), • Optionally, one or more compounds selected from a group of bases, such as ammonia, alkali metal hydroxides, such as KOH, alkaline earth metal hydroxides, such as Ca(OH)2, such as Mg(OH)2, such as amines, or salts of any of these, • Optionally, the components in the form of urea, • Optionally, a component in the form of a more reactive or less reactive silicone, Optionally, hydrocarbon oils and • Optionally, one or more surfactants, • Water and The aqueous binder composition consists of, but preferably, however, the aqueous binder composition is • Molecular weight M of 500 or less W epoxy compounds having It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is ·Formula R-[C(O)R1] x A carbonyl compound selected from the aldehyde and carbonyl compounds, wherein in the above formula, R represents a saturated or unsaturated linear, branched, or cyclic hydrocarbon group, a group containing an aromatic nucleus consisting of one or more five or six carbon atoms, or a group containing an aromatic heterocycle containing one or more four or five carbon atoms and an oxygen atom, a nitrogen atom, or a sulfur atom. This R group may contain other functional groups. R1 is a hydrogen atom or C1~C 10 Represents an alkyl group, x is a carbonyl compound in the range of 1 to 10. It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is • Polyamines It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is • Monosaccharides and oligosaccharides It does not contain any crosslinking agents selected from the above.

[0155] In one embodiment, the aqueous binder composition according to the present invention is essentially • One or more lignosulfonate lignins, which are components in the form of lignosulfonate lignin having a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignin, and / or • One or more crosslinking agents as components (ii) • One or more coupling agents, for example, components in the form of organically functional silanes (iv) Optionally, one or more compounds selected from ammonia, amines, or salts thereof, as components. • Optionally, the component in the form of urea, • Optionally, a component in the form of a more reactive or less reactive silicone. Optional: hydrocarbon oils, • Optional selection of one or more surfactants The aqueous binder composition consists of, but preferably, however, the aqueous binder composition is • Molecular weight M of 500 or less W epoxy compounds having It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is ·Formula R-[C(O)R1] x A carbonyl compound selected from the aldehyde and carbonyl compounds, wherein in the above formula, R represents a saturated or unsaturated linear, branched, or cyclic hydrocarbon group, a group containing an aromatic nucleus consisting of one or more five or six carbon atoms, or a group containing an aromatic heterocycle containing one or more four or five carbon atoms and an oxygen atom, a nitrogen atom, or a sulfur atom. This R group may contain other functional groups. R1 is a hydrogen atom or C1~C 10 Represents an alkyl group, x is a carbonyl compound in the range of 1 to 10. It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is • Polyamines It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is • Monosaccharides and oligosaccharides It does not contain any crosslinking agents selected from the above.

[0156] In one embodiment, the aqueous binder composition according to the present invention is essentially • Component (i) is a lignosulfonate lignin of one or more types, having a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignin. • One or more crosslinking agents as components (ii), • One or more coupling agents, for example, a component in the form of an organically functional silane (iv), Optionally, one or more compounds selected from the group consisting of ammonia, amines, or salts thereof, • Optionally, the components in the form of urea, • Optionally, a component in the form of a more reactive or less reactive silicone, Optionally, hydrocarbon oils and • Optionally, one or more surfactants The aqueous binder composition consists of, but preferably, however, the aqueous binder composition is • Molecular weight M of 500 or less W epoxy compounds having It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is ·Formula R-[C(O)R1] x A carbonyl compound selected from the aldehyde and carbonyl compounds, wherein in the above formula, R represents a saturated or unsaturated linear, branched, or cyclic hydrocarbon group, a group containing an aromatic nucleus consisting of one or more five or six carbon atoms, or a group containing an aromatic heterocycle containing one or more four or five carbon atoms and an oxygen atom, a nitrogen atom, or a sulfur atom. This R group may contain other functional groups. R1 is a hydrogen atom or C1~C 10 Represents an alkyl group, x is a carbonyl compound in the range of 1 to 10. It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is • Polyamines It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is • Monosaccharides and oligosaccharides It does not contain any crosslinking agents selected from the above.

[0157] The inventors have surprisingly found that mineral fiber products containing mineral fibers that come into contact with the binder during the curing of the aqueous binder composition described above exhibit extremely high stability both when newly manufactured and after aging conditions.

[0158] Furthermore, the inventors have found that even higher product stability can be obtained by using a curing temperature exceeding 230°C.

[0159] In one embodiment, the present invention is therefore directed to mineral fiber products containing mineral fibers in contact with a binder resulting from the curing of an aqueous binder composition as described above, in which a curing temperature of 230°C or higher is used.

[0160] The inventors have further discovered that the stability of the mineral fiber product can be further enhanced by the following means. • Lower line capacity, meaning longer curing time. • Addition of silicone resin, • Addition of large amounts of crosslinking agents, • Addition of a combination of two or more different crosslinking agents. • Addition of small amounts of cationic species, such as polyvalent metal ions, such as calcium, and / or organic cationic species, such as amines, and / or organically modified inorganic compounds, such as amine-modified montmorillonite clay.

[0161] Mineral fiber products containing mineral fibers in contact with the binder resulting from the curing of a binder composition containing components (i) and (iia). In one embodiment, the present invention is • Component (i) in the form of lignosulfonate trinin 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 trinin, • One or more modifier components (iia) and A mineral fiber product containing mineral fibers that have come into contact with a binder resulting from the curing of a binder composition for mineral fibers containing, preferably, however, the aqueous binder composition is • Molecular weight M of 500 or less W epoxy compounds having It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is ·Formula R-[C(O)R1] xA carbonyl compound selected from the aldehyde and carbonyl compounds, wherein in the above formula, R represents a saturated or unsaturated linear, branched, or cyclic hydrocarbon group, a group containing an aromatic nucleus consisting of one or more five or six carbon atoms, or a group containing an aromatic heterocycle containing one or more four or five carbon atoms and an oxygen atom, a nitrogen atom, or a sulfur atom. This R group may contain other functional groups. R1 is a hydrogen atom or C1~C 10 Represents an alkyl group, x is a carbonyl compound in the range of 1 to 10. It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is • Polyamines It does not contain a crosslinking agent selected from and / or However, the aqueous binder composition is • Monosaccharides and oligosaccharides It is intended for mineral fiber products that do not contain crosslinking agents selected from the available options.

[0162] The present inventors have found that excellent binder properties can also be achieved by a two-component system comprising 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 (i), one or more modifiers (iia), and optionally any of the other components listed above and below.

[0163] In one embodiment, component (iia) is a modifier in the form of one or more compounds selected from the group consisting of an epoxy compound having a molecular weight greater than 500, such as an epoxidized oil based on fatty acid triglycerides, or one or more flexible oligomers or polymers 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, such as a β-hydroxyalkylamide group, such as a low-Tg acrylic polymer, such as a low-Tg vinyl polymer, such as a low-Tg polyether.

[0164] In one embodiment, component (iia) is one or more modifiers selected from the group consisting of polyethyleneimines, polyvinylamines, and fatty amines.

[0165] In one embodiment, component (iia) is one or more modifiers selected from polyfunctional carbodiimides, such as aliphatic polyfunctional carbodiimides.

[0166] Component (iia) may also be a mixture of any of the above compounds.

[0167] While we do not wish to be bound by any particular theory, the inventors believe that the excellent binder properties achieved by the mineral fiber binder composition comprising components (i) and (iia) and any further optional components are at least partially attributable to the effect that the modifier used as component (iia) performs at least partially the functions of a plasticizer and a crosslinking agent.

[0168] In one embodiment, the inda composition contains component (iia) in an amount of 1 to 40% by weight, for example, 4 to 20% by weight, for example, 6 to 12% by weight, based on the dry weight of component (i).

[0169] Manufacturing methods for mineral fiber products The mineral fiber product of the present invention can be prepared by a conventional method for manufacturing mineral fiber products, which involves bonding mineral fibers using the above-mentioned binder composition. Accordingly, the mineral fiber product of the present invention is preferably prepared by a method that includes the step of contacting mineral fibers with an uncured, preferably aqueous, binder composition containing one or more lignosulfonates and lignins.

[0170] Preferably, the lignosulfonate lignin has a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignin.

[0171] In particular, the present invention relates to a method for producing a mineral fiber product comprising mineral fibers bound together by a cured binder composition, wherein the uncured binder composition comprises one or more lignosulfonates and lignins, and the mineral fiber product optionally has a water-leaching chloride content of less than 10 mg / kg in accordance with EN13468:2001, and the method is a) A step of providing an uncured aqueous binder composition containing one or more lignosulfonates and water, b) A step of bringing mineral fibers into contact with the above-mentioned uncured aqueous binder composition, c) A step of curing the above binder composition in contact with mineral fibers. The uncured aqueous binder composition contains at least a portion or all of the water which is added unpurified water, which is preferably selected from tap water, rainwater, process water, or a combination thereof.

[0172] Preferably, the lignosulfonate lignin has a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignin.

[0173] In a preferred embodiment of the method of the present invention, the proportion of unpurified water added is in the range of 30 to 100% by weight, more preferably 50 to 100% by weight, based on the total weight of water contained in the uncured binder composition.

[0174] In a more preferred embodiment of the method of the present invention, the water content in the uncured aqueous binder composition is in the range of 40 to 90% by weight, preferably 60 to 85% by weight, based on the total weight of the uncured aqueous binder composition.

[0175] The mineral fiber product obtained by the method according to the present invention may have all the features described herein for the mineral fiber product of the present invention, and therefore refer to them.

[0176] In a preferred embodiment, the uncured aqueous binder composition is • One or more components in the form of lignosulfonate lignin (i), • One or more crosslinking agents as components (ii), • Optionally, one or more components in the form of plasticizers (iii) and Includes.

[0177] Preferably, the lignosulfonate lignin has a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignin.

[0178] As described above, in a preferred embodiment, the uncured binder composition for use is prepared by diluting the concentrated binder composition by adding unpurified water.

[0179] hardening The uncured binder composition in a mineral fiber product precursor such as a web, in which the mineral fibers are in contact with the binder composition, is cured by chemical and / or physical reactions of the binder components.

[0180] In one embodiment, curing is performed in a curing apparatus.

[0181] In one embodiment, curing is carried out at a temperature of 100-300°C, for example 170-270°C, for example 180-250°C, for example 190-230°C.

[0182] In one embodiment, curing is carried out in a conventional curing oven for mineral wool production operating at a temperature of 150-300°C, for example 170-270°C, for example 180-250°C, for example 190-230°C.

[0183] In one embodiment, curing takes place over a period of time of 30 seconds to 20 minutes, for example, 1 to 15 minutes, for example, 2 to 10 minutes.

[0184] In a typical embodiment, curing is carried out at a temperature of 150-250°C for 30 seconds to 20 minutes.

[0185] 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, which, in the case of chemical reactions, typically increase the molecular weight of the compounds in the binder composition, thereby increasing the viscosity of the binder composition, usually until the binder composition reaches a solid state.

[0186] In one embodiment, the curing process includes pressure drying. This pressure may be applied by blowing air or gas through / on the mixture of mineral fibers and binder.

[0187] Mineral fiber products according to the present invention The present invention is directed to mineral fiber products that include mineral fibers in contact with the cured binder composition described above, that is, mineral fibers in contact with a cured binder resulting from the curing of the binder composition described above, preferably an aqueous binder composition.

[0188] The mineral fibers used may be any of the following: artificial glass fibers (MMVF), glass fibers, ceramic fibers, basalt fibers, slag fibers, rock fibers, stone fibers, etc. These fibers may exist as wool products, such as stone wool products. In preferred embodiments, the mineral fibers are stone fibers or stone wool, respectively.

[0189] Fiber / Melted Composition Man-made vitreous fibers (MMVF) can have any suitable oxide composition. The fibers may be glass fibers, ceramic fibers, basalt fibers, slag fibers, or rock fibers or stone fibers. The fibers are preferably of the type generally known as rock fibers, stone fibers or slag fibers, and most preferably stone fibers.

[0190] Stone fibers usually comprise the following oxides in weight percent. SiO₂: 30 to 51 Al₂O₃: 12 to 30 CaO: 8 to 30 MgO: 2 to 25 FeO (including Fe₂O₃): 2 to 15 Na₂O+K₂O: 10 or less CaO+MgO: 10 to 30

[0191] In a preferred embodiment, the MMVF has the following element levels, calculated as oxides in weight percent. SiO₂: at least 30, 32, 35 or 37; 51, 48, 45 or 43 or less Al₂O₃: at least 12, 16 or 17; 30, 27 or 25 or less CaO: at least 8 or 10; 30, 25 or 20 or less MgO: at least 2 or 5; 25, 20 or 15 or less FeO (including Fe₂O₃): at least 4 or 5; 15, 12 or 10 or less FeO+MgO: at least 10, 12 or 15; 30, 25 or 20 or less Na₂O+K₂O: zero or at least 1; 10 or less CaO+MgO: at least 10 or 15; 30 or 25 or less TiO₂: zero or at least 1; 6, 4 or 2 or less TiO₂+FeO: at least 4 or 6; 18 or 12 or less B₂O₃: zero or at least 1; 5 or 3 or less P₂O₅: zero or at least 1; 8 or 5 or less Others: zero or at least 1; 8 or less or 5 or less

[0192] The MMVF produced by the method of the present invention preferably has the following composition in weight percent. SiO2 35~50 Al2O3 12~30 up to 2 TiO2 Fe2O3 3~12 CaO 5~30 up to 15 MgO Na2O 0~15 K2O 0~15 up to 3 P2O5 up to 3 MnO up to 3 B2O3

[0193] Another preferred composition for MMVF is as follows in weight percent: SiO2 39~55%, preferably 39~52% Al2O3 16~27%, preferably 16~26% CaO 6~20%, preferably 8~18% MgO 1~5%, preferably 1~4.9% Na2O 0~15%, preferably 2~12% K2O 0~15%, preferably 2~12% R2O (Na2O+K2O) 10~14.7%, preferably 10~13.5% P2O5 0~3%, 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%

[0194] Glass fibers usually contain the following oxides in weight percent. SiO2: 50~70 Al2O3: 10~30 CaO: 27 or less MgO: 12 or less

[0195] Glass fibers may also contain the following oxides by weight percentage: Na2O + K2O: 8-18, especially more than CaO + MgO. B2O3: 3-12

[0196] Several glass fiber compositions, Al2O3: Less than 2% It can contain.

[0197] In a preferred embodiment, the mineral fiber is a hydrophobically treated mineral fiber, preferably a hydrophobically treated stone wool. Hydrophobic treatment is a common treatment and may be carried out, for example, by adding at least one hydrophobic agent such as mineral oil, siloxane, or reactive or non-reactive silicone during the mineral fiber manufacturing process to form a hydrophobic film around the fiber. Therefore, the hydrophobically treated mineral fiber preferably has a hydrophobic film on its surface.

[0198] A suitable fiber formation method and subsequent manufacturing process for producing mineral fiber products are conventional in the art. Generally, the binder is sprayed onto airborne mineral fibers immediately after fibrillation of the mineral molten material. The uncured, preferably aqueous, binder composition is typically applied (coated) in an amount of 0.1 to 18% by weight, preferably 0.2 to 8% by weight, on a dry basis, to the bound mineral fiber product.

[0199] Spray-coated mineral fiber webs are generally cured in a curing oven by a hot airflow. The hot airflow may be introduced into the mineral fiber web from below, above, or alternating directions in separate zones along the length of the curing oven.

[0200] Typically, curing ovens are operated at temperatures ranging from approximately 150°C to 300°C, for example, 170-270°C, 180-250°C, or 190-230°C. Generally, the residence time in the curing oven is 30 seconds to 20 minutes, for example, 1-15 minutes, or 2-10 minutes, depending on the product density.

[0201] In an exemplary embodiment, the mineral fiber product according to the present invention is cured at a temperature of 150°C to 250°C for a period of 30 seconds to 20 minutes.

[0202] If desired, the mineral fiber web may be subjected to a forming process before curing. The bonded mineral fiber product exiting the curing oven may be cut into a desired shape, for example in the form of a batt.

[0203] In a preferred embodiment, the mineral fiber product according to the present invention is a heat insulating product and / or a sound insulating product, preferably a heat insulating product.

[0204] The mineral fiber product may have the form of a preformed pipe section, a wired mat or a slab.

[0205] The preformed pipe section may be in the form of a hollow (circular) cylinder or a part thereof. The dimensions of the preformed pipe section are adapted to fit the pipe to be insulated. The wired mesh-reinforced blanket is a lightly bonded mineral fiber mat stitched onto a galvanized wire mesh using galvanized wire.

[0206] In a preferred embodiment, the mineral fiber product according to the present invention is a heat insulating material and / or sound insulating material for pipes, storage tanks, boilers, vessels or columns, preferably for pipes.

[0207] In a preferred embodiment, the mineral fiber product according to the present invention has a thickness in the range of 20 mm to 500 mm, or 25 mm to 300 mm, preferably 30 mm to 300 mm, for example 50 mm to 150 mm, and generally, the mineral fiber product is in the form of a sheet.

[0208] The mineral fiber product according to the present invention generally has a density of 6 to 250 kg / m 3 , preferably 20 to 200 kg / m 3It has a density within the range of [value missing]. The mineral fiber product generally has a loss on ignition (LOI) in the range of 0.3 to 18.0%, preferably 0.5 to 8.0%.

[0209] Use of mineral fiber products according to the present invention The use of mineral fiber products according to the present invention is directed towards use as thermal insulation and / or soundproofing materials, particularly as non-corrosive thermal insulation and / or soundproofing materials.

[0210] In this specification, the term “non-corrosive” means that the thermal insulation and / or soundproofing material does not contribute to increased corrosion. “Non-corrosive” does not imply that corrosion may not occur, in which case the corrosion is caused by factors other than the thermal insulation and / or soundproofing material itself.

[0211] Accordingly, the present invention relates to the use of mineral fiber products comprising mineral fibers bound by a cured binder composition as thermal and / or soundproofing materials, particularly non-corrosive thermal and / or soundproofing materials, wherein the uncured binder composition comprises one or more lignosulfonates and lignins. Generally, the mineral fiber products preferably have a water-leaching chloride content of less than 10 mg / kg in accordance with EN13468:2001.

[0212] Preferably, the lignosulfonate lignin has a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignin.

[0213] In preferred embodiments of use according to the present invention, mineral fiber products are used as thermal insulation and / or soundproofing materials, particularly non-corrosive thermal insulation and / or soundproofing materials, for objects selected from pipes, storage tanks, boilers, containers, or columns, preferably pipes. Pipes or piping also include exhaust ducts.

[0214] In a preferred embodiment of use according to the present invention, mineral fiber products are used as thermal and / or soundproofing materials for objects made of metal, which are generally hollow objects, examples of which are shown above. The metal is preferably selected from copper or steel, with steel being preferred. The steel is preferably carbon steel, stainless steel, austenitic stainless steel, non-alloy steel, or low-alloy steel. In a particularly preferred embodiment, the object is a steel pipe.

[0215] In a preferred embodiment of use according to the present invention, use is preferably in the range of -20°C to 320°C, more preferably 0°C to 200°C, for example, 50°C to 175°C. Temperature refers to the temperature of the object insulated by the mineral fiber product, i.e., the operating temperature. Operation may be continuous or periodic with respect to temperature. In the case of periodic operation, the above temperature range generally refers to the maximum operating temperature.

[0216] Objects covered with mineral fiber products as thermal and / or soundproofing materials, particularly non-corrosive thermal and / or soundproofing materials, generally contain a medium which may be selected from gases, vapors, or fluids. Mineral fiber products for use according to the present invention may have all the features described above for the mineral fiber products of the present invention, and therefore refer to them.

[0217] Hollow object having thermal insulation and / or soundproofing material according to the present invention The present invention also relates to a hollow object covered with a mineral fiber product as a thermal and / or soundproofing material, wherein the mineral fiber product comprises mineral fibers bound together by a cured binder composition, and the uncured binder composition comprises one or more lignosulfonates and lignins.

[0218] Preferably, the lignosulfonate lignin has a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignin.

[0219] The above mineral fiber product preferably has a water-leaching chloride content of less than 10 mg / kg in accordance with EN13468:2001.

[0220] In a preferred embodiment, the hollow object is selected from a pipe, storage tank, boiler, container, or column, preferably a pipe. The pipe or piping also includes exhaust ducts.

[0221] In a preferred embodiment, the hollow object is made of metal. This metal is preferably selected from copper or steel, with steel being preferred. The steel is preferably carbon steel, stainless steel, austenitic stainless steel, non-alloy steel, or low-alloy steel. In a particularly preferred embodiment, the object is a steel pipe.

[0222] A mineral fiber product covering a hollow object according to the present invention may have all the features described above for the mineral fiber product of the present invention, and therefore refer to them. [Examples]

[0223] In the following examples, several binders that fall under the definition of the present invention were prepared and compared with binders according to the prior art.

[0224] Lignosulfonates were supplied by Borregaard, Norway and LignoTech, Florida, as liquids with approximately 50% solids content. Primid XL552 was supplied by EMS-CHEMIE AG. PEG200 was supplied by Sigma-Aldrich and used as is, assumed to be anhydrous for simplicity. 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 supplied form.

[0225] The following characteristics were measured for the binder according to the present invention and the binder according to the prior art.

[0226] Determination of water-leaching chloride content in mineral fiber products The water-leaching chloride content of mineral fiber products is measured according to EN13468:2001. This standard specifies the apparatus and procedures for determining trace amounts of water-soluble chloride in aqueous extracts of products. Please refer to this standard. The water-leaching chloride content is given in mg of chloride per kg of mineral fiber product.

[0227] Determination of Loss on Ignition (LOI) for Mineral Fiber Products The amount of organic material (loss on ignition) is determined as the weight loss of the sample obtained by the burning (combustion removal) of the organic material. This is done as specified in EN13820. The binder content is denoted as the LOI. The binder includes oil and other binder additives, if present.

[0228] Determination of binder dry solids The contents of the binder after hardening are called "binder solids."

[0229] Disk-shaped stone wool samples (5 cm in diameter; 1 cm in height) were cut from the stone wool and heat-treated at 580°C for at least 30 minutes to remove all organic matter. The solid content of the binder mixture was measured by distributing a sample of the binder mixture (approximately 2 g) onto the heat-treated stone wool discs in a tin foil container. The weight of the tin foil containers containing the stone wool discs was weighed before and immediately after the addition of the binder mixture. Two stone wool discs were prepared by filling the tin foil containers with such binder mixtures, and then heated at 200°C for 1 hour. After cooling and storage at room temperature for 10 minutes, the samples were weighed and the binder solid content was calculated as the average of the two results.

[0230] Unless otherwise specified, the following reagents were used as they were obtained. PEG200: Supplied by Sigma-Aldrich, and assumed to be anhydrous for simplicity, was used as is. Primid XL552: Hydroxyalkylamide crosslinking agent supplied by EMS-CHEMIE AG

[0231] Binder example, reference binder A3 (phenol-formaldehyde resin modified with urea and dextrose, PUF-resol) This binder is urea-modified phenol-formaldehyde resin, PUF-resol.

[0232] The phenol-formaldehyde resin is prepared by reacting 606 g of a 37% formaldehyde aqueous solution and 189 g of phenol in the presence of 25.5 g of a 46% potassium hydroxide aqueous solution at a heating rate of approximately 1°C per minute, reaching a reaction temperature of 84°C. This reaction is continued at 84°C until the resin's acid resistance reaches 4 and most of the phenol is converted. Then, 241 g of urea is added, and the mixture is cooled.

[0233] 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 criteria in binder manufacturing, and an acid tolerance of less than 4 indicates the end of the binder reaction.

[0234] To measure AT, prepare a titrant by diluting 2.5 ml of concentrated sulfuric acid (>99%) with 1 L of deionized water. Then, titrate 5 mL of the binder to be examined with this titrant at room temperature, keeping the binder moving by manual shaking. If preferred, use a magnetic stirrer and magnetic stirring rod. Continue titration until a slight cloudiness appears on the binder that does not disappear when the binder is shaken.

[0235] Acid resistance (AT) is calculated by dividing the amount of acid (mL) used in the titration by the amount of sample (mL). AT = (Titration volume used (mL)) / (Sample volume (mL))

[0236] Using the obtained urea-modified phenol-formaldehyde resin, a binder is prepared by adding 25% aqueous ammonia (90 mL) and ammonium sulfate (13.2 g), followed by the addition of water (1.30 kg).

[0237] To the above mixture, 18% dextrose (127.5 g) was added based on the dry matter of the binder and dextrose. Then, the binder solids content was measured as described above, and this mixture was diluted with the required amount of water and silane (15% binder solids solution, 0.5% silane of the binder solids) for the manufacture of an insulating (thermal) product.

[0238] The diluent used in reference binder A3 was process water.

[0239] Binder examples A1 and A2 The binder was prepared as described in Example A3, except that dextrose was not added. Process water was used for Binder Example A1, and leachate was used for Binder Example A2.

[0240] Binder examples, reference binders B1 and B2 A mixture of 75.1% aqueous glucose syrup (19.98 kg; therefore efficiently equivalent to 15.0 kg of glucose syrup), 50% hypophosphorous acid aqueous solution (0.60 kg; therefore efficiently equivalent to 0.30 kg, 4.55 mol of 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. Then, 28% aqueous ammonia (0.80 kg; therefore efficiently equivalent to 0.22 kg, 13.15 mol of ammonia) was added dropwise until the pH reached 7.9.

[0241] Next, the binder solids content was measured (21.2%). For the study of mechanical strength (15% binder solids solution, 0.5% silane of the binder solids), the above binder mixture was diluted with water (0.403 kg / kg binder mixture) and a 10% silane aqueous solution (0.011 kg / kg binder mixture, Momentive VS-142). The final binder mixture had a pH of 7.9 and was used in the manufacture of insulating products.

[0242] Rainwater was used for binder B1, and process water was used for binder B2.

[0243] Examples 1, 2 and 3 - Mineral wool products according to the present invention The stone wool products according to Examples 1, 2, and 3 were manufactured using the following binders.

[0244] Example 1 1163.0 kg of ammonium lignosulfonate was placed in a mixing vessel, to which 14 L of NH4OH (24.7%) was added and stirred. Then, 240 kg of Primid XL552 solution (a pre-prepared 31 wt% aqueous solution) and 68 kg of PEG200 (100% solids) were added and mixed, followed by the addition of 21 kg of silane (Momentive VS-142 40% active, 10% aqueous solution).

[0245] Example 2 1910.0 kg of ammonium lignosulfonate was placed in a mixing vessel, to which 22 L of NH4OH (24.7%) was added and stirred. Then, 395 kg of Primid XL552 solution (a pre-prepared 31 wt% aqueous solution) and 112 kg of PEG200 (100% solids) were added and mixed, followed by the addition of 34 kg of silane (Momentive VS-142 40% active, 10% aqueous solution).

[0246] Example 3 1395.0 kg of ammonium lignosulfonate was placed in a mixing vessel, to which 16 L of NH4OH (24.7%) was added and stirred. Then, 289 kg of Primid XL552 solution (a pre-prepared 31 wt% aqueous solution) and 82 kg of PEG200 (100% solids) were added and mixed, followed by the addition of 25 kg of silane (Momentive VS-142 40% active, 10% aqueous solution) and 76 kg of silicone (Wacker BS 1052, 12% aqueous solution).

[0247] Using this binder, stone wool products according to Examples 1, 2, and 3 shown in Table 1 were manufactured. The curing oven temperature was set to 255°C for Examples 1 and 2, and to 275°C for Example 3.

[0248] Stone wool products (products of the present invention) using reference binders A1-A3, reference binders B1 and B2, and binder examples 1-3 were manufactured in a standard stone wool factory using the specific water types shown in Table 1.

[0249] The obtained stone wool products were tested for binder-dried solids, loss on ignition, chloride content, and pH value according to the method described above. The results are shown in Table 1.

[0250] [Table 1]

Claims

1. A mineral fiber product comprising mineral fibers bound together by a cured binder composition, wherein the uncured binder composition is Component (i) in the form of lignosulfonate trinin, having one or more lignosulfonate trinins, wherein the carboxylic acid group content is 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate trinin. Includes, The component (i) is in the form of one or more lignosulfone lignins having an average carboxylic acid group content of less than 1.4 groups per polymer, taking into consideration the Mn of the component (i). The aforementioned mineral fiber product has a water-leaching chloride content of less than 10 mg / kg in accordance with EN13468:2001. The aforementioned mineral fiber product is a thermal insulation mineral fiber product in the form of a pre-formed pipe section or a wire mesh reinforced blanket. Mineral fiber products.

2. The mineral fiber product according to claim 1, wherein the mineral fiber product has a water-leaching chloride content of less than 6 mg / kg in accordance with EN13468:2001.

3. A mineral fiber product according to claim 1 or claim 2, which is a heat insulating product and a soundproofing product.

4. The aforementioned mineral fiber products are insulation and / or soundproofing materials for pipes, storage tanks, boilers, containers or columns, and / or The aforementioned mineral fiber product has a thickness ranging from 20 mm to 500 mm. A mineral fiber product according to any one of claims 1 to 3.

5. The mineral fiber product according to any one of claims 1 to 4, wherein the uncured binder composition is an aqueous binder composition.

6. The uncured binder composition is Component (i) in the form of a lignosulfonate lignin having a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignin, One or more crosslinking agents as components (ii), A mineral fiber product according to any one of claims 1 to 5, including the following:

7. The uncured binder composition is A mineral fiber product according to any one of claims 1 to 6, comprising one or more components (iii) in the form of plasticizers.

8. The mineral fiber product according to any one of claims 1 to 7, 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.

9. The mineral fiber product according to any one of claims 1 to 8, wherein the component (i) is in the form of one or more lignosulfonate lignins having an average carboxylic acid group content of less than 1.1 groups per polymer, taking into consideration the Mn of the component (i).

10. The mineral fiber product according to any one of claims 1 to 9, wherein component (i) contains 0.3 to 2.5 mmol / g of phenolic OH groups based on the dry weight of the lignosulfonate lignin.

11. The mineral fiber product according to any one of claims 1 to 10, wherein component (i) has an aliphatic OH group content of 1.0 to 8.0 mmol / g based on the dry weight of the lignosulfonate lignin.

12. The mineral fiber product according to any one of claims 1 to 11, wherein component (i) comprises ammonium lignosulfonate and / or calcium lignosulfonate and / or magnesium lignosulfonate, or any combination thereof.

13. The above component (i) comprises ammonium lignosulfonate and calcium lignosulfonate, and NH ４ ＋ vs Ca ２＋ The mineral fiber product according to any one of claims 1 to 12, wherein the molar ratio is in the range of 5:1 to 1:

5.

14. The mineral fiber product according to any one of claims 5 to 13, wherein the aqueous binder composition contains an amount of added sugar of 0 to less than 5% by weight based on the weight of lignosulfonate and sugar.

15. The mineral fiber product according to any one of claims 6 to 14, wherein the binder composition comprises 50 to 98% by weight of component (i) based on the dry weight of components (i) and (ii).

16. The mineral fiber product according to any one of claims 6 to 15, wherein the binder composition comprises 50 to 88% by weight of component (i) based on the dry weight of components (i) and (ii).

17. The mineral fiber product according to any one of claims 6 to 16, wherein the aqueous binder composition comprises 50 to 98% by weight of component (i) based on the dry weight of components (i) and (ii).

18. The aforementioned component (ii) is, a) β-hydroxyalkylamide crosslinking agents and / or oxazoline crosslinking agents, and / or b) Polyfunctional organic amines, diamines, triamines, and / or c) Epoxy compounds having a molecular weight greater than 500, and / or d) One or more crosslinking agents selected from the group consisting of polyethyleneimine, polyvinylamine, and fatty amine, and / or e) One or more crosslinking agents in the form of fatty amides, and / or f) One or more crosslinking agents selected from polyester polyols, and / or g) One or more crosslinking agents selected from the group consisting of starch, modified starch, and CMC, and / or h) One or more crosslinking agents in the form of aliphatic polyfunctional carbodiimides, and / or i) One or more crosslinking agents selected from melamine-based crosslinking agents A mineral fiber product according to any one of claims 6 to 17, wherein the crosslinking agent is in the form of one or more selected from the above.

19. The mineral fiber product according to claim 18, wherein component (ii) comprises one or more crosslinking agents selected from β-hydroxyalkylamide crosslinking agents and / or oxazoline crosslinking agents.

20. A mineral fiber product according to any one of claims 6 to 19, comprising 1 to 50% by weight of component (ii) based on the dry weight of component (i).

21. A mineral fiber product according to any one of claims 6 to 20, comprising 1 to 50% by weight of component (ii) based on the dry weight of component (i).

22. The aforementioned component (ii) is, β-hydroxyalkylamide crosslinking agent, and / or A group consisting of polyfunctional organic amines, diamines, and / or Epoxy compounds having a molecular weight greater than 500, and / or One or more crosslinking agents in the form of polyfunctional carbodiimides A mineral fiber product according to any one of claims 6 to 21, wherein the crosslinking agent is in the form of one or more selected from the above.

23. The aforementioned component (ii) is, A mineral fiber product according to any one of claims 6 to 22, comprising a β-hydroxyalkylamide crosslinking agent.

24. A mineral fiber product according to any one of claims 17 to 23, comprising 2 to 90% by weight of component (ii) based on the dry weight of component (i).

25. The aforementioned component (iii) is, One or more plasticizers selected from the group consisting of fatty alcohols and monohydroxy alcohols, and / or Plasticizers comprising alkoxylates, 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, azelate, butyrate, and valerate, and / or One or more plasticizers selected from the group consisting of phenol derivatives, and / or One or more plasticizers selected from the group consisting of silanols and siloxanes, and / or One or more plasticizers selected from the group consisting of sulfates, and / or One or more plasticizers in the form of hydroxy acids, and / or One or more plasticizers selected from the group consisting of monomer amides, and / or One or more plasticizers selected from the group consisting of quaternary ammonium compounds, and / or One or more plasticizers selected from the group consisting of vegetable oils, and / or Tall oil, and / or One or more plasticizers selected from the group consisting of hardened oils and acetylated oils, and / or One or more plasticizers selected from methyl acid esters, and / or One or more plasticizers selected from the group consisting of alkyl polyglucosides, gluconamides, aminoglucoseamides, sucrose esters, and sorbitan esters, and / or One or more plasticizers selected from the group consisting of polyethylene glycol and polyethylene glycol ether, and / or Plasticizers comprising polyols, and / or Triethanolamine A mineral fiber product according to any one of claims 6 to 24, contained in the uncured binder composition in the form of the mineral fiber product according to any one of claims 6 to 24.

26. The mineral fiber product according to any one of claims 7 to 25, wherein the component (iii) is in the form of propylene glycol, a phenol derivative, silanol, siloxane, hydroxy acid, vegetable oil, polyethylene glycol, polyethylene glycol ether, triethanolamine, or a mixture thereof.

27. The mineral fiber product according to any one of claims 7 to 25, wherein the component (iii) comprises one or more plasticizers having a boiling point of 100 to 380°C.

28. The mineral fiber product according to any one of claims 7 to 25, wherein the component (iii) comprises one or more polyethylene glycols having an average molecular weight of 150 to 50,000 g / mol.

29. The mineral fiber product according to any one of claims 7 to 25, wherein component (iii) is present in an amount of 0.5 to 60% by weight based on the dry weight of component (i).

30. A mineral fiber product according to any one of claims 1 to 29, comprising one or more components (iv) in the form of a coupling agent.

31. The mineral fiber product according to any one of claims 1 to 30, further comprising component (v) in the form of one or more components selected from bases or salts thereof.

32. A further component in the form of urea, based on the dry weight of component (i), according to any one of claims 1 to 31.

33. A mineral fiber product according to any one of claims 1 to 32, comprising one or more reactive or non-reactive silicone components (vi).

34. Use as thermal insulation and / or soundproofing material of a mineral fiber product according to any one of claims 1 to 33, comprising mineral fibers bound together by a cured binder composition.

35. The use according to claim 34, wherein the mineral fiber product is used as an insulating and / or soundproofing material for an object selected from pipes, storage tanks, boilers, containers, or columns.

36. Use according to claim 34 or claim 35 at temperatures in the range of -20°C to 320°C.

37. The use of the mineral fiber product according to any one of claims 34 to 36, wherein the mineral fiber product is used as an insulating and / or soundproofing material for an object made of metal.

38. A method for producing a mineral fiber product comprising mineral fibers bound together by a cured binder composition, wherein the uncured binder composition comprises one or more lignosulfonate lignins, the lignosulfonate lignins having a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignins, The aforementioned method, a) Providing an uncured aqueous binder composition comprising one or more lignosulfonate lignins, having a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignins, and having an average carboxylic acid group content of less than 1.4 groups per polymer, taking into account the Mn of the one or more lignosulfonate lignins, and water; b) A step of bringing mineral fibers into contact with the uncured aqueous binder composition, c) A step of curing the aqueous binder composition in contact with the mineral fibers. A method comprising, wherein at least a portion or all of the water contained in the uncured aqueous binder composition is added unpurified water.

39. The proportion of unpurified water added is in the range of 30 to 100% by weight based on the total weight of water contained in the uncured binder composition, and / or The water content in the uncured aqueous binder composition is in the range of 40 to 90% by weight based on the total weight of the uncured aqueous binder composition. The method according to claim 38.

40. The method according to claim 38 or claim 39, wherein the mineral fiber product is the mineral fiber product according to any one of claims 1 to 33.

41. A hollow body covered with a mineral fiber product as an insulating and / or soundproofing material, wherein the mineral fiber product comprises mineral fibers bound together by a cured binder composition, and the uncured binder composition comprises one or more lignosulfonate lignins having a carboxylic acid group content of 0.03 to 1.4 mmol / g based on the dry weight of the lignosulfonate lignins, and having an average carboxylic acid group content of less than 1.4 groups per polymer, taking into account the Mn of the one or more lignosulfonate lignins.

42. The hollow object according to claim 41, wherein the hollow object is selected from a pipe, a storage tank, a boiler, a container, or a column, and / or the hollow object is made of metal.

43. The aforementioned mineral fiber product is the mineral fiber product according to any one of claims 1 to 33, or the hollow object according to claim 41 or 42.

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