Mineral Wool Insulation Formaldehyde Emission Reduction
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Solution Overview
Problem
Thermal and/or acoustic insulation products based on mineral wool bonded with thermosetting resins, particularly resol type, face challenges with formaldehyde emissions during manufacturing and usage, which are not adequately addressed by existing methods, including the use of urea-formaldehyde condensates that degrade under temperature conditions, leading to increased formaldehyde release.
Innovation Solution
A process is introduced that involves applying an agent capable of reacting with formaldehyde, such as active methylene compounds, to the insulation product after the thermosetting resin has crosslinked, which helps in reducing formaldehyde emissions by reacting with free formaldehyde present in the resin and emitted during product use, without significantly affecting the insulation properties or requiring substantial modifications to the production line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If urea is added to the resol to react with free formaldehyde, then the level of free formaldehyde is reduced, but the resin becomes unstable under temperature conditions and releases formaldehyde and ammonia during crosslinking
Solution Approach 1:
The patent applies a formaldehyde-trapping agent to the insulation product after the thermosetting resin has already crosslinked. This preliminary action of treating the finished product with a formaldehyde-trapping agent (such as amino compounds or activated carbon) prevents formaldehyde emissions during product use without interfering with the crosslinking process, thereby resolving the contradiction between reducing formaldehyde levels and maintaining resin stability.
Solution Approach 2:
The patent introduces a formaldehyde-trapping agent as an intermediary substance that reacts with free formaldehyde released during product use. This intermediary agent (such as amino compounds including melamine, guanidine, or activated carbon) captures formaldehyde molecules, preventing their emission into the atmosphere while not affecting the resin's crosslinking stability.
2Strength
If phenol-formaldehyde resol is used as the thermosetting resin, then good affinity with mineral fibers and elasticity are achieved, but free formaldehyde is present in quantities that cause emissions during manufacturing and use
Solution Approach 1:
The patent introduces a formaldehyde-trapping agent as an intermediary substance applied to the finished insulation product. This agent (such as amino compounds or activated carbon) captures free formaldehyde released during product use, preventing emissions while not affecting the phenol-formaldehyde resin's bonding strength or elasticity properties.
Solution Approach 2:
The patent changes the chemical parameter of the insulation product by applying a formaldehyde-trapping agent that chemically reacts with or adsorbs free formaldehyde. This parameter change reduces formaldehyde emissions during product use while maintaining the original resin's mechanical and physical properties.
3Object-affected harmful factors
If the insulation product is treated with formaldehyde-trapping agents before crosslinking, then formaldehyde emissions are reduced, but the crosslinking process is interfered with and product quality deteriorates
Solution Approach 1:
The patent applies the formaldehyde-trapping agent after the crosslinking process is complete, not before. This timing ensures that the resin crosslinks properly to achieve the required product quality, and then the formaldehyde-trapping agent is applied to reduce emissions during product use without interfering with the crosslinking process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively limits formaldehyde emissions while maintaining the thermal and acoustic insulation properties, mechanical strength, and dimensional stability of the products, meeting stringent regulatory requirements and ensuring the process is industrially viable and easy to implement.
Implementation Method 1
a step consisting of applying an agent capable of reacting with formaldehyde chosen from active methylene(s) compounds on the insulation product, after the thermosetting resin has crosslinked
Implementation Method 2
The sheet of fibers coated with the sizing is subjected to a heat treatment (at a temperature generally above 100°C) in order to carry out the polycondensation of the resin and thus obtain a thermal and/or acoustic insulation product
Implementation Method 3
the material being projected towards the peripheral wall of the device under the action of the centrifugal force and 'by escaping in the form of filaments
Implementation Method 4
At the exit of the centrifugal device, the filaments are stretched and driven by a gas current having a high temperature and speed, towards a receiving member
Data Source
AI summary
The present invention relates to a process for manufacturing thermal and/or acoustic insulation products based on mineral wool, especially on rock wool or glass wool, bound by a sizing composition based on a thermosetting resin, in particular of resol type, which aims to limit the emissions of formaldehyde. The process is characterized in that it comprises a step that consists in applying a composition of an agent capable of reacting with formaldehyde, chosen from compounds having active methylene(s), to the insulation product, after the thermosetting resin has crosslinked. Another subject of the present invention is the device for carrying out the aforementioned process and the insulating products based on mineral fibres that are obtained.