Sizing composition based on a non-reducing saccharide and a hydrogenated saccharide, and insulating products obtained
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Solution Overview
Problem
Insulating products based on mineral wool exhibit insufficient resistance to aging in humid environments, limiting their use on building exteriors, and existing sizing compositions contain undesirable formaldehyde emissions due to unstable urea-formaldehyde condensates.
Innovation Solution
Aqueous sizing composition comprising a non-reducing saccharide, a hydrogenated saccharide, and a polycarboxylic organic acid, which forms a polymeric network through ester bonds and dehydration reactions, enhancing hydrolytic resistance while avoiding formaldehyde emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If phenolic resins containing urea are used to treat formaldehyde in sizing compositions, then formaldehyde emissions are reduced, but the resistance to aging in humid environments deteriorates due to decomposition of urea-formaldehyde condensates
Solution Approach 1:
The invention extracts and removes urea from the sizing composition formulation. By eliminating urea entirely and replacing it with alternative binders (specifically polyols and carboxylic acids), the patent avoids the decomposition issue of urea-formaldehyde condensates while still controlling formaldehyde emissions through the use of formaldehyde-free phenolic resins or reduced formaldehyde content resins
Solution Approach 2:
The invention changes the chemical parameters of the sizing composition by substituting urea with polyols and carboxylic acids. This parameter change modifies the binding mechanism from urea-formaldehyde condensation to esterification and hydrogen bonding, thereby improving hydrolytic stability and resistance to aging in humid environments while maintaining formaldehyde emission control
2Object-generated harmful factors
If conventional sizing compositions with urea-formaldehyde condensates are used, then formaldehyde emissions are controlled, but the mechanical properties and durability deteriorate after aging in humid conditions
Solution Approach 1:
The invention converts the potential harm of formaldehyde emissions into a benefit by using phenolic resins that can control formaldehyde release while the primary binding mechanism shifts to urea-free polyol-carboxylic acid systems. This approach maintains formaldehyde emission control through resin selection while the alternative binding chemistry provides improved mechanical durability after aging
Solution Approach 2:
The invention creates a composite binding system combining phenolic resins with polyol-carboxylic acid complexes. This composite approach leverages the formaldehyde-emission control properties of phenolic resins while the polyol-carboxylic acid component provides enhanced hydrolytic stability and mechanical property retention after aging in humid conditions
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
The composition improves the hydrolytic resistance and mechanical properties of mineral wool insulating products, ensuring better durability in humid conditions without generating harmful emissions.
Implementation Method 1
comprises a non-reducing saccharide, a hydrogenated saccharide and a polycarboxylic organic acid
Implementation Method 2
which forms a polymeric network through ester bonds and dehydration reactions
Implementation Method 3
The web of fibers coated with the size is subjected to a heat treatment, at a temperature generally of greater than 100° C., in order to bring about the polycondensation of the resin
Data Source
AI summary
A sizing composition, in particular for insulating products based on mineral wool, in particular of glass or of rock, includes at least one non-reducing saccharide, at least one hydrogenated saccharide, and at least one polycarboxylic organic acid.