Sizing composition for mineral wool based on maltitol and insulation products therefrom
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Solution Overview
Problem
Current thermal and acoustic insulation products based on mineral wool face challenges with formaldehyde emissions from traditional thermosetting resins, which are harmful to human health and the environment, and require improved tensile strength and thickness recovery properties.
Innovation Solution
A sizing composition is developed for mineral wool insulation products, comprising a mixture of hydrogenated sugars with at least 25% maltitol and a polyfunctional crosslinking agent, such as citric acid, to form a binder that provides enhanced cohesion and stability without formaldehyde release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional thermosetting resins (phenolic resins) are used in sizing composition, then good sprayability and fiber binding capability are achieved, but formaldehyde emissions occur which are harmful to human health and environment
Solution Approach 1:
The invention changes the chemical composition parameters of the sizing composition by replacing phenolic resins with hydrogenated sugars (maltitol, sorbitol, xylitol) combined with polyfunctional crosslinking agents. This substitution maintains the binding functionality while eliminating formaldehyde emissions, as the sugar-based system undergoes caramelization and crosslinking instead of formaldehyde release.
Solution Approach 2:
The invention creates a composite sizing composition combining hydrogenated sugars with polyfunctional crosslinking agents (citric acid, phosphoric acid, or boric acid). This composite system leverages the binding capability of sugars and the crosslinking efficiency of the acids to achieve effective fiber binding without harmful formaldehyde emissions.
2Ease of manufacture
If phenolic resins are used to ensure good affinity for mineral fibers and water solubility, then manufacturing cost is reduced and application performance is improved, but environmental pollution and health risks increase
Solution Approach 1:
The invention changes the chemical nature of the sizing composition from phenolic resin-based to sugar-based. Hydrogenated sugars inherently possess water solubility and good affinity for mineral fibers, maintaining the manufacturing advantages while eliminating the environmental and health risks associated with phenolic resins and formaldehyde.
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 solution achieves improved tensile strength, thickness recovery, and reduced formaldehyde emissions, resulting in more environmentally friendly and effective thermal and acoustic insulation products with enhanced durability and water resistance.
Implementation Method 1
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 2
The surprising result has been that the polyfunctional crosslinking agents, in the presence of the hydrogenated sugars, make it possible to carry out the crosslinking at lower temperatures, with evolution of water
Data Source
Figure 1
AI summary
The present invention relates to a sizing composition for insulating products based on mineral wool, in particular rock or glass, characterized in that it comprises - a mixture of hydrogenated sugars containing at least 25% by weight of maltitol , calculated on the basis of the dry matter of the hydrogenated sugars, and - at least one polyfunctional crosslinking agent. It also relates to insulating products based on mineral fibers thus obtained.