CN101688343A - 无甲醛的矿物纤维绝缘产品 - Google Patents
无甲醛的矿物纤维绝缘产品 Download PDFInfo
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- E04B1/7658—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres
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Abstract
一种包装的矿物纤维绝缘材料,具有:a)至少95%标称厚度的回复厚度;和b)至少95g/g的普通分离强度;和c)至少75g/g的风化分离强度;该材料包括矿物纤维和数量少于15wt%的有机无甲醛粘结剂,优选少于10wt%,所述粘结剂以液体形式以大于5的pH值已被施加到绝缘材料的纤维上。
Description
技术领域
本发明涉及一种矿物纤维绝缘产品,其具有低甲醛或无甲醛的粘结剂。
背景技术
用于纤维绝缘体(例如玻璃棉和岩棉(rock wool)绝缘体)的工业标准粘结剂是基于苯酚甲醛。尽管这种粘结剂能够给绝缘产品提供合适的性能,但一段时间以来希望远离苯酚甲醛的使用,尤其是出于对环境的考虑。
以前曾建议传统的基于聚酯的粘结剂体系,但在绝缘工业中并未获得认可,尤其是由于它们将矿物纤维保持在一起的强度,特别是当其暴露于潮湿或者风化的条件中时,会显现的不够充足。
迄今为止,只有一种基于低甲醛的矿物绝缘体粘结剂体系以工业规模已用于玻璃棉绝缘体,它是基于聚丙烯酸并由罗门哈斯(Rohm&Haas)提供。不幸的是,这些类型粘结剂的高度酸特性会对制造装置产生过多的腐蚀,除非对于耐酸设备进行巨大的投资。US专利5,977,232公开了基于聚羧酸的用于玻璃棉绝缘体的无甲醛粘结剂。欧洲专利申请EP1698598A公开了使用腐蚀仪(corrosionmeter)来努力减少和基于聚羧酸的玻璃纤维粘结剂树脂相关的问题。另外,尽管这些粘结剂的强度对于一些应用而言是可接受的,但是,它并不像通常使用的基于苯酚甲醛的粘结剂一样好。
还从未考虑有可能提供一种可以工业规模使用的以下无甲醛粘结剂体系:为矿物棉绝缘产品赋予所要求的特征(包括强度),而不会遭遇与高度酸性液体粘结剂体系相关的困难。
发明内容
根据一个方面,本发明提供一种如权利要求1所限定的包装的矿物纤维绝缘材料。另外的方面限定于其它独立权利要求。优选的和/或可选择的特征限定于从属权利要求。
如这里所使用的,术语“无甲醛”的意思是指组合物基本上不含甲醛,优选不会由于干燥或固化而释放明显的甲醛,和/或优选包含少于百万分之一(以重量计)的甲醛。
由粘结剂赋予一些矿物棉绝缘产品的所需特征可以通过测量回复厚度(Recovered Thickness)和/或普通分离强度(Ordinary Parting Strength)和/或风化分离强度(Weathered Parting Strength)来评价。用于测量这些特征的程序阐述如下。这特别是对于低密度和中密度的绝缘产品,例如,具有5-40kg/m3的密度,例如,用于顶楼和/或空心墙的卷状绝缘体(roll insulation)和/或玻璃棉热绝缘体。
一些矿物棉绝缘产品的所需特征可以通过测量普通压缩强度(OrdinaryCompression Strength)和/或风化压缩强度(Weathered Compression Strength)来评价。用于测量这些特征的程序阐述如下。这特别是对于较高密度的绝缘产品,例如,适用于以下用途的绝缘板或材料:防火墙;防火措施;建筑物的覆层;天花板的瓦片;屋面板;用于高温机械(例如,发电机,烘箱和工业装置)的热绝缘体。所述产品可以由岩棉制造。
粘结剂在施加时的pH值可以基本上是中性或碱性;这可以有助于操作和避免显著的腐蚀和/或环境问题。当施加时它的pH值可以是:大于或等于7,和/或小于或等于10;在7-10之间;在8-10之间。
本发明的一个重要方面是当施加到纤维上时采取液体形式的粘结剂的pH值,因为这是其中粘结剂将与制造设备具有显著接触的形式,当新鲜制备的和在洗涤水体系中。当粘结剂固化时,它可以改变它的pH值;当粘结剂固化时,它可以变得具有更高酸性。尽管如此,一旦固化,粘结剂具有与制造设备的较少直接接触。而且,固化的粘结剂基本上不溶于水,优选的是这种情况,这样几乎没有来自固化的粘结剂的酸污染的风险。
令人惊讶的是,15wt%或者更少的这种类型的粘结剂就能够赋予绝缘产品所需要的特征。粘结剂的这种数量与采用基于苯酚甲醛的粘结剂所通常使用的粘结剂含量是相当的。固化的粘结剂含量可以是12wt%或更少或10wt%或更少;它可以在3-8wt%的范围内,尤其是3.5-6wt%的范围内。粘结剂含量可以通过烧失量确定。上述粘结剂的含量尤其适用于低密度和中密度的产品。尤其地对于较高密度的产品,固化的粘结剂含量可以在0.5-5wt%的范围内。
粘结剂可以:
·基于还原糖;和/或
·基于reductosis;和/或
·基于含醛的糖;和/或
·包括碳水化合物反应物和胺反应物的至少一种反应产物;和/或
·包括还原糖和胺反应物的至少一种反应产物;和/或
·包括碳水化合物反应物和多元羧酸铵盐反应物的至少一种反应产物;和/或
·包括由梅拉德反应(Maillard reaction)得到的至少一种反应产物。
粘结剂可以基于多元羧酸(如柠檬酸)、糖(如葡萄糖)和氨源(如氨溶液)的组合。它可以基于柠檬酸铵和葡萄糖的组合。当粘结剂基于糖和/或柠檬酸和/或包括显著的-OH基,尤其令人吃惊的是可以得到所述水平的风化分离强度。据信-OH基(如糖和/或柠檬酸中)易于经历水解,从而粘结剂在潮湿和/或风化的条件中将失去显著的强度。
粘结剂可以包括含硅的化合物,尤其是硅烷;这可以是氨基取代的化合物;它可以是甲硅烷基醚,它可以促进粘结剂与矿物纤维的粘附。
粘结剂可以包括蛋白黑素;它可以是热固型粘结剂;它可以是可热固化的。
粘结剂可以是国际专利申请号PCT/US2006/028929中公开的那些粘结剂之一,该申请内容在此引用作为参考。
该绝缘材料可以被包装或以包装的形式提供,该包装可以包括排列和/或结合(bound)在一起的一个或多个矿物棉绝缘产品,例如以有助于运输;它可以包括包封薄膜,例如,塑料材料。该包装可以包括一卷绝缘材料或者绝缘材料的独立板(slab)的组合体,或者该包装可以由它们构成。
该绝缘材料,尤其当它是低密度或中密度产品时,可以具有:
.在60-260mm范围内的标称厚度;和/或
.热阻率R,R≥3m2K/W,优选在200mm的厚度处,R≥4m2K/W;和/或
.在5-40kg/m3范围内的密度,尤其地5-18kg/m3或7-12kg/m3,例如对于低密度的卷状产品。
该绝缘材料,特别当它是绝缘板或较高密度的产品时,可以具有:
.在20-200mm范围内的标称厚度;和/或
.热阻率R,R≥1.7m2K/W,优选在100mm的厚度处,R≥2m2K/W;和/或
.在100-200kg/m3范围内的密度,尤其地是130-190kg/m3。
矿物纤维可以是玻璃棉或岩棉;该纤维可以具有2-9微米的平均直径或可以是具有更小直径的微纤维;它们可以具有8-80mm的平均长度。
该矿物纤维可以是卷曲的。
根据另一方面,本发明提供具有以下特征中的至少一个特征的矿物纤维绝缘材料:
.该绝缘材料具有切割边缘
.该绝缘材料具有在其至少一个主表面上提供的饰面,例如包括湿气渗透阻隔层和/或牛皮纸和/或铝箔和/或塑料层和/或包括多个单独层的层压板和/或机织织物或非织造织物;该饰面可以提供在绝缘材料的每个主表面上;
.该绝缘材料是例如通过一个或多个包装原件保持在压缩下的包装的绝缘材料,例如通过包封包装薄膜;该绝缘材料可以被压缩到其未压缩厚度的80%或更少;
.该绝缘材料采取管状绝缘体的形式,具有大于30cm的长度;横截面可以基本上是环形的;
.该绝缘材料采取压缩的材料卷的形式;
.该绝缘材料采取压缩的材料板的形式;
.该绝缘材料是卷状或板状,具有的长度大于或等于1m,优选大于或等于2m;
.该绝缘材料是卷状或板状,具有的宽度大于或等于0.3m,优选大于或等于0.5m;
.该绝缘材料具有的标称厚度是至少45mm,优选至少50mm,密度在5-40kg/m3的范围内。
该绝缘材料可以具有这些特征的任意组合;这些特征也可以和在此描述的其它特征和/或方面组合。
具体实施方式
本发明的非限制性实施例参照图1描述如下,其显示了用于试验分离强度的样品的形态。
通过一起混合来制备含水粘结剂:
近似的重量% | |
粉未状葡萄糖一水合物 | 12.9% |
粉末状无水柠檬酸 | 2.3% |
28%的氨水 | 2.6% |
硅烷A-1100 | 0.05% |
水 | 82.1% |
该粘结剂用于在标准生产线上生产玻璃纤维绝缘产品,刚好在使用内部纺丝机纤维化之后就将粘结剂喷涂到玻璃纤维上,收集涂布的纤维,组合成毡,并以通常方式固化。
当施加到玻璃纤维上时,粘结剂具有的pH值大约是8。
固化的玻璃纤维绝缘产品具有:
.粘结剂含量大约是5wt%,通过烧失量确定
.厚度大约是150mm
.密度大约是9kg/m3
这适合作为低密度住宅用卷状绝缘产品;它在压缩下被包装成为卷状。
在表1中示出了所需的特征和获得的结果:
表1:
单位 | 接受限度 | 优选 | 更优选 | 最优选 | 获得的结果 | |
回复厚度 | 标称值的% | ≥95 | ≥100 | ≥110 | ≥120 | 103 |
普通分离强度 | g/g | ≥95 | ≥100 | ≥150 | ≥200 | 122 |
风化分离强度 | g/g | ≥75 | ≥80 | ≥100 | ≥150 | 112 |
回复厚度的试验:
回复厚度根据英国标准BS EN 823:1995的附录A来试验和测量(这里引入作为参考),并表达为所测量的产品的标称或宣称厚度的%。
普通分离强度和风化分离强度的试验:
分离强度是矿物纤维毡的拉伸强度的量度,其通过如下测定:将O形的样品放置在圆柱形夹具上,使夹具分离并测量使纤维断裂的负荷。虽然分离强度可以测量为牛顿/克,但是也可以表达为克/克(g/g),它是六个试验试样的总断裂负荷除以它们的总重量。
在用于试验的按原样的矿物纤维毡上进行所述试验(普通分离强度),和在如下述所解释的加速风化试验之后进行所述试验(风化分离强度)。
从待试验的矿物纤维毡上切割下第一组六个具有图1所示形态和尺寸的样品;样品的长轴应该与运输机方向(conveyor direction)平行,和应该横穿所述矿物毡的整个宽度获得样品。然后,按照相同方式获得第二组六个样品。
图1中的尺寸用mm计量。
第一组6个样品的总重量记为W1,以克计。
第二组6个样品的总重量记为W2,以克计;然后将这些样品放置在预热的高压釜中,在远离室底部的金属丝网支架上在35kN/m2湿蒸汽条件下调理1小时。然后将它们移出,在100℃的烘箱中干燥5分钟,和立即试验分离强度。
为了试验分离强度,将每个样品依次安装在拉伸强度机的夹具上,和记录以克或牛顿计的最大断裂负荷。如果断裂负荷以牛顿计,通过将其乘以101.9将其转化为克。对于每组样品,获得以克计的六个结果:第一组样品G1 G2 G3 G4G5和G6,第二组样品G7 G8 G9 G10 G11和G12。
普通分离强度使用以下公式由第一组样品计算:
普通分离强度=(G1+G2+G3+G4+G5+G6)/W1。
风化分离强度使用以下公式由第二组样品计算:
风化分离强度=(G7+G8+G9+G10+G11+G12)/W2。
在另一个实施例中,通过一起混合来制备含水粘结剂:
近似的重量% | |
粉末状葡萄糖一水合物 | 19.1% |
粉末状无水柠檬酸 | 3.4% |
28%的氨水 | 2.6% |
硅烷A-1100 | 0.07% |
水 | 73.5% |
该粘结剂用于在标准生产线上生产岩棉屋面板,刚好在纤维化之后就将粘结剂喷涂到纤维上,收集涂布的纤维,组合成毡,并以通常方式压缩和固化。
固化的屋面板具有:
.粘结剂含量大约是3wt%,通过烧失量确定
.厚度大约是80mm
.密度大约是150kg/m3
它被包装为绝缘板的堆叠体的一部分。
在表2中示出了所需的特征和获得的结果:
表2
单位 | 接受限度 | 优选 | 更优选 | 最优选 | 获得的结果 | |
普通压缩强度 | kPa | ≥60 | ≥70 | ≥80 | ≥90 | 72.3 |
风化压缩强度 | kPa | ≥25 | ≥30 | ≥40 | ≥50 | 54.6 |
普通压缩强度和风化压缩强度的试验:
普通压缩强度根据英国标准BS EN 826:1996来进行测量(这里引入作为参考)。
风化压缩强度根据英国标准BS EN 826:1996在已经经历以下加速风化程序的样品上进行测量:将样品切割至一定尺寸,然后把它们放置在预热的高压釜中,在远离室底部的金属丝网支架上在35kN/m2湿蒸汽条件下调理1小时。然后将它们移出,在100℃的烘箱中干燥5分钟,和立即试验压缩强度。
在两种情况下,压缩强度沿着所述产品的厚度方向测定,所述样品的与压缩试验装置接触的面的尺寸优选为200mmx200mm。
Claims (15)
1.包装的矿物纤维绝缘材料,具有:
a)至少95%标称厚度的回复厚度;和
b)至少95g/g的普通分离强度;和
c)至少75g/g的风化分离强度;
该材料包括矿物纤维和数量少于15wt%的有机无甲醛粘结剂,所述粘结剂以液体形式以大于5的pH值已被施加于该绝缘材料的纤维。
2.根据权利要求1所述的包装的矿物纤维绝缘材料,其中该回复厚度是至少100%,优选至少110%。
3.根据在前的任一权利要求所述的包装的矿物纤维绝缘材料,其中该普通分离强度是至少100g/g,优选至少150g/g。
4.根据在前的任一权利要求所述的包装的矿物纤维绝缘材料,其中该风化分离强度是至少80g/g,优选至少100g/g。
5.根据在前的任一权利要求所述的包装的矿物纤维绝缘材料,其中该绝缘材料是密度为5-40kg/m3的卷状产品,其在压缩下被包装。
6.包装的密度在100-200kg/m3范围内的矿物纤维绝缘材料,其包括矿物纤维和有机无甲醛粘结剂,并且具有:
a)至少60kPa的普通压缩强度;和
b)至少25kPa的风化压缩强度;
该材料包括矿物纤维和数量少于15wt%的有机无甲醛粘结剂,所述粘结剂以液体形式以大于5的pH值已被施加于该绝缘材料的纤维。
7.根据权利要求6所述的包装的矿物纤维绝缘材料,其中该普通压缩强度是至少70kPa,优选至少80kPa。
8.根据6-7任一权利要求所述的包装的矿物纤维绝缘材料,其中该风化压缩强度是至少30kPa,优选至少40kPa。
9.根据在前的任一权利要求所述的包装的矿物纤维绝缘材料,其中该粘结剂以液体形式以小于11的pH值被施加于该绝缘材料的纤维。
10.根据在前的任一权利要求所述的包装的矿物纤维绝缘材料,其中该粘结剂以液体形式以6-10的pH值被施加于该绝缘材料的纤维。
11.根据在前的任一权利要求所述的包装的矿物纤维绝缘材料,其中该粘结剂含量是2wt%-8wt%。
12.根据在前的任一权利要求所述的包装的矿物纤维绝缘材料,其中该粘结剂基于还原糖。
13.根据在前的任一权利要求所述的包装的矿物纤维绝缘材料,其中该粘结剂包括至少一种梅拉德反应产物。
14.根据在前的任一权利要求所述的包装的矿物纤维绝缘材料,其中该粘结剂基于通过固化包含柠檬酸、氨和葡萄糖的水溶液获得的反应产物。
15.制造选自以下的包装的矿物纤维绝缘材料的方法:
(i)材料,具有
a)至少95%的回复厚度;和
b)至少95g/g的普通分离强度;和
c)至少75g/g的风化分离强度;和
(ii)材料,具有
a)至少60kPa的普通压缩强度;和
b)至少25kPa的风化压缩强度;
包括以下步骤:
i)将有机无甲醛粘结剂以水溶液形式以大于5的pH值施加于矿物纤维,和
ii)固化产品,以致它含有数量少于15wt%的粘结剂,和
iii)包装绝缘材料。
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-
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- 2007-01-25 ES ES07704143.2T patent/ES2526345T3/es active Active
- 2007-01-25 PL PL14184412.6T patent/PL2826903T3/pl unknown
- 2007-01-25 PT PT77041432T patent/PT2126179E/pt unknown
- 2007-01-25 EP EP20070704143 patent/EP2126179B1/en not_active Revoked
- 2007-01-25 SI SI200731556T patent/SI2126179T1/sl unknown
- 2007-01-25 SI SI200732197T patent/SI2826903T1/sl unknown
- 2007-01-25 CN CN2007800503742A patent/CN101688343B/zh active Active
- 2007-01-25 DK DK14184412.6T patent/DK2826903T3/da active
- 2007-01-25 DK DK07704143T patent/DK2126179T3/da active
- 2007-01-25 PL PL07704143T patent/PL2126179T3/pl unknown
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- 2007-01-25 ES ES14184412T patent/ES2945888T3/es active Active
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- 2007-01-25 BR BRPI0721233-0A patent/BRPI0721233A2/pt not_active Application Discontinuation
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2010
- 2010-11-05 US US12/940,601 patent/US20110089074A1/en not_active Abandoned
Cited By (4)
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CN104334567A (zh) * | 2012-04-05 | 2015-02-04 | 克瑙夫绝缘私人有限公司 | 粘结剂和相关产品 |
CN105051278A (zh) * | 2012-12-11 | 2015-11-11 | 罗克伍尔国际公司 | 形成固化矿物纤维产品的方法 |
CN107257821A (zh) * | 2015-03-02 | 2017-10-17 | 圣戈班伊索福公司 | 热固泡沫和使用还原糖和胺的制造方法 |
CN107257821B (zh) * | 2015-03-02 | 2020-04-21 | 圣戈班伊索福公司 | 热固泡沫和使用还原糖和胺的制造方法 |
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BRPI0721233A2 (pt) | 2013-01-01 |
US20110089074A1 (en) | 2011-04-21 |
SI2826903T1 (sl) | 2023-10-30 |
EP2826903B1 (en) | 2023-04-26 |
ES2945888T3 (es) | 2023-07-10 |
ES2526345T3 (es) | 2015-01-09 |
EP2126179A1 (en) | 2009-12-02 |
WO2008089851A1 (en) | 2008-07-31 |
EP2826903B8 (en) | 2023-06-07 |
SI2126179T1 (sl) | 2014-12-31 |
US20100080976A1 (en) | 2010-04-01 |
DK2826903T3 (da) | 2023-06-06 |
EP2826903A1 (en) | 2015-01-21 |
CN101688343B (zh) | 2011-12-14 |
US7854980B2 (en) | 2010-12-21 |
PL2126179T3 (pl) | 2015-02-27 |
PT2126179E (pt) | 2014-12-29 |
PL2826903T3 (pl) | 2023-07-24 |
EP2126179B1 (en) | 2014-10-22 |
DK2126179T3 (da) | 2014-11-03 |
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