CA2078306A1 - Binder for mineral wool product - Google Patents
Binder for mineral wool productInfo
- Publication number
- CA2078306A1 CA2078306A1 CA002078306A CA2078306A CA2078306A1 CA 2078306 A1 CA2078306 A1 CA 2078306A1 CA 002078306 A CA002078306 A CA 002078306A CA 2078306 A CA2078306 A CA 2078306A CA 2078306 A1 CA2078306 A1 CA 2078306A1
- Authority
- CA
- Canada
- Prior art keywords
- compounds
- range
- binder
- weight
- total dry
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24C—DOMESTIC STOVES OR RANGES ; DETAILS OF DOMESTIC STOVES OR RANGES, OF GENERAL APPLICATION
- F24C15/00—Details
- F24C15/34—Elements and arrangements for heat storage or insulation
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
- C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C04B26/12—Condensation polymers of aldehydes or ketones
- C04B26/122—Phenol-formaldehyde condensation polymers
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Combustion & Propulsion (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Adhesives Or Adhesive Processes (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
Abstract
ABSTRACT OF THE INVENTION
A binder for an insulation product of mineral fibers comprises phenol-formaldehyde resin within the range of from about 75% to about 85% of the total dry bonding solids by weight, an alkyl glucoside within the range of from about 10% to about 25% of the total dry bonding solids by weight, and no more than about 5% of material from the group consisting essentially of urea compounds, melamine compounds and dicyandiamide compounds.
A binder for an insulation product of mineral fibers comprises phenol-formaldehyde resin within the range of from about 75% to about 85% of the total dry bonding solids by weight, an alkyl glucoside within the range of from about 10% to about 25% of the total dry bonding solids by weight, and no more than about 5% of material from the group consisting essentially of urea compounds, melamine compounds and dicyandiamide compounds.
Description
: :
TECHNICAL FIELD
This invention pertains to products made from mineral fibers, such as glass fibers. More particularly, this invention pertains to resinous binders useful in bonding the mineral fibers to each other in order to form an insulation product with desirable properties.
BACRGROUND ART
In the manufacture of insulation products from mineral fibers, a resinous thermosetting binder is typically added or sprayed on the fibers in order to provide a cohesive insulation product. Typically, the binder is sprayed on the fibers shortly after the fibers are formed, and prior to the collection of the fibers on a forming conveyor. ;~
Insulation products from mineral fibers, and particularly from glass fibers, comprise insulation for buildings, vehicles, appliances, and industrial equipment.
Typical binders for such products are thermosetting resins ; which are generally comprised of phenol-formaldehyde -condensation products. The binder-coated mineral fibers .,, ; . .
.,~.~ ~ :
J ;;
TECHNICAL FIELD
This invention pertains to products made from mineral fibers, such as glass fibers. More particularly, this invention pertains to resinous binders useful in bonding the mineral fibers to each other in order to form an insulation product with desirable properties.
BACRGROUND ART
In the manufacture of insulation products from mineral fibers, a resinous thermosetting binder is typically added or sprayed on the fibers in order to provide a cohesive insulation product. Typically, the binder is sprayed on the fibers shortly after the fibers are formed, and prior to the collection of the fibers on a forming conveyor. ;~
Insulation products from mineral fibers, and particularly from glass fibers, comprise insulation for buildings, vehicles, appliances, and industrial equipment.
Typical binders for such products are thermosetting resins ; which are generally comprised of phenol-formaldehyde -condensation products. The binder-coated mineral fibers .,, ; . .
.,~.~ ~ :
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2~7 ~ 6 232~3A
are moved through a curing oven where hot gases at temperatures up to about 500F. pass through the insulation product. The hot gases advance the thermosetting binder to a cured stage.
Phenol-formaldehyde binder systems for mineral fiber products usually contain modifiers such as coupling agents, oils, dyes, extenders, and catalysts. In order to prevent the release of harmful or noxious phenol compounds in the condensation reaction between phenol-formaldehyde, an excess amount of formaldehyde is typically used. At the conclusion of the condensation reaction, there is a remainder of excess formaldehyde. Frequently, amide type compounds, such as urea, dicyandiamide, or melamine, or derivatives of these nitrogenous compounds, are used to scavenge the excess formaldehyde. The amide compounds also help flexibilize the phenol-formaldehyde resin, which would otherwise be brittle. A typical binder for appliance insulation might include a premix of 61% by weight of a phenol-formaldehyde resol, 11~ urea, and 28%
dicyandiamide. Most binaers for mineral fiber insulation products made today are primarily phenol-formaldehyde based, with modification by one or more of these amide type compounds.
One of the problems with binders used in some mineral fiber insulation products is that under certain high temperature operating conditions the insulation products pr~duce noxious odors and undesirable particulate material, such as dust and smoke. This is particularly true with the use of insulation products for insulating residential self-cleaning ranges. The self-cleaning feature of residential self-cleaning ranges involves the process of heating the range to temperatures exceeding ~'f ~
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are moved through a curing oven where hot gases at temperatures up to about 500F. pass through the insulation product. The hot gases advance the thermosetting binder to a cured stage.
Phenol-formaldehyde binder systems for mineral fiber products usually contain modifiers such as coupling agents, oils, dyes, extenders, and catalysts. In order to prevent the release of harmful or noxious phenol compounds in the condensation reaction between phenol-formaldehyde, an excess amount of formaldehyde is typically used. At the conclusion of the condensation reaction, there is a remainder of excess formaldehyde. Frequently, amide type compounds, such as urea, dicyandiamide, or melamine, or derivatives of these nitrogenous compounds, are used to scavenge the excess formaldehyde. The amide compounds also help flexibilize the phenol-formaldehyde resin, which would otherwise be brittle. A typical binder for appliance insulation might include a premix of 61% by weight of a phenol-formaldehyde resol, 11~ urea, and 28%
dicyandiamide. Most binaers for mineral fiber insulation products made today are primarily phenol-formaldehyde based, with modification by one or more of these amide type compounds.
One of the problems with binders used in some mineral fiber insulation products is that under certain high temperature operating conditions the insulation products pr~duce noxious odors and undesirable particulate material, such as dust and smoke. This is particularly true with the use of insulation products for insulating residential self-cleaning ranges. The self-cleaning feature of residential self-cleaning ranges involves the process of heating the range to temperatures exceeding ~'f ~
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800F., and reaching as high as 950F. in order to clean soiled areas within the oven. Unfortunately, present day binder systems tend to offgas noxious odors and undesirable particulate material, such as smoke.
Fay, in U.S. Patent 4,595,630, attempted to solve the problem of unappealing smoke and odor during th~
self-cleaning cycle of a range by providing a dual staged curing step for the glass fiber insulation product.
Although this process has been partially effective in reducing some of the highly odorous byproducts of the self-cleaning cycle, the level of undesirable particulate material driven off by the self-cleaning cycle is not substantially improved. ~-Others have modified phenol-formaldehyde resins for various purposes for use in mineral fiber insulation products. For example, MacPherson et al., in U.S. Patent 4,339,361, disclose the replacement of some of the phenol-formaldehyde resin by sugar-type compounds. While it may be desirable to remove some of the phenol-formaldehyde resin, the sugars tend to caramelize and are thermally unstable in the self-cleaning cycle of the range.
Further, the sugars tend to hydrolyze in the water of the aqueous binder solution.
Other modifications to traditional binders for ; `
mineral fibers include the use of carbohydrates, such as starch and cellulose gums. However, if used in significant amounts (up to 20~) the viscosity of the binder mix increases so much as to be unsuitable for use in spraying as a binder for mineral fibers.
There is a need for a modification to existing ; insulation binder systems in order to reduce the noxious ; odors and particulate material driven off in the self-.. .: .: .
: . . ~
207~306 cleaning cycle o~ insulated residential ranges. Such modifications to existing ~inder systems should take into account the need to scavenge free formaldehyde remaining from the condensation reactions between phenol and formaldehyde. Further, the modification should still maintain the flexiblizing character which is needed to prevent the brittleness which would result from a pure phenol-formaldehyde binder.
DISCLOSURE OF THE INVENTION
There is now provided a binder for use with ~ineral fibers containing a phenol-formaldehyde resin and up to about 40% of a glucoside compound. The glucoside compound flexiblizes the phenol-formaldehyde condensation product, and scavenges free formaldehyde from the product.
The binder of the invention is thermally stable. The binder contains little, if any, nitrogenous compounds and, therefore, neither noxious odors nor undesirable 'r particulate material is released during the self-cleaning cycle of a residential range.
According to this invention, there is provided a bindèr for an insulation product of mineral fibers comprising phenol-formaldehyde resin within the range of ; from about 55% to about 95% of the total dry bonding solids by weight, and an alky~ glucoside within the range of from about S% to about 40% of the total dry bonding - -~
solids by weight, and no more than about 5% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
ln a preferred embodiment of the invention, the binder comprises phenol-formaldehyde resin within the range of from about 75% to about 85% of the total dry bonding solids by weight, and an alkyl glucoside within ",, 2~8~
800F., and reaching as high as 950F. in order to clean soiled areas within the oven. Unfortunately, present day binder systems tend to offgas noxious odors and undesirable particulate material, such as smoke.
Fay, in U.S. Patent 4,595,630, attempted to solve the problem of unappealing smoke and odor during th~
self-cleaning cycle of a range by providing a dual staged curing step for the glass fiber insulation product.
Although this process has been partially effective in reducing some of the highly odorous byproducts of the self-cleaning cycle, the level of undesirable particulate material driven off by the self-cleaning cycle is not substantially improved. ~-Others have modified phenol-formaldehyde resins for various purposes for use in mineral fiber insulation products. For example, MacPherson et al., in U.S. Patent 4,339,361, disclose the replacement of some of the phenol-formaldehyde resin by sugar-type compounds. While it may be desirable to remove some of the phenol-formaldehyde resin, the sugars tend to caramelize and are thermally unstable in the self-cleaning cycle of the range.
Further, the sugars tend to hydrolyze in the water of the aqueous binder solution.
Other modifications to traditional binders for ; `
mineral fibers include the use of carbohydrates, such as starch and cellulose gums. However, if used in significant amounts (up to 20~) the viscosity of the binder mix increases so much as to be unsuitable for use in spraying as a binder for mineral fibers.
There is a need for a modification to existing ; insulation binder systems in order to reduce the noxious ; odors and particulate material driven off in the self-.. .: .: .
: . . ~
207~306 cleaning cycle o~ insulated residential ranges. Such modifications to existing ~inder systems should take into account the need to scavenge free formaldehyde remaining from the condensation reactions between phenol and formaldehyde. Further, the modification should still maintain the flexiblizing character which is needed to prevent the brittleness which would result from a pure phenol-formaldehyde binder.
DISCLOSURE OF THE INVENTION
There is now provided a binder for use with ~ineral fibers containing a phenol-formaldehyde resin and up to about 40% of a glucoside compound. The glucoside compound flexiblizes the phenol-formaldehyde condensation product, and scavenges free formaldehyde from the product.
The binder of the invention is thermally stable. The binder contains little, if any, nitrogenous compounds and, therefore, neither noxious odors nor undesirable 'r particulate material is released during the self-cleaning cycle of a residential range.
According to this invention, there is provided a bindèr for an insulation product of mineral fibers comprising phenol-formaldehyde resin within the range of ; from about 55% to about 95% of the total dry bonding solids by weight, and an alky~ glucoside within the range of from about S% to about 40% of the total dry bonding - -~
solids by weight, and no more than about 5% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
ln a preferred embodiment of the invention, the binder comprises phenol-formaldehyde resin within the range of from about 75% to about 85% of the total dry bonding solids by weight, and an alkyl glucoside within ",, 2~8~
the range of from about 10% to about 25% of the total dry bonding solids by weight, and no more than about 5% of material from the group comprising urea compounds, - ~
melamine compounds and dicyandiamide compounds. ~-S In a specific embodiment of the invention the alkyl radical in the alkyl glucoside has 1 to 4 carbon ;~
atoms. Preferably, the alkyl glucoside is a methyl ~ -glucoside. Most preferably, the methyl glucoside comprises a mixture of alpha and beta isomers.
In a specific embodiment of the invention, there is substantially no material from the group comprising urea compounds, melamine compounds, and dicyandiamide ;~
compounds. --In yet another preferred embodiment of the invention, the binder contains, up to 40% by weight based on the bonding solids, one or more additives of the group -comprising dispersants, phosphoric acid, ammonium -~
hydroxide, silanes, and oil emulsion.
According to this invention there is also provided an insulation product of mineral fibers containing a binder comprising phenol-formaldehyde resin ~ ~-within the range of from about 55% to about 95% of the ; total dry bonding solids by weight, an alkyl glucoside within the range of from about 5% to about 40% of the total dry bonding solids by weight, and no more than about 5% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
Preferably, the insulation product contains a binder comprising phenol-formaldehyde resin within the range of from about 75% to about 85% of the total dry bonding solids by weight, an alkyl glucoside within the range of ~' ~
~.
: ~ -from about 10~ to about 25% of the total dry bonding solids by weight.
According to this in~ention there is also provided a range adapte~ with a self-cleaning cycle which raises the internal temperature of the range to at least 800-F, the range being insulated with an insulation product containing a binder comprising phenol-formaldehyde resin within the range of from about 55~ to about 95% of the total dry bonding solids by weight, an alkyl glucoside within the range of from about 5% to about 40~ of the total dry bonding solids by weight, and no more than about 5% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds, the insulation being characterized by releasing substantially no offensive odors from the compounds from the group co~prising cyanide, isocyanate, cyanuric acid and trimethylamine when the range goes through its self-cleaning cycle. Preferably, the range is insulated with an insulation product containing a binder comprising phenol-formaldehyde resin within the range of from about 75% to about 85% of the total dry bonding solids by ;~ weight, an alkyl glucoside within the range of from about 10% to about 25% of the total dry bonding solids by weight. Preferably, the range is an electric range, although it is to be understood that the range can be alternati~ely fueled, such as a gas range.
- BRIEF DESCRIPTION OF THE DRAWING --The drawing figure illustrates an electric range insulated with an insulation product according to the invention.
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BEST MODE FOR CARRYING OUT THE INVENTION
Although the invention is described as being an insulation product, or a binder for an insulation product, comprised of glass fibers, it is to be understood that the fibers can be other mineral fibers, such as rock fibers, slaq fibers, or basalt fibers.
As shown in the drawing, electric range 10 is insulated in its walls with insulation product 12. The insulation product is shown in the cut away portion of the walls. -The glucoside used with the binder of the invention is preferably an alkyl glucoside, and most preferably a methyl glucoside. Methyl glucoside is a stable, very low odor material derived from starch. A
preferred glucoside is Sta-Meg 200 methyl glucoside from Horizon Chemical, Decatur, Illinois. Horizon's product literature suggests that Sta-Meg methyl glucoside be used to replace or extend components in phenolic or melamine resins. The Horizon literature suggests that the use of Sta-Meg methyl glucoside will enhance the qualities of -~
phenolic resins used in glass insulation, by improving the storage stability of water soluble phenolic resins and ; improving the resin clarity and flow during processing.
Further, the Horizon literature suggests that adding Sta-Meg methyl glucoside to the binder solution reduces formaldehyde emissions, thereby resulting in a perception ~ ?
of reduc~ed odors by consumers. There is no suggestion in the Horizon Chemical literature that glucoside can be used to replace t~e nitrogenous compounds, and that the result would be an acceptable binder having reduced nitrogenous-based noxious odors during the self-cleaning cycle of an electric range.
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The glucoside is added to the phenol-formaldehyde as an aqueous solution. Although some additives, such as oils and dispersants can be added, the resinous premix contains no more than about 5~ of amide compounds fron the group consisting essentially of urea compounds, melamine compounds and dicyandiamide compounds.
Preferably, there are no more than about 3% of these amide compounds. More preferably, there are no more than about 1% of these amide compounds. Most preferably, there are substantially none of these compounds.
One of the additional benefits of removing most, if not all, of the a~ide compounds from the binder is the elimination of the offgasing of the noxious gas SO2 during the self-cleaning cycle of the range. The S2 iS a result of ammonium sulphate added to conventional binders as a catalyst for the amide compounds.
The viscosity of the binder of the invention should be less than about 20 cps and preferably within the range of from about 10 cps to 15 cps. The pH condition of the binder should be within the range of from about 7 to about 11.
Exam~le 1 A calcium catalyzed phenol-formaldehyde resin ~ -according to the invention was prepared by mixing an aqueous solution of phenol with formaldehyde in a formaldehyde-to-phenol mole ratio of 3.7:1. The resin was cooked to a resol stage in the presence of a Ca(OH) 2 catalyst. Thereafter, the phenol-formaldehyde resol was mixed with enough Sta-Meg 200 so that the glucoside constituted 20% by weight of the total dry bonding solids.
The total binder formulation included these ingredients~
Table 1 Ingredients In Bonding Additives (% Based ~ t~
Order Q~ Addition Solids Ratio On Bondina Solids) Water ;~
Resin 80 Sta-Meg 200 20 ;
EXI-45 (dispersant) 0.08 + 0.02 Phosphoric Acid pH 8.0 + 0.2 Ammonium Hydroxide 7.20 + 0.50 ~-Silane 0.50 + 0.25 l ;
Oil Emulsion 18.0 + 2.0 ;~
The viscosity of the binder was about 12 cps. The pH
condition of the binder was adjusted to about 8.5 with the ~ ammonium hydroxide. ;~
i~ The binder was applied to glass fibers, and the glass fibers were made into an insulation product having approximately 1-1/2% by weight binder, and the product was cured in a conventional fiberglass curing oven at ~;~` approx~mately 500~F. A one foot square sample of the --product was then heated on a hot plate at approximately 850-F. for a period of 30 minutes. It was observed that the amount of noxious emissions, particularly ammonia, was reduced compared with the emissions from a control product made with conventional binder formulations having amide ' ;~ ' ''~ '~ ~' -lO- 2~306 components. Physical irritation to the eyes and mucous membranes was also reduced.
Example 2 ~~
An insulation product having a binder prepared according to Example 1 was tested for emissions under conditions of heating at a temperature in excess of 850F.
for two hours. The emissions from the insulation sample of the invention were compared with the emissions from samples prepared with conventional binders. Gas sampling measurements indicated substantially reduced levels of noxious components compared to the emissions of the conventional products. Specifically, no ammonia or sulfur dioxide was detected. Also, there were substantially no cyanuric acid, cyanide or isocyanate emissions.
ExamDle 3 In another test, two ranges were placed in large environmental rooms for an odor panel comparison. One -~
range was insulated with the binder and insulation product of the invention, prepa~ed according to Example 1. The other range was insulated with conventional insulation having nitrogenous compounds. Each range was cycled through its self-cleaning cycle. After one hour the particulate levels in the two rooms were compared. The control range produced a particulate level (smoke) of 4.84 mg/cubic meter, whereas the range of the invention produced a particulate level of 0.21 mg/cubic meter.
Thus, the binder and insulation product of the invention significantly reduce levels of particulates (smoke) during a self-cleaning cycle.
During the tests in Examples 2 and 3, it was ~ound that the insulation sample of the invention released substantially no compounds from the group comprising -11- 2-~7~
cyanide, isocyanate, cyanuric acid and trimethylamine when the range went through its self-cleaning cycle, or when ;;
the sample was heated to a temperature of 850F. Further, the insulation sample of the invention released substantially no offensive odors from the compounds from the group comprising cyanide, isocyanate, cyanuric acid and trimethylamine when the sample range went through its ~ -~
self-cleaning cycle, or when the sample was heated to a temperature of 850-F. The use of the term "substantially no compounds" means less than about 10 parts per million of these compounds. The use of the term "substantially no offensive odors from the compounds" means the absence of, or extremely low level of, noxious odors of the type which offend the olfactory senses and/or cause irritation in the eyes and mucous membranes of human beings. ~-It has been found that the insulation material of the invention produces significantly less dust during~
fabrication of the insulation material into the electric ranges than the amount of dust produced by insulation products having conventional binders.
INDUSTRIAL APPLICABILITY -~
This invention will be found to be useful in making mineral fiber insulation products for electric ranges. ~-
melamine compounds and dicyandiamide compounds. ~-S In a specific embodiment of the invention the alkyl radical in the alkyl glucoside has 1 to 4 carbon ;~
atoms. Preferably, the alkyl glucoside is a methyl ~ -glucoside. Most preferably, the methyl glucoside comprises a mixture of alpha and beta isomers.
In a specific embodiment of the invention, there is substantially no material from the group comprising urea compounds, melamine compounds, and dicyandiamide ;~
compounds. --In yet another preferred embodiment of the invention, the binder contains, up to 40% by weight based on the bonding solids, one or more additives of the group -comprising dispersants, phosphoric acid, ammonium -~
hydroxide, silanes, and oil emulsion.
According to this invention there is also provided an insulation product of mineral fibers containing a binder comprising phenol-formaldehyde resin ~ ~-within the range of from about 55% to about 95% of the ; total dry bonding solids by weight, an alkyl glucoside within the range of from about 5% to about 40% of the total dry bonding solids by weight, and no more than about 5% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
Preferably, the insulation product contains a binder comprising phenol-formaldehyde resin within the range of from about 75% to about 85% of the total dry bonding solids by weight, an alkyl glucoside within the range of ~' ~
~.
: ~ -from about 10~ to about 25% of the total dry bonding solids by weight.
According to this in~ention there is also provided a range adapte~ with a self-cleaning cycle which raises the internal temperature of the range to at least 800-F, the range being insulated with an insulation product containing a binder comprising phenol-formaldehyde resin within the range of from about 55~ to about 95% of the total dry bonding solids by weight, an alkyl glucoside within the range of from about 5% to about 40~ of the total dry bonding solids by weight, and no more than about 5% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds, the insulation being characterized by releasing substantially no offensive odors from the compounds from the group co~prising cyanide, isocyanate, cyanuric acid and trimethylamine when the range goes through its self-cleaning cycle. Preferably, the range is insulated with an insulation product containing a binder comprising phenol-formaldehyde resin within the range of from about 75% to about 85% of the total dry bonding solids by ;~ weight, an alkyl glucoside within the range of from about 10% to about 25% of the total dry bonding solids by weight. Preferably, the range is an electric range, although it is to be understood that the range can be alternati~ely fueled, such as a gas range.
- BRIEF DESCRIPTION OF THE DRAWING --The drawing figure illustrates an electric range insulated with an insulation product according to the invention.
~, ~ .
:
.,. . ~ ,~ ~, .i,. . . ~ . .
BEST MODE FOR CARRYING OUT THE INVENTION
Although the invention is described as being an insulation product, or a binder for an insulation product, comprised of glass fibers, it is to be understood that the fibers can be other mineral fibers, such as rock fibers, slaq fibers, or basalt fibers.
As shown in the drawing, electric range 10 is insulated in its walls with insulation product 12. The insulation product is shown in the cut away portion of the walls. -The glucoside used with the binder of the invention is preferably an alkyl glucoside, and most preferably a methyl glucoside. Methyl glucoside is a stable, very low odor material derived from starch. A
preferred glucoside is Sta-Meg 200 methyl glucoside from Horizon Chemical, Decatur, Illinois. Horizon's product literature suggests that Sta-Meg methyl glucoside be used to replace or extend components in phenolic or melamine resins. The Horizon literature suggests that the use of Sta-Meg methyl glucoside will enhance the qualities of -~
phenolic resins used in glass insulation, by improving the storage stability of water soluble phenolic resins and ; improving the resin clarity and flow during processing.
Further, the Horizon literature suggests that adding Sta-Meg methyl glucoside to the binder solution reduces formaldehyde emissions, thereby resulting in a perception ~ ?
of reduc~ed odors by consumers. There is no suggestion in the Horizon Chemical literature that glucoside can be used to replace t~e nitrogenous compounds, and that the result would be an acceptable binder having reduced nitrogenous-based noxious odors during the self-cleaning cycle of an electric range.
~~: -~,; ....
The glucoside is added to the phenol-formaldehyde as an aqueous solution. Although some additives, such as oils and dispersants can be added, the resinous premix contains no more than about 5~ of amide compounds fron the group consisting essentially of urea compounds, melamine compounds and dicyandiamide compounds.
Preferably, there are no more than about 3% of these amide compounds. More preferably, there are no more than about 1% of these amide compounds. Most preferably, there are substantially none of these compounds.
One of the additional benefits of removing most, if not all, of the a~ide compounds from the binder is the elimination of the offgasing of the noxious gas SO2 during the self-cleaning cycle of the range. The S2 iS a result of ammonium sulphate added to conventional binders as a catalyst for the amide compounds.
The viscosity of the binder of the invention should be less than about 20 cps and preferably within the range of from about 10 cps to 15 cps. The pH condition of the binder should be within the range of from about 7 to about 11.
Exam~le 1 A calcium catalyzed phenol-formaldehyde resin ~ -according to the invention was prepared by mixing an aqueous solution of phenol with formaldehyde in a formaldehyde-to-phenol mole ratio of 3.7:1. The resin was cooked to a resol stage in the presence of a Ca(OH) 2 catalyst. Thereafter, the phenol-formaldehyde resol was mixed with enough Sta-Meg 200 so that the glucoside constituted 20% by weight of the total dry bonding solids.
The total binder formulation included these ingredients~
Table 1 Ingredients In Bonding Additives (% Based ~ t~
Order Q~ Addition Solids Ratio On Bondina Solids) Water ;~
Resin 80 Sta-Meg 200 20 ;
EXI-45 (dispersant) 0.08 + 0.02 Phosphoric Acid pH 8.0 + 0.2 Ammonium Hydroxide 7.20 + 0.50 ~-Silane 0.50 + 0.25 l ;
Oil Emulsion 18.0 + 2.0 ;~
The viscosity of the binder was about 12 cps. The pH
condition of the binder was adjusted to about 8.5 with the ~ ammonium hydroxide. ;~
i~ The binder was applied to glass fibers, and the glass fibers were made into an insulation product having approximately 1-1/2% by weight binder, and the product was cured in a conventional fiberglass curing oven at ~;~` approx~mately 500~F. A one foot square sample of the --product was then heated on a hot plate at approximately 850-F. for a period of 30 minutes. It was observed that the amount of noxious emissions, particularly ammonia, was reduced compared with the emissions from a control product made with conventional binder formulations having amide ' ;~ ' ''~ '~ ~' -lO- 2~306 components. Physical irritation to the eyes and mucous membranes was also reduced.
Example 2 ~~
An insulation product having a binder prepared according to Example 1 was tested for emissions under conditions of heating at a temperature in excess of 850F.
for two hours. The emissions from the insulation sample of the invention were compared with the emissions from samples prepared with conventional binders. Gas sampling measurements indicated substantially reduced levels of noxious components compared to the emissions of the conventional products. Specifically, no ammonia or sulfur dioxide was detected. Also, there were substantially no cyanuric acid, cyanide or isocyanate emissions.
ExamDle 3 In another test, two ranges were placed in large environmental rooms for an odor panel comparison. One -~
range was insulated with the binder and insulation product of the invention, prepa~ed according to Example 1. The other range was insulated with conventional insulation having nitrogenous compounds. Each range was cycled through its self-cleaning cycle. After one hour the particulate levels in the two rooms were compared. The control range produced a particulate level (smoke) of 4.84 mg/cubic meter, whereas the range of the invention produced a particulate level of 0.21 mg/cubic meter.
Thus, the binder and insulation product of the invention significantly reduce levels of particulates (smoke) during a self-cleaning cycle.
During the tests in Examples 2 and 3, it was ~ound that the insulation sample of the invention released substantially no compounds from the group comprising -11- 2-~7~
cyanide, isocyanate, cyanuric acid and trimethylamine when the range went through its self-cleaning cycle, or when ;;
the sample was heated to a temperature of 850F. Further, the insulation sample of the invention released substantially no offensive odors from the compounds from the group comprising cyanide, isocyanate, cyanuric acid and trimethylamine when the sample range went through its ~ -~
self-cleaning cycle, or when the sample was heated to a temperature of 850-F. The use of the term "substantially no compounds" means less than about 10 parts per million of these compounds. The use of the term "substantially no offensive odors from the compounds" means the absence of, or extremely low level of, noxious odors of the type which offend the olfactory senses and/or cause irritation in the eyes and mucous membranes of human beings. ~-It has been found that the insulation material of the invention produces significantly less dust during~
fabrication of the insulation material into the electric ranges than the amount of dust produced by insulation products having conventional binders.
INDUSTRIAL APPLICABILITY -~
This invention will be found to be useful in making mineral fiber insulation products for electric ranges. ~-
Claims (20)
1. A binder for an insulation product of mineral fibers consisting essentially of phenol-formaldehyde resin within the range of from 55% to 95% of the total dry bonding solids by weight, an alkyl glucoside within the range of from 5% to 40% of the total dry bonding solids by weight, and up to 3% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
2. The binder of claim 1 consisting essentially of phenol-formaldehyde resin within the range of from 75%
to 85% of the total dry bonding solids by weight, an alkyl glucoside within the range of from 10% to 25% of the total dry bonding solids by weight, and up to 3% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
to 85% of the total dry bonding solids by weight, an alkyl glucoside within the range of from 10% to 25% of the total dry bonding solids by weight, and up to 3% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
3. The binder of claim 2 wherein the alkyl radical has 1 to 4 carbon atoms.
4. The binder of claim 3 in which the alkyl glucoside comprises a methyl glucoside.
5. The binder of claim 4 in which the methyl glucoside comprises a mixture of alpha and beta isomers.
6. The binder of claim 5 having a pH within the range of from about 7 to about 11.
7. The binder of claim 6 in which there is no more than about 3% from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
8. me binder of claim 6 in which there is up to 1% from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
9. The binder of claim 8 in which there is substantially no material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
10. The binder of claim 2 in an aqueous solution which further contains, up to 40% by weight based on the bonding solids, one or more additives of the group comprising dispersants, phosphoric acid, ammonium hydroxide, silanes, and oil emulsion.
11. An insulation product of mineral fibers containing a binder consisting essentially of phenol-formaldehyde resin within the range of from 55% to 95% of the total dry bonding solids by weight, an alkyl glucoside within the range of from 5% to 40% of the total dry bonding solids by weight, and up to 3% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
12. The insulation product of claim 11 consisting essentially of phenol-formaldehyde resin within the range of from 75% to 85% of the total dry bonding solids by weight, an alkyl glucoside within the range of from 10% to 25% of the total dry bonding solids by weight, and up to 3% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
13. The insulation product of claim 12 wherein the alkyl radical has 1 to 4 carbon atoms.
14. The insulation product of claim 13 in which the alkyl glucoside comprises a methyl glucoside.
15. The insulation product of claim 14 in which the methyl glucoside comprises a mixture of alpha and beta isomers.
16. The insulation product of claim 15 in which there is substantially no material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
17. A range adapted with a self-cleaning cycle which raises the internal temperature of the range to at least 800°F, the range being insulated with an insulation product containing a binder consisting essentially of phenol-formaldehyde resin within the range of from 55% to 95% of the total dry bonding solids by weight, an alkyl glucoside within the range of from 5% to 40% of the total dry bonding solids by weight, and up to 3% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds, the insulation being characterized by releasing substantially no offensive odors from the compounds from the group comprising cyanide, isocyanate, cyanuric acid and trimethylamine when the range goes through its self-cleaning cycle.
18. A range of claim 17 consisting essentially of phenol-formaldehyde resin within the range of from 75%
to 85% of the total dry bonding solids by weight, an alkyl glucoside within the range of from 10% to 25% of the total dry bonding solids by weight, and up to 3% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
to 85% of the total dry bonding solids by weight, an alkyl glucoside within the range of from 10% to 25% of the total dry bonding solids by weight, and up to 3% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
19. A range adapted with a self-cleaning cycle which raises the internal temperature of the range to at least 800-F, the range being insulated with an insulation product containing a binder consisting essentially of phenol-formaldehyde resin within the range of from 55% to 95% of the total dry bonding solids by weight, an alkyl glucoside within the range of from 5% to 40% of the total dry bonding solids by weight, and up to 3% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds, the insulation being characterized by releasing substantially no compounds from the group comprising cyanide, isocyanate, cyanuric acid and trimethylamine when the range goes through its self-cleaning cycle.
20. A range of claim 19 consisting essentially of phenol-formaldehyde resin within the range of from 75%
to 85% of the total dry bonding solids by weight, an alkyl glucoside within the range of from 10% to 25% of the total dry bonding solids by weight, and up to 3% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
to 85% of the total dry bonding solids by weight, an alkyl glucoside within the range of from 10% to 25% of the total dry bonding solids by weight, and up to 3% of material from the group comprising urea compounds, melamine compounds and dicyandiamide compounds.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002078306A CA2078306A1 (en) | 1992-09-15 | 1992-09-15 | Binder for mineral wool product |
| JP4285287A JPH06136237A (en) | 1992-09-15 | 1992-09-30 | Binding agent for insulation article made of mineral fiber |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002078306A CA2078306A1 (en) | 1992-09-15 | 1992-09-15 | Binder for mineral wool product |
| JP4285287A JPH06136237A (en) | 1992-09-15 | 1992-09-30 | Binding agent for insulation article made of mineral fiber |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2078306A1 true CA2078306A1 (en) | 1994-03-16 |
Family
ID=25675526
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002078306A Abandoned CA2078306A1 (en) | 1992-09-15 | 1992-09-15 | Binder for mineral wool product |
Country Status (2)
| Country | Link |
|---|---|
| JP (1) | JPH06136237A (en) |
| CA (1) | CA2078306A1 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5358748A (en) * | 1992-05-19 | 1994-10-25 | Schuller International, Inc. | Acidic glass fiber binding composition, method of use and curable glass fiber compositions |
| FR2810031B1 (en) * | 2000-06-13 | 2003-03-07 | Saint Gobain Isover | INSULATION PRODUCT, ESPECIALLY THERMAL, AND ITS MANUFACTURE |
| CN106832167B (en) * | 2017-01-16 | 2019-02-22 | 浙江农林大学 | The preparation method of Scrimber impregnated phenolic resin |
-
1992
- 1992-09-15 CA CA002078306A patent/CA2078306A1/en not_active Abandoned
- 1992-09-30 JP JP4285287A patent/JPH06136237A/en not_active Withdrawn
Also Published As
| Publication number | Publication date |
|---|---|
| JPH06136237A (en) | 1994-05-17 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Discontinued |