JP7112807B2 - バインダー - Google Patents
バインダー Download PDFInfo
- Publication number
- JP7112807B2 JP7112807B2 JP2019135987A JP2019135987A JP7112807B2 JP 7112807 B2 JP7112807 B2 JP 7112807B2 JP 2019135987 A JP2019135987 A JP 2019135987A JP 2019135987 A JP2019135987 A JP 2019135987A JP 7112807 B2 JP7112807 B2 JP 7112807B2
- Authority
- JP
- Japan
- Prior art keywords
- binder
- less
- binder solution
- mineral
- curing
- 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.)
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- 239000011230 binding agent Substances 0.000 title claims description 189
- 239000002557 mineral fiber Substances 0.000 claims description 46
- 239000002243 precursor Substances 0.000 claims description 43
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 claims description 36
- 239000002253 acid Substances 0.000 claims description 35
- 238000000034 method Methods 0.000 claims description 31
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 26
- 235000000346 sugar Nutrition 0.000 claims description 24
- 238000009413 insulation Methods 0.000 claims description 23
- 235000014633 carbohydrates Nutrition 0.000 claims description 17
- 150000001720 carbohydrates Chemical class 0.000 claims description 16
- 238000000926 separation method Methods 0.000 claims description 16
- 239000000835 fiber Substances 0.000 claims description 15
- 239000000203 mixture Substances 0.000 claims description 14
- 150000003863 ammonium salts Chemical class 0.000 claims description 13
- 239000011490 mineral wool Substances 0.000 claims description 12
- 239000007787 solid Substances 0.000 claims description 12
- 239000000654 additive Substances 0.000 claims description 11
- WQZGKKKJIJFFOK-GASJEMHNSA-N Glucose Natural products OC[C@H]1OC(O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-GASJEMHNSA-N 0.000 claims description 10
- 238000006243 chemical reaction Methods 0.000 claims description 10
- 150000007524 organic acids Chemical class 0.000 claims description 10
- 150000003839 salts Chemical class 0.000 claims description 10
- 229910019142 PO4 Inorganic materials 0.000 claims description 8
- 239000008103 glucose Substances 0.000 claims description 8
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 claims description 7
- 229910000077 silane Inorganic materials 0.000 claims description 7
- 229910052500 inorganic mineral Inorganic materials 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 239000011707 mineral Substances 0.000 claims description 6
- 238000005507 spraying Methods 0.000 claims description 6
- 229920001187 thermosetting polymer Polymers 0.000 claims description 5
- 239000011491 glass wool Substances 0.000 claims description 4
- 230000007935 neutral effect Effects 0.000 claims description 4
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 claims description 3
- 150000008064 anhydrides Chemical class 0.000 claims description 3
- 238000001035 drying Methods 0.000 claims description 3
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 claims description 2
- 239000010452 phosphate Substances 0.000 claims description 2
- 229910021653 sulphate ion Inorganic materials 0.000 claims description 2
- 230000000996 additive effect Effects 0.000 claims 1
- 238000001704 evaporation Methods 0.000 claims 1
- 239000000243 solution Substances 0.000 description 74
- 239000000463 material Substances 0.000 description 45
- 238000001723 curing Methods 0.000 description 36
- 239000000047 product Substances 0.000 description 35
- QGZKDVFQNNGYKY-UHFFFAOYSA-N ammonia Natural products N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 32
- 238000012360 testing method Methods 0.000 description 31
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 description 29
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 16
- 229910021529 ammonia Inorganic materials 0.000 description 15
- MNNHAPBLZZVQHP-UHFFFAOYSA-N diammonium hydrogen phosphate Chemical compound [NH4+].[NH4+].OP([O-])([O-])=O MNNHAPBLZZVQHP-UHFFFAOYSA-N 0.000 description 15
- 150000008163 sugars Chemical class 0.000 description 15
- 229910000148 ammonium phosphate Inorganic materials 0.000 description 14
- 239000004254 Ammonium phosphate Substances 0.000 description 13
- 235000019289 ammonium phosphates Nutrition 0.000 description 13
- 229940077731 carbohydrate nutrients Drugs 0.000 description 13
- BFNBIHQBYMNNAN-UHFFFAOYSA-N ammonium sulfate Chemical compound N.N.OS(O)(=O)=O BFNBIHQBYMNNAN-UHFFFAOYSA-N 0.000 description 12
- 210000000988 bone and bone Anatomy 0.000 description 12
- 239000002023 wood Substances 0.000 description 12
- 229910052921 ammonium sulfate Inorganic materials 0.000 description 11
- 235000011130 ammonium sulphate Nutrition 0.000 description 11
- 230000008901 benefit Effects 0.000 description 10
- WQZGKKKJIJFFOK-VFUOTHLCSA-N beta-D-glucose Chemical compound OC[C@H]1O[C@@H](O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-VFUOTHLCSA-N 0.000 description 10
- 229960001031 glucose Drugs 0.000 description 10
- ATRRKUHOCOJYRX-UHFFFAOYSA-N Ammonium bicarbonate Chemical compound [NH4+].OC([O-])=O ATRRKUHOCOJYRX-UHFFFAOYSA-N 0.000 description 9
- 239000001099 ammonium carbonate Substances 0.000 description 9
- 229960004106 citric acid Drugs 0.000 description 9
- 235000012501 ammonium carbonate Nutrition 0.000 description 8
- 229910052757 nitrogen Inorganic materials 0.000 description 8
- PAWQVTBBRAZDMG-UHFFFAOYSA-N 2-(3-bromo-2-fluorophenyl)acetic acid Chemical compound OC(=O)CC1=CC=CC(Br)=C1F PAWQVTBBRAZDMG-UHFFFAOYSA-N 0.000 description 7
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical compound [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 7
- 235000021317 phosphate Nutrition 0.000 description 7
- 235000011114 ammonium hydroxide Nutrition 0.000 description 6
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 6
- 150000002823 nitrates Chemical class 0.000 description 6
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 6
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 6
- 210000002268 wool Anatomy 0.000 description 6
- 239000011324 bead Substances 0.000 description 5
- 150000001732 carboxylic acid derivatives Chemical class 0.000 description 5
- 238000002156 mixing Methods 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- 239000007864 aqueous solution Substances 0.000 description 4
- 239000011094 fiberboard Substances 0.000 description 4
- 238000009472 formulation Methods 0.000 description 4
- 239000011521 glass Substances 0.000 description 4
- 229910017053 inorganic salt Inorganic materials 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 150000007522 mineralic acids Chemical class 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- 239000004033 plastic Substances 0.000 description 4
- 229920003023 plastic Polymers 0.000 description 4
- 239000000376 reactant Substances 0.000 description 4
- -1 reducing sugars) Chemical class 0.000 description 4
- 239000004575 stone Substances 0.000 description 4
- 230000002378 acidificating effect Effects 0.000 description 3
- 239000000908 ammonium hydroxide Substances 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 238000012662 bulk polymerization Methods 0.000 description 3
- 239000011810 insulating material Substances 0.000 description 3
- 235000005985 organic acids Nutrition 0.000 description 3
- 238000006116 polymerization reaction Methods 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- 229920002472 Starch Polymers 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
- 150000007513 acids Chemical class 0.000 description 2
- 150000001412 amines Chemical class 0.000 description 2
- ZRIUUUJAJJNDSS-UHFFFAOYSA-N ammonium phosphates Chemical compound [NH4+].[NH4+].[NH4+].[O-]P([O-])([O-])=O ZRIUUUJAJJNDSS-UHFFFAOYSA-N 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 239000007822 coupling agent Substances 0.000 description 2
- 230000018044 dehydration Effects 0.000 description 2
- 238000006297 dehydration reaction Methods 0.000 description 2
- 239000008121 dextrose Substances 0.000 description 2
- KPUWHANPEXNPJT-UHFFFAOYSA-N disiloxane Chemical compound [SiH3]O[SiH3] KPUWHANPEXNPJT-UHFFFAOYSA-N 0.000 description 2
- 239000011152 fibreglass Substances 0.000 description 2
- SLGWESQGEUXWJQ-UHFFFAOYSA-N formaldehyde;phenol Chemical compound O=C.OC1=CC=CC=C1 SLGWESQGEUXWJQ-UHFFFAOYSA-N 0.000 description 2
- 239000012774 insulation material Substances 0.000 description 2
- 238000002386 leaching Methods 0.000 description 2
- 230000007774 longterm Effects 0.000 description 2
- 229920001568 phenolic resin Polymers 0.000 description 2
- 238000001556 precipitation Methods 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 238000011084 recovery Methods 0.000 description 2
- 150000004756 silanes Chemical class 0.000 description 2
- 235000019698 starch Nutrition 0.000 description 2
- 239000008107 starch Substances 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- YWYZEGXAUVWDED-UHFFFAOYSA-N triammonium citrate Chemical compound [NH4+].[NH4+].[NH4+].[O-]C(=O)CC(O)(CC([O-])=O)C([O-])=O YWYZEGXAUVWDED-UHFFFAOYSA-N 0.000 description 2
- XISYMCYXGZPFRD-OVNWPFPBSA-N triazanium;2-hydroxypropane-1,2,3-tricarboxylate;(2r,3s,4r,5r)-2,3,4,5,6-pentahydroxyhexanal Chemical compound [NH4+].[NH4+].[NH4+].OC[C@@H](O)[C@@H](O)[C@H](O)[C@@H](O)C=O.[O-]C(=O)CC(O)(CC([O-])=O)C([O-])=O XISYMCYXGZPFRD-OVNWPFPBSA-N 0.000 description 2
- 239000001993 wax Substances 0.000 description 2
- 230000004580 weight loss Effects 0.000 description 2
- XDIYNQZUNSSENW-UUBOPVPUSA-N (2R,3S,4R,5R)-2,3,4,5,6-pentahydroxyhexanal Chemical compound OC[C@@H](O)[C@@H](O)[C@H](O)[C@@H](O)C=O.OC[C@@H](O)[C@@H](O)[C@H](O)[C@@H](O)C=O XDIYNQZUNSSENW-UUBOPVPUSA-N 0.000 description 1
- SPFMQWBKVUQXJV-BTVCFUMJSA-N (2r,3s,4r,5r)-2,3,4,5,6-pentahydroxyhexanal;hydrate Chemical compound O.OC[C@@H](O)[C@@H](O)[C@H](O)[C@@H](O)C=O SPFMQWBKVUQXJV-BTVCFUMJSA-N 0.000 description 1
- WCWOEQFAYSXBRK-GASJEMHNSA-N (3r,4s,5s,6r)-2-amino-6-(hydroxymethyl)oxane-3,4,5-triol Chemical compound NC1O[C@H](CO)[C@@H](O)[C@H](O)[C@H]1O WCWOEQFAYSXBRK-GASJEMHNSA-N 0.000 description 1
- 229910000013 Ammonium bicarbonate Inorganic materials 0.000 description 1
- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonium chloride Substances [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 description 1
- 229920003043 Cellulose fiber Polymers 0.000 description 1
- 229920002245 Dextrose equivalent Polymers 0.000 description 1
- 239000005696 Diammonium phosphate Substances 0.000 description 1
- 208000007976 Ketosis Diseases 0.000 description 1
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 229920002125 Sokalan® Polymers 0.000 description 1
- 229920002522 Wood fibre Polymers 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 125000003172 aldehyde group Chemical group 0.000 description 1
- 150000001299 aldehydes Chemical class 0.000 description 1
- 150000001323 aldoses Chemical class 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 125000003277 amino group Chemical group 0.000 description 1
- 235000012538 ammonium bicarbonate Nutrition 0.000 description 1
- PRKQVKDSMLBJBJ-UHFFFAOYSA-N ammonium carbonate Chemical class N.N.OC(O)=O PRKQVKDSMLBJBJ-UHFFFAOYSA-N 0.000 description 1
- LFVGISIMTYGQHF-UHFFFAOYSA-N ammonium dihydrogen phosphate Chemical compound [NH4+].OP(O)([O-])=O LFVGISIMTYGQHF-UHFFFAOYSA-N 0.000 description 1
- 229910000387 ammonium dihydrogen phosphate Inorganic materials 0.000 description 1
- DVARTQFDIMZBAA-UHFFFAOYSA-O ammonium nitrate Chemical class [NH4+].[O-][N+]([O-])=O DVARTQFDIMZBAA-UHFFFAOYSA-O 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 229960004543 anhydrous citric acid Drugs 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 150000001735 carboxylic acids Chemical class 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000011093 chipboard Substances 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 229960000673 dextrose monohydrate Drugs 0.000 description 1
- 229910000388 diammonium phosphate Inorganic materials 0.000 description 1
- 235000019838 diammonium phosphate Nutrition 0.000 description 1
- 238000002845 discoloration Methods 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 239000012153 distilled water Substances 0.000 description 1
- 238000000921 elemental analysis Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000004880 explosion Methods 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 235000013305 food Nutrition 0.000 description 1
- 239000003517 fume Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000002209 hydrophobic effect Effects 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 239000000543 intermediate Substances 0.000 description 1
- 150000002584 ketoses Chemical class 0.000 description 1
- WSFSSNUMVMOOMR-NJFSPNSNSA-N methanone Chemical compound O=[14CH2] WSFSSNUMVMOOMR-NJFSPNSNSA-N 0.000 description 1
- 239000002480 mineral oil Substances 0.000 description 1
- 235000019837 monoammonium phosphate Nutrition 0.000 description 1
- 239000006012 monoammonium phosphate Substances 0.000 description 1
- 150000002772 monosaccharides Chemical class 0.000 description 1
- 229910017604 nitric acid Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 150000002989 phenols Chemical class 0.000 description 1
- 239000004584 polyacrylic acid Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 108090000623 proteins and genes Proteins 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 239000002210 silicon-based material Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 238000001029 thermal curing Methods 0.000 description 1
- 239000001393 triammonium citrate Substances 0.000 description 1
- 235000011046 triammonium citrate Nutrition 0.000 description 1
- 150000003627 tricarboxylic acid derivatives Chemical class 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 239000002351 wastewater Substances 0.000 description 1
- 239000002025 wood fiber Substances 0.000 description 1
Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L59/00—Thermal insulation in general
- F16L59/02—Shape or form of insulating materials, with or without coverings integral with the insulating materials
- F16L59/028—Composition or method of fixing a thermally insulating material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
- C03C25/10—Coating
- C03C25/24—Coatings containing organic materials
- C03C25/26—Macromolecular compounds or prepolymers
- C03C25/32—Macromolecular compounds or prepolymers obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds
- C03C25/321—Starch; Starch derivatives
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
- B27N3/002—Manufacture of substantially flat articles, e.g. boards, from particles or fibres characterised by the type of binder
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C13/00—Fibre or filament compositions
- C03C13/06—Mineral fibres, e.g. slag wool, mineral wool, rock wool
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
- C03C25/10—Coating
- C03C25/24—Coatings containing organic materials
- C03C25/26—Macromolecular compounds or prepolymers
- C03C25/32—Macromolecular compounds or prepolymers obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
- C03C25/10—Coating
- C03C25/24—Coatings containing organic materials
- C03C25/26—Macromolecular compounds or prepolymers
- C03C25/32—Macromolecular compounds or prepolymers obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds
- C03C25/34—Condensation polymers of aldehydes, e.g. with phenols, ureas, melamines, amides or amines
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07H—SUGARS; DERIVATIVES THEREOF; NUCLEOSIDES; NUCLEOTIDES; NUCLEIC ACIDS
- C07H11/00—Compounds containing saccharide radicals esterified by inorganic acids; Metal salts thereof
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07H—SUGARS; DERIVATIVES THEREOF; NUCLEOSIDES; NUCLEOTIDES; NUCLEIC ACIDS
- C07H3/00—Compounds containing only hydrogen atoms and saccharide radicals having only carbon, hydrogen, and oxygen atoms
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07H—SUGARS; DERIVATIVES THEREOF; NUCLEOSIDES; NUCLEOTIDES; NUCLEIC ACIDS
- C07H99/00—Subject matter not provided for in other groups of this subclass
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08H—DERIVATIVES OF NATURAL MACROMOLECULAR COMPOUNDS
- C08H8/00—Macromolecular compounds derived from lignocellulosic materials
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
- C08K3/24—Acids; Salts thereof
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/16—Nitrogen-containing compounds
- C08K5/17—Amines; Quaternary ammonium compounds
- C08K5/175—Amines; Quaternary ammonium compounds containing COOH-groups; Esters or salts thereof
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K7/00—Use of ingredients characterised by shape
- C08K7/02—Fibres or whiskers
- C08K7/04—Fibres or whiskers inorganic
- C08K7/14—Glass
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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Description
-炭水化物と、
-無機塩から誘導され得る酸前駆体と、
-窒素の供給源と、
-任意には有機酸またはその前駆体と、
-任意にはアンモニアと
を溶解することによって得られ得る溶液を含むバインダー溶液を提供する。
/m3未満のホルムアルデヒドを放出する。
・未硬化バインダー溶液の、乾燥重量で少なくとも5%、好ましくは少なくとも7%、より好ましくは少なくとも9%;および/または
・未硬化バインダー溶液の、乾燥重量で25%もしくは20%未満、好ましくは18%未満、より好ましくは16%未満を構成していてもよい。
ーテルであってもよく、シリルエーテルが存在すると、特に風化後のバインダーの長期強度をかなり改善し得ると考えられている。
これは少なくとも、バインダーが結合すべき材料に適用される状態、および/または廃水回復系において回収される状態におけるものである。バインダーがこうした中性またはアルカリ性のpHを有することで、いくつかの本質的に酸性の先行技術バインダー系で起こっていたような製造機器の腐食の問題が軽減され得る。こうした先行技術バインダーは、ポリアクリル酸またはポリマーポリカルボン酸から本質的になるバインダーを含む。よって本発明の特定的な利点の1つは、こうした中性またはアルカリ性の条件で動作できるバインダー系の使用である。硬化されるとき、バインダーは硬化プロセスの間に酸性になるかもしれない。しかし、この状態にあるときの製造機器とバインダーとの接触は最小限であるため、この場合の機器腐食の問題はあまり重要ではない。バインダーのpHは13以下、好ましくは12、11または10以下であってもよい。好ましいpHは、7.5から9.5、特に8から9の範囲内であってもよい。結合すべき材料に適用され、その後水に溶解されるバインダーは、6より大きいpHを有してもよい。
技術バインダー系に起こったような、溶液中のバインダー構成要素を予め反応することに関する問題が軽減されてもよい。こうした先行技術バインダーは、結合すべき材料に適用される予め反応させたポリマーまたは樹脂から本質的になるバインダーを含む。結合すべき材料の上に、粘着性、粘稠またはべたつく液体の形態で実質的に未反応のバインダーが存在することにより、バインダー構成要素間の反応は実質的に乾燥状態で起こってもよい。この反応は溶媒の利益を受けずに起こるため、バルク重合と言われることもある。よって本発明の特定的な利点は、実質的に乾燥状態で、またはバルク重合によって重合できるバインダー系の使用である。
・溶融したミネラル混合物からミネラル繊維を形成するステップ;
・ミネラル繊維に実質的にホルムアルデヒドフリーのバインダー溶液を噴霧するステップ、バインダー溶液は以下を含む:炭水化物(特に還元糖)、無機塩から誘導され得る酸前駆体、および窒素の供給源;
・バインダー溶液が適用されたミネラル繊維を集めてミネラル繊維の芯を形成するステップ;および
・芯を硬化オーブンに通すことによって、ミネラル繊維とバインダーとを含む芯を硬化して、実質的に水不溶性の硬化バインダーによってともに保持されたミネラル繊維の芯を提供するステップ。
断できる。
・炭水化物、好ましくは還元糖;
・無機塩から誘導され得る酸前駆体、好ましくは硫酸アンモニウムまたはリン酸アンモニウム;
・窒素の供給源;および
・水。
この調合物は、アンモニア水溶液の形態で提供される任意または付加的なアンモニアを含んでもよい。水は洗浄水または再利用されたプロセス水を含んでもよい。
・少なくとも5%、10%、15%もしくは18%の固体、および/または
・70%もしくは60%未満(特に木材ボード適用の場合)、または50%、40%もしくは20%未満の固体(特にミネラル繊維絶縁材適用の場合)
これは特に、140℃にて2時間乾燥した後のベークアウト固体の重量として決定されるものである。
、中密度繊維ボード、木部表面材製品を含む)、鋳物砂。
・約1.5Pa.s未満、好ましくは約1×10-2Pa.s未満;および/または
・約2×10-4Pa.sより大きい、好ましくは約5×10-4Pa.sより大きい。
・2.5%、3%もしくは5%より多く;および/または
・25%、22%もしくは20%未満。
・500mg/kg、750mg/kg、1000mg/kgもしくは1500mg/kgより多く;および/または
・5000mg/kg、4000mg/kgまたは3000mg/kg未満。
表示されてもよい。
・1%、2%、2.5%、3%、3.5%もしくは4%より多く;および/または
・20%、15%、10%もしくは8%未満
これは完成製品の乾燥重量で測定されたものである。
通常の分離強度が
・少なくとも120g/g、好ましくは少なくとも150g/g;および/または
・400g/g未満
風化分離強度が
・少なくとも120g/g、好ましくは少なくとも150g/g;および/または
・400g/g未満
通常の分離強度と風化分離強度との間の損失%が
・10%未満、好ましくは5%未満。
・密度が5kg/m3、8kg/m3または10kg/m3より大きい;
・密度が200kg/m3、180kg/m3または150kg/m3未満である;
・ガラスウール繊維を含み、密度が5kg/m3、8kg/m3もしくは10kg/m3より大きく、および/または80kg/m3、60kg/m3もしくは50kg/m3未満である;
・ストーンウール繊維を含み、密度が15kg/m3、20kg/m3もしくは25kg/m3より大きく、および/または220kg/m3、200kg/m3もしくは180kg/m3未満である;
・熱伝導率λが0.05W/mK未満、および/または0.02W/mKより大きい;
・99重量%未満および/または80重量%より大きいミネラル繊維を含む;
・厚さが10mm、15mmもしくは20mmより大きく、および/または400mm、350mmもしくは300mm未満である。
・寸法が少なくとも50cm×80cm、好ましくは少なくとも1m×2m
・厚さが少なくとも11mm、12mmまたは15mm
・硬化時間が25分、15分、12分または10分未満
・EN319に従って測定された内部結合強度が少なくとも0.4N/mm2もしくは0.45N/mm2(特にパーティクルボードまたは繊維ボードに対して)、またはEN300に従って測定されたものが少なくとも0.28N/mm2(特に配向性ストランドボード対して)
・EN317に従った20℃における水中での24時間後の厚さ膨張が12%未満、好ましくは10%未満
・20℃における水中での24時間後の水吸収が40%未満、好ましくは30%未満
・EN310に従った弾性係数が少なくとも1800N/mm2(特にパーティクルボードまたは繊維ボードに対して)、または2500N/mm2(特に配向性ストランドボード対して)、または3500N/mm2もしくは4800N/mm2
・曲げ強度(MOR)が少なくとも14N/m2(特にパーティクルボードまたは繊維
ボードに対して)、または18N/mm2(特に配向性ストランドボード対して)、または20N/mm2または28N/mm2
・添加剤としてのワックス、たとえば0.1重量%から2重量%、好ましくは0.5重量%から1重量%の範囲で
・樹脂含有量(乾燥木材粒子の重量に対する乾燥樹脂の重量)が8重量%から18重量%、好ましくは10重量%から16重量%、より好ましくは12重量%から14重量%の範囲
・圧搾機中で、特に180℃もしくは200℃より高いか、および/または280℃もしくは260℃未満の温度のプラテンの間で硬化される。
次のステップによって、バインダーを水溶液として調製した:
・オープンな非加熱反応容器中で所望のバインダー調合物の成分を組合せるステップ
・蒸留水を加えるステップ
・その後にシラン溶液を加えるステップ
・液体を加える間およびその後の数分間撹拌して、固体を完全に溶解させるステップ。バインダー溶液は、溶液の総重量のパーセンテージとして約45%の溶解した固体を含有するようにした。この溶液の2gサンプルは、約200℃から210℃における8分間の熱硬化の際に30%の固体をもたらした(重量損失は、熱硬化性バインダー形成の際の脱水に起因する)。
℃から約243℃(約440°Fから約470°F)の範囲であった。
・機器:5500R Instron機
・テストの直前に各シェルボーンをプラスチック袋から取出し、その重量および厚さを記録した。
・予熱した湿度チャンバ(65℃、95%相対湿度)中での16時間の風化
・取出されたシェルボーンを個別のプラスチック貯蔵袋に密閉して、直ちにテストに用いた。
150℃に設定したホットプレートの中央に少量のバインダー(2.0ml)を加えて、ストップウォッチを始動させる。サンプルを引張って長いひも状にすることが可能になるまで、バインダーをスパチュラで動かす。バインダーを加えてからひも形成までにかかった時間がゲル時間である。
DMH=ブドウ糖一水和物
CA=クエン酸
NH4OH=水酸化アンモニウム
ISIO200=シラン
AmSO4=硫酸アンモニウム
AmPO4=リン酸アンモニウム
テスト結果-無機酸前駆体をクエン酸と比較:
ミネラル繊維絶縁製品におけるバインダー系の比較テストから以下の結果が得られた:
テスト手順:
バインダー含有量LOI(強熱減量)
ウールとバインダーとの計量されたサンプルを、550℃に設定したマッフル炉に入れ
る。設定時間の後にウールを炉から取出し、デシケータに入れて冷却し、再計量する。重量の損失が元のサンプル重量のパーセンテージとして表わされ、これはバインダー含有量または強熱減量(LOI)として公知である。
単一の芯(またはスラブ)を、1メートル離して壁に配置された2本のポール(各々長さ500mm、直径20mm)に渡して置く。芯の中央のたるみの程度を記録する。これをパック中のすべての芯およびいくつかのパックに対して繰り返す。一定の期間にわたる設定点でパックを測定することによって、芯に対する圧縮の長期の影響を定める。
分離強度は、6つのテスト試料の合計破壊荷重をそれらの総重量で割ったグラム/グラムで表わされる。
r:半径12.7mm;
DC:中心間の距離44.5mm;
a:25.4mm;
b:121mm。
(項1)
水に
-還元糖と、
-硫酸アンモニウム塩、リン酸アンモニウム塩、硝酸アンモニウム塩および炭酸アンモニウム塩からなるリストより選択される材料と、
-任意にはカルボン酸またはその前駆体と、
-任意にはアンモニアと
を溶解することによって得られ得る溶液から本質的になる、実質的にホルムアルデヒドフリーのバインダー溶液。
(項2)
水に
-還元糖と、
-硫酸アンモニウム塩、リン酸アンモニウム塩、硝酸アンモニウム塩および炭酸アンモニウム塩からなるリストより選択される材料と、
-任意にはカルボン酸またはその前駆体と、
-任意にはアンモニアと
を溶解することによって得られる溶液から本質的になる、上記項1に記載の実質的にホルムアルデヒドフリーのバインダー溶液。
(項3)
前記還元糖はブドウ糖から本質的になる、上記項1または2に記載の実質的にホルムアルデヒドフリーのバインダー溶液。
(項4)
前記カルボン酸はアンモニウム塩の形態で与えられる、先行する上記項のいずれかに記載の実質的にホルムアルデヒドフリーのバインダー溶液。
(項5)
前記溶液のpHは7より大きい、先行する上記項のいずれかに記載の実質的にホルムアルデヒドフリーのバインダー溶液。
(項6)
前記バインダー溶液のpHは、使用条件において硫酸塩、リン酸塩、硝酸塩または炭酸塩の析出を防ぐものである、先行する上記項のいずれかに記載の実質的にホルムアルデヒドフリーのバインダー溶液。
(項7)
硫酸アンモニウム塩、リン酸アンモニウム塩、硝酸アンモニウム塩および炭酸アンモニウム塩からなるリストより選択される材料は、前記バインダー溶液の乾燥重量の5%と25%の間を構成する、先行する上記項のいずれかに記載の実質的にホルムアルデヒドフリーのバインダー溶液。
(項8)
前記バインダー溶液は少なくとも5%の固体および50%未満の固体を含む、先行する上記項のいずれかに記載の実質的にホルムアルデヒドフリーのバインダー溶液。
(項9)
硫酸アンモニウム塩、リン酸アンモニウム塩、硝酸アンモニウム塩および炭酸アンモニウム塩からなるリストより選択される材料に対する還元糖の乾燥重量での比率は、(還元糖の乾燥重量/アンモニウム塩の乾燥重量)で表わされるときに2.5から13の範囲内である、先行する上記項のいずれかに記載の実質的にホルムアルデヒドフリーのバインダー溶液。
(項10)
前記バインダー溶液は、溶解されたバインダー固体として算出されるときに0.1%と1%の間のシランまたはシリコン含有カップリング剤を含む、先行する上記項のいずれかに記載の実質的にホルムアルデヒドフリーのバインダー溶液。
(項11)
製品を製造する方法であって、
・疎性物質の集合を与えるステップと;
・上記項1から10のいずれか1項に記載の実質的にホルムアルデヒドフリーのバインダー溶液で疎性物質の前記集合を処理するステップと;
・前記バインダー溶液で処理された疎性物質の前記集合を基体の形態に配置するステップと;
・エネルギーの供給源を適用することによって前記バインダーを硬化するステップと
を含む、方法。
(項12)
前記バインダーを前記硬化するステップは、前記基体を、230℃~300℃の範囲内の温度の硬化オーブンの少なくとも1つのゾーンに、30秒から20分の範囲内のオーブン滞在時間で通すことによって行なわれる、上記項11に記載の方法。
(項13)
前記バインダーを前記硬化するステップは、圧搾機のプラテンの間で行なわれる、上記項11に記載の方法。
(項14)
実質的にホルムアルデヒドフリーのバインダーによってともに維持される疎性物質の集合を含む材料であって、前記材料は、硫酸塩、リン酸塩、硝酸塩および炭酸塩からなる群より選択される種を500mg/kgより多く含むことを特徴とする、材料。
(項15)
硫酸塩、リン酸塩、硝酸塩および炭酸塩からなる群より選択される前記種は、バインダ
ー前駆体から本質的に誘導される、上記項14に記載の材料。
(項16)
前記バインダーは硬化され、メラノイジンを含む、上記項14から15のいずれか1項に記載の材料。
(項17)
疎性物質の集合と、未硬化であるかまたは部分的に硬化された実質的にホルムアルデヒドフリーのバインダーとを含む材料であって、前記バインダーは水に溶解されるときに6より大きいpHを有し、かつ
-還元糖と、
-硫酸アンモニウム塩、リン酸アンモニウム塩、硝酸アンモニウム塩および炭酸アンモニウム塩からなるリストより選択される材料と、
-任意にはカルボン酸またはその前駆体と、
-任意にはアンモニアと
を含むことを特徴とする、材料。
(項18)
前記疎性物質はミネラル繊維を含む、上記項14から17のいずれか1項に記載の材料。
(項19)
前記材料はミネラル繊維断熱材料である、上記項18に記載の材料。
(項20)
前記材料は木材ボードである、上記項14から17のいずれか1項に記載の材料。
Claims (20)
- i)5kg/m3より大きくかつ80kg/m3未満の密度を有しそして80重量%より多くかつ99重量%未満の不織ミネラル繊維を含むガラスウールミネラル繊維断熱製品およびii)15kg/m3より大きくかつ220kg/m3未満の密度を有しそして80重量%より多くかつ99重量%未満の不織ストーンウールミネラルを含むストーンウールミネラル繊維断熱製品から選択されるミネラル繊維断熱製品を製造する方法であって、以下の逐次的ステップ:
-溶融したミネラル混合物からミネラル繊維を形成するステップ;
-該ミネラル繊維に実質的にホルムアルデヒドフリーのバインダー溶液を噴霧するステップであって、該バインダー溶液は、
i)還元糖を含む炭水化物;および
ii)乾燥重量で少なくとも5%の、1つ以上の無機アンモニウム塩から選択される酸前駆体
を含む、ステップ;
-該バインダー溶液が適用された該ミネラル繊維を集めてミネラル繊維の芯を形成するステップ;および
-該芯を硬化オーブンに通すことによって、該ミネラル繊維と該バインダーとを含む芯を硬化することにより、水不溶性の硬化した熱硬化バインダーによってともに保持されたミネラル繊維の芯を提供するステップ
を含み、
ここで、該製品は、5ppm未満の遊離ホルムアルデヒドを含む、
方法。 - 前記ミネラル繊維に前記実質的にホルムアルデヒドフリーのバインダー溶液を噴霧するステップが、形成された直後の熱いミネラル繊維に、該実質的にホルムアルデヒドフリーのバインダー溶液を噴霧することにより、ミネラル繊維の残留熱によって、該バインダー溶液中の水のかなりの部分が蒸発するステップを含む、請求項1に記載の方法。
- 前記ミネラル繊維に適用された状態の前記バインダー溶液が、140℃にて2時間乾燥した後のベークアウト固体の重量として決定される、少なくとも5%の固体および20%未満の固体を含む、請求項1または請求項2に記載の方法。
- 硬化オーブン内での前記硬化が、強制熱風循環を用いて行なわれる、請求項1~3のいずれか1項に記載の方法。
- 前記硬化が、20分以下の持続時間で行われる、請求項1~4のいずれか1項に記載の方法。
- 前記硬化が、230℃~300℃の範囲内の温度の前記硬化オーブンの少なくとも1つのゾーンに、30秒から20分の範囲のオーブン滞在時間で、前記芯を通すことによって行われる、請求項1~5のいずれか1項に記載の方法。
- ミネラル繊維断熱製品が、
i)少なくとも120g/gかつ400g/g未満の通常の分離強度;および
ii)少なくとも120g/gかつ400g/g未満の風化分離強度
を有する、請求項1~6のいずれか1項に記載の方法。 - 前記硬化された芯を圧縮するステップを含む、請求項1~7のいずれか1項に記載の方法。
- ミネラルウール絶縁材が、0.05W/mK未満の熱伝導率λを有する、請求項1~8のいずれか1項に記載の方法。
- 前記還元糖の量/前記酸前駆体の量の乾燥重量での比率は2.5以上かつ13以下である、請求項1~9のいずれか1項に記載の方法。
- 前記芯中に含まれるバインダーが、1つまたはそれ以上の添加剤を含み、そしてここで、該添加剤の総量が、5重量%未満である、請求項1~10のいずれか1項に記載の方法。
- 前記バインダー溶液が、シラン添加剤を含む、請求項1~11のいずれか1項に記載の方法。
- 前記バインダー溶液が、乾燥重量で、0.1%~1%の間のシランを含む、請求項1~12のいずれか1項に記載の方法。
- 前記酸前駆体が、硫酸塩およびリン酸塩から選択される種を含む、請求項1~13のいずれか1項に記載の方法。
- 前記酸前駆体が、前記未硬化バインダー溶液の、乾燥重量で少なくとも7%を構成する、請求項1~14のいずれか1項に記載の方法。
- 前記酸前駆体が、前記未硬化バインダー溶液の、乾燥重量で25%未満を構成する、請求項1~15のいずれか1項に記載の方法。
- 前記炭水化物が、ブドウ糖を含む、請求項1~16のいずれか1項に記載の方法。
- 前記バインダー溶液が、該バインダーが前記繊維に適用された状態で、アルカリ性または中性のpHを有する、請求項1~17のいずれか1項に記載の方法。
- 硬化の際の前記バインダーの前記反応は、メイラード型反応である、請求項1~18のいずれか1項に記載の方法。
- 前記バインダー溶液が、有機酸またはその前駆体、塩または無水物をさらに含む、請求項1~19のいずれか1項に記載の方法。
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