WO2002053819A2 - Insulating element - Google Patents
Insulating element Download PDFInfo
- Publication number
- WO2002053819A2 WO2002053819A2 PCT/DK2002/000015 DK0200015W WO02053819A2 WO 2002053819 A2 WO2002053819 A2 WO 2002053819A2 DK 0200015 W DK0200015 W DK 0200015W WO 02053819 A2 WO02053819 A2 WO 02053819A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- insulating element
- polymer
- fibres
- mineral fibre
- fibre layer
- Prior art date
Links
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
Definitions
- This invention relates to an insulating element comprising a mineral fibre layer which is at least partially coated with a fibrous web of polymer fibres prepared by melt blowing directly on the mineral fibre layer .
- WO 98/54245 discloses an insulating element of the above- mentioned type and comprising a coating of polypropylene fibres containing a flame retardant in the form of a blend of antimony trioxide and a chlorinated paraffin, the flame retardant constituting from 15 to 30% by weight of the propylene fibres.
- a fibrous coating consisting of polypropylene fibres on an insulating mineral fibre element reduces the fire resistance of said insulating element due to the relatively high calorific value, i.e. 43-46 MJ/kg of polypropylene.
- the known insulating elements also suffer from the defect that due to the presence of antimony trioxide and halogenated paraffins, it is likely that in the future the disposal of such products will be severely restricted for environmental reasons.
- the object of the present invention is to provide an insulating element having a fibrous coating of organic fibres having a lower calorific value than polypropylene fibres and a flame retardant which is environmentally harmless .
- a fibrous coating essentially consisting of a polymer selected from a group consisting of polytrimethylene terephthalate (PTT) , polybutylene terephthalate (PBT) , polyethylene terephthalate (PET) and polyamide (PA) and a flame retardant in the form of a cyclic phosphonic acid ester.
- the above-mentioned polymers typically have calorific values of between 15 and 35 MJ/kg, and they can be converted into very fine fibres, i.e. fibres having a diameter of less than 20 ⁇ m by a melt blowing technique.
- the flame retardant used m the polymer fibres does not contain noxious components and consequently the disposal of waste products of insulating elements according to the invention will not present environmental problems.
- the flame retardant used in the polymer fibres is so effective that it is sufficient to use it in amounts of between 2 and 4% by weight, although it may also be used in higher amounts, e.g. up to 6% by weight .
- Flame retardants of the type used in the coatings of the insulating elements of the invention preferably comprise one or more phosphonic acid esters having the formula 0
- R and R 1 each is C ⁇ -C 4 -alkyl or C ⁇ -C hydroxyalkyl
- ANTIBLAZE 1045 is composed of a mixture of phosphonic acid, methyl-bis (5-ethy1-2-methy1-1, 3, 2-d ⁇ oxaphosphor- man-5-yl) ester, P,P 1 -d ⁇ ox ⁇ de and phosphonic acid, methyl- ( 5-e hyl-2-methyl- 1, 3, 2-d ⁇ oxaphosphorinan-5-yl ) - methyl methyl ester, P-oxide.
- the mineral fibre layer of the insulating element of the invention preferably consists of rock fibres or slag fibres, but may also be made of glass fibres or other synthetic inorganic fibres.
- the mineral fibre layer preferably has the form of a batt, a mat or a slab comprising two main surfaces (an upper and a lower side) and side and end surfaces.
- the mineral fibre layer may also have other forms depending on the contemplated field of application, e.g. it may be in the form of a web, a sheet or a tube.
- the fibrous coating preferably fully surrounds the mineral fibre layer so as to prevent any loose fibres, dust and other loose particles to be released from the mineral fibre layer.
- the mineral fibre layer when in the form of a batt comprising two main surfaces, two side surfaces and two end surfaces the coating preferably extends over all six surfaces.
- the coating is preferably applied to the mineral fibre layer in such an amount that the weight of the coating is between 5 and 15 g/m 2 .
- the polymer fibres may contain minor amounts of conventional additives such as an antioxidant, a stabilizer and a dye, such as Ti0 2 .
- additives such as an antioxidant, a stabilizer and a dye, such as Ti0 2 .
- Each of such additives is preferably present in an amount not exceeding 1% by weight and more preferably in an amount of between 0.1 and 1% by weight of the polymer.
- the insulating elements according to the invention can be used for obtaining thermal or acoustical insulation or both. They are preferably used in the form of batts for the thermal insulation of building, e.g. for the thermal insulation of ceilings and walls.
- thermoinsulatmg batts Four different coated thermoinsulatmg batts were prepared from batts of rock fibres having a density of 31 kg/m 3 .
- the batts were coated on one side with a fibrous web of polymer fibres by a melt blowing process using a melt blowing apparatus as described in WO 98/54388.
- the polymers used contained 2% by weight of the flame retardant ANTIBLAZE 1045.
- composition of the four coated insulating batts and their properties are summarized in the following table.
- coated insulating batts having a coating of a fibrous web of polyamide fibres which has a calorific value of 32 MJ/kg constitute particularly preferred embodiments of the invention.
Abstract
Insulating element comprising a mineral fibre layer which is at least partially coated with a fibrous web essentially consisting of polymer fibres selected from a group of polytrimethylene terephthalate, polybutylene terephthalate, polyethylene terephthalate and polyamide fibres and a flame retardant in the form of a cyclic phosphonic acid ester.
Description
Insulating element
This invention relates to an insulating element comprising a mineral fibre layer which is at least partially coated with a fibrous web of polymer fibres prepared by melt blowing directly on the mineral fibre layer .
WO 98/54245 discloses an insulating element of the above- mentioned type and comprising a coating of polypropylene fibres containing a flame retardant in the form of a blend of antimony trioxide and a chlorinated paraffin, the flame retardant constituting from 15 to 30% by weight of the propylene fibres.
The presence of a fibrous coating consisting of polypropylene fibres on an insulating mineral fibre element reduces the fire resistance of said insulating element due to the relatively high calorific value, i.e. 43-46 MJ/kg of polypropylene.
The known insulating elements also suffer from the defect that due to the presence of antimony trioxide and halogenated paraffins, it is likely that in the future the disposal of such products will be severely restricted for environmental reasons.
The object of the present invention is to provide an insulating element having a fibrous coating of organic fibres having a lower calorific value than polypropylene fibres and a flame retardant which is environmentally harmless .
This and other objects which will appear from the following description are achieved with a fibrous coating essentially consisting of a polymer selected from a group consisting of polytrimethylene terephthalate (PTT) , polybutylene terephthalate (PBT) , polyethylene terephthalate (PET) and polyamide (PA) and a flame retardant in the form of a cyclic phosphonic acid ester.
The above-mentioned polymers typically have calorific values of between 15 and 35 MJ/kg, and they can be converted into very fine fibres, i.e. fibres having a diameter of less than 20 μm by a melt blowing technique.
The flame retardant used m the polymer fibres does not contain noxious components and consequently the disposal of waste products of insulating elements according to the invention will not present environmental problems.
It has been found that the flame retardant used in the polymer fibres is so effective that it is sufficient to use it in amounts of between 2 and 4% by weight, although it may also be used in higher amounts, e.g. up to 6% by weight .
Flame retardants of the type used in the coatings of the insulating elements of the invention preferably comprise one or more phosphonic acid esters having the formula
0
wherein R and R1 each is Cι-C4-alkyl or Cι-C hydroxyalkyl
Such compounds are described in US patent No. 3 789 091 which also describes methods of preparing such flame retardants .
A particularly preferred flame retardant of the above- mentioned type is marketed under the trade name ANTIBLAZE 1045 and is described in US patent No. 6 054 515. ANTIBLAZE 1045 is composed of a mixture of phosphonic acid, methyl-bis (5-ethy1-2-methy1-1, 3, 2-dιoxaphosphor- man-5-yl) ester, P,P1-dιoxιde and phosphonic acid, methyl- ( 5-e hyl-2-methyl- 1, 3, 2-dιoxaphosphorinan-5-yl ) - methyl methyl ester, P-oxide.
The mineral fibre layer of the insulating element of the invention preferably consists of rock fibres or slag fibres, but may also be made of glass fibres or other synthetic inorganic fibres.
The mineral fibre layer preferably has the form of a batt, a mat or a slab comprising two main surfaces (an upper and a lower side) and side and end surfaces.
The mineral fibre layer may also have other forms depending on the contemplated field of application, e.g. it may be in the form of a web, a sheet or a tube.
The fibrous coating preferably fully surrounds the mineral fibre layer so as to prevent any loose fibres, dust and other loose particles to be released from the mineral fibre layer.
Thus, when the mineral fibre layer is in the form of a batt comprising two main surfaces, two side surfaces and two end surfaces the coating preferably extends over all six surfaces.
The coating is preferably applied to the mineral fibre layer in such an amount that the weight of the coating is between 5 and 15 g/m2.
In addition to the flame retardant the polymer fibres may contain minor amounts of conventional additives such as an antioxidant, a stabilizer and a dye, such as Ti02. Each of such additives is preferably present in an amount not exceeding 1% by weight and more preferably in an amount of between 0.1 and 1% by weight of the polymer.
Particularly suitable processes and apparatuses for forming coatings on mineral fibre layers by a blow mounding technique are described in WO 93/16874.
The insulating elements according to the invention can be used for obtaining thermal or acoustical insulation or both. They are preferably used in the form of batts for the thermal insulation of building, e.g. for the thermal insulation of ceilings and walls.
EXAMPLE
Four different coated thermoinsulatmg batts were prepared from batts of rock fibres having a density of 31 kg/m3.
The batts were coated on one side with a fibrous web of polymer fibres by a melt blowing process using a melt blowing apparatus as described in WO 98/54388.
The polymers used contained 2% by weight of the flame retardant ANTIBLAZE 1045.
The composition of the four coated insulating batts and their properties are summarized in the following table.
TABLE
Release of coating from the mineral fibre batt and formation and drawn out threads determined visually after the batt has been cut through with a mineral wool cutting knife
Determined by visual evaulation of adhesion of the fibrous coating to the mineral fibre layer along the cutting edge following cutting.
Resistance of coating against formation of holes by manual handling of the batt and a finger is pressed against the coating
As will appear from said table coated insulating batts having a coating of a fibrous web of polyamide fibres which has a calorific value of 32 MJ/kg constitute particularly preferred embodiments of the invention.
Claims
1. Insulating element comprising a mineral fibre layer which is at least partially coated with a fibrous web of polymer fibres prepared by melt blowing directly on the mineral fibre layer, CHARACTERIZED in that the fibrous coating essentially consists of a polymer selected from the group consisting of PTT, PBT, PET and PA and a flame retardant in the form of a cyclic phosphonic acid ester.
2. Insulating element according to claim 1, CHARACTERIZED in that the polymer is PA.
3. Insulating element according to claims 1 and 2, CHARACTERIZED in that the flame retardant is a compound having the formula
0
4. Insulating element according to any of the preceding claims, CHARACTERIZED in that the mineral fibre layer consists of rock fibre or slag fibres.
5. Insulating element according to any of the preceding claims, CHARACTERIZED in that the weight of the coating is between 5 and 15 g/m2.
6. Insulating element according to any of the preceding claims, CHARACTERIZED in that the polymer additionally contains additives, each of said additives being present in an amount not exceeding 1% by weight of the polymer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2002219019A AU2002219019A1 (en) | 2001-01-08 | 2002-01-08 | Insulating element |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US25987101P | 2001-01-08 | 2001-01-08 | |
| US60/259,871 | 2001-01-08 |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| WO2002053819A2 true WO2002053819A2 (en) | 2002-07-11 |
| WO2002053819A3 WO2002053819A3 (en) | 2002-10-03 |
| WO2002053819A8 WO2002053819A8 (en) | 2002-12-12 |
Family
ID=22986771
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/DK2002/000015 WO2002053819A2 (en) | 2001-01-08 | 2002-01-08 | Insulating element |
Country Status (3)
| Country | Link |
|---|---|
| AU (1) | AU2002219019A1 (en) |
| DK (1) | DK200100038A (en) |
| WO (1) | WO2002053819A2 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2011082207A2 (en) * | 2009-12-30 | 2011-07-07 | E. I. Du Pont De Nemours And Company | Flame retardant poly(trimethylene terephthalate) compositions |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3789091A (en) * | 1971-11-15 | 1974-01-29 | Mobil Oil Corp | Cyclic phosphonate esters and their preparation |
| WO1993016874A1 (en) * | 1992-02-28 | 1993-09-02 | Rockwool International A/S | Process for preparing a mineral fibre element comprising a surface coating and apparatus for carrying out the process |
| US5501872A (en) * | 1995-04-19 | 1996-03-26 | Exxon Chemical Patents, Inc. | Method and apparatus for coating a six-sided fibrous batting |
| WO1998054245A1 (en) * | 1997-05-28 | 1998-12-03 | Rockwool International A/S | An insulating element and a process for the preparation thereof |
| US5900298A (en) * | 1996-07-22 | 1999-05-04 | Guardian Fiberglass, Inc. | Mineral fiber insulation batt impregnated with extruded synthetic fibers, and apparatus for making same |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS63222713A (en) * | 1987-03-12 | 1988-09-16 | 東洋クロス株式会社 | Light blocking curtain |
| DE9207367U1 (en) * | 1992-05-30 | 1992-09-10 | Hoechst Ag, 6230 Frankfurt, De |
-
2001
- 2001-01-11 DK DK200100038A patent/DK200100038A/en not_active Application Discontinuation
-
2002
- 2002-01-08 AU AU2002219019A patent/AU2002219019A1/en not_active Abandoned
- 2002-01-08 WO PCT/DK2002/000015 patent/WO2002053819A2/en not_active Application Discontinuation
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3789091A (en) * | 1971-11-15 | 1974-01-29 | Mobil Oil Corp | Cyclic phosphonate esters and their preparation |
| WO1993016874A1 (en) * | 1992-02-28 | 1993-09-02 | Rockwool International A/S | Process for preparing a mineral fibre element comprising a surface coating and apparatus for carrying out the process |
| US5501872A (en) * | 1995-04-19 | 1996-03-26 | Exxon Chemical Patents, Inc. | Method and apparatus for coating a six-sided fibrous batting |
| US5900298A (en) * | 1996-07-22 | 1999-05-04 | Guardian Fiberglass, Inc. | Mineral fiber insulation batt impregnated with extruded synthetic fibers, and apparatus for making same |
| WO1998054245A1 (en) * | 1997-05-28 | 1998-12-03 | Rockwool International A/S | An insulating element and a process for the preparation thereof |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2011082207A2 (en) * | 2009-12-30 | 2011-07-07 | E. I. Du Pont De Nemours And Company | Flame retardant poly(trimethylene terephthalate) compositions |
| WO2011082207A3 (en) * | 2009-12-30 | 2011-11-17 | E. I. Du Pont De Nemours And Company | Flame retardant poly(trimethylene terephthalate) compositions |
| CN102686703A (en) * | 2009-12-30 | 2012-09-19 | 纳幕尔杜邦公司 | Flame retardant poly(trimethylene terephthalate) compositions |
| CN102686703B (en) * | 2009-12-30 | 2015-02-25 | 纳幕尔杜邦公司 | Flame retardant poly(trimethylene terephthalate) compositions |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2002053819A3 (en) | 2002-10-03 |
| AU2002219019A1 (en) | 2002-07-16 |
| DK200100038A (en) | 2002-01-09 |
| WO2002053819A8 (en) | 2002-12-12 |
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