WO2016001607A1

WO2016001607A1 - Mat of mineral fibres and bituminated products incorporating said mat

Info

Publication number: WO2016001607A1
Application number: PCT/FR2015/051851
Authority: WO
Inventors: Alexandre Garcia; Agnès BEAUGENDRE
Original assignee: Saint-Gobain Adfors
Priority date: 2014-07-04
Filing date: 2015-07-03
Publication date: 2016-01-07
Also published as: FR3023283A1; WO2016001606A1

Abstract

The present invention relates to a mat made from mineral fibres, in particular glass, bound by an organic binder which comprises at least one melamine formaldehyde resin or phenol formaldehyde resin and at least one adhesion promoter selected from the group consisting of the homopolymers of methacrylic acid and the copolymers of methacrylic acid and of at least one ethylenic monomer unsaturated in C₂-C₈ excluding styrene. The invention also relates to bituminated products incorporating said mat made from mineral fibres, in particular a bituminated membrane and a shingle.

Description

MATERIAL OF MINERAL FIBERS AND BITUMEN PRODUCTS INCORPORATING

LEDIT MAT

The present invention relates to the field of mineral fiber-based mats bound by an organic binder, in particular for the production of bituminous products for roofing.

The invention relates more particularly to asphalted membranes composed of said mat of mineral fibers provided with a coating based on bitumen. Such bituminous membranes are intended in particular for the manufacture of shingles ("shingles" in English) by the application of an additional surface layer consisting of inorganic granules.

The mineral fiber mats (also referred to as "non-woven" or "sails") may be manufactured by known methods operating dry or wet.

In the dry process, molten mineral matter contained in an oven is fed to a set of dies from which filaments flow by gravity and are drawn by a gaseous fluid. The mineral filaments are harvested on a conveyor where they intermingle forming a mat.

On the upper face of the mat thus formed, an organic binder is applied using a suitable device, most often operating by curtain deposition, and the excess organic binder is removed by suction at the opposite side. . The mat then enters a device containing hot air whose temperature, of the order of 200 to 250 ° C, is adapted to remove the water and crosslink the organic binder in a very short time, of the order from ten seconds to 1 minute, then the mat of mineral fibers is collected in the form of a coil.

In the wet process, the mat is obtained from an aqueous dispersion of cut mineral fibers which is deposited by means of a forming head on a conveyor provided with perforations and the water is extracted through the conveyor through to a suction box. Fibers cut mineral remaining on the conveyor form a mat that is treated under the same conditions as those described for the dry process.

In the abovementioned processes, the function of the organic binder is to bind the mineral fibers together and to give the mat which contains them mechanical properties suited to the desired use, in particular a rigidity sufficient to be easily handled without any risk, especially because it can be torn.

The organic binder to be applied to the mineral fibers is generally in the form of an aqueous solution containing at least one thermosetting resin and additives such as a crosslinking catalyst of the resin, a silane (coupling agent), a water repellent The most commonly used thermosetting resins are urea-formaldehyde and melamine-formaldehyde resins, which have the advantage of being compatible with the bitumen thus making it possible to confer good mechanical properties on the final bituminous product, and in addition they are inexpensive.

On the fiberglass mat thus obtained, a layer of bitumen comprising mineral stabilizers and optionally additives in the form of polymers is then deposited. Deposition of the bitumen can be done by spraying on one side or on both sides, or by immersion in a bath of molten bitumen. Mineral granules are then applied to the softened bitumen and embedded in it to obtain a shingle.

It is important that the mineral fiber mat has good tensile strength in the dry state, but also in the presence of hot bitumen. The mat advantageously exhibits tensile strength under wet aging conditions, as well as good tear strength.

The object of the present invention is to improve the adhesion of hot bitumen to the mineral fiber mat, thus making it possible to improve the mechanical properties of the bitumen product, in particular its resistance to tensile failure.

This object is achieved through the use of an organic binder which comprises at least one melamine-formaldehyde or phenol-formaldehyde resin and at least one adhesion promoter selected from the group consisting of (meth) acrylic acid homopolymers and acid copolymers (meth) acrylic and at least one ethylenically unsaturated C ₂ -C ₈ monomer other than styrene.

The melamine-formaldehyde and phenol-formaldehyde resins are chosen from known resins having the properties which are suitable for application to the mat based on mineral fibers. The resins according to the invention can be obtained conventionally by condensation of melamine or phenol and formaldehyde in the presence of a base, for example sodium hydroxide, in a formaldehyde / melamine or formaldehyde / higher phenol molar ratio. at 1, preferably less than 3.0.

The homopolymers according to the invention are preferably homopolymers of acrylic acid.

The copolymers according to the invention are preferably copolymers of (meth) acrylic acid and ethylene, propene and / or butene, advantageously copolymers of acrylic acid and ethylene.

The adhesion promoter is used in an amount ranging from 0.5 to 30 parts by weight per 100 parts by weight of melamine-formaldehyde or phenol-formaldehyde resin and optional additives, preferably 5 to 15 parts.

As indicated above, the organic binder may further comprise conventional additives, for example, an extender such as starch, a plasticizer such as polyvinyl alcohol and polyvinyl acetate, an anti-blocking agent. such as colloidal silica, antifoaming agent, a biocide and pigments.

The basic organic binder (excluding adhesion promoter) preferably comprises the constituents below in the following proportions (in mass%):

5 to 100% of melamine-formaldehyde or phenol-formaldehyde resin,

0 to 95% of starch, and

0 to 30% of plasticizers.

The organic binder is in the form of an aqueous solution, an emulsion or an aqueous dispersion. The organic binder is applied to fiber mats made of glass or rock, especially basalt, and preferably glass.

Conventionally, the organic binder is deposited on the mat of mineral fibers (formed by the dry route or the wet route), then the mat is treated at a temperature permitting the crosslinking of the organic binder which then becomes infusible. The crosslinking of the organic binder according to the invention is carried out at a temperature which generally varies from 180 to 250 ° C., preferably from 200 to 220 ° C., and for a very short time, of the order of a few seconds to 1 minute. .

The adhesion promoter is preferably incorporated into the organic binder applied to the mineral fiber mat. However, application of the adhesion promoter separately from that of the organic base binder can not be ruled out on the mineral fiber mat.

The mineral fibers are both filaments and yarns composed of a multitude of filaments bonded together, in particular by a sizing, and assemblies of such threads.

Thus, according to a first embodiment, the mineral fiber mat is composed of discontinuous mineral filaments of length up to 150 mm, preferably ranging from 20 to 100 mm and advantageously from 50 to 70 mm, and having a diameter that can vary. to a large extent, for example from 5 to 30 μιτι.

According to a second embodiment, the mineral fiber mat is composed of mineral threads.

The mineral threads may be yarns composed of a multitude of mineral filaments (or base yarns) or assemblies of these basic yarns in rovings ("rovings").

The aforementioned son may be son without torsion or twisted son (or son textile), preferably without torsion.

The mineral threads, especially glass, are generally cut to a length of up to 100 mm, preferably ranging from 6 to 30 mm, advantageously from 8 to 20 mm and more preferably from 10 to 18 mm.

The diameter of the glass filaments constituting the son can vary to a large extent, for example 5 to 30 μιτι. In the same way, variations can occur in the linear density of the yarn which can range from 34 to 1500 tex.

The glass entering the constitution of the filaments can be of any type, for example C, E, R, AR (alkali-resistant). C-glass and E-glass are preferred.

The mat may, if necessary, be reinforced by continuous fibers which are generally deposited on the mat conveying device in the direction of advancement of the mat and distributed over all or part of the width of the mat. These fibers are generally deposited in the thickness of the mat of fibers, in particular mineral, before the application of the organic binder.

Reinforcing fibers are usually made of glass.

The mineral fiber mat generally has a basis weight which varies from 10 to 1100 g / m ² , preferably from 30 to 350 g / m ² , advantageously from 35 to 80 g / m ² .

The organic binder generally represents 5 to 40% by weight of the fiber mat, in particular mineral, preferably 10 to 30%.

The aforementioned mineral fiber mat is then treated with a bitumen composition which may contain additives such as oils and petroleum residues, polymers, especially styrene-butadiene-styrene, mineral stabilizing agents, antistatic agents and agents. anti-UV, especially an atactic polypropylene. These additives can represent up to 15% of the bitumen mass.

The purpose of the bitumen is to render the mineral fiber mat watertight while giving great flexibility to the final material. It also plays the role of support for mineral granules in a shingle. The bitumen can be oxidized.

The amount of bitumen applied to the mineral fiber mat can vary to a large extent, until a bitumen product having a basis weight of from 1000 to 10,000 g / m 2, and preferably from 1500 to 7500 g / m, is obtained. ² .

The application of the bitumen composition may be carried out by any means known to those skilled in the art, for example by softening, spraying or dipping in one or more passes. Another aspect of the invention is the mineral fiber mat coated with bitumen. It can be used in particular as a waterproofing membrane for roofing, including rooftop terrace, and for the manufacture of shingle by applying an additional layer of mineral granules on at least one of its faces.

The following examples illustrate the invention without limiting it.

In these examples, the tensile tensile strength is measured on the mat of glass fibers and on the matte mat under the conditions of the NF EN ISO 13934-1 standard. The measurement is performed on 10 samples 25 cm long and 5 cm wide. For example 2, the measurement is made in the transverse direction, the reinforcing son being located in the length of the sample.

EXAMPLE 1

a) manufacture of the mineral fiber mat

A fiberglass mat is made wet.

5.08 g of cut glass yarn (diameter of the filaments: 13 μιτι, length: 18 mm) are dispersed in 25 liters of water containing 3.75 g of a surfactant ⁽¹⁾ , 62.5 g of a thickener ' ² ' and 0.87 g of an antifoaming agent ⁽³⁾ .

The dispersion is poured into a container whose bottom is provided with a sieve and the water is removed by gravity through the sieve. The glass filaments uniformly distributed on the sieve are recovered in the form of a mat.

The mat is immersed in an aqueous organic binder bath of the following composition (in% solids):

- Melamine-formaldehyde resin ¹ '24.5

- Homopolymer of acrylic acid ⁽⁵⁾ 10.0

- Starch ⁽⁶⁾ 68.6

- Poly (polyvinyl alcohol) ⁽⁷⁾ 2.0

- Polyvinyl acetate ⁽⁸⁾ 4.9

The organic binder contains 7.5% solids.

After immersion, the mat is dried in an oven at 210 ° C for 1 minute.

b) manufacture of asphalt mat The mat obtained in step a) is immersed in a bath of molten bitumen (180 ° C.) and then cooled to room temperature.

For comparison (comparative example 1), a bituminous mat is prepared under the same conditions from a mat of glass fibers and an organic binder containing no adhesion promoter.

The properties of the mats obtained are given in Table 1.

EXAMPLE 2

a) manufacture of the mineral fiber mat

In an industrial installation, a mat consisting of glass filaments C reinforced with glass yarns (68 Tex) is formed by the dry route.

The reinforcing threads are deposited on a conveyor in the machine direction (warp) with a spacing of 16 mm, after the deposition of a portion of the filaments on the conveyor, so that the reinforcement threads are embedded in the web. thickness of the mat, then a binder is applied by curtain on the mat. The conveyor then enters a 50 m long oven heated to a temperature ranging from 240 ° C (inlet) to 200 ° C (outlet) at a speed of 125 m / min. The mat is wound in the form of a winding.

The organic binder has the composition of Example 1 modified in that the adhesion promoter is an ethylene-acrylic acid copolymer ( ¹¹⁾ .

b) Manufacture of the asphalt mat

The fiberglass mat obtained in step a) is immersed in a bath of molten bitumen (200 ° C.) by the dip coating method. The mat is then cooled to room temperature and coiled under the shape of a coil.

By way of comparison, an organic binder containing no ethylene-acrylic acid copolymer is used to produce a mat of glass fibers and a matt mat under the conditions described above.

The properties of the mats are shown in Table 1.

Reference Aerosol G61 marketed by Cytec

Reference Agitan ^® marketed by Munzing

Tylose ^® reference marketed by ShinEtsu

Reference Préfère ^® 71 0463J marketed by Préfère Resins

Reference Plextol ^® BV595 sold by the company Synthomer ^<6) Reference Tackidex ^® G076 marketed by the company Roquette ^<7) Reference Mowiol ^® 40-88 marketed by the company Clariant

( ⁸⁾ Winacet ^® DP reference sold by the company Synthos

Reference Michem ^® Prime 4983R marketed by the company Synthomer

Table 1

Claims

A mineral fiber mat comprising an organic binder, characterized in that the organic binder comprises at least one melamine-formaldehyde or phenol-formaldehyde resin and at least one adhesion promoter selected from the group consisting of homopolymers of acid ( meth) acrylic and copolymers of (meth) acrylic acid and at least one ethylenically unsaturated C ₂ -C ₈ monomer other than styrene.

2. Mat according to claim 1, characterized in that the homopolymer is a homopolymer of acrylic acid.

3. Mat according to claim 1, characterized in that the copolymer is a copolymer of (meth) acrylic acid and ethylene, propene and / or butene, preferably a copolymer of acrylic acid and ethylene.

4. Mat according to one of claims 1 to 3, characterized in that the amount of adhesion promoter varies from 0.5 to 30 parts by weight per 100 parts by weight of melamine-formaldehyde resin or phenol-formaldehyde and optional additives, preferably 5 to 15 parts.

5. Mat according to one of claims 1 to 4, characterized in that the organic base binder (excluding adhesion promoter) comprises the following constituents in the following proportions (in mass%):

5 to 100% of melamine-formaldehyde or phenol-formaldehyde resin,

0 to 95% of starch, and

0 to 30% of plasticizers.

6. Mat according to one of claims 1 to 5, characterized in that it has a weight per unit area which varies from 10 to 1100 g / m ² , preferably from 30 to 350 g / m ² and preferably from 35 to 80 g / m ² .

7. Mat according to one of claims 1 to 6, characterized in that the amount of organic binder is 5 to 40% by weight of the fiber mat, and preferably 10 to 30%.

8. asphalt mat, characterized in that it comprises a glass mat according to one of claims 1 to 7.

9. Mat according to claim 8, characterized in that it has a mass per unit area which varies from 1000 to 10 000 g / m, and preferably from 1500 to 7500 g / m ² .

10. Shingle comprising a bitumen mat according to claim 8 or 9 and a layer of mineral granules on at least one of its faces.