阅读说明：本技术 一种防火隔热产品及此类产品的用途 (Fireproof heat-insulating product and application thereof ) 是由 T·海尔姆加德 T·蒂勒曼 于 2017-11-13 设计创作，主要内容包括：本发明涉及一种防火隔热产品,所述防火隔热产品包括气流成网的矿棉纤维和粘结剂,所述粘结剂是固化包含至少一种水胶体的粘结剂组合物的结果,并且所述产品还包含颗粒状吸热材料。(The present invention relates to a fire protection and insulation product comprising air-laid mineral wool fibres and a binder as a result of curing a binder composition comprising at least one hydrocolloid, and further comprising a particulate heat absorbing material.)

1. A fire protection and thermal insulation product comprising air-laid mineral wool fibers and a binder as a result of curing a binder composition comprising at least one hydrocolloid, and further comprising a particulate heat absorbing material.

2. The product of claim 1, wherein the binder further comprises at least one fatty acid glyceride.

3. The product of claim 1 or 2, wherein the particulate heat absorbing material is uniformly distributed within the fire protection insulation product.

4. The product according to claim 1 or 2, wherein the product has a first face section and a second face section with a core section in between, and wherein the particulate heat absorbing material is distributed such that the concentration of heat absorbing material in the core section of the mineral wool fiber product is higher than the concentration of heat absorbing material in the face section.

5. The product according to any one of claims 1 to 4, wherein the heat absorbing material is selected from the group consisting of gypsum, magnesium hydroxide, hydromagnesite, aluminium hydroxide and aluminium trihydroxide.

6. The product according to any of the preceding claims, wherein the at least one hydrocolloid is selected from the group consisting of gelatin, pectin, starch, algin, agar, carrageenan, gellan gum, guar gum, gum arabic, locust bean gum, xanthan gum, cellulose derivatives such as carboxymethyl cellulose, arabinoxylan, cellulose, curdlan, β -glucan.

7. The product according to any of the preceding claims, wherein the at least one hydrocolloid is a polyelectrolyte hydrocolloid.

8. The product according to claim 7, wherein the binder is obtained from the curing of a binder composition, wherein the at least one hydrocolloid is selected from the group consisting of gelatin, pectin, algin, carrageenan, gum arabic, xanthan gum, cellulose derivatives such as carboxymethyl cellulose.

9. The product according to any of the preceding claims, wherein the binder is obtained from the curing of a binder composition comprising at least two hydrocolloids, wherein one hydrocolloid is gelatin and at least one other hydrocolloid is selected from the group consisting of pectin, starch, algin, agar, carrageenan, gellan gum, guar gum, gum arabic, locust bean gum, xanthan gum, cellulose derivatives such as carboxymethyl cellulose, arabinoxylan, cellulose, curdlan, β -glucan.

10. The product according to claim 9, wherein the binder results from curing of a binder composition comprising gelatin, wherein the gelatin is present in the binder in an amount of 10 to 95 wt. -%, such as 20 to 80 wt. -%, such as 30 to 70 wt. -%, such as 40 to 60 wt. -%, based on the weight of the hydrocolloid.

11. The product according to any of claims 9 or 10, wherein the adhesive results from curing of an adhesive composition, wherein the one hydrocolloid and the at least other hydrocolloid have complementary charges.

12. The product according to any one of claims 2 to 11, wherein the at least one fatty acid glyceride is in the form of a vegetable oil and/or an animal oil.

13. The product according to any one of claims 2 to 12, wherein the at least one fatty acid glyceride is a vegetable-based oil.

14. The product according to any one of claims 2 to 13, wherein the at least one fatty acid glyceride is selected from one or more components of the group consisting of linseed oil, olive oil, tung oil, coconut oil, hemp oil, rapeseed oil and sunflower oil.

15. The product according to any one of claims 2 to 12, wherein the at least one fatty acid glyceride is in the form of an animal oil, such as fish oil.

16. The product according to any one of claims 2 to 15, wherein the at least one fatty acid glyceride comprises a vegetable oil and/or an animal oil having an iodine value of 75 or more, such as 75 to 180, such as 130 or more, such as 130 to 180.

17. The product according to any one of claims 2 to 15, wherein the at least one fatty acid glyceride comprises a vegetable oil and/or an animal oil having an iodine value of ≤ 100, such as ≤ 25.

18. The product according to any of claims 2 to 17, wherein the content of fatty acid glycerides is from 0.5 to 40 wt. -%, such as from 1 to 30 wt. -%, such as from 1.5 to 15 wt. -%, such as from 3 to 10 wt. -%, such as from 4 to 7.5 wt. -%, based on the dry weight of the hydrocolloid.

19. The product according to any of the preceding claims, wherein the Loss On Ignition (LOI) is in the range of 0.1 to 25.0%, such as 0.3 to 18.0%, such as 0.5 to 12.0%, such as 0.7 to 8.0% by weight.

20. The product according to any of the preceding claims, wherein the binder is obtained from curing a binder composition at a temperature below 95 ℃, such as from 5 ℃ to 95 ℃, such as from 10 ℃ to 80 ℃, such as from 20 ℃ to 60 ℃, such as from 40 ℃ to 50 ℃.

21. The product of any of the preceding claims, wherein the binder results from curing of a binder composition that is not a thermosetting binder composition.

22. The product of any of the preceding claims, wherein the binder results from curing of a binder composition that does not comprise poly (meth) acrylic acid, a salt of poly (meth) acrylic acid, or an ester of poly (meth) acrylic acid.

23. The product according to any one of the preceding claims, wherein the adhesive results from curing of an adhesive composition comprising at least one hydrocolloid, the at least one hydrocolloid being a biopolymer or modified biopolymer.

24. The product of any of the preceding claims, wherein the binder results from curing of a formaldehyde-free binder composition.

25. The product of any of the preceding claims, wherein the binder results from curing of a binder composition consisting essentially of:

-at least one hydrocolloid;

-at least one fatty acid glyceride;

-optionally at least one pH adjusting agent;

-optionally at least one cross-linking agent;

-optionally at least one antifouling agent;

-optionally at least one anti-swelling agent;

-water.

26. The product of any of the preceding claims, wherein the binder is not crosslinked.

27. The product of any of the preceding claims, wherein the binder is crosslinked.

28. The product according to any of the preceding claims, wherein the binder composition is cured by a drying process, in particular by blowing air or gas over/through the mineral wool product or by increasing the temperature.

29. The product according to any of the preceding claims, wherein the curing is performed at a temperature of 5 ℃ to 95 ℃, such as 10 ℃ to 80 ℃, such as 20 ℃ to 60 ℃, such as 40 ℃ to 50 ℃.

30. The product according to any of the preceding claims, wherein the mineral wool product has a density of 10kg/m³To 1200kg/m³Such as 30kg/m³To 800kg/m³Such as 40kg/m³To 600kg/m³Such as 50kg/m³To 250kg/m³Such as 60kg/m³To 200kg/m³Within the range of (1).

31. Use of a product according to any of the preceding claims for fire protection of a structure, such as a building structure.

32. Use of the product of any one of claims 1 to 30 as an insert for a fire door.

33. Use of a product according to any of claims 1 to 30 for fire protection of ventilation ducts.

Technical Field

The present invention relates to a fire-resistant and heat-insulating product comprising mineral wool fibres.

Background

Mineral wool fiber products are known to have fire-retardant properties. Examples are known from EP 1086055, EP 1928796, WO 97/20780 or EP 3187474 a 1.

Conventionally, phenol-formaldehyde resins which can be produced in an economical manner have been used as binder compositions for binding mineral wool fibres together.

However, these binders have the disadvantage that they contain formaldehyde, so they are potentially harmful, and it is desirable to replace these conventional binders with formaldehyde-free binders.

The non-phenol-formaldehyde binder is typically a sugar-based binder such as, for example, the compositions disclosed in EP2990494a1, PCT/EP2015/080758, WO2007/014236, WO2011/138458 and WO 2009/080938.

However, all these binders have the disadvantage that they require high temperatures to cure, which makes it necessary to apply heat for a long time to cure the binder and to bond the mineral fibres to each other. Thus, in production, the binder must be cured after the product is formed. This curing is achieved by heating the product in an oven to a temperature of 200-250 c for a certain period of time. Such heating increases production time and costs, precisely because it sets some constraints for adding material to the product, since the material must be able to withstand such elevated heating. Furthermore, the high temperature curing of these known binders leads to the emission of harmful or irritating substances which have to be disposed of.

It is therefore an object of the present invention to provide a fire protection and insulation product which reduces or eliminates the above mentioned disadvantages.

Disclosure of Invention

These objects are achieved with a fire-protecting and heat-insulating product comprising air-laid mineral wool fibres and a binder as a result of curing a binder composition comprising at least one hydrocolloid, and which product further comprises a particulate heat-absorbing material.

It has surprisingly been found that a binder which can be cured at relatively low temperatures can be used, which binder allows the addition of further substances to the mineral wool fire protection product in order to further improve the fire protection properties of the product. Furthermore, since the binder for the product in some embodiments does not typically contain any harmful substances and does not typically release any harmful substances during curing, a more environmentally friendly production may be achieved.

Preferably, the binder further comprises at least one fatty acid glyceride.

In one embodiment, the particulate heat absorbing material is uniformly distributed within the fire insulating product.

However, in a preferred embodiment, the product has a first face section and a second face section with a core section in between, and the particulate heat absorbing material is distributed such that the concentration of heat absorbing material in the core section of the mineral wool fibre product is higher than the concentration of heat absorbing material in the face section. This is advantageous because in the mineral wool product according to the invention the heat absorbing material absorbs energy, thereby delaying the diffusion of heat from the fire from one side to the other. By having the particulate material mainly in the core section, the risk of the particulate material falling out of the product during handling can be minimized. Furthermore, this is advantageous because such products provide equally good fire resistance from either side thereof.

In one embodiment of the invention, the heat absorbing material is selected from the group consisting of: gypsum, magnesium hydroxide, hydromagnesite, aluminum hydroxide, and aluminum trihydroxide.

In a second aspect of the invention, there is provided the use of a fire protection and insulation product comprising air-laid mineral wool fibres and a binder, the binder being the result of curing a binder composition comprising at least one hydrocolloid, and the product comprising a particulate heat absorbing material.

Thus, the product according to the invention may be used for fire protection of structures, such as building structures, as an insert for fire doors or for ventilation ducts.

Detailed Description

Mineral wool element

Mineral wool elements typically comprise man-made vitreous fibres (MMVF), such as for example glass fibres, ceramic fibres, basalt fibres, slag wool, mineral wool and rock wool, bonded together by a cured mineral wool binder, which is conventionally a thermosetting polymeric binder material. Bonded mineral fiber mats for use as thermal or acoustical insulation products are typically produced by converting a melt made from suitable raw materials into fibers in a conventional manner, such as by a spinning cup process or a cascade rotor process. The fibers are blown into a forming chamber and the airborne fibers are sprayed with a binder solution while hot and randomly deposited as a mat or web on a traveling conveyor. The fibrous web is then transferred to a curing oven where heated air is blown through the web to cure the binder and firmly bond the mineral fibers together.

If desired, the web may be subjected to a forming process prior to curing. The bonded mineral fibre elements may be cut into a desired form, for example in the form of a mat. Thus, mineral wool elements are for example in the form of woven and non-woven fabrics, mats, felts, boards, sheets, discs, strips, rolls, granulates and other shaped articles which can be used, for example, as thermal or acoustic insulation materials, vibration damping, construction materials, exterior wall insulation, reinforcing materials for roofing or flooring applications, filter materials, horticultural growth media and other applications. Mineral wool elements are also known to have excellent fire retardant properties and are therefore often used in structures such as building structures, fire protection of technical installations or as inserts in fire doors.

Mineral wool binder

The adhesive in the present invention is produced by curing an adhesive composition comprising at least one hydrocolloid. In a preferred embodiment, the binder composition further comprises at least one fatty acid glyceride.

In a preferred embodiment, the binder used in the present invention is formaldehyde-free.

For the purposes of this application, the term "formaldehyde-free" is defined as characterizing mineral wool products, from whichThe emission of formaldehyde from mineral wool products is less than 5 mu g/m²H, preferably less than 3. mu.g/m²H is used as the reference value. Preferably, the test is performed according to ISO16000 for testing formaldehyde emissions.

A surprising advantage of embodiments of the mineral wool product according to the invention is that it exhibits self-healing properties. When the mineral wool product looses a part of its strength after exposure to very severe conditions, the mineral wool product according to the invention can regain a part or all of or even exceed the initial strength. In an embodiment, the aged strength is at least 80%, such as at least 90%, such as at least 100%, such as at least 130%, such as at least 150% of the unaged strength. This is in contrast to conventional mineral wool products, where the loss of strength after exposure to harsh environmental conditions is irreversible. While not wishing to be bound by any particular theory, the inventors believe that this surprising property in the mineral wool product according to the invention is due to the complex nature of the bonds formed in the network of the cured binder composition, such as a protein cross-linked by phenolic and/or quinone-containing compounds, or a protein cross-linked by enzymes, which also includes quaternary structure and hydrogen bonds, and which allows the bonds in the network to be established after returning to normal environmental conditions. This is an important advantage for the long-term stability of the products, for example for the use as insulation and fire protection measures for technical installations which may sometimes be operated at high temperatures.

Hydrocolloid

Hydrocolloids are hydrophilic polymers of plants, animals, microorganisms or artificial synthesis, usually containing a number of hydroxyl groups, and may be polyelectrolytes. Hydrocolloids are widely used to control functional properties of aqueous foodstuffs.

Hydrocolloids may be proteins or polysaccharides and are completely or partially soluble in water and are mainly used to increase the viscosity of the continuous phase (aqueous phase), i.e. as gelling or thickening agents. Hydrocolloids can also be used as emulsifiers, since their stabilizing effect on emulsions results from an increase in the viscosity of the aqueous phase.

Hydrocolloids are generally composed of mixtures of similar but non-identical molecules, and are produced from different sources and methods of preparation. The heat treatment and, for example, the salt content, pH and temperature all affect the physical properties that it exhibits. The description of hydrocolloids generally presents an idealized structure, but the structure may differ from the ideal structure because it is a natural product (or derivative) with a structure determined, for example, by random enzyme action, rather than by a precise programming of the genetic code (laydown).

Many hydrocolloids are polyelectrolytes (e.g., algin, gelatin, carboxymethyl cellulose, and xanthan gum).

Polyelectrolytes are polymers in which a large number of the repeating units have electrolyte groups. Polycations and polyanions are polyelectrolytes. These groups dissociate in aqueous solutions (water), charging the polymer. Thus, polyelectrolytes behave like electrolytes (salts) and polymers (high molecular weight compounds) and are sometimes referred to as poly-salts.

The charged groups ensure strong hydration, especially on a per molecule basis. The presence of counterions and co-ions (ions of the same charge as the polyelectrolyte) introduces a complex property of ion specificity.

The proportion of counterions remains closely associated with the polyelectrolyte trapped in its electrostatic field, thereby reducing the activity and mobility of the counterions.

In one embodiment, the binder composition comprises a metal selected from Mg²⁺、Ca²⁺、Sr²⁺、Ba²⁺One or more counter ions of the group (b).

Another characteristic of polyelectrolytes is a high linear charge density (number of charged groups per unit length).

Generally, neutral hydrocolloids are less soluble, while polyelectrolytes are more soluble.

Many hydrocolloids also gel. Gels are liquid water-containing networks exhibiting a solid-like behavior, the characteristic strength of which depends on their concentration, and the hardness and brittleness of which depends on the structure of the hydrocolloid present.

Hydrogels are hydrophilic crosslinked polymers that can swell to absorb and retain large amounts of water. The use of hydrogels in hygiene products is particularly known. Commonly used materials use polyacrylates, but hydrogels can be made by crosslinking soluble hydrocolloids to make insoluble, but elastic and hydrophilic polymers.

Examples of hydrocolloids include: agar, algin, arabinoxylan, carrageenan, carboxymethyl cellulose, curdlan, gelatin, gellan gum, beta-glucan, guar gum, gum arabic, locust bean gum, pectin, starch, xanthan gum. In one embodiment, the at least one hydrocolloid is selected from the group consisting of gelatin, pectin, starch, algin, agar, carrageenan, gellan gum, guar gum, gum arabic, locust bean gum, xanthan gum, cellulose derivatives such as carboxymethyl cellulose, arabinoxylan, cellulose, curdlan, β -glucan.

Examples of polyelectrolyte hydrocolloids include: gelatin, pectin, algin, carrageenan, gum arabic, xanthan gum, cellulose derivatives such as carboxymethyl cellulose.

In one embodiment, the at least one hydrocolloid is a polyelectrolyte hydrocolloid.

In one embodiment, the at least one hydrocolloid is selected from the group consisting of gelatin, pectin, algin, carrageenan, gum arabic, xanthan gum, cellulose derivatives such as carboxymethyl cellulose.

In one embodiment, the at least one hydrocolloid is a gel former.

In one embodiment, at least one hydrocolloid is in the form of a salt such as Na⁺、K⁺、NH₄ ⁺、Mg²⁺、Ca²⁺、Sr²⁺、Ba²⁺The salt form is used.

Gelatin

Gelatin is derived from the chemical degradation of collagen. Gelatin may also be produced by recombinant techniques. Gelatin is water soluble and has a molecular weight of 10.000 to 500.000g/mol, such as 30.000 to 300.000g/mol, depending on the hydrolysis grade. Gelatin is a widely used food product and it is therefore widely accepted that this compound is completely non-toxic and therefore no precautions need to be taken when handling gelatin.

Gelatin is a heterogeneous mixture of single or multi-chain polypeptides, typically exhibiting a helical structure. Specifically, the triple helix of type I collagen extracted from skin and bone as a source of gelatin consists of two α 1(I) chains and one α 2(I) chain.

Gelatin solutions may undergo a coiled-coil (coil-helix) transition.

Type a gelatin is produced by acidic treatment. Type B gelatin is produced by alkaline treatment.

Chemical crosslinking can be incorporated into gelatin. In one embodiment, transglutaminase is used to link lysine to a glutamine residue; in one embodiment, glutaraldehyde is used to attach lysine to lysine, and in one embodiment, tannin is used to attach lysine residues.

Gelatin can also be further hydrolyzed into smaller fragments as small as 3000 g/mol.

Upon cooling the gelatin solution, a collagen-like helix may be formed.

Other hydrocolloids may also comprise helical structures, such as collagen-like helices. Gelatin may form a helical structure.

In one embodiment, the cured adhesive comprising hydrocolloid comprises a helical structure.

In one embodiment, the at least one hydrocolloid is a low strength gelatin, such as a gelatin having a gel strength of 30 Bloom to 125 Bloom.

In one embodiment, the at least one hydrocolloid is a medium strength gelatin, such as a gelatin having a 125 bloom to 180 bloom gel strength.

In one embodiment, the at least one hydrocolloid is a high strength gelatin, such as a gelatin having a gel strength of 180 bloom to 300 bloom.

In a preferred embodiment, the gelatine is preferably derived from mammals, birds, such as from cattle, pigs, horses, poultry and/or from one or more sources from the group consisting of fish scales, fish skins.

In one embodiment, urea may be added to the binder composition used in the present invention. The inventors have found that the addition of even small amounts of urea results in gelatin denaturation, which slows gelation, which may be desirable in some embodiments. The addition of urea can also lead to softening of the product.

The present inventors have found that carboxylic acid groups in gelatin interact strongly with trivalent and tetravalent ions (e.g., aluminum salts). This is particularly true for type B gelatin which contains more carboxylic acid groups than type a gelatin.

The inventors have found that in some embodiments, curing/drying of the binder composition comprising gelatin for use in the present invention should not start at very high temperatures.

The inventors have found that starting the cure at low temperature can result in a stronger product. Without being bound by any particular theory, the inventors hypothesize that initiating cure at elevated temperatures may result in the outer shell of the binder composition being impermeable, impeding water from coming out of the bottom.

Surprisingly, the binder comprising gelatin used in the present invention is very heat resistant. The inventors have found that in some embodiments, the cured binder can withstand temperatures up to 300 ℃ without degradation.

Pectin

Pectin is a heterogeneous group of acidic structural polysaccharides that are present in fruits and vegetables that form acid stable gels.

Typically, pectins do not have a precise structure, but may contain up to 17 different monosaccharides and more than 20 different types of linkages (links).

The D galacturonic acid residues form the majority of the molecule.

Gel Strength dependent on Ca²⁺Increasing in concentration, but with increasing temperature and acidity (pH)<3) And decreases.

Pectin can form a helical structure.

The gelling power of the dication is similar to that found with algin (Mg)²⁺Much less than Ca²⁺，Sr²⁺Less than Ba²⁺)。

Algin

Algin is a scaffold polysaccharide produced from brown seaweed.

Algin is a linear non-branched polymer comprising β - (1,4) -linked D-mannuronic acid (M) and α - (1,4) -linked L-guluronic acid (G) residues. The algin may also be a bacterial algin, such as additionally O-acetylated. Algin is not a random copolymer but, depending on the source algae, is composed of blocks of similar and strictly alternating residues (i.e., MMMMMM, gggggggg, and GMGMGMGM), each with different conformational preferences and behavior. Algins can be prepared with a wide range of average molecular weights (50 to 100000 residues). The free carboxylic acid has water molecules H3O + that are strongly hydrogen bonded to the carboxylate groups. The Ca2+ ion can displace this hydrogen bonding, pulling (zipping) guluronic acid, but not mannuronic acid, stoichiometrically together in a so-called egg-box conformation. Recombinant epimerases with different specificities can be used to produce engineered algins.

Algin can form a helix structure.

Carrageenan

Carrageenan is a generic term for a polysaccharide of the scaffold type prepared by alkaline extraction (and modification) from red seaweed.

Carrageenan is a linear polymer of about 25,000 galactose derivatives, with a regular but not exact structure depending on the source and extraction conditions.

Kappa-carrageenan (carrageenan kappa-carrageenan) is produced by alkaline elimination of mu-carrageenan isolated mainly from the tropical seaweed kappaphycus alvarezii (also known as Eucheuma cottonii).

Iota-carrageenan (ca. talca carrageenan) is produced by alkaline elimination of v-carrageenan isolated mainly from the seaweed eucheuma philippinensis (also known as eucheuma Spinosum).

Lambda carrageenan (lambda carrageenan), which is mainly isolated from gynoecium (Gigartina pisillata) or carrageen (Chondrus crispus), is converted to theta carrageenan (theta carrageenan) by alkaline elimination, but at a much slower rate than the rate that leads to the production of I-carrageenan and kappa-carrageenan.

The most intense gel of kappa-carrageenan consists of K⁺Instead of Li⁺、Na⁺、Mg²⁺、Ca²⁺Or Sr²⁺And (4) forming.

All carrageenans may form a helical structure.

Arabic gum

Gum arabic is a complex and variable mixture of arabinogalactan oligosaccharides, polysaccharides and glycoproteins. Gum arabic is composed of a mixture of polysaccharides of lower relative molecular mass and glycoproteins of higher molecular mass rich in widely variable hydroxyproline.

Gum arabic incorporates both hydrophilic carbohydrates and hydrophobic proteins.

Xanthan gum

Xanthan gum is a microbial desiccation-tolerant (desiccation-resistant) polymer prepared by aerobic submerged fermentation of, for example, Xanthomonas campestris (xanthmonas campestris).

Xanthan gum is an anionic polyelectrolyte with a β - (1,4) -D-glucopyranose glucan (as cellulose) backbone with D-mannopyranose- (2,1) - β -D-glucuronic acid- (4,1) - β -D-mannopyranose side chains on alternating residues, linked to- (3,1) - α -.

Xanthan has been proposed to be naturally a bimolecular antiparallel duplex. The transition between the ordered duplex conformation and the more flexible single-stranded strand may occur between 40 ℃ and 80 ℃. Xanthan gum can form a helical structure.

The xanthan gum may comprise cellulose.

Cellulose derivatives

An example of a cellulose derivative is carboxymethyl cellulose.

Carboxymethyl cellulose (CMC) is a chemically modified derivative of cellulose formed by the reaction of cellulose with alkali and chloroacetic acid.

The CMC structure is based on a β - (1,4) -D-glucopyranose polymer of cellulose. Different formulations may have different degrees of substitution, but typically range from 0.6 to 0.95 derivatives per monomer unit.

Agar-agar

Agar is a scaffold polysaccharide prepared from the same family of red seaweed (Rhodophyceae) as carrageenan. Agar is commercially available from the species Gelidium (Gelidium) and Gracilaria (Gracilaria).

Agar consists of a mixture of agarose and agar gel. Agarose is a linear polymer of about 120,000 relative molecular mass (molecular weight) based on- (1,3) - β -D-galactopyranose- (1,4) -3, 6-anhydride- α -L-galactopyranose units.

Agar gel is a heterogeneous mixture with smaller molecules present in smaller amounts.

Agar can form a helix.

Arabinoxylan

Arabinoxylans are naturally present in the bran of grasses (gramineae).

Arabinoxylans are composed of α -L-arabinofuranose residues linked to a β - (1,4) -linked D-xylopyranose polymer backbone as a branch point.

Arabinoxylans can form helical structures.

Cellulose, process for producing the same, and process for producing the same

Cellulose is a scaffold polysaccharide found in plants as microfibrils (2nm to 20nm in diameter and 100nm to 40000 nm in length). Cellulose is mainly prepared from wood pulp. Cellulose is also produced in a highly hydrated form by some bacteria, such as Acetobacter xylinum.

Cellulose is a linear polymer of β - (1,4) -D-glucopyranose units in a 4C1 conformation. There are four crystalline forms: i α, I β, II and III.

The cellulose derivative can be methylcellulose, hydroxypropyl methylcellulose, hydroxyethyl cellulose, and hydroxypropyl cellulose.

Gel polysaccharide

Curdlan (Curdlan) is a polymer prepared commercially from mutant strains of the Alcaligenes faecalis variety (Alcaligenes faecalis. myxogenes). Curdlan (curdlan gum) is a medium relative molecular mass, unbranched, linear 1,3 β -D glucan, and has no side chains.

Curdlan can form a helical structure.

Curdlan is not soluble in cold water, but is plasticized and dissolved shortly before the aqueous suspension is heated to about 55 ℃ to produce a reversible gel. Heating at higher temperatures produces a more resilient irreversible gel, which is then retained by cooling.

Scleroglucan is also a1, 3 β -D glucan, but has an additional 1,6 β -linkage that confers solubility under ambient conditions.

Gellan gum

Gellan is a linear tetrasaccharide 4) -L-rhamnopyranosyl- (. alpha. -1,3) -D-glucopyranosyl- (. beta. -1,4) -D-glucopyranosuronosyl- (. beta. -1,4) -D-glucopyranosyl- (. beta. -1) with an O (2) L-glyceryl and O (6) acetyl substituent on the 3-linked glucose.

Gellan gum may form a helical structure.

Beta-glucan

Beta-glucan is present in grass bran (Gramineae).

Beta-glucans are composed of linear unbranched polysaccharides of linked beta- (1,3) -and beta- (1,4) -D-glucopyranose units in a non-repeating, but non-random order.

Guar gum

Guar gum (also known as guarana) is a reserve polysaccharide (seed flour) extracted from the seeds of the leguminous shrub guar (cyamopsistetraponoloba).

Guar gum is a galactomannan similar to locust bean gum, consisting of a (1,4) -linked β -D-mannopyranose backbone with a branch point at the 6 position linked to an α -D-galactose (i.e. a1, 6-linked- α -D-galactopyranose).

Guar gum is formed from a non-ionic polydisperse rod polymer.

Unlike locust bean gum, guar gum does not form a gel.

Locust bean gum

Locust bean gum (also known as carob gum and carbobin (carobin)) is a reserve polysaccharide (seed flour) extracted from the seeds (inner core) of the carob (Ceratonia siliqua).

Locust bean gum is a galactomannan similar to guar gum, consisting of a (1,4) -linked β -D-mannopyranose backbone with a branch point at the 6 position linked to an α -D-galactose (i.e. a1, 6-linked α -D-galactopyranose).

Locust bean gum is a polydispersion made up of non-ionic molecules.

Starch

Starch is composed of two types of molecules, amylose (typically 20% to 30%) and amylopectin (typically 70% to 80%). Both of these are composed of polymers of alpha-D-glucose units in a 4C1 conformation. In amylose, the linkages are- (1,4) -, with the epoxy atoms on the same side, while in amylopectin, about every twenty units are also linked to- (1,6) -, forming branch points. The relative proportions of amylose to amylopectin and the- (1,6) -branch points depend on the starch source. The starch may be derived from corn (maize), wheat, potato, tapioca and rice. Amylopectin (amylose-free) can be isolated from 'waxy' maize starch, whereas amylose (amylopectin-free) is optimally isolated after specific hydrolysis of amylopectin with pullulanase.

Amylose can form a helical structure.

In one embodiment, the at least one hydrocolloid is a functional derivative of starch, such as cross-linked, oxidized, acetylated, hydroxypropylated and partially hydrolyzed starch.

In a preferred embodiment, the binder composition comprises at least two hydrocolloids, wherein one hydrocolloid is gelatin and at least one other hydrocolloid is selected from the group consisting of pectin, starch, algin, agar, carrageenan, gellan, guar gum, gum arabic, locust bean gum, xanthan gum, cellulose derivatives such as carboxymethyl cellulose, arabinoxylan, cellulose, curdlan, β -glucan.

In one embodiment, the adhesive composition comprises at least two hydrocolloids, wherein one hydrocolloid is gelatin and at least the other hydrocolloid is pectin.

In one embodiment, the adhesive composition comprises at least two hydrocolloids, wherein one hydrocolloid is gelatin and at least the other hydrocolloid is algin.

In one embodiment, the adhesive composition comprises at least two hydrocolloids, wherein one hydrocolloid is gelatin and at least the other hydrocolloid is carboxymethyl cellulose.

In a preferred embodiment, the adhesive composition for use in the present invention comprises at least two hydrocolloids, wherein one hydrocolloid is gelatin, and wherein the gelatin is present in the aqueous adhesive composition in an amount of from 10 to 95 wt. -%, such as from 20 to 80 wt. -%, such as from 30 to 70 wt. -%, such as from 40 to 60 wt. -%, based on the weight of the hydrocolloid.

In one embodiment, the adhesive composition comprises at least two hydrocolloids, wherein one hydrocolloid and at least the other hydrocolloid have complementary charges.

In one embodiment, one hydrocolloid is one or more of gelatine or gum arabic having a complementary charge, selected from one or more hydrocolloids of the group of pectin, algin, carrageenan, xanthan gum or carboxymethylcellulose.

In one embodiment, the adhesive composition is capable of curing at a temperature of no more than 95 ℃, such as from 5 ℃ to 95 ℃, such as from 10 ℃ to 80 ℃, such as from 20 ℃ to 60 ℃, such as from 40 ℃ to 50 ℃.

In one embodiment, the aqueous binder composition used in the present invention is not a thermosetting binder.

The thermosetting composition is in a soft solid or viscous liquid state, preferably comprising a prepolymer, preferably a resin, which upon curing irreversibly converts to a non-fusible, insoluble polymer network. Curing is usually caused by the action of heat, whereby temperatures above 95 ℃ are usually required.

The cured thermoset resin is referred to as a thermoset or thermoset plastic/polymer-when used as a host material in a polymer composite, it is referred to as a thermoset polymer matrix. In one embodiment, the aqueous binder composition used in the present invention does not comprise poly (meth) acrylic acid, salts of poly (meth) acrylic acid, or esters of poly (meth) acrylic acid.

In one embodiment, the at least one hydrocolloid is a biopolymer or modified biopolymer.

Biopolymers are polymers produced by living organisms. Biopolymers may comprise monomeric units covalently bonded to form larger structures.

There are three main classes of biopolymers classified according to the monomer units used and the structure of the biopolymers formed: polynucleotides (RNA and DNA), which are long polymers consisting of 13 or more nucleotide monomers; polypeptides, such as proteins, which are polymers of amino acids; polysaccharides, such as linearly bonded polymeric carbohydrate structures.

The polysaccharide may be linear or branched; they are usually linked by glycosidic bonds. In addition, many saccharide units can undergo various chemical modifications and can form part of other molecules such as glycoproteins.

In one embodiment, the at least one hydrocolloid is a biopolymer or modified biopolymer having a polydispersity index of the relevant molecular mass distribution of 1, such as 0.9 to 1.

In one embodiment, the binder composition comprises a protein from an animal source, including collagen, gelatin and hydrolyzed gelatin, and the binder composition further comprises at least one phenolic and/or quinone containing compound, such as a tannin selected from one or more of the group consisting of tannic acid, condensed tannins (procyanidins), hydrolysable tannins, gallotannins, ellagitannins, complex tannins, and/or tannins derived from one or more of oak, chestnut, carageenan (Staghorn sumac) and big ear cup (ringing cups).

In one embodiment, the binder composition comprises proteins from animal sources, including collagen, gelatin and hydrolyzed gelatin, and wherein the binder composition further comprises at least one enzyme selected from the group consisting of transglutaminase (EC 2.3.2.13), protein disulfide isomerase (EC 5.3.4.1), thiol oxidase (EC 1.8.3.2), polyphenol oxidase (EC 1.14.18.1), in particular catechol oxidase, tyrosine oxidase and phenol oxidase, lysyl oxidase (EC1.4.3.13) and peroxidase (EC 1.11.1.7).

Fatty acid glycerides

In a preferred embodiment, the binder composition further comprises a component in the form of at least one fatty acid glyceride.

Fatty acids are carboxylic acids having an aliphatic chain, which are saturated or unsaturated.

Glycerol is a polyol compound having the IUPAC name propane-1, 2, 3-triol.

Naturally occurring fats and oils are glycerides (also known as triglycerides) with fatty acids.

For the purposes of the present invention, the term fatty acid glyceride refers to mono-, di-and tri-esters of glycerol and fatty acids.

Although the term fatty acid may in the context of the present invention be any carboxylic acid having an aliphatic chain, it is preferred that it is a carboxylic acid with an aliphatic chain having from 4 to 28 carbon atoms, preferably an even number of carbon atoms. Preferably, the aliphatic chain of the fatty acid is unbranched.

In a preferred embodiment, the at least one fatty acid glyceride is in the form of a vegetable oil and/or an animal oil. In the context of the present invention, the term "oil" comprises at least one fatty acid glyceride in the form of an oil or fat.

In a preferred embodiment, the at least one fatty acid glyceride is a vegetable-based oil.

In a preferred embodiment, the at least one fatty acid glyceride is in the form of: pulp fats such as palm oil, olive oil, avocado oil; kernel seed fats, such as lauric oils, such as coconut oil, palm kernel oil, babassu oil, and other palm seed oils, lauric oils of other sources; palm-stearate oils, such as cocoa butter, shea butter, shorea tallow (borneo tall) and related fats (vegetable fats); palmitic acid oils such as cottonseed oil, kapok oil and related oils, pumpkin seed oil, corn (maize) oil, corn oil; oleic-linoleic acids oils such as sunflower oil, sesame oil, linseed oil, perilla oil, hemp seed oil, tea seed oil, safflower and nigers seed oil (nigered oils), grape seed oil, poppy seed oil, soybean oils such as soybean oil, peanut oil, lupin oil; cruciferous oils, such as rapeseed oil, mustard seed oil; conjugated acid oils such as tung oil and related oils, brazil nut oil and related oils; substituted fatty acid oils such as castor oil, chaulmoogra \ hydnocarpus \ gorli oil, vernonia oil; animal fats, such as terrestrial animal fats, such as lard, tallow, lamb fat, horse fat, goose fat, chicken fat; marine oils such as whale oil and fish oil.

In a preferred embodiment, the at least one fatty acid glyceride is in the form of a vegetable oil, in particular one or more components selected from the group consisting of linseed oil, olive oil, tung oil, coconut oil, hemp oil, rapeseed oil and sunflower oil.

In a preferred embodiment, the at least one fatty acid glyceride is selected from the group consisting of vegetable oils having an iodine value in the range of about 136 to 178 (such as linseed oil having an iodine value in the range of about 136 to 178), vegetable oils having an iodine value in the range of about 80 to 88 (such as olive oil having an iodine value in the range of about 80 to 88), vegetable oils having an iodine value in the range of about 163 to 173 (such as tung oil having an iodine value in the range of about 163 to 173), vegetable oils having an iodine value in the range of about 7 to 10 (such as coconut oil having an iodine value in the range of about 7 to 10), one or more components of the group consisting of vegetable oils having an iodine value in the range of about 140 to 170 (such as hemp oil having an iodine value in the range of about 140 to 170), vegetable oils having an iodine value in the range of about 94 to 120 (such as rapeseed oil having an iodine value in the range of about 94 to 120), vegetable oils having an iodine value in the range of about 118 to 144 (such as sunflower oil having an iodine value in the range of about 118 to 144).

In one embodiment, the at least one fatty acid glyceride is not of natural origin.

In one embodiment, the at least one fatty acid glyceride is a modified vegetable or animal oil.

In one embodiment, the at least one fatty acid glyceride comprises at least one trans fatty acid.

In an alternative preferred embodiment, the at least one fatty acid glyceride is in the form of an animal oil, such as fish oil.

The inventors have found that an important parameter of the fatty acid glycerides used in the binder of the present invention is the amount of unsaturation in the fatty acids. The amount of unsaturation in a fatty acid is typically measured by the iodine number (also known as the iodine number or iodine uptake value or iodine index). The higher the iodine number, the more C ═ C bonds are present in the fatty acid. To determine the iodine value as a measure of the unsaturation of fatty acids, we refer to Thomas, Alfred (2002) "Fats and fatty oils" in Ullmann's encyclopedia of Industrial chemistry, Weinheim, Wiley-VCH.

In a preferred embodiment, the at least one fatty acid glyceride comprises a vegetable oil and/or an animal oil having an iodine value of 75 or more, such as 75 to 180, such as 130 or more, such as 130 to 180.

In an alternative preferred embodiment, the at least one fatty acid glyceride comprises a vegetable oil and/or an animal oil having an iodine value of 100 or less, such as 25 or less.

In one embodiment, the at least one fatty acid glyceride is a drying oil. For the definition of Drying oils, see Poth, Ulrich (2012) "Drying oils and related products" in Ullmann's encyclopedia of Industrial chemistry, Weinheim, Wiley-VCH.

Thus, the inventors have found that particularly good results are obtained when the iodine value is in a rather high range, or alternatively in a rather low range. While not wishing to be bound by any particular theory, the inventors believe that the advantageous properties caused by fatty acid esters with a high iodine value on the one hand and fatty acid esters with a low iodine value on the other hand are based on different mechanisms. The inventors postulate that the advantageous properties of fatty acid glycerides with high iodine values may be due to the participation of C ═ C double bonds in the crosslinking reaction present at high values in these fatty acids, whereas fatty acid glycerides with low iodine values and lacking a high content of C ═ C double bonds may allow to stabilize the cured binder by van der waals interactions.

In a preferred embodiment, the content of fatty acid glycerides is from 0.5 to 40 wt. -%, such as from 1 to 30 wt. -%, such as from 1.5 to 20 wt. -%, such as from 3 to 10 wt. -%, such as from 4 to 7.5 wt. -%, based on the dry weight of the hydrocolloid.

In one embodiment, the binder composition comprises gelatin, and the binder composition further comprises tannins of one or more components selected from the group consisting of tannic acid, condensed tannins (procyanidins), hydrolysable tannins, gallotannins, ellagitannins, complex tannins and/or tannins derived from one or more of oak, chestnut, caraway and cupflower, preferably tannic acid, and the binder composition further comprises at least one fatty acid glyceride, such as at least one fatty acid glyceride of one or more components selected from the group consisting of linseed oil, olive oil, tung oil, coconut oil, hemp oil, rapeseed oil and sunflower oil.

In one embodiment, the binder composition comprises gelatin, and the binder composition further comprises at least one enzyme that is transglutaminase (EC 2.3.2.13), and the binder composition further comprises at least one fatty acid glyceride, such as at least one fatty acid glyceride of one or more components selected from the group consisting of linseed oil, olive oil, tung oil, coconut oil, hemp oil, rapeseed oil, and sunflower oil.

In one embodiment, the aqueous binder composition is formaldehyde-free.

In one embodiment, the adhesive composition consists essentially of:

at least one hydrocolloid;

at least one fatty acid glyceride;

optionally at least one pH adjusting agent;

optionally at least one cross-linking agent;

optionally at least one antifoulant;

optionally at least one anti-swelling agent;

and (3) water.

In one embodiment, oil may be added to the binder composition.

In one embodiment, the at least one oil is a non-emulsified hydrocarbon oil.

In one embodiment, the at least one oil is an emulsified hydrocarbon oil.

In one embodiment, the at least one oil is a vegetable-based oil.

In one embodiment, the at least one cross-linking agent is a tannin of one or more components selected from the group consisting of tannic acid, condensed tannins (procyanidins), hydrolysable tannins, gallotannins, ellagitannins, complex tannins, and/or a tannin derived from one or more of oak, chestnut, caraus and cupflower.

In one embodiment, the at least one cross-linking agent is an enzyme selected from the group consisting of transglutaminase (EC 2.3.2.13), protein disulfide isomerase (EC 5.3.4.1), thiol oxidase (EC 1.8.3.2), polyphenol oxidase (EC 1.14.18.1), in particular catechol oxidase, tyrosine oxidase and phenol oxidase, lysyl oxidase (EC1.4.3.13) and peroxidase (EC 1.11.1.7).

In one embodiment, the at least one anti-swelling agent is tannic acid and/or tannin.

In one embodiment, at least one antifouling agent is an antimicrobial agent.

The antimicrobial agent can be benzoic acid, propionic acid, sodium benzoate, sorbic acid, and potassium sorbate to inhibit the growth of bacterial and fungal cells. However, natural biological preservatives can be used. Chitosan (Chitosan) is considered to be antifungal and antibacterial. The most frequently used antimicrobial biological preservatives are lysozyme and nisin. Common other biological preservatives that can be used are bacteriocins such as nisin and pediocin and antimicrobial enzymes such as chitinase and glucose oxidase. In addition, the use of Lactoperoxidase (LPS) exhibits antifungal and antiviral activity. Natural antimicrobials such as tannins, rosemary and garlic essential oils, oregano oil, lemon grass (lemon grass) or cinnamon oil may also be used in varying concentrations.

Mineral fibre product

In the fire protection and thermal insulation product according to the present invention, the mineral fibers are bonded by the binder as described above.

In one embodiment, the Loss On Ignition (LOI) of the mineral wool product according to the invention is in the range of 0.1 to 25.0%, such as 0.3 to 18.0%, such as 0.5 to 12.0%, such as 0.7 to 8.0% by weight.

In one embodiment, the binder is not crosslinked.

In an alternative embodiment, the binder is crosslinked.

Reaction of the Binder Components

The inventors have found that in some embodiments of the mineral wool product according to the invention, the mineral wool product is best produced when the binder is applied to the mineral fibres under acidic conditions. Thus, in a preferred embodiment, the binder applied to the mineral fibres comprises a pH adjusting agent, in particular in the form of a pH buffer.

In a preferred embodiment, the pH of the binder in its uncured state is less than 8, such as less than 7, such as less than 6.

The inventors have found that in some embodiments, the curing of the binder is strongly accelerated under alkaline conditions. Thus, in one embodiment, the binder composition for mineral fibres comprises a pH adjusting agent, which is preferably a base, such as an organic base, such as an amine or a salt thereof; inorganic bases such as metal hydroxides, such as KOH or NaOH, ammonia or its salt forms.

In a particularly preferred embodiment, the pH adjusting agent is an alkaline metal hydroxide, in particular NaOH.

In a preferred embodiment, the pH of the binder composition used in the present invention is from 7 to 10, such as from 7.5 to 9.5, such as from 8 to 9.

Other additives may be components such as one or more reactive or non-reactive silicones, and may be added to the binder. Preferably, the one or more reactive or non-reactive silicones are chosen from the following silicones: the backbone constituting the silicone consists of organosiloxane residues, in particular diphenylsiloxane residues, alkylsiloxane residues, preferably dimethylsiloxane residues, having at least one hydroxyl, acyl, carboxyl or anhydride, amine, epoxy or vinyl functional group which is capable of reacting with at least one component of the adhesive composition, and preferably the silicone is present in an amount of 0.1 to 15 wt. -%, preferably 0.1 to 10 wt. -%, more preferably 0.3 to 8 wt. -%, based on the total mass of the adhesive.

In one embodiment, an antifoulant may be added to the binder.

In a preferred embodiment, the anti-fouling agent is a tannin, in particular a tannin of one or more components selected from the group consisting of tannic acid, condensed tannins (procyanidins), hydrolysable tannins, gallotannins, ellagitannins, complex tannins, and/or a tannin derived from one or more of oak, chestnut, caraway and cupflower.

In one embodiment, an anti-swelling agent, such as tannic acid and/or tannin, may be added to the binder.

The additional additive may be an additive comprising calcium ions and an antioxidant.

In one embodiment, the adhesive composition used in the present invention comprises an additive in the form of a linker comprising an acyl group and/or an amine group and/or a thiol group. These joints may reinforce and/or modify the network of cured binder.

In one embodiment, the binder composition for use in the present invention comprises further additives in the form of additives selected from the group consisting of PEG-type reagents, silanes and hydroxyapatite.

Characteristics of mineral wool products

In a preferred embodiment, the mineral wool fireproofing has a density of 10kg/m³To 1200kg/m³Such as 30kg/m³To 800kg/m³Such as 40kg/m³To 600kg/m³Such as 50kg/m³To 250kg/m³Such as 60kg/m³To 200kg/m³Within the range of (1).

Fiber forming device

There are various types of centrifugal spinning machines for fiberizing mineral melts.

A conventional centrifugal spinning machine is a cascade spinning machine comprising a series of top (or first) and subsequent (or second) rotors and optionally other subsequent rotors such as third and fourth rotors. Each rotor rotates about a different substantially horizontal axis, with the direction of rotation of the rotor being opposite to the direction of rotation of the or each adjacent rotor in the series. The different horizontal axes are arranged such that the melt to be poured on the top rotor is thrown in sequence onto the peripheral surface of the or each subsequent rotor and the fibres are thrown from the or each subsequent rotor and optionally also from the top rotor.

In one embodiment, a cascade spinning machine or other spinning machine is arranged to fiberize the melt and entrain the fibers in the air as a cloud of fibers.

Many fiber forming apparatuses include a disc or cup that rotates about a substantially vertical axis. Several of these spinning machines are then usually arranged in series, i.e. substantially in A first direction, as described for example in GB-A-926,749, US-A-3,824,086 and WO-A-83/03092.

There is typically an air flow associated with the or each fiberising rotor whereby fibres are entrained in the air as they form from the surface of the rotor.

In one embodiment, the binder and/or additives are added to the fiber cloud by known means. The amount of binder and/or additive used for each spinning machine may be the same or it may be different.

In one embodiment, hydrocarbon oil may be added to the fiber cloud.

As used herein, the term "gathering web" is intended to include any mineral fibers that have been collected and gathered on a surface, i.e., they are no longer entrained by gas, such as fiberized mineral fibers, granulated, tufted, or recycled web waste. The gathered web may be a primary web formed by collecting fibers on a conveyor belt and provided as a starting material without being cross-folded (cross-lap) or otherwise consolidated.

Alternatively, the gathered web may be a secondary web formed by cross-folding or otherwise consolidating a primary web. Preferably, the gathered web is a primary web.

The particulate heat absorbing material may be added to the collecting web at any suitable stage in the production.

In one embodiment, after providing the gathered web, mixing of the binder with the mineral fibers is completed in the following steps:

the gathered web of mineral fibers is subjected to a disentangling treatment,

the mineral fibres are suspended in the main air flow,

the binder composition is mixed with the mineral fibers before, during or after the disentangling process, thereby forming a mixture of mineral fibers and binder.

A method of producing a mineral wool product comprising the disentanglement process step described in EP 10190521.

In one embodiment, the disentangling process comprises supplying a gathered web of mineral fibres from a duct having a lower relative airflow to a duct having a higher relative airflow. In this embodiment, it is believed that disentanglement occurs because the fibers entering the conduit with the higher relative air flow are first pulled apart from the subsequent fibers in the web. This type of disentanglement enables a particularly efficient production of opened fibre flocks without producing dense lumps which may lead to an uneven distribution of material in the product.

According to a particularly preferred embodiment, the disentangling treatment comprises: the gathered web is supplied to at least one roller which rotates about its longitudinal axis and has spikes projecting from its circumferential surface. In this embodiment, the rotating roller will also generally contribute at least in part to the generation of said higher relative air flow. Typically, the rotation of the roller is the only source of the relatively high relative airflow.

In a preferred embodiment, the mineral fibers and optionally the binder are fed to the rolls from above. It is also preferred that the disentangled mineral fibers and optionally binder are ejected from the roll in a transverse direction from a lower portion of the circumference of the roll. In the most preferred embodiment, the mineral fibers are carried by the rollers about 180 degrees before they are thrown out.

The binder may be mixed with the mineral fibres before, during or after the disentanglement process. In some embodiments, it is preferred that the binder is mixed with the fibers prior to the disentangling process. In particular, the fibers may be in the form of an uncured, binder-containing, gathered web.

It is also possible to premix the binder with the aggregate web of mineral fibres before the disentanglement process. Further mixing may be performed during and after the disentanglement process. Alternatively, the binder may be supplied separately to the main air flow and mixed in the main air flow.

The mixture of mineral fibres and binder is collected from the main gas stream by any suitable means. In one embodiment, the primary air flow is introduced into the top of a cyclone chamber (cyclone chamber) whose lower end is open and from which the mixture is collected.

The mixture of mineral fibres and binder is preferably fed into the forming chamber from a disentanglement process.

After the disentanglement process, the mixture of mineral fibres and binder is collected and pressed and cured. Preferably, the mixture is collected on a foraminous conveyor belt having a suction mechanism disposed thereunder.

In a preferred method according to the invention, the collected mixture of binder and mineral fibres is pressed and cured.

In a preferred method according to the invention, the collected mixture of binder and mineral fibres is trimmed before pressing and curing.

The method may be performed in a batch mode, but according to one embodiment, the method is performed on a mineral wool production line, wherein a primary or secondary mineral wool web is supplied to a defibration treatment process, which provides a particularly cost-effective and versatile method for providing a composite material having good mechanical and thermal insulation properties over a wide density range.

At the same time, the likelihood of spotting of the uncured adhesive is significantly reduced due to curing at ambient temperature.

The particulate heat absorbing material may be added to the web at any suitable stage in production.

Curing

The web is cured by chemical and/or physical reaction of the binder components.

In one embodiment, the curing occurs in a curing apparatus.

In one embodiment, curing is carried out at a temperature of 5 ℃ to 95 ℃, such as 5 ℃ to 80 ℃, such as 5 ℃ to 60 ℃, such as 8 ℃ to 50 ℃, such as 10 ℃ to 40 ℃.

In one embodiment, curing takes place in a conventional curing oven for operating mineral wool production at a temperature of 5 ℃ to 95 ℃, such as 5 ℃ to 80 ℃, such as 10 ℃ to 60 ℃, such as 20 ℃ to 40 ℃.

The curing process may begin immediately after the binder is applied to the fibers. Curing is defined as a process whereby the binder composition undergoes a physical and/or chemical reaction, typically until the binder composition reaches a solid state, wherein, in the case of a chemical reaction, the molecular weight of the compounds in the binder composition is typically increased and thereby the viscosity of the binder composition is increased.

In one embodiment, the curing process includes crosslinking and/or the addition of water as water of crystallization (inclusion).

In one embodiment, the cured binder contains crystal water in an amount that may decrease and increase depending on the prevailing temperature, pressure and humidity conditions.

In one embodiment, the curing process comprises a drying process.

In a preferred embodiment, the curing of the binder in contact with the mineral fibers takes place in a hot press.

The curing of the binder in contact with the mineral fibres in the hot press has the particular advantage that a high density product can be produced.

In one embodiment, the curing process comprises drying by pressure. The pressure may be applied by blowing air or gas over/through the mixture of mineral fibers and binder. The blowing process may be accompanied by heating or cooling, or it may be at ambient temperature.

In one embodiment, the curing process is performed in a humid environment.

The humid environment may have a relative humidity RH of 60% to 99%, such as 70% to 95%, such as 80% to 92%. Curing in a humid environment may be followed by curing or drying to obtain a universal humidity state.

In one embodiment, the curing is performed in an oxygen deficient environment.

Without wishing to be bound by any particular theory, applicants believe that curing in an oxygen-deficient environment is particularly beneficial when the binder composition comprises an enzyme, as it increases the stability of the enzyme component, particularly transglutaminase, in some embodiments, thereby increasing the crosslinking efficiency. In one embodiment, the curing process is thus carried out in an inert atmosphere, in particular in an atmosphere of an inert gas (e.g. nitrogen).

In some embodiments, particularly embodiments in which the binder composition includes a phenolic, particularly a tannin, an oxidizing agent may be added. Oxidizing agents are useful as additives to increase the rate of oxidation of phenols, particularly tannins. One example is tyrosinase, which oxidizes phenol to hydroxyphenol/quinone, thus accelerating the binder formation reaction.

In another embodiment, the oxidizing agent is oxygen supplied to the binder.

In one embodiment, the curing is performed in an oxygen-rich environment.

The mineral wool product may be in any conventional configuration, such as mat or board, and may be cut and/or shaped before, during or after the binder is cured.