METHOD OF REDUCING THE FORMALDEHYDE EMISSION OF A MINERAL FIBER PRODUCT, AND MINERAL FIBER PRODUCT WITH REDUCED FORMALDEHYDE EMISSION

Abstract

A method of reducing the formaldehyde emission of a mineral fiber product bonded with a urea-modified phenol-formaldehyde resol resin-type binder comprises adding dextrose to the binder composition during and/or after preparation of the binder composition but before curing of the binder composition applied to the mineral fibers.

Claims

1. A method of reducing the formaldehyde emission of a mineral fiber product bonded with a urea-modified phenol-formaldehyde resol resin-type binder composition, wherein the method comprises adding dextrose to the binder composition during and/or after preparation of the binder composition but before curing of the binder composition applied to the mineral fibers.

2. The method of claim 1, wherein dextrose is used as pure dextrose or in the form of a dextrose preparation having a DE equivalent of about 70 to 100.

3. The method of claim 2, wherein the dextrose preparation has a DE equivalent of 90 to 100.

4. The method of claim 1, wherein phenol is reacted with formaldehyde in aqueous solution in a molar ratio of from 1:2.5 to 1:6; preferably from 1:3 to 1:5, in the presence of a base catalyst.

5. The method of claim 4, wherein phenol is reacted with formaldehyde in aqueous solution in a molar ratio of from 1:3 to 1:5.

6. The method of claim 1, wherein urea is used in an amount of from 20 to 60 wt %, based on total dry solids of the phenol-formaldehyde resol resin and urea.

7. The method of claim 6, wherein urea is used in an amount of from 30 to 50 wt %.

8. The method of claim 1, wherein dextrose is used in an amount of from 15 to 70 wt %, based on total dry solids of urea-modified phenol-formaldehyde resol resin and dextrose.

9. The method of claim 8, wherein dextrose is used in an amount of from 20 to 50 wt %.

10. The method of claim 6, wherein dextrose is used in an amount of from 15 to 70 wt %, based on total dry solids of urea-modified phenol-formaldehyde resol resin and dextrose.

11. The method of claim 7, wherein dextrose is used in an amount of from 20 to 50 wt %, based on total dry solids of urea-modified phenol-formaldehyde resol resin and dextrose.

12. The method of claim 1, wherein the method affords a mineral fiber product which satisfies formaldehyde emission requirements of Finnish Standard RTS-M1.

13. The method of claim 1, wherein the method affords a mineral fiber product which satisfies formaldehyde emission requirements of US Standard CDHS.

14. The method of claim 1, wherein the method affords a mineral fiber product which satisfies formaldehyde emission requirements of Japanese Standard JIS A 19012003 (E).

15. The method of claim 1, wherein the method affords a ceiling tile having a density of from 50 to 220 kg/m.sup.3.

16. The method of claim 1, wherein the method affords a roof board having a density of from 100 to 250 kg/m.sup.3.

17. The method of claim 1, wherein the method affords a building insulation product board or roll having a density of from 5 to 70 kg/m.sup.3.

18. A method of scavenging formaldehyde in a urea-modified phenol-formaldehyde resol resin-type binder composition for a mineral fiber product, wherein the method comprises adding to the binder composition dextrose as a formaldehyde scavenger.

19. The method of claim 18, wherein the mineral fiber product is selected from: a roof board having a density of from 100 to 250 kg/m.sup.3 and having been manufactured using a non-cured binder composition and dextrose in an amount of from 20 to 50 wt %; a ceiling tile having a density of from 50 to 220 kg/m.sup.3 and having been manufactured using a non-cured binder composition and dextrose in an amount of from 20 to 70 wt %; a building insulation product board having a density of from 5 to 70 kg/m.sup.3 and having been manufactured using a non-cured binder composition and dextrose in an amount of from 10 to 50 wt %; the weight percentages being based on total dry solids of phenol-formaldehyde resol resin and dextrose.

20. An apparatus for making a mineral fiber product having reduced formaldehyde emission and being bonded with a cured dextrose-containing urea-modified phenol-formaldehyde resol resin-type binder composition, wherein the apparatus comprises a device for fiberizing a mineral melt into mineral fibers, separate tanks for the binder composition and dextrose; a device for mixing the binder composition and the dextrose, a device for applying a mixture of binder composition and dextrose to the mineral fibers, a collection chamber for the mineral fibers having the mixed binder composition and dextrose applied thereto, a curing oven for curing the mixed binder composition and dextrose applied to the mineral fibers to form a cured web, and a device for confectioning the cured web to a mineral fiber product.

Description

DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS

[0031] Urea-Modified Phenol-Formaldehyde Resol Resin

[0032] In accordance with the present invention, the nature of the urea-modified phenol-formaldehyde resol resin is not critical, and any urea-modified phenol-formaldehyde resol resin known in the art may be used.

[0033] However, in accordance with the invention, preferably no substantive urea-formaldehyde (UF) resin formation is taking place, i.e. a dedicated UF formation giving the resin the character of a UF resin is preferably not aimed at.

[0034] Specific examples of suitable urea-modified phenol-formaldehyde resol resins are, for instance, those disclosed in EP-A-148050, EP-A-810981, CA-A-1001788 and US-A-5371140; the emulsifiable phenolic resins disclosed in EP-A-1084167; the overcondensed phenolic resins disclosed in WO 99/03906 and WO 2009/136106, the disclosures of which are hereby incorporated by reference.

[0035] The proportion of phenol to aldehyde is selected to yield a resol-type resin (stoichiometric excess of aldehyde), when phenol and formaldehyde are used, the mole ratio of phenol to formaldehyde preferably being from about 1:2.5 to 1:6, and more preferably from about 1:3 to 1:5.

[0036] The catalyst used in the process of preparing the resol resin can include at least one basic alkali metal or alkaline earth metal compound or amine catalyst, such as triethyl amine (TEA). Examples of alkali metal bases which can be used include the hydroxides of sodium, potassium and lithium. Examples of alkaline earth metal bases which can be used include the oxides and hydroxides of calcium, barium and strontium, such as calcium oxide and calcium hydroxide.

[0037] The exothermic condensation reaction of the phenol and the aldehyde is initiated after mixing the phenol and the aldehyde by addition of the catalyst. In a preferred embodiment, an aqueous mixture of phenol and formaldehyde is maintained at a first temperature of, for instance, 40 to 50° C., as the basic catalyst is added. The temperature is then permitted to rise to a second reaction temperature of, for instance, 60 to 90° C. Preferably, the reaction is carried out for a sufficient reaction time and at a suitable temperature to provide a resol resin having an acid tolerance of 8, preferably within the range of 0.5 to 7, more preferably 3 to 5. The degree of conversion of phenol is preferably 95%, more preferably 97%.

[0038] Acid tolerance is a measure of the reaction degree and is determined as follows:

[0039] As acid is used a diluted solution of sulphuric acid (2.5 ml of concentrated sulphuric acid is added to 1 litre of ion-exchanged water). 5.0 ml of binder is transferred into an Erlenmeyer flask. Diluted acid is then added from a burette while keeping the binder in motion. The titration is continued until a slight cloud appears in the binder, which does not disappear when the binder is shaken. The acid tolerance is calculated by dividing the amount of acid in ml used for the titration with the amount of ml of the sample.

[0040] The reaction mixture may be inactivated by addition of a latent acid such as ammonium sulphate or an acid such as sulfuric acid.

[0041] For modification of the phenol-formaldehyde resol resin with urea, urea is preferably added and/or reacted in an amount of from about 20 to 60 wt %, preferably 20 to 50 wt %, based on total dry solids of phenol-formaldehyde resol resin and urea. The urea may be added to the resol resin during its preparation or in a post-reaction step.

[0042] Dextrose

[0043] In accordance with the present invention, dextrose is added to the binder composition during and/or after preparation of the binder composition but before curing of the binder composition applied to the mineral fibers.

[0044] For use as a formaldehyde scavenger, dextrose may be used as pure dextrose (glucose) or in the form of a dextrose preparation having a DE equivalent of about 70 to 100, preferably about 90 to 100.

[0045] Dextrose is normally produced by subjecting an aqueous slurry of starch to hydrolysis by means of heat, acid or enzymes. Depending on the reaction conditions employed in the hydrolysis of starch, a variety of mixtures of glucose and intermediates is obtained which may be characterized by their DE number. DE is an abbreviation for Dextrose Equivalent and is defined as the content of reducing sugars, expressed as the number of grams of anhydrous D-glucose per 100 g of the dry matter in the sample, when determined by the method specified in International Standard ISO 5377-1981 (E). This method measures reducing end groups and attaches a DE of 100 to pure glucose (=dextrose) and a DE of 0 to pure starch.

[0046] In accordance with the present invention, pure dextrose or high DE glucose syrup are preferably used as formaldehyde scavengers.

[0047] Binder Composition

[0048] The non-cured binder composition according to the present invention generally contains dextrose in an amount of from 15 to 70 wt %, preferably 20 to 50 wt %, based on total dry solids of phenol-formaldehyde resol resin and dextrose. Preferred lower concentrations of dextrose are 15 wt %, 20 wt %, 25 wt %, 30 wt %, 35 wt %, 40 wt % and 45 wt %. Preferred higher concentrations of dextrose are 50 wt %, 55 wt %, 60 wt %, 65 wt % and 70 wt %. Depending on the properties desired and on the type and amount of formaldehyde generators present, the skilled person will employ dextrose in appropriate concentration ranges between these values.

[0049] In addition to the urea-modified phenol-formaldehyde resole resin and dextrose, the aqueous binder compositions according to the present invention may comprise one or more conventional binder additives. These include, for instance, curing accelerators such as the free acid and salt forms of strong acids such as boric acid, sulphuric acid, nitric acid and p-toluenesulphonic acid which may be used either alone or in combination with guanidine carbonate. Other suitable binder additives are, for example, silane coupling agents such as γ-aminopropyltriethoxysilane; thermal stabilizers; UV stabilizers; emulsifiers; surface active agents, particularly nonionic surfactants; biocides; plasticizers; anti-migration aids; coalescents; fillers and extenders such as starch, clay, silicates and magnesium hydroxide; pigments such as titanium dioxide; hydrophobizing agents such as fluorinated compounds, mineral oils and silicone oils; flame retardants; corrosion inhibitors such as thiourea; antifoaming agents; antioxidants; and others.

[0050] These binder additives and adjuvants may be used in conventional amounts generally not exceeding 20 wt. % of the binder solids. The amount of curing accelerator in the binder composition is generally between 0.05 and 5 wt. %, based on solids.

[0051] The final aqueous binder composition generally has a solids content of from 1 to 20 wt. % and a pH of 6 or higher.

[0052] The binder composition according to the present invention preferably does not contain any one of the following components:

[0053] hydroxylamine; amino alcohols; alkanol amines; polycarboxylic acids and ammonium salts of polycarboxylic acids; sugar alcohols.

[0054] Mineral Fiber Product

[0055] The mineral fibers employed may be any of man-made vitreous fibers (MMVF), glass fibers, ceramic fibers, basalt fibers, slag fibers, rock fibers, stone fibers and others. These fibers may be present as a wool product, e.g. like a rock wool product.

[0056] Suitable fiber formation methods and subsequent production steps for manufacturing the mineral fiber product are those conventional in the art. Generally, the binder is sprayed immediately after fibrillation of the mineral melt on to the airborne mineral fibers. The aqueous binder composition is normally applied in an amount of 0.1 to 10%, preferably 0.2 to 8% by weight, of the bonded mineral fiber product on a dry basis.

[0057] The spray-coated mineral fiber web is generally cured in a curing oven by means of a hot air stream. The hot air stream may be introduced into the mineral fiber web from below, or above or from alternating directions in distinctive zones in the length direction of the curing oven.

[0058] Typically, the curing oven is operated at a temperature of from about 150 to 350° C. Preferably, the curing temperature ranges from about 200 to about 300° C. Generally, the curing oven residence time is from 30 seconds to 20 minutes, depending on, for instance, the product density.

[0059] If desired, the mineral wool web may be subjected to a shaping process before curing. The bonded mineral fiber products emerging from the curing oven may be cut to a desired format e.g., in the form of a batt. Thus, the mineral fiber products produced may, for instance, have the form of mats, batts, slabs, sheets, plates, strips, rolls, pipe sections, granulates, and other shaped articles.

[0060] A specific type of bonded mineral fiber product is a horticultural growth substrate product. Such horticultural growth substrate products may be in any of the known forms for growth substrate products, such as those usually known as plugs, blocks, slabs and mats. In particular the invention is beneficial in the case where the product is in a form generally known for use as a substrate for the propagation stage.

[0061] The horticultural growth substrate product has a greater uniformity of environment across the set of seeds being grown, leading to greater uniformity of the end-product plants; this leads to generally improved plant quality.

[0062] The growth substrate product may further comprise a wetting agent. This can be a conventional non-ionic surfactant but preferably the wetting agent is an ionic surfactant, more preferably an anionic surfactant. Particularly preferred wetting agents are anionic surfactants such as linear alkyl benzene sulphonates wherein the alkyl chain has from 5 to 20 carbon atoms. Preferably the amount (by weight) of ionic surfactant based on the weight of binder (dry matter) is in the range 0.01 to 5%, preferably 0.1 to 4%.

[0063] This type of surfactant provides particularly beneficial water distribution properties for growth substrates of relatively large height and also provides excellent re-saturation properties and does not lead to foaming problems in the irrigation water.

[0064] In accordance with the present invention, it is also possible to produce composite materials by combining the bonded mineral fiber product with suitable composite layers or laminate layers such as, e.g., metal, glass surfacing mats and other woven or non-woven materials.

[0065] The mineral fiber products according to the present invention generally have a density within the range of from 5 to 250 kg/m.sup.3, preferably 20 to 200 kg/m.sup.3.

[0066] A particular group of mineral fiber products according to the present invention are ceiling tiles having a density of from 50 to 220 kg/m.sup.3 and manufactured using a non-cured binder composition comprising dextrose in an amount of 20 to 70 wt %, preferably 40 to 70 wt %, based on total dry solids of phenol-formaldehyde resol resin and dextrose.

[0067] Another group of mineral fiber products according to the present invention are roof boards having a density of from 100 to 250 kg/m.sup.3 and manufactured using a non-cured binder composition comprising dextrose in an amount of 20 to 50 wt %, preferably 20 to 40 wt %, based on total dry solids of phenol-formaldehyde resol resin and dextrose.

[0068] There are essentially two types of roof boards: mono density and dual density roof boards such as disclosed, e.g., in EP-A-889981 and EP-A-1456444, the disclosure of which is incorporated herein by reference.

[0069] In preferred dual density roof boards, the mineral fiber batts include an upper layer having a density of around 100 to 250 kg/m.sup.3 and a lower layer with a density which is usually not more than 80% but usually more than 30% of the density of the upper layer, often around 40 to 70% of the density of the upper layer. Usually, the upper and lower layers in the final product have a total thickness of 30 to 300 mm. The lower layer is usually 25 to 275 mm thick and is usually at least 75 mm thick. Generally, it is at least 50%, and often 75 to 95%, of the combined thickness of the upper and lower layers.

[0070] The mineral fiber products according to the present invention are light-coloured and often brownish to a varying degree, depending on the amount of dextrose.

[0071] The mineral fiber products according to the present invention satisfy the formaldehyde emission requirements of international building industry standards.

[0072] For instance, tests with mineral fiber products according to the invention showed that the formaldehyde emission requirements of Finnish Standard RTS-M1 (limit 50 μg/m.sup.2 h) for a roof board can be met by using >20 wt % of dextrose. The Finnish Standard RTS-M1 standard determines the emission of the sample after 4 weeks in a testing chamber according to ISO-16000-9, first edition, corrected version 2006-06-15.

[0073] Similarly, the formaldehyde emission requirements of U.S. Standard CDHS (version 15 Jul. 2004; limit 16.5 μg/m.sup.3) for a roof board can be met by using >30 wt % of dextrose, and the formaldehyde emission requirements of Japanese Standard JIS A 1901-2003 (E) (limit 12 μg/m.sup.3, the F*** limit) can be met by using about 47 wt % of dextrose.

[0074] Another standard that is met by the product according to the present invention is the Greenguard Children and Schools standard limit, which corresponds to a specific emission rate of approximately 35 μg/m.sup.2 h. Preferably, this standard is met for a building insulation product board or roll having a density of from 5 to 70 kg/m.sup.3 and manufactured using a non-cured binder composition comprising dextrose in an amount of 10 to 50 wt %, preferably 20 to 40 wt %, based on total dry solids of phenol-formaldehyde resol resin and dextrose.

[0075] The following examples are intended to illustrate the invention without limiting its scope. Unless indicated otherwise, the solids content (dry matter) is herein determined at 200° C., 1 hour and expressed as wt. %.

Example 1

[0076] A phenol-formaldehyde resin is prepared by reacting formaldehyde and phenol in a molar ratio of 3.7 to 1 in the presence of a catalyst (6 wt % KOH, relative to the amount of phenol) at a reaction temperature of 84° C. The reaction is continued until the acid tolerance of the resin is 4 and most of the phenol is converted. Urea is then added in an amount corresponding to 52 parts by weight of phenol-formaldehyde resin and 48 parts by weight of urea.

[0077] Using the urea-modified phenol-formaldehyde resin obtained, a binder is made by addition of ammonium sulphate in equimolar amounts to the catalyst so as to inactivate the catalyst. The final PUF resin has a free formaldehyde content of <0.5%, relative to the solids.

[0078] The thus obtained PUF binder is mixed with a dextrose preparation, Sirodex® 431 from Syral (DE value 95), in the amounts indicated in Table 1 below.

[0079] Further, the binder is diluted with water to a solids content equal to 22%, and a commercial prehydrolysed aminosilane is added in an amount corresponding to 0.5% of the solids.

[0080] The binder composition obtained is used for production of monolayer roof boards (“A-Tagplade”). Further details are given in the following table.

TABLE-US-00001 TABLE 1 Binder content Product PUF Binder Dextrose of product * density % % (%) (kg/m.sup.3) A 100 0 3.62 141 B 80 20 3.94 139 C 43 57 4.92 135 The PUF binder content (%) and the dextrose content (%) are weight percentages based on total dry solids of phenol-formaldehyde resol resin and dextrose. * The binder content of product (%) is defined as loss-on ignition (LOI) (%) − impregnation oil (%)

Example 2

[0081] A commercial resin PF-0415M from Hexion is used for the test. The resin is a phenol-formaldehyde resin modified with urea and ammonia. Free formaldehyde is <0.3% based on the liquid resin. The amount of urea is 28% in relation to the solids content.

[0082] The resin is mixed with a dextrose preparation, Sirodex® 431 (DE value 95) from Syral, in the amounts indicated in Table 2 below. For comparison, a glucose syrup, i.e. C Sweet® 01403 (DE value 30) from Cargill, is used in the amount indicated in Table 2 (Sample H).

[0083] The composition is diluted to 15% with water to provide a binder composition and further added with 0.5% of a commercial silane of the type pre-hydrolysed amino silane.

[0084] The binder composition obtained is used for production of monolayer roof boards (DP-GF). Further details are given in the following table.

TABLE-US-00002 TABLE 2 Binder content Product PUF Binder Dextrose of product* density % % (%) (kg/m.sup.3) D 100 0 3.43 155 3.20 150 E 72 28 3.63 146 F 54 46 3.59 151 G 50 50 3.66 155 H 80 20 3.12 141 The PUF binder content (%) and the dextrose content (%) are weight percentages based on total dry solids of phenol-formaldehyde resol resin and dextrose. * Binder content of product (%) = LOI (%) − impregnation oil (%)

Example 3

[0085] The formaldehyde emission is measured for the products A-H of Examples 1 and 2 and stated in Table 3 below as formaldehyde emission in μg/m.sup.3. The emissions were measured in the climate chamber at the Danish Technological Institute (TI) according to standard EN 717-1.

[0086] The actually determined values are compared with the expected values (assuming a pure dilution effect of dextrose). The value of 80 for 100 parts of PUF is used as a reference and the expected values are calculated with reference to the value. For instance, the 50/50 PUF/dextrose expected value is (50 PUF/100 PUF)×80=40.

TABLE-US-00003 TABLE 3 Expected Measured A 100/0 PUF/Dextrose 80 83 B 80/20 PUF/Dextrose 64 36 C 43/57 PUF/Dextrose 40 13 D 100/0 PUF/Dextrose 80 83 (77) E 72/28 PUF/Dextrose 58 36 F 54/46 PUF/Dextrose 43  7 G 50/50 PUF/Dextrose 40 16 H 80/20 PUF/DE 30 syrup 64 65

[0087] As can be seen from Table 3, the use of dextrose results in a significant reduction of the formaldehyde emission of the bonded mineral fiber products which cannot be explained by a pure dilution effect.

[0088] Sample H is a comparative sample where the dextrose is substituted with a glucose syrup of low dextrose content having a DE-value of 30. Sample H using this sugar syrup does not show a significant reduction in formaldehyde emission compared to the high dextrose content syrups of Examples A-G. Instead, the measured value for the formaldehyde emission of Sample H is as expected when assuming a pure dilution effect.