SIZING COMPOSITION FOR MINERAL WOOL, COMPRISING LIGNOSULFONATE AND A CARBONYL COMPOUND, AND RESULTING INSULATING PRODUCTS

Abstract

A sizing composition for insulating products based on mineral wool, in particular glass or rock wool, which includes at least one ammonium lignosulfonate or alkali metal or alkaline earth metal salt of lignosulfonic acid, and at least one carbonyl compound of formula: R—[C(O)R.sub.1].sub.x (I) in which: R represents a saturated or unsaturated and linear, branched or cyclic hydrocarbon radical, a radical including one or more aromatic nuclei which consist of 5 or 6 carbon atoms, a radical including one or more aromatic heterocycles containing 4 or 5 carbon atoms and an oxygen, nitrogen or sulfur atom, it being possible for the R radical to contain other functional groups, in particular hydroxyl or alkoxy groups, especially methoxy groups, R.sub.1 represents a hydrogen atom or a C.sub.1-C.sub.10 alkyl radical, and x varies from 1 to 10.

Claims

1. A sizing composition for insulating products based on mineral wool, comprising: at least one ammonium lignosulfonate or one alkali metal or alkaline earth metal salt of lignosulfonic acid, and at least one carbonyl compound of formula:
R—[C(O)R.sub.1].sub.x   (I) in which: R represents a saturated or unsaturated and linear, branched or cyclic hydrocarbon radical, a radical including one or more aromatic nuclei which consist of 5 or 6 carbon atoms, a radical including one or more aromatic heterocycles containing 4 or 5 carbon atoms and an oxygen, nitrogen or sulfur atom, it being possible for the R radical to contain other functional groups, R.sub.1 represents a hydrogen atom or a C.sub.1-C.sub.10 alkyl radical, and x varies from 1 to 10.

2. The composition as claimed in claim 1, wherein the composition is devoid of hydrogenated sugar and of melamine.

3. The composition as claimed in claim 1, wherein R.sub.1 represents a hydrogen atom and x is at most equal to 6.

4. The composition as claimed in claim 1, wherein the carbonyl functional group is provided in the form of an acetal or of a hemiacetal of following formula (II): ##STR00004## in which: R.sub.2 represents a C.sub.1-C.sub.10 alkyl radical, and R.sub.3 represents a hydrogen atom or a C.sub.1-C.sub.10 alkyl radical.

5. The composition as claimed in claim 3, wherein the carbonyl compound is chosen from the group consisting of acetaldehyde, propionaldehyde, dimethoxyethanal, butyraldehyde, glyoxal, malonaldehyde, succinaldehyde, glutaraldehyde, 2-hydroxyglutaraldehyde, 3-methylglutaraldehyde, adipaldehyde, suberaldehyde, sebacaldehyde, malealdehyde, fumaraldehyde, poly(acroleins), dialdehyde starch, furfural (2-furancarboxyaldehyde), 5-methylfurfural (2-methyl-5-furancarboxyaldehyde), hydroxymethylfurfural (2-hydroxymethyl-5-furancarboxyaldehyde), 2,5-furancarboxydialdehyde, vanillin and vanillin polymers, cinnamaldehyde and cinnamaldehyde polymers, phthalaldehyde, isophthalaldehyde, terephthalaldehyde and the oligomers of following formulae (III) and (IV): ##STR00005## in which: A represents a divalent —CH.sub.2—, —CH(OH)— or —CH.sub.2—O—CH.sub.2— radical, n varies from 1 to 8, ##STR00006## in which n′ varies from 1 to 9.

6. The composition as claimed in claim 1, wherein the ammonium lignosulfonate or the alkali metal or alkaline earth metal salt of lignosulfonic acid represents from 10 to 95% of the weight of the mixture consisting of ammonium lignosulfonate or the alkali metal or alkaline earth metal salt of lignosulfonic acid and the carbonyl compound of formula (I).

7. The composition as claimed in claim 1, wherein the composition contains an ammonium lignosulfonate and at least one compound chosen from phosphorus-containing compounds and ammonium sulfate.

8. The composition as claimed in claim 7, wherein the phosphorus-containing compound and the ammonium sulfate are present in an amount at most equal to 20 parts by weight per 100 parts by weight of ammonium lignosulfonate and of carbonyl compound of formula (I).

9. The composition as claimed in claim 1, further comprising the additives below in the following proportions, calculated on the basis of 100 parts by weight of ammonium lignosulfonate or of alkali metal or alkaline earth metal salt of lignosulfonic acid and of carbonyl compound of formula (I): 0 to 5 parts of silane, 0 to 20 parts of oil, 0 to 30 parts of glycerol, 0 to 5 parts of a silicone, 0 to 40 parts of an organic phosphate, 0 to 20 parts of an extender selected from carbohydrates, and animal or plant proteins.

10. The composition as claimed in claim 1, wherein the composition contains an ammonium lignosulfonate and urea.

11. The composition as claimed in claim 10, wherein the amount of urea represents up to 30 parts by weight per 100 parts by weight of ammonium lignosulfonate and of carbonyl compound of formula (I).

12. An acoustic and/or thermal insulating product based on mineral wool, sized using a sizing composition for insulating products based on mineral wool comprising, at least one ammonium lignosulfonate or one alkali metal or alkaline earth metal salt of lignosulfonic acid, and at least one carbonyl compound of formula:
R—[C(O)R.sub.1].sub.x   (I) in which: R represents a saturated or unsaturated and linear, branched or cyclic hydrocarbon radical, a radical including one or more aromatic nuclei which consist of 5 or 6 carbon atoms, a radical including one or more aromatic heterocycles containing 4 or 5 carbon atoms and an oxygen, nitrogen or sulfur atom, it being possible for the R radical to contain other functional groups, R.sub.1 represents a hydrogen atom or a C.sub.1-C.sub.10 alkyl radical, and x varies from 1 to 10.

13. The acoustic and/or thermal insulating product based on mineral wool as claimed in claim 12, wherein the mineral wool is glass or rock wool.

14. The acoustic and/or thermal insulating product based on mineral wool as claimed in claim 12, wherein the composition is devoid of hydrogenated sugar and of melamine,

15. The acoustic and/or thermal insulating product based on mineral wool as claimed in claim 12, wherein the carbonyl compound is chosen from the group consisting of acetaldehyde, propionaldehyde, dimethoxyethanal, butyraldehyde, glyoxal, malonaldehyde, succinaldehyde, glutaraldehyde, 2-hydroxyglutaraldehyde, 3-methylglutaraldehyde, adipaldehyde, suberaldehyde, sebacaldehyde, malealdehyde, fumaraldehyde, poly(acroleins), dialdehyde starch, furfural (2-furancarboxyaldehyde), 5-methylfurfural (2-methyl-5-furancarboxyaldehyde), hydroxymethylfurfural (2-hydroxymethyl-5-furancarboxyaldehyde), furancarboxydialdehyde, vanillin and vanillin polymers, cinnamaldehyde and cinnamaldehyde polymers, phthalaldehyde, isophthalaldehyde, terephthalaldehyde and the oligomers of following formulae (III) and (IV): ##STR00007## in which: A represents a divalent —CH.sub.2—, —CH(OH)— or —CH.sub.2—O—CH.sub.2— radical, n varies from 1 to 8, ##STR00008## in which n′ varies from 1 to 9.

16. The acoustic and/or thermal insulating product based on mineral wool as claimed in claim 12, wherein the ammonium lignosulfonate or the alkali metal or alkaline earth metal salt of lignosulfonic acid represents from 10 to 95% of the weight of the mixture consisting of ammonium lignosulfonate or the alkali metal or alkaline earth metal salt of lignosulfonic acid and the carbonyl compound of formula (1).

17. The acoustic and/or thermal insulating product based on mineral wool as claimed in claim 12, wherein the composition is formaldehyde-free.

18. The composition as claimed in claim 1, wherein the composition is formaldehyde-free.

Description

EXAMPLES 1 TO 9

[0067] Sizing compositions comprising the constituents appearing in table 1 (in parts by weight) are prepared. The reference sizing composition (denoted Ref.) is representative of the state of the art described in WO 2012/172262.

[0068] The sizing compositions are prepared by adding the lignosulfonate to a container containing water with stirring until completely dissolved and by then successively introducing the other compounds with vigourous stirring, until a stable emulsion is obtained.

[0069] The solids content of the sizing compositions is equal to 30%.

[0070] The results are given in table 1.

[0071] Examples 1 to 9 according to the invention exhibit a lower contact angle than the Reference, which is reflected by a better wetting of the glass fibers.

[0072] At an identical amount of ammonium lignosulfonate, example 2 exhibits a higher crosslinking start rate than the Reference.

[0073] Example 1, the amount of ammonium lignosulfonate of which is higher than the Reference, exhibits a lower crosslinking start temperature than the Reference and an identical crosslinking start rate.

[0074] Examples 5, 6, 8 and 9 exhibit a lower crosslinking start temperature than the Reference.

[0075] In addition, calcium lignosulfonate (examples 8 and 9) makes it possible to obtain a higher crosslinking start rate than the Reference.

TABLE-US-00001 TABLE 1 Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex. 6 Ex. 7 Ex. 8 Ex. 9 Ref. Sizing composition Ammonium lignosulfonate.sup.(1) 80 60 — — — — — — — 60 Sodium lignosulfonate.sup.(2) — — 95 — — 80 — — — — Magnesium lignosulfonate.sup.(3) — — — 95 — — 80 — — — Calcium lignosulfonate.sup.(4) −20 −40 — — 95 — — 80 60 — Hydroxymethylfurfural — — 5 5 5 20 20 20 40 — Glucose — — — — — — — — — 40 Diammonium phosphate — — — — — — — 5 Properties pH 4.9 4.7 7.8 3.4 4.8 7.1 3.2 4.7 4.8 6.4 Viscosity (mPa .Math. s) at 25° C. 3.8 3.6 5.4 3.1 3.9 2.9 2.2 2.9 4.1 3.8 at 50° C. 2.4 1.8 2.9 1.7 2.1 1.9 1.4 2.0 2.0 2.3 Contact angle (°) 16 9 19 19 18 18 13 16 11 24 Crosslinking start temperature T.sub.c (° C.) 106 108 158 n.d. 128 115 n.d. 108 113 140 Crosslinking start rate R (MPa/° C.) 8 18 7 n.d. 5.3 8.2 n.d. 11 19 8 Loss of weight (%) at 200° C. 3 4 3 4 3 3 4 3 4 2 at 300° C. 19 15 16 16 20 15 13 17 15 16 at 400° C. 34 29 30 36 34 30 33 30 25 26 .sup.(1)T11N5, sold by Tembec .sup.(2)Arbo N18, sold by Tembec .sup.(3)Arbo MGLS, sold by Tembec .sup.(4)C12, sold by Tembec