MINERAL WOOL PRODUCT

Abstract

The present invention relates to a mineral wool product comprising mineral fibres bound by a cured formaldehyde-free binder, wherein the binder in its uncured state comprises carbohydrate in a content of 70 to 97 wt. % of the total binder component solids; the mineral wool product has an unaged delamination strength of 20 kPa or more; the mineral wool product has a ratio between the aged delamination strength and the unaged delamination strength of more than 40%.

Claims

1.-18. (canceled)

19. 1. A mineral wool product, wherein the product comprises mineral fibers bonded by a cured formaldehyde-free binder and the binder in its uncured state comprises from 70 to 97% by weight of carbohydrate, based on total binder component solids; the product exhibits an unaged delamination strength of at least 20 kPa; and a ratio of aged delamination strength and unaged delamination strength of the product is higher than 40%.

20. The mineral wool product of claim 19, wherein the ratio of aged delamination strength and unaged delamination strength of the product is higher than 50%.

21. The mineral wool product of claim 19, wherein the ratio of aged delamination strength and unaged delamination strength of the product is higher than 60%.

22. The mineral wool product of claim 19, wherein the product is a flat roof insulation product.

23. The mineral wool product of claim 19, wherein the product is a facade product.

24. The mineral wool product of claim 19, wherein the product exhibits an unaged delamination strength of at least 30 kPa.

25. The mineral wool product of claim 19, wherein the product has a density of from 60 to 200 kg/m.sup.3.

26. The mineral wool product of claim 19, wherein the product has a density of from 80 to 150 kg/m.sup.3.

27. The mineral wool product of claim 19, wherein the product is a non-lamellar product.

28. The mineral wool product of claim 19, wherein the binder in its uncured state has a pH of higher than 6.

29. The mineral wool product of claim 19, wherein the binder in its uncured state comprises from 70% to 84% by weight of carbohydrate, based on total binder component solids.

30. The mineral wool product of claim 19, wherein the carbohydrate comprises one or more of a hexose, a pentose, and a glucose syrup.

31. The mineral wool product of claim 30, wherein the carbohydrate comprises one or both of dextrose and a glucose syrup having a Dextrose Equivalent (DE) value of from 85 to 99.

32. The mineral wool product of claim 30, wherein the carbohydrate is a glucose syrup having a Dextrose Equivalent (DE) value of from 15 to 50.

33. The mineral wool product of claim 19, wherein the binder comprises, in its uncured state: a component (i) in the form of one or more compounds selected from compounds of the following formula, and salts thereof: ##STR00003## in which R1 represents H, alkyl, monohydroxyalkyl, dihydroxyalkyl, polyhydroxyalkyl, alkenyl, alkoxy, amino; compounds of the following formula, and salts thereof: ##STR00004## in which R2 represents H, alkyl, monohydroxyalkyl, dihydroxyalkyl, polyhydroxyalkyl, alkenyl, alkoxy, amino; and a component (ii) selected from one or more of ammonia, amines, and salts thereof.

34. The mineral wool product of claim 19, wherein the binder comprises, in its uncured state, a component (ii) selected from one or more of ammonia, amines, polyamines, monoethanolamine, diethanolamine, triethanolamine.

35. The mineral wool product of claim 19, wherein the binder further comprises, in its uncured state, a component (iii) selected from one or more of sulfamic acid, derivatives of sulfamic acid, and salts of sulfamic acid.

36. The mineral wool product of claim 19, wherein the binder further comprises, in its uncured state, urea.

37. The mineral wool product of claim 19, wherein the binder further comprises, in its uncured state, hypophosphorous acid or a salt thereof.

38. A method of producing the mineral wool product of claim 19, wherein the method comprises contacting mineral fibers with a formaldehyde-free binder which in its uncured state comprises from 70 to 97% by weight of carbohydrate, based on total binder component solids, and thereafter curing the binder.

Description

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] In a preferred embodiment, the ratio between the aged delamination strength and the unaged delamination strength of the mineral wool product according to the present invention is more than 50%, preferably more than 60%.

[0035] It is highly surprising that it is possible to produce a mineral wool product bound by a cured formaldehyde free binder having a carbohydrate content of 70% or more and at the same time having such a high ratio of aged to unaged delamination strength.

Mineral Wool Product (Mineral Fibre Product)

[0036] The mineral fibres employed may be any of man-made vitreous fibres (MMVF), glass fibres, ceramic fibres, basalt fibres, slag fibres, rock fibres, stone fibres and others. These fibres may be present as a wool product, e.g. like a rock wool product or a glass wool product.

[0037] Suitable fibre formation methods and subsequent production steps for manufacturing the mineral fibre product are those conventional in the art. Generally, the binder is sprayed immediately after fibrillation of the mineral melt on to the air-borne mineral fibres. The aqueous binder composition is normally applied in an amount corresponding to an LOI of 0.1 to 18.0%, preferably 0.3 to 12.0%, more preferably 0.5 to 8.0% by weight.

[0038] The spray-coated mineral fibre 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 fibre web from below, or above or from alternating directions in distinctive zones in the length direction of the curing oven.

[0039] Typically, the curing oven is operated at a temperature of from about 150 C. to about 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.

[0040] If desired, the mineral wool web may be subjected to a shaping process before curing. The bonded mineral fibre product emerging from the curing oven may be cut to a desired format e.g., in the form of a batt. Thus, the mineral fibre products produced, for instance, have the form of woven and nonwoven fabrics, mats, batts, slabs, sheets, plates, strips, rolls, granulates and other shaped articles which find use, for example, as thermal or acoustical insulation materials, vibration damping, construction materials, facade insulation, reinforcing materials for roofing or flooring applications, as filter stock, as horticultural growing media and in other applications.

[0041] In accordance with the present invention, it is also possible to produce composite materials by combining the bonded mineral fibre product with suitable composite layers or laminate layers such as, e.g., metal, glass surfacing mats and other woven or non-woven materials.

[0042] The mineral fibre products according to the present invention generally have a density within the range of from 6 to 250 kg/m.sup.3, preferably 20 to 200 kg/m.sup.3. The mineral fibre products generally have a loss on ignition (LOI) within the range of 0.1 to 18.0%, preferably 0.3 to 12.0%, more preferably 0.5 to 8.0% by weight.

[0043] In a preferred embodiment, the mineral wool product according to the present invention is in form of a flat roof insulation product or a facade product.

[0044] Whereby it is possible to produce the mineral wool product according to the present invention in the whole range of densities commonly used for such products, it is preferred that the density of the mineral wool product is in the range of 60-200 kg/m.sup.3, such as 70-180 kg/m.sup.3, in particular 80-150 kg/m.sup.3.

[0045] It is further preferred, that the mineral wool product is a non-lamellae product. A lamellae product is defined as a mineral wool product consisting of lamellae of cured mineral wool. The lamellae have been formed by first producing a conventional mineral wool product and secondly cutting this product in lamellae.

[0046] Thirdly, the lamellae are glued to each other to form a lamellae product. A lamellae product has a general fibre direction orthogonal to the major surface of the product. It is an alternative product to first changing the general fibre direction of the web while still uncured and secondly curing the web with the changed general fibre direction.

[0047] In a preferred embodiment, the mineral wool product has an unaged delamination strength of 25 kPa or more, such as 30 kPa or more, such as 35 kPa or more.

[0048] While there is in principle no limitation concerning the pH which the binder is having in its uncured state, it is preferred that the binder in its uncured state has a pH of more than 6. In one embodiment the binder in its uncured state has a pH of 2 to 6.

Carbohydrate Component of the Organic Binder

[0049] In a particular preferred embodiment, the binder in its uncured state comprises carbohydrate in a content of 70 to 84 wt.-% of the total binder component solids.

[0050] Preferably, the carbohydrate is selected from the group consisting of hexose, such as dextrose, fructose, pentose such as xylose and/or sucrose, glucose syrup.

[0051] Preferably, the carbohydrate is selected from the group of dextrose and/or a glucose syrup with a Dextrose Equivalent (DE) value of 85 to 99.

[0052] In a further preferred embodiment, the carbohydrate is a glucose syrup with a Dextrose Equivalent (DE) value of 15 to 50.

[0053] In a further preferred embodiment, the carbohydrate is a carbohydrate with a Dextrose Equivalent (DE) value of 50 to 85.

[0054] In a preferred embodiment, the carbohydrate is selected from hexoses, in particular allose, altrose, glucose, mannose, gulose, idose, galactose, talose, psicose, fructose, sorbose and/or tagatose; and/or pentoses, in particular arabinose, lyxose, ribose, xylose, ribulose and/or xylulose; and/or tetroses, in particular erythrose, threose, and/or erythrulose.

[0055] Starch may be used as a raw material for various carbohydrates such as glucose syrups and dextrose. Depending on the reaction conditions employed in the hydrolysis of starch, a variety of mixtures of dextrose 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 dextrose and a DE of 0 to pure starch.

[0056] In a preferred embodiment, the carbohydrate is selected from sucrose, reducing sugars, in particular dextrose, polycarbohydrates, and mixtures thereof, preferably dextrins and maltodextrins, more preferably glucose syrups, and more preferably glucose syrups with a dextrose equivalent value of DE=15-99, such as DE=50-85, such as DE=15-50, such as DE=60-99 such as DE=85-99.

[0057] The term dextrose as used in this application is defined to encompass glucose and the hydrates thereof.

[0058] In a further preferred embodiment, the carbohydrate is selected from the group of dextrose and/or glucose syrup with a dextrose equivalent (DE) value of 85 to 99. In a further preferred embodiment, the carbohydrate is glucose syrup with a dextrose equivalent (DE) value of 15 to 50.

Other Components of the Binder

[0059] The binders according to the present invention are formaldehyde free. For the purpose of the present application, the term formaldehyde free is defined to characterise a mineral wool product where the emission is below 5 g/m.sup.2/h of formaldehyde from the mineral wool product, preferably below 3 g/m.sup.2/h. Preferably the test is carried out in accordance with ISO 16000 for testing aldehyde emissions.

[0060] Preferably, the binder composition does not contain added formaldehyde. In a preferred embodiment, the mineral wool product according to the present invention is such that the binder does not comprise, in its uncured state, a carboxylic acid, such as a dicarboxylic acid.

[0061] Preferably, the mineral wool products according to the present invention is such that the binder further comprises, in its uncured state: [0062] a component (i) in the form of one or more compounds selected from [0063] compounds of the formula, and any salts thereof:

##STR00001## [0064] in which R1 corresponds to H, alkyl, monohydroxyalkyl, dihydroxyalkyl, polyhydroxyalkyl, alkylene, alkoxy, amine; [0065] compounds of the formula, and any salts thereof:

##STR00002## [0066] in which R2 corresponds to H, alkyl, monohydroxyalkyl, dihydroxyalkyl, polyhydroxyalkyl, alkylene, alkoxy, amine; [0067] a component (ii) in the form of one or more compounds selected from the group of ammonia, amines or any salts thereof.

[0068] Preferably, the binders according to the present invention have a pH of 6-9.

[0069] Preferably, alkyl is C.sub.1-C.sub.10 alkyl.

[0070] Preferably, monohydroxyalkyl is monohydroxy C.sub.1-C.sub.10 alkyl.

[0071] Preferably, dihydroxyalkyl is dihydroxy C.sub.1-C.sub.10 alkyl.

[0072] Preferably, polyhydroxyalkyl is polyhydroxy C.sub.1-C.sub.10 alkyl.

[0073] Preferably, alkylene is alkylene C.sub.1-C.sub.10 alkyl.

[0074] Preferably, alkoxy is alkoxy C.sub.1-C.sub.10 alkyl.

[0075] Preferably, component (i) is in the form of one or more components selected from ascorbic acid or isomers or salts or derivatives, preferably oxidized derivatives, thereof.

[0076] In a preferred embodiment, component (i) is selected from L-ascorbic acid, D-iso-ascorbic acid, 5,6-isopropylidene ascorbic acid, dehydroascorbic acid and/or any salt of the compounds, preferably calcium, sodium, potassium, magnesium or iron salts.

[0077] In a further preferred embodiment, component (i) is selected from L-ascorbic acid, D-isoascorbic acid, 5,6-isopropylidene ascorbic acid and dehydroascorbic acid.

[0078] In a preferred embodiment, the mineral wool product according to the present invention is such that the binder comprises, in its uncured state: a component (ii) in form of one or more compounds selected from the group consisting of ammonia and/or amines, such as piperazine, polyamine, such as hexamethylenediamine, m-xylylenediamine, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, and/or monoethanolamine, diethanolamine, and/or triethanolamine.

[0079] In a preferred embodiment, the proportion of components (i), (ii) and carbohydrate is within the range of 1 to 50 weight-% component (i) based on the mass of component (i) and carbohydrate, 50 to 99 weight-% carbohydrate based on the mass of component (i) and carbohydrate, and 0.1 to 10.0 molar equivalents of component (ii) relative to component (i).

[0080] In a preferred embodiment, the mineral wool product according to the present invention is such that the binder further comprises, in its uncured state: a component (iii) in the form of one or more compounds selected from sulfamic acid, derivatives of sulfamic acid or any salt thereof.

[0081] In a preferred embodiment, component (iii) is selected from the group consisting of sulfamic acid and any salt thereof, such as ammonium sulfamate, calcium sulfamate, sodium sulfamate, potassium sulfamate, magnesium sulfamate, cobalt sulfamate, nickel sulfamate, N-cyclohexyl sulfamic acid and any salt thereof, such as sodium N-cyclohexyl sulfamate.

[0082] In a particularly preferred embodiment, component (iii) is ammonium sulfamate.

[0083] In a preferred embodiment, the aqueous binder composition according to the present invention comprises glucose syrup having a DE of 60 to less than 100, in particular of 60 to 99, more particular 85 to 99 and a component (iii) in form of sulfamic acid and/or its salts, preferably ammonium sulfamate and/or N-cyclohexyl sulfamic acid and/or its salts.

[0084] In a preferred embodiment, the proportion of carbohydrate and (iii) is within the range of 0.5-15 wt.-%, in particular 1-12 wt.-%, more particular 2-10 wt.-% component (iii), based on the mass of carbohydrate.

[0085] In a particularly preferred embodiment, the component (iii) is in form of N-cyclohexyl sulfamic acid and any salt thereof and the proportion of carbohydrate and component (iii) in form of N-cyclohexyl sulfamic acid and any salt thereof is within the range of 0.5-20 wt.-%, in particular 1-15 wt.-%, more particular 2-10 wt.-% component (iii), based on the mass of carbohydrate.

[0086] In a preferred embodiment, the mineral wool product according to the present invention is such that the binder further comprises, in its uncured state urea preferably in an amount of 0 to 40 weight-% urea, preferably 0 to 20 weight-% urea, based on the mass of components (i) and/or (iii), and carbohydrate.

[0087] In a preferred embodiment, the mineral wool product according to the present invention is such that the binder further comprises, in its uncured state hypophosphorous acid or any salts thereof.

[0088] In a particularly preferred embodiment, the hypophosphorous acid or salts thereof, preferably the sodium salt of hypophosphorous acid is present in an amount of 0.05 to 10 weight-%, such as 1 to 7 weight-%, based on the mass of component (i), and carbohydrate, whereby component (ii) is preferably present in the amount of 0.1 to 10 molar equivalents of component (ii) relative to the combined molar equivalents of component (i) and hypophosphorous acid.

[0089] In a preferred embodiment, the mineral wool product according to the present invention is such that the binder comprises, in its uncured state, component (i) in the form of ascorbic acid; component (ii) in the form of ammonia; carbohydrate in the form of dextrose and/or a glucose syrup with a DE of 60-99; component (iii) in the form of sulfamic acid and/or its salts, preferably ammonium sulfamate; and hypophosphorous acid and/or its salts, preferably ammonium hypophosphite.

[0090] In a preferred embodiment, the mineral wool product according to the present invention is such that the binder further comprises in its uncured state a further component, which is in form of one or more reactive or non-reactive silicones.

[0091] In a preferred embodiment, the one or more reactive or non-reactive silicones is selected from the group consisting of silicone constituted of a main chain composed of organosiloxane residues, especially diphenylsiloxane residues, alkylsiloxane residues, preferably dimethylsiloxane residues, bearing at least one hydroxyl, carboxyl or anhydride, amine, epoxy or vinyl functional group capable of reacting with at least one of the constituents of the binder composition and is preferably present in an amount of 0.1 to 15 weight-%, preferably 0.1 to 10 weight-%, more preferably 0.3 to 8 weight-%, based on the binder solids.

Further Components of the Binder Composition

[0092] Optionally, the aqueous binder composition according to the present invention can contain further components besides the components mentioned above. However, in a preferred embodiment >95 weight-% of the total solids content of the composition is formed by carbohydrate, component (i), component (ii), component (iii), hypophosphorous acid or salts thereof and urea based on the binder component solids content.

[0093] In other words, any further components, if present, are present preferably in an amount of <5 weight-% of the total binder component solids content of the binder composition.

Method of Producing the Mineral Wool Product

[0094] The present invention is also directed to a method of producing a mineral wool product as described above which comprises steps of contacting mineral fibers with the binder composition as described above and curing the binder composition.

EXAMPLES

[0095] Several binders were used in the test production of a mineral wool product DP-GF (Dachplatte-Grossformat) for flat roof insulation.

[0096] The binders were used by spraying the binder solutions near a cascade rotor apparatus into the formed cloud of fibres in the forming chamber. The coated fibres were collected on transport conveyors and transferred into a curing oven for a curing time of 5-15 minutes at a curing temperature in the interval of 250 C. to 280 C.

[0097] The products shown in Table 1-1 and Table 1-2 were tested for density, loss on ignition (LOI), unaged delamination strength and aged delamination strength.

[0098] The binders used in the test production are further described in the following.

[0099] The amounts of reactants used in the mineral wool production tests were scaled up from the amounts given in the Binder Examples below.

Binder Component Solids Content

[0100] The content of each of the components in a given binder solution before curing is based on the anhydrous mass of the components.

Binder Solids

[0101] The content of binder after curing is termed binder solids. Disc-shaped stone wool samples (diameter: 5 cm; height 1 cm) were cut out of stone wool and heat-treated at 580 C. for at least 30 minutes to remove all organics.

[0102] The binder solids of a given binder solution was measured by distributing two samples of the binder solution (each approx. 2.0 g) onto two of the heat treated stone wool discs which were weighed before and after application of the binder solution. The binder loaded stone wool discs were then heated at 200 C. for 1 hour.

[0103] After cooling and storing at room temperature for 10 minutes, the samples were weighed and the binder solids was calculated as an average of the two results. A binder with a desired binder solids could then be produced by diluting with the required amount of water or water and 10% aq. silane (Momentive VS-142).

[0104] The glucose syrup used has a DE-value of 95 to less than 100 (C*sweet D02767 ex Cargill), except otherwise stated.

Binder Example, reference A

[0105] This binder is a mixture of a Hexion 0415M (a commercially available phenol-formaldehyde resin modified with urea) and a DE=30 glucose syrup, (Cleardex 31/42 Corn Syrup from Cargill) said glucose syrup being present in 25 wt. % of the total binder component solids.

Binder Example, Reference B

[0106] This binder is a mixture of a Hexion 1764M30 (a commercially available phenol-formaldehyde resin modified with urea) and a DE=30 glucose syrup, (Cleardex 31/42 Corn Syrup from Cargill) said glucose syrup being present in 25 wt. % of the total binder component solids. .

Binder Example, Binder 1

[0107] A mixture of L-ascorbic acid (3.75 g, 21.3 mmol) and 75.1 wt. % aq. glucose syrup (15.0 g; thus efficiently 11.3 g glucose syrup) in water (31.3 g) was stirred at room temperature until a clear solution was obtained. 50% aq. hypophosphorous acid (0.60 g; thus efficiently 0.30 g, 4.55 mmol hypophosphorous acid) was then added (pH 1.3). 28% aq. ammonia (1.93 g; thus efficiently 0.54 g, 31.7 mmol ammonia) was then added dropwise until pH=6.1. The binder solids were measured (19.4%) and the binder mixture was diluted with water (0.286 g/g binder mixture) and 10% aq. silane (0.010 g/g binder mixture). The final binder mixture had pH=6.0.

Binder Example, Binder 3

[0108] A mixture of L-ascorbic acid (1.50 g, 8.52 mmol) and 75.1 wt. % aq. glucose syrup (18.0 g; thus efficiently 13.5 g glucose syrup) in water (30.5 g) was stirred at room temperature until a clear solution was obtained. 50% aq. hypophosphorous acid (0.60 g; thus efficiently 0.30 g, 4.55 mmol hypophosphorous acid) was then added (pH 1.3). 28% aq. ammonia (0.99 g; thus efficiently 0.28 g, 16.3 mmol ammonia) was then added dropwise until pH=6.7. The binder solids were measured (20.1%) and the binder mixture was diluted with water (0.331 g/g binder mixture) and 10% aq. silane (0.010 g/g binder mixture). The final binder mixture had pH=6.4.

Binder Example, Binder 5

[0109] A mixture of L-ascorbic acid (1.50 g, 8.52 mmol) and 75.1 wt. % aq. glucose syrup (18.0 g; thus efficiently 13.5 g glucose syrup) in water (30.5 g) was stirred at room temperature until a clear solution was obtained. Urea (0.75 g) and 50% aq. hypophosphorous acid (0.60 g; thus efficiently 0.30 g, 4.55 mmol hypophosphorous acid) was then added (pH 1.2). 28% aq. ammonia (1.09 g; thus efficiently 0.31 g, 17.9 mmol ammonia) was then added dropwise until pH=6.5. The binder solids were measured (20.7 wt. %) and the binder mixture was diluted with water (0.370 g/g binder mixture) and 10% aq. silane (0.010 g/g binder mixture). The final binder mixture had pH=6.7.

Binder Example, Binder 8

[0110] A mixture of 75.1 wt. % aq. glucose syrup (20.0 g; thus efficiently 15.0 g glucose syrup) and ammonium sulfamate (0.75 g, 6.57 mmol) in water (35.0 g) was stirred at room temperature until a clear solution was obtained (pH 4.2). 28% aq. ammonia (0.069 g; thus efficiently 0.02 g, 1.13 mmol ammonia) was then added dropwise until pH=8.1. The binder solids were measured (19.0%) and the binder mixture was diluted with water (0.250 g/g binder mixture) and 10% aq. silane (0.019 g/g binder mixture). The final binder mixture had pH=8.3.

Binder Example, Binder 10

[0111] A mixture of 75.1 wt. % aq. glucose syrup (20.0 g; thus efficiently 15.0 g glucose syrup), ammonium sulfamate (0.75 g, 6.57 mmol) and urea (1.50 g) in water (35.0 g) was stirred at room temperature until a clear solution was obtained (pH 4.4). 28% aq. ammonia (0.035 g; thus efficiently 0.01 g, 0.58 mmol ammonia) was then added dropwise until pH=8.0. The binder was then measured (21.1wt. %) and the binder mixture was diluted with water (0.384 g/g binder mixture) and 10% aq. silane (0.021 g/g binder mixture). The final binder mixture had pH=8.5.

Binder Example, Binder 12

[0112] A mixture of xylose (15.0 g) and ammonium sulfamate (0.75 g, 6.57 mmol) in water (40.0 g) was stirred at room temperature until a clear solution was obtained (pH 4.3). 28% aq. ammonia (0.055 g; thus efficiently 0.02 g, 0.90 mmol ammonia) was then added dropwise until pH=8.2. The binder solids were measured (18.4 wt. %) and the binder mixture was diluted with water (0.210 g/g binder mixture) and 10% aq. silane (0.018 g/g binder mixture). The final binder mixture had pH=6.8.

[0113] The other binders mentioned in Table 1-1 and 1-2 were prepared in a manner analogous to the preparation described above.

TABLE-US-00001 TABLE 1-1 A B Hexion Hexion 0415M 1764M30 25% Glycose 25% Glycose syrup syrup Binder DE = 30 DE = 30 1 2 3 4 5 6 7 Binder composition Ascorb. acid or deriv. (%-wt.) L-Ascorbic acid .sup.[a] 25 20 10 10 10 10 10 Carbohydrate (%-wt.) Glucose syrup .sup.[a] 75 80 90 90 90 90 90 Xylose Additive (%-wt.) .sup.[a] Urea 5 5 10 15 Hypophosphorous acid 2 2 2 2 2 2 Ammonium sulfamate Amine (equiv.) .sup.[b] Ammonia (added) 1.2 1.5 1.2 1.6 1.4 1.2 1.6 Silane (% of binder solids) 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Product properties Density (kg/m.sup.3) 144 140 143 143 146 139 148 137 140 LOI (%) 3.6 3.5 4.2 3.4 3.4 4.0 3.4 3.6 3.8 Unaged delamination (kPa) 36 34 32 34 34 20 37 22 20 Aged delamination (kPa) 18 19 18 22 23 10 23 13 12 Aged/unaged delamination (%) 50 56 56 65 68 50 62 59 60 .sup.[a] Of ascorbic acid (or derivative) + carbohydrate. .sup.[b] Molar equivalents relative to ascorbic acid + additives.

TABLE-US-00002 TABLE 1-2 A B Hexion Hexion 0415M 1764M30 25% Glycose 25% Glycose syrup syrup Binder DE = 30 DE = 30 8 8 9 10 11 12 Binder composition Ascorb. acid or deriv. (%-wt.) L-Ascorbic acid 0 0 0 0 0 0 Carbohydrate (%-wt.) Glucose syrup 100 100 100 100 100 Xylose 100 Additive (%-wt.).sup.[a] Urea 5 10 15 Ammonium sulfamate 5 5 5 5 5 5 Amine (equiv.) .sup.[b] Ammonia (added) 0.2 0.2 0.1 0.1 0.1 0.1 Silane (% of binder solids) 0.5 0.5 1.0 1.0 1.0 1.0 1.0 0.5 Product properties Density (ka/m.sup.3) 144 140 153 145 145 144 146 149 LOI (%) 3.6 3.5 3.3 4.4 4.2 3.5 3.6 3.9 Unaged delamination (kPa) 36 34 36 35 30 32 23 29 Aged delamination (kPa) 18 19 19 16 14 20 14 16 Aaed/unaaed delamination (%) 50 56 53 46 47 63 61 55 .sup.[a]Of carbohydrate. .sup.[b] Molar equivalents relative to ammonium sulfamate.