TWI431084B - 黏結劑 - Google Patents

黏結劑 Download PDF

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Publication number
TWI431084B
TWI431084B TW097129551A TW97129551A TWI431084B TW I431084 B TWI431084 B TW I431084B TW 097129551 A TW097129551 A TW 097129551A TW 97129551 A TW97129551 A TW 97129551A TW I431084 B TWI431084 B TW I431084B
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Taiwan
Prior art keywords
binder
binder solution
solution
formaldehyde
free
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TW097129551A
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English (en)
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TW200914560A (en
Inventor
Carl Hampson
Charles Appley
Gert Mueller
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Knauf Insulation Ltd
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Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=38529209&utm_source=***_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=TWI431084(B) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Knauf Insulation Ltd filed Critical Knauf Insulation Ltd
Publication of TW200914560A publication Critical patent/TW200914560A/zh
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Publication of TWI431084B publication Critical patent/TWI431084B/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00—Thermal insulation in general
    • F16L59/02—Shape or form of insulating materials, with or without coverings integral with the insulating materials
    • F16L59/028—Composition or method of fixing a thermally insulating material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/002—Manufacture of substantially flat articles, e.g. boards, from particles or fibres characterised by the type of binder
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C13/00—Fibre or filament compositions
    • C03C13/06—Mineral fibres, e.g. slag wool, mineral wool, rock wool
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/24—Coatings containing organic materials
    • C03C25/26—Macromolecular compounds or prepolymers
    • C03C25/32—Macromolecular compounds or prepolymers obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/24—Coatings containing organic materials
    • C03C25/26—Macromolecular compounds or prepolymers
    • C03C25/32—Macromolecular compounds or prepolymers obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds
    • C03C25/321—Starch; Starch derivatives
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/24—Coatings containing organic materials
    • C03C25/26—Macromolecular compounds or prepolymers
    • C03C25/32—Macromolecular compounds or prepolymers obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds
    • C03C25/34—Condensation polymers of aldehydes, e.g. with phenols, ureas, melamines, amides or amines
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07H—SUGARS; DERIVATIVES THEREOF; NUCLEOSIDES; NUCLEOTIDES; NUCLEIC ACIDS
    • C07H11/00—Compounds containing saccharide radicals esterified by inorganic acids; Metal salts thereof
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07H—SUGARS; DERIVATIVES THEREOF; NUCLEOSIDES; NUCLEOTIDES; NUCLEIC ACIDS
    • C07H3/00—Compounds containing only hydrogen atoms and saccharide radicals having only carbon, hydrogen, and oxygen atoms
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07H—SUGARS; DERIVATIVES THEREOF; NUCLEOSIDES; NUCLEOTIDES; NUCLEIC ACIDS
    • C07H99/00—Subject matter not provided for in other groups of this subclass
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08H—DERIVATIVES OF NATURAL MACROMOLECULAR COMPOUNDS
    • C08H8/00—Macromolecular compounds derived from lignocellulosic materials
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/24—Acids; Salts thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/16—Nitrogen-containing compounds
    • C08K5/17—Amines; Quaternary ammonium compounds
    • C08K5/175—Amines; Quaternary ammonium compounds containing COOH-groups; Esters or salts thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/02—Fibres or whiskers
    • C08K7/04—Fibres or whiskers inorganic
    • C08K7/14—Glass
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K9/00—Use of pretreated ingredients
    • C08K9/08—Ingredients agglomerated by treatment with a binding agent
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L101/00—Compositions of unspecified macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L101/00—Compositions of unspecified macromolecular compounds
    • C08L101/02—Compositions of unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups
    • C08L101/025—Compositions of unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups containing nitrogen atoms
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L101/00—Compositions of unspecified macromolecular compounds
    • C08L101/02—Compositions of unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups
    • C08L101/06—Compositions of unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups containing oxygen atoms
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L97/00—Compositions of lignin-containing materials
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L97/00—Compositions of lignin-containing materials
    • C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L99/00—Compositions of natural macromolecular compounds or of derivatives thereof not provided for in groups C08L89/00 - C08L97/00
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D197/00—Coating compositions based on lignin-containing materials
    • C09D197/02—Lignocellulosic material, e.g. wood, straw or bagasse
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D199/00—Coating compositions based on natural macromolecular compounds or on derivatives thereof, not provided for in groups C09D101/00 - C09D107/00 or C09D189/00 - C09D197/00
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D201/00—Coating compositions based on unspecified macromolecular compounds
    • C09D201/02—Coating compositions based on unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups
    • C09D201/025—Coating compositions based on unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups containing nitrogen atoms
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D201/00—Coating compositions based on unspecified macromolecular compounds
    • C09D201/02—Coating compositions based on unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups
    • C09D201/06—Coating compositions based on unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups containing oxygen atoms
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C—CHEMISTRY; METALLURGY
    • C13—SUGAR INDUSTRY
    • C13K—SACCHARIDES OBTAINED FROM NATURAL SOURCES OR BY HYDROLYSIS OF NATURALLY OCCURRING DISACCHARIDES, OLIGOSACCHARIDES OR POLYSACCHARIDES
    • C13K1/00—Glucose; Glucose-containing syrups
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/7654—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings
    • E04B1/7658—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/7654—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings
    • E04B1/7658—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres
    • E04B1/7662—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres comprising fiber blankets or batts

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  • Chemical & Material Sciences (AREA)
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  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Materials Engineering (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Wood Science & Technology (AREA)
  • General Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Architecture (AREA)
  • Textile Engineering (AREA)
  • Biochemistry (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Inorganic Chemistry (AREA)
  • Acoustics & Sound (AREA)
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  • Civil Engineering (AREA)
  • Electromagnetism (AREA)
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  • Composite Materials (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Nonwoven Fabrics (AREA)
  • Phenolic Resins Or Amino Resins (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
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Description

黏結劑
本發明係關於用於(例如)玻璃棉或石棉絕緣之黏結劑。
WO2007/014236(其以引用方式併入本文中)係關於黏結劑，其包括含Maillard反應物之黏結劑。所揭示之一種特定黏結劑係基於由混合右旋糖單水合物、無水檸檬酸、水及氨水獲得之檸檬酸三銨－右旋糖系統。該黏結劑系統的多個優點中的一者係其不含甲醛。
本發明之一個態樣提供如請求項1之黏結劑溶液；附屬請求項定義替代及/或較佳實施例。
在另一態樣中，本發明提供黏結劑溶液，其包含藉由溶解下列物質可獲得的溶液：－碳水化合物，－源自無機鹽之酸前體，－氮源－視情況選用之有機酸或其前體及－視情況選用之氨。
本發明所用黏結劑溶液可"基本不含甲醛"，亦即由於乾燥及/或固化(或模擬乾燥及/或固化之適宜測試)其釋放低於5 ppm之甲醛。該等黏結劑溶液較佳"不含甲醛"，亦即在該等條件下其釋放低於1 ppm之甲醛。
納入黏結劑之本發明產品(例如絕緣材料或木板)可"基本不含甲醛"，亦即其包含低於5 ppm或低於可檢測限值之游離甲醛及/或由總共包含小於游離甲醛之該等量及/或在適於模擬其一般使用之標準測試中甲醛釋放含量之材料組成，此使其歸為無甲醛釋放或不可檢測含量之甲醛釋放的材料。較佳地，根據ISO 16000自測試開始24－48小時時期內，該等產品釋放小於10 μg/m3 、更佳小於5 μg/m3 之甲醛。
已發現，與(例如)WO 2007/014236之檸檬酸三銨－右旋糖系統相比，本發明之黏結劑可具有至少與其等效但實際上經改良之特性。WO 2007/014236教示黏結劑系統尤其基於碳水化合物(例如還原糖)、氨及羧酸之組合且表明Maillard型反應可形成固化化學之基礎。據認為所用酸之性質將對固化黏結劑之特性具有顯著影響，尤其如果酸前體及/或其衍生物係併入該固化黏結劑之結構中。因此，令人驚訝的係源自無機鹽之酸前體將在原本明顯相似的黏結劑系統中提供適宜酸前體。
使用源自無機鹽之酸前體在成本、可用性及易於處理方面可具有顯著優點。該黏結劑溶液源自無機鹽之酸前體可包含選自由硫酸鹽、磷酸鹽、硝酸鹽及碳酸鹽組成之群之物質。可藉由使用一或多種無機銨鹽(例如硫酸銨、磷酸銨或碳酸銨)達成特定優點。銨鹽可提供酸前體或其一部分及/或氮源或其一部分及/或pH控制系統或其一部分。硝酸銨亦可運作良好；然而，硝酸銨可氧化碳水化合物之醛 基團(例如在右旋糖情形下)及/或需要預防措施以避免***。
硫酸銨尤其有用，但除硫酸銨外可使用磷酸銨或替代硫酸銨。磷酸銨可為磷酸一銨、磷酸二銨或磷酸三銨；其可為磷酸氫銨。碳酸銨單獨或與本文揭示之其他材料組合亦可提供良好結果。碳酸銨可為碳酸氫銨。
酸前體、尤其當其主要由無機銨鹽組成時可構成．以乾重計未固化黏結劑溶液的至少5%、較佳至少7%、更佳至少9%；及/或．以乾重計未固化黏結劑溶液的小於25%或20%、較佳小於18%、更佳小於16%。
詞語"由...組成或主要由...組成"意欲將請求項之範圍限於特定材料或步驟及彼等不實質上影響所主張本發明之基本及新穎特徵者。
酸可包含：硫酸、磷酸、硝酸或弱酸。
黏結劑以乾重計相對於碳水化合物(尤其當其係糖時)可包含介於5%與25%之間、較佳10%－20%、更佳15%－20%的酸前體(尤其當其係無機銨鹽時)。
當黏結劑包含源自無機鹽之酸前體與有機酸二者時，該等以乾重計相對於碳水化合物(尤其當其係糖時)可以下述量存在：
當使用有機酸時，其較佳係源自銨鹽。例如，檸檬酸銨、尤其檸檬酸三銨可用作檸檬酸源。
用於礦棉絕緣之先前技術苯酚甲醛黏結劑系統可添加約2重量%作為固化劑的硫酸銨來使用。然而，該等苯酚甲醛黏結劑系統之化學性質並不能與本發明不基於苯酚及/或甲醛及/或其他酚系化合物之黏結劑系統相比。
碳水化合物可用於黏結劑溶液中而不是特定還原糖並可包含呈(例如)其醛糖或酮糖形式之單糖。較佳地，碳水化合物包含糖、更佳還原糖或在熱固化條件下原位產生還原糖之反應物；其可包含葡萄糖(即右旋糖)。碳水化合物可包含具有還原醛之碳水化合物。據信使用還原糖及特定右旋糖可獲得良好的黏結劑強度，尤其對於礦棉絕緣產品之製造。右旋糖不需100%的純度，但吾人認為使用右旋糖當量值為至少0.85、較佳至少0.9且更佳至少0.95之材料係有利的。可認為右旋糖當量值DE為i)解聚之量度且粗略為：DE＝100/dp，其中dp代表聚合度或ii)按D－葡萄糖(右旋糖)計算以乾基計還原糖之總量。
較佳地，黏結劑溶液及/或黏結劑不含或基本不含澱粉；認為大量澱粉之存在可增加固化時間及/或降低固化黏結劑之強度。黏結劑溶液及/或黏結劑可不含或基本不含蛋白質。
可使用工業非食品級右旋糖作為還原糖；可使用諸如Sirodex331之產品，其係自Tate and Lyle獲得DE值為94.5之75%固體的糖溶液。
還原糖可主要由右旋糖組成。具體而言，在此情形下且更具體而言，當另外酸前體主要由銨鹽(例如硫酸銨)組成時，以亁重計還原糖之量/酸前體量之比率可大於或等於2.5及/或小於或等於13。
氮源可為胺或胺反應物；其可衍生自與酸前體相同之源，例如源自無機銨鹽。較佳係存於溶液中之氨。
可使用獲得所提及材料之前體及/或反應物。
在一個實施例中，黏結劑係主要源自水溶液中的還原糖及無機銨鹽。
在另一實施例中，黏結劑亦可包含有機酸、具體而言羧酸；其可為多羧酸、具體而言二羧酸或三羧酸、較佳係檸檬酸；較佳為單體。有機酸(或其前體、鹽或酐)與可源自無機鹽之酸前體之組合可呈現各種優點。首先，此組合可降低燻燒(punking)風險(以該等僅基於有機酸之黏結劑觀察到此情況)同時提供可接受強度。燻燒係在礦物纖維絕緣區域中之技術術語，其一般表示黏結劑相當快的氧化並在最終且一般經包裝的絕緣產品中伴隨產生熱。燻燒通常導致煙霧之產生及絕緣材料脫色。其可與增加整個絕緣材料厚度之溫度之放熱反應相關；此可破壞絕緣產品之完整性及/或存在火災危險。
或者或另外，有機酸(或其前體、鹽或酐)與可源自無機鹽之酸前體之組合可緩和固化期間出現之酸條件且由此降低該等條件對所黏結材料產生顯著損害之風險或趨勢。此一組合可尤其有利地用作石棉絕緣之黏結劑，石棉絕緣的 纖維可比(例如)玻璃棉絕緣對潛在酸損害更敏感。
在另一實施例中，黏結劑主要源自：水溶液中之碳水化合物、無機銨鹽、及有機酸及/或有機酸前體。
包含本文所闡述之組份或主要由本文所闡述之組份組成之黏結劑可包括添加劑，例如選自各者之添加劑：矽烷、礦物油、偶合劑、聚矽氧或矽氧烷(尤其用於拒水性)、含矽之化合物、表面活性劑、親水性添加劑、疏水性添加劑、蠟、用於控制pH之物質(例如氫氧化銨)及氨。使用時，氫氧化銨與實際上其他添加劑可提供該氮源及/或額外氮源。
較佳地，添加劑總量(排除氨)小於5重量%(排除所存在水之重量)、更佳小於3重量%或小於2重量%。
尤其對於礦物纖維產品，較佳包括矽烷作為添加劑。黏結劑及/或黏結劑溶液以亁重計可包含至少0.1%及/或小於1%之矽烷。矽烷可經胺基取代；其可為甲矽烷基醚且據信其存在可顯著改良黏結劑之長期強度，尤其風化後。
黏結劑之pH較佳為： 至少在其中黏結劑施加於欲黏結之材料及/或在廢水再生系統中回收之情況下。該黏結劑之此一中性或鹼性pH可緩解製造設備之腐蝕問題，該等問題在某些主要酸性先前技術黏結劑系統已遇到。該等先前技術黏結劑包括主要由聚丙烯酸或聚合物聚羧酸組成之黏結劑。因此，本發明之一 個特別優點係使用可在該等中性或鹼性條件下運行之黏結劑系統。當固化時，黏結劑可在固化過程期間變為酸性。然而，由於在此狀態下製造設備與黏結劑之間之接觸最少，故在此情形下設備腐蝕因素較不重要。黏結劑之pH可小於或等於13，較佳小於或等於12、11或10。較佳pH可介於7.5至9.5、較佳8至9之間。已應用於待黏結材料且隨後溶於水中之黏結劑的pH可大於6。
較佳地，調整黏結劑溶液pH於適宜位準以防止其成份沈澱且尤其確保源自無機鹽之酸前體保留於溶液中。此尤其係其中磷酸銨提供酸前體之情形。可藉由使用包含銨鹽酸前體且不含沈澱物之均一黏結劑溶液來達成較好乾及/或經風化強度及/或更均一產品，尤其當使用磷酸銨且黏結劑溶液不含磷酸鹽沈澱物時。
可以水溶液形式提供黏結劑組合物；其溶液中可含有游離氨或過量氨。可藉由與存於黏結劑溶液中之酸基團相比過量鹼性基團(例如，部分或基本因溶液中氨之存在)產生黏結劑之中性或鹼性pH。可將額外氨添加至黏結劑溶液中，例如0.2重量%－1重量%，或實際上更多；此可幫助保持洗滌水系統長期為鹼性，尤其對於礦棉絕緣之製造。
在此情形或尤其用於熱絕緣產品之礦棉纖維，當剛形成礦棉纖維後即將黏結劑溶液噴塗於熱礦棉纖維上時，礦棉纖維之殘餘熱可導致黏結劑溶液中任何水之大部分蒸發。因此，然後收集以形成棉絮之礦棉纖維可具有以黏稠(sticky、viscous或tacky)液體形式存在於其上之黏結劑。 此可經由黏結劑促進個別纖維間之黏結。
該黏結劑系統的許多優點之一係其係在基本未反應狀態下使用，例如噴塗至礦棉纖維上。在基本未反應狀態下應用黏結劑溶液之能力可緩解與溶液中預先反應黏結劑組份相關聯之問題，該等問題在其中某些組份預先反應之先前技術黏結劑系統已遇到。該等先前技術黏結劑包括主要由預先反應的聚合物或樹脂組成且用於待黏結材料之黏結劑。用在待黏結材料上以黏稠(sticky、viscous或tacky)液體形式存在之基本未反應黏結劑，黏結劑組份問的反應可在基本乾燥狀態下發生。可將該反應闡述為本體聚合，此乃因其可不利用溶劑而發生。因此，本發明之特定優點係使用可在基本乾燥狀態下或藉助本體聚合來聚合之黏結劑系統。
本發明上下文中所用礦物纖維可藉由內部或外部紡絲形成。當用黏結劑溶液噴塗時，其可具有介於20℃至200℃、一般30℃至100℃或150℃之間之溫度。所噴塗黏結劑之量可與或不與額外水噴射一起使用以幫助將礦物纖維冷卻至其形成與其收集間之期望溫度以形成棉絮。
使用溶液中之氨來控制施加於礦物纖維之黏結劑溶液pH的一個特定優點係黏著於纖維之黏結劑溶液的至少一部分氨可由於礦棉纖維之殘餘熱而閃蒸出。因此，塗佈纖維之黏結劑溶液可具有比噴塗黏結劑溶液低的pH。
本發明延伸至製造礦物纖維熱絕緣產品之方法，其包含以下連續步驟： ．自熔融礦物混合物形成礦物纖維；．在該礦物纖維上噴塗基本不含甲醛之黏結劑溶液，該黏結劑溶液包含：碳水化合物(尤其還原糖)、源自無機鹽之酸前體及氮源；．收集已施加黏結劑溶液之礦物纖維以形成礦物纖維棉絮；及．藉由使包含礦物纖維與黏結劑之棉絮穿過固化爐來固化該棉絮以提供由基本水不溶性固化黏結劑保持在一起之礦物纖維棉絮。
可在礦物纖維形成及其收集間將洗滌水噴塗於其上以形成棉絮，至少部分洗滌水噴塗在礦物纖維上且隨後返回至洗滌水系統以作為洗滌水再利用。黏結劑溶液可包含洗滌水。
黏結劑係可固化的；其可在(例如)固化爐中固化；其可形成熱固性黏結劑。在其固化形式中，黏結劑可：包含類黑精；及/或係熱固性；及/或係水不溶或基本水不溶。黏結劑溶液可基本無色或白色至米色；固化後，黏結劑可呈現深色，尤其深棕色。固化產物可為深色，尤其深棕色。黏結劑可不含蛋白質；其可不含纖維素原料。該黏結劑系統的多個優點之一係可由顏色確定固化程度。基本脫水之黏結劑呈現白色或米色。當逐漸固化至較高程度時，黏結劑逐漸呈現較深顏色(較深棕色陰影)。當施加於礦物纖維時，礦棉絕緣已固化程度由其顏色確定。
當施加於待黏結材料時及/或固化前，黏結劑可不含或 基本不含類黑精及/或源自固化之其他反應產物。黏結劑之固化可產生葡萄糖胺，尤其作為中間產物。因此，固化或尤其部分固化產物可包含葡萄糖胺。
黏結劑固化時之反應可主要係如(例如)美國專利申請案第20070027283號或WO 2007/14236中闡述之Maillard型反應。黏結劑可包含含以下物質之混合物的聚合產物：還原糖及選自由硫酸銨、磷酸銨、硝酸銨及碳酸銨組成之群之材料。
黏結劑溶液可藉由合併下列物質來調配：．碳水化合物，較佳還原糖；．源自無機鹽、較佳硫酸銨或磷酸銨之酸前體；．氮源；及．水。
調配物可包含以氨水溶液形式提供之可選或額外氨。水可包含洗滌水或循環處理水。
自碳水化合物及包含無機銨鹽之酸前體形成黏結劑溶液可提供一種尤其有利之製備方法。此可在敞開及/或處於常壓下的簡單混合室中達成。可以粉末或液體形式添加碳水化合物及/或酸前體。較佳於室溫下實施製備。較佳地，不需提供熱來製備黏結劑溶液；然而，可在其製備過程中加熱黏結劑溶液，例如加熱至範圍為20℃－80℃之溫度，尤其其中此可促進其成分之溶解及/或混合。
黏結劑溶液、尤其在施加於待黏結材料之狀態下可包含： ．至少5%、10%、15%或18%之固體及/或．小於70%或60%(尤其在木板應用之情形下)或小於50%、40%或20%之固體(尤其在礦物纖維絕緣應用之情形下)
此尤其以於140℃下乾燥2小時後以重量計烘乾固體來確定。
藉由黏結劑溶液方法黏結在一起之鬆散物質之集合可包含選自下列各者之材料：纖維、纖維材料、礦物纖維、玻璃纖維、石棉纖維、纖維素纖維(包括木質纖維、刨花、小木塊及鋸屑)、薄木板、面板、木面板、顆粒、紡織或非紡織材料、鬆散裝配的材料。
黏結劑溶液及/或黏結劑較佳係有機物。
鬆散物質可藉助黏結劑成形及/或定尺寸及/或模製。所產生材料可係選自：熱絕緣材料、礦物纖維產品、木板產品(包括粗紙板、定向條狀板、粒片板、中密度纖維板、木面板產品)、鑄造用砂。
當應用黏結劑時，待黏結之物質可處於範圍為20℃至100℃之溫度下。尤其在木板產品之情形下，黏結劑及鬆散物質可藉由(例如)翻滾機械混合。
尤其當施加於鬆散物質時，黏結劑溶液可具有適於藉由噴塗或傾注應用之黏度。於20℃下其黏度可為：．小於約1.5 Pa.s，較佳小於約1 x 10－2 Pa.s；及/或．大於約2 x 10－4 Pa.s，較佳大於約5 x 10－4 Pa.s。
黏結劑之固化可在固化爐中使用(例如)強制熱空氣循環 發生；其可在壓力機中發生。固化可包含黏結劑之脫水；其可包含聚合；其可包含本體聚合反應。固化可持續實施20分鐘或更少，較佳10分鐘或更少；其可藉由使產品(例如礦物纖維棉絮)穿過溫度在範圍230℃－300℃下之固化爐至少一個區域來實施，其中爐停留時間介於30秒至20分鐘之間。黏結劑之固化較佳發生在黏結劑溶液(水已自其蒸發)與鬆散物質接觸時；其可在基本常壓下發生。固化可係基本乾燥固化，亦即藉由應用乾燥熱及/或基本乾燥或加熱之大氣而非使用蒸氣或加熱水蒸汽。
尤其在礦物纖維絕緣產品之情形下，可隨產品密度及/或厚度變化選擇固化溫度與時間。在該等情形下固化爐可具有複數個溫度在範圍200℃至350℃(通常230℃至300℃)內之加熱區。薄低密度產品(12 kg/m3 或更少)可藉由在僅僅20秒內穿過固化爐來固化；厚高密度產品(80 kg/m3 或更多)可需要在固化爐中經過15分鐘或更長時間。在固化過程中產品可達到範圍為180℃－220℃之溫度。
固化黏結劑以質量計可包含大於2%及/或小於8%之氮，如由元素分析所確定。
黏結劑在其未固化狀態下以亁重計可包含以下含量的硫酸鹽、磷酸鹽、碳酸鹽及/或硝酸鹽：．大於2.5%、3%或5%；及/或．小於25%、22%或20%。
使用本發明之黏結劑系統製造之最終材料可具有殘餘含量的明顯源自用作酸前體的無機鹽之硫酸鹽、磷酸鹽、碳 酸鹽及/或硝酸鹽。該等物質可以下列量存在：．大於500、750、1000或1500 mg/kg；及/或．小於5000、4000或3000 mg/kg。
該等物質之存在可在溶出測試中評估且在所用黏結劑系統之最終產品中提供說明。
尤其在礦棉絕緣之情形下，最終產品中黏結劑的量可為：．大於：1%、2%、2.5%、3%、3.5%或4%；及/或．小於：20%、15%、10%或8%
其以最終產品之乾重量測。
尤其在礦物纖維絕緣情形下，產品可具有一或多種下述分離強度(parting strength)： 普通分離強度 ．至少120 g/g，較佳至少150 g/g；及/或．小於400 g/g 經風化之分離強度 ．至少120 g/g，較佳至少150 g/g；及/或．小於400 g/g 普通及經風化之分離強度間之%損失 ．小於10%，較佳小於5%。
在產品為礦棉絕緣之情況可具有一或多個下述特徵：．密度大於5、8或10 kg/m3 ；．密度小於200、180或150 km/m3 ．包含玻璃棉纖維且密度大於5、8或10 kg/m3 及/或小於 80、60或50 kg/m3 ．包含石棉纖維且密度大於15、20或25 kg/m3 及/或小於220、200或180 kg/m3 ；．熱傳導係數λ小於0.05 W/mK及/或大於0.02 W/mK．包含小於99重量%及/或大於80重量%之礦物纖維．厚度大於10 mm、15 mm或20 mm及/或小於400 mm、350 mm或300 mm。
在產物係木板產物之情況下，其可具有一或多個下述特徵：．尺寸為至少50 cm x 80 cm，較佳至少1 m x 2m．厚度為至少11 mm、12 mm或15 mm．固化時間小於25、15、12或10分鐘．根據EN319所量測之內部黏結強度至少：0.4 N/mm2 或0.45 N/mm2 (尤其對於粒片板或纖維板)，或根據EN300所量測為至少0.28 N/mm2 (尤其對於定向條狀板)．根據EN317在20℃下於水中24小時後，膨脹厚度小於12%、較佳小於10%．在20℃下於水中24小時後，吸水率小於40%、較佳小於30%．根據EN310之彈性模數至少為：1800 N/mm2 (尤其對於粒片板或纖維板)或2500 N/mm2 (尤其對於定向條狀板)或3500 N/mm2 或4800 N/mm2 ．彎曲強度(MOR)至少為：14 N/m2 (尤其對於粒片板或 纖維板)或18 N/mm2 (尤其對於定向條狀板)或20 N/mm2 或28 N/mm2 ．蠟作為添加劑係介於(例如)0.1－2重量%之間、較佳0.5－1重量%．樹脂含量(乾樹脂之重量比乾小木塊之重量)係介於8－18重量%之間、較佳10－16重量%、更佳12－14重量%．在壓力機下固化，尤其在溫度大於180℃或200℃及/或280℃或260℃之壓板間。
現在將參照圖1以舉例說明方式闡述本發明之實施例，其中圖1係礦物纖維試樣之平面圖。
殼體骨架測試：
黏結劑可藉由如下製成水溶液：．在敞開未加熱的反應容器中合併期望黏結劑調配物之成分．添加蒸餾水．隨後添加矽烷溶液．在添加液體期間及之後攪拌數分鐘以達成固體完全溶解以使黏結劑溶液以溶液總重量百分比計含有大約45%之溶解固體。2－g此溶液樣品於約200℃至210℃下熱固化8分鐘時可產生30%固體(重量損失係歸因於熱固性黏結劑形成期間之脫水)。
含玻璃珠殼體骨架之乾燥及"經風化"抗伸強度之評估提供纖維玻璃絕緣或由彼特定黏結劑製備之其他材料之可能抗伸強度與可能耐久性之說明。所預測之耐久性係基於殼 體骨架之風化抗伸強度與其乾燥抗伸強度之比率。
為了製備殼體骨架，使用電混合器以將大約75g黏結劑與727.5g玻璃珠(等效於Quality Ballotini Impact Beads，Spec.AD，美國篩70－140，106－212微米－7號，自Potters Industries，公司)混合約兩分鐘。使用抹刀將來自混合攪拌器側與來自混合缽側及底部之任何團塊在混合到約一半時且亦在混合結束時手動混合攪拌。
將所製備玻璃珠/黏結劑混合物添加至已預先加熱至約218℃(425℉)之殼體骨架模具的模具腔中(Dietert Foundry Testing Equipment；Heated Shell Curing Accessory，366型)。使每一腔中之混合物表面變平，同時刮掉過量混合物以為殼體骨架提供均勻表面區域。存在於任何腔之任何不一致性或間隙用額外玻璃珠/黏結劑混合物填充且然後使其變平。迅速將上壓板置於下壓板上(以避免產生具有兩個不同固化層之殼體骨架)。7分鐘後將固化殼體骨架移除、在金屬絲架上冷卻至室溫、標記且單獨置於塑料儲存袋中。如果不能在殼體骨架製成的當天進行測試，則可將含殼體骨架之塑料袋置於乾燥器單元中。固化期間，下壓板溫度在約204℃至約221℃(約400℉至約430℉)之範圍內，同時上壓板溫度在約227℃至約243℃(約440℉至約470℉)之範圍內。
測定斷裂強度之程序：．設備：5500 R Instron機器．測試之前，將每一殼體骨架自其塑料袋中取出並記錄 其重量及厚度。
殼體骨架之風化程序：．在已預先加熱濕室內(65℃，95%相對濕度)風化16小時．取出後，將殼體骨架密封於單獨塑料袋中且立即實施測試。
量測膠凝時間之程序：將少量黏結劑(2.0 ml)添加至設定為150℃之熱板中心並開始計時。用抹刀處理黏結劑直至可將樣品拉成長線為止。自添加黏結劑至線形成所用時間係膠凝時間。
所測試黏結劑調配物－無機酸前體與檸檬酸比較：
所測試黏結劑調配物－無機酸前體及檸檬酸之組合與僅檸檬酸及僅無機酸前體比較：
關鍵字：DMH＝右旋糖單水合物 CA＝檸檬酸NH4OH＝氫氧化銨ISIO200＝矽烷AmSO4＝硫酸銨AmPO4＝磷酸銨
測試結果－無機酸前體與檸檬酸比較：
測試結果－無機酸前體及檸檬酸之組合與僅檸檬酸及僅無機酸前體比較：
來自同時實施之測試(測試A－G係在一個時間段實施且測試H－K係在另一時間段實施)的結果提供該等結果相對於在同一測試時間段間獲得之其他結果之有用說明。比較來自不同測試時間段之測試結果不可靠。
對絕緣產品之第一比較測試：
對礦物纖維絕緣產品之黏結劑系統之比較測試給出以下結果：
測試產品黏結劑含量LOI(燒失量)重量%：
懸垂測試(指定時期後所量測以mm表示之平均數)：
厚度(根據英國標準BS EN 823：1995指定時期後所量測以mm表示之平均數)
密度(指定時期後所量測以kg/m3 表示之平均數)
所存在硫酸鹽之量(以mg/kg表示)
分離強度(g/g)
測試程序：
黏結劑含量LOI(燒失量)
將羊毛加黏結劑之稱重樣品置於設定為550℃之高溫爐中。經過設定時間後，自爐中移除羊毛，置於乾燥器中冷卻且再次稱重。重量損失係以原始樣品重量之百分比表示且稱為黏結劑含量或燒失量(LOI)。
懸垂測試
將單一棉絮(或厚板)跨越兩個置入壁中相距1米之柱(每個長500 mm、直徑20 mm)放置。記錄棉絮中心之下垂程度。對一個包裝中所有棉絮及多個包裝重複此操作。於設定點經一段時間量測包裝以確定壓縮對棉絮的長期影響。
密度：量測經受懸垂測試之樣品
所存在硫酸鹽的量：根據英國標準BS EN 12457－2於L/S10使用溶析液分析用於水中之粒狀廢棄物的溶出測試。
分離強度
分離強度係以克(grams/gram)表示，其係六個測試試樣之總斷裂荷載除以其總重量。
該測試係針對所接收用於測試(普通分離強度)及如下文所述加速風化測試(風化分離強度)後之礦物纖維墊實施。
圖1所示形式與尺寸之第一組六個樣品係自待測試之礦物纖維墊切割出。尺寸係：r：半徑12.7 mm；DC：中心距44.5 mm；a：25.4 mm；b：121 mm。
樣品長軸應平行於輸送機方向且樣品應在礦物墊之整個寬度上獲得。然後以相同方式獲得第二組六個樣品。
記錄第一組六個樣品之總重量W1(以克表示)。
記錄第二組六個樣品之總重量W2(以克表示)；然後將該等樣品置於預熱高壓釜中且金屬網支架上遠離室底部於35 kN/m2 下在濕蒸汽下處理一小時。然後將其移除，在100℃下於爐中乾燥5分鐘並立即測試分離強度。
為了測試分離強度，將每一樣品依次安裝於5500 Instron抗伸強度機器之夾具上且記錄最大斷裂荷載(以克或牛頓(Newton)表示)。如果所量測斷裂荷載係以牛頓表示，則藉由將其乘以101.9轉化為克數。針對每一組樣品獲得六個結果(以克表示)：第一組樣品G1、G2、G3、G4、G5及G6及第二組樣品G7、G8、G9、G10、G11及G12。
自第一組樣品使用公式普通分離強度＝(G1＋G2＋G3＋G4＋G5＋G6)/W1來計算普通分離強度。
自第二組樣品使用公式風化分離強度＝(G7＋G8＋G9＋G10＋G11＋G12)/W2來計算風化分離強度。
對絕緣產品之第二比較測試：
樣品：測試以下纖維玻璃棉絮樣品：
結論
圖1顯示礦物纖維試樣之平面圖。
(無元件符號說明)

Claims (24)

  1. 一種基本不含甲醛之黏結劑溶液，其包含：- 包含還原糖之碳水化合物或在熱固化條件下會於原位產生還原糖之碳水化合物反應物，- 選自由硫酸銨鹽、磷酸銨鹽、硝酸銨鹽及碳酸銨鹽組成之群之酸前體，- 視情況選用之羧酸或其前體，及- 視情況選用之存於水中之氨；其中該黏結劑溶液包含：基於該未固化黏結劑溶液重量為至少5%乾重之酸前體，及其中該還原糖乾重/該酸前體乾重之比率係大於或等於2.5且小於或等於13。
  2. 如請求項1之基本不含甲醛之黏結劑溶液，其中該還原糖包含右旋糖。
  3. 如請求項1之基本不含甲醛之黏結劑溶液，其中該羧酸係以銨鹽形式提供。
  4. 如請求項1之基本不含甲醛之黏結劑溶液，其中該溶液之pH係大於7。
  5. 如請求項1之基本不含甲醛之黏結劑溶液，其中該黏結劑溶液之pH在其使用條件下可防止硫酸鹽、磷酸鹽、硝酸鹽或碳酸鹽沈澱。
  6. 如請求項1之基本不含甲醛之黏結劑溶液，其中該黏結劑溶液包含至少5%之固體且小於50%之固體。
  7. 如請求項1之基本不含甲醛之黏結劑溶液，其中該黏結 劑溶液按所溶解的黏結劑固體計算包含介於0.1%與1%之間之矽烷。
  8. 如請求項1之基本不含甲醛之黏結劑溶液，其中該黏結劑溶液包含一或多種選自下列之添加劑：矽烷、礦物油、偶合劑、聚矽氧或矽氧烷、含矽之化合物、表面活性劑、親水性添加劑、疏水性添加劑、蠟及用於控制pH之物質；及其中該添加計之總重係少於5%乾重。
  9. 如請求項1之基本不含甲醛之黏結劑溶液，其中該黏結劑溶液包含基於該未固化黏結劑溶液重量為至少7%乾重之酸前體。
  10. 一種製造選自熱絕緣材料、礦物纖維產品、木板產品及鑄造用砂之產品之方法，其包含以下步驟：˙提供非紡織鬆散物質之集合；˙將黏結劑溶液施加於該鬆散物質之集合上，該黏結劑溶液係基本不含甲醛之黏結劑溶液，其包含：- 包含還原糖之碳水化合物或在熱固化條件下會於原位產生還原糖之碳水化合物反應物，- 基於未固化黏結劑溶液重量為至少5%乾重之可衍生自無機鹽之酸前體，及- 氮來源；及˙在與該鬆散物質接觸下固化該黏結劑。
  11. 如請求項10之方法，其中該鬆散物質包含礦物纖維，且該產品為礦物纖維熱絕緣材料。
  12. 如請求項10之方法，其中該產品為木板。
  13. 如請求項10之方法，其中固化該黏結劑之步驟係藉由使 該基材穿過溫度在230℃至300℃範圍內之固化爐的至少一個區域以及爐停留時間在30秒至20分鐘之範圍內來施加能量源而發生。
  14. 如請求項12之方法，其中固化該黏結劑之步驟係在壓力機之壓板間發生。
  15. 如請求項10之方法，其中該黏結劑固化時之反應基本上為Maillard反應。
  16. 如請求項10之方法，其中該黏結劑係藉由噴塗來施加。
  17. 如請求項10之方法，其中施加於該鬆散物質之集合之黏結劑溶液於20℃下具有小於1.5Pa.s且大於2 x 10-4 Pa.s之黏度。
  18. 如請求項10、11或12之方法，其中該黏結劑溶液係如請求項1至9中任一項之黏結劑溶液。
  19. 如請求項10之方法，其中該木板產品包括粗紙板、定向條狀板、粒片板、中密度纖維板及/或木面板產品。
  20. 一種材料，其包含由基本不含甲醛之黏結劑維持在一起之鬆散物質之集合，其特徵在於該材料包含多於500mg/kg選自由硫酸鹽、磷酸鹽、硝酸鹽及碳酸鹽組成之群之物質。
  21. 如請求項20之材料，其中該選自由硫酸鹽、磷酸鹽、硝酸鹽及碳酸鹽組成之群之物質主要源自黏結劑前體。
  22. 如請求項20或請求項21之材料，其中該黏結劑係經固化且包含類黑精。
  23. 如請求項20之材料，其中該鬆散物質包含礦物纖維，且 該材料係礦物纖維熱絕緣材料。
  24. 如請求項20或21之材料，其中該黏結劑係經固化且包含氮。
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