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ES2986038T3 - Tablero de fibras minerales - Google Patents

Tablero de fibras minerales Download PDF

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ES2986038T3
ES2986038T3 ES07712115T ES07712115T ES2986038T3 ES 2986038 T3 ES2986038 T3 ES 2986038T3 ES 07712115 T ES07712115 T ES 07712115T ES 07712115 T ES07712115 T ES 07712115T ES 2986038 T3 ES2986038 T3 ES 2986038T3
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insulation board
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Roger Jackson
Tony Aindow
George Baybutt
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Knauf Insulation SPRL
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
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    • 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
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/10—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing oxygen
    • D06M13/184—Carboxylic acids; Anhydrides, halides or salts thereof
    • D06M13/207—Substituted carboxylic acids, e.g. by hydroxy or keto groups; Anhydrides, halides or salts thereof
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/322—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing nitrogen
    • D06M13/46—Compounds containing quaternary nitrogen atoms
    • D06M13/463—Compounds containing quaternary nitrogen atoms derived from monoamines
    • 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
    • E04B1/78—Heat insulating elements
    • E04B1/80—Heat insulating elements slab-shaped
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
    • D06M2101/40—Fibres of carbon
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M2200/00—Functionality of the treatment composition and/or properties imparted to the textile material
    • D06M2200/30—Flame or heat resistance, fire retardancy properties
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00—Inorganic fibres
    • D10B2101/02—Inorganic fibres based on oxides or oxide ceramics, e.g. silicates
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/06—Load-responsive characteristics
    • D10B2401/063—Load-responsive characteristics high strength
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/02—Cross-sectional features
    • D10B2403/024—Fabric incorporating additional compounds
    • D10B2403/0243—Fabric incorporating additional compounds enhancing functional properties
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/20—Industrial for civil engineering, e.g. geotextiles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]

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Abstract

Un tablero de fibra mineral de alta densidad que tiene un aglutinante libre de formaldehído tiene una resistencia aceptable y una buena estabilidad dimensional. (Traducción automática con Google Translate, sin valor legal)

Description

DESCRIPCIÓN
Tablero de fibras minerales
Esta invención se refiere a un producto aislante de fibra mineral que tiene un aglutinante libre de formaldehído.
Aglutinantes estándar de la industria usados para el aislamiento de fibra, por ejemplo, el aislamiento de lana de vidrio y lana de roca, se basan en fenol formaldehído. Aunque tales aglutinantes pueden proporcionar propiedades adecuadas a los productos aislantes, desde hace algún tiempo existe el deseo de abandonar el uso de fenol formaldehído, particularmente debido a consideraciones medioambientales.
Se han propuesto anteriormente sistemas aglutinantes tradicionales a base de poliéster, pero no han ganado aceptación en la industria del aislamiento, particularmente porque su resistencia para mantener unidas las fibras minerales, especialmente cuando se exponen a la humedad o la intemperie, se ha percibido como insuficiente.
Hasta la fecha, sólo se ha utilizado a escala industrial un sistema aglutinante de aislamiento mineral con bajo contenido de formaldehído en aislamiento de lana de vidrio; el mismo está basado en ácido poliacrílico y lo suministra Rohm&Haas. Desafortunadamente, la naturaleza altamente ácida de este tipo de aglutinantes puede causar una corrosión excesiva en la planta de fabricación a menos que se realice una inversión significativa en equipos resistentes a ácidos. La patente US-5.977.232 describe un aglutinante libre de formaldehído para aislamiento de lana de vidrio basado en un ácido policarboxílico. La solicitud de patente europea EP1698598A describe el uso de un medidor de corrosión para intentar mitigar los problemas asociados con las resinas aglutinantes de fibra de vidrio basadas en ácido policarboxílico. Además, si bien la resistencia de estos aglutinantes es aceptable para algunas aplicaciones, no es tan buena como la de los aglutinantes a base de fenol formaldehído comúnmente utilizados.
El documento US-4720295 describe un proceso controlado para fabricar una masa fundida químicamente homogénea para producir aislamiento de lana mineral. El documento EP0768283A1 describe la producción de fibras minerales. El documento EP0911361A1 describe polisacáridos termoendurecibles. El documento US-5977232 describe una composición acuosa de curado acelerado, libre de formaldehído, para unir telas no tejidas resistentes al calor de fibra de vidrio. El documento US-2004/033747A1 describe una composición acuosa libre de formaldehído y un aislamiento de fibra de vidrio que la incluye. El documento EP1396509A1 describe un tablero de baja emisión de formaldehído. El documento WO2005/080659A1 describe un aislamiento compuesto de fibras inorgánicas. El documento US-2006/005580A1 divulga un producto aislante, tal como un producto de aislamiento térmico, y un procedimiento de producción del mismo. El documento EP1698598A1 describe un procedimiento para reducir la corrosión de un sistema de agua de lavado para líneas de formación de fibra de vidrio. El documento WO2007/014236A2 (presentado como PCT/US-2006/028929) describe aglutinantes y materiales fabricados con los mismos.
No se ha pensado que sea posible proporcionar un sistema aglutinante libre de formaldehído utilizable a escala industrial que confiera características a los productos aislantes de lana mineral que puedan igualar o incluso superar las obtenidas con aglutinantes de formaldehído.
Según un aspecto, la presente invención proporciona un tablero aislante de fibra mineral como se define en la reivindicación 1. Otros aspectos se definen en otras reivindicaciones independientes. Características preferidas y/o alternativas se definen en las reivindicaciones dependientes.
Como se usa en el presente documento, el término libre de formaldehído significa que la composición está sustancialmente libre de formaldehído, preferiblemente no libera formaldehído sustancial como resultado del secado o curado y/o preferiblemente comprende menos de una parte por millón en peso de formaldehído.
Las características deseadas del tablero aislante de fibra mineral se pueden evaluar midiendo la resistencia a la compresión ordinaria y/o la resistencia a la compresión erosionada y/o el cambio de espesor después del autoclave.
La invención puede ser particularmente útil en aplicaciones en donde la estabilidad dimensional del tablero aislante es importante. Es sorprendente que un aglutinante libre de formaldehído pueda conferir la resistencia y/o estabilidad dimensional que se ha encontrado.
El tablero aislante puede ser: una barrera contra incendios; una protección contra incendios; revestimiento para edificios; una teja del techo; un tablero del techo; aislamiento térmico para maquinaria de alta temperatura, por ejemplo, generadores, hornos y plantas industriales; aislamiento de paredes de cimientos, por ejemplo, para uso en sótanos o en una pared o partición entre una habitación y una capa de tierra y/o roca. El tablero aislante podrá utilizarse para proporcionar aislamiento térmico y/o acústico.
El contenido de aglutinante curado puede estar en el intervalo de 0,5 % - 15 % en peso determinado, por ejemplo, por pérdida por ignición. Un contenido de aglutinante curado de 0,5-5 % en peso, particularmente 1,5-3,5 % en peso puede proporcionar características adecuadas, particularmente con respecto a uno o más de los productos mencionados anteriormente.
El aglutinante se basa en un azúcar reductor. El aglutinante puede:
• basarse en reductosis; y/o
• basarse en un aldehído que contenga azúcares y/o
• incluir al menos un producto de reacción de un reactivo de carbohidrato y un reactivo de amina; y/o
• incluir al menos un producto de reacción de un azúcar reductor y un reactivo de amina; y/o
• incluyen al menos un producto de reacción de un reactivo de carbohidrato y un reactivo de sal de amonio de ácido policarboxílico; y/o
• incluye al menos un producto de reacción de una reacción de Maillard.
El aglutinante puede estar basado en una combinación de un ácido policarboxílico, por ejemplo, ácido cítrico, un azúcar, por ejemplo, dextrosa, y una fuente de amoniaco, por ejemplo una solución de amoniaco. Puede estar basado en una combinación de citrato de amonio y dextrosa. Cuando el aglutinante se basa en azúcares y/o ácido cítrico y/o comprende grupos -OH significativos, es particularmente sorprendente que se puedan alcanzar tales niveles de rendimiento. Se habría pensado que los grupos -OH, por ejemplo, en los azúcares y/o el ácido cítrico, estarían fácilmente sujetos a hidrólisis y que esto sería perjudicial para la resistencia, particularmente la resistencia a la intemperie y/o la estabilidad dimensional.
El aglutinante puede comprender un compuesto que contiene silicio, particularmente un silano; éste puede ser un compuesto aminosustituido; puede ser un éter sililico; puede facilitar la adherencia del aglutinante a las fibras minerales.
El aglutinante puede comprender melanoidinas; puede ser un aglutinante termoestable; puede ser curable térmicamente.
El aglutinante puede ser uno de los descritos en la solicitud de patente internacional n° PCT/US2006/028929.
El tablero aislante puede tener
• un espesor nominal en el intervalo de 20 a 200 mm; y/o
• una resistencia térmica R de R > 1,7 m2K/W, preferiblemente R > 2 m2K/W en un espesor de 100 mm; y/o • una densidad comprendida entre 100 y 200 kg/m3, en particular entre 130 y 190 kg/m3.
La densidad puede ser del orden de 110 kg/m3, por ejemplo, en el intervalo de 100 a 120 kg/m3; puede ser del orden de 140 kg/m3, por ejemplo en el intervalo de 130 a 150 kg/m3; del orden de 180 kg/m3, por ejemplo en el intervalo de 170 a 190 kg/m3. Tal densidad puede proporcionar productos con características deseables.
Las fibras minerales pueden ser lana de vidrio o lana de roca; las fibras pueden tener un diámetro medio comprendido entre 2 y 9 micrómetros o ser microfibras de menor diámetro; pueden tener una longitud media entre 8 y 80 mm. Las fibras minerales pueden estar rizadas.
Preferiblemente, el tablero aislante tiene buena estabilidad en una prueba de contracción a alta temperatura. El rendimiento en dicha prueba generalmente depende del espesor y la densidad del tablero. La Tabla 1 muestra el rendimiento deseado para un tablero de 80 mm de espesor con una densidad de 150 kg/m3 . El bajo nivel de contracción de alta densidad es particularmente sorprendente ya que se suponía que la contracción estaba determinada principalmente por la composición de la fibra y poco influenciada por el aglutinante.
A continuación, se describe un ejemplo no limitativo de la invención.
Se preparó un aglutinante acuoso mezclando entre sí:
Este aglutinante se utilizó en la fabricación de un tablero para techos de lana de roca en una línea de fabricación estándar, rociándose el aglutinante sobre las fibras justo después de la fibración y recogiéndose las fibras recubiertas, ensamblándolas en una estera, comprimiéndolas y curándolas de la forma habitual.
El tablero de techo curado tenía:
• un contenido de aglutinante de aproximadamente 3 % en peso, determinado por pérdida por ignición
• un espesor de unos 80 mm
• una densidad de unos 150 kg/m3
Las características deseadas y los resultados obtenidos se establecen en la Tabla 1:
Tabla 1
La comparación en la tabla con un producto equivalente que no contiene un aglutinante de fenol formaldehído muestra que, sorprendentemente, la invención puede proporcionar una estabilidad dimensional mejorada, es decir, menos cambio de espesor después del autoclave y una contracción de alta densidad mejorada.
Pruebas de resistencia a la compresión ordinaria y resistencia a la compresión desgastada:
La resistencia a la compresión ordinaria se determina según la norma británica BS EN 826: 1996 (incorporada aquí como referencia).
La resistencia a la compresión desgastada se determina según la norma británica BS EN 826: 1996 sobre muestras que han sido sometidas al siguiente procedimiento de intemperismo acelerado: las muestras se cortan al tamaño adecuado y luego se colocan en un autoclave precalentado y se acondicionan en un estante de malla de alambre lejos del fondo de la cámara bajo vapor húmedo a 35 kN/m2 durante un hora. Luego se retiran, se secan en un horno a 100 0C durante cinco minutos y se prueba inmediatamente su resistencia a la compresión.
En ambos casos, la resistencia a la compresión se determina en la dirección del espesor del producto; las dimensiones de la cara de las muestras en contacto con el aparato de prueba de compresión son preferiblemente 200 mm x 200 mm.
Prueba de cambio de espesor después del autoclave:
El espesor de las muestras se determina, por ejemplo, según la norma británica BS EN 823: 1995 y se registra. Luego las muestras se colocan en un autoclave precalentado y se acondicionan en un estante de malla de alambre lejos del fondo de la cámara bajo vapor húmedo a 35 kN/m2 durante una hora. A continuación, se retiran, se secan en estufa a 100 0C durante cinco minutos e inmediatamente se vuelve a medir su espesor. El cambio de espesor después del autoclave se calcula como (((espesor después del autoclave)-(espesor antes del autoclave))/(espesor antes del autoclave)) x 100.
Prueba de contracción de alta densidad:
Se cortan al azar cuatro muestras de 100 mm x 75 mm de un tablero aislante para probarlas utilizando una sierra de cinta o equivalente para garantizar bordes cuadrados y rectos. La anchura y la longitud en la posición central de las caras superior e inferior se miden, por ejemplo, utilizando una regla metálica en mm. La longitud promedio l1 y el ancho promedio w1 se calculan a partir de estas mediciones para cada muestra. Para cada muestra, se mide el espesor en la posición central de cada borde de la muestra y se calcula el espesor medio t1 a partir de estas mediciones.
Cada muestra se coloca individualmente en el centro de un horno de mufla mantenido a una temperatura de 800 °C. La muestra se retira del horno después de 30 minutos y se deja enfriar a temperatura ambiente sobre una bandeja de alambre. Cuando está fría, el ancho, largo y espesor de la muestra se miden de la misma manera que antes y el ancho promedio w2, largo l2 y espesor t2 se calculan de la misma manera.
La contracción de la muestra se calcula mediante la fórmula:
Contracción = (((l1xw1xt1)-(l2xw2xt2))/(l1xw1xt1)) x 100
La contracción de alta densidad se calcula como el promedio del % de contracción de las cuatro muestras.

Claims (11)

  1. REIVINDICACIONES
    i.Un tablero aislante de fibra mineral que tiene una densidad en el intervalo de 100-200 kg/m3 que comprende fibras minerales y un aglutinante orgánico libre de formaldehído basado en un azúcar reductor y que tiene:
    a) una resistencia a la compresión ordinaria de al menos 60 kPa; y
    b) una resistencia a la compresión intemperizada de al menos 25 kPa; y
    c) un cambio de espesor inferior al 6 % después del autoclave.
  2. 2. Un tablero aislante de fibra mineral según la reivindicación 1, en donde la resistencia a la compresión ordinaria es de al menos 70 kPa, preferiblemente de al menos 80 kPa.
  3. 3. Un tablero aislante de fibra mineral según cualquiera de las reivindicaciones anteriores, en donde la resistencia a la compresión a la intemperie es de al menos 30 kPa, preferiblemente de al menos 40 kPa.
  4. 4. Un tablero aislante de fibra mineral según cualquiera de las reivindicaciones anteriores, en donde el cambio de espesor después del autoclave es inferior al 5 %, preferiblemente inferior al 2 %.
  5. 5. Un tablero aislante de fibra mineral según cualquiera de las reivindicaciones anteriores, en donde las fibras son fibras de lana de roca.
  6. 6. Un tablero aislante de fibra mineral según cualquiera de las reivindicaciones anteriores, en donde el contenido de aglutinante está entre 0,5 y 5 % en peso.
  7. 7 Un tablero aislante de fibra mineral según cualquiera de las reivindicaciones anteriores, en donde el aglutinante comprende al menos un producto de reacción de Maillard.
  8. 8. Un tablero aislante de fibra mineral según cualquiera de las reivindicaciones anteriores, en donde el aglutinante se basa en productos de reacción obtenidos curando una solución acuosa que comprende ácido cítrico, amoníaco y dextrosa.
  9. 9. Un tablero aislante de fibra mineral según cualquier reivindicación anterior, en donde el producto tiene una densidad en el intervalo de 130 a 190 kg/m3.
  10. 10. Uso de un tablero aislante de fibra mineral según cualquier reivindicación anterior para una aplicación seleccionada entre:
    a) una barrera contra incendios
    b) protección contra incendios
    c) revestimiento para edificios
    d) tejas del techo
    e) un tablero de techo
    f) aislamiento térmico para maquinaria de alta temperatura
    g) muro de cimentación para sótanos.
  11. 11. Un procedimiento para fabricar un tablero aislante de fibra mineral que tiene una densidad en el intervalo de 100 a 200 kg/m3 que tiene:
    a) una resistencia a la compresión ordinaria de al menos 60 kPa; y
    b) una resistencia a la compresión intemperizada de al menos 25 kPa; y
    c) un cambio en el espesor de menos del 6 % después del autoclave que comprende las etapas de: i) aplicar a las fibras minerales un aglutinante orgánico libre de formaldehído a base de un azúcar reductor en solución acuosa y
    ii) curar el producto.
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