• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    A method of manufacturing mineral wool self-adhesive insulating products, comprising (a) forming mineral fibers by centrifugation of molten glass or molten rock, (b) spraying the mineral fibers, immediately after their formation, into a first liquid organic binder composition, (c) forming a mineral fiber mat coated with the first liquid organic binder composition, by depositing on a conveyor, (d) covering one side of the fiber mat. mineral by a glass fiber or organic fiber with high thermal resistance, (e) heating the mineral fiber mat, covered with the glass mat, in an oven for a period of time and at a temperature sufficient to harden the organic binder, a second liquid composition of organic binder being applied, after step (c), on the web and / or on the face of the mineral fiber mat intended to come into contact with the web of veil; the second liquid organic binder composition preferably containing components capable of reacting with the components of the first liquid organic binder composition.
    公开号:FR3049278A1
    申请号:FR1652569
    申请日:2016-03-24
    公开日:2017-09-29
    发明作者:Fabrice Ruisi；Vincent Hoffmann；Michel Janas
    申请人:Saint Gobain Isover SA France；
    IPC主号:
    专利说明:

    PROCESS FOR PRODUCING MINERAL WOOL MATTRESS
    self-adhesive
    The present invention relates to self-adhesive insulating products based on mineral wool, as well as a process for producing them.
    The manufacture of insulating products based on mineral wool comprises a step of forming the glass or rock fibers respectively by internal or external centrifugation. At the exit of the centrifugation device the very hot and still plastic fibers are stretched and carried away by a gaseous stream. Then, the still hot fibers are sprayed with a sizing composition, also called a binder. The sized fibers are then collected and plated as a mat on a collection mat, or conveyor, which passes into an oven where the binder is dried and cured by heating to temperatures of about 200 ° C.
    The conveyor is generally a gas permeable metal mat, for example a metal grid. A suction device may be provided below the conveyor.
    Due to this mode of formation of the fiber mat, the fibers do not have a random orientation, but a preferential orientation parallel to the general plane of the flat product formed. The mechanical properties of the product, such as tensile strength or compressive thickness recovery, depend essentially on the nature and amount of the cured organic binder that binds the fibers together. For obvious reasons of cost limitation and optimization of the fire resistance of the products, the organic binder content is as low as possible, generally of the order of 3 to 7% by weight.
    The mineral wool insulation products may further comprise a surfacing, typically Kraft paper, a glass mat, an aluminum foil, adhered to one or both sides of the mineral wool mat. The surfacing is typically placed on the mat of mineral fibers glued before entering the oven or out of the oven for surfacing not resistant to temperature, such as Kraft paper or some colored surfacing.
    When the Applicant has attempted to make one of the faces of such an insulating product adhesive by applying an adhesive composition directly to the surface of the fiber mat or to a surfacer of the paper or glass veil type, it has been faced with the following problem: the product, glued with its adhesive side on a vertical support such as a wall, did not stay in place. The mineral wool mattress was removed from the wall by the adhesive layer, which was still firmly attached to the vertical support. Cohesive failure within the mineral wool could be seen between the superficial layers or layers of the fiber mat and the adhesive layer closest to the substrate, whereas the layers or layers of the mattress beyond would fall under the effect of their own weight.
    Several solutions had already been proposed to remedy this lack of cohesion: wrapping of the fiber mat and use of the casing as a surfacing element made adhesive by applying a self-adhesive device such as an adhesive tape or double-adhesive film; face or glue; - Cutting and arrangement of the mineral wool fibers in an orientation perpendicular to the plane of the adhesive layer: the fibers are thus anchored in depth of the thickness of the mattress and do not tear easily; the product ISOVER CLIMCOVER Lamella Fix of the Applicant can be cited as an example of such a product - mesh in the thickness of the product: a network of son provides the connection between two surfacing; the ISOVER CLIMAVER 504 product of the Applicant, in its self-adhesive version, corresponds to this type of product. The wrapping has the disadvantage of prohibiting the cutting of the product after manufacture. The last two solutions require complex industrial processes and may prove impossible to implement for thick products.
    Of course, the Applicant could have remedied the problem of tearing the surface fibers by improving the intrinsic strength of the mineral wool mattress, that is to say by simply increasing the organic binder content of the product until the network of bonded fibers is sufficiently strong. In the field of mineral wool insulation products, however, such a practice is unsatisfactory because it would adversely affect the mechanical properties of the product, undesirably reduce the reaction to fire of the products and increase the production costs.
    The present invention therefore aims to provide a method of manufacturing insulating products based on mineral wool of which at least one side is self-adhesive and which, when they are bonded to a substrate (for example a vertical wall or a ceiling ) do not exhibit a cohesive rupture under the effect of their own weight. The problem of the lack of cohesion found at the level of the surface layer of the mattress must be overcome without the overall binder content of the insulation product being significantly increased. In other words, the binder content of the product must be substantially identical to that of the equivalent non-adhesive products available on the market, typically between 1 and 10%, preferably between 2 and 7% by weight of dry binder relative to the total weight of the product. mattress.
    After numerous tests, the Applicant has developed a relatively simple method of manufacturing insulation products, little different from the known method, which overcomes the problem of cohesive failure without significantly increasing the overall content of organic binder product insulation. In the process of the present invention the solution to the problem described above is to increase the binder content of the glass fiber mat only in the zone of weakness noted, ie the layer closest to the interfacing. The additional supply of organic binder thus selectively strengthens the cohesion of the outer layer of the mattress and effectively prevents breakage. The amount of additional binder (hereinafter sometimes referred to as "over-gluing") is, however, sufficiently low not to modify the fire resistance of the product.
    There are several ways to introduce an excess of organic binder only into the surface layer of the mineral wool mat.
    The first is to soak an interface product, such as a veil of glass or organic fibers with high thermal resistance, with a binder composition and to put this veil soaked with liquid composition on the mineral wool mat before the entering the oven, that is to say at a stage where the binder of the mattress is not yet polymerized. The excess binder provided by the web will flow, under the effect of gravity, into the fiber layer immediately in contact with the interfacing. An excess of binder content is formed locally to reinforce the bonds of the layers to be brought into contact with the self-adhesive device. In the oven, the additional binder hardens and, if necessary, reacts with the binder composition not yet hardened on the fibers and a sufficiently strong bond is formed.
    Another way of locally introducing an additional amount of binder to the surface of the mattress is to homogeneously spray the top of the fiber mat with a liquid binder composition before applying the interfacing and baking the mattress assembly. interfacing in the oven. These two types of binder introduction (application on the interfacing, application on the mattress) can of course be combined.
    The Applicant has noted with satisfaction and with a certain surprise that by proceeding in the manner described above, that is to say by bringing locally an additional amount of binder, the final self-adhesive insulation product exhibited satisfactory cohesiveness. ; the zone of fragility had disappeared and was not simply moved to greater depths of the mattress, as one might have thought a priori.
    The subject of the present invention is therefore a process for the manufacture of self-adhesive insulating products based on mineral wool, said method comprising, in order, the following successive steps: (a) forming mineral fibers by centrifugation of glass melted or molten rock, (b) spraying the mineral fibers, immediately after their formation, with a first liquid organic binder composition, (c) forming a mineral fiber mat coated with the first liquid composition of organic binder, by deposition on a conveyor, (d) the covering of a face of the mineral fiber mat with a glass fiber or organic fibers with high thermal resistance, (e) the heating of the mineral fiber mat, covered with veil of glass or organic fibers with high thermal resistance, in an oven for a period of time and at a temperature sufficient to harden the organic binder, said process being characterized by applying a second liquid organic binder composition to the web and / or the face of the mineral fiber mat to contact the web, the second liquid organic binder composition preferably containing components capable of reacting with the components of the first organic binder liquid composition, the application of the second liquid binder composition being carried out after the step (c) of forming the mattress and, preferably, before step (d) covering the mattress with the glass mat.
    The organic binder used to bond the mineral fibers to one another can be any known crosslinkable polymer system used for this purpose. By way of example, mention may be made of phenol and formaldehyde resins, phenol, urea and formaldehyde resins, phenol, urea, amine and formaldehyde resins, acrylic polymers and polyesters obtained by means of polyesters. polycondensations of monomers and / or oligomers with acid and hydroxyl functions, for example of carbohydrates and citric acid, the products resulting from the Maillard reaction between a reducing sugar and an amine. Advantageously, binder compositions containing a phenol, amine and formaldehyde-based resin having a reduced formaldehyde content as described in application WO 2008/043960 will be used.
    The first liquid composition of organic binder, sprayed onto the fibers immediately after the exit of the centrifugation device and before formation of the mattress, is not necessarily identical to the second liquid organic binder composition applied locally on one side of the mattress and / or on the glass veil. It is essential, however, that the reactive components of the two compositions be compatible with one another to produce a homogeneous or mixed or interpenetrated polymer matrix. Preferably, the reactive components of the two compositions can react together and form covalent bonds.
    In a preferred embodiment of the process of the invention the second liquid organic binder composition essentially contains the same reactive components as the first liquid organic binder composition. The second liquid binder composition may however be more concentrated or less concentrated than the first. It may also be free of certain sizing adjuncts present in the first liquid organic binder composition.
    The first and second organic binder liquid compositions are preferably water-based compositions.
    In principle, it is possible to use as interfacing any foil or organic fiber with high thermal resistance available on the market, compatible with the intended use of the finished product. It is preferably a non-woven glass fleece or a polyester fiber web as described in WO 2006/061540. A glass mat will preferably be used.
    Before being impregnated with the second liquid organic binder composition, the glass or high thermal resistance organic fiber film advantageously has a basis weight of between 20 and 100 g / m 2, preferably between 30 and 90 g / m 2. and in particular between 35 and 80 g / m 2.
    Its content of organic binder, before supersizing, is preferably between 10 and 25%, preferably between 11 and 20% by weight.
    In a preferred embodiment of the process of the present invention, the second binder composition is applied to the glass web. This application can be done for example by spraying the second binder composition by means of nozzles, by immersing the web in the second binder composition, or by coating with a "roller-liner". that is, a rotating cylinder which is in contact with both the second binder composition and the glass web.
    This third mode of application is preferred because it allows both easy control of the amount of composition transferred to the web and the use of a second binder composition significantly more viscous than the first.
    The second liquid organic binder composition preferably has a solids content of between 100 g / liter and 400 g / liter, preferably between 120 g / liter and 300 g / liter, in particular between 150 g / liter and 200 g / liter. liter.
    It must be, on the one hand, sufficiently fluid to flow along the mineral fibers in the surface layer of the fiber mat, and on the other hand sufficiently viscous so that the increase in the cohesion due to the over-gluing is sufficient.
    The dry matter content and the total amount of second organic binder liquid composition, applied to the glass mat and / or the face of the mineral fiber mat intended to come into contact with the glass mat, are such that the contribution The amount of organic binder dry matter is between 2 g / m 2 and 50 g / m 2, preferably between 3 and 30 g / m 2, and in particular between 4 and 25 g / m 2 of finished product.
    After contacting the glass web or organic fibers with high thermal resistance and the mineral fiber mat, the product not yet hardened is advantageously subjected to the action of an air flow or a vertically moving mobile conveyor a mechanical stress of compression. This flow of air, which can be created for example by a suction system located under the conveyor, promotes the flow and even spreading of the second binder composition in the surface layer of the mineral fiber mat. The step of heating the mineral fiber mat, covered with the haze, in an oven has no particularity and can be implemented in a known manner at a temperature of, for example, between 180 ° C. and 240 ° C., preferably between 200 ° C and 220 ° C for a period of between 30 seconds and 4 minutes.
    The temperature and the duration of heating will of course be adjusted according to the chemical nature of the organic binder used so as to ensure the most complete cure possible while limiting a possible thermal degradation of the cured binder.
    The intermediate insulation product obtained at the outlet of the oven is then made self-adhesive. For this, is applied to the exposed face of the glass veil a "self-adhesive device". This term includes any means, fixed on the glass veil, for sticking by simply placing the insulation product in contact with a support, usually a flat support.
    In one embodiment, the self-adhesive device is a double-sided adhesive sheet, for example a fiber-based structure (non-woven or paper) or a polymer film, having on each of its faces a layer, continuous or discontinuous, a Pressure Sensitive Adhesive (PSA).
    Pressure sensitive adhesives (PSAs) are adhesives generally present as a thin layer carried by a support. They stick almost immediately, by simple contact and application of pressure, to the material to be bonded. Although there are some PSAs with very high adhesive power, the vast majority of PSAs are considered non-structural or semi-structural adhesives, ie bonding is reversible. The glass transition temperature of the PSAs is always significantly lower than the intended use temperature. At ambient temperature, the polymer network forming the adhesive layer is therefore a viscoelastic fluid, the high mobility of the polymer chains being indeed a prerequisite for the formation of a multitude of weak bonds (van der Waals and hydrogen bonds) between the adhesive and the surface to be bonded.
    PSAs are generally characterized by tack, peel strength, and shear strength.
    There are typically three main chemical classes of pressure-sensitive adhesives: - elastomer-based PSA, - acrylic PSA and - silicone-based PSA.
    The PSAs used in the present invention are preferably acrylic PSAs.
    In a second embodiment of the process of the invention, a PSA is applied directly to the glass film of the intermediate insulation product. The manufacturing method according to the invention therefore preferably comprises, after the heating step (e), a step (f) of applying a pressure-sensitive adhesive to the exposed face of the glass mat. This PSA is preferably an acrylic adhesive.
    This step advantageously comprises spraying an aqueous solution or dispersion of the adhesive and drying and / or hardening the deposited adhesive layer, optionally with a supply of energy by heating and / or irradiation.
    The amount of PSA, expressed as dry matter, applied to the exposed face of the glass film is advantageously between 10 and 50 g / m 2, preferably between 12 and 40 g / m 2, in particular between 15 and 30 g / m 2. m ^.
    It is also conceivable to apply the PSA to the glass mat by spraying a powder of a hot-melt PSA and heating.
    The PSA layer applied to the exposed face of the glass web is not necessarily a continuous layer. It may be a discontinuous layer formed of a combination of adhesive areas, for example in the form of strips or islands, and non-adhesive areas.
    Such a discontinuous adhesive layer may be deposited for example by printing a PSA adhesive composition.
    A peelable protective polymer film can then be applied in a known manner to the adhesive layer.
    The present invention further relates to a self-adhesive insulation product based on mineral wool obtained by the method described above.
    The mineral wool self-adhesive insulating product of the present invention comprises - a mineral wool mat formed of mineral fibers bonded together by a hardened, insoluble organic binder, said mineral wool mat being able to be coated with or without a coating on the side opposite to the self-adhesive, - on one side of the mattress, a veil of glass or organic fibers with high thermal resistance bonded to the mattress by a cured organic binder, insoluble, and - a layer of a tack-sensitive adhesive. pressure (PSA) on the side of the exposed face of the glass mat, and is characterized in that the organic binder content in the surface layer of the mineral wool mat that is in contact with the glass mat is significantly greater than the organic binder content in the rest of the mineral wool mat.
    The term "surface layer" here means a layer representing approximately 10% by weight of the mineral wool mat (without the glass mat), and by "the rest of the mineral wool mattress" the complementary part up to 100% by weight of the mattress.
    The organic binder content of the rest of the mineral wool mat is due solely to the first liquid binder composition. It is assimilated in the present application to the content of combustible materials determined in accordance with EN ISO 1887. This content of combustible materials (loss on ignition, LOI) is in principle substantially the same throughout the thickness of the mattress, at the same time. except for the surface layer where the organic binder content due to over-sizing is also found. that is to say the addition of organic binder by the second liquid organic binder composition.
    The difference between the organic binder content in the surface layer (LOho) and the organic binder content of the remainder of the mattress (LOIgo) preferably corresponds to an addition of organic binder (Q) of between 2 g / m 2 and 50 g. in particular between 3 and 30 g / m 2, and ideally between 4 and 25 g / m 2 of insulation product.
    The over-sizing, or supply of organic binder by the second liquid organic binder composition, can be determined as follows:
    A sample of a surface (S) (at least 0.5 m 2) is cut from the finished product. The bonded glass veil is separated from the mineral wool mat using a suitable cutting tool taking care to separate as little as possible of the mineral fibers from the mattress.
    The total mass (Mj) of the surface sample S, freed from the haze, is determined. Then, using a suitable cutting tool, a surface layer (previously in contact with the web) corresponding to about 10% by weight of the sample is separated from the remainder of the mattress corresponding to about 90% by weight of the mattress. The mass (Mio) of the surface layer and that of the remainder of the mattress (Mgo) are precisely determined.
    In accordance with EN ISO 1887: 2014, the fuel content (LOho and LOIgo) of the two respective mass portions Mio and Mgo are determined.
    Due to the addition of binder by the second liquid organic binder composition, the LOho (expressed in%) of the surface layer of mass Pio (expressed in g) will be greater than the LOIgo (expressed in%) of the remainder of the Pgo mass (expressed in g).
    The over-sizing, that is to say the amount (Q) of binder provided by the second organic binder composition (expressed in g) can be calculated in the following manner Q = (LOIio-LOIgo) X Mio
    This value can then be expressed in g per unit area S (expressed in m 2) of finished product.
    Although the method according to the invention can be used in principle to manufacture all kinds of self-adhesive insulation products based on mineral wool, the technical problem underlying the present invention is more crucial for the products having the once a fairly low density and a large thickness. The very dense and compact products, on the one hand, and the very thin products, on the other hand, are unlikely to present a cohesive rupture as described in the introduction.
    The self-adhesive insulating products based on mineral wool of the present invention therefore advantageously have a density determined according to the NF EN 823 standard of between 10 kg / m 2 and 100 kg / m 2, preferably between 15 kg / m 2. m ^ and 80 kg / m 2, in particular between 20 kg / m 2 and 70 kg / m 2.
    Their thickness, determined according to standard NF EN 823, is advantageously between 15 mm and 200 mm, preferably between 30 mm and 150 mm, in particular between 50 mm and 120 mm.
    权利要求:
    Claims (11)
    [1" id="c-fr-0001]
    A process for manufacturing mineral wool self-adhesive insulation products, comprising (a) forming mineral fibers by centrifugation of molten glass or molten rock, (b) spraying on the mineral fibers, immediately after their formation of a first organic binder liquid composition, (c) forming a mineral fiber mat coated with the first liquid organic binder composition, by depositing on a conveyor, (d) covering one side of the mattress of mineral fibers by a veil of glass or organic fibers with high thermal resistance, (e) heating the mineral fiber mat, covered with the glass mat, in an oven for a time and at a temperature sufficient to harden the organic binder characterized in that - after step (c) and preferably before step (d) - a second organic binder liquid composition is applied to the glass veil and / o on the face of the mineral fiber mat intended to come into contact with the glass mat, the second liquid organic binder composition preferably containing components capable of reacting with the components of the first liquid organic binder composition.
    [2" id="c-fr-0002]
    2. Method according to claim 1, characterized in that the second liquid organic binder composition contains essentially the same reactive components as the first liquid organic binder composition.
    [3" id="c-fr-0003]
    3. Method according to claim 1 or 2, characterized in that it further comprises, after the step (e) of heating, a step (f) of application of a pressure-sensitive adhesive (PSA) on the exposed side of the glass veil.
    [4" id="c-fr-0004]
    4. Method according to claim 3, characterized in that the PSA is an acrylic adhesive.
    [5" id="c-fr-0005]
    5. Method according to claim 2 to 4, characterized in that the PSA is applied to the exposed face of the glass film in an amount of between 10 and 50 g / m 2, preferably between 12 and 40 g / m 2 in particular between 15 and 30 g / m 2.
    [6" id="c-fr-0006]
    6. Method according to any one of the preceding claims, characterized in that the glass film has, before application of the second liquid organic binder composition, a weight per unit area of between 20 and 100 g / m 2, preferably between 30 and 90 g / m 2 and in particular between 35 and 80 g / m 2.
    [7" id="c-fr-0007]
    7. Method according to any one of the preceding claims, characterized in that the second liquid organic binder composition has a solids content of between 100 g / liter and 400 g / liter.
    [8" id="c-fr-0008]
    8. Method according to any one of the preceding claims, characterized in that the solids content and the total amount of second organic binder liquid composition, applied to the glass mat and / or the face of the mineral fiber mat. intended to come into contact with the glass mat, are such that the dry matter supply of organic binder is between 2 g / m 2 and 50 g / m 2 of insulation product.
    [9" id="c-fr-0009]
    9. Self-adhesive insulating product based on mineral wool comprising - a mineral wool mat formed of mineral fibers bonded together by a hardened, insoluble organic binder, - on one side of the mattress, a veil of glass or organic fibers high heat resistance, bonded to the mattress by a hardened, insoluble organic binder, and - a layer of a pressure-sensitive adhesive on the exposed side of the glass mat, the organic binder content in the surface layer of the wool mattress mineral which is in contact with the glass web or organic fibers with high thermal resistance being significantly higher than the organic binder content in the rest of the mineral wool mat.
    [10" id="c-fr-0010]
    10. Self-adhesive insulation product according to claim 9, characterized in that the difference between the organic binder content in the surface layer (LOho) and the organic binder content of the rest of the mattress (LOIgo) corresponds to a contribution of organic binder (Q) of between 2 g / m 2 and 50 g / m 2 of insulation product.
    [11" id="c-fr-0011]
    11. Self-adhesive insulation product according to claim 9 or 10, characterized in that it has a density of between 10 kg / m 2 and 100 kg / m 2, preferably between 15 kg / m 2 and 80 kg. / m®, in particular between 20 kg / m 2 and 70 kg / m 2.
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    同族专利:
    公开号 | 公开日
    FR3049278B1|2018-04-13|
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    WO2017162955A1|2017-09-28|
    RU2728750C2|2020-07-30|
    EP3433215A1|2019-01-30|
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    CN109071335A|2018-12-21|
    CN109071335B|2021-07-27|
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    US10941073B2|2021-03-09|
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    US20190100458A1|2019-04-04|
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    法律状态:
    2017-03-24| PLFP| Fee payment|Year of fee payment: 2 |
    2017-09-29| PLSC| Publication of the preliminary search report|Effective date: 20170929 |
    2018-03-22| PLFP| Fee payment|Year of fee payment: 3 |
    2020-03-25| PLFP| Fee payment|Year of fee payment: 5 |
    2021-03-31| PLFP| Fee payment|Year of fee payment: 6 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1652569A|FR3049278B1|2016-03-24|2016-03-24|METHOD FOR MANUFACTURING SELF-ADHESIVE MINERAL WOOL MATTRESS|
    FR1652569|2016-03-24|FR1652569A| FR3049278B1|2016-03-24|2016-03-24|METHOD FOR MANUFACTURING SELF-ADHESIVE MINERAL WOOL MATTRESS|
    PCT/FR2017/050572| WO2017162955A1|2016-03-24|2017-03-14|Method for manufacturing self-adhesive mineral wool pads|
    RU2018137221A| RU2728750C2|2016-03-24|2017-03-14|Method of producing self-adhesive mats from mineral wool|
    CN201780019323.7A| CN109071335B|2016-03-24|2017-03-14|Method for producing self-adhesive mineral wool mats|
    EP17714858.2A| EP3433215B1|2016-03-24|2017-03-14|Method for manufacturing self-adhesive mineral wool pads|
    BR112018067729A| BR112018067729A2|2016-03-24|2017-03-14|self-adhesive mineral wool mattress manufacturing process|
    US16/085,801| US10941073B2|2016-03-24|2017-03-14|Method for manufacturing self-adhesive mineral wool pads|
    CA3016268A| CA3016268A1|2016-03-24|2017-03-14|Method for manufacturing self-adhesive mineral wool pads|
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