Mineral Wool Fiber Mats, Method for Producing Same, and Use

Abstract

The invention relates to mineral wool fiber mats, which are stabilized by means of a binder made of polymers funtionalized with epoxy groups and/or with carboxyl groups and selected cross-linking agents. Said mats can be used as an insulating material and are characterized by low or no formaldehyde emissions.

1 . A mineral wool fiber mat bound with a binder containing an epoxy and/or carboxyl functionalized emulsion copolymer and an amine and/or an amine
 derivative as crosslinker.   
     
     
         2 . The mineral wool fiber mat according to  claim 1  wherein the epoxy and/or carboxyl functionalized emulsion copolymer is a polyvinyl ester, a polyacrylate or a polyalkenyl aromatic including interpolymerized units derived from glycidyl
 esters of ethylenically unsaturated mono- or dicarboxylic acids, and/or including interpolymerized units derived from ethylenically unsaturated mono- or dicarboxylic acids, salts or anhydrides. 
 
     
     
         3 . The mineral wool fiber mat according to  claim 2  wherein the epoxy and/or carboxyl functionalized emulsion copolymer derives from alkenyl aromatics, preferably from styrene, and/or from esters of acrylic acid and/or methacrylic acid and includes interpolymerized units derived from glycidyl esters of ethylenically unsaturated monocarboxylic acids, preferably from glycidyl esters of acrylic acid and/or methacrylic acid, and/or includes interpolymerized units derived from ethylenically unsaturated mono- or dicarboxylic acids, salts or anhydrides. 
     
     
         4 . The mineral wool fiber mat according to  claim 2  wherein the epoxy and/or carboxyl functionalized emulsion copolymer derives from esters of α, β-ethylenically unsaturated C 3 -C 8 -mono- or dicarboxylic acids and includes interpolymerized units derived from glycidyl esters of ethylenically unsaturated monocarboxylic acids, preferably from glycidyl esters of acrylic acid and/or methacrylic acid, and/or includes interpolymerized units derived from ethylenically unsaturated mono- or dicarboxylic acids, salts or anhydrides. 
     
     
         5 . The mineral wool fiber mat according to  claim 2  wherein the epoxy and/or carboxyl functionalized emulsion copolymer derives from one or more vinyl esters and includes interpolymerized units derived from glycidyl esters of ethylenically unsaturated monocarboxylic acids, preferably from glycidyl esters of acrylic acid and/or methacrylic acid, and/or includes interpolymerized units from ethylenically unsaturated mono- or dicarboxylic acids, salts or anhydrides, and/or includes interpolymerized units derived from ethylenically unsaturated mono- or dicarboxylic acids, salts or anhydrides. 
     
     
         6 . The mineral wool fiber mat according to  claim 5  wherein the epoxy functionalized emulsion copolymer in addition to the structural units derived from one or more vinyl esters contains further structural units derived from esters of α, β-ethylenically unsaturated C 3 -C 8 -mono- or dicarboxylic acids with C 1 -C 8  alkanols, from α, β-ethylenically unsaturated C 3 -C 8 -mono- or dicarboxylic acids, from olefins or from a combination of two or more of these monomers. 
     
     
         7 . The mineral wool fiber mat according to  claim 2  wherein the epoxy functionalized emulsion copolymer is selected from the group of copolymers derived from vinyl esters of saturated carboxylic acids and from glycidyl esters of ethylenically unsaturated carboxylic acids, of copolymers derived from vinyl esters of saturated carboxylic acids, from esters of acrylic acid and/or methacrylic acid and/or fumaric acid and/or maleic acid with C 1 -C 8 -alkanols and from glycidyl esters of ethylenically unsaturated carboxylic acids, of copolymers derived from vinyl esters of saturated carboxylic acids, from ethylene, from ethylenically unsaturated carboxylic acids and and from glycidyl esters of ethylenically unsaturated carboxylic acids, of copolymers derived from vinyl esters, ethylene, esters of acrylic acid and/or methacrylic acid and/or fumaric acid and/or maleic acid with C 1 -C 8 -alkanols, from ethylenically unsaturated carboxylic acids and from glycidyl esters of ethylenically unsaturated carboxylic acids, of copolymers derived from esters of acrylic acid and/or methacrylic acid, of ethylenically unsaturated carboxylic acids and from glycidyl esters of ethylenically unsaturated carboxylic acids, of copolymers derived from styrene with butadiene and/or from esters of acrylic acid and/or methacrylic acid with C 1 -C 8 -alkanols, from ethylenically unsaturated carboxylic acids and from glycidyl esters of ethylenically unsaturated carboxylic acids. 
     
     
         8 . The mineral wool fiber mat according to  claim 7  wherein the polymer is an epoxy functionalized polyvinyl ester containing at least 50% by weight of vinyl acetate monomer units. 
     
     
         9 . The mineral wool fiber mat according to at least one of  claim 1  wherein the binder is introduced in the form of an aqueous dispersion of the polymer. 
     
     
         10 . The mineral wool fiber mat according to at least one of  claim 1  wherein the binder content is in the range from 0.1% to 10% by weight and preferably in the range from 0.5% to 5% by weight. 
     
     
         11 . The mineral wool fiber mat according to at least one of  claim 1  wherein the crosslinker is selected from the group of mono- or polyamines, preferably aliphatic mono- or diamines or aromatic mono- or diamines. 
     
     
         12 . The mineral wool fiber mat according to at least one of  claim 1  wherein the crosslinker is selected from the group of amides having one or more amide groups, more particularly polyaminoamides and very particularly preferably the condensation products of unsaturated aliphatic acids with polyamines. 
     
     
         13 . The mineral wool fiber mat according to  claim 12  wherein the crosslinker is selected from the group of polyaminoamides having an ASTM D 2073 amine number between 100 and 2000 mg of KOH/g of crosslinker, preferably between 250 and 1000 mg of KOH/g of crosslinker. 
     
     
         14 . The mineral wool fiber mat according to  claim 12  wherein the crosslinker used is neither alkoxylated nor hydroxyalkylated. 
     
     
         15 . The mineral wool fiber mat according to at least one of  claim 1  wherein the crosslinker is used in amounts ranging from 0.1% to 10% by weight, based on the binder, preferably between 1-10% by weight and more particularly between 2-7% by weight. 
     
     
         16 . A process for producing the mineral wool fiber mat according to  claim 1  comprising the steps of
 i) applying a crosslinkable composition containing an epoxy and/or carboxylfunctionalized emulsion copolymer and a crosslinker selected from the group of amines or amine derivatives to mineral wool fibers, and 
 ii) consolidating the mineral wool fibers to form a bound mineral wool fiber mat by crosslinking the binder. 
 
     
     
         17 . The process according to  claim 16  wherein the crosslinkable composition is applied in the form of an aqueous dispersion. 
     
     
         18 . The use of the mineral wool fiber mat according to any one of  claim 1  as an insulating material, more particular more particularly for insulating, more particularly thermally insulating built structures and structural objects of any kind, preferably for insulating roofs.