DE102005056790A1 - Binder for production of formaldehyde-free bound mineral wool or glass wool product e.g. insulating board comprises aqueous curable phenol-formaldehyde resin binder dispersion containing hydroxy(alkyl)amine or diamine and activated silane - Google Patents

Abstract

Binder (I) for mineral wool contains aqueous phenol-formaldehyde resin dispersion, (alkylated) hydroxy(alkyl)amine or diamine compound(s) of molecular weight not > 20000 g/mole and activated silane(s) obtained by reacting organosilane(s) with an enolizable ketone having carbonyl or hydroxyl group(s) and aromatic hydroxyl compound(s) and/or activated heterocycle(s). Binder (I) mineral wool contains an aqueous dispersion of phenol-formaldehyde resin(s), optionally alkylated hydroxy(alkyl)amine or diamine compound(s) of formula (1) and of molecular weight not > 20000 g/mole and activated silane(s) obtained by reacting organosilane(s) selected from mono-, di- and tri-alkoxysilanes having a 1-8 carbon (C) alkoxy group containing 2-10 C aminoalkyl or 2-10 C N-aminoalkyl group(s), 3-(2-aminoethylamino)propyl-trimethoxysilane, di[3-(trimethoxysilyl)propyl]amine, 3-aminopropylsilantriol, aminosilane with ethoxylated nonyl-phenolate and/or trimethoxy-{3-[3-(benzylaminopropyl)]-aminopropyl}-silane hydrochloride with a 3-12 C enolizable ketone having carbonyl or hydroxyl group(s) and also aromatic hydroxyl compound(s), selected from dihydroxybenzenes, especially 1,3-, 1,2- and 1,4-dihydroxybenzene, and their hydroxymethylated compounds, especially hydroxymethylated resorcinol or pyrocatechol, e.g. 2,4- and 2,3-dihydroxyphenylmethanol, and polyhydroxymethylated derivatives of these activated aromatics, e.g. 2,3-dihydroxy-4-hydroxymethyl- and 4,5-dihyddroxy-2-hydroxymethyl-phenylmethanol, trihydroxybenzenes, especially 1,3,5- and 1,2,3-trihydroxybenzene, their mono- and dihydroxymethylated compounds, e.g. 2,3,4- and 2,4,6-trihydroxyphenylmethanol, C-alkylated compounds of phenol or resorcinol, e.g. 1-hydroxy-2-, -3- and -4-methylbenzene, 2-methylresorcinol, self-condensation products of the hydroxymethylated compounds, e.g. bis-2,4-dihydroxyphenylmethane, activated heterocycle(s), e.g. pyrrole, thiophene, their mono- or dialkylated compounds or condensed ring derivatives, especially indole, thioindole, di- and tri-hydroxynaphthalenes and mixtures of these substances: (R2)(R3)N-[-CH2]n-O-R1 (1); R1 : H or -[CH2])n-N(R2)(R3); n : 2-10; R2, R3 : H or -[(CH2)n-O]m-R1; m : 1-50 . Independent claims are included for (1) composition containing the cited components; (2) binder for mineral wool containing the composition; (3) production of formaldehyde-free bound mineral wool with this binder; (4) bound mineral wool product. An independent claim is included for bound mineral wool products produced by this process.

Description

The The present invention relates to a mineral wool binder according to the claim 1 and a method for producing bonded mineral wool according to claim 13th

In the production of bonded mineral wool products from a glass or mineral melt, it has long been proven, after the fraying of the melt to apply a binder phenol-formaldehyde resin-based on the still hot fibers. This is preferably done in the chute following the defibration, for example, according to the Düsenblasverfahren according to the DE 35 09 426 A1 ,

in this connection is a phenol-formaldehyde resin as the best known binder of the Prior art preferably on the fibers as an aqueous solution, or Dispersion, sprayed, the phenol-formaldehyde resin is then due to still relatively polymerize high temperatures of the fibers on the fiber surface begins and by the polymerization process the individual fibers, especially at intersections of fibers, interconnects, because the fibers that lie on top of each other at a crossing point pass through there solidified resin droplets more or less embedded and thus the displaceability the individual fibers is initially hindered each other and later at Harden by means of hot gases, For example, in a tunnel oven, substantially completely prevented becomes.

Such a binder is used for example in the US 3,231,349 described. For reasons of environmental protection and occupational safety reasons, more and more attempts are now being made to replace the conventional phenolic resin binders with alternative, formaldehyde-free binders, due to their formaldehyde content and their formaldehyde emission.

For example, describes the EP 0 583 086 B2 a curable, formaldehyde-free aqueous binder composition for glass fibers based on polymeric polyacids having at least two carboxylic acid groups or anhydride groups comprising a polyol having at least two hydroxyl groups and a phosphorus-containing catalyst, wherein an equivalent ratio of COOH group to OH group is 0: 0.01 to 1: 3 must exist.

As a polymeric polyacid is in the EP 0 583 086 B2 For example, polyacrylic acid described.

When Polyol is preferably a β-hydroxyalkylamide, For example, (N, N-di (β-hydroxyethyl)] - adipamide, used, however, you can for example, ethylene glycol, glycerol, pentaerythrol, trimethylolpropane, Sorbitol, sucrose, glucose, resorcinol, catechol, pyrogallol, glycosylated Ureas, 1,4-cyclohexanediol, Diethanolamine or triethanolamine can be used.

Similar binder compositions for mineral fibers, for example, from the US 6,331,350 B1 . EP 0 990 727 A1 . EP 0 990 728 A1 and EP 0 990 729 A1 known. The enumerated documents of the prior art also employ a polyacrylic acid as the polymeric polyacid. The polyol used there are also alkanolamines and glycols.

In addition, the describes EP 0 882 074 B1 Binder compositions for mineral fibers based on polyacrylic acids and glycols as polyols.

All to phenol-formaldehyde resins alternative binder compositions However, the state of the art is currently mainly because of their lack of water resistance only conditionally for the production of mineral wool products suitable, so that, for example, based on polyacrylate resins Binders the practical use for the production of mineral wool products usually denied so far.

On the one hand These disadvantages could be detected for the first time with the parallel application of the Applicant of the present application with the same filing date and the title "Formaldehyde-free Binders ", attorney docket GH0780, application number ... can be eliminated. On this application will hereby incorporated by reference.

On the other hand, the chemical industry has now made available precondensed phenol-formaldehyde resins, which in and of themselves already have a reduced free formaldehyde content, but are postcrosslinked with additional formaldehyde to improve the resin and binder properties, in particular the water resistance have to. As a result, formaldehyde emissions are on due to its high vapor pressure and the relatively slow cross-linking reaction between polymer chains almost inevitable.

outgoing from the prior art of the commercially available formaldehyde-reduced Phenolharzbindemittel has the applicant in the development new environmentally friendly Binder in addition to an altered one Basic chemistry of binders - such as in the cited patent application - for the purposes of mineral wool production the task is set, with the classical phenol formaldehyde resins despite their formaldehyde content to formaldehyde-free binders to get.

The solution This object is achieved by a composition according to claim 2 and a binder according to claim 1 and 11.

One Process for the production of formaldehyde-free bonded mineral wool according to claim 13 solves the Task as well.

• – wenigstens eine Amin-Verbindung mit der allgemeinen Formel (1)
  
  worin R1, R2 und R3 unabhängig voneinander gleich oder ungleich H und R1 der allgemeinen Formel (2) entspricht:
  
  mit einem Wert für n von 2 – 10 und R2 und R3 unabhängig voneinander gleich oder ungleich H sind oder der allgemeinen Formel (3) entsprechen:
  
  , wobei m einen Wert von 1 – 50 annehmen kann und die Molekularmasse der Amin-Verbindung ungefähr 20 000 g/mol nicht übersteigt;
• – wenigstens ein aktiviertes Silan, • welches erhältlich ist durch eine Umsetzung eines Silans, ausgewählt aus der Gruppe: Mono-, Di-, und Trialkoxysilanen mit einer C₁ bis C₈-Alkoxygruppe, wobei das Alkoxysilan wenigstens eine C₂ bis C₁₀-Aminoalkylgruppe oder eine C₂ bis C₁₀-N-aminoalkylgruppe trägt; 3(2-Aminoethylamino)propyl-trimethoxysilan; (MeO)₃-Si-(CH₂)₃-NH-(CH₂)₃-Si-(OMe)₃; 3-Aminopropylsilantriol; Aminosilan mit ethoxyliertem Nonylphenolat; Phenyl-CH₂-NH-(CH₂)₃-NH-(CH₂)₃-Si-(OMe)₃·HCl; sowie deren Mischungen; mit • einem enolisierbaren Keton mit wenigstens einer Carbonylgruppe oder einem Keton mit wenigstens einer OH-Gruppe, wobei das Keton 3 bis 12 C-Atome enthält; sowie
• – wenigstens eine aromatische Hydroxyverbindung, ausgewählt aus der Gruppe bestehend aus: Dihydroxybenzolen, insbesondere 1,3-Dihydroxybenzol,, 1,2-Dihydroxybenzol, 1,4-Dihydroxybenzol, sowie deren hydroxymethylierte Verbindungen, besonders hydroxymethylierte Derivate des Resorcins oder Prenzcatechins, etwa 2,4-Dihydroxyphenylmethanol oder 2,3-Dihydroxyphenylmethanol, aber auch mehrfach hydroxymethylierte Abkömmlinge dieser aktivierten Aromaten beispielsweise 2,3-Dihydroxy-4-hydroxymethylphenylmethanol oder 4,5-Dihydroxy-2-hydroxymethylphenylmethanol, Trihydroxybenzolen, insbesondere 1,3,5-Trihydroxybenzol, 1,2,3-Trihydroxybenzol; deren mono- und dihydroxymethylierte Verbindungen, etwa das 2,3,4-Trihydroxyphenylmethanol oder 2,4,6-Trihydroxyphenylmethanol, C-alkylierte Verbindungen des Phenols oder des Resorcins, beispielsweise 1-Hydroxy-2-methylbenzol, 1-Hydroxy-3-methylbenzol, 1-Hydroxy-4-methylbenzol; 2-Methylresorcin, Selbstkondensationsprodukte der hydroxymethylierten Verbindungen, etwa Bis-2,4-dihydroxyphenylmethan, aktivierte Heterocyclen, beispielsweise Pyrrol, Thiophen; deren mono- oder dialkylierte Verbindungen oder deren anellierte Derivate, insbesondere Indol oder Thioindol, Di- und Trihydroxyderivate des Naphthalins, sowie deren Mischungen oder Mischungen die diese Substanzen enthalten.

In particular, the present invention relates to a binder and a composition comprising:
an aqueous dispersion of at least one phenol-formaldehyde resin;

• At least one amine compound having the general formula (1)
  
  in which R1, R2 and R3, independently of one another, are identical or different from H and R1 of the general formula (2):
  
  with a value for n of 2-10 and R2 and R3, independently of one another, are identical or different from H or correspond to the general formula (3):
  
  where m can take a value of 1-50 and the molecular weight of the amine compound does not exceed about 20,000 g / mol;
• At least one activated silane obtainable by reacting a silane selected from the group consisting of mono-, di- and trialkoxysilanes having a C ₁ to C ₈ alkoxy group, the alkoxysilane having at least one C ₂ to C ₁₀ Aminoalkyl group or a C ₂ to C ₁₀ -N-aminoalkyl group; 3 (2-aminoethylamino) propyl trimethoxysilane; (MeO) ₃ -Si (CH ₂ ) ₃ -NH- (CH ₂ ) ₃ -Si- (OMe) ₃ ; 3-aminopropyl-silane triol; Aminosilane with ethoxylated nonylphenolate; Phenyl-CH ₂ -NH- (CH ₂ ) ₃ -NH- (CH ₂ ) ₃ -Si- (OMe) ₃ · HCl; as well as their mixtures; with an enolizable ketone having at least one carbonyl group or a ketone having at least one OH group, wherein the ketone contains 3 to 12 C atoms; such as
• At least one aromatic hydroxy compound selected from the group consisting of: dihydroxybenzenes, in particular 1,3-dihydroxybenzene, 1,2-dihydroxybenzene, 1,4-dihydroxybenzene, and their hydroxymethylated compounds, especially hydroxymethylated derivatives of resorcinol or prenzatecate, about 2 , 4-dihydroxyphenylmethanol or 2,3-dihydroxyphenylmethanol, but also multiple hydroxymethylated derivatives of these activated aromatics, for example 2,3-dihydroxy-4-hydroxymethylphenylmethanol or 4,5-dihydroxy-2-hydroxymethylphenylmethanol, trihydroxybenzenes, in particular 1,3,5-trihydroxybenzene 1,2,3-trihydroxybenzene; their mono- and dihydroxymethylated compounds, such as 2,3,4-trihydroxyphenylmethanol or 2,4,6-trihydroxyphenylmethanol, C-alkylated compounds of phenol or resorcinol, for example 1-hydroxy-2-methylbenzene, 1-hydroxy-3- methylbenzene, 1-hydroxy-4-methylbenzene; 2-methylresorcinol, self-condensation products of hydroxymethylated Compounds such as bis-2,4-dihydroxyphenylmethane, activated heterocycles, for example, pyrrole, thiophene; their mono- or dialkylated compounds or their fused derivatives, especially indole or thioindole, di- and trihydroxy derivatives of naphthalene, and mixtures or mixtures containing these substances.

Especially in that the composition according to the invention contains at least one aromatic hydroxy compound it is possible trap free formaldehyde from the resin used and under the given conditions chemically to such molecules not to convert reversibly, which itself to the crosslinking reaction of the resin. By this measure on the one hand, no additional Formaldehyde be added more for post-crosslinking and on the other hand In the phenol resin used free formaldehyde is chemically bound. Thus, neither in the resin nor in a bound Mineral wool product free formaldehyde ago.

When Aromatic hydroxy compounds are those which are suitable in particular selected are selected from the group consisting of: dihydroxybenzenes, in particular 1,3-dihydroxybenzene, 1,2-dihydroxybenzene, 1,4-Dihydroxybenzene, and their hydroxymethylated compounds, especially hydroxymethylated derivatives of resorcinol or prenzatecate, about 2,4-dihydroxyphenylmethanol or 2,3-dihydroxyphenylmethanol, but also several times hydroxymethylated derivatives These activated aromatics, for example, 2,3-dihydroxy-4-hydroxymethylphenylmethanol or 4,5-dihydroxy-2-hydroxymethylphenylmethanol, Trihydroxybenzenes, especially 1,3,5-trihydroxybenzene, 1,2,3-trihydroxybenzene; their mono- and dihydroxymethylated compounds, such as 2,3,4-trihydroxyphenylmethanol or 2,4,6-trihydroxyphenylmethanol, C-alkylated compounds of the Phenols or resorcinol, for example 1-hydroxy-2-methylbenzene, 1-hydroxy-3-methylbenzene, 1-hydroxy-4-methyl benzene; 2-methyl, Self-condensation products of hydroxymethylated compounds, for example bis-2,4-dihydroxyphenylmethane, activated heterocycles, for example Pyrrole, thiophene; their mono- or dialkylated compounds or their fused derivatives, such as indole or thioindole, di- and trihydroxy derivatives of naphthalene. Of course can also mixtures of these substances and mixtures containing them used become.

Modification on a complex multi-species mixture - such as a phenol-formaldehyde resin or a mineral wool binder made therefrom with different additives presents a difficult problem, especially since the resin is a very unstable intermediate. Depending on the usually unknown history of this preparation, the reactive components are present in different concentrations and thus have a sensitive influence on the material properties of the finished product. The main constituents of a typical phenol-formaldehyde resin and their effect as polymer building blocks are shown in the following formula scheme:

ever by ratio the individual components is a plastic polymer with different Properties formed.

It can be several case distinctions of Polymersiation and thus the resulting polymers with different properties meet, which are shown schematically below:

Case 1:

If predominantly only simple building blocks are present, then a chain-like polymer with few points of connection between the individual chains is built up, ie the simple building blocks polymerize with themselves, which can be schematically represented by the following formula scheme using the above-defined formula abbreviations:

in the The prior art has been such, substantially linear and poorly branched polymer chains later crosslinked with formaldehyde, to an increased To achieve water resistance. Want this addition of formaldehyde avoid the inventors. In particular, because formaldehyde a volatile Substance is and because these are more under the production conditions the heightened Temperature tends to expelling, as they are relatively slow Crosslinking reaction with the polymer chains enters.

Case 2:

If there is a mixture of monosubstituted and doubly substituted building blocks which polymerize with themselves, a polymer with more crosslinked chains is obtained, which can be schematically represented by the following formula scheme using the above-defined formula abbreviations:

The resistance such binder resins and mineral wool products produced therewith against swelling processes wet, on the construction site in bad weather or outdoors, is across from increased the uncrosslinked polymer chains.

Case 3:

In case three, there are mono-, di- and trisubstituted-substituted compounds which polymerize with themselves, which can be schematically represented by the following formula scheme using the above-defined formula abbreviations:

The resistance such a plastic against swelling is very high. Indeed can ever after concentration the higher substituted building blocks depending from the pH and the concentration of formaldehyde or this releasing Compounds, the shelf life and the processing time be reduced.

On the whole, however, a resin according to Case 3 is desired, but in the prior art this could only be achieved with formaldehyde-containing phenolic resins which still contain small amounts of formaldehyde release.

Due to the addition of at least one aromatic hydroxy compound, it is possible, on the one hand, to scavenge excess formaldehyde contained in the resin used so that its release is prevented and, on the other hand, the compounds formed from the reaction of the formaldehyde with the aromatic hydroxide form molecules which form the Molecular species from case 3 are very similar, which is shown below using the example of resorcinol:
Chemical scavenging of free formaldehyde:

It can be seen from the following formula scheme that the polymer unit (3) has a strong similarity to the molecular species (4) resulting from the capture reaction:

by virtue of this similarity can the molecular species (4) in addition to the chemical fixation of free formaldehyde also at the desired Cross-linking reactions participate and thus ultimately formaldehyde-free phenolic resins and binders thereof for mineral wool to lead.

It is therefore also possible commercially available to use aromatic hydroxy compounds already with formaldehyde to some extent have been implemented to cross-link yet continue to drive forward.

It it is preferred to use such commercially available phenolic resins, which at most about 8% by mass, in particular less than about 3% by mass, preferably contain less than about 1% by mass of free formaldehyde.

When Phenolic resin is particularly suitable resins with monomeric building blocks the type of benzyl alcohol which is also chainlike or cyclic, oligomeric alkylverbrückte aromatic polycyclic compounds with a molecular weight of up to 3000 g / mol can contain.

The Composition according to the invention can additionally a carboxylic acid, especially hydroxycarboxylic acid, preferably hydroxyacetic acid, contain.

It is a preferred embodiment of the present invention, the alkanolamine from the group: ethanolamine, Diethanolamine, and select triethanolamine.

One preferred silane of the composition of the invention is 3-aminopropyltriethoxysilane. It is commercially low priced available.

As ketones for the preparation of the activated silane are dihydroxyacetone or acetylacetone their for ease of availability, however, the activated silane can also be prepared with an enolizable ketone having at least one carbonyl group or a ketone having at least one OH group, wherein the ketone contains from 3 to 12 carbon atoms.

Further it is often desirable that the composition in addition contains at least one crosslinker, preferred are those selected from the group consisting of: glycerol, polyols, neopentyl glycol, trimethylallylamine, 1,3,5-triallyl-2-methoxybenzene, 1,1,1-tris (4-hydroxyphenyl) ethane, Triallyl neopentyl ether, pentaerythritol, sugars, sugar molasses, in particular beet molasses; as well as their mixtures.

It it is particularly preferred that the composition according to the invention has a pH in the range of about 7.0 to 10, especially 8-9. This is on the one hand ensures that pipes and nozzles, in particular spray nozzles, are less susceptible to corrosion. On the other hand, compositions work by far the mineral or glass fiber in the preferred pH range not so much as the most significantly acidic compositions on Polyacrylatbasis of the prior art.

Without being bound to it, the activation of the silane with the carbonyl compound may possibly proceed according to the following reaction scheme, shown with two different carbonyl compounds:

By activation of silane - im The above reaction scheme using the example of the hydrolysis of 3-aminopropyltriethoxysilane emerged γ-aminopropylsilane triol - by Reaction with an enolisable ketone with at least one carbonyl group or a ketone having at least one OH group, wherein the ketone Contains 3 to 12 C atoms, arises at the activated molecule a "plastic side", which by the N part formed will be added to a glass side formed by the Si part.

in the The prior art has been the amino group of the silane with formaldehyde to a ship's Base reacted, which in turn reacted with the phenol-formaldehyde resin.

Consequently is a necessary in the art formaldehyde content of the binder no longer necessary because the activated silane carries an N-containing moiety, the to the plastic - according to the invention to the Phenol resin or amine functions of nitrogen-containing polymers - couple can, which is so over the silane linker is bound to the glass surface of the hot fiber.

Thus, both via the described molecular species (4) and via the silane linker one finds Crosslinking takes place.

Diese hydrolytischen Verknüpfungen laufen auf der noch heißen Faser schnell ab.The reactions of the activated silanes used according to the invention on the glass surface - represented here by a silicic acid tetrahedron - are shown below schematically and by way of example without being bound thereto:

These hydrolytic linkages rapidly drain on the still hot fiber.

Further Advantages and features of the present invention are due to the description of embodiments as well as the drawing.

It shows:

1 : A schematic view of silane coupled via the Si portion of an activated silane to a glass fiber; and

2 FIG. 3: a schematic view of a plastic bound to a glass surface on a fiber via an activated silane. FIG.

The overall context of the composition and binder according to the invention in connection with the production of mineral or glass fibers is again illustrative in 1 and 2 shown.

in this connection The illustrated molecular arrangement may only be considered a schema be understood. Of course as described above, for example with the molecular species (4) and the alkanolamine or other additional crosslinkers still within of the plastic, in the example of phenol resin, crosslinking reactions occur.

Of course, it is also possible that unintentional side reactions - as with any polymerization may occur. Therefore one can see the content of 1 and 2 merely as a model, but helpful in understanding the invention.

The Composition according to the invention is ideal as a binder for mineral wool. For one thing, so absolutely formaldehyde-free mineral wool products are produced and on the other hand are the hardened ones inventive binder and of course also the mineral wool products water test.

to Production of formaldehyde-free bonded mineral wool with the inventive binder bring the binder after the defibration of a Mineral melt on the still hot fibers and sets the treated with the binder mineral wool product a curing process out.

in this connection the binder is sprayed the extracted from the mineral melt fibers in the chute the fibers applied, in particular sprayed.

One according to the inventive method produced bound mineral wool product meets all mechanical and chemical Requirements such as one bound using classical phenol-formaldehyde resin Mineral wool product.

embodiments

The commercially available formaldehyde-reduced phenolic resins were tested by conventional investigation methods on the finished product. The results were compared with those of a standard phenolic resin compared. The solutions chosen here are set out in the following examples and represent only a small selection of the test results. As the person skilled in the art very easily recognizes, the substances used can be varied in extraordinary breadth, the only important factors for the capture of formaldehyde are the pH and the reactivity of the aromatics used. The resorcinol used can be easily replaced by similar reactive systems, such as pyrocatechol, pyrrole or thiophene. The control of the reactivity can conveniently be carried out via the acid-base ratio. The activation of the silane is possible both via carbonyl compounds and heterocyclic systems, such as the phthalimide. The addition of renewable raw materials such as molasses, the processing friendliness of the resins can be further improved.

at The said binders generally became a target concentration of about 40% total solids sought.

Comparative example

• Binder 1 - Standard Comparative Example: A typical alkali-catalyzed phenolic resin was used with one Total solids content of 44%. Composition: 150 kg phenolic resin; 35.5 kg of urea; 1.0 kg of ammonium sulfate; 2.0 kg of ammonia solution (25%); 25.8 kg of 3-aminopropyltriethoxysilane (2%); 44.6 kg of water. The free formaldehyde content was 6 hours after addition of the urea about 0.5 mass%.

activation of the silane

In the following embodiments The invention is subject to the following general specification for presentation of an activated silane: In a boiler with mechanical stirrer more suitable Size is a part of the dilution water submitted. Subsequently the appropriate amount of the carbonyl compound is added and until the complete resolution touched. For poorly soluble in water Connections are warmed gently or under strong stir added a dispersing aid. To the solution, the silane is added and subsequently until clear discoloration the solution touched. The color well shows the formation of imine as activated silane at. The thus activated silane is added to the binder mixture. To Homogenization, the binder is ready for use.

example 1

• Binder 2: A commercially available one was used unneutralized phenolic resin with a total solids of 43.5% and a proportion of free formaldehyde of about 1 mass%.
• Composition: 150 kg phenolic resin; 4.7 kg resorcinol; 0.2 kg glycolic acid; 0.3 kg of ethanolamine; 0.4 kg of 3-aminopropyltriethoxysilane; 0.2 kg of dihydroxyacetone; 21.3 kg of water.

Of the pH of the finished binder is about 8.

Example 2

• Binder 3: A commercially available material was used unneutralized phenolic resin with a total solids of 46.5% and a proportion of free formaldehyde of about 2% by mass.
• Composition: 150 kg phenolic resin; 11.7 kg resorcinol; 0.4 kg phloroglucinol; 0.2 kg of glycolic acid; 0.7 kg of ethanolamine; 0.4 kg of 3-aminopropyltriethoxysilane; 0.2 kg of dihydroxyacetone; 43.2 kg of water.

Of the pH of the finished binder is about 8.

Example 3

• Binder 4 :: A commercially available one was used unneutralized phenolic resin with a total solids of 46.5% and a proportion of free formaldehyde of about 2%.
• Composition: 150 kg phenolic resin; 11.2 kg of resorcinol; 0.4 kg phloroglucinol; 27.9 kg of beet molasses; 0.2 kg of glycolic acid; 0.8 kg of ethanolamine; 0.5 kg of 3-aminopropyltriethoxysilane; 0.3 kg of dihydroxyacetone; 68.1 kg of water.

Of the pH of the finished binder is about 8.

Performance of quality checks

1. Laboratory tests

1.1 decrease of the free formaldehyde content

First, be to the binder 2 - 4 the decrease of free formaldehyde after the addition of phloroglucin or resorcinol compared to the standard binder 1 shown (Table 1).

Table 1: Decrease in the content of free formaldehyde

2. Tests with mineral wool products, which with the binder according to the invention were manufactured

With the above binders according to the examples 1 to 3, mineral wool products were produced, the binder in usual Way following the defibration of the melt, for example after the nozzle blowing method, in the chute on the still hot Fibers sprayed on becomes.

The resulting products were then subjected to a series of tests, which are described below. A façade insulation panel with a nominal density of 75 kg / m ³ and a target glow loss of 3.7% was generally tested.

2.1 Tear resistance of insulating materials according to DIN 52274 / EN 1607 before and after autoclaving

Out a finished product are cuboid test specimens with an edge length from 200 × 200 mm cut out. The half the sample thus obtained is between two with eyelets provided steel plates glued and torn with a suitable device. The other part is 15 minutes at 105 ° C in saturated with water vapor Air aged and then torn in the same way. The measured tear forces make a statement about the Strength of the overall system glass fibers - plastic after manufacture and their consistency under normal conditions of use. For standard products of this Class without water repellents are residual strength by 60% after Autoclaving normally. The results are summarized in Table 2.

Table 2: Tear resistance of insulating materials according to DIN 52274 / EN 1607 before and after autoclaving

2.2 Tear resistance according to DIN 52274 / EN 1607 of insulating materials to north test

to execution These tests are made using a finished product specimen an edge length of 200 × 200 mm cut out. Part of the test specimen is analogous to the autoclave test torn before aging. The other part will be according to the specifications of the north test for 7 days at 70 ° C and 95% relative humidity stored. After re-drying, the strength the aged specimen by tearing determined. An accurately made insulation should be after this very drastic aging method at least one residual strength of 50%. The results are shown in Table 3.

Table 3: Tear-off strength according to DIN 52274 / EN 1607 from insulating materials to Nordtest

Consequently to confirm the performed Investigations that the composition of the invention as formaldehyde-free Binder for The mineral wool production is not only fundamentally suitable, but also after received product quality, processability and economy is practicable. The existing mechanical equipment needs not changed to become.

Claims (16)

Binder for mineral wool, characterized in that it contains at least the following constituents: an aqueous dispersion of at least one phenol-formaldehyde resin; At least one amine compound having the general formula (1)

in which R1, R2 and R3, independently of one another, are identical or different from H and R1 of the general formula (2):

with a value for n of 2-10 and R2 and R3, independently of one another, are identical or different from H or correspond to the general formula (3):

where m can take a value of 1-50 and the molecular weight of the amine compound does not exceed about 20,000 g / mol; At least one activated silane obtainable by reacting a silane selected from the group consisting of mono-, di- and trialkoxysilanes having a C ₁ to C ₈ alkoxy group, the alkoxysilane having at least one C ₂ to C ₁₀ Aminoalkyl group or a C ₂ to C ₁₀ -N-aminoalkyl group; 3 (2-aminoethylamino) propyl trimethoxysilane; (MeO) ₃ -Si (CH ₂ ) ₃ -NH- (CH ₂ ) ₃ -Si- (OMe) ₃ ; 3-aminopropyl-silane triol; Aminosilane with ethoxylated nonylphenolate; Phenyl-CH ₂ -NH- (CH ₂ ) ₃ -NH- (CH ₂ ) ₃ -Si- (OMe) ₃ · HCl; as well as their mixtures; with an enolizable ketone having at least one carbonyl group or a ketone having at least one OH group, wherein the ketone contains 3 to 12 C atoms; and at least one aromatic hydroxy compound selected from the group consisting of: dihydroxybenzenes, in particular 1,3-dihydroxybenzene, 1,2-dihydroxybenzene, 1,4-dihydroxybenzene, and their hydroxymethylated compounds, especially hydroxymethylated derivatives of resorcinol or prenzatecate, about 2 , 4-dihydroxyphenylmethanol or 2,3-dihydroxyphenylmethanol, but also multiple hydroxymethylated derivatives of these activated aromatics, for example 2,3-dihydroxy-4-hydroxymethylphenylmethanol or 4,5-dihydroxy-2-hydroxymethylphenylmethanol, trihydroxybenzenes, in particular 1,3,5-trihydroxybenzene 1,2,3-trihydroxybenzene; their mono- and dihydroxymethylated compounds, such as 2,3,4-trihydroxyphenylmethanol or 2,4,6-trihydroxyphenylmethanol, C-alkylated compounds of phenol or resorcinol, for example 1-hydroxy-2-methylbenzene, 1-hydroxy-3- methylbenzene, 1-hydroxy-4-methylbenzene; 2-methylresorcinol, self-condensation products of the hydroxymethylated compounds, such as bis-2,4-dihydroxyphenylmethane, activated heterocycles, for example pyrrole, thiophene; their mono- or dialkylated compounds or their fused derivatives, especially indole or thioindole, di- and trihydroxy derivatives of naphthalene, and mixtures or mixtures containing these substances. Composition comprising: an aqueous dispersion of at least one phenol-formaldehyde resin; At least one amine compound having the general formula (1)

in which R1, R2 and R3, independently of one another, are identical or different from H and R1 of the general formula (2):

with a value for n of 2-10 and R2 and R3, independently of one another, are identical or different from H or correspond to the general formula (3):

where m can take a value of 1-50 and the molecular weight of the amine compound about 20 Does not exceed 000 g / mol; At least one activated silane obtainable by a reaction of a silane selected from the group consisting of mono-, di- and trialkoxysilanes having a C ₁ to C ₈ -alkoxy group, the alkoxysilane having at least one C ₂ to C ₁₀ Aminoalkyl group or a C ₂ to C ₁₀ -N-aminoalkyl group; 3 (2-aminoethylamino) propyl trimethoxysilane; (MeO) ₃ -Si (CH ₂ ) ₃ -NH- (CH ₂ ) ₃ -Si- (OMe) ₃ ; 3-aminopropyl-silane triol; Aminosilane with ethoxylated nonylphenolate; Phenyl-CH ₂ -NH- (CH ₂ ) ₃ -NH- (CH ₂ ) ₃ -Si- (OMe) ₃ · HCl; as well as their mixtures; with an enolizable ketone having at least one carbonyl group or a ketone having at least one OH group, wherein the ketone contains 3 to 12 C atoms; and - at least one aromatic hydroxy compound selected from the group consisting of: dihydroxybenzenes, in particular 1,3-dihydroxybenzene, 1,2-dihydroxybenzene, 1,4-dihydroxybenzene, and their hydroxymethylated compounds, especially hydroxymethylated derivatives of resorcinol or prenzatecate, for example 2,4-dihydroxyphenylmethanol or 2,3-dihydroxyphenylmethanol, but also polyhydroxymethylated derivatives of these activated aromatics, for example 2,3-dihydroxy-4-hydroxymethylphenylmethanol or 4,5-dihydroxy-2-hydroxymethylphenylmethanol, trihydroxybenzenes, in particular 1,3,5- Trihydroxybenzene, 1,2,3-trihydroxybenzene; their mono- and dihydroxymethylated compounds, such as 2,3,4-trihydroxyphenylmethanol or 2,4,6-trihydroxyphenylmethanol, C-alkylated compounds of phenol or resorcinol, for example 1-hydroxy-2-methylbenzene, 1-hydroxy-3- methylbenzene, 1-hydroxy-4-methylbenzene; 2-methylresorcinol, self-condensation products of the hydroxymethylated compounds, such as bis-2,4-dihydroxyphenylmethane, activated heterocycles, for example pyrrole, thiophene; their mono- or dialkylated compounds or their fused derivatives, especially indole or thioindole, di- and trihydroxy derivatives of naphthalene, and mixtures or mixtures containing these substances. Composition according to Claim 2, characterized that the phenol formaldehyde resin at most about 8% by mass, in particular less than about 2% by mass, preferably contains less than about 1% by mass of free formaldehyde. Composition according to Claim 2 or 3, characterized that the phenol-formaldehyde resin is monomeric building blocks of the benzyl alcohol type and / or chain-shaped and or. cyclic, oligomeric alkyl-bridged aromatic polycyclic compounds containing a molecular mass of up to 3,000 g / mol. A composition according to any one of claims 2 to 4, characterized in that it additionally contains a carboxylic acid, in particular hydroxy, preferably hydroxyacetic acid (Glycolic acid), contains. A composition according to any one of claims 2 to 5, characterized in that the amine compound is selected from the group consisting of: a C ₂ to C ₁₀ alkanolamine, in particular ethanolamine, diethanolamine, triethanolamine. A composition according to any one of claims 2 to 6, characterized in that the silane is 3-aminopropyltriethoxysilane is. A composition according to any one of claims 2 to 7, characterized in that the ketone dihydroxyacetone or acetylacetone, is. A composition according to any one of claims 2 to 8, characterized in that it comprises at least one further crosslinker contains. Composition according to Claim 9, characterized that the crosslinker is selected is from the group consisting of: Glycerol, polyols, neopentyl glycol, Trimethylallylamine, 1,3,5-triallyl-2-methoxybenzene, 1,1,1-tris (4-hydroxyphenyl) ethane, Triallyl neopentyl ether, pentaerythritol, sugars, sugar molasses, in particular beet molasses; such as their mixtures. A composition according to any one of claims 2 to 10, characterized in that it has a pH in the range of about 7.0 to 10, especially 8 - 9 having. Binder for Mineral wool containing a composition according to at least one of the claims 2 to 11. Process for the preparation of substantially formaldehyde-free bonded mineral wool with a binder according to claim 12, wherein the binder after the defibering of a Mineral melt applied to the still hot fibers and the treated with the binder mineral wool product a curing process exposes. Method according to claim 13, characterized in that that the binder by spraying the extracted from the mineral melt fibers in the chute the fibers are applied. Tied mineral wool product, available after a method according to claim 13 or 14. Use of a composition according to any the claims 2 to 11 for the preparation of a substantially formaldehyde-free bonded Mineral wool product.