MINERAL WOOL BINDER
The invention relates to a formaldehyde-free binder composition for mineral fibres comprising at least one phenol and/or quinone containing compound, and at least one protein.
1 .- 20 . (canceled)
21 . A binder composition for mineral fibers, wherein the composition is formaldehyde-free and comprises at least one phenol and/or quinone containing compound and at least one protein.
22 . The binder composition of claim 21 , wherein the at least one phenol and/or quinone containing compound is selected from one or more of hydroxybenzoic acids, hydroxybenzoic aldehydes, hydroxyacetophenones, hydroxy-phenylacetic acids, cinnamic acids, cinnamic acid esters, cinnamyl aldehydes, cinnamyl alcohols, coumarins, isocoumarins, chromones, flavonoids, chalcones, dihydrochalcones, aurones, flavanones, flavanonols, flavans, leucoanthocyanidines, flavan-3-ols, flavones, anthocyanidines, deoxyanthocyanidines, anthocyanins, biflavonyls, benzophenones, xanthones, stilbenes, benzoquinones, naphthoquinones, anthraquinones, betacyanines, polyphenols and/or polyhydroxyphenols, lignans, neolignans (dimers or oligomers from coupling of monolignols), lignins synthesized primarily from monolignol precursors p-coumaryl alcohol, coniferyl alcohol and sinapyl alcohol, tannins, benzoquinones, naphthoquinones, anthraquinones, lawsone.
23 . The binder composition of claim 22 , wherein the tannins are selected from one or more of tannic acid, condensed tannins (proanthocyanidines), hydrolysable tannins, gallotannins, ellagitannins, complex tannins, and/or tannins originating from one or more of oak, chestnut, staghorn sumac, and fringe cups.
24 . The hinder composition of claim 21 , wherein the phenol and/or quinone containing compound comprises one or more synthetic or semisynthetic molecules which contain phenols, polyphenols and/or quinones, including proteins, peptides, peptoids or arylopeptoids modified with phenol and/or quinone containing side chains, dendrimers decorated with phenol and/or quinone containing side chains.
25 . The binder composition of claim 21 , wherein the at least one protein is selected from one or more of proteins of animal origin, including collagen, gelatin, hydrolyzed gelatin, and protein from milk (casein, whey), eggs; proteins of plant origin, including proteins from legumes, cereals, whole grains, nuts, seeds and fruits, protein from buckwheat, oats, rye, millet, maize (corn), rice, wheat, bulgar, sorghum, amaranth, quinoa, soybeans (soy protein), lentils, kidney beans, white beans, mung beans, chickpeas, cowpeas, lima beans, pigeon peas, lupines, wing beans, almonds, Brazil nuts, cashews, pecans, walnuts, cotton seeds, pumpkin seeds, hemp seeds, sesame seeds, and sunflower seeds; polyphenolic protein, including mussel foot protein.
26 . The binder composition of claim 25 , wherein the collagen or gelatin originates from one or more of mammal, bird species, including cow, pig, horse, fowl, and/or from scales, skin of fish.
27 . The binder composition of claim 23 , wherein one or more tannins are present in a concentration of from 1 to 70 wt. %, based on dry protein.
28 . The binder composition of claim 21 , wherein a mass ratio of (lysine+cysteine) in the protein to (phenol+quinone) in e phenol and/or quinone containing compound is from 1:5.78 to 1:0.08.
29 . The binder composition of claim 21 , wherein the binder composition further comprises one or more additives selected from oxidants, metal ions, pH-adjusters.
30 . The binder composition of claim 21 , wherein the binder composition has a pH of higher than 7.
31 . The binder composition of claim 21 , wherein the binder composition comprises at east one additive selected from linkers containing amine groups and/or thiol groups.
32 . A mineral wool product, wherein the product comprises mineral fibers bonded by a cured binder composition of claim 21 .
33 . The mineral wool product of claim 32 , wherein the product has a density of from 10 kg/m 3 to 1200 kg/m 3 .
34 . The mineral wool product of claim 32 , wherein the product exhibits a loss on ignition (LOI) of from 0.1% to 25.0%.
35 . A method of producing a mineral wool product, wherein the method comprises contacting mineral fibers with the binder composition of claim 21 and curing the binder composition.
36 . The method of claim 35 , wherein the method comprises making a melt of raw materials, fiberizing the melt by a fiber forming apparatus to form mineral fibers, providing the mineral fibers in the form of a collected web, mixing the binder composition with the mineral fibers before, during or after providing the collected web to form a mixture of mineral fibers and binder composition, and curing the mixture of mineral fibers and binder composition.
37 . The method of claim 36 , wherein mixing of the binder composition with the mineral fibers is carried out after providing the collected web and comprises subjecting the collected web of mineral fibers to a disentanglement process, suspending the mineral fibers in a primary air flown and mixing the binder composition with the mineral fibers before, during or after the disentanglement process to form a mixture of mineral fibers and binder composition.
38 . The method of claim 35 , wherein curing of the binder composition is carried out at a temperature of from 5° C. to 95° C.
39 . The method of claim 35 , wherein curing comprises a drying process.
40 . The method of claim 39 , wherein curing comprises blowing air or gas over the mineral wool product and/or a temperature increase.