Silicone-coated mineral wool insulation materials and methods for making and using them
The present disclosure relates to silicone-coated mineral wool insulation materials, methods for making them using specific coating methods, and methods for using them. One aspect of the disclosure is a method for making a silicone-coated mineral wool, the method comprising: providing a mineral wool comprising a collection of mineral wool fibers; applying to the mineral wool a solvent-borne coating composition comprising a silicone, the silicone of the coating composition having a number-average molecular weight of at least 25 kDa; and allowing the solvent to evaporate to provide silicone-coated mineral wool.
1. A method for making an unbound loose-fill silicone-coated mineral wool, the method comprising:
providing a loose-fill mineral wool comprising a collection of loose mineral wool fibers;
applying to the loose-fill mineral wool a solvent-borne coating composition comprising a silicone, the silicone of the coating composition having a number-average molecular weight of at least 40 kDa; and
allowing the solvent to evaporate to provide silicone-coated mineral wool,
wherein the rate of application of the coating composition to the mineral wool is in the range of 0.1-10 mg silicone per gram mineral wool,
wherein the mineral wool is at a temperature in range of 200-500° C. when it is coated with the solvent-borne coating composition.
2. The method according to claim 1 , wherein the mineral wool is a glass wool.
3. The method according to claim 1 , wherein the mineral wool is at a temperature in range of 285-500° C. when it is coated with the solvent-borne coating composition.
4. The method according to claim 1 , wherein the mineral wool has a soak test pH in the range of 8 to 11 just before it is coated.
5. The method according to claim 1 , wherein the amount of silicone on the fibers after application is in the range of 0.1-5 mg silicone per gram mineral wool.
6. The method according to claim 1 , wherein the amount of silicone on the fibers after application is in the range of 0.1-2 mg silicone per gram mineral wool.
7. The method according to claim 1 , wherein the amount of silicone on the fibers after application is in the range of 0.2-10 mg silicone per gram mineral wool.
8. The method according to claim 1 , wherein the silicone of the coating composition has a number-average molecular weight of at least 60 kDa.
9. The method according to claim 1 , wherein the silicone is a poly(dimethylsiloxane).
10. The method according to claim 1 , wherein the silicone is a polymer or copolymer of one or more of an alkylsiloxane; and arylsiloxane; and a functionalized siloxane.
11. The method according to claim 1 , wherein the concentration of the silicone in the coating composition is in the range of 0.01-5% by weight.
12. The method according to claim 1 , wherein the application of the solvent-borne coating composition to the mineral wool lowers the temperature of the mineral wool to in the range of 50° C. to 250° C.
13. The method according to claim 1 , further comprising applying an effective amount of an antistatic additive to the mineral wool, and/or a dedusting oil to the mineral wool in an amount in the range of 0.4-4% by weight of the mineral wool.
14. The method according to claim 1 , wherein the solvent-borne coating composition is an aqueous emulsion comprising the silicone.
15. The method according to claim 14 , wherein the silicone is a poly(dimethylsiloxane).
16. A silicone-coated mineral wool comprising a collection of unbound mineral wool fibers having a silicone coating made by the method according to claim 1 .
17. An insulated structure having an interior surface, and a silicone-coated mineral wool according to claim 16 disposed against the interior surface.
18. An insulated structure having an interior surface and an exterior surface, and a silicone-coated mineral wool according to claim 16 disposed in and at least partially filling a cavity between the interior surface and the exterior surface.
19. An insulated cavity having an interior surface and an exterior surface, and a silicone-coated mineral wool according to claim 16 disposed in and at least partially filling the cavity between the interior surface and the exterior surface.