CN101821212A - 粘结剂 - Google Patents

粘结剂 Download PDF

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CN101821212A
CN101821212A CN200880101807A CN200880101807A CN101821212A CN 101821212 A CN101821212 A CN 101821212A CN 200880101807 A CN200880101807 A CN 200880101807A CN 200880101807 A CN200880101807 A CN 200880101807A CN 101821212 A CN101821212 A CN 101821212A
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ammonium
binder solution
formaldehyde
binding agent
essentially
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CN101821212B (zh
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C·哈姆普森
G·穆勒
C·爱普雷
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Knauf Insulation Ltd
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Knauf Insulation Ltd
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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Abstract

用于粘结松散物质的未反应的基本上无甲醛的可固化粘结剂溶液主要由可通过将还原糖、铵盐酸前体、任选的羧酸或其前体和任选的氨溶解在水中获得的溶液构成。

Description

粘结剂
本发明涉及粘结剂，例如用于玻璃棉或岩棉绝缘材料的粘结剂。
WO 2007/014236(引入本文供参考)涉及粘结剂，包括含梅拉德反应物的粘结剂。所公开的一种具体的粘结剂基于柠檬酸三铵-葡萄糖体系，该体系源自混合葡萄糖一水合物、无水柠檬酸、水和氨水。这种粘结剂体系的许多优点之一是它无甲醛。
本发明的一个方面提供根据权利要求1的粘结剂溶液；从属权利要求限定备选和/或优选的实施方案。
在另一个方面中，本发明提供粘结剂溶液，它包括可通过将以下物质溶解获得的溶液：
-碳水化合物，
-可由无机盐衍生的酸前体，
-氮源，
-任选的有机酸或其前体，和
-任选的氨。
根据本发明使用的粘结剂溶液可以是″基本上无甲醛的″，就是说，它们由于干燥和/或固化(或模拟干燥和/或固化的适当试验)释放不到5ppm甲醛。此类粘结剂溶液优选是″无甲醛的″，就是说它们在这些条件下释放不到1ppm甲醛。
根据本发明的包含粘结剂的产品(例如绝缘材料或木板)可以是″基本上无甲醛的″，就是说，它们包含小于5ppm或小于检测极限的游离甲醛和/或由一起包含小于这些量的游离甲醛的材料构成和/或在适合于模拟它们的正常应用的标准化测验标准化试验中释放的甲醛水平允许它们被分类为没有甲醛释放或有不可检测水平的甲醛释放。优选地，这些产品从根据ISO 16000的试验起始起在24-48小时的期间释放小于10μg/m3，更优选小于5μg/m3甲醛。
已经发现，根据本发明的粘结剂可以具有与例如，WO 2007/014236的柠檬酸三铵-葡萄糖体系相比至少等效和实际上改进的性能。WO2007/014236揭示了尤其基于碳水化合物(例如还原糖)、氨和羧酸的组合的粘结剂体系并表明梅拉德典型反应可以形成固化化学过程的基础。已认为，所使用的酸的性质将对固化粘结剂的性能具有显著影响，尤其是如果将酸前体和/或得自其的衍生物结合到固化粘结剂的结构中时。因此令人意外的是，可衍生自无机盐的酸前体会在其它表观类似的粘结剂体系中提供适合的酸前体。
可衍生自无机盐的酸前体的使用在成本、可获得性和容易处理方面可能具有显著的优点。粘结剂溶液的可由无机盐衍生的酸前体可以包含选自硫酸盐、磷酸盐、硝酸盐和碳酸盐的物质。可以使用一种或多种无机铵盐，例如，硫酸铵、磷酸铵或碳酸铵达到特定的优点。铵盐可以提供酸前体或部分酸前体和/或提供氮源或部分的氮源和/或提供pH值控制体系或部分pH值控制体系。也可以使用硝酸铵；然而，硝酸铵可能氧化碳水化合物(例如在葡萄糖的情况下)的醛基和/或要求预防措施以避免爆炸。
硫酸铵是尤其有利的，但是可以使用磷酸铵与之联用或代替它。磷酸铵可以是磷酸单铵、磷酸二铵或磷酸三铵；它可以是磷酸氢铵。碳酸铵(单独地或与本文公开的其它材料结合地)也可以提供好的结果。碳酸铵可以是碳酸氢铵。
酸前体，尤其是当它主要由无机铵盐构成时，可以构成
·按干燥重量计，未固化的粘结剂溶液的至少5％，优选至少7％，更优选至少9％；和/或
·按干燥重量计，未固化的粘结剂溶液的小于25％或20％，优选小于18％，更优选小于16％。
术语″由...构成或主要由...构成″旨在将要求的范围限制到规定的材料或步骤和不本质上影响本发明基本和新颖的特征的那些材料或步骤。
酸可以包含：硫酸、磷酸、硝酸或弱酸。
粘结剂可以按干燥重量计包含5％-25％，优选10％-20％，更优选15％-20％酸前体(尤其是当它是无机铵盐时)至碳水化合物(尤其是当它是糖时)。
当粘结剂既包含可衍生自无机盐的酸前体又包含有机酸时，它们可以按相对于碳水化合物(尤其是当它是糖时)的按干燥重量计的以下量存在：
  优选   更优选   最优选
  可衍生自无机盐的酸前体   至少2.5％   至少5％
  有机酸   至少2.5％   至少5％
  有机酸和可衍生自无机盐的酸前体的组合   5-25％   10-20％   15-20％
当使用有机酸时，它优选衍生自铵盐。例如，可以使用柠檬酸铵，尤其是柠檬酸三铵作为柠檬酸源。
现有技术的用于矿棉绝缘材料的苯酚甲醛粘结剂体系已经在添加大约2wt％作为固化剂的硫酸铵的情况下使用。然而，此种苯酚甲醛粘结剂体系的化学作用不可与本发明的不基于苯酚和/或甲醛和/或其它酚类化合物的粘结剂体系相比较。
除了还原糖之外，碳水化合物可以用于粘结剂溶液，并且可以包含单糖，例如呈其醛糖或酮糖形式。优选地，碳水化合物包含糖，更优选还原糖或在热固化条件下就地产生还原糖的反应物；它可以包含右旋糖(即葡萄糖)。碳水化合物可以包含具有还原醛的碳水化合物。据信，使用还原糖，尤其是葡萄糖产生好的粘结剂强度，尤其是对于矿棉绝缘产品的制造。葡萄糖不必是100％纯的，但是使用具有至少0.85，优选至少0.9，更优选至少0.95的葡萄糖当量值的材料认为是有利的。葡萄糖当量值DE可以看作是i)去聚合的量度并且粗略地是：DE＝100/dp，其中dp代表聚合度或ii)作为D-右旋糖(葡萄糖)计算的还原糖按干基的总量。
优选地，粘结剂溶液和/或粘结剂不含或基本上不含淀粉；相当大量淀粉的存在认为增加固化时间和/或降低固化粘结剂的强度。粘结剂溶液和/或粘结剂可以不含或基本上不含蛋白质。
工业、非食品级葡萄糖可以用作还原糖；可以使用诸如Sirodex331的产品，它是可从Tate和Lyle获得的DE值为94.5的75％固体糖溶液。
还原糖可以主要由葡萄糖构成。尤其是在这种情况下并且更尤其是还当酸前体主要由铵盐，例如硫酸铵构成时，还原糖的量/酸前体的量的按干燥重量的比例可以大于或等于2.5和/或小于或等于13。
氮源可以是胺或胺反应物；它可衍生自与酸前体，例如，无机铵盐相同的源。它优选是在溶液中的氨。
可以使用所涉及的材料的前体和/或产生这种材料的反应物。
在一个实施方案中，粘结剂主要衍生自还原糖和在水溶液中的无机铵盐。
在另一个实施方案中，粘结剂还可以包含有机酸，尤其是羧酸；它可以是多元羧酸，尤其是二羧酸或三羧酸，优选柠檬酸；它优选是单体的。有机酸(或其前体、盐或酸酐)与可衍生自无机盐的酸前体的组合可以提供各种优点。首先，此种组合可以降低废品的风险(这已在仅基于有机酸的此类粘结剂的情况下观察到)，同时提供可接受的强度。废品是矿物纤维绝缘材料领域中的技术术语，它一般表示制成的和一般包装的绝缘产品中的粘结剂伴随放热的相当快速的氧化。废品通常引起烟气的产生和绝缘材料的变色。它可能与放热反应相联系，该放热反应提高整个绝缘材料的厚度的温度；这可能破坏绝缘产品的完整性和/或导致火灾。
备选或另外地，有机酸(或其前体、盐或酸酐)与可衍生自无机盐的酸前体的组合可以缓和在固化期间发生的酸条件并因此降低这些条件对正被粘结的材料引起显著损坏的风险或倾向。此种组合可能尤其有利作为岩棉绝缘材料的粘结剂，该岩棉绝缘材料的纤维可能对酸引起的潜在损坏比例如，玻璃棉绝缘材料更敏感。
在另一个实施方案中，粘结剂主要衍生自：在水溶液中的碳水化合物；无机铵盐；和有机酸和/或有机酸前体。
包含或主要构成自本文所述组分的粘结剂可以包括添加剂，例如，选自以下的添加剂：硅烷、矿物油、偶联剂、硅酮或硅氧烷(尤其是用于防水)、含硅化合物、表面活性剂、亲水性添加剂、疏水性添加剂、蜡、可用于控制pH值的物质(例如氢氧化铵)和氨。当使用时的氢氧化铵，和甚至其它添加剂可以提供氮源和/或氮的附加源。优选地，添加剂(排除氨)的总量小于5wt％(排除存在的水的重量)，更优选小于3wt％或小于2wt％。
尤其是对于矿物纤维产品，优选包括硅烷作为添加剂。粘结剂和/或粘结剂溶液按干燥重量计可以包含至少0.1％和/或小于1％硅烷。硅烷可以是氨基取代的；它可以是甲硅烷基醚并且据信它的存在可以显著地改进粘结剂的长期强度，尤其是在风化后。
至少在其中将粘结剂应用于待在废水再生体系中粘结和/或回收的材料的状态下，粘结剂的pH值的优先选择是
  优选   更优选   最优选
  粘结剂的pH值   ≥7   ≥8   ≥9
粘结剂的此种中性或碱性pH值可以减轻已经遇到一些主要是酸性的现有技术粘结剂体系的工艺设备的腐蚀问题。此种现有技术粘结剂包括主要由聚丙烯酸或聚合物多元羧酸构成的粘结剂。本发明的一个特定的优点是因此使用可以在这些中性或碱性条件下操作的粘结剂体系。当固化时，粘结剂可以在固化过程中变得酸性。然而，在这种情况下设备腐蚀顾虑是不太显著的，这归因于当在这种状态下时工艺设备和粘结剂间的最小接触。粘结剂的pH值可以小于或等于13，优选小于或等于12、11或10。优选的pH值可以在7.5-9.5，尤其是8-9的范围内。已经应用于待粘结的材料并随后溶解在水中的粘结剂可以具有大于6的pH值。
优选安排粘结剂溶液的pH值处于适当的水平以防止其成分的沉淀并尤其是确保可衍生自无机盐的酸前体保持在溶液中。当磷酸铵提供酸前体时，情况尤其如此。通过使用均匀粘结剂溶液可以实现更好干燥和/或风化强度和/或更均匀产品，该均匀粘结剂溶液包含没有沉淀物的铵盐酸前体，尤其是当使用磷酸铵并且粘结剂溶液没有磷酸盐沉淀时。
粘结剂组合物可以以水溶液的形式提供；它可以含有游离氨或过量在溶液中的氨。粘结剂的中性或碱性pH值可以通过与粘结剂溶液中存在的酸基相比过量的碱性基产生，例如，这部分地或基本上归因于氨在溶液中的存在。可以将附加的氨添加到粘结剂溶液中，例如0.2wt％-1wt％，或甚至更多；这可以帮助保持洗涤水体系长期处于碱性，尤其是对于矿棉绝缘材料的制造。
在尤其是用于绝热产品的矿棉纤维的情况下，当将粘结剂溶液喷涂到刚刚形成的热矿棉纤维上时，矿棉纤维的残余热可能引起该粘结剂溶液中的任何水的大部分蒸发。因此，然后收集形成毛毡的矿棉纤维可以具有以粘性、粘稠或发粘液体的形式存在于它们上的粘结剂。这可以促进各个纤维间经由粘结剂的粘结。
这种粘结剂体系的许多优点之一是以基本上未反应状态将它施加，例如喷涂到矿棉纤维上。以基本上未反应状态施加粘结剂溶液的能力可以缓和与粘结剂组分在溶液中预反应相联系的问题，这些问题被一些其中组分预反应的现有技术粘结剂体系遇到。这些现有技术粘结剂包括主要由施加于待粘结材料上的预反应聚合物或树脂构成的粘结剂。由于基本上未反应的粘结剂以粘性、粘稠或发粘液体的形式存在于待粘结的材料上，所以粘结剂组分间的反应可以以基本上干燥状态进行。可以将这种反应描述为本体聚合，因为它在没有溶剂帮助下进行。本发明的一个特定的优点是使用可以在基本上干燥状态下或经由本体聚合进行聚合的粘结剂体系。
本发明范围中使用的矿物纤维可以通过内部或外部纺丝形成。当用粘结剂溶液喷涂时，它们可以具有20℃-200℃，通常30℃-100℃或150℃的温度，喷涂的粘结剂溶液的量可以在有或者没有附加水雾的情况下用来帮助将矿物纤维冷却到在它们的形成和它们的收集形成毛毡之间的所需温度。
使用溶液中的氨控制施加于矿物纤维上的粘结剂溶液的pH值的特定优点是粘结剂溶液的粘到纤维上的氨的至少一部分可以由于矿棉纤维的残余热而闪蒸掉。因此，涂覆纤维的粘结剂溶液可以具有比喷涂的粘结剂溶液低的pH值。
本发明延伸到矿物纤维绝热产品的制造方法，包括以下顺序步骤：
·由熔融矿物混合物形成矿物纤维；
·将基本上无甲醛的粘结剂溶液喷涂到该矿物纤维上，该粘结剂溶液包含：碳水化合物(尤其是还原糖)、可衍生自无机盐的酸前体和氮源；
·收集粘结剂溶液已经施加于其上的矿物纤维以形成矿物纤维的毛毡；和
·通过让该毛毡经过固化炉使该包含矿物纤维和粘结剂的毛毡固化以致提供由基本上水不溶性固化粘结剂保持在一起的矿物纤维的毛毡。
可以在矿物纤维的形成和收集成毛毡之间将洗涤水喷在它们上，至少一部分洗涤水已经喷在矿物纤维上并随后返回到洗涤水体系以便作为洗涤水再使用。粘结剂溶液可以包含洗涤水。
粘结剂是可固化的；可以例如在固化炉中使它固化；它可以形成热固性粘结剂。呈其固化形式，粘结剂可以：包含蛋白黑素；和/或是热固性的；和/或是水不溶性的或基本上水不溶性的。粘结剂溶液可以基本上是无色或白色到灰白色的；在固化后，粘结剂可以呈现深色，尤其是暗棕色。固化产物可以是暗色的，尤其是暗棕色的。粘结剂可以不含蛋白质；它可以不含纤维素质原料。这种粘结剂体系的许多优点之一是可以通过颜色确定固化程度。基本上脱水的粘结剂看起来是白色或灰白色的。随着固化到更大程度，粘结剂看起来越来愈暗(棕色的暗色)。当施加于矿物纤维上时，可以通过其颜色确定矿棉绝缘材料已经固化的程度。
当施加于待粘结的材料上时和/或在固化之前，粘结剂可以不含或基本上不含蛋白黑素和/或其它源自固化的反应产物。粘结剂的固化可以产生葡糖基胺，尤其是作为中间产物。因此，固化的或尤其是部分固化的产物可以包含葡糖基胺。
粘结剂在固化时的反应可以主要地是梅拉德型反应，例如US专利申请20070027283或WO2007/14236中所述那样。粘结剂可以包含混合物的聚合产物，该混合物包含还原糖和选自硫酸铵、磷酸铵、硝酸铵和碳酸铵的材料。
粘结剂溶液可以通过将以下物质结合来配制：
·碳水化合物，优选还原糖；
·可衍生自无机盐，优选硫酸铵或磷酸铵的酸前体；
·氮源；和
·水。
配方可以包含呈氨水溶液形式提供的任选的或附加的氨。水可以包含洗涤水或再循环工艺用水。
由碳水化合物和包含无机铵盐的酸前体成形粘结剂溶液提供一种尤其有利的制备方法。这可以在简单的混合室中进行，该混合室可以打开和/或处于大气压下。碳水化合物和/或酸前体可以以粉末或液体形式添加。制备优选在室温下进行。优选地，不必供热来制备粘结剂溶液；然而，可以在粘结剂溶液的制备期间加热它，例如加热到20℃-80℃的温度，尤其是当这促进其成分的溶解和/或混合时。
粘结剂溶液，尤其是在施加于待粘结的材料的状态下，可以包含：
·至少5％、10％、15％或18％固体和/或
·小于70％或60％(尤其是在木板应用情况下)或小于50％、40％或20％固体(尤其是在矿物纤维绝缘材料应用情况下)尤其是在140℃下干燥2小时后作为烘干固体按重量测定的。
利用粘结剂溶液粘结在一起的一堆松散物质可以包含选自以下的材料：纤维、纤维材料、矿物纤维、玻璃纤维、岩棉纤维、纤维素纤维(包括木质纤维、木削片、木材颗粒和锯屑)、木饰面板、面料、木材面料、颗粒、纺织或无纺织材料、松散集合的材料、纺织或无纺织材料。
粘结剂溶液和/或粘结剂优选是有机的。
可以借助于粘结剂将松散物质成形和/或定尺度和/或模塑。制备的材料可以选自：绝热材料、矿物纤维产品、木板产品(包括粗纸板、取向绞合板、颗粒板、中密度纤维板、木材面料产品)、铸模砂。
当施加粘结剂时，待粘结的物质可以处于20℃-100℃的温度。尤其是在木板产品的情况下，可以将粘结剂和松散物质机械混合，例如通过翻滚。粘结剂溶液，尤其是当施加于松散物质上时，可以具有适合于通过喷涂或倾倒施加的粘度。它的20℃粘度可以是：
·小于大约1.5Pa.s，优选小于大约1×10-2Pa.s；和/或
·大于大约2×10-4Pa.s，优选大于大约5×10-4Pa.s
粘结剂的固化可以在固化炉中进行，例如使用强制热空气循环；它可以存在于压力机中。固化可以包括粘结剂的脱水；它可以包括聚合；它可以包括本体聚合反应。固化可以进行20分钟或更少，优选10分钟或更少；它可以通过让产品(例如矿物纤维毛毡)穿过固化炉的处于230℃-300℃的温度的至少一个区段来进行，其中固化炉停留时间为30秒-20分钟。粘结剂的固化优选在粘结剂溶液(可以已经从其蒸发掉水)与松散物质接触时发生；它可以在基本上大气压下发生。固化可以是基本上干固化，就是说，通过施加干热和/或基本上干或热的大气空气而不是使用蒸汽或热水蒸气。
尤其是在矿物纤维绝缘产品的情况下，固化温度和时间可以根据产品密度和/或厚度进行选择。在此情况下，固化炉可以具有多个温度在200℃-350℃(通常230℃-300℃)的范围内的加热区。可以通过以少到20秒穿过固化炉固化薄、低密度的产品(12kg/m3或更低)；厚、高密度的产品(80kg/m3或更高)可能要求在固化炉中经过15分钟或更多。在固化过程中，产品可以达到180℃-220℃的温度。
固化粘结剂可以包含通过元素分析测定的按质量计大于2％和/或小于8％的氮。
粘结剂在其未固化状态下可以按干燥重量计包含以下水平的硫酸盐、磷酸盐、碳酸盐和/或硝酸盐：
·大于2.5％、3％或5％；和/或
·小于25％、22％或20％。
使用根据本发明的粘结剂体系制造的成品材料可以具有残留水平的硫酸盐、磷酸盐、碳酸盐和/或硝酸盐，这些盐特别衍生自充当酸前体的无机盐。这些物质可以按以下量存在：
·大于500、750、1000或1500mg/kg；和/或
·小于5000、4000或3000mg/kg。
这些物质的存在可以按浸析试验评价并提供在所使用的粘结剂体系的最终产品中的指标。
成品中的粘结剂的量(尤其是在矿棉绝缘材料的情况下)可以是：
·大于：1％、2％、2.5％、3％、3.5％或4％；和/或
·小于：20％、15％、10％或8％，这是按成品的干燥重量测量的。
尤其是在矿物纤维绝缘材料的情况下，产品可以具有以下分离强度中的一种或多种：
普通分离强度：
·至少120g/g，优选至少150g/g；和/或
·小于400g/g
风化分离强度：
·至少120g/g，优选至少150g/g；和/或
·小于400g/g
普通分离强度和风化分离强度间的％损失：
·小于10％，优选小于5％。
当产品是矿棉绝缘材料时，可以具有以下特性中的一种或多种：
·大于5、8或10kg/m3的密度；
·小于200、180或150kg/m3的密度；
·包含玻璃棉纤维并具有大于5、8或10kg/m3和/或小于80、60或50kg/m3的密度；
·包含岩棉纤维并具有大于15、20或25kg/m3和/或小于220、200或180kg/m3的密度；
·小于0.05W/mK和/或大于0.02W/mK的导热率λ；
·包含小于99wt％和/或多于80wt％矿物纤维。
·大于10mm、15mm或20mm和/或小于400mm、350mm或300mm的厚度。
当产品是木板产品时，它可以具有以下特性中的一种或多种：
·至少50cm×80cm，优选至少1m×2m的尺度；
·至少11mm、12mm或15mm的厚度；
·小于25、15、12或10分钟的固化时间；
·根据EN319测量的至少0.4N/mm2或0.45N/mm2(尤其是对于颗粒板或纤维板)或根据EN 300测量的至少0.28N/mm2(尤其是对于取向绞合板)的内结合强度；
·在水中在20℃下24小时之后根据EN317的小于12％，优选小于10％的厚度溶胀；
·在水中在20℃下在24小时后小于40％，优选小于30％的吸水率；
·根据EN310的至少：1800N/mm2(尤其是对于颗粒板或纤维板)或2500N/mm2(尤其是对于取向绞合板)或3500N/mm2或4800N/mm2的弹性模量；
·至少：14N/m2(尤其是对于颗粒板或纤维板)或18N/mm2(尤其是对于取向绞合板)或20N/mm2或28N/mm2的抗弯强度(MOR)；
·蜡作为添加剂，例如0.1-2wt％，优选0.5-1wt％；
·8-18wt％，优选10-16wt％，更优选12-14wt％的树脂含量(干树脂重量对干木颗粒的重量)。
·在压力机中固化，尤其是在温度大于180℃或200℃和/或小于280℃或260℃的压盘之间。
现将参照图1举例描述本发明的实施方案，图1是矿物纤维试验样品的俯视图。
壳骨试验：
如下制备为水溶液的粘结剂
·将所需粘结剂配方的成分在开放、未加热的反应容器中结合
·添加蒸馏水
·随后添加硅烷溶液
·在液体的添加期间和之后数分钟进行搅拌以达到固体的完全溶解
满足粘结剂溶液含有大约45％溶解的固体，作为溶液总重量的百分率。在大约200℃-210℃下热固化8分钟后，这一溶液的2g样品将产生30％固体(重量损失归因于在热固性粘结剂形成期间的脱水)。
含玻璃珠的壳骨的干和″风化″拉伸强度的评价提供采用该特定粘结剂制备的玻璃纤维绝缘材料或其它材料的可能的拉伸强度和可能的耐久性的示值。预计的耐久性基于壳骨的风化拉伸强度与其干拉伸强度的比例。
为了制备壳骨，使用电力混合器大约两分钟以将大约75g粘结剂与727.5g玻璃珠(相当于Quality Ballotini Impact Beads，Spec.AD，US Sieve 70-140，106-212微米-#7，得自Potters Industries，Inc.)混合。在整个混合的大约一半以及在混合结束时，使用抹刀人工地将混合器扫帚侧面和混合碗侧面和底部的任何块体混入。
将制备的玻璃珠/粘结剂混合物添加到已经预加热到大约218℃(425°F)的壳骨模具(Dietert Foundry Testing Equipment；HeatedShell Curing Accessory，Model 366)的模具内腔。弄平每个内腔中的混合物的表面，同时刮去过量的混合物以赋予该壳骨均匀的表面区域。用另外的玻璃珠/粘结剂混合物填充存在于任何内腔中的任何不一致或间隙，然后弄平。迅速地将顶压盘放置到底压盘上(以避免产生两个差别固化层的壳骨)。在七分钟后取出固化壳骨，在线架上上冷却至室温，标记并单独地放置在塑料储存袋中。如果不能在制备它们的当天试验壳骨，则将该含壳骨的塑料袋放入干燥器装置中。在固化期间，底压盘的温度为大约204℃-大约221℃(大约400°F-大约430°F)，而顶压盘的温度为大约227℃-大约243℃(大约440°F-大约470°F)。
试验断裂强度的程序：
·设备：5500 R Instron机器
·刚好在试验之前从塑料袋取出每个壳骨并记录其重量和厚度。
壳骨的风化程序：
·在预热的湿度室(65℃，95％相对湿度)中16小时风化
·在取出后，将壳骨密封在各塑料储存袋中并在立即用于试验。
测量胶凝时间的程序：
将少量粘结剂(2.0ml)添加到设定到150℃的热板的中央并启动秒表。用抹刀处理该粘结剂直到可以将样品拉伸成长绳。从添加粘结剂到绳子形成花费的时间是胶凝时间。
试验的粘结剂配方-与柠檬酸相比的无机酸前体
  试验索引：   粘结剂配方(按干燥重量)
  A   85％DMH+15％CA+4.8％NH4OH+0.3％ISI0200
  B   90％DMH+10％AmSO4+4.8％NH4OH+0.3％ISI0200
  C   85％DMH+15％AmSO4+4.8％NH4OH+0.3％ISI0200
  D   80％DMH+20％AmSO4+4.8％NH4OH+0.3％ISI0200
  E   90％DMH+10％AmPO4+4.8％NH4OH+0.3％ISI0200
  F   85％DMH+15％AmPO4+4.8％NH4OH+0.3％ISI0200
  G   80％DMH+20％AmPO4+4.8％NH4OH+0.3％ISI0200
试验的粘结剂配方-与单独的柠檬酸和单独的无机酸前体相比的无机酸前体和柠檬酸的组合
  试验索引：   粘结剂配方(按干燥重量)
  H   85％DMH+15％CA+4.8％NH4OH+0.3％ISI0200
  I   85％DMH+10％CA+5％AmSO4+4.8％NH4OH+0.3％ISI0200
  J   85％DMH+5％CA+10％AmSO4+4.8％NH4OH+0.3％ISI0200
  K   85％DMH+15％AmSO4+4.8％NH4OH+0.3％ISI0200
脚注：
DMH＝葡萄糖一水合物
CA＝柠檬酸
NH4OH＝氢氧化铵
ISIO200＝硅烷
AmSO4＝硫酸铵
AmPO4＝磷酸铵
试验结果-与柠檬酸相比的无机酸前体：
  试验索引：   干断裂强度(MN/m2)   风化断裂强度(MN/m2)   由于风化的断裂强度损失/％   粘结剂溶液的凝胶时间(s)   就在与珠子混合之前粘结剂溶液的pH值
  A   1,455   1,567   -7,70   343   9,54
  B   1,271   0,895   29,57   280   10,28
  C   1,550   0,856   44,79   362   10,24
  D   1,877   1,156   38,39   327   10,13
  E   1,499   1,069   28,68   356   10,18
  F   1,281   0,848   33,82   334   9,99
  G   1,123   0,801   28,74   287   9,73
试验结果-与单独的柠檬酸和单独的无机酸前体相比的无机酸前体和柠檬酸的组合
  试验索引：   干断裂强度(MN/m2)   风化断裂强度(MN/m2)   由于风化的断裂强度损失/％   粘结剂溶液的凝胶时间(s)   就在与珠子混合之前粘结剂溶液的pH值
  H   1.69   1.50   11.32   363   9.39
  I   1.50   1.18   21.37   341   9.71
  J   1.21   1.05   13.19   375   9.99
  K   1.47   1.02   30.33   376   9.97
一起进行的试验的结果(在一个阶段进行试验A-G，在另一阶段进行试验H-K)提供相对于在相同试验阶段期间获得的其它结果的有用的结果示值。比较不同试验阶段的试验结果可能是不可靠的。
对绝缘产品的第一比较试验：
粘结剂体系对矿物纤维绝缘产品的比较试验获得以下结果：
  试验的粘结剂   描述   配方
  PF1   对比实施例-标准苯酚甲醛粘结剂   树脂，脲，木素，氨，硅烷
  AC1   对比实施例-柠檬酸铵基粘结剂   葡萄糖85％柠檬酸15％氨4.8％硅烷0.3％
  Ex1   本发明的实施例1   葡萄糖85％硫酸铵15％氨4.8％硅烷0.3％
  用于试验的产品：   玻璃棉纤维绝缘产品，标称密度16kg/m3，标称厚度75mm，标称宽度455mm
试验产品的粘结剂含量，LOI(烧失量)wt％：
  粘结剂   平均LOI
  PF1   6.22％
  AC1   6.91％
  Ex1   6.78％
悬挂试验(在规定周期后测量的平均值，单位为mm)：
Figure GPA00001013891900151
厚度(在规定周期后根据英国标准BS EN 823：1995测量的平均值，单位为mm)
Figure GPA00001013891900152
Figure GPA00001013891900161
密度(在规定周期后测量的平均值，单位为kg/m3)
Figure GPA00001013891900162
存在的硫酸盐的量，mg/kg
Figure GPA00001013891900163
分离强度(g/g)
试验程序：
粘结剂含量LOI(烧失量)
将棉毛加上粘结剂的称重样品放入设定至550℃的马弗炉中。在规定时间后，从该炉子中取出该棉毛，放入干燥器中冷却并再称重。重量损失表示为原始样品重量的百分率并称为粘结剂含量或烧失量(LOI)。
悬挂试验
将单个毛毡(或厚片)横放在设定到相隔1米的壁中的两个杆(每个500mm长，20mm直径)上。记录在该毛毡中央的下垂度数。对一包中的所有毛毡和对数包这样重复。在时期内的设定点测量包装以测定压缩对毛毡的长期效应。
密度：对经历了悬挂试验的样品测量
存在的硫酸盐的量：用根据英国标准BS EN 12457-2在L/S10的洗出液分析对在水中的颗粒废物进行浸析试验
分离强度
分离强度以克/克表示，是六个试样的总断裂载荷除以它们的总重量。对收到用于试验(普通分离强度)和在下面阐明的加速风化试验后(风化分离强度)的矿物纤维毡进行试验。从待试验的矿物纤维毡上剪下具有图1所示的形式和尺度的第一组六个样品。尺度是：
r：半径12.7mm；
DC：中心距44.5mm；
a：25.4mm；
b：121mm。
样品的长轴应该平行于输送机方向并且样品应该跨过矿物毡的总宽度。然后以同样的方式取得第二组六个样品。
记录第一组六个样品的总重量W1(克)。记录第二组六个样品的总重量W2(克)；然后将这些样品放入预加热的高压釜中并在远离腔室底部的线网支架上在湿蒸汽下在35kN/m2下调理一小时。然后取出它们，在烘箱中在100℃下干燥五分钟并立即试验分离强度。
为了试验分离强度，又将每个样品安装在5500 Instron拉伸强度机的狭口上并记录最大断裂载荷(克或牛顿)。如果断裂载荷以牛顿测量，则通过让它乘以101.9转换成克。对于每组样品获得六个结果(克)：对于第一组样品的G1 G2 G3 G4 G5和G6，对于第二组样品的G7 G8 G9 G10 G11和G12。
由第一组样品使用公式普通分离强度＝(G1+G2+G3+G4+G5+G6)/W1计算普通分离强度。
由第二组样品使用公式风化分离强度＝(G7+G8+G9+G10+G11+G12)/W2计算风化分离强度。
对绝缘产品的第二比较试验：
  用于试验的产品：   玻璃棉纤维绝缘产品，标称密度7.2kg/m3，标称厚度159mm
样品：试验以下玻璃纤维毛毡的样品：
  实施例   粘结剂描述   产品的目标粘结剂含量(LOI)
  PF2   树脂，脲，氨，硅烷的标准苯酚甲醛粘结剂   4.5％
  2.1   葡萄糖85％硫酸铵15％硅烷0.3％(粘结剂溶液中10.6％固体)   4.5％
  2.2   葡萄糖85％硫酸铵15％硅烷0.3％Norjohn oil(粘结剂溶液中11.4％固体)   4.5％
  实施例   粘结剂描述   产品的目标粘结剂含量(LOI)
  2.3   葡萄糖85％硫酸铵15％硅烷0.3％，2.4％NH3(粘结剂溶液中10.6％固体)   4.5％
  2.4   葡萄糖85％硫酸铵15％硅烷0.3％，2.4％NH3(粘结剂溶液中10.6％固体)   6.0％
结果
  PF2   2.1   2.2   2.3   2.4
  恢复   158mm   157mm   163mm   160mm   166mm
  恢复％标称   99.4％   99.0％   102.8％   100.6％   104.8％
  分离强度(ASTM C-686)   190.8g/g   131.7g/g   146.7g/g   159.9g/g   143.9g/g
  风化后的分离强度(ASTMC-686，在90°F，90％相对湿度下调理7天后)   145.9g/g   100.0g/g   110.3g/g   124.9g/g   114.3g/g

Claims (20)

1.基本上无甲醛的粘结剂溶液，主要由可通过将以下物质溶解在水中获得的溶液构成：
-还原糖，
-选自铵的硫酸盐、铵的磷酸盐、铵的硝酸盐和铵的碳酸盐的一种材料，
-任选的羧酸或其前体，和
-任选的氨。
2.根据权利要求1的基本上无甲醛的粘结剂溶液，主要由通过将以下物质溶解在水中获得的溶液构成：
-还原糖，
-选自铵的硫酸盐、铵的磷酸盐、铵的硝酸盐和铵的碳酸盐的一种材料，
-任选的羧酸或其前体，和
-任选的氨。
3.根据权利要求1或权利要求2的基本上无甲醛的粘结剂溶液，其中所述还原糖主要由葡萄糖构成。
4.根据上述任一权利要求的基本上无甲醛的粘结剂溶液，其中所述羧酸以铵盐形式提供。
5.根据上述任一权利要求的基本上无甲醛的粘结剂溶液，其中所述溶液的pH值大于7。
6.根据上述任一权利要求的基本上无甲醛的粘结剂溶液，其中所述粘结剂溶液具有在它的使用条件下防止硫酸盐、磷酸盐、硝酸盐或碳酸盐沉淀的pH值。
7.根据上述任一权利要求的基本上无甲醛的粘结剂溶液，其中选自铵的硫酸盐、铵的磷酸盐、铵的硝酸盐和铵的碳酸盐的材料按干燥重量计构成粘结剂溶液的5％-25％。
8.根据上述任一权利要求的基本上无甲醛的粘结剂溶液，其中所述粘结剂溶液包含至少5％固体且小于50％固体。
9.根据上述任一权利要求的基本上无甲醛的粘结剂溶液，其中还原糖与选自铵的硫酸盐、铵的磷酸盐、铵的硝酸盐和铵的碳酸盐的材料的表示为(还原糖的干重/铵盐的干重)的按干燥重量的比例是2.5-13。
10.根据上述任一权利要求的基本上无甲醛的粘结剂溶液，其中所述粘结剂溶液包含作为溶解的粘结剂固体计算的0.1％-1％的含硅烷或硅的偶联剂。
11.产品的制造方法，包括以下步骤：
·提供一堆松散物质；
·用根据权利要求1-10中任一项的基本上无甲醛的粘结剂溶液处理该一堆松散物质；
·将该用粘结剂溶液处理的一堆松散物质以基材的形式布置；
·通过施加能量源使该粘结剂固化。
12.根据权利要求11的方法，其中通过让该基材经过230℃-300℃的温度下的固化炉的至少一个区段进行该粘结剂的固化，其中固化炉停留时间为30秒-20分钟。
13.根据权利要求11的方法，其中通过在压力机的压盘之间进行该粘结剂的固化。
14.包含通过基本上无甲醛的粘结剂维持在一起的一堆松散物质的材料，其特征在于该材料包含多于500mg/kg选自硫酸盐、磷酸盐、硝酸盐和碳酸盐的物质。
15.根据权利要求14的材料，其中选自硫酸盐、磷酸盐、硝酸盐和碳酸盐的物质主要衍生自粘结剂前体。
16.根据权利要求14-15中任一项的材料，其中该粘结剂是固化的并包含蛋白黑素。
17.包含一堆松散物质和未固化或部分固化的基本上无甲醛的粘结剂的材料，其特征在于该粘结剂当溶解在水中时具有大于6的pH值并包含
-还原糖，
-选自铵的硫酸盐、铵的磷酸盐、铵的硝酸盐和铵的碳酸盐的一种材料，
-任选的羧酸或其前体，和
-任选的氨。
18.根据权利要求14-17中任一项的材料，其中所述松散物质包含矿物纤维。
19.根据权利要求18的材料，其中该材料是矿物纤维绝热材料。
20.根据权利要求14-17中任一项的材料，其中该材料是木板。
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CN108368399A (zh) * 2015-12-18 2018-08-03 汉高股份有限及两合公司 水性粘结组合物
CN109154155A (zh) * 2016-05-13 2019-01-04 洛科威国际有限公司 向结构提供隔离的方法
CN110366588A (zh) * 2017-02-24 2019-10-22 松下知识产权经营株式会社 用于热压成型的粘合剂、木质板及其制造方法
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