Method of reducing the formaldehyde emission of a mineral fiber product, and mineral fiber product with reduced formaldehyde emission

Abstract

A method of reducing the formaldehyde emission of a mineral fibre product bonded with a urea-modified phenol-formaldehyde resol resin-type binder comprises the step of adding dextrose to the binder composition during and/or after preparation of the binder composition but before curing of the binder composition applied to the mineral fibres.

1 .- 16 . (canceled) 
     
     
         17 . A method of reducing the formaldehyde emission of a mineral fiber product bonded with a urea-modified phenol-formaldehyde resol resin-type binder composition, wherein the method comprises adding dextrose to the binder composition at least one of during and after preparation of the binder composition but before curing the binder composition applied to mineral fibers. 
     
     
         18 . The method of  claim 17 , wherein dextrose is used as pure dextrose or in the form of a dextrose preparation having a DE equivalent of from about 70 to about 100. 
     
     
         19 . The method of  claim 17 , wherein dextrose is used as in the form of a dextrose preparation having a DE equivalent of from about 90 to about 100. 
     
     
         20 . The method of  claim 17 , wherein phenol is reacted with a molar excess of formaldehyde in aqueous solution in a molar ratio of from 1:2.5 to 1:6 in a presence of a base catalyst. 
     
     
         21 . The method of  claim 20 , wherein phenol is reacted with a molar excess of formaldehyde in aqueous solution in a molar ratio of from 1:3 to 1:5. 
     
     
         22 . The method of  claim 17 , wherein urea is used in an amount of from 20 to 60 wt %, based on total dry solids of the phenol-formaldehyde resol resin and urea. 
     
     
         23 . The method of  claim 21 , wherein urea is used in an amount of from 30 to 50 wt %, based on total dry solids of the phenol-formaldehyde resol resin and urea. 
     
     
         24 . The method of  claim 17 , wherein dextrose is used in an amount of from 15 to 70 wt %, based on total dry solids of urea-modified phenol-formaldehyde resol resin and dextrose. 
     
     
         25 . The method of  claim 23 , wherein dextrose is used in an amount of from 20 to 50 wt %, based on total dry solids of urea-modified phenol-formaldehyde resol resin and dextrose. 
     
     
         26 . A mineral fiber product having reduced formaldehyde emission and bonded with a cured urea-modified phenol-formaldehyde resol resin-type binder composition, wherein the non-cured binder composition comprises dextrose in an amount of from 10 wt % to 70 wt %, based on total dry solids of phenol-formaldehyde resol resin and dextrose. 
     
     
         27 . The mineral fiber product of  claim 26 , wherein the non-cured binder composition comprises at least 15 wt % of dextrose. 
     
     
         28 . The mineral fiber product of  claim 26 , wherein the non-cured binder composition comprises at least 20 wt % of dextrose. 
     
     
         29 . The mineral fiber product of  claim 26 , wherein the non-cured binder composition comprises at least 30 wt % of dextrose 
     
     
         30 . The mineral fiber product of  claim 26 , wherein the product satisfies formaldehyde emission requirements of at least one of Finnish Standard RTS-M1, US Standard CDHS, and Japanese Standard JIS A 19012003 (E). 
     
     
         31 . The mineral fiber product of  claim 26 , wherein the product is a ceiling tile having a density of from 50 to 220 kg/m 3  and has been manufactured using a non-cured binder composition comprising dextrose in an amount of from 20 to 70 wt %, based on total dry solids of phenol-formaldehyde resol resin and dextrose. 
     
     
         32 . The mineral fiber product of  claim 26 , wherein the product is a roof board having a density of from 100 to 250 kg/m 3  and has been manufactured using a non-cured binder composition comprising dextrose in an amount of from 20 to 50 wt %, based on total dry solids of phenol-formaldehyde resol resin and dextrose. 
     
     
         33 . The mineral fiber product of  claim 26 , wherein the product is a building insulation product board or roll having a density of from 5 to 70 kg/m 3  and has been manufactured using a non-cured binder composition comprising dextrose in an amount of from 10 to 50 wt %, based on total dry solids of phenol-formaldehyde resol resin and dextrose. 
     
     
         34 . A method of scavenging formaldehyde in a urea-modified phenol-formaldehyde resol resin-type binder composition for a mineral fiber product, wherein the method comprises adding to the binder composition dextrose as a formaldehyde scavenger. 
     
     
         35 . The method of  claim 34 , wherein the mineral fiber product is selected from
 a roof board having a density of from 100 to 250 kg/m 3  and having been manufactured using a non-cured binder composition and dextrose in an amount of 20 to 50 wt %;   a ceiling tile having a density of from 50 to 220 kg/m 3  and having been manufactured using a non-cured binder composition and dextrose in an amount of from 20 to 70 wt %; and   a building insulation product board having a density of from 5 to 70 kg/m 3  and having been manufactured using a non-cured binder composition and dextrose in an amount of from 10 to 50 wt %;   the indicated weight percentages being based on total dry solids of phenol-formaldehyde resol resin and dextrose.   
     
     
         36 . An apparatus for making a mineral fiber product having reduced formaldehyde emission and bonded with a cured dextrose-containing urea-modified phenol-formaldehyde resol resin-type binder composition, wherein the apparatus comprises
 a device for fiberizing a mineral melt into mineral fibers,   separate tanks for the binder composition and dextrose;   a device for mixing the binder composition and the dextrose,   a device for applying a mixture of binder composition and dextrose to the mineral fibers,   a collection chamber for the mineral fibers having the mixed binder composition and dextrose applied thereto,   a curing oven for curing the mixed binder composition and dextrose applied to the mineral fibers to form a cured web, and   a device for confectioning the cured web to a mineral fiber product.