Use of Surfactants To Improve Aged Properties of Fiberglass Insulation Products

Abstract

Fibrous insulation products manufactured with surfactants and methods for making are disclosed. The surfactant may be neutral or charged and, if charged, may be anionic, cationic or zwitterionic, although neutral or non-ionic provide suitable results. The surfactant may be of any chemical structure class, although ethoxylated alcohols and ethoxylated ethers have been found most suitable. Surfactant may be sprayed onto mineral fibers as a separate dispersion or as part of a binder dispersion. The surfactant my optionally be used with an organo-silane coupling agent, such as an amino-silane.

What is claimed is: 
     
         1 . A method for manufacturing a fibrous insulation product having improved mechanical properties upon aging, the method comprising:
 forming a fibrous product from a plurality of mineral fibers,   applying a thermosetting binder to the fibers of the fibrous product, the thermosetting binder including a polyhydroxyl compound and a polycarboxylic acid, the polyhydroxyl compound and the polycarboxylic acid being capable of forming crosslinks, and   applying a surfactant to the fibers of the fibrous product, the surfactant being applied to achieve a normalized concentration of about 0.01% to about 10% based on the dry weight of the fibrous product.   
     
     
         2 . The method of  claim 1 , wherein the thermosetting binder is a natural binder comprising a carbohydrate-based polyhydroxyl compound and a polycarboxylic acid. 
     
     
         3 . The method of  claim 2 , wherein the carbohydrate-based polyhydroxyl compound comprises a polysaccharide selected from a starch, a maltodextrin, a dextrin and a syrup. 
     
     
         4 . The method of  claim 2 , wherein the carbohydrate-based polyhydroxyl compound has a dextrose equivalent (DE) from about 2 to about 20. 
     
     
         5 . The method of  claim 2 , wherein the polycarboxylic acid is selected from a polyacrylic acid and an organic di- or tri-carboxylic acid. 
     
     
         6 . The method of  claim 2 , wherein the surfactant is applied as a dispersion also containing the natural binder. 
     
     
         7 . The method of  claim 1 , wherein the surfactant is applied at a normalized concentration from about 0.05% to about 1%, based on the dry weight of the fibrous product. 
     
     
         8 . The method of  claim 1 , wherein the surfactant is a non-ionic surfactant. 
     
     
         9 . The method of  claim 8 , wherein the non-ionic surfactant is an ethoxylated polyalcohol. 
     
     
         10 . The method of  claim 9 , wherein the non-ionic surfactant is selected from the Surfynol® series  420 ,  440 ,  465 , and  485 . 
     
     
         11 . The method of  claim 1 , further comprising improving a mechanical property selected from recovery, sag, compressive strength, and tensile strength. 
     
     
         12 . The method of  claim 1 , further comprising improving an aged mechanical property selected from recovery, sag, compressive strength, and tensile strength. 
     
     
         13 . The method of  claim 12 , wherein recovery is improved by at least 2% compared to the same product made with without surfactant. 
     
     
         14 . The method of  claim 12 , wherein sag is improved by at least 10% compared to the same product made with without surfactant. 
     
     
         15 . The method of  claim 12 , wherein compressive strength is improved by at least 5% compared to the same product made with without surfactant. 
     
     
         16 . The method of  claim 1 , wherein the surfactant is applied in combination with a silane coupling agent. 
     
     
         17 . A method for improving the aged mechanical properties of a fibrous insulation product, the method comprising:
 forming a fibrous product from a plurality of mineral fibers and a natural, thermosetting binder, the binder including a carbohydrate-based polyhydroxyl compound and a polycarboxylic acid, the polyhydroxyl compound and the polycarboxylic acid being capable of forming crosslinks, and   applying a surfactant to the fibers of the fibrous product, the surfactant being applied to achieve a normalized concentration of about 0.05% to about 5% based on the dry weight of the fibrous product; wherein at least one aged mechanical property is improved by at least 2% compared to fibrous product not containing the surfactant.   
     
     
         18 . The method of  claim 17 , wherein the aged mechanical property is selected from recovery, sag, compressive strength, and tensile strength. 
     
     
         19 . The method of  claim 17 , wherein the surfactant is a non-ionic ethoxylated polyalcohol.