Low Formaldehyde Binders for Mineral Wool Insulation: A Review.

Thomas M Bennett,John F Allan,Jennifer A Garden,Michael P Shaver

doi:10.1002/gch2.202100110

Thomas M Bennett, John F Allan + Show 2 more

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https://doi.org/10.1002/gch2.202100110

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Abstract

Insulating materials are ubiquitous in a built environment and play a critical role in reducing the energy consumed to maintain habitable indoor environments. Mineral wool insulation (MWI) products, including glass, stone, and slag variants, are the most widely used class of insulating materials in Europe and account for more than 50% of the total market by volume. MWI typically consists of two key components: a mesh of inorganic fibers that are several micrometers in diameter, and an organic thermosetting adhesive commonly referred to as the “binder.” Traditional phenol‐formaldehyde‐urea (PFU) binders used in the manufacture of MWI are increasingly being scrutinized for the formaldehyde released during their manufacture and service lifetime. The recent classification of formaldehyde as a carcinogen by various safety organizations has accelerated a paradigm shift within the industry toward alternative binder technologies that minimize or indeed eliminate formaldehyde emissions. This review examines more recent strategies for achieving low‐ or zero‐added formaldehyde binders for MWI, with a particular focus on the patent literature. The chemistry underpinning traditional PFU binders is presented and compared to new strategies involving scavenging molecules that decrease formaldehyde emissions, as well as zero‐added formaldehyde binder technologies such as polyester, Maillard, and epoxide thermosets.

Highlights

The primary role of insulating materials in society is to passively reduce unwanted energy emissions
The purpose of this review is to provide a detailed summary of recent developments in technologies underlying the production of Mineral wool insulation (MWI) products, focusing in particular on strategies to reduce, or eliminate, the quantity of formaldehyde released by the binder before and during their service lifetimes
Traditional PFU thermoset binders used in the manufacture of MWI products are rapidly becoming undesirable because free formaldehyde is released during their manufacture and service lifetime into atmospheres breathed directly by humans

Summary

Introduction

The primary role of insulating materials in society is to passively reduce unwanted energy emissions This is predominantly thermal energy, yet their use extends to other associated areas including electrical, typically consists of two key components: a mesh of inorganic fibers that acoustic, fire resistance, radiation, and are several micrometers in diameter, and an organic thermosetting adhesive commonly referred to as the “binder.” Traditional phenol-formaldehydeurea (PFU) binders used in the manufacture of MWI are increasingly being scrutinized for the formaldehyde released during their manufacture and service lifetime. Fibrous inorganic materials—namely, mineral wools comprised of glass or stone—are one of the most effective and well-established classes of insulation materials globally and represent an ≈58% market share by volume in Europe (Figure 1).[3,4] Mineral scavenging molecules that decrease formaldehyde emissions, as well as zero-added formaldehyde binder technologies such as polyester, Maillard, and epoxide thermosets

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