(12) United States Patent
`JacksOn et al.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 7,854,980 B2
`Dec. 21, 2010
`
`US00785498OB2
`
`(54) FORMALDEHYDE-FREEMINERAL FIBRE
`NSULATION PRODUCT
`(75) Inventors: Roger Jackson, Merseyside (GB); Tony
`Aindow, Merseyside (GB); George
`Baybutt, Merseyside (GB)
`(73) Assignee: Knauf Insulation Limited, St. Helens,
`Merseyside (GB)
`
`(*) Notice:
`
`(21) Appl. No.:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by O. davs.
`(b) by
`yS
`12/524,491
`
`4/1931 Meigs
`1,801,053 A
`1,886,353 A 1 1/1932 Novotny et al.
`2,392,105 A
`1/1946 Sussman
`3,232,821 A
`2, 1966 Moore et al.
`SE A ;: E. et al.
`3,826,767 A
`7, 1974 Hoover et al.
`3,856,606 A 12/1974 Fan et al.
`3,911,048 A 10/1975 Vargiu et al.
`4,028,290 A
`6/1977 Reid
`4,048,127 A
`9, 1977 Gibbons et al.
`4,054,713. A 10/1977 Sakaguchi et al.
`4,097.427 A
`6, 1978 Aitken et al.
`(Continued)
`FOREIGN PATENT DOCUMENTS
`
`(22) PCT Filed:
`(86). PCT No.:
`S371 (c)(1)
`(2), (4) Date:
`
`C
`
`s
`
`Jan. 25, 2007
`PCT/EP2007/050750
`
`Nov. 12, 2009
`
`EP
`
`O 524518
`7, 1992
`(Continued)
`OTHER PUBLICATIONS
`International Search Report and Written Opinion for PCT/EP2007/
`050750, completed Nov. 28, 2007.
`(Continued)
`Primary Examiner N. Edwards
`(74) Attorney, Agent, or Firm Barnes & Thornburg LLP
`
`(87) PCT Pub. No.: WO2008/089851
`PCT Pub. Date: Jul. 31, 2008
`D
`P
`Pub
`rior Publication Data
`ABSTRACT
`(57)
`US 2010/0080976A1
`Apr. 1, 2010
`A packaged mineral fibre insulating material has: a) a Recov
`(51) Int. Cl
`ered Thickness of at least 95% nominal thickness; and b) an
`(2006.01)
`i2h 3/02
`Ordinary Parting Strength of at least 95 g/g, and c) a Weath
`428/45: 428/47: 524/487
`(52) U.S. Cl
`ered Parting Strength of at least 75 g/g, the material compris
`ir grgro
`s
`s
`f
`(58) Field of Classist s ash 1.524/487. T ing mineral fibres and an organic, formaldehyde free binderin
`See application file for com lete search histo
`a quantity of less than 15% by weight, preferably less than
`pp
`p
`ry.
`10% by weight, said binder having been applied to the fibres
`References Cited
`of the insulating material in liquid form at pH of greater than
`5.
`
`(65)
`
`(56)
`
`U.S. PATENT DOCUMENTS
`1,801,052 A
`4/1931 Meigs
`
`20 Claims, 1 Drawing Sheet
`
`
`
`a
`5.
`|
`
`i
`
`3.
`|- is -- SS - -- 3 is -
`|
`|
`|
`|
`l
`N3.7
`Ys. y
`
`i
`
`:
`
`^
`
`s
`s
`
`“xx...sex
`
`PGR2022-00022 - Petitioner’s Exhibit 1007 – Page 1
`
`

`

`US 7,854,980 B2
`Page 2
`
`U.S. PATENT DOCUMENTS
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`
`
`
`FOREIGN PATENT DOCUMENTS
`
`EP
`EP
`EP
`EP
`EP
`
`O 5478.19
`O 583 086
`O 67272O
`O714754 B1
`O 826 710
`
`6, 1993
`2, 1994
`9, 1995
`12/1995
`4f1998
`
`PGR2022-00022 - Petitioner’s Exhibit 1007 – Page 2
`
`

`

`US 7,854,980 B2
`Page 3
`
`EP
`EP
`EP
`EP
`EP
`EP
`EP
`EP
`EP
`EP
`EP
`FR
`GB
`JP
`JP
`JP
`SU
`WO
`WO
`WO
`WO
`
`10, 1998
`O 873 976
`12/1998
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`4f1999
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`4/2000
`O 990 729
`9, 2000
`1038 433
`4/2002
`1 193288
`1, 2004
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`7/2005
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`
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`WO
`WO WO2006/0443.02
`WO WO2007/O14236
`
`9, 2004
`4/2006
`2, 2007
`
`OTHER PUBLICATIONS
`
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`English Translation of Japanese Abstract for 03173680, Jul. 26, 1991,
`1 page.
`English Translation of Japanese Abstract for 07034023, Feb. 3, 1995,
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`English Translation of Russian Abstract for 374400, Mar. 20, 1973, 1
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`Ames, J. M.. “The Maillard Browning Reaction—an Update'.
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`
`* cited by examiner
`
`PGR2022-00022 - Petitioner’s Exhibit 1007 – Page 3
`
`

`

`U.S. Patent
`U.S. Patent
`
`Dec. 21, 2010
`Dec. 21, 2010
`
`US 7,854,980 B2
`US 7,854,980 B2
`
`Fig 1
`Fig 1
`
`
`
`
`
`
`
`
`
`
`
`ensSilgermeencnnnseseCOCtEEOAUBALELONGAGPADDTLLEASEADERIATULTETAULELLELUELELEUITISASISIALTILSLEAIPOLAhdtheasASORISATAA/SAELenyapabésisiseispicsétosaspseicipssiisaisttsntsAGE
`peeteeeqegeetanwe
`ppewnnCPRCERAitareneOeetotrWemARAebeBOREPOLCRSatbEtEey,
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`LEELAAATAOREARAMCENCEGENEDEATEAARPROLCOOCCLOIBEHg
`ny,i~.+oYv
`
`vef
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`Org}
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`YR?
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`agow
`eee
`
`PGR2022-00022 - Petitioner's Exhibit 1007 — Page 4
`
`PGR2022-00022 - Petitioner’s Exhibit 1007 – Page 4
`
`
`

`

`US 7,854,980 B2
`
`1.
`FORMALDEHYDE-FREEMINERAL FIBRE
`NSULATION PRODUCT
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`This application is a U.S. national counterpart application
`of international application serial no. PCT/EP2007/050750
`filed Jan. 25, 2007.
`
`FIELD OF THE INVENTION
`
`This invention relates to a mineral fibre insulating product
`having a low formaldehyde or formaldehyde free binder.
`
`BACKGROUND
`
`10
`
`15
`
`2
`Strength and/or Weathered Parting Strength. The procedures
`for measuring these characteristics are set out below. This is
`particularly the case for low and medium density insulating
`products, for example, having a density in the range 5-40
`kg/m, for example roll insulation and/or glass wool thermal
`insulation for lofts and/or cavity walls.
`Desired characteristics for some mineral wool insulation
`product can be assessed by measuring Ordinary Compression
`Strength and/or Weathered Compression Strength. The pro
`cedures for measuring these characteristics are set out below.
`This is particularly for higher density insulating products, for
`example, insulating boards or materials adapted for use as: a
`fire barrier, a fire protection; cladding for a building; a ceiling
`tile; a roof board; thermal insulation for high temperature
`machinery for example, generators, ovens and industrial
`plant. Such products may be made of rock wool.
`The pH of the binder when applied may be substantially
`neutral or alkaline; this may facilitate handling and avoid
`significant corrosion and/or environmental problems. Its pH
`when applied may be: greater than or equal to 7 and/or less
`than or equal to 10; between 7 and 10; between 8 and 10.
`An important aspect of the invention is the pH of the binder
`in liquid form when applied to the fibres as this is the form in
`which the binder will have significant contact with manufac
`turing equipment as freshly prepared and in a wash water
`system. The binder may change its pH as it cures; it may
`become more acidic as it cures. Nevertheless, once cured, the
`binder has less direct contact with the manufacturing equip
`ment. Furthermore, where the cured binder is substantially
`insoluble in water, which is preferably the case, there is little
`risk of acid contamination from the cured binder.
`It is surprising that binders of this type at 15% or less by
`weight can confer the desired characteristics on the insulating
`product. This amount of binder is comparable with the binder
`contents commonly used with phenol formaldehyde based
`binders. The cured binder content may be 12% or less or 10%
`or less; it may be within the range of 3-8%, particularly
`3.5-6% by weight. The binder content may be determined by
`loss on ignition. Such binder contents are particularly Suitable
`for low and medium density products. Particularly for higher
`density products, the cured binder content may be in the range
`0.5-5% by weight.
`The binder may:
`be based on a reducing Sugar, and/or
`be based on reductosis; and/or
`be based on an aldehyde containing SugarS/and/or
`include at least one reaction product of a carbohydrate
`reactant and an amine reactant; and/or
`include at least one reaction product of a reducing Sugar
`and an amine reactant; and/or
`include at least one reaction product of a carbohydrate
`reactant and a polycarboxylic acid ammonium salt reac
`tant; and/or
`include at least one reaction product from a Maillard reac
`tion.
`The binder may be based on a combination of a polycar
`boxylic acid, for example citric acid, a Sugar, for example
`dextrose, and a source of ammonia, for example ammonia
`Solution. It may be based on a combination of ammonium
`citrate and dextrose. Where the binder is based on sugars
`and/or citric acid and or comprises significant—OH groups,
`it is particularly surprising that such levels of Weathered
`Parting Strength can be achieved. It would have been thought
`that the -OH groups for example in the Sugars and/or citric
`acid would be readily subject to hydrolysis and that the binder
`would consequently loose significant strength in humid and/
`or weathering conditions.
`
`25
`
`30
`
`Industry standard binders used for fibre insulation, for
`example glass wool and rock wool insulation are based on
`phenol formaldehyde. Whilst such binders can provide suit
`able properties to the insulating products there has for some
`time been a desire to move away from the use of phenol
`formaldehyde, particularly due to environmental consider
`ations.
`Traditional polyester based binder systems have previ
`ously been proposed but have not gained acceptance in the
`insulation industry, particularly as their strength in holding
`the mineral fibres together, especially when exposed to mois
`ture or weathering, has been perceived as insufficient.
`To date, only one low formaldehyde based mineral insula
`tion binder system has been used on an industrial scale on
`glass wool insulation; this is based on polyacrylic acid and
`supplied by Rohm&Haas. Unfortunately, the highly acid
`nature of these types of binders can cause excessive corrosion
`of manufacturing plant unless significant investment is made
`in acid resistant equipment. U.S. Pat. No. 5,977,232 discloses
`a formaldehyde free binder for glass wool insulation based on
`a polycarboxylic acid. European patent application
`EP1698598A discloses use of a corrosion meter to try to
`mitigate problems associated with polycarboxylic acid-based
`fibreglass binder resins. In addition, whilst the strength of
`40
`these binders is acceptable for Some applications it is not as
`good as the commonly used phenol formaldehyde based
`binders.
`It has not been thought possible to provide a formaldehyde
`free binder system useable on an industrial scale that will
`confer required characteristics, including strength, to mineral
`wool insulating products without encountering the difficul
`ties associated with highly acidic liquid binder systems.
`
`35
`
`45
`
`SUMMARY
`
`According to one aspect, the present invention provides a
`packaged mineral fibre insulating material as defined in claim
`1. Other aspects are defined in other independent claims.
`Preferred and/or alternative features are defined in the depen
`dent claims.
`
`DETAILED DESCRIPTION
`
`50
`
`55
`
`As used herein, the term formaldehyde free means that the
`composition is substantially free from formaldehyde, prefer
`ably does not liberate substantial formaldehyde as a result of
`drying or curing and/or preferably comprises less than one
`part per million by weight of formaldehyde.
`Desired characteristics to be conferred by the binder on
`Some mineral wool insulation product can be assessed by
`measuring Recovered Thickness and/or Ordinary Parting
`
`60
`
`65
`
`PGR2022-00022 - Petitioner’s Exhibit 1007 – Page 5
`
`

`

`US 7,854,980 B2
`
`5
`
`10
`
`15
`
`25
`
`35
`
`3
`The binder may comprise a silicon containing compound,
`particularly a silane; this may be an amino-Substituted com
`pound; it may be a silyl ether; it may facilitate adherence of
`the binder to the mineral fibres.
`The binder may comprise melanoidins; it may be a ther
`moset binder; it may be thermally curable.
`The binder may be one of those disclosed in International
`patent application n° PCT/US2006/028929, the contents of
`which is hereby incorporated by reference.
`The insulating material may be packaged or be provided in
`the form of a package; the package may comprise one or more
`mineral wool insulating products arranged and/or bound
`together, for example to facilitate transport; it may comprise
`an enveloping film, for example of a plastics material. The
`package may comprise or consist of a roll of insulating mate
`rial or an assembly of individual slabs of insulating material.
`The insulating material, particularly when it is a low or
`medium density product, may have
`a nominal thickness in the range 60-260 mm; and/or
`a thermal resistance R of R23 mK/W, preferably R24
`m’K/W at a thickness or 200 mm; and/or
`a density in the range 5-40 kg/m, particularly 5-18 kg/m
`or 7-12 kg/m, for example for low density roll products.
`The insulating material, particularly when it is an insulat
`ing board or a higher density product, may have
`a nominal thickness in the range 20 to 200 mm; and/or
`a thermal resistance R of R21.7 mK/W, preferably R22
`m’K/W at a thickness or 100 mm; and/or
`a density in the range 100 to 200 kg/m, particularly 130 to
`30
`190 kg/m.
`The mineral fibres may be glass wool or rock wool; the
`fibres may have an average diameter between 2 and 9 microns
`or be microfibres of smaller diameter; they may have an
`average length between 8 and 80 mm.
`The mineral fibres may be crimped.
`According to a further aspect, the present invention pro
`vides a mineral fibre insulating material having at least one of
`the following features:
`40
`the insulating material having cut edges;
`the insulating material having a facing provided on at least
`one of its major Surface, for example comprising a mois
`ture penetration barrier and/or a Kraft paper and/or an
`aluminium foil and/or a plastics layer and/or a laminate
`sheet comprising a plurality of individual layers and/or a
`woven or non-woven fabric; a facing may be provided
`on each major Surface of the insulating material;
`the insulating material being a packaged insulating mate
`rial held under compression for example by one or more
`packaging components, for example by an enveloping
`packaging film; the insulating material may be com
`pressed to 80% or less of its non-compressed thickness;
`
`4
`the insulating material being in the form of pipe insulation
`having a length of greater than 30 cm; the cross-section
`may be substantially annular,
`the insulating material being in the form of a compressed
`roll of material;
`the insulating material being in the form of a compressed
`slab of material;
`the insulating material being a roll or slab having a length
`of greater than or equal to 1 m, preferably greater than or
`equal to 2 m;
`the insulating material being a roll or slab having a width of
`greater than or equal to 0.3 m, preferably greater than or
`equal to 0.5 m;
`the insulating material having a nominal thickness of at
`least 45 mm, preferably at least 50 mm, and a density in
`the range 5-40 kg/m
`The insulating material may have any combination of these
`features; these features may be combined with other features
`and/or aspects described herein.
`
`EXAMPLES
`
`Non-limiting examples of the invention are described
`below with reference to FIG. 1 which shows the form of
`samples used for testing parting strength.
`An aqueous binder was prepared by mixing together:
`
`Approximate % by weight
`
`Powdered dextrose monohydrate
`Powdered anhydrous citric acid
`28% aqueous ammonia
`Silane A-1100
`Water
`
`12.9%
`2.3%
`2.6%
`O.05%
`82.1%
`
`This binder was used in the manufacture of a fibre glass
`insulating product on a standard manufacturing line, the
`binder being sprayed onto glass fibres just after fiberising
`using internal spinners and the coated fibres being collected,
`assembled in to a mat and cured in the usual way.
`The binder had a pH of about 8 when applied to the glass
`fibres.
`The cured glass fibre insulating product had:
`a binder content of about 5% by weight as determined by
`loss on ignition
`a thickness of about 150 mm
`a density of about 9 kg/m
`This is suitable as a low density residential roll insulation
`product; it was packaged in a roll under compression.
`Desired characteristics and results achieved are set out in
`Table 1:
`
`45
`
`50
`
`TABLE 1.
`
`Acceptance
`limit
`
`Most
`Preferred More Preferred preferred
`
`Result
`achieved
`
`eS5
`
`eS5
`
`e1OO
`
`e1OO
`
`e110
`
`e150
`
`e120
`
`e2OO
`
`103
`
`122
`
`is 75
`
`e8O
`
`e100
`
`e150
`
`112
`
`Units
`
`% of
`nominal
`gig
`
`gig
`
`Recovered
`Thickness
`Ordinary
`Parting
`Strength
`Weathered
`Parting
`strength
`
`PGR2022-00022 - Petitioner’s Exhibit 1007 – Page 6
`
`

`

`5
`Testing of Recovered Thickness:
`Recovered Thickness is tested and measured in accordance
`with Annex A of British standard BS EN 823: 1995 (incor
`porated herein by reference) and expressed as a % of the
`nominal or announced thickness for the product measured.
`Testing of Ordinary Parting Strength and Weathered Parting
`Strength:
`Parting strength is a measure of the tensile strength of
`mineral fibre mats determined by placing an Oshaped sample
`over cylindrical jaws, separating the jaws and measuring the
`load to break the fibres. Although it can be measured in
`Newtons per gram, the parting strength is expressed in grams/
`gram being the total breaking load of six test specimens
`divided by their total weight.
`The test is carried out on mineral fibre mats as received for
`testing (Ordinary Parting Strength) and after an accelerated
`weathering test as explained below (Weathered Parting
`Strength).
`A first set of six samples of the form and dimensions shown
`in FIG. 1 are cut from the mineral fibre mat to be tested; the
`long axis of the samples should be parallel to the conveyor
`direction and the samples should be taken across the full
`width of the mineral mat. A second set of six samples is then
`taken in the same way. The dimensions in FIG. 1 are in mm.
`The total weight of the first group of six samples W1 in
`grams is recorded.
`The total weight of the second group of six samples W2 in
`grams is recorded; these samples are then placed in a pre
`heated autoclave and conditioned on a wire mesh shelf away
`from the bottom of the chamber under wet steam at 35 kN/m
`for one hour. They are then removed, dried in an oven at 100°
`C. for five minutes and tested immediately for parting
`strength.
`To test the parting strength, each sample is mounted in turn
`on the jaws of the tensile strength machine and the maximum
`breaking load in grams or Newtons is recorded. If the break
`ing load is measured in Newtons it is converted to grams by
`multiplying it by 101.9. Six results in grams are obtained for
`each set of samples: G1 G2 G3 G4 G5 and G6 for the first set
`of samples and G7 G8 G9 G10 G11 and G12 for the second set
`of samples.
`The Ordinary Parting Strength is calculated from the first
`set of samples using the formula Ordinary Parting Strength=
`(G1+G2+G3+G4+G5+G6)/W1.
`The Weathered Parting Strength is calculated from the
`second set of samples using the formula Weathered Parting
`Strength=(G7+G8+G9+G10+G11+G12)/W2.
`In another example, an aqueous binder was prepared by
`mixing together:
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`Approximate % by weight
`
`Powdered dextrose monohydrate
`Powdered anhydrous citric acid
`28% aqueous ammonia
`Silane A-1100
`Water
`
`19.1%
`3.4%
`2.6%
`O.07%
`73.5%
`
`This binder was used in the manufacture of a rock wool
`roofboard on a standard manufacturing line, the binder being
`sprayed onto the fibres just after fiberising and the coated
`fibres being collected, assembled into a mat, compressed and
`cured in the usual way.
`
`US 7,854,980 B2
`
`10
`
`15
`
`25
`
`30
`
`35
`
`6
`The cured roof board had:
`a binder content of about 3% by weight as determined by
`loss on ignition
`a thickness of about 80 mm
`a density of about 150 kg/m
`It was packaged as part of a stack of insulation boards.
`Desired characteristics and results achieved are set out in
`Table 2:
`
`TABLE 2
`
`Accept
`8CC.
`limit
`
`Units
`
`More
`Pre-
`ferred Preferred
`
`Most
`preferred
`
`Result
`achieved
`
`kPa
`
`e60
`
`se70
`
`e8O
`
`e.90
`
`72.3
`
`kPa
`
`e25
`
`e3O
`
`240
`
`e50
`
`54.6
`
`Ordinary
`Compression
`Strength
`Weathered
`Compression
`Strength
`
`Testing of Ordinary Compression Strength and Weathered
`Compression Strength:
`Ordinary Compression Strength is measured according to
`British Standard BS EN 826: 1996 (incorporated herein by
`reference).
`Weathered Compression Strength is measured according
`to British Standard BS EN 826: 1996 on samples that have
`been Subjected to the following accelerated weathering pro
`cedure: samples are cut to size and then placed in a preheated
`autoclave and conditioned on a wire mesh shelf away from the
`bottom of the chamber under wet steam at 35 kN/m for one
`hour. They are then removed, dried in an oven at 100° C. for
`five minutes and tested immediately for compression
`strength.
`In both cases, compression strength is determined in the
`direction of the thickness of the product; the dimensions of
`face of the samples in contact with the compression test
`apparatus are preferably 200 mmx200 mm.
`What is claimed is:
`1. A mineral fiber insulating material comprising mineral
`fibers and less than about 15% by weight of an organic binder,
`wherein
`a) the organic binder is a formaldehyde free product of
`curing an aqueous Solution having a pH of greater than 5
`when applied to the mineral fibers,
`b) the mineral fiber insulating material has a recovered
`thickness of at least about 95% as determined according
`to Annex A of British standard BS EN 823: 1995,
`c) the mineral fiber insulating material having an ordinary
`parting strength of at least about 95 g/g,
`d) the mineral fiber insulating material having a weathered
`parting strength of at least about 75 g/g, and
`e) the mineral fiber insulating material is packaged.
`2. The mineral fiber insulating material of claim 1, wherein
`the recovered thickness is at least about 100%.
`3. The mineral fiber insulating material of claim 1, wherein
`the ordinary parting strength is at least about 100 g/g.
`4. The mineral fiber insulating material of claim 1, wherein
`the weathered parting strength is at least about 80 g/g.
`5. The mineral fiber insulating material of claim 1, wherein
`the mineral fiberinsulating material is a rolled product having
`a density between about 5 and about 40kg/m and the mineral
`fiber insulating material is packaged under compression.
`6. The mineral fiber insulating material of claim 1, wherein
`the organic, formaldehyde free binder is the product of drying
`
`PGR2022-00022 - Petitioner’s Exhibit 1007 – Page 7
`
`

`

`US 7,854,980 B2
`
`10
`
`15
`
`30
`
`7
`and curing the aqueous solution with the pH being less than
`about 11 when applied to the mineral fibers.
`7. The mineral fiber insulating material of claim 6, wherein
`the organic, formaldehyde free binder is the product of drying
`and curing the aqueous Solution with the pH being between
`about 6 and about 10 when applied to the mineral fibers.
`8. The mineral fiber insulating material of claim 1, wherein
`the organic, formaldehyde free binder is between about 2%
`and about 8% of the mineral fiber insulating material by
`weight.
`9. The mineral fiber insulating material of claim 1, wherein
`the organic, formaldehyde free binder comprises a product of
`a reaction including a reducing Sugar.
`10. The mineral fiber insulating material of claim 1,
`wherein the organic, formaldehyde free binder comprises at
`least one Maillard reaction product.
`11. A mineral fiber insulating material having a density in
`a range of 100 to 200 kg/m comprising mineral fibers and
`less than 15% by weight an organic, formaldehyde free
`binder, wherein
`a) the mineral fiber insulating material has an ordinary
`compression strength of at least about 60 kPa,
`b) the mineral fiber insulating material has a weathered
`compression strength of at least about 25 kPa,
`25
`c) the organic, formaldehyde free binder is a product of
`drying and curing an aqueous solution with a pH of
`greater than about 5 when applied to the mineral fibers,
`and
`d) the mineral fiber insulating material is packaged.
`12. The mineral fiber insulating material of claim 11,
`wherein the ordinary compression strength is at least about 70
`kPa.
`13. The mineral fiber insulating material of claim 11,
`wherein the weathered compression strength is at least about
`30 kPa.
`14. The mineral fiber insulating material of claim 11,
`wherein the organic, formaldehyde free binder is the product
`
`35
`
`8
`of drying and curing the aqueous Solution with the pH being
`less than about 11 when applied to the mineral fibers.
`15. The mineral fiber insulating material of claim 11,
`wherein the organic, formaldehyde free binder is the product
`of drying and curing the aqueous Solution with the pH being
`between about 6 and about 10 when applied to the mineral
`fibers.
`16. The mineral fiber insulating material of claim 11,
`wherein the organic, formaldehyde free binder is between
`about 2% and about 8% of the mineral fiber insulating mate
`rial by weight.
`17. The mineral fiber insulating material of claim 11,
`wherein the organic, formaldehyde free binder comprises a
`product of a reaction including a reducing Sugar.
`18. The mineral fiber insulating material of claim 11,
`wherein the organic, formaldehyde free binder comprises at
`least one Maillard reaction product.
`19. The mineral fiber insulating material of claim 11,
`wherein the aqueous Solution further comprises citric acid,
`ammonia and dextrose.
`20. A method of manufacturing a packaged mineral fibre
`insulating material selected from the group consisting of
`(i) material having
`a) a Recovered Thickness of at least 95%; and
`b) an Ordinary Parting Strength of at least 95 g/g; and
`c) a Weathered Parting Strength of at least 75 g/g; and
`(ii) material having
`a) an Ordinary Compression Strength of at least 60 kPa;
`and
`b) a Weathered Compression Strength of at least 25 kPa;
`comprising the steps of
`i) applying an organic, formaldehyde free binder in aque
`ous solution to the mineral fibres at a pH of greater than
`5 and
`ii) curing the product so that it contains a quantity of less
`than 15% by weight of binder and
`iii) packaging the insulating material.
`
`k
`
`k
`
`k
`
`k
`
`k
`
`PGR2022-00022 - Petitioner’s Exhibit 1007 – Page 8
`
`