# US 11,299,418 B2 · Unfired heat and/or sound insulation product and insulation blanket obtained therefrom > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,299,418 B2 - Document ID: US11299418B2 - Status: Granted - Kind: B2 - Application number: 16/316,700 - Filed: 2017-07-19 - Published: 2019-06-20 - Granted: 2022-04-12 - Earliest claimed: 2016-07-22 - Assignees: Saint-Gobain Isover - Applicants: Saint-Gobain Isover - Inventors: Julien Thiery - Web page: https://patentgrep.com/patent/US11299418B2 ## CPC - C03B 37/04: by using centrifugal force {, e.g. spinning through radial orifices; Construction of the spinner cups therefor (bonder application C03C25/00)} - B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)} - B32B 5/022: {Non-woven fabric} - B32B 5/024: {Woven fabric} - B32B 5/06: characterised by a fibrous {or filamentary} layer {mechanically connected, e.g. by needling} to another layer, e.g. of fibres, of paper - B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} - B32B 17/04: bonded with or embedded in a plastic substance - B32B 19/02: {the layer of fibres or particles being impregnated or} embedded in a plastic substance - B32B 19/06: next to a fibrous or filamentary layer - B60R 13/0815: {Acoustic or thermal insulation of passenger compartments (wall or roof liners integrating the insulating function B60R13/02; insulating floor mats or carpets B60N3/04)} - C03C 25/34: Condensation polymers of aldehydes, e.g. with phenols, ureas, melamines, amides or amines - C03C 25/36: Epoxy resins - D04H 1/4209: Inorganic fibres - D04H 1/4218: Glass fibres - D04H 1/58: by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives (in combination with needling D04H1/488) - D04H 1/587: characterised by the bonding agents used - E04B 1/88: Insulating elements for both heat and sound - G10K 11/162: Selection of materials - B32B 2255/02: on fibrous or filamentary layer - B32B 2255/26: Polymeric coating - B32B 2260/021: Fibrous or filamentary layer - B32B 2260/046: Synthetic resin - B32B 2262/02: Synthetic macromolecular fibres - B32B 2262/0253: Polyolefin fibres - B32B 2262/0276: Polyester fibres - B32B 2262/101: Glass fibres - B32B 2262/106: Carbon fibres, e.g. graphite fibres - B32B 2307/102: Insulating - B32B 2307/304: Insulating - B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant - B32B 2307/7145: Rot proof, resistant to bacteria, mildew, mould, fungi - B32B 2307/718: Weight, e.g. weight per square meter - B32B 2307/73: Hydrophobic - B32B 2307/732: Dimensional properties - B32B 2581/00: Seals; Sealing equipment; Gaskets - C03C 2217/76: Hydrophobic and oleophobic coatings - D10B 2401/04: Heat-responsive characteristics - E04B 2103/04: of plastics, fibrous material or wood - C03B: MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR - C03C: CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS - D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B) - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) - G10K: SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR - D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES ## Abstract The invention relates to an uncured thermal and/or sound insulation product, based on mineral wool, advantageously on glass wool, that is in the form of a ply comprising a mineral wool layer sized by at least one binder, said sized layer having: a surface density, or basis weight, of less than or equal to 350 g/m2, preferably less than or equal to 300 g/m2, or less than or equal to 250 g/m2, and, optionally, greater than or equal to 200 g/m2, a micronaire of at most 3 under 5 grams, preferably of at most 15 l/min, better still of at most 12 l/min, and of at least 9 l/min, and the ply having a thickness of greater than 10 mm, or greater than or equal to 15 mm, or even greater than or equal to 25 mm. The invention makes it possible to propose a thermal and/or sound insulation product that is lighter while retaining satisfactory thermal and/or sound insulation properties and a good mechanical strength. ## Claims ### Claim 1 An uncured thermal and/or sound insulation product, based on mineral wool, comprising a cut mineral wool ply sized by at least one uncured binder, said cut mineral wool ply sized by the at least one uncured binder having: a surface density, or basis weight, of less than or equal to 350 g/m2, measured according to the EN 822 standard, a micronaire of at most 3 under 5 grams, and a final thickness equal to or greater than 15 mm. ### Claim 2 (depends on 1) The product of claim 1, comprising between 8% and 14% by weight of binder, relative to the total weight of the mineral wool and binder, and is chosen from thermosetting binders. ### Claim 3 (depends on 2) The product of claim 2, wherein the binder is chosen from thermosetting binders based (i) on phenol-formaldehyde resin, (ii) on polyepoxides, or (iii) on carbohydrates. ### Claim 4 (depends on 1) The product of claim 1, wherein the mineral wool fibers are laid on a hydrophobic and/or oleophobic, woven or nonwoven web. ### Claim 5 (depends on 4) The product of claim 4, wherein the web has, in addition, flame retardant and/or fungicidal properties owing to a compound fixed to said web by impregnation, coating or heat setting. ### Claim 6 (depends on 4) The product of claim 4, wherein the web is a polyester-based woven web or a needle-punched nonwoven web based (i) on polyester and/or viscose fibers, (ii) on polypropylene fibers, or (iii) on carbon fibers, or a polyester-reinforced glass web. ### Claim 7 (depends on 1) A lining obtained from the product of claim 1 by molding into a shape at a polymerization temperature of the binder, the lining conforming to contours of a support surface on which the lining is mounted. ### Claim 8 (depends on 7) The lining of claim 7, having a thermal conductivity of less than or equal to 42 mW/(m·K), measured according to the ISO 8301 standard at 10° C., and/or having: an air flow resistivity of greater than or equal to 28 000 N·s/m4, measured according to the ISO 9053 standard, when said mineral wool ply has a thickness of greater than or equal to 10 mm, or an air flow resistivity of greater than or equal to 13 500 N·s/m4, measured according to the ISO 9053 standard, when said mineral wool ply has a thickness of greater than or equal to 15 mm, or an air flow resistivity of greater than or equal to 8000 N·s/m4, measured according to the ISO 9053 standard, when said mineral wool ply has a thickness of greater than or equal to 25 mm. ### Claim 9 (depends on 7) The lining of claim 7, having a sound absorption of greater than or equal to 0.8 between 1300 and 9000 Hz, measured according to the DA 49 1997 standard. ### Claim 10 (depends on 1) A process for manufacturing the product of claim 1, with the aid of a facility comprising an internal centrifugation device that comprises at least one spinner capable of rotating about an axis X, and the peripheral band of which is pierced by a plurality of orifices for delivering filaments of a molten material, a high-temperature gas attenuating means in the form of an annular burner that attenuates the filaments into fibers, and a receiving belt associated with suction means for receiving the fibers, consisting in regulating a combination of parameters which are at least: the pressure of the burner, which is between 250 and 750 mm WC, the temperature of the burner, which is between 1350° C. to 1450° C., the daily fiber output per spinner orifice, which is at most 1 kg, the total output being at most 26 tons/day, and the product (P) of the run speed of the receiving belt and the width of said belt, which is between 38 and 90 m2/min. ### Claim 11 (depends on 10) The process of claim 10, wherein the rotational speed of the spinner is between 1500 to 3000 revolutions/minute, and/or the diameter of the spinner is between 200 and 800 mm, and/or wherein the mineral wool fibers are received on the receiving belt in the form of rovings having a length of between 10 and 50 cm. ### Claim 12 (depends on 10) The process of claim 10, wherein the run speed of the receiving belt is between 30 m/min and 50 m/min and wherein the width of the receiving belt is between 700 mm and 1800 mm. ### Claim 13 (depends on 7) A process for manufacturing the lining of claim 7, comprising: manufacturing a thermal and/or sound insulation product with the aid of a facility comprising an internal centrifugation device that comprises at least one spinner capable of rotating about an axis X, and the peripheral band of which is pierced by a plurality of orifices for delivering filaments of a molten material, a high-temperature gas attenuating means in the form of an annular burner that attenuates the filaments into fibers, and a receiving belt associated with suction means for receiving the fibers, consisting in regulating a combination of parameters which are at least: the pressure of the burner, which is between 250 and 750 mm WC, the temperature of the burner, which is between 1350° C. to 1450° C., the daily fiber output per spinner orifice, which is at most 1 kg, the total output being at most 26 tons/day, and the product (P) of the run speed of the receiving belt and the width of said belt, which is between 38 and 90 m2/min, followed by a step of thermocompression, simultaneously carrying out (i) a process for heating said product to a temperature sufficient to soften or polymerize the binder within said product and (ii) a process for deforming said product which thus conforms to the desired shape of the lining. ### Claim 14 (depends on 7) The lining of claim 7, wherein the lining is thermal and/or sound insulation in a vehicle, on a ceiling, a wall or a partition, under a roof or in a household electrical appliance. ### Claim 15 (depends on 1) The product of claim 1, wherein the mineral wool is a glass wool. ### Claim 16 (depends on 1) The product of claim 1, wherein the surface density is less than or equal to 250 g/m2. ### Claim 17 (depends on 1) The product of claim 1, wherein the surface density is greater than or equal to 200 g/m2. ### Claim 18 (depends on 1) The product of claim 1, wherein the micronaire is at most 12 L/min. ### Claim 19 (depends on 1) The product of claim 1, wherein the micronaire is at least 9 L/min. ### Claim 20 (depends on 1) The product of claim 1, wherein the final thickness is greater than or equal to 25 mm. ### Claim 21 (depends on 1) The product of claim 1, wherein said product has a thickness recovery of greater than or equal to 10 mm following packaging in a roll for at least 6 weeks. ### Claim 22 (depends on 1) The product of claim 1, wherein the mineral wool of said cut mineral wool ply consists of mineral wool fibers solely coated with said at least one uncured binder, the at least one uncured binder consisting of a resin and a reactant with said resin.