DE4222207C3 - Process for producing mineral fiber products and device for carrying out the process - Google Patents

Abstract

When manufacturing mineral fiber products with compressed surface areas made of mineral fiber webs, in which the fibers extend substantially parallel, perpendicular or obliquely to the large surfaces of the mineral fiber web, which contains an uncured binder, it is very important to achieve a high tearing resistance and a strong fiber connection between the compressed surface areas or layers and the remaining part of the mineral fiber web. It is therefore proposed to expose at least one surface area to needling down to a predetermined penetration depth, in order to felt the fibers and at the same time to compress the surface area.

Description

The invention relates to a method for Manufacture of mineral fiber products with compacted Surface areas made of mineral fiber webs, whereby the fibers within the mineral fiber web essentially Chen parallel or perpendicular or oblique to the big ones Surfaces of the mineral fiber web run and where the mineral fiber web is an uncured binder contains.

A method of the aforementioned type and a pre The direction to carry out the procedure is above all through Canadian Patent 1,057,183 Service. For the production of a compacted surface area or a surface layer is here by a horizontal, parallel to the big ones Cut surfaces of the mineral fiber web cut a partial web. This partial web will then deducted from the remaining mineral fiber web lifted and pressed between pressure rollers and thus condensed. This densified partial web will then back to the rest of the mineral fiber web guided. Then there is a joint through run through a hardening furnace, in which until then uncured in the mineral fiber web and also in the Partial web binder is cured. In In practice, however, it has been found that the fibers in the lifted partial web through the high static we compressive forces crushed and the part web is pressed apart, comparable with a bread dough that is rolled out. This ent are relatively inhomo within the partial web gene densified zones. The one in the Canadian patent teaching taught in writing was also further developed wraps, and became a relatively thin Partial web cut open, pressed together and then then wrinkled using a pendulum device again on the remaining mineral fiber web introduced. In all cases it has been shown that none reliable permanent fiber composite between the achieved two differently treated layers could be. The ultimately manufactured as an end product mineral fiber boards with different raw densities always had in the two aforementioned layers an inadequate tear resistance in practice. For example when laying such panels or also longer tracks on a flat roof of a Ge building or when attached to building walls ha the densified surface layers differ from the underlying undensified mineral fiber web solved and sometimes even adopted waveform, because the compacted material tended to again, if only slightly, to expand. here in principle, nothing would change if you the thought would come between the two subbahs an adhesive layer bring in, in addition to being significant Additional costs would arise and a curing in a hardening furnace leads to considerable difficulties.

The easiest and most obvious way to get one compacted surface area or a surface the mineral fiber web would be to create a layer not cut into partial webs, but directly egg to exert pressure on the surface. With a Mi general fiber web, in which the binder is still unhardened tet, however, no surface area or compress a surface layer because the mate rial of a pressure load due to considerable ver removes formations and at best the fibers directly Near the surface.

Another method is known from DE 37 01 592 A1 for the production of mineral fiber products with ver sealed surface areas made of mineral fiber NEN known, the fibers within the Mineralfa serbahn essentially parallel or perpendicular or at an angle to the large surfaces of the mineral fiber run and with the mineral fiber web an un contains hardened binder. The condensing of Surface areas is made in such a way that a primary fleece in two or more sub-webs is split up and that partial webs are lifted off and be subjected to pressure treatment so that they be compressed in their entire height. After the The compacted partial webs are compacted the remaining non-compressed primary fleece performed and takes place in a subsequent hardening furnace the joint curing of the binder.

Furthermore, EP 03 88 062 A2 describes a needle treatment of surface areas up to a pre given depth of penetration known, namely at a Material that medical or surgical Zwec ken serves. So this is a material of textile Area that should be suitable, body fluids injured or operated person men. Needling makes compaction aimed at the surface of this material at the same time but the absorbency of the liquid through the promoted numerous pinpricks.

Furthermore, from the publication DE-Z Melliand Textile reports 12/1982, page 855, "Needling from an organic fibers "known a mechanical compound Needling with glass fibers or stone want to make. The explanations refer also on rock fibers used for insulation purposes get dressed by. The required strength should be need of mats through needling the. Furthermore, the use of binders by the Needling process are reduced. It will but said nothing about whether the needling over surface areas or rather over the ge should extend the entire thickness of the mat in question. But above all, with this state of the art Needling made on a material at the binder has already hardened. At a such material from glass and rock fibers occurs high fiber breakage due to the action of the needle, and therefore numerous measures have to be taken be to the disadvantages of the emerging fine To avoid fiber dust. So the specialist becomes with such material prevented one Needling process, because the first hung of fine fiber dust must under all circumstances which are avoided.

In another state of the art according to DE OS 19 47 789 deals with the production of nonwovens fen with increased strength, these nonwovens egg a distinctive textile character, such as a soft feel and smooth case. Are material the nonwovens listed here do not contain mineral fibers comparable products. To ensure the firmness of To increase servlieses overall, binders will over Hollow needles introduced into the fleece.

From DE 30 29 333 A1 are finally under different constructions of felting needles known.

In contrast, the invention has the object Basically, a process for making mineral fiber products  with densified surface areas to create or layers, through which high tear-off strengths and an intense connection between the matted and compacted surface area on the other hand and the remaining part of the mineral fiber web can be achieved on the other hand.

The object is achieved according to the invention by the features of claim 1.

In this way there is the main advantage that in a simple and targeted way a surface rich or a surface layer up to a be certain depth can be compacted without the rest to influence part of the mineral fiber web but also a high tear resistance at the same time obtain a high bending strength of the end product becomes. The end product are mostly slabs that follow Passage of the treated mineral fiber web through the Cut the hardening furnace to a specified length the.

The stroke frequency of the needles in relation to the usual Conveying speed of the mineral fiber web provides an important factor for both the degree of compression as well as for matting. A change the strength properties of the end product can al can be achieved so that the stroke frequency of the Needle strokes are changeable and adjustable. At high Stroke frequency has the advantage that the Needles not hit mineral fiber layer on the ground the inertia is not deformed or even compressed becomes.

It goes without saying that the tightness of the needles, d. H. the distance of side by side and / or behind standing needles, an important influence has the final product, but the number to choose is the Needles and their distance from each other for one size re to define the right product group through trials. A change in the strength properties of an end product can be achieved in a simple way that the stroke and depth of penetration of the needles are changeable and adjustable.

An advantageous further development of the process is further achieved in that an endless mineral fiber web is continuously moved, a first me subjected to mechanical pre-compression, then due to needles in the given surface area is further compacted and matted and under a two th compression of a heat treatment for curing tion of the binder is supplied.

When a plate-shaped end product is obtained it should, it is appropriate that the needle strokes to Compacting and matting in the entire surface be distributed evenly.

In practice there are numerous applications for a plate-shaped mineral fiber product in which both Sides or the two large surfaces compacted and possibly also have hard layers len, e.g. B. for free-standing building partitions or for external wall thermal and acoustic insulation, if in the latter case one side of the panel on the building wall and a plaster on the outside should be applied. To achieve such pro products, it is advantageous that the needle impact treatment on both parallel surfaces areas of the mineral fiber web becomes.

The production for plate material can be done at constant conveying speed thereby increasing gladly that the mineral fiber web after hardening of the Binder in a cutting plane parallel to the gro ß surfaces is cut open, so that two mine ral fibreboard with a compacted layer hen.

There is a great need for mineral fiber products ten on curved surfaces, e.g. B. to pipes must be brought. It is then recommended that Ver drive in such a way that the needle hits in rows in the longitudinal and / or transverse direction of the mine ralfaserbahn be made so that the finished Product plates can be bent or bent polygonally are. In this way you get a product which in addition to flexibility and kinkability zones of great compressive strength.

A matting between the compacted surface layer and the uncompressed mineral fiber Layer can still benefit from this and the tear-off Stigkeit be increased that the treatment with under different needle types or needle shapes. In In this context, it is advantageous that means short front needles a compression and matting of the Surface area is made, and that with Part of the fibers from the outer compressed surface area inside ren undensified area of the mineral fiber web will come across.

Without time-consuming redesigns at the fro You have to have to perform a position machine achieve numerous variants in the end product, that the thickness of the compacted layer in the surface range by choosing the penetration depth of the needles, by the stroke frequency and determined by the needle shape becomes, such that on the one hand shallow depths of penetration, high Stroke frequencies and needles with great effectiveness Cross section result in thin, highly compressed layers and on the other hand great depths of penetration, low stroke fre quenz and needles with a small cross-section, thick result in denser layers.

If a plate-shaped end product is required - which is as hard and pressure-resistant as possible Has surface layer, so you can in simple cher way that additional additives by hollow needles for additional reinforcement of the Surface area are introduced. This addi After curing, it can be said that, like small stamps work. But you can also in the Be injected that they in the area between penetrate the neighboring fibers and thus an even greater cohesion within the ver provide sealed surface layer. The additives but can also in the uncompressed Mineralfa can be introduced into it, so that in addition to the matting in the area between the densified and the undensified layer numerous additional anchorages can be achieved. It stays with these products, as with all others after Products producible according to the method of the invention get the advantage that a good vapor diffusion ability is given.

For a board material that is covered with a plaster, a Paint or other coating should be, it is advantageous that a thin fleece a fiber material, preferably made of glass fibers laid on the surface of the mineral fiber web and there after the needle punching process is done so that some of the nonwoven fibers are inserted into the mineral fiber web is bedded.

An alternative to this results from the fact that a  Tissue on the surface of the mineral fiber web placed and then the needle pushing process men, so that part of the tissue in the Mineralfa serbahn is embedded. The thin fleece or the Ge weave can also be made from a different fiber material than Mineral fibers exist, e.g. B. made of plastic fibers, Textile fibers or metal fibers.

In the drawing, embodiments of the inventions are device according to the invention shown in the diagram, and show:

Fig. 1 a schematic diagram of the conveyance path a mineral fiber web conveying means and a compacting and Verfilzungsmaschine,

Fig. 2 shows an embodiment of a needle,

Fig. 3 shows another embodiment of a needle and

Fig. 4 is a side view of a detail of a mineral fiber web compressed and matted on both sides in an enlarged view and

Fig. 5 is a schematic diagram of FIG. 1, but with both sides compression and felting machines.

In the embodiment of an inventive SEN device according to Fig. 1 a mineral fiber web 1 in the direction of arrow 22 between endless conveyor belts 2 and 3 of a certain thickness supplied continu ously. The mineral fiber web comes from a known, unsigned collection chamber in which the mineral fibers produced are deposited on a breathable conveyor belt to form a layer after the addition of a binder. The Mineralfa serbahn 1 is then first kept in a relatively loose state between the two conveyor belts 2 , 3 , which are guided around pulleys 4 and 5 . There is then a certain somewhat exaggerated pre-compression of the mineral fiber web 1 between pressure rollers 6 , 7 to 8 , 9 or between accordingly arranged and guided conveyor belts. Since the binder within the mineral fiber web 1 , 10 , 17 has not yet hardened and the mineral fibers run essentially parallel to the large surfaces of the web due to the previous manufacturing process, the mineral fiber web 1 can be mechanically precompressed very homogeneously into this first conveying section until a pre-compressed mineral fiber web 10 of a predetermined thickness is created.

The mineral fiber web 10 thus pre-compressed then arrives in a compression and felting device, which is shown in simplified form in FIG. 1. You will be seated a plurality of needles 13 , which are connected in groups or together with a lifting device which carries out a high-frequency lifting movement in the direction of arrow 15 . Such a lifting device is arranged at least on one surface side, either on the top or bottom, of the mineral fiber web 10 , 17 and provided with a Huban not shown. In this embodiment, the needles 13 are attached to a plate-like carrier 11 . This plate-like carrier is connected to the lifting device and the drive, in such a way that the Na needles penetrate periodically into the surface area of the mineral fiber web 10 , 17 up to a predetermined depth of penetration and compress the area in the preselected surface area and simultaneously matt it.

The stroke of the lifting device is advantageously adjustable and adjustable to a certain height, and the stroke frequency can be regulated via the drive. It is also advantageous if the impact forces of the needles 13 are adjustable. By limiting the impact forces, the compression needles 13 are prevented from inclusion within the mineral fiber web when unwanted wool is present, so that the risk of breakage at the needle 13 is reduced. In practice, these settings and controls can be accomplished in a simple manner by the fact that the Hubvor direction can be actuated pneumatically or hydraulically.

The needles 13 , in particular those of the compression needles, have a chisel-like widened head 27 or 30 which, according to FIGS. 2 and 3, are molded onto the end of the needle shaft 26 and 29, respectively. The needle head 27 has a Schnei de 28 at the lower end, which force the fibers into a loop shape when they hit them and thus result in a matting with the adjacent fibers. In the exemplary embodiment of the needle according to FIG. 3, a downwardly projecting needle tip 31 is provided on the chisel head 30 . Instead, several re needle tips can be arranged. Advantageously, the needle tips have small side hooks 32 and 33 , which lead to further deformation and entanglement of mineral fibers, especially in the boundary area between the compressed surface area on the one hand and the uncompressed loading area of the mineral fiber web. The same goal of Ver felting and connection between the two aforementioned layers serves a different constructive execution, according to which at least two different needle groups, namely a group of short needles and a group of longer needles are provided. In order to achieve the effect of good felting, the needles or plungers have a larger diameter and, as shown in FIGS . 2 and 3, other shapes than are known from the textile industry, for example in multi-needle sewing machines. The arrangement of the compression needles should suffice for a tangle arrangement so that the outer surface areas or layers are pre-compressed as uniformly and evenly as possible in a punctiform manner and according to the stroke frequency to be set. It is important to concentrate the impact stress from the needles on a small area in relation to the surface of the entire mineral fiber web, so that the impact forces compress the outer zones explained and due to the force distribution at point loads, the stresses below the layers are only slight Experienced. By an appropriate choice of Ver sealing needles, for. B. with a short needle, who the fibers from the outer compressed layers in the underlying undensified fiber layers th forced, so that additional connections are ent, which continue to influence the bending and tear behavior of the finished product favorably. The compaction needles themselves are advantageously made of light and abrasion-resistant material. The goal is to reduce the mass to be moved of the needles and the components to be moved along with them, so that accordingly higher stroke frequencies are possible. This is particularly important at high line speeds in the production of mineral fiber webs.

The compression and matting can be done either on the top or bottom of the mineral fiber web or, as illustrated in FIG. 5 and in particular FIG. 4 on a larger scale, on both sides. The mineral fiber web 17 compressed on both sides then has two compressed and matted surface areas 34 and 35 and an intermediate undensified and non-matted middle layer 17 and 37 , however, a good connection between the layers is ensured. If, according to the practical application of the end product plates, only a unilaterally compacted and matted layer is desired, a slicer, not shown, for slicing a mutually matted and compacted mineral fiber web 17 or 21 corresponding to the separating cut 36 ( FIG. 4) in two partial webs may be provided.

As shown in FIGS. 1 and 5 also illustrate, is selected from the needling or Verfilzungsmaschine from passing compacted mineral fiber web 17 by conveying rollers 18, 19 or corresponding endless conveyor a curing oven 20 is supplied, in which the mineral fiber web 21, for example between non-drawn endless Belts can receive a further slight densification, especially to smooth the surfaces. In the curing oven 20 , the previously uncured binder is then finally cured. The mineral fiber web emerges in the direction of arrow 23 from the hardening furnace and can be separated into suitable plate pieces and processed into the end product, or the described cut 36 according to FIG. 4 can cause the separation into plate parts.

Figs. 1 and 5 show still tung another Ausgestal of the device according to the invention, namely that on one side (Fig. 1) or both sides (Fig. 5) between the plate-like needle carriers 11 and 12 on the one hand and the mineral fiber web 10, 17 on the other hand in each case a further plate 24 and 25 is provided, in which the needles 13 , 14 are guided. These plates 24 and 25 can also be connected to the lifting device. They can bring about a certain additional surface compaction, but above all these plates can be used to push fibers that may have been torn out of the surface back into the surface.

The 5 mutually arranged Hubvor FIG. Are devices operated gentakt advantageously in the direction of arrows 15 and 16 with the same stroke frequency and Ge, that is, when the upper Hubvorrich processing moves downward is under the lifting device simultaneously moves upwards, and vice versa during the return stroke , Since the device according to FIG. 5 is configured essentially symmetrically or mirror-image to the horizontal center plane, the same reference numerals have been used for the same or equivalent parts.

Another embodiment of the invention is there achieved by that the needles are formed as hollow needles det and to a feed device for additives, preferably liquid additives are connected. in the especially at higher conveyor speeds Mineral fiber web, it is advantageous that the needles for Adaptation to the conveying speed of the mineral fibrous web during the puncture in cycles Movable conveying direction, preferably swiveling, are mounted on the lifting device. In this way the needles are spared, friction and thus a Avoiding warming and an Ab Risk of breakage practically completely eliminated. These movements of the needles during the puncture in the mineral fiber web in its direction of conveyance and the back movements of the needles after the exit from the mineral fiber web to the original position through simple mechanical gear arrangements, so z. B. by means of eccentrics.

In terms of materials, Mine was always general above Ral fibers or mineral fiber material spoken. It is but here particularly emphasized that both the method and the device particularly ge are suitable for the production of rock wool products. Furthermore, not only material webs with a company Server run parallel to the large surfaces tet, but also lamellar webs or plat ten, where the fibers are vertical or under one other angles to the large surfaces.

Claims (19)

1. A method of making mineral fiber products from an endless, continuously moving mineral fiber web, the fibers within the mineral fiber web being substantially parallel to the large surfaces of the mineral fiber web and the mineral fiber web containing an uncured binder being first subjected to mechanical pre-compression, thereby characterized in that at least one surface area of the endless and continuously moving mineral fiber web is then subjected to needle shocks with variable and adjustable stroke frequency as well as the stroke and penetration depth of the needles up to a predetermined penetration depth after the mechanical pre-compression, so that the fibers in the surface area become matted and at the same time the Surface area is compacted to a certain depth, and then the mineral fiber web exposed to a second compaction during the curing of the binder in a hardening furnace becomes. 2. The method according to claim 1, characterized records that the needle shots for compression and Matting the same in the entire surface area be distributed moderately. 3. The method according to claim 1 or 2, characterized ge indicates that the needle impact treatment on two parallel surfaces areas of the mineral fiber web men and that the mineral fiber web after the Hardening of the binder in a cutting plane cut parallel to the large surfaces is so that two mineral fiber boards with one-sided densified layer arise. 4. The method according to claim 1, characterized shows that the needle hits in rows in longitudinal and / or transverse direction of the mineral fiber web be taken so that the finished product ten are flexible or polygonal. 5. Method according to one of the preceding An sayings, characterized in that the treatment with such different needle types or Needle shapes are made using short front needles a densification and matting of the surfaces area is made, and that by means of Län some needles from the outside Outer compacted surface area in the our undensified area of the mineral fiber is pushed. 6. Method according to one of the preceding An sayings, characterized in that the thickness the compacted layer in the surface area is determined such that on the one hand low A deep penetration, high stroke frequencies and needles large effective cross section thin high ver dense layers result and on the other hand large Depths of penetration, low stroke frequency and needles  with a small cross section thick, less compressed Layers. 7. Method according to one of the preceding An sayings, characterized in that additional Additives through hollow needles for additional ver Reinforcement of the surface area introduced become. 8. Method according to one of the preceding An sayings, characterized in that a thin Nonwoven made from a fiber material, preferably from Glass fibers, on the surface of the mineral fiber applied and then the needle pushing process is made so that part of the nonwoven fibers is embedded in the mineral fiber web. 9. The method according to any one of claims 1 to 7, characterized in that a fabric on the Surface of the mineral fiber web laid on and there after the needle punching process is done, so that part of the fabric in the mineral fiber web is embedded.   10. Device for performing the method according to one of the preceding claims, characterized in that conveyor rollers ( 6 , 7 , 8 , 9 ) or belts ( 2 , 3 ) on both sides of the continuously moving endless mineral fiber web ( 1 , 10 , 17 ) For their pre-compression, a plurality of needles ( 13 , 14 ) are connected in groups or together with a lifting device ( 15 , 16 ) which is arranged on at least one surface side of the mineral fiber web ( 10 , 17 ) and is provided with a drive, so that the needles ( 13 , 14 ) penetrate into the mineral fiber web ( 1 , 10 , 17 ) intermittently up to a predetermined penetration depth and matt them in the surface area and at the same time compact that the stroke of the lifting device is adjustable and adjustable and the stroke frequency can be regulated via the drive and that further conveyor rollers ( 18 , 19 ) or belts for feeding the mineral fiber web for compaction in a hardening furnace ( 20 ) are provided. 11. The device according to claim 10, characterized in that the needles ( 13 , 14 ), in particular needles serving for compaction, have a chisel-like widened head ( 27 , 30 ). 12. The apparatus according to claim 11, characterized in that at least one protruding needle tip ( 31 ) is seen on the chisel head ( 27 , 30 ) min. 13. Device according to one of claims 10 to 12, characterized in that the needles ( 13 , 14 ) are designed as hollow needles and are connected to a feed device for additives, preferably liquid additives. 14. Device according to one of claims 10 to 13, characterized in that the needles are attached to a plate-like support ( 11 , 12 ) which is connected to the lifting device and the drive. 15. The apparatus according to claim 14, characterized in that between the plate-like carrier ( 11 , 12 ) and the mineral fiber web ( 10 , 17 ) a further plate ( 24 , 25 ) is provided in which the needles ( 13 , 14 ) are guided and which is also connected to the lifting device. 16. The device according to one of claims 10 to 15, characterized in that at least two different needle groups, a group of short front needles and a group of longer ones Needles are provided. 17. The device according to one of claims 10 to 16, characterized by a Aufschneidevorrich device for cutting a bilaterally matted and compressed mineral fiber web ( 21 ) in two partial webs. 18. Device according to one of claims 10 to 17, characterized in that the needles ( 13 , 14 ) to adapt to the conveying speed of the mineral fiber web ( 10 , 17 ) during the puncture in cycles in the conveying direction ( 22 , 23 ) movable bar, preferably pivotable, are mounted on the lifting device. 19. Device according to one of claims 10 to 18, characterized in that the lifting device device can be operated pneumatically or hydraulically.