EP0889981B1 - Verfahren und vorrichtung zur herstellung von einer mineralfaserplatte - Google Patents

Verfahren und vorrichtung zur herstellung von einer mineralfaserplatte Download PDF

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Publication number
EP0889981B1
EP0889981B1 EP97914299A EP97914299A EP0889981B1 EP 0889981 B1 EP0889981 B1 EP 0889981B1 EP 97914299 A EP97914299 A EP 97914299A EP 97914299 A EP97914299 A EP 97914299A EP 0889981 B1 EP0889981 B1 EP 0889981B1
Authority
EP
European Patent Office
Prior art keywords
fleece
thickness
compression
conveyor
bonding station
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Revoked
Application number
EP97914299A
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English (en)
French (fr)
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EP0889981A1 (de
Inventor
Peter Wyss
Fredy Zimmermann
Bent Jacobsen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Flumroc AG
Rockwool AS
Original Assignee
Flumroc AG
Rockwool International AS
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Priority claimed from CH00768/96A external-priority patent/CH691816A5/de
Priority claimed from CH02169/96A external-priority patent/CH691960A5/de
Application filed by Flumroc AG, Rockwool International AS filed Critical Flumroc AG
Priority to EP01102183A priority Critical patent/EP1111113B1/de
Priority to SI9730262T priority patent/SI0889981T1/xx
Priority to EP08007764A priority patent/EP1942217A3/de
Publication of EP0889981A1 publication Critical patent/EP0889981A1/de
Application granted granted Critical
Publication of EP0889981B1 publication Critical patent/EP0889981B1/de
Anticipated expiration legal-status Critical
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D04H1/645—Impregnation followed by a solidification process
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D04H1/4226—Glass fibres characterised by the apparatus for manufacturing the glass fleece
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/593—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives to layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D04H1/655—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions characterised by the apparatus for applying bonding agents
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H13/00—Other non-woven fabrics

Definitions

  • This invention relates to a process and apparatus for the production of a mineral fibreboard.
  • Many processes involving length compression also include a significant thickness compression step after the length compression and before the final curing.
  • a web is subjected to significant length compression in a plurality of stages and is then subjected to thickness compression at the entry to the curing oven.
  • the resultant product has a substantially isotropic fibre orientation.
  • the compressed fleece has a weight per unit area of 2 to 10W, this is substantially equivalent to say that the longitudinal compression may be effected to approximately 0.5 to 0.1 times the original length of the web.
  • the invention also includes processes for the continuous production of a bonded mineral fibre board in which a fibre felt is precompressed in the direction of the thickness to a thickness of 1 to 3 times the thickness of the end product (preferably to substantially the same thickness as the nominal thickness of the end product) and is then subjected to a longitudinal compression by means of at least 2 conveyor pairs driven at different speeds to produce a longitudinally compressed felt and is then bonded at a bonding station (25) to give a bonded mineral fibreboard, characterised in that the thickness of the felt in the longitudinal compression stage and before the bonding station respectively is between approximately 0.9 and 1.3 times the thickness of the end product, the longitudinal compression is effected substantially without thickness compression, the longitudinal compression is effected to approximately 0.5 to 0.1 times the original length, the compression is effected in a continuous compression zone, and the felt is held in order to prevent break-out between the longitudinal compression unit and the bonding station.
  • the invention also includes novel apparatus, as defined in the claims.
  • the fleece is under significant longitudinal compression, it is liable to buckle-up away from the conveyor by which it is being carried, and so appropriate means have to be applied to constrain the fleece against break-out (ie buckling away from the support) as it is being transported between the longitudinal compression unit and the bonding station.
  • These constraining means can be a belt, rollers or other guides that will adequately confine the longitudinal compressed fleece to the desired longitudinal path and prevent significant deviation of the fleece from the desired path.
  • the quantity of fibre required to achieve specific physical values can be up to 15 - 25% less.
  • the products produced by the new process are therefore much lighter than conventional products having the same physical properties. Since the production costs are substantially related to the quantity of fibre used, significant cost savings can also be achieved with the new process.
  • the relatively loose fleece is precompressed to a specific weight w (kg/m 2 ) and then further compressed to the end weight in the longitudinal compression unit, which can also be referred to as an optimisation unit.
  • w kg/m 2
  • the extraordinarily high compression of the already precompressed fleece to 2 to 10 times, preferably 2 to 6 times, the weight of the precompressed fleece does not result in practice in any pleating at the fleece surface.
  • a multiplication of the weight/unit area of the fleece or felt can be obtained by appropriate longitudinal compression of the fleece with substantially equal spacing of the upper and lower conveyors, for example in accordance with the nominal thickness of the end product.
  • the longitudinal compression of the fleece can be achieved in a series of stages, the longitudinal compression of the fleece is preferably effected in one stage, the longitudinally compressed fleece and the bonded board having a weight per unit area of 2 - 6 times, preferably 2.5 - 5 times and most preferably 2.5 - 3.5 times the weight of the precompressed fleece.
  • the resulting products have a high compressive strength and good insulation value.
  • longitudinal compression is effected by feeding the fleece by a first conveyor device to a second conveyor device, the second conveyor device being driven at a lower speed than the first conveyor device.
  • the conveyor device can consist of belt, roller or chain conveyors.
  • roller conveyors are used, because the gross microdensities obtainable with these are extremely homogeneous.
  • the roller diameter and the spacing between the rollers in the conveying direction or the spacing between the conveyors is preferably such as to render any break-out or pleating of the fleece substantially impossible.
  • the distance between two neighbouring rollers is between 1 and approximately 50 mm, advantageously between 2 and 30 mm and most preferably less than 20 mm.
  • the permissible roller spacing depends substantially on the fleece density, the degree of longitudinal compression in the compression unit and the thickness of the board for production. With a small roller spacing it is possible to produce products of different thickness and high density.
  • the rollers can be individually driven, in a preferred embodiment they are combined to form groups each comprising a plurality of rollers.
  • the fleece is stretched in the conveying direction after longitudinal compression.
  • the fleece can first be over-compressed, for example by 20 to 40%, with respect to the required density of the end product, and then de-compressed by the stretching. This helps to avoid undesirable pleating of the fleece web.
  • the gross microdensity can also be improved. Decompression by stretching can particularly be important in the case of high-density products, e.g. products having a density of more than 140 kg/m3. Compression and decompression operations can also be repeated.
  • the fleece may consist of glass wool fibres, rock wool fibres or other synthetic fibres.
  • the fleece consists substantially of rock wool fibres or other man-made vitreous fibres and contains non-cured binder.
  • the binder content by weight is often between approximately 0.7 and 7%, generally 1 to 4%.
  • the binder is preferably curable in a curing oven. Bonding of the fleece can, however, also be effected by needling or felting instead of or in addition to bonding by curing a bonding agent.
  • mineral fibres are used of an average length of between approximately 0.3 and 50 mm, preferably between approximately 0.5 and 15 mm and of a thickness of between approximately 1 to 12 ⁇ m, preferably between approximately 3 and 8 ⁇ m.
  • mineral fibres of an average length of between approximately 1 and 10 mm, preferably between approximately 2 and 6 mm and of an average thickness between approximately 2 to 10 ⁇ m, preferably between approximately 3 to 6 or 7 ⁇ m can be used.
  • the average length of rock wool fibres, which are usually shorter than glass fibres, is as a rule 2 to 4 mm, and the average diameter is 3 to 4 ⁇ m.
  • the predominant orientation of the fibres is changed or partially evened out.
  • This can be effected, for example, by means of a spinning member adapted to swing at an angle to the direction of transport, or by means of an air curtain.
  • the density distribution of the fleece can thus be improved and the fibre orientation changed, this having a favourable effect on the mechanical properties of the resulting products.
  • the primary fleece is deposited in layers on the collecting belt by means of a pendulum belt adapted to swing at an angle to the direction of transport.
  • the primary fleece is formed by cross-lapping. In this way the fibres are partially re-oriented and the homogeneity (transverse distribution) of the fleece deposited on the collecting belt can be improved.
  • 2 to approximately 60 layers are deposited one upon the other. In these conditions a certain reorientation of the fibres is obtained.
  • the fleece can, for example, be deflected transversely of the direction of transport, a compression, more particularly longitudinal compression, being simultaneously effected.
  • the thickness and longitudinally compressed fleece is divided into two or more sub-webs parallel to the large surfaces, while to prevent any deformation in the thickness direction the sub-webs are each held at the opposite large surfaces. At least one of the webs is compressed in the direction of the thickness and/or longitudinally and the sub-webs are then combined and subsequently bonded. Multi-ply products can be produced by this process.
  • the contact surfaces of the sub-webs can be sprayed or impregnated with binder before being combined.
  • the combined webs held together by suitable means can be thickness compressed once again.
  • the webs are longitudinally compressed before bonding.
  • the longitudinal compression can be effected in a ratio of 1.1 : 1 to maximum 2 : 1.
  • the contact surfaces can be increased in size by a final longitudinal compression so that the bonding of the sub-webs is improved.
  • the novel apparatus may have individually driven rollers, it preferably comprises at least two roller groups of two or more rollers. Preferably, at least approximately 10 to 12 rollers are provided in the compression unit in order to compress the felt.
  • the compressed felt can thus be given an advantageous corrugated fibre structure.
  • Other advantageous embodiments are defined in the sub-claims.
  • the invention also includes a process for the continuous production of a single-ply or multi-ply fibreboard, in which process a fibre felt is subjected to a precompression and, by means of at least two conveyor pairs driven at different speeds, a longitudinal compression or a longitudinal/thickness compression, and then fixed, characterised in that the fibre felt (20) is precompressed to approximately 1 to 3, usually about 1 to 1.5 times the nominal thickness of the finished product and then subjected to a longitudinal/thickness compression operation or just a longitudinal compression operation in an optimisation unit (19) by means of conveyors each having two opposite roller groups each comprising two or more rollers, the longitudinal compression being effected to 0.5 - 0.1 times the original length in a continuous or quasi-continuous compression zone and substantially the nominal thickness of the finished produce being attained in the optimisation unit.
  • the invention also includes apparatus for performing the process described above and comprising at least one collecting belt to receive a fibre felt, a precompression stage for compressing a fibre felt, at least two consecutive conveyors driven at different speeds for the longitudinal or longitudinal/thickness compression of the fibre felt and a curing oven for fixing the longitudinally and thickness-compressed fibre-felt, characterised by an optimisation unit comprising conveyors each having two opposite roller groups each comprising two or more rollers, so that during operation a continuous or quasi-continuous compression zone extending over a plurality of rollers or roller groups is obtained.
  • the preferred variant wherein the longitudinally compressed fleece is divided into two or more sub-webs at least one of which is then longitudinally compressed before they are recombined is a process of wider applicability and value than being utilised solely as a second stage in the process of the invention described above.
  • first transport means for transporting the fleece to a separating device
  • a separating device for separating the fleece into two or more sub-webs means for compressing at least one sub-web in the direction of the thickness
  • second transport means for subsequently combining the sub-webs and transporting the same on to the bonding station in which the fleece is bonded
  • the first transport means comprise the longitudinal compression device and comprise at least two conveyor pairs disposed consecutively in the conveying direction, and in that means are provided to prevent break-out of the tensioned subwebs between the compression unit (19) and the bonding station.
  • the processes and apparatus of this aspect of the invention differ from known processes and apparatus essentially in that the precompressed web is compressed further in the thickness and/or longitudinal direction.
  • the sub-webs produced can already have relatively high densities and different fibre structures before being split.
  • the advantage of this for example, in the case of two-ply boards, is that the lower-density layer, unlike conventional boards, has a better compressive strength and tensile strength perpendicularly to the large surfaces. A specific tensile and compressive strength can therefore be achieved with reduced use of material, particularly a smaller quantity of fibre, compared with the known processes.
  • suitable hold-down means and/or conveyors are advantageously provided to hold the fleece webs at the large surfaces.
  • At least one of the split sub-webs can be thickness-compressed.
  • a higher piercing strength can be obtained in this way.
  • the one thickness-compressed sub-web can also be longitudinally compressed. Rolling the reoriented fibres flat by thickness compression may necessitate compensation of the resulting elongation.
  • the contact surfaces of the sub-webs can additionally be provided with binder before being combined.
  • the quantity of binder initially applied to the fibres is already sufficient to achieve a good bond between the sub-webs on curing of the binder.
  • Another possibility for improving the bond between the sub-webs is to compress the combined webs in length before curing. By contracting the webs, e.g. in a ratio of 1.1 : 1 to a maximum 2 : 1 it is possible to enlarge the contact surfaces and hence obtain a better bond between the layers.
  • One problem in connection with the continuous production of two-ply or multi-ply products may be soiling of the band knife used by the binder adhering to the fibres.
  • One advantageous variant of the process therefore proposes continuously cleaning the separating device. This can be effected, for example, by means of a solvent jet, e.g. water, directed to the cutting edge of the band knife.
  • the longitudinal compression is effected by passing the fleece through a compression unit comprising a plurality of conveyor pairs disposed consecutively in the direction of conveyance, the speed of at least one conveyor pair being less than that of the preceding conveyor pair.
  • the precompressed fleece is longitudinally compressed in at least one stage. Longitudinal compression enables the fibres to be reoriented so that, in particular, the compressive strength and tensile strength perpendicularly to the large surfaces are improved. As a result of the fibre structure optimisation it is possible to reduce the resources used.
  • the spacing of the opposite conveyors of a conveyor pair is set to approximately 0.5 to 0.1 times the spacing of the following conveyors, the conveying path defined by the two conveyor pairs being disposed substantially in alignment and the circumferential speed at least of the directly following pair being less than the circumferential speed of the preceding conveyor pair.
  • the spacing of the opposite conveyors of a conveyor pair is set to approximately 0.5 to 0.1 times the spacing of the following conveyors, the conveying path defined by the two conveyor pairs being disposed substantially in alignment and the circumferential speed at least of the directly following pair being less than the circumferential speed of the preceding conveyor pair.
  • the fleece before entry to the compression unit, is already compressed to approximately 0.8 to 1.5 times, preferably 0.9 to 1.3 times the nominal thickness and quite particularly preferably to the approximate nominal thickness of the finished product, so that there is substantially only a longitudinal compression by the conveyors of the compression unit.
  • the longitudinal compression can take place in a continuous compression zone in which the nominal thickness of the product is maintained.
  • a very homogeneous gross microdensity can be obtained if the fleece is already precompressed to approximately the nominal thickness of the finished product before the compression unit and is then only longitudinally compressed.
  • the mineral fibre fleece is advantageously compressed in length by a factor of 2 to 10, preferably by a factor of 2.5 to 5 and quite particularly preferably by a factor of about 2.5 to 3.5. In some cases, for example when the density of the bottom subweb of the finished product is to be less than approximately 100 kg/m3, a simultaneous longitudinal and thickness compression may be indicated.
  • the degree of thickness compression is advantageously less than 2 and preferably less than 1.5.
  • the conveyors of the compression unit may be conveyor belts
  • the conveyors in a particularly preferred embodiment are constructed as roller conveyors.
  • rollers have the advantage that the fleece is repeatedly expanded and compressed by the rollers during compression.
  • the fibres are uniformly felted and no preferential fibre orientation can be detected (Fig. 11).
  • Fig. 11 On an enlarged scale it has been found that the random-orientation fibres are partly arranged in a corrugated pattern. This type of fibre structure is designated a corrugated fibre structure by the inventors.
  • Another desirable effect is the compaction of the fleece web surfaces which is possible by means of rollers.
  • each roller conveyor comprises in each case two opposite groups of at least two rollers in each case, the rollers of a conveyor each being driven at the same circumferential speed. Since the rollers are combined in groups of at least two rollers, the compression unit and its control are greatly simplified.
  • the fleece is stretched in the conveying direction before the separating device. Expanding the fleece can prevent unwanted pleating or breaking-out of the fleece web, e.g. on transition from the compression unit to the separating device.
  • the fleece may consist of glass wool, rock wool or other synthetic fibres.
  • the fleece consists essentially of rock wool fibres and contains non-cured binder.
  • the binder content by weight can be between approximately 0.7 and 4%.
  • the binder is preferably curable in a curing oven. Bonding of the fleece can, however, be effected by needling or felting.
  • mineral fibres of an average length between approximately 0.3 and 50 mm preferably between approximately 0.5 and 15 mm and of a thickness between approximately 1 to 12 ⁇ m, preferably between approximately 3 and 8 ⁇ m are used.
  • mineral fibres of an average length of between approximately 1 and 10 mm preferably between approximately 2 and 6 mm and of an average thickness of between approximately 2 to 10 ⁇ m, preferably between approximately 3 to 7 ⁇ m.
  • the average length of rock wool fibres, which are usually shorter than glass fibres, is as a rule 2 to 4 mm and the average diameter is 3 to 4 ⁇ m.
  • the predominant orientation of the fibres is changed or partially evened out.
  • This can be effected, for example, by means of a spinning member adapted to swing at an angle to the direction of transport, or by means of air curtain.
  • the density distribution of the fleece can thus be improved and the fibre orientation changed, this having a favourable effect on the mechanical properties of the resulting products.
  • the primary fleece is deposited on the collecting belt in layers by means of a pendulum belt adapted to swing at an angle to the transport direction. In this way the fibres are partially reoriented and the homogeneity (transverse distribution) of the fleece deposited on the collecting belt can be improved.
  • 2 to approximately 60 layers are deposited one above the other. This results in some reorientation of the fibres.
  • the fleece can, for example, be deflected transversely of the direction of transport, while a compression, more particularly longitudinal compression, can take place at the same time.
  • At least the separating device and the following hold-down device are adjustable independently of one another perpendicularly to the belt surface in the region of the multi-ply unit, so that the apparatus can be used selectively for the production of singleply or multi-ply products.
  • the means for compressing the at least one sub-web comprise at least two independently driven conveyor pairs.
  • the split sub-web can also be compressed in length.
  • the conveyor pairs are advantageously roller conveyors, the roller spacing being adjustable. As a result the sub-webs can be compressed both in thickness and in length.
  • the bonding station is a curing oven, coolable feed rollers being provided before the said oven.
  • the circumferential speeds of the transport means between the separating device and the bonding station and the circumferential speed of the conveyor belts in the oven are individually adjustable so that, for example, compression or decompression can also be effected before the curing oven.
  • Fig. 1 shows a mineral wool product produced by thickness compression and having a fibre orientation substantially parallel to the surface.
  • Fig. 2 shows a pleated product comprising a majority of fibres disposed perpendicularly to the surfaces.
  • Fig. 3 shows a two-ply product, the upper layer of which has increased density.
  • Fig. 4 shows a product with substantially homogeneous density and random-orientation fibres.
  • Fig. 5 shows a product in which a layer having random-orientation fibres is combined with a layer of increased density.
  • Fig. 6 is a simplified view of an apparatus for the production of a single-ply mineral fibreboard a) in a continuous process and in a continuous compression zone respectively and b) in a single-stage process.
  • Fig. 7 is a diagram showing the principle of an apparatus for the continuous production of a single-ply or multi-ply mineral fibreboard of different densities; a) in a continuous process and in a continuous compression zone respectively and b) in a single-stage process.
  • Fig. 8 is a front elevation of a compression unit in detail.
  • Fig. 9 is a side elevation of the compression unit of Fig. 8.
  • Fig. 10 is a plan view of the compression unit of Fig. 8.
  • Fig. 11 shows the breaking zone of a) a board having a substantially parallel fibre orientation and b) and c) rock wool boards made by the new process and pulled apart perpendicularly to the board plane.
  • Fig. 12 is a perspective section through a two-ply board, the fibre structure being shown on an enlarged scale and Fig. 13 is a diagram showing various possible arrangements of four conveyor pairs disposed consecutively in the conveying direction.
  • Figs. 1 to 5 illustrate the fibre orientations frequently occurring in softboards.
  • Boards having fibres disposed parallel to the surface (Fig. 1) have comparatively poor mechanical properties.
  • the fibres are frequently strengthened with binder and the density increased.
  • Products having fibres arranged perpendicularly to the surface can be obtained if a board of the kind shown in Fig. 1 is cut into strips, the strips are turned through 90° and are then bundled.
  • This type of manufacture is complex and correspondingly uneconomic.
  • the fleece is pleated (pleating process, Fig. 2).
  • These products have a substantially better compressive and tensile strength perpendicularly to the board plane than boards of the kind shown in Fig. 1.
  • Boards having pleated fibres can bend and can therefore be used for insulating pipes or for lining curved areas.
  • a disadvantage on the other hand, is that these products tend to break along the pleats, and the piercing strength is inadequate.
  • Another disadvantage of the known products of this kind is that there may be relatively considerable differences in density within the board.
  • Fig. 3 shows a two-ply product, the top layer of which has an increased density. These products are suitable for applications requiring high tread strength or enhanced surface protection. As a result of the increased density of the top layer the average density can be reduced.
  • Fig. 4 shows a product with substantially isotropic fibre orientation with a substantially random fibre orientation.
  • These products have excellent mechanical properties, such as high compressive, tread, and piercing strength, and high tensile strength perpendicularly to the board plane. They do not break and their thermal conductivity is substantially the same as the products shown in Fig. 1. Generally, these products are lighter than comparable products having substantially parallel fibres for comparable or improved mechanical properties.
  • Fig. 5 shows a product in which the advantages of increased density of the top layer and of the fibre structure shown in Fig. 4 are combined.
  • the object of the invention is particularly further to improve the properties of products of the kind shown in Figs. 4 and 5.
  • the apparatus 11' shown in Fig. 6 for performing the process according to the invention comprises, as considered in the conveying direction F, a precompression stage 17', an optimisation or compression unit 19' adjoining the precompression stage 17' and consisting of two conveyor pairs 30, 32 for compressing the felt or fleece, and also a conveyor belt 40 and a hold-down belt 42 and feed rollers 63, 65 for conveying the compressed fleece to a curing oven 25. Finally, conveyor belts 67, 67' are provided in the curing oven 25 to transport the compressed fleece through the oven and hold the same at the opposite large surfaces during curing of the binder.
  • the precompression stage 17' consists of a lower conveyor belt 27 and a pressing belt 29.
  • the primary fleece deposited preferably in layers on a collecting belt 15 is precompressed to such an extent that the fleece denoted by reference 20 can be introduced into the compression unit 19'.
  • the pressing belt 29 is adjustable as to height.
  • the conveyor pairs 30, 32 of the compression unit 19' consist of upper and lower roller groups 30', 30'' and 32', 32'' each consisting of six rollers 39.
  • the upper and lower roller groups 30', 30''; 32', 32'' each have a separate drive (not shown in detail) so that the conveyors can be driven at different speeds respectively.
  • the upper roller group 30', 32' are adjustable as to height, so that the apparatus 11' can be used for the production of products of different thicknesses.
  • the distance between the upper and lower roller groups 30', 30''i 32', 32'' is preferably identical.
  • the fleece is precompressed in the precompression stage to approximately the nominal thickness of the finished product and then longitudinally compressed with a conveyor spacing corresponding approximately to the nominal thickness of the finished product.
  • the conveyor 30 is driven at a first speed and the conveyor 32 at a second speed which is usually not more than half the first speed so that a corresponding longitudinal compression of the fleece 20 results.
  • another conveyor could be provided in order to expand the fleece somewhat after longitudinal compression. The latter step can prevent the highly compressed fleece from pleating or breaking out in the upward direction on transport into the curing oven 25.
  • the compression unit 19 is followed by a conveyor belt 40 and a hold-down device 42 in order to constrain the compressed fleece 20 against breaking out, ie buckling upwards off the conveyor 40.
  • the hold-down device 42 consists of an uncoilable relatively heavy belt which is placed on the conveyed fleece web.
  • the belt can be additionally loaded by applied weights.
  • Feed rollers 63, 65 are provided before the curing oven 25 and are preferably coolable.
  • the distances between the lower and upper roller groups are each set to approximately the nominal thickness of the end product. This has the advantage that once the fibre orientation has been set in the compression unit 19 it is no longer changed.
  • the apparatus 11 shown in Fig. 7 differs from that shown in Fig. 6 basically in that the compression unit 19 has four conveyors each with four rollers.
  • a multiply unit is also provided which can be used for the production of multi-ply boards and can in principle also be used together with the apparatus 11'.
  • the same references are used in the following description as in the description of the apparatus 11' for like parts.
  • the apparatus 11 shown in Fig. 7 for the production of mineral fibre boards comprises essentially, arranged consecutively in the direction of conveyance F, a pendulum belt 13 and a collecting belt 15 for the respective deposition and reception of fibres produced by a fibre production unit (not shown in detail), and a precompression stage 17 and an optimisation or compression unit 19 for forming a felt or fleece 20 having optimised fibre orientation and homogeneity.
  • the compression unit 19 for optimising the compression is followed by an optional multi-ply unit 21 which can be used for the production of multi-ply mineral fibre boards.
  • the multi-ply unit 21 is followed by transport means 23 which hold the compressed fleece clamped at the opposite large surfaces and feed the same to a bonding station, e.g. a curing oven 25.
  • the above-mentioned fibre production unit serves for the continuous production of fibres by one of the known methods, e.g. the cascade spinning process.
  • the fibres produced also termed the "primary fleece" are sprayed (not shown) with a binder and pass by means of a conveyor (not shown) to the pendulum belt 13.
  • the latter belt is situated above the collecting belt 15 and swings transversely to the direction of transport of the collecting belt 15.
  • a different orientation of the pendulum movement e.g. in the transport direction, is however also possible.
  • the primary fleece 26 is deposited as cross-laps, as will be seen from Fig. 7, on the forwardly moving collecting belt 15, depending on the speed of the latter and the frequency of the pendulum movement.
  • the precompression stage 17 consists of a lower conveyor belt 27 and a pressing belt 29.
  • the latter is adjustable as to height so that the fleece 26 can be precompressed to different degrees.
  • the precompression stage 17 provides precompression and a certain homogenisation of the relatively loose fleece 20 before the same is introduced into the optimisation unit 19.
  • the two belts 27, 29 preferably have separate independent drives so that they can be operated at different circumferential speeds.
  • the optimisation unit 19 consists of a plurality of conveyors or conveyor pairs 31, 33, 35, 37.
  • Each pair 31, 33, 35, 37 has a lower and an upper roller group each consisting of four rollers 39.
  • the clearance between the individual roller groups 31', 31''; 33', 33''; 35', 35''; 37', 37'' is adjustable.
  • the roller groups are also adapted to be inclined relatively to one another preferably in the direction of transport. The latter property enables the fleece 20 to be continuously compressed in thickness or be decompressed on passage through a conveyor pair 31, 33, 35, 37.
  • the fleece optimisation can be obtained as a result of the possibility of adjusting the distance between the opposite roller groups and their speeds. In this way the product properties can be quite different. Also, because of these adjustment facilities, the fibre structure can be controllably optimised and, for example, undesirable pleating at the fleece surface can be prevented.
  • At least the lower and upper roller groups 31" and 31' respectively of the first conveyor pair 31 are adjustable as to height. This enables the fleece to be subjected to bending, as shown in Fig. 7, for example in order to smooth and compact the fleece surface.
  • the upper and lower roller groups 31', 31"; 33', 33"; 35', 35"; 37', 37" of the conveyor pairs 31, 33, 35, 37 each have a separate drive not shown in detail in Fig. 7.
  • the drives used are preferably infinitely variable within a specific range, so that, for example, the upper and lower roller groups can have different circumferential speeds.
  • a slightly higher circumferential speed of the upper roller group is necessary, for example, if the same is disposed, not horizontally, but at an angle to the lower roller group.
  • Figs. 8 to 10 show an exemplified embodiment of a compression unit 19 in which the conveyors with the roller groups 31', 31''; 33', 33''; 35', 35''; 37', 37'' having the rollers 39 are disposed on a supporting structure 71.
  • Chain wheels 115 (Fig. 10) are provided at one end of each of the rollers 39.
  • Each four or five rollers 39 are interconnected by drive chains (not shown) and form a roller group.
  • a drive 117', 117'', 117''', 117'''', 118', 118'', 118''', 118'''', 118''''' is provided for each roller group.
  • the upper and lower roller groups 31', 31'' of the first conveyor pair 31 considered in the direction of conveyance are vertically adjustable.
  • the vertical adjustment of the upper roller group 31' is effected by means of a drive member 81 which drives the spindles 73, 73' via the Cardan shafts 77, 77'.
  • a drive member 83 driving the spindles 75, 75' via the Cardan shafts 79, 79' is used for the vertical adjustment of the bottom roller group 31''.
  • the position of the remaining roller groups is either not adjustable (at the bottom) or adjustable only jointly (at the top).
  • the rear bottom three rollers groups 33", 35", 37" as considered in the direction of conveyance are disposed on a stationary frame 85 while the upper three roller groups 33', 35', 37' are disposed on a vertically adjustable frame 87.
  • the latter frame 87 is vertically adjustable at the top part of the supporting structure 71.
  • Linear guides 93 at the columns 95, 95', 97, 97' provide vertical guidance of the frame 87.
  • a drive member 103 which by way of the Cardan shafts 99, 99', 101, 101' drives the spindles 89, 89', 91, 91' arranged in pairs on the supporting structure 71 is provided for vertical adjustment of the frame 87.
  • the upper roller groups 33', 35', 37', the last of which has 5 rollers 39, are disposed on support rails 105 pivotally connected to the frame 87 by the pivot 107.
  • the front end of the rails 105 as considered in the direction of conveyance is connected to the vertically adjustable frame 87 by another pair of spindles 109, 109'.
  • the spindles 109, 109' are also interconnected via Cardan shafts 111, 111' so that here again one drive 113 is sufficient to adjust them.
  • Fig. 13 shows various possibilities of how four conveyor pairs can be arranged in principle.
  • the adjustments according to Figs. 13b and 13c cannot be made with the compression unit according to Figs. 8 to 10.
  • An arrangement of the roller groups 31', 31'', 33', 33'', 35', 35'', 37', 37'' according to Fig. 13d is advisable, for example, if light products are to be made.
  • the optimisation unit 19 comprising a plurality of conveyor pairs is followed by the optional multi-ply unit 21, which in the exemplified embodiment illustrated is in the form of a dual density device.
  • This comprises a separating device 41, for example, a band saw or a band knife, which is shown only in outline in Fig. 7 for separating the compressed fleece 20 into two webs 43 and 45.
  • the multi-ply unit 21 also comprises conveyors 47, 49, 50 and 51, e.g. conveyor belts, which fix the compressed sub-webs 43, 45 in thickness. Any gaps occurring for geometric reasons between the separating device and, for example, the conveyor belt 49 or 50 can be bridged where possible by guide plates. These prevent the fleece web 43, which is compressed to varying degrees, from breaking out.
  • the separating device 41 and following conveyor is preferably adjustable as to height. This enables the fleece emerging from the compression unit 19 to be cut into lower and upper webs 43, 45 of practically any thickness.
  • the separating device 41 and the conveyor belt 49 can also be displaced independently of one another and upwardly to an extent such that they are disposed outside the range of transport of the fleece.
  • the conveyor belt 49 then serves as a hold-down belt.
  • the apparatus 11 can be used optionally for the production of single-ply or multi-ply boards. Basically, a plurality of separating devices and corresponding hold-down belts can be provided to enable boards to be produced with three or even more layers. Also, the distance between the upper and lower rollers is adjustable so that outer layers of different thicknesses can be made.
  • the conveyor pairs 53, 54 provided after the conveyors 50, 51 serve for thickness and longitudinal compression of the upper web 45.
  • the conveyor pairs 53, 54 preferably comprise rollers S5, which are combined in each case to form upper and lower roller groups with three rollers in each case.
  • the conveyor pairs 53, 54 are each drivable at different circumferential speeds so that the elongations which may occur as a result of thickness compression can be compensated by subsequent longitudinal compression. Also, the distance between the upper and lower rollers is adjustable so that outer layers of different thicknesses can be made.
  • Conveyor belts, chutes and/or guide plates combine the compressed web 45' with the lower web 43. In most cases a hold-down belt for the highly compressed web 45' can be dispensed with.
  • a metering device 57 for a binder is provided in the zone where the webs 43, 45 meet. With this arrangement it is possible to apply binder to the contact surfaces of the upper and/or lower webs 43, 45' so that a better bonding is obtained after curing of the binder. In most cases, particularly if any elongations occurring have been compensated previously, a metering device 57 can also be dispensed with.
  • Feed belts 59, 61 and feed rollers 63, 65 press the combined webs 43, 45' together and transport the same into the curing oven 25.
  • the circumferential speeds of the feed belts 59, 61 and feed rollers 63, 65 are advantageously individually adjustable so that compression or decompression of the compressed webs 43, 45' can be effected as required.
  • At least the feed rollers 63, 65 are preferably coolable.
  • Air-permeable conveyor belts 67, 67' are preferably provided in the curing oven 25. The belts 67, 67' hold the webs 43, 45' together during the curing process and thus substantially determine the nominal thickness of the finished boards.
  • the belts 67, 67' like the conveyors 59, 61, 63, 65, are vertically adjustable and can thus be adjusted to the fleece thicknesses coming from the multi-ply unit 21 or the compression unit 19.
  • the production of the multi-ply board can be carried out as follows: the primary fleece delivered from a collecting chamber (not shown) and provided with binder and, in the case of rock wool fibres usually of a weight of about 200 - 800 g/m2, preferably 200 400 g/m2, with an approximately average thickness of 15 - 20 mm, or frequently up to 75 mm, is fed to the pendulum belt 13.
  • the latter deposits the primary fleece on the continuously advancing collecting belt 15.
  • a larger or smaller number of fleece layers is formed on the belt 15 in the vertical direction.
  • the number of layers is selected according to the required board properties, e.g. weight, compressive strength etc., of the end product.
  • the number of layers also depends on the fibre formulation, i.e. the individual fibre processing stages between the fibre production unit and the curing oven 25. Usually 2 to 40 to 50 layers are deposited on the collecting belt 15.
  • Depositing the primary fleece 26 by means of the pendulum belt 13 not only provides good transverse distribution of the fibre material on the collecting belt 15, but also contributes to uniform fibre orientation and a certain homogenisation.
  • the fibre orientation can be further controllably influenced by changing the direction of the pendulum movement.
  • the deposited fleece is subjected to a precompression in the precompression stage 17.
  • the precompression is usually such that the fleece can be engaged by the rollers of the first conveyor pair (required nominal thickness plus at maximum approximately 40% of the roller diameter).
  • Some deflection of the fleece after precompression is desirable so that, on entry into the compression unit, sufficient adhesion between the fleece and the rollers is achieved to give the required reorientation of the fibres. Since, in the case of products having a density of less than approximately 80 to 90 kg/m3 the expansion forces prevailing in the fleece during longitudinal compression are much lower, a moderate thickness compression in addition to the longitudinal compression is usually necessary in the production of these products in order to set the required tension and avoid undesirable pleating at the fleece surface.
  • the fleece surfaces In the case of doubling, i.e. when the primary fleece is deposited in layers, the fleece surfaces have steps showing to varying degrees. These steps can be at least partially evened out in the precompression stage 17, by driving the upper belt 29 at a slightly higher speed than would be necessary for further transport.
  • the partially smoothed fleece can be subjected to further smoothing in the optimisation unit 19.
  • the first and second conveyor pairs can be disposed so as to be out of alignment. It is also possible for any other pairs of conveyors to be disposed out of alignment.
  • the out-of-alignment arrangement subjects the conveyed fleece 20 to a bending or transverse deflection, which can effect smoothing of the fleece surfaces. The smoothing effect can be enhanced if the second conveyor pair runs somewhat more slowly than the first.
  • a longitudinal compression of 2:1 to 6:1 (corresponding to the circumferential speeds of the first and the last conveyor pairs 31 and 37) is effected in the compression unit 19 substantially with a roller spacing corresponding to the nominal thickness of the board being produced (i.e. compaction by longitudinal compression without thickness compression).
  • a longitudinal compression together with simultaneous moderate thickness compression may be advantageous.
  • each two conveyor pairs 31, 33 and 35, 37 can be driven jointly by one drive.
  • rollers are preferred, because the tendency to pleating at the fleece surfaces is relatively minor, even with a considerable degree of longitudinal compression.
  • the fleece can be greatly longitudinally compressed with rollers 39 without appreciable pleating at the fleece surface.
  • One possible explanation for this is that there is only a slight adhesion between the rollers and the fleece.
  • the rollers also promote the reorientation of the fibres, since the fleece can expand somewhat between the rollers in each case but without pleating.
  • the compressed fleece can be separated into two or more webs 43, 45. It is also possible to omit the multi-ply unit or position it outside the conveying path and feed the fleece with the optimised fibre structure to the curing oven direct.
  • Separation of the fleece 20 is effected by a band saw or a band knife in manner known per se.
  • the upper web 45 with the optimised fibre structure is then subjected to a thickness and longitudinal compression. In this, the fibres of the upper layer 45 are further compacted by the thickness and subsequent longitudinal compression.
  • the thickness-compressed web 45' is then returned to the continuously moving lower web 43.
  • the compressed fleece 43, 45', more particularly the web 43 under tension, is guided between the compression stage 19 and the curing oven 25 by the conveyors 47, 49, 59, 61, 63, 65, for example belts, chains or roller systems, preferably conveyor belts, in order to prevent any break-out or bulging.
  • the conveyors 47, 49, 59, 61, 63, 65 for example belts, chains or roller systems, preferably conveyor belts, in order to prevent any break-out or bulging.
  • the binder in the fleece is cured. Curing of the binder takes place at temperatures between 180 and 300°C, preferably at about 200 to 250°C.
  • the binder also ensures a firm bonding between the two webs 43, 45' of low and high gross density.
  • the contact points thereof can be provided with a solid or liquid adhesive (metering device 57) on the multi-ply unit before being combined.
  • the bonding between the two webs 43 and 45' can be improved if the webs are contracted somewhat before the curing oven 25, preferably in a ratio of 1.1:1 to 2:1. Depending on the degree of contraction, this may result in some pleating of the webs. The contraction results in the contact surfaces increasing in size and the adhesion/felting of the webs can thus be improved.
  • the fleece or felt is longitudinally compressed preferably in a single stage.
  • the apparatus can also be so operated that a plurality of compression zones or a continuous compression zone form during the compression.
  • the weight in boards produced by the new process can be reduced by up to 25 to 40% for otherwise substantially identical mechanical properties.
  • the tensile strength perpendicularly to the board plane is greatly improved, this being evident from the highly structured breaking zone (Figs. 11b and 11c).
  • Products according to the invention can be used for any of the conventional purposes of synthetic fibres, e.g. for boards, webs, used for thermal insulation, fireproofing and fire protection or soundproofing and sound control, or in suitable form in horticulture as a growth medium.

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Claims (38)

  1. Kontinuierliches Verfahren zur Herstellung einer gebundenen Mineralfaserplatte mit einer Dicke t aus einem Vlies mit einer Dicke von mehr als 2 t, umfassend
    das Komprimieren des Vlieses in Tiefenrichtung im wesentlichen ohne gleichzeitige Komprimierung in Längsrichtung auf eine erste Dicke und ein Gewicht w pro Flächeneinheit,
    das anschließende Komprimieren des Vlieses in Längsrichtung, wobei das Vlies auf eine zweite Dicke gezwungen wird, und dadurch Herstellen eines in Längsrichtung komprimierten Vlieses, das Transportieren des in Längsrichtung komprimierten Vlieses zu einer Bindungsstation (25) und
    das Binden des Vlieses in der Bindungsstation (25) unter Bildung einer gebundenen Mineralfaserplatte,
       dadurch gekennzeichnet, daß die erste Dicke im Bereich von 0,8 bis 1,5 t, bevorzugt zwischen 0,9 und 1,3 t, liegt,
    die zweite Dicke im Bereich zwischen 1 und 1,3 t, bevorzugt 1 bis 1,1 t, liegt,
    die Komprimierung in Längsrichtung kontinuierlich oder in einer oder mehreren Stufen im wesentlichen ohne Falten des Vlieses ausgeführt wird und ein in Längsrichtung komprimiertes Vlies mit einem Gewicht pro Flächeneinheit von 2 bis 10 w erzeugt und
    das Ausbrechen des Vlieses beim Transport zwischen der Komprimierung in Längsrichtung und der Bindungsstation verhindert wird.
  2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß die Komprimierung des Vlieses in Längsrichtung in einer Stufe bewirkt wird.
  3. Verfahren nach Anspruch 1 oder Anspruch 2, in welchem das in Längsrichtung komprimierte Vlies und die gebundene Platte ein Gewicht pro Flächeneinheit von 2 bis 6 w, bevorzugt 2,5 bis 4 w, aufweisen.
  4. Verfahren nach irgendeinem der Ansprüche 1 bis 3, in welchem die Komprimierung in Längsrichtung durch Zuführen des Vlieses mit Hilfe einer ersten Fördereinrichtung (30) zu einer zweiten Fördereinrichtung (32) bewirkt wird, wobei die zweite Fördereinrichtung (32) mit einer geringeren Geschwindigkeit als die erste Fördereinrichtung angetrieben wird und wobei jede Fördereinrichtung (30, 32) zwei gegenüberliegende Rollengruppen (30', 30") umfaßt, die jeweils mindestens zwei beabstandete Rollen (39) umfassen.
  5. Verfahren nach Anspruch 4, in welchem die gegenüberliegenden Rollengruppen mindestens einer Fördereinrichtung (30, 32; 31, 33, 35, 37) mit verschiedenen Geschwindigkeiten angetrieben werden.
  6. Verfahren nach irgendeinem vorhergehenden Anspruch, in welchem das Ausbrechen des Vlieses beim Transport des Vlieses zwischen der Komprimierung in Längsrichtung und der Bindungsstation durch eine Beschränkungseinrichtung verhindert wird, wobei die Beschränkungseinrichtung ein Band, Rollen oder andere Führungen umfaßt, die eine signifikante Abweichung vom gewünschten Weg verhindern.
  7. Verfahren nach Anspruch 4, in welchem das Ausbrechen des Vlieses beim Transport zwischen der Komprimierung in Längsrichtung und der Bindungsstation durch Expandieren des Vlieses durch ein anderes Förderwerk nach der zweiten Fördereinrichtung verhindert wird.
  8. Verfahren nach irgendeinem vorhergehenden Anspruch, in welchem das Vlies nach der Komprimierung in Längsrichtung in Längsrichtung gestreckt wird.
  9. Verfahren nach irgendeinem vorhergehenden Anspruch, in welchem das Vlies aus künstlichen, glasartigen Fasern, bevorzugt Steinwollfasern, gebildet wird und nicht gehärtetes Bindemittel enthält und das Bindemittel durch Erwärmen in der Bindungsstation gehärtet wird.
  10. Verfahren nach irgendeinem vorhergehenden Anspruch, in welchem das Vlies durch kreuzweises Übereinanderlegen gebildet wird.
  11. Verfahren nach irgendeinem vorhergehenden Anspruch, in welchem das in Längsrichtung komprimierte Vlies vor der Bindungsstation parallel zu den Hauptoberflächen in zwei oder mehrere Unterbahnen aufgeteilt wird und jede Unterbahn auf ihrem Weg in Richtung der Bindungsstation gegen Ausbrechen beschränkt wird und mindestens eine der Bahnen in Dickenrichtung und/oder Längsrichtung komprimiert wird und die Unterbahnen dann vereint und in der Bindungsstation gebunden werden.
  12. Verfahren nach Anspruch 11, in welchem die Kontaktoberflächen vor der Vereinigung mit einem Bindemittel versehen werden.
  13. Verfahren nach Anspruch 11 oder Anspruch 12, dadurch gekennzeichnet, daß die vereinten Bahnen vor der Bindungsstation in Längsrichtung komprimiert werden.
  14. Verfahren zur kontinuierlichen Herstellung einer gebundenen Mineralfaserplatte, in welchem ein Faserfilz in Dickenrichtung auf eine Dicke des 1- bis 3-fachen des Endprodukts vorkomprimiert wird und dann einer Komprimierung in Längsrichtung mit Hilfe von mindestens zwei Förderpaaren, die mit unterschiedlichen Geschwindigkeiten angetrieben werden, unterworfen wird, um einen in Längsrichtung komprimierten Filz zu erzeugen, und dann in einer Bindungsstation (25) gebunden wird, um eine gebundene Mineralfaserplatte zu ergeben, dadurch gekennzeichnet, daß die Dicke des Filzes in der Stufe der Komprimierung in Längsrichtung bzw. vor der Bindungsstation etwa zwischen dem 0,9- und 1,3-fachen der Dicke des Endprodukts liegt, die Komprimierung in Längsrichtung im wesentlichen ohne Komprimierung in der Dicke bewirkt wird, die Komprimierung in Längsrichtung auf etwa das 0,5- bis 0,1-fache der Originallänge erfolgt, die Komprimierung in einer kontinuierlichen Komprimierungszone bewirkt wird und der Filz gehalten wird, um ein Ausbrechen zwischen der Einheit für die Komprimierung in Längsrichtung (19, 19') und der Bindungsstation (25) zu verhindern.
  15. Verfahren nach Anspruch 14, dadurch gekennzeichnet, daß die Dicke des Filzes in der Zone der Komprimierung in Längsrichtung im wesentlichen die gleiche ist wie die nominale Dicke des Endprodukts.
  16. Vorrichtung, die zur Ausführung des Verfahrens nach Anspruch 1 geeignet ist und umfaßt eine Fördereinrichtung (19, 40; 19, 23) zum Transport des Vlieses zu einer Bindungsstation (25), ein Einrichtung (17) zur Dickenkomprimierung des Vlieses, ein Einrichtung zur Komprimierung des Vlieses in Längsrichtung (19; 19'), das der Einrichtung zur Dickenkomprimierung (17) folgt, eine Bindungsstation (25) zum Binden des in Längsrichtung komprimierten Vlieses, dadurch gekennzeichnet, daß die Vorrichtung eine Einrichtung (59, 61; 40, 42) zur Verhinderung des Ausbrechens des Vlieses zwischen der Einrichtung zur Komprimierung in Längsrichtung und der Bindungsstation (25) beinhaltet und die Einrichtung zur Komprimierung in Längsrichtung mindestens zwei Rollenförderwerke (30, 32), die nacheinander in Förderrichtung angeordnet sind, wobei jedes Rollenförderwerk (30, 32) zwei gegenüberliegende Gruppen von mindestens zwei Rollen (39) umfaßt, wobei die gegenüberliegenden Rollengruppen einen Förderweg (F) für das Vlies bilden, eine Antriebseinrichtung zum Antrieb der Rollen (39) jeder Gruppe im wesentlichen mit der gleichen Umfangsgeschwindigkeit, eine Einrichtung zur Steuerung der Umfangsgeschwindigkeit der Rollen (39, 39') jeder einzelnen Gruppe unabhängig von der Geschwindigkeit der Rollen in jeder anderen Gruppe und eine Einrichtung zur Einstellung des Abstandes zwischen den gegenüberliegenden Rollengruppen (30', 30"; 32', 32") der Förderwerke (30, 32) unabhängig von dem Abstand der Rollen in anderen Förderwerken umfaßt.
  17. Vorrichtung nach Anspruch 16, dadurch gekennzeichnet, daß zwei Rollenförderwerke (30, 32) vorgesehen sind, die nacheinander in Förderrichtung (F) angeordnet sind.
  18. Vorrichtung nach Anspruch 16 oder Anspruch 17, dadurch gekennzeichnet, daß jede Rollengruppe 2 bis 8 Rollen, bevorzugt 4 bis 6 aufeinanderfolgende Rollen, umfaßt.
  19. Vorrichtung nach irgendeinem der Ansprüche 16 bis 18, dadurch gekennzeichnet, daß mindestens eines der Rollenförderwerke (30, 32) eine Einrichtung zum Schrägstellen der gegenüberliegenden Rollengruppen relativ zueinander aufweist, z.B. um eine sich in Förderrichtung verjüngende Vliesbahn herzustellen.
  20. Vorrichtung nach irgendeinem der Ansprüche 16 bis 19, dadurch gekennzeichnet, daß der Rollendurchmesser und der Abstand zwischen den Rollen (39) in Förderrichtung derart sind, daß irgendein Ausbrechen oder Falten des Vlieses im wesentlichen verhindert wird.
  21. Vorrichtung nach irgendeinem der Ansprüche 16 bis 20, dadurch gekennzeichnet, daß der Rollendurchmesser kleiner als etwa 18 cm ist und bevorzugt zwischen etwa 60 und 160 mm und besonders bevorzugt zwischen 80 und 120 mm liegt.
  22. Vorrichtung nach irgendeinem der Ansprüche 16 bis 20, dadurch gekennzeichnet, daß zumindest das erste Förderwerk (30) eine Einrichtung zur Einstellung der Position des Förderwegs durch das genannte Förderwerk relativ zur Position des Förderwegs durch das oder die folgende(n) Förderwerk(e) (32) aufweist.
  23. Vorrichtung nach irgendeinem der Ansprüche 16 bis 22, dadurch gekennzeichnet, daß die Förderwerke (30, 32) horizontal angeordnet sind.
  24. Vorrichtung nach irgendeinem der Ansprüche 16 bis 22, dadurch gekennzeichnet, daß eine Trenneinrichtung (41) zur Trennung des Vlieses in zwei oder mehrere Unterbahnen zwischen den Rollenförderwerken (31, 33, 35, 37) und der Bindungsstation (25) vorgesehen ist, mindestens eine Komprimierungsstufe (53, 54) zur Dicken- und/oder Längskomprimierung mindestens einer Unterbahn vorgesehen ist und Förderwerke (59, 61, 63, 65) vorgesehen sind, um das komprimierte Vlies und die Unterbahnen auf dem Weg zur Bindungsstation (25) zu halten, um jede Deformation in Richtung der Dicke oder ein Ausbrechen zu verhindern.
  25. Vorrichtung nach Anspruch 24, dadurch gekennzeichnet, daß die Trenneinrichtung (41) und mindestens das Förderwerk (47) bezüglich der Höhe einstellbar sind, so daß die Vorrichtung optional für die Herstellung von einlagigen oder mehrlagigen Erzeugnissen verwendet werden kann.
  26. Vorrichtung nach den Ansprüchen 24 oder 25, dadurch gekennzeichnet, daß eine Einrichtung (57) für die dosierte Zugabe eines Bindemittels für die gegenseitigen Kontaktoberflächen der Unterbahnen vorgesehen ist.
  27. Vorrichtung nach irgendeinem der Ansprüche 16 bis 26, dadurch gekennzeichnet, daß eine Einrichtung zum Antrieb der Fördereinrichtungen zwischen der Komprimierungsstufe und der Bindungsstation und in der Bindungsstation unabhängig voneinander vorgesehen ist.
  28. Verfahren nach irgendeinem der Ansprüche 1 bis 15, umfassend die Zuführung des in Längsrichtung komprimierten Vlieses zu einer Trenneinrichtung (41) vor dem Transport zur Bindungsstation, das Trennen des Vlieses mit Hilfe der Trenneinrichtung (41) in zwei oder mehrere Unterbahnen (43, 45), das Komprimieren mindestens einer Unterbahn (45) in Dickenrichtung, anschließendes Vereinen der Unterbahnen (43, 45') und Transportieren derselben zur Bindungsstation (25), in welcher das Vlies gebunden wird, wobei das Ausbrechen der unter Spannung stehenden Unterbahnen (43, 45) zwischen der Komprimierungseinheit (19) und der Bindungsstation (25) durch eine Beschränkungseinrichtung (49, 50, 51, 59, 61, 63, 65) verhindert wird.
  29. Verfahren nach Anspruch 28, dadurch gekennzeichnet, daß zumindest die eine, bezüglich der Dicke komprimierte Unterbahn (45) in Längsrichtung komprimiert wird.
  30. Verfahren nach Anspruch 28 oder Anspruch 29, dadurch gekennzeichnet, daß die Kontaktoberflächen der Unterbahnen (44, 45) vor der Vereinigung mit einem Bindemittel versehen werden.
  31. Verfahren nach irgendeinem der Ansprüche 28 bis 30, dadurch gekennzeichnet, daß die vereinten Bahnen (44, 45') vor dem Binden in Längsrichtung komprimiert werden.
  32. Verfahren nach irgendeinem der Ansprüche 28 bis 31, dadurch gekennzeichnet, daß die Trenneinrichtung (41) kontinuierlich gereinigt wird.
  33. Vorrichtung nach irgendeinem der Ansprüche 16 bis 27, die beinhaltet eine erste Transporteinrichtung (19) zum Transport des Vlieses zu einer Trenneinrichtung (41), eine Trenneinrichtung (41) zur Trennung des Vlieses in zwei oder mehrere Unterbahnen (43, 45), eine Einrichtung zum Komprimieren mindestens einer Unterbahn (45) in Richtung der Dicke, eine zweite Transporteinrichtung (23) zum anschließenden Vereinen der Unterbahnen (43, 45') und zum Transportieren derselben zur Bindungsstation (25), in der das Vlies gebunden wird, wobei die erste Transporteinrichtung (19) die Einrichtung zur Komprimierung in Längsrichtung umfaßt und mindestens zwei Förderpaare (31, 33, 35, 37) umfaßt, die nacheinander in Förderrichtung angeordnet sind, und eine Einrichtung (49, 50, 51, 59, 61, 63, 65) vorgesehen ist, um das Ausbrechen der unter Spannung stehenden Unterbahnen (43, 45) zwischen der Komprimierungseinheit (19) und der Bindungsstation (25) zu verhindern.
  34. Vorrichtung nach Anspruch 33, dadurch gekennzeichnet, daß eine Einrichtung (57) vorgesehen ist, um die Unterbahnen vor der erneuten Vereinigung mit einem Bindemittel zu versehen.
  35. Vorrichtung nach Anspruch 33 oder Anspruch 34, dadurch gekennzeichnet, daß die Trenneinrichtung (41) aus einem Bandmesser oder einer Bandsäge besteht.
  36. Vorrichtung nach irgendeinem der Ansprüche 33 bis 35, dadurch gekennzeichnet, daß eine Reinigungsvorrichtung zur kontinuierlichen oder diskontinuierlichen Reinigung des Bandmessers oder der Bandsäge vorgesehen ist.
  37. Vorrichtung nach irgendeinem der Ansprüche 33 bis 36, dadurch gekennzeichnet, daß zumindest die Trenneinrichtung (41) und die anschließende Niederhalteinrichtung (49) im Bereich der Mehrlageneinheit (21) vertikal einstellbar sind.
  38. Vorrichtung nach irgendeinem der Ansprüche 33 bis 37, dadurch gekennzeichnet, daß zur Herstellung von im wesentlichen gefalteten Erzeugnissen der Abstand der gegenüberliegenden Förderwerke eines Förderpaares (31, 33, 35) auf etwa das 0,5- bis 0,1-fache des Abstandes der Förderwerke des folgenden Förderpaares (33, 35, 37) einstellbar ist und der durch die beiden Förderpaare definierte Förderweg im wesentlichen ausgerichtet ist.
EP97914299A 1996-03-25 1997-03-24 Verfahren und vorrichtung zur herstellung von einer mineralfaserplatte Revoked EP0889981B1 (de)

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EP01102183A EP1111113B1 (de) 1996-03-25 1997-03-24 Verfahren und Vorrichtung zur Herstellung einer Mineralfaserplatte
SI9730262T SI0889981T1 (en) 1996-03-25 1997-03-24 Process and apparatus for the production of a mineral fibreboard
EP08007764A EP1942217A3 (de) 1996-03-25 1997-03-24 Verfahren und Vorrichtung zur Herstellung einer Mineralfaserplatte

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CH76896 1996-03-25
CH768/96 1996-03-25
CH00768/96A CH691816A5 (de) 1996-03-25 1996-03-25 Verfahren und Vorrichtung zur Herstellung einer ein- oder mehrschichtigen Faserplatte.
CH02169/96A CH691960A5 (de) 1996-09-02 1996-09-02 Verfahren und Vorrichtung zur Herstellung einer zwei- oder mehrschichtigen Mineralfaserplatte.
CH216796 1996-09-02
CH216796 1996-09-02
CH2167/96 1996-09-02
CH2169/96 1996-09-02
CH216996 1996-09-02
PCT/EP1997/001490 WO1997036035A1 (en) 1996-03-25 1997-03-24 Process and apparatus for the production of a mineral fibreboard

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WO2004099095A2 (fr) * 2003-05-07 2004-11-18 Saint-Gobain Isover Produit a base de fibres minerales, dispositif d’obtention des fibres et procede d’obtention
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WO1997036035A1 (en) 1997-10-02
ATE395452T1 (de) 2008-05-15
SI0889981T1 (en) 2002-06-30
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DK1111113T3 (da) 2008-09-15
PL184688B1 (pl) 2002-11-29
AU2159897A (en) 1997-10-17
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BA98344A (bs) 2001-09-14
ATE209715T1 (de) 2001-12-15
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EA000493B1 (ru) 1999-08-26
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HU225208B1 (hu) 2006-08-28
DE69708613T2 (de) 2002-08-01
EP1111113B1 (de) 2008-05-14
EP1942217A3 (de) 2008-11-05
SI1111113T1 (sl) 2008-12-31
PL186337B1 (pl) 2003-12-31
SK12862001A3 (sk) 2002-01-07
CZ302498A3 (cs) 1999-09-15
HU223013B1 (hu) 2004-03-01
EP0889981A1 (de) 1999-01-13
DE69738694D1 (de) 2008-06-26
PL329169A1 (en) 1999-03-15
CZ291473B6 (cs) 2003-03-12
SK286867B6 (sk) 2009-06-05

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