EP1448828B2 - Mineral fibre batts - Google Patents

Mineral fibre batts Download PDF

Info

Publication number
EP1448828B2
EP1448828B2 EP02787646.5A EP02787646A EP1448828B2 EP 1448828 B2 EP1448828 B2 EP 1448828B2 EP 02787646 A EP02787646 A EP 02787646A EP 1448828 B2 EP1448828 B2 EP 1448828B2
Authority
EP
European Patent Office
Prior art keywords
batt
outer portion
bonded
network
mineral fibre
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.)
Expired - Lifetime
Application number
EP02787646.5A
Other languages
German (de)
French (fr)
Other versions
EP1448828A1 (en
EP1448828B1 (en
Inventor
Oskar Meres
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.)
Rockwool AS
Original Assignee
Rockwool International AS
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=8182458&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=EP1448828(B2) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Rockwool International AS filed Critical Rockwool International AS
Priority to EP02787646.5A priority Critical patent/EP1448828B2/en
Priority to DE60222691.0T priority patent/DE60222691T3/en
Publication of EP1448828A1 publication Critical patent/EP1448828A1/en
Application granted granted Critical
Publication of EP1448828B1 publication Critical patent/EP1448828B1/en
Publication of EP1448828B2 publication Critical patent/EP1448828B2/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/78—Heat insulating elements
    • 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
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • 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
    • D04H13/00—Other non-woven fabrics
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/7654—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings
    • E04B1/7658—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres
    • E04B1/7662—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres comprising fiber blankets or batts

Definitions

  • This invention relates to a use of a batt as insulation according to claim 1.
  • a conventional mineral fibre batt comprises a bonded mineral fibre network bonded by a cured bonding agent.
  • Batts having different stiffness at different levels through the thickness of the batt can be made by laminating, with intermeshing at the lamination face, preformed cured batts having different stiffness. Usually it is better to make the batt by curing a mineral fibre web containing uncured bonding agent and which has variable fibre density through the depth or variable binder concentration through the depth.
  • the web may be made by, for instance, centrifugal fiberisation of a mineral melt of glass, rock, stone or slag, for instance using one or more cascade spinners or one or more spinning cups.
  • the production of a cured batt having varying binder concentration through the depth may be achieved as described in EP-A-374112 .
  • the production of a batt by curing a web having higher fibre density in one layer than the rest may be achieved by conventional dual density processes. In these the mineral fibres and bonding agent are collected as a web, the upper layer of the web is separated and consolidated and rejoined on to the remainder of the web, and the web is then subjected to curing.
  • the batt is made notably stiff even when the amount of bonding agent is as low as is reasonably satisfactory to achieve minimum coherence of the batt.
  • this stiffness is highly desirable. However there are some instances when the stiffness created by low binder amounts is undesirable and there are other cases where it would be desirable to provide a surface layer of lower stiffness in a product which has high binder amounts and/or high density and so is, overall, very stiff.
  • a mineral fibre batt disclosed herein has first and second major surfaces and comprises a bonded mineral fibre network which is bonded by a cured bonding agent and which has an inner portion and an outer portion wherein the second surface of the batt is provided by the outer surface of the outer portion, and wherein the outer portion has a depth of at least 5mm and has reduced stiffness due to post-cure compression of the bonded network in the outer portion.
  • the inner portion adjacent the outer portion has the same fibre content type (e.g., average dimensions and chemical type) and distribution, and the same bonding agent and amount, as the outer portion, in which event it is meaningful simply to compare the stiffness of the outer portion with the stiffness of the adjacent inner portion.
  • the adjacent inner portion exhibits also some additional difference, e.g., in fibre content or binder.
  • the invention is a use of a batt as insulation according to claim 1.
  • the bonding agent is usually a conventional bonding agent for mineral fibre batts, for instance a phenolic or other curable thermosetting resin.
  • a product is formed in which the outer portion is less stiff than the inner portion. This presumably is due to fracturing of the bonded network in the outer portion as a result of the compression after curing the bonding agent.
  • the height compression is applied predominantly from the second face by passing the bonded and cured batt through a nip between a surface which supports the first face and compression means for temporarily compressing the batt at the second face. This will result in fracturing the bonded network in the bonded outer portion of the second face, leaving the bonded network closer to the first layer substantially unchanged.
  • the preferred compression means comprise at least one compression-applying roller having a diameter less than the total thickness of the batt and which defines a nip which has a depth of 20 to 90% of the thickness of the batt after curing (giving 10 to 80% temporary height compression).
  • the nip has a depth of at least 30 or 40% of the thickness of the batt and generally not more than 70 or 80% of the height of the batt. For instance it may have a depth of around 55% of the height of the batt, thus giving 45% temporary height compression.
  • the diameter of the or each compression applying roller must be relatively small in order to concentrate the compression forces in the desired region.
  • the diameter is usually less than 75%, and often less than 50%, of the thickness of the batt. It is usually at least 30mm, and is usually below 75mm, often below 40 or 50mm.
  • the support surface is preferably substantially planar but it can be a surface with a large radius of curvature and which thus gives substantially the same support as a planar surface.
  • the support can be a planar plate or conveyor or drum of large diameter, e.g., at least 5 times the thickness of the batt.
  • the compression means comprise a plurality of parallel, compression applying, rollers each having a diameter less than the thickness of the batt (as explained above) and which define with the substantially planar support a nip which decreases in distance as the batt enters the nip, and the final, narrowest, nip preferably is within the range described above.
  • the nip increases in distance as the batt leaves the nip.
  • each roller, in plan view overlaps each adjacent roller and preferably each defines a step of 3 to 15, often 5 to 10mm, up (or down) from the next.
  • the binder content is usually relatively low, for instance 0.2 to 1.5%, often around 0.3 to 1 or 1.2%.
  • the fibre density is usually relatively low, for instance 20 to 100kg/m 3 , often around 30 to 90kg/m 3 .
  • a batt is to be fixed against a non-planar surface, for instance a surface having surface irregularities with a depth of at least 3mm, and often 5 or 10mm or even 15mm.
  • a non-planar surface for instance a surface having surface irregularities with a depth of at least 3mm, and often 5 or 10mm or even 15mm.
  • mineral wool batts against brickwork or other stone walls and these often have an irregular surface.
  • a soft glass fibre panel can be applied to such a surface but this tends to be unsatisfactory since irregularities in the surface are then manifested in the wall, to some extent, in the first surface of the glass fibre panel.
  • any irregular surface on to which a bonded mineral fibre batt is to be secured is normally given a smoothing coat of plaster so as to provide a flat surface against which the batt can be secured firmly. This is wasteful of materials and time.
  • the invention provides a solution to this problem because the batt can now be secured firmly to the irregular surface since the soft outer portion will absorb the irregularities of up to, for instance 15mm, without causing the irregularities to be manifested in the first surface.
  • the batt has a density of 20 to 150, often 50 to 80 or 100, kg/m 3 and a thickness of 20 to 150mm, often 30 to 90mm.
  • It may have a dual density structure, with the outer portion being in the lower density layer for isntance as described in WO88/00265 or a triple layer, for instance as described in WO00/7360 .
  • the batt may have conventional structure and appearance except for the softened rear outer portion, which is typically 10 to 50mm, often 20 to 40mm, deep.
  • the softening can be increased by cutting (for instance to the desired depth of the softened portion) a check or other pattern into the outer portion prior to the mechanical compression.
  • the invention can also be applied to products where the softened portion itself has a relatively high binder content and/or a high fibre density.
  • the softened portion itself has a relatively high binder content and/or a high fibre density.
  • it can have a binder content of above 1%, typically 2 to 6%, for instance 3 to 4 or 5%. It can have a density of above 100kg/m 3 , often at least 160kg/m 3 , up to 180 or even 250kg/m 3 .
  • the mineral fibre network which extends inwardly from the second face has an inner portion and an outer portion wherein the second major face of the batt is provided by the outer face of the outer portion and wherein the outer portion has a depth of at least 5mm and is softer than the inner portion and merges with the inner portion through a transition portion of at least 5mm over which the stiffness increases gradually.
  • the outer portion has a depth of at least 5mm and is softer than the inner portion and merges with the inner portion through a transition portion of at least 5mm over which the stiffness increases gradually.
  • Stiffness for the purposes of this invention can be considered to be modulus of elasticity (EN826), wherein an increasing numerical value for the modulus of elasticity indicates increasing stiffness.
  • the stiffness of the outer portion is less than 90% of what the stiffness would have been if the network had not been fractured and most preferably it is less than 80% or even less than 70% of the stiffness of what the stiffness would have been if the network had not been fractured. It is usually at least 20%, and generally at least 40%, of what the stiffness would have been if the network had not been fractured.
  • the low stiffness, outer, portion generally has a depth of at least 10mm and often at least 10%, and preferably at least 20% or even 30% of the total thickness of the batt.
  • the outer portion can constitute as much as, for instance, 70% or even 80% of the thickness of the batt.

Abstract

A cured mineral fibre batt is provided with a less stiff surface portion by fracturing the bonded mineral fibre network in that portion, for instance by mechanical depthwise compression of the batt after curing the binder.

Description

  • This invention relates to a use of a batt as insulation according to claim 1.
  • A conventional mineral fibre batt comprises a bonded mineral fibre network bonded by a cured bonding agent.
  • Batts having different stiffness at different levels through the thickness of the batt can be made by laminating, with intermeshing at the lamination face, preformed cured batts having different stiffness. Usually it is better to make the batt by curing a mineral fibre web containing uncured bonding agent and which has variable fibre density through the depth or variable binder concentration through the depth.
  • The web may be made by, for instance, centrifugal fiberisation of a mineral melt of glass, rock, stone or slag, for instance using one or more cascade spinners or one or more spinning cups.
  • The production of a cured batt having varying binder concentration through the depth may be achieved as described in EP-A-374112 . The production of a batt by curing a web having higher fibre density in one layer than the rest may be achieved by conventional dual density processes. In these the mineral fibres and bonding agent are collected as a web, the upper layer of the web is separated and consolidated and rejoined on to the remainder of the web, and the web is then subjected to curing.
  • In practice it is always necessary to have some binder throughout the batt in order that it retains coherence during handling and use. When using the conventional bonding agents for mineral fibre batts, the batt is made notably stiff even when the amount of bonding agent is as low as is reasonably satisfactory to achieve minimum coherence of the batt.
  • For many purposes this stiffness is highly desirable. However there are some instances when the stiffness created by low binder amounts is undesirable and there are other cases where it would be desirable to provide a surface layer of lower stiffness in a product which has high binder amounts and/or high density and so is, overall, very stiff.
  • A process is described in US-A-4,415,51.7 of slitting the surface of a batt and compressing the batt while binder in the batt is partially cured, so as to prevent spring back problems.
  • A mineral fibre batt disclosed herein has first and second major surfaces and comprises a bonded mineral fibre network which is bonded by a cured bonding agent and which has an inner portion and an outer portion wherein the second surface of the batt is provided by the outer surface of the outer portion, and wherein the outer portion has a depth of at least 5mm and has reduced stiffness due to post-cure compression of the bonded network in the outer portion.
  • Often the inner portion adjacent the outer portion has the same fibre content type (e.g., average dimensions and chemical type) and distribution, and the same bonding agent and amount, as the outer portion, in which event it is meaningful simply to compare the stiffness of the outer portion with the stiffness of the adjacent inner portion. Sometimes however the adjacent inner portion exhibits also some additional difference, e.g., in fibre content or binder.
  • The invention is a use of a batt as insulation according to claim 1.
  • The bonding agent is usually a conventional bonding agent for mineral fibre batts, for instance a phenolic or other curable thermosetting resin. As a result of applying compression from the second face after curing the bonding agent, a product is formed in which the outer portion is less stiff than the inner portion. This presumably is due to fracturing of the bonded network in the outer portion as a result of the compression after curing the bonding agent.
  • The height compression is applied predominantly from the second face by passing the bonded and cured batt through a nip between a surface which supports the first face and compression means for temporarily compressing the batt at the second face. This will result in fracturing the bonded network in the bonded outer portion of the second face, leaving the bonded network closer to the first layer substantially unchanged.
  • The preferred compression means comprise at least one compression-applying roller having a diameter less than the total thickness of the batt and which defines a nip which has a depth of 20 to 90% of the thickness of the batt after curing (giving 10 to 80% temporary height compression). Usually the nip has a depth of at least 30 or 40% of the thickness of the batt and generally not more than 70 or 80% of the height of the batt. For instance it may have a depth of around 55% of the height of the batt, thus giving 45% temporary height compression.
  • The diameter of the or each compression applying roller must be relatively small in order to concentrate the compression forces in the desired region. The diameter is usually less than 75%, and often less than 50%, of the thickness of the batt. It is usually at least 30mm, and is usually below 75mm, often below 40 or 50mm.
  • The support surface is preferably substantially planar but it can be a surface with a large radius of curvature and which thus gives substantially the same support as a planar surface. For instance the support can be a planar plate or conveyor or drum of large diameter, e.g., at least 5 times the thickness of the batt.
  • Preferably the compression means comprise a plurality of parallel, compression applying, rollers each having a diameter less than the thickness of the batt (as explained above) and which define with the substantially planar support a nip which decreases in distance as the batt enters the nip, and the final, narrowest, nip preferably is within the range described above. Preferably the nip increases in distance as the batt leaves the nip. Preferably each roller, in plan view, overlaps each adjacent roller and preferably each defines a step of 3 to 15, often 5 to 10mm, up (or down) from the next.
  • When it is desired that the outer portion should be very soft, and thus have a low modulus of elasticity, the binder content is usually relatively low, for instance 0.2 to 1.5%, often around 0.3 to 1 or 1.2%. Also, the fibre density is usually relatively low, for instance 20 to 100kg/m3, often around 30 to 90kg/m3. In such products, it is usually then desired for the batt to have a first face of substantially higher density and/or substantially higher binder content, e.g., a density of 100 to 280kg/m3 and a binder content of 1.5 to 6%. Suitable products are described in WO 03/042468 (which was our application filed by us even date herewith reference PRL04394WO claiming priority from EPA 01309600.3 ).
  • Another instance when it is particularly desirable to utilise the invention is when a batt is to be fixed against a non-planar surface, for instance a surface having surface irregularities with a depth of at least 3mm, and often 5 or 10mm or even 15mm. For instance it is known to be desirable to fit mineral wool batts against brickwork or other stone walls and these often have an irregular surface. In GB-A-1,306,225 it is proposed that a soft glass fibre panel can be applied to such a surface but this tends to be unsatisfactory since irregularities in the surface are then manifested in the wall, to some extent, in the first surface of the glass fibre panel. In practice any irregular surface on to which a bonded mineral fibre batt is to be secured is normally given a smoothing coat of plaster so as to provide a flat surface against which the batt can be secured firmly. This is wasteful of materials and time.
  • The invention provides a solution to this problem because the batt can now be secured firmly to the irregular surface since the soft outer portion will absorb the irregularities of up to, for instance 15mm, without causing the irregularities to be manifested in the first surface. Typically the batt has a density of 20 to 150, often 50 to 80 or 100, kg/m3 and a thickness of 20 to 150mm, often 30 to 90mm.
  • It may have a dual density structure, with the outer portion being in the lower density layer for isntance as described in WO88/00265 or a triple layer, for instance as described in WO00/7360 .
  • In general, the batt may have conventional structure and appearance except for the softened rear outer portion, which is typically 10 to 50mm, often 20 to 40mm, deep.
  • The softening can be increased by cutting (for instance to the desired depth of the softened portion) a check or other pattern into the outer portion prior to the mechanical compression.
  • The invention can also be applied to products where the softened portion itself has a relatively high binder content and/or a high fibre density. For instance it can have a binder content of above 1%, typically 2 to 6%, for instance 3 to 4 or 5%. It can have a density of above 100kg/m3, often at least 160kg/m3, up to 180 or even 250kg/m3.
  • Broadly it is often preferred that the mineral fibre network which extends inwardly from the second face (and which may be all the second layer and part of the intermediate layer if present or just all or part of the second layer) has an inner portion and an outer portion wherein the second major face of the batt is provided by the outer face of the outer portion and wherein the outer portion has a depth of at least 5mm and is softer than the inner portion and merges with the inner portion through a transition portion of at least 5mm over which the stiffness increases gradually. Thus there is a softer or less stiff outer portion which merges gradually with a stiffer inner portion.
  • Stiffness for the purposes of this invention, can be considered to be modulus of elasticity (EN826), wherein an increasing numerical value for the modulus of elasticity indicates increasing stiffness. Preferably the stiffness of the outer portion is less than 90% of what the stiffness would have been if the network had not been fractured and most preferably it is less than 80% or even less than 70% of the stiffness of what the stiffness would have been if the network had not been fractured. It is usually at least 20%, and generally at least 40%, of what the stiffness would have been if the network had not been fractured.
  • The low stiffness, outer, portion generally has a depth of at least 10mm and often at least 10%, and preferably at least 20% or even 30% of the total thickness of the batt. The outer portion can constitute as much as, for instance, 70% or even 80% of the thickness of the batt.

Claims (3)

  1. Use of a batt as insulation fitted against an irregular surface wherein the batt is a mineral fibre batt which has first and second major surfaces and which comprises a bonded mineral fibre network which is bonded by a cured bonding agent and which has an inner portion and an outer portion wherein the second surface of the batt is provided by the outer surface of the outer portion and wherein the outer portion has a depth of at least 5mm and has reduced stiffness due to post-cure compression of the bonded network in the outer portion and wherein the second face is compressed against the irregular surface and the soft outer portion absorbs the irregularities without causing the irregularities to be manifested in the first surface.
  2. A use according to claim 1, in which the reduced stiffness in the outer portion is due to fracturing of the bonded network in the outer portion.
  3. A use according to claim 1 or claim 2, wherein the batt comprises a first layer bonded by a bonding agent and which extends inwardly from the first surface and one or more intermeshed layers each comprising a bonded mineral network bonded by a bonding agent and wherein the first face of the batt is the outer surface of an outer layer which has higher density than the other layers.
EP02787646.5A 2001-11-14 2002-11-12 Mineral fibre batts Expired - Lifetime EP1448828B2 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP02787646.5A EP1448828B2 (en) 2001-11-14 2002-11-12 Mineral fibre batts
DE60222691.0T DE60222691T3 (en) 2001-11-14 2002-11-12 MINERAL FIBER FLEECE

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
EP01309601 2001-11-14
EP01309601 2001-11-14
PCT/EP2002/012615 WO2003042445A1 (en) 2001-11-14 2002-11-12 Mineral fibre batts
EP02787646.5A EP1448828B2 (en) 2001-11-14 2002-11-12 Mineral fibre batts

Publications (3)

Publication Number Publication Date
EP1448828A1 EP1448828A1 (en) 2004-08-25
EP1448828B1 EP1448828B1 (en) 2007-09-26
EP1448828B2 true EP1448828B2 (en) 2020-04-08

Family

ID=8182458

Family Applications (1)

Application Number Title Priority Date Filing Date
EP02787646.5A Expired - Lifetime EP1448828B2 (en) 2001-11-14 2002-11-12 Mineral fibre batts

Country Status (6)

Country Link
EP (1) EP1448828B2 (en)
AT (1) ATE374271T1 (en)
DE (1) DE60222691T3 (en)
DK (1) DK1448828T4 (en)
ES (1) ES2292833T5 (en)
WO (1) WO2003042445A1 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1645698A1 (en) 2004-10-05 2006-04-12 Rockwool International A/S A roof structure
EP1826335A1 (en) 2006-02-28 2007-08-29 Rockwool International A/S Insulated façade system

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3203622A1 (en) † 1981-09-17 1983-04-07 Deutsche Rockwool Mineralwoll-GmbH, 4390 Gladbeck Method and apparatus for manufacturing a sound- and/or heat-insulating mineral fibre slab or web
WO1988000265A1 (en) † 1986-06-30 1988-01-14 Rockwool International A/S Method for continuous production of mineral wool slabs
WO1993004092A1 (en) † 1991-08-12 1993-03-04 The Procter & Gamble Company Absorbent foam materials for aqueous body fluids and absorbent articles containing such materials
WO1994019555A1 (en) † 1993-02-17 1994-09-01 Rockwool International A/S Insulating batt
WO2002096756A1 (en) † 2001-05-26 2002-12-05 Deutsche Rockwool Mineralwoll Gmbh & Co. Ohg Method for producing a packaging and/or transport unit for plate-shaped insulating material consisting of mineral fibres, packaging and/or transport unit, and insulating plates

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4415517A (en) * 1981-07-31 1983-11-15 Manville Service Corporation Method and apparatus for shaping fiber mats
EA000397B1 (en) * 1996-03-25 1999-06-24 Роквул Интернэшнл А/С Process and apparatus for the production of a mineral fibreboard
GB2317403B (en) * 1996-09-20 2001-01-24 Rockwool Int A process for the preparation of a layered insulating board,and a layered insulating board
DE19831752A1 (en) * 1998-07-15 2000-02-03 Rockwool Mineralwolle Process for the production of pipe insulation elements and pipe insulation element
PL204045B1 (en) * 1999-05-27 2009-12-31 Rockwool Int Mineral fibre insulating board comprising a rigid surface layer, a process for the preparation thereof and a use of the insulating product for roofing and facade covering

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3203622A1 (en) † 1981-09-17 1983-04-07 Deutsche Rockwool Mineralwoll-GmbH, 4390 Gladbeck Method and apparatus for manufacturing a sound- and/or heat-insulating mineral fibre slab or web
WO1988000265A1 (en) † 1986-06-30 1988-01-14 Rockwool International A/S Method for continuous production of mineral wool slabs
WO1993004092A1 (en) † 1991-08-12 1993-03-04 The Procter & Gamble Company Absorbent foam materials for aqueous body fluids and absorbent articles containing such materials
WO1994019555A1 (en) † 1993-02-17 1994-09-01 Rockwool International A/S Insulating batt
WO2002096756A1 (en) † 2001-05-26 2002-12-05 Deutsche Rockwool Mineralwoll Gmbh & Co. Ohg Method for producing a packaging and/or transport unit for plate-shaped insulating material consisting of mineral fibres, packaging and/or transport unit, and insulating plates

Also Published As

Publication number Publication date
EP1448828A1 (en) 2004-08-25
ES2292833T3 (en) 2008-03-16
DE60222691T2 (en) 2008-06-19
DE60222691D1 (en) 2007-11-08
DE60222691T3 (en) 2020-10-01
WO2003042445A1 (en) 2003-05-22
EP1448828B1 (en) 2007-09-26
DK1448828T3 (en) 2008-02-04
DK1448828T4 (en) 2020-07-06
ATE374271T1 (en) 2007-10-15
ES2292833T5 (en) 2020-11-23

Similar Documents

Publication Publication Date Title
KR101609567B1 (en) Non-woven material and method of making such material
KR101676351B1 (en) Non-woven material and method of making such material
EP2347059B1 (en) Facade insulation system
EP1743076B1 (en) Acoustic elements and their production
CZ282594B6 (en) Process for producing insulating boards
JP2002508715A (en) How to press sandwich panels
EP1448828B2 (en) Mineral fibre batts
EP1219755B1 (en) Insulating board for façades and process for producing the same
US20030211262A1 (en) Duct board having two facings
US5041178A (en) Method of manufacturing a fibrous board
US10351463B2 (en) Fibrous product and method and apparatus for making the product
EA036877B1 (en) Improved building wall or roof system comprising fibrous insulation
WO1990012934A1 (en) Ceiling panel and method of manufacture
EP1709132B2 (en) Process for manufacturing panels of mineral wool
JP5290275B2 (en) Facade heat insulation board for heat insulation of exterior facade of building, composite heat insulation system including the facade heat insulation board, and method for manufacturing facade heat insulation board
EP1444408B2 (en) Layered mineral fibre element and its method of manufacture
CN109982836B (en) Method for producing a laminated composite material
JP3003520B2 (en) Method of manufacturing rock wool products
CN112236309A (en) Panel with stone facing
JPS584605B2 (en) Manufacturing method of fiber reinforced cement board
JPH03221435A (en) Manufacture of inorganic fibrous molded member
WO2005105406A1 (en) Process for manufacturing insulating panels with polimeric foam and mineral wool
JPS58224741A (en) Inorganic fiber board
JPH11198110A (en) Fiber board and manufacture thereof

Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

17P Request for examination filed

Effective date: 20040422

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): AT BE BG CH CY CZ DE DK EE ES FI FR GB GR IE IT LI LU MC NL PT SE SK TR

AX Request for extension of the european patent

Extension state: AL LT LV MK RO SI

GRAC Information related to communication of intention to grant a patent modified

Free format text: ORIGINAL CODE: EPIDOSCIGR1

GRAP Despatch of communication of intention to grant a patent

Free format text: ORIGINAL CODE: EPIDOSNIGR1

GRAS Grant fee paid

Free format text: ORIGINAL CODE: EPIDOSNIGR3

GRAA (expected) grant

Free format text: ORIGINAL CODE: 0009210

AK Designated contracting states

Kind code of ref document: B1

Designated state(s): AT BE BG CH CY CZ DE DK EE ES FI FR GB GR IE IT LI LU MC NL PT SE SK TR

REG Reference to a national code

Ref country code: GB

Ref legal event code: FG4D

REG Reference to a national code

Ref country code: CH

Ref legal event code: EP

REF Corresponds to:

Ref document number: 60222691

Country of ref document: DE

Date of ref document: 20071108

Kind code of ref document: P

REG Reference to a national code

Ref country code: IE

Ref legal event code: FG4D

REG Reference to a national code

Ref country code: SE

Ref legal event code: TRGR

REG Reference to a national code

Ref country code: GR

Ref legal event code: EP

Ref document number: 20070403517

Country of ref document: GR

REG Reference to a national code

Ref country code: DK

Ref legal event code: T3

ET Fr: translation filed
REG Reference to a national code

Ref country code: ES

Ref legal event code: FG2A

Ref document number: 2292833

Country of ref document: ES

Kind code of ref document: T3

REG Reference to a national code

Ref country code: CH

Ref legal event code: PL

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: LI

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20070926

Ref country code: CH

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20070926

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: SK

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20070926

Ref country code: PT

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20080226

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: MC

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20071130

PLBI Opposition filed

Free format text: ORIGINAL CODE: 0009260

PLAX Notice of opposition and request to file observation + time limit sent

Free format text: ORIGINAL CODE: EPIDOSNOBS2

26 Opposition filed

Opponent name: SAINT-GOBAIN ISOVER

Effective date: 20080626

NLR1 Nl: opposition has been filed with the epo

Opponent name: SAINT-GOBAIN ISOVER

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: IE

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20071112

PLAF Information modified related to communication of a notice of opposition and request to file observations + time limit

Free format text: ORIGINAL CODE: EPIDOSCOBS2

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: EE

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20070926

PLBB Reply of patent proprietor to notice(s) of opposition received

Free format text: ORIGINAL CODE: EPIDOSNOBS3

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: CY

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20070926

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: BG

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20071226

Ref country code: LU

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20071112

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: TR

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20070926

APBM Appeal reference recorded

Free format text: ORIGINAL CODE: EPIDOSNREFNO

APBP Date of receipt of notice of appeal recorded

Free format text: ORIGINAL CODE: EPIDOSNNOA2O

APAH Appeal reference modified

Free format text: ORIGINAL CODE: EPIDOSCREFNO

APBM Appeal reference recorded

Free format text: ORIGINAL CODE: EPIDOSNREFNO

APBP Date of receipt of notice of appeal recorded

Free format text: ORIGINAL CODE: EPIDOSNNOA2O

APBQ Date of receipt of statement of grounds of appeal recorded

Free format text: ORIGINAL CODE: EPIDOSNNOA3O

APBQ Date of receipt of statement of grounds of appeal recorded

Free format text: ORIGINAL CODE: EPIDOSNNOA3O

REG Reference to a national code

Ref country code: DE

Ref legal event code: R082

Ref document number: 60222691

Country of ref document: DE

Representative=s name: MEISSNER, BOLTE & PARTNER GBR, DE

Ref country code: DE

Ref legal event code: R082

Ref document number: 60222691

Country of ref document: DE

Representative=s name: MEISSNER BOLTE PATENTANWAELTE RECHTSANWAELTE P, DE

REG Reference to a national code

Ref country code: DE

Ref legal event code: R082

Ref document number: 60222691

Country of ref document: DE

Representative=s name: MEISSNER, BOLTE & PARTNER GBR, DE

REG Reference to a national code

Ref country code: FR

Ref legal event code: PLFP

Year of fee payment: 14

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: GR

Payment date: 20151029

Year of fee payment: 14

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: AT

Payment date: 20151027

Year of fee payment: 14

Ref country code: CZ

Payment date: 20151104

Year of fee payment: 14

PLAB Opposition data, opponent's data or that of the opponent's representative modified

Free format text: ORIGINAL CODE: 0009299OPPO

REG Reference to a national code

Ref country code: FR

Ref legal event code: PLFP

Year of fee payment: 15

R26 Opposition filed (corrected)

Opponent name: SAINT-GOBAIN ISOVER

Effective date: 20080626

APBU Appeal procedure closed

Free format text: ORIGINAL CODE: EPIDOSNNOA9O

PLAY Examination report in opposition despatched + time limit

Free format text: ORIGINAL CODE: EPIDOSNORE2

REG Reference to a national code

Ref country code: AT

Ref legal event code: MM01

Ref document number: 374271

Country of ref document: AT

Kind code of ref document: T

Effective date: 20161112

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: CZ

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20161112

Ref country code: GR

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20170612

PLBC Reply to examination report in opposition received

Free format text: ORIGINAL CODE: EPIDOSNORE3

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: AT

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20161112

REG Reference to a national code

Ref country code: FR

Ref legal event code: PLFP

Year of fee payment: 16

PLAY Examination report in opposition despatched + time limit

Free format text: ORIGINAL CODE: EPIDOSNORE2

PLAT Information related to reply to examination report in opposition deleted

Free format text: ORIGINAL CODE: EPIDOSDORE3

PLBC Reply to examination report in opposition received

Free format text: ORIGINAL CODE: EPIDOSNORE3

PLBC Reply to examination report in opposition received

Free format text: ORIGINAL CODE: EPIDOSNORE3

PUAH Patent maintained in amended form

Free format text: ORIGINAL CODE: 0009272

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: PATENT MAINTAINED AS AMENDED

27A Patent maintained in amended form

Effective date: 20200408

AK Designated contracting states

Kind code of ref document: B2

Designated state(s): AT BE BG CH CY CZ DE DK EE ES FI FR GB GR IE IT LI LU MC NL PT SE SK TR

REG Reference to a national code

Ref country code: DE

Ref legal event code: R102

Ref document number: 60222691

Country of ref document: DE

REG Reference to a national code

Ref country code: SE

Ref legal event code: RPEO

REG Reference to a national code

Ref country code: DK

Ref legal event code: T4

Effective date: 20200702

REG Reference to a national code

Ref country code: NL

Ref legal event code: FP

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: GR

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20200709

REG Reference to a national code

Ref country code: ES

Ref legal event code: DC2A

Ref document number: 2292833

Country of ref document: ES

Kind code of ref document: T5

Effective date: 20201123

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: NL

Payment date: 20211126

Year of fee payment: 20

Ref country code: GB

Payment date: 20211129

Year of fee payment: 20

Ref country code: FI

Payment date: 20211126

Year of fee payment: 20

Ref country code: ES

Payment date: 20211201

Year of fee payment: 20

Ref country code: DK

Payment date: 20211129

Year of fee payment: 20

Ref country code: FR

Payment date: 20211124

Year of fee payment: 20

Ref country code: SE

Payment date: 20211127

Year of fee payment: 20

Ref country code: DE

Payment date: 20211126

Year of fee payment: 20

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: IT

Payment date: 20211122

Year of fee payment: 20

Ref country code: BE

Payment date: 20211129

Year of fee payment: 20

REG Reference to a national code

Ref country code: DE

Ref legal event code: R071

Ref document number: 60222691

Country of ref document: DE

REG Reference to a national code

Ref country code: DK

Ref legal event code: EUP

Expiry date: 20221112

REG Reference to a national code

Ref country code: NL

Ref legal event code: MK

Effective date: 20221111

REG Reference to a national code

Ref country code: ES

Ref legal event code: FD2A

Effective date: 20221125

REG Reference to a national code

Ref country code: BE

Ref legal event code: MK

Effective date: 20221112

Ref country code: GB

Ref legal event code: PE20

Expiry date: 20221111

REG Reference to a national code

Ref country code: SE

Ref legal event code: EUG

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: GB

Free format text: LAPSE BECAUSE OF EXPIRATION OF PROTECTION

Effective date: 20221111

Ref country code: ES

Free format text: LAPSE BECAUSE OF EXPIRATION OF PROTECTION

Effective date: 20221113