EP1456444B2 - Glasfasermatten und ihre herstellung - Google Patents

Glasfasermatten und ihre herstellung Download PDF

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Publication number
EP1456444B2
EP1456444B2 EP02805344.5A EP02805344A EP1456444B2 EP 1456444 B2 EP1456444 B2 EP 1456444B2 EP 02805344 A EP02805344 A EP 02805344A EP 1456444 B2 EP1456444 B2 EP 1456444B2
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EP
European Patent Office
Prior art keywords
web
sub
compression
thickness
webs
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Expired - Lifetime
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EP02805344.5A
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English (en)
French (fr)
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EP1456444B1 (de
EP1456444A1 (de
Inventor
Fredy Zimmermann
Hans-Peter Ackermann
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Rockwool AS
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Rockwool International AS
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Application filed by Rockwool International AS filed Critical Rockwool International AS
Priority to SI200230881T priority Critical patent/SI1456444T2/sl
Priority to EP02805344.5A priority patent/EP1456444B2/de
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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
    • D04H1/70—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
    • D04H1/72—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 randomly arranged
    • D04H1/736—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 randomly arranged characterised by the apparatus for arranging 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
    • D04H1/44—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
    • D04H1/70—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
    • D04H1/72—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 randomly arranged
    • D04H1/732—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 randomly arranged by fluid current, e.g. air-lay
    • 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)

Definitions

  • This invention relates to mineral fibre batts of the type which are conventionally known as "dual density" batts. These are bonded mineral fibre products comprising an upper layer intermeshed with a lower layer having a lower density than the upper layer, each layer being a bonded non-woven mineral fibre network.
  • the usual way of making dual density products is by providing a continuous mineral fibre web which contains binder, separating this web depthwise into upper and lower sub-webs, subjecting the upper sub-web to thickness compression so as to increase density, rejoining the sub-webs to form an uncured batt and then curing the binder to form the cured batt.
  • the upper sub-web thus provides the higher density upper layer intermeshed with the lower density lower layer.
  • Typical disclosures of conventional dual density processes are given in, for instance, WO88/00265 and US-A-4,917,750 .
  • the web which is separated into sub-webs is a web as formed initially on a conveyor.
  • the web may be formed by cross lapping.
  • the web is passed under some rollers as it approaches a device for separating the web into upper and lower sub-webs.
  • the fibres in the web will be substantially oriented parallel to the conveyor, because this is the predominant orientation during normal fibre lay-down processes.
  • the web is subjected to longitudinal compression before it is separated with the result that the fibres no longer have an orientation substantially parallel to the conveyor but instead have an orientation which has either a macro vertical component (so as to give significant visible pleats as shown in Figure 2 of EP-A-1,111,113 ) or a micro configuration (in which the vertical reconfiguration of the fibres has occurred but is not so visible to the naked eye, for instance as described in Figure 12 of EP-A-0,889,981 ).
  • the thickness compression results in some length extension of the upper web.
  • EP-A-1,111,113 it is also possible to subject the upper web to longitudinal compression to compensate for the elongation of the upper web.
  • the invention broadly provides a continuous method of forming a bonded mineral fibre batt comprising an upper layer intermeshed with a lower layer having a lower density than the upper layer in which each layer is a bonded non-woven fibre network, wherein the method comprises providing a continuous mineral fibre web which contains binder, separating the web depthwise into upper and lower sub-webs, subjecting the sub-webs separately to lengthwise compression, and subjecting the upper sub-web to thickness compression before, during or after longitudinal' compression and optionally subjecting the lower sub-web to thickness compression generally before the lengthwise compression, whereby the upper layer of the batt has higher density than the lower layer, and then rejoining the sub-webs to form an uncured batt wherein the upper sub-web provides the upper layer of the batt, and curing the binder.
  • either or both sub-webs may also be subjected to lengthwise stretching.
  • the upper sub-web is subjected to a very much greater thickness compression than the lower sub-web to give the required higher density (and indeed it is not absolutely essential for the lower layer to be subjected to any thickness compression), and some or all of the thickness compression on the upper sub-web is usually after longitudinal compression.
  • the effect of the lengthwise compression on the two layers leads to very different fibre orientations in the two sub-layers even though the lengthwise compressions nominally may be substantially the same.
  • the two sub-webs are subjected to the same lengthwise compression, and they have substantially the same speed of travel when they are separated and when they rejoin. Minor differences in speed just before they rejoin can be tolerated provided that any resultant tension in other or both sub-webs when they are rejoined is so low that there is no distortion or delamination of the batt. Either or both may be subjected to lengthwise stretching.
  • the path lengths of the two sub-webs are not significantly different.
  • the path length of the longer (usually the upper) sub-web is usually not more than 50%, preferably not more than 30% and most preferably not more than 15% longer than the path length of the lower sub-web, between the separating and rejoining points.
  • the web at this stage may be a web formed by direct collection of mineral fibres by air-laying to the desired thickness or it may be a web formed by laying several such primary webs on one another or, more usually, by cross lapping a primary web to form a web of the desired thickness, optionally followed by mild thickness compression.
  • the web is then separated depthwise into upper and lower sub-webs in conventional manner by a knife or other splitting device which is usually arranged substantially horizontally at a desired spacing above a conveyor on which the web is carried continuously.
  • the positioning of the separating device is chosen to provide the appropriate relative thicknesses of the upper and lower webs.
  • the thickness of the upper sub-web, at the time of separation is usually from 10 to 90% of the thickness of the total web. Usually it is at least 20% and often at least 30% of the total thickness, because the upper web is usually subjected to very high thickness compression and requires adequate thickness after this.
  • the upper sub-web is not more than about 70% or, at the most, about 80% of the total web thickness because usually it is required that the lower layer has sufficient thickness and structural content to impart significant properties to the final product.
  • the apparatus required for carrying out the process does not have to include preliminary lengthwise compression apparatus, for instance as described in EP-A-1,111,113 . Instead, the entire apparatus can be confined within approximately the space occupied solely by the thickness compression stages for the upper sub-web shown in that specification or, for instance, in US 4,917,750 or. WO88/00265 .
  • the upper sub-web, and optionally also the lower sub-web, is subjected to thickness compression between the separating and rejoining stages.
  • the extent of thickness compression can be indicated by the percentage reduction in thickness. It is possible to perform the process without any thickness compression of the lower sub-web but generally it is subjected to a thickness compression of at least 5% (i.e., so that its thickness after the thickness compression is not more than 95% of its thickness when initially separated from the upper sub-web) and is usually at least 10%.
  • the thickness compression of the lower layer is not more than 60%, and preferably not more than 50%.
  • the actual thickness compression of the lower sub-web is equivalent to about 0.5 to 2 times, most preferably about 0.7 to 1.5 times the thickness of the upper sub-web at the time when it rejoins the lower sub-web.
  • the extent to which the lower sub-web is subjected to thickness compression is such that its thickness is reduced by the thickness of the upper sub-web at the time of rejoining, so that the uncured batt formed by rejoining the sub-webs has the same, or substantially the same, thickness as the thickness of the lower sub-web when it was initially separated from the upper sub-web.
  • the thickness compression of the upper sub-web is always large, in order that this sub-web provides the required high density upper layer.
  • the overall thickness compression of the upper sub-web when it rejoins the lower sub-web is above 50%, preferably above 70% and most preferably above 85% (so that the final thickness of the upper sub-web is less than 15% of its thickness when initially separated from the lower sub-web.
  • the overall thickness compression is less than 97%, and most preferably less than 95% of the initial thickness.
  • the thickness compression of the lower sub-web (when this is applied) is preferably conducted, and usually completed, before the longitudinal compression of the lower sub-web.
  • significant thickness compression is applied to the upper sub-web after it is subjected to some or all of the longitudinal compression to which it is to be subjected.
  • the upper sub-web is subjected to at least half, usually at least three quarters and preferably substantially all of its longitudinal compression and is then subjected to significant thickness compression.
  • the thickness compression which is applied.after the longitudinal compression may be the only thickness compression which is applied to the upper sub-web but usually the upper sub-web is also subjected to thickness compression before the longitudinal compression.
  • the upper sub-web is subjected to moderate thickness compression between separation and the longitudinal compression, for instance being reduced in thickness to from 90% to 30% of its original thickness, is then subjected to most or all of its longitudinal compression, and is then subjected to subsequent thickness compression which reduces the thickness of the sub-web to less than 50%, and usually less than 30%, of the thickness of the sub-web after the preceding thickness compression.
  • the process can usually be optimised by subjecting the upper layer to substantially all the longitudinal compression before subjecting it to the final half or three quarters, or more, of the total thickness compression.
  • the unusual stresses created on the upper sub-web by the preferred process of the invention are such that the thickness compression after the longitudinal compression is preferably achieved by passage of the upper sub-web between converging endless surfaces.
  • These may be converging conveyors, or a conveyor and a plate which converge.
  • the lengthwise compression in each of the upper and lower webs should be at least 1.2:1 and preferably at least 1.5:1 (i.e., the speed of the web leaving the lengthwise compression is not more than two thirds of the speed of the web entering the lengthwise compression stage). It is generally not more than 5:1 and often not more than 3:1.
  • Each longitudinal compression can be achieved in conventional manner by passing the relevant sub-web from one set of conveying surfaces (which may be belts or rollers) to a second set which are travelling slower.
  • the upper sub-web may be passed from a series of rollers or belts travelling at one speed to the converging passage between two conveyors which are travelling at a slower speed (so as to cause lengthwise compression followed by thickness compression).
  • the lengthwise compression of the lower sub-web can be achieved by passage from rollers or converging belts that provide thickness compression to a set of rollers or belts which are moving slower and which are parallel to one another so that they do not provide thickness compression.
  • uncured binder in the upper and lower sub-webs Although there is uncured binder in the upper and lower sub-webs, and this may be sufficient to achieve adequate integrity of the final batt, it is generally preferred to apply additional binder at the interface between the upper and lower sub-webs where they are rejoined, so as to promote the integrity of the final batt.
  • the uncured batt is formed by pressing the upper and lower webs together with sufficient pressure to achieve intermeshing and integrity but preferably insufficient to cause thickness compression, because additional thickness compression at this stage is unnecessary, and indeed is generally undesirable since it may impair the pronounced' vertical fibre orientation which is'preferably achieved in the lower layer.
  • the batt is then passed through a curing oven in order to cure the total binder in conventional manner.
  • the invention not only includes the process but also includes the novel apparatus comprising the means for separating the web into sub-webs, subjecting each sub-web independently to treatments selected from lengthwise compression and thickness compression and rejoining the sub-webs, and wherein preferably the apparatus' is supplied with web direct from a fibre lay-down process or direct from a cross-lapping process.
  • the invention also includes the mineral fibre batts made by the process and batts having the structural characteristics of these.
  • the preferred batts have an upper layer having a density of 100 to 300kg/m 3 , often around 120 to 250kg/m 3 . They have a lower layer which has a density which is usually not more than 80% but usually more than 30% of the density of the upper layer, often around 40 to 70% of the density of the upper layer. It is usually 50 to 150kg/m 2 .
  • the upper and lower layers in the final product have a thickness of 30 to 300mm.
  • the lower layer is usually 25 to 275mm thick and is usually at least 75mm thick. Generally it is at least 50%, and often 75 to 95%, of the combined thickness of the upper and lower layers.
  • the mineral fibres may be any suitable mineral fibres such as glass, rock, stone or slag.
  • the invention is of particular value when applied to mineral fibres obtained by centrifugal fiberisation, and in particular by fiberisation of a rock, stone or slag melt by a cascade centrifugal spinner.
  • a web 1 is supplied direct from a cross lapping system which, in turn, is supplied direct from the collector of a collecting chamber from a conventional cascade spinner for rock fibres. Accordingly the overall and predominant orientation of the fibres in the web 1 is substantially parallel to the upper and lower surfaces of the web.
  • the web 1 may have been vertically compressed and has a thickness TW and the rollers 2 and 3, and all the associated components with those, are set at a spacing corresponding to TW.
  • the web 1 enters the apparatus at speed VW.
  • a separating knife 4 separates the web depthwise into an upper web 5 having a thickness TU1 and a lower web 6 having a thickness TL1.
  • TU1 and TL1 are approximately the same, but they can be different.
  • Lower web 6 passes between converging belts 7 and 8 driven by roller train 9 in the direction of travel of the web, as a result of which the belts 7 and 8 cause thickness compression of the lower web 6.
  • TL2 thickness of TL1.
  • the web then passes through upper and lower roller trains 11 and then through upper and lower roller trains 12. Within each of the roller trains, all the rollers rotate at the same speed to carry the web forward. Longitudinal compression is achieved by roller train 12 rotating slower than the rollers 9 and thus the belts 7 and 8. If roller train 11 rotates at the same speed as roller train 12 then longitudinal compression will be applied at position 10. If roller train 11 rotates at the same speed as roller train 9 then longitudinal compression will be applied at position 13. Often roller train 12 rotates slower than roller train 11 which rotates slower than roller train 9, in which event longitudinal compression is applied both at positions 10 and 13. The objective is that the speed of travel as the lower web 6 passes through guide rolls 14 should be the speed VB of the final batt as it enters the curing oven 15, with the ratio VW:VB generally being at least 1.5:1.
  • the upper web 5 is carried between a conveyor belt 16 and its supporting rollers 17 and a converging belt 18 and guide rolls 19. As a result of this the thickness of the upper web 5 is reduced from TU1 to TU2.
  • TU2 may be, for instance, one third of TU1.
  • Conveyors 16 and 18 and rollers 19 all travel at the same speed and the upper web 5 travels from them to between converging belts 20 and 21 driven, respectively, by roller trains 22 and 23. Rollers trains 22 and 23 all rotate at the same speed, and at a-speed less than the roller trains 17 and 19.
  • longitudinal compression is applied at position 24.
  • the extent of this longitudinal compression is such that the speed of the upper web when it emerges from between the converging belts 20 and 21 is sufficiently close to VB that there will be no unacceptable distortions of the upper or lower layers when they are rejoined at 26 to form batt 29.
  • any stretching or compressing of either or both sub-webs, due to tension in either or both when they are rejoined, should be so low that there is no distortion or delamination of the batt 29.
  • the converging belts 20 and 21 apply substantial thickness compression to the upper web whereby the upper sub-web 5, when it emerges from between the converging belts, has an ultimate thickness (after any relaxation which occurs) of TU3, where TU3 is usually well below half of TU2 and typically below one fifth of TU1.
  • the upper sub-web may then slide over a supporting plate 25 as it travels down to the position 26 at which it rejoins the lower web. Binder is' sprayed between the webs as they are rejoined, from applicator 27.
  • the rollers 28 apply enough pressure to press the upper and lower webs together to form an intermeshed batt 29 but' insufficient pressure to cause any significant thickness compression of it.
  • the uncured batt 29 then passes into the curing oven 15 and is then cured and subjected to conventional post treatments, such as cutting into slabs of the desired size.
  • the rolls 19 are arranged as separate sets 19a and 19b each of which is covered by a band and is driven.
  • the roller train 17 has been divided into two sets, one set covered by conveyor 16a and the other set covered by conveyor 16b.
  • Bands 16, 18 and 19a operate together at the same speed, and bands 16b and 19b operate together at the same speed, which can be lower. Lengthwise compression therefore can occur at both 40 and 24.
  • the ratio of the speeds of the belts 7:rolls 11:rolls 12: rolls 14 and 28 is 3:3:0.9:1 giving length compression at 13 and stretching between 12 and 14.
  • the ratio is 3:2:0.9:1, giving length compression at 10 and 13 and stretching between 12 and 14. This results in the lower layer being more relaxed, with less risk of the product distorting out of a planar configuration. Accordingly it can be desirable to subject the lower web to a plurality of length compressions.
  • products A, B and C were made using apparatus described above wherein the operating conditions were as follows: Value Product A Product B Product C TW 110mm 380mm 360mm TL1 65mm 330mm 225mm TL2 60mm 185mm 185mm TU1 45mm 50mm 135mm TU2 6mm 6mm 10mm TU3 12mm 15mm 30mm TB 60mm 200mm . 215mm VW 32m/min 6.9m/min 6.3m/min VB 16m/min 2.3m/min 2.1m/min
  • novel fibre orientation obtainable by the methods of the invention is also obtainable by other methods, and thus is another aspect of the invention.
  • this product aspect of the invention we provide a dual density layer wherein the lower, lower density, layer is definable by its Kappa and Tau values in one or more cross sections, wherein these values are obtained by scanning examination of parts of each respective cross section through the thickness of the layer and Fast Fourier Transformation of the data.
  • this product aspect of the invention we provide a dual density layer wherein the lower, lower density, layer is definable by its Kappa and Tau values in one or more cross sections, wherein these values are obtained by measuring parts of each respective cross section through the thickness of the layer in a flatbed scanner like Hewlett Packard ScanJet 6100C.
  • the product to be examined is placed on the scanner so that it fits on top of the scanner with the shortest distance perpendicular to the scanning direction, see drawing.
  • the scanner-software Desk Scan II For the set-up of the scanner use was made of the scanner-software Desk Scan II with the following settings: Sharp B, and W. Photo, Resolution 120x120dpi, and automatic adjustment of brightness and contrast.
  • the scanned image (110mm x 270mm) was divided into a number of local windows in a pattern comprising 8 rows each with 33 windows of equal size (32x32pixels) in which the dominant fibre orientation was estimated using Fast Fourier Transformation.
  • a two-dimensional pattern for instance of parallel stripes
  • Fast Fourier Transformation as a small number of dots
  • a complex two-dimensional pattern such as a cross section of a mineral fibre network
  • Fast Fourier Transformation as a large number of dots.
  • These dots will be arranged in a pattern, which may be circular but more usually is elliptical.
  • the Tau value for the cross section is defined as the geometric mean of the ratio of the length of the ellipse to the width for each of the 33 local windows and thus a high value indicates a local well organised pattern (high consistency locally) and a lower value near 1 indicates that the pattern locally cannot be defined.
  • the Kappa value is an indication of the statistical distribution of the different angles at which the ellipse is arranged locally for different parts of the overall structure, which is being examined. A high Kappa value indicates a narrow statistical distribution of angles whilst a low Kappa value indicates a broad distribution.
  • novel mineral fibre batts of the invention there is an, upper layer having a density of 100 to 300kg/m 3 intermeshed with a lower layer having a lower density than the upper layer wherein each layer is formed of a bonded non-woven mineral fibre network the fibre orientation of which is definable by the Tau and Kappa values derived from Fourier Transformation of scanned images of thickness cross sections of the layers wherein T x and K x are the Tau and Kappa values determined on the thickness cross section of the layers in the lengthwise production direction X of the batt, and T y and K y are the Tau and Kappa values determined on the thickness cross section of the layers in direction Y which is perpendicular to the production direction X.
  • K x is always less than K y and that K x is below 2, for instance 0.7 to 1.4.
  • K x is greater than K y
  • K x :K y preferably being at least 1.3:1 and often at least 2:1, for instance up to 5:1.
  • K x is below about 1.5, but in the invention K x is preferably at least 2.5 and most preferably at least 3.
  • T x is always less than T y but in the invention T x is preferably above T y .
  • T x is at least 1.2:1 and usually at least 1.5:1 and is often as much as 3:1 or more.
  • T x of the lower layer in conventional products normally has a value of 2.6 or less but in the invention T x is preferably above 3, and most preferably above 3.5. For instance it may be up to 7 or more.
  • a product made by the method described above had K x 3.8, K y 1.2, T x 4.2 and T y 2.6.
  • the upper layer of the commercial product had Kappa and Tau values in each direction substantially the same as the Kappa and Tau values of the upper layer of the product made by the present process, but the point load resistance of the products made by the present process was very much greater than the point load resistance of the commercial product. Although there was some difference in density and surface weight per unit area, the difference in point load resistance could not be explained by this and so, instead, can be attributed almost entirely to the benefits of the novel fibre orientation in the lower layer.
  • the lengthwise production direction X can usually be determined by observing the pattern impressed on the upper and lower surfaces of the batt by the curing oven, when cured in conventional manner.
  • the invention may be utilised for production of roof boards, facade boards or similar boards produced from bonded mineral fibres when a certain point load resistance is required. They may be used generally for thermal insulation, fire proofing, fire protection, sound proofing, sound protection, and as horticultural growth medium.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Nonwoven Fabrics (AREA)
  • Glass Compositions (AREA)
  • Laminated Bodies (AREA)

Claims (11)

  1. Kontinuierliches Verfahren zur Herstellung eines gebundenen Mineralfaservlieses (29), umfassend eine obere Schicht, die mit einer unteren Schicht vermascht ist, welche eine geringere Dichte hat und in welchem jede Schicht ein gebundenes Mineralfaservlies-Netzwerk ist, wobei das Verfahren umfasst:
    Bereitstellen einer kontinuierlichen Mineralfaserbahn (1), welche Bindemittel enthält,
    Auftrennen der Bahn in der Tiefe in obere und untere Teilbahnen (5, 6),
    Unterwerfen jeder Teilbahn (5, 6) auf unabhängige Weise Behandlungen ausgewählt aus Längskompression, Längsdehnung und Dickenkompression,
    Wiederverbinden der Teilbahnen (5, 6), wodurch die obere Teilbahn die obere Schicht des Vlieses (29) bereitstellt, und Härten des Bindemittels,
    dadurch gekennzeichnet, dass beide Teilbahnen (5, 6) der gleichen Längskompression unterworfen werden und die obere Teilbahn vor, während oder nach der Längskompression der Dickenkompression unterworfen wird und wahlweise die untere Teilbahn (6) der Dickenkompression unterrworfen wird derart, dass die obere Schicht des Vlieses (29) eine höhere Dichte als die untere Schicht hat;
    und in welchem die Bahn (1) eine Bahn ist, hergestellt durch Sammeln von Fasern durch einen Luftlegevorgang, um eine Primärbahn zu erzeugen und dann entweder;
    (a) Übereinanderlegen mehrerer solcher Primärbahnen oder;
    (b) Zickzackstapeln der Primärbahn,
    ohne Längskompression vor dem Auftrennen der Bahn (1) in die oberen und unteren Teilbahnen (5, 6).
  2. Verfahren gemäß Anspruch 1, bei welchem nach der Längskompression der unteren Teilbahn (6), die untere Teilbahn (6) und das Vlies (29) zu einer Position transportiert werden, an welcher das Vlies ohne die untere Teilbahn gehärtet wird oder das Vlies der Dickenkompression unterworfen wird.
  3. Verfahren gemäß Anspruch 1 oder Anspruch 2, bei welchem die obere Teilbahn (5) mindestens der Hälfte ihrer gesamten Längskompression (24) unterworfen wird und dann einer nachfolgenden Dickenkompression (20, 21) unterworfen wird, welche ihre Dicke (TU3) auf weniger als die Hälfte der Dicke (TU2) unmittelbar vor der Längskompression verringert.
  4. Verfahren gemäß Anspruch 3, bei welchem die obere Teilbahn der Dickenkompression unterworfen wird, um ihre anfängliche Dicke (TU1) zu verringern, um eine Dicke (TU2) bereitzustellen, welche geringer als die Hälfte der anfänglichen Dicke (TU1) ist, und dann der Längskompression unterworfen wird und dann der Dickenkompression unterworfen wird, um eine Dicke (TU3) bereitzustellen, welche geringer als die Hälfte ihrer Dicke unmittelbar vor der Längskompression (TU2) ist.
  5. Verfahren nach Anspruch 3 oder Anspruch 4, bei welchem die Dickenkompression der oberen Bahn (5) nach der Längskompression durch Hindurchgehen zwischen konvergierenden ebenen Oberflächen (20, 21) durchgeführt wird.
  6. Verfahren gemäß irgendeinem der Ansprüche 1 bis 5, bei welchem die Längskompression von jeder der Teilbahnen (5, 6) zwischen 1,5:1 und 5:1 beträgt.
  7. Verfahren nach irgendeinem der Ansprüche 1 bis 6, bei welchem Bindemittel zwischen die oberen und unteren Teilbahnen (5, 6) aufgebracht (27) wird, wenn diese wieder verbunden (26) werden.
  8. Verfahren gemäß irgendeinem der Ansprüche 1 bis 7, bei welchem das Vlies (29) eine obere Schicht mit einer Dichte von 100 bis 300 kg/m3 aufweist, welche mit einer unteren Schicht vermascht ist, die eine Dichte von weniger als 80% der oberen Schicht aufweist.
  9. Verfahren gemäß irgendeinem der Ansprüche 1 bis 8, bei welchem die Teilbahnen die gleichen Weglängen oder Weglängen haben, die sich um nicht mehr als um ein Verhältnis von 1,5:1 unterscheiden.
  10. Verfahren nach irgendeinem der Ansprüche 1 bis 9, bei welchem das Produkt ein Produkt gemäß Anspruch 1 ist.
  11. Vorrichtung umfassend Mittel (2, 3) zum kontinuierlichen Zuführen einer Mineralfaserbahn (1) zu einer Trennvorrichtung (4), durch welche die Bahn (1) in der Tiefe zu oberen und unteren Teilbahnen (5, 6) aufgetrennt wird,
    Mittel zum Unterwerfen jeder Teilbahn (5, 6) auf unabhängige Weise Behandlungen ausgewählt aus Längskompression (16, 18, 19; 20, 21; 9; 11; 12) und Dickenkompression (16, 18; 20, 21; 7, 8),
    Mittel (28) zum Wiederverbinden der Teilbahnen (5, 6) und einen Härtungsofen (15) zum Härten des Bindemittels, dadurch gekennzeichnet, dass die Mittel (16, 18; 20, 21) zur Dickenkompression der oberen Teilbahn (5) und irgendwelche Mittel (7, 8) zur Dickenkompression der unteren Teilbahn (6) solche sind, dass die obere Teilbahn und die obere Schicht des Vlieses eine höhere Dichte haben als die untere Teilbahn und die untere Schicht, und
    Mittel (16, 18, 19; 20, 21) vorhanden sind zum Aufbringen von Längskompression auf die obere Teilbahn (5) und Mittel (9, 11, 12) zum Aufbringen von Längskompression auf die untere Teilbahn (6) vorhanden sind, und
    die Mittel zum Zuführen der Bahn (1) zu der Trennvorrichtung (4) Mittel zum Sammeln von Fasern durch einen Luftlegevorgang umfassen, um eine Primärbahn zu erzeugen, und zwar Mittel zum entweder
    (a) Übereinanderlegen mehrerer solcher Primärbahnen oder
    (b) Zickzackstapeln der Primärbahn,
    und zum Zuführen der geschichteten oder zickzack-gestapelten Bahn zu der Trennvorrichtung (4) ohne Längskompression der geschichteten oder zickzack-gestapelten Bahn, wobei die Mittel zum Aufbringen der Längskompression auf die obere und die untere Terilbahn jeweils die gleiche Längskompression bereitstellen.
EP02805344.5A 2001-12-21 2002-12-20 Glasfasermatten und ihre herstellung Expired - Lifetime EP1456444B2 (de)

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SI200230881T SI1456444T2 (sl) 2001-12-21 2002-12-20 Mineralne vlaknene koprene in njihova izdelava
EP02805344.5A EP1456444B2 (de) 2001-12-21 2002-12-20 Glasfasermatten und ihre herstellung

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EP01310777 2001-12-21
EP01310777 2001-12-21
PCT/EP2002/014640 WO2003054264A1 (en) 2001-12-21 2002-12-20 Mineral fibre batts and their production
EP02805344.5A EP1456444B2 (de) 2001-12-21 2002-12-20 Glasfasermatten und ihre herstellung

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DE102007018774A1 (de) † 2007-04-20 2008-10-23 Saint-Gobain Isover G+H Ag Fassadendämmplatte für die Dämmung von Außenfassaden von Gebäuden, Wärmedamm-Verbundsystem mit derartigen Fassadendämmplatten sowie Verfahren zur Herstellung einer Fassadendämmplatte
EP2596159A1 (de) 2010-07-23 2013-05-29 Rockwool International A/S Gebondetes mineralfaserprodukt mit hoher flamm- und selbsterwärmungsbeständigkeit
RU2591951C2 (ru) 2010-12-06 2016-07-20 Роквул Интернэшнл А/С Способ уменьшения выделения формальдегида из минерально-волокнистого изделия и минерально-волокнистое изделие с уменьшенным выделением формальдегида
EA027765B1 (ru) 2011-05-17 2017-08-31 Роквул Интернэшнл А/С Ростовые субстраты и их применение
FR3015472A1 (fr) 2013-12-23 2015-06-26 Rockwool Int Methode pour reduire les emissions de formaldehyde et de composes organiques volatils (cov) dans un produit a base de fibres minerales
US10214840B2 (en) 2014-11-24 2019-02-26 Rockwool International A/S Method of producing a sandwich panel core of mineral wool fibres
US10920348B2 (en) 2015-02-16 2021-02-16 Rockwool International A/S Method of compressing man-made vitreous fibre web
RU2652728C1 (ru) 2016-07-06 2018-04-28 Закрытое акционерное общество "Минеральная Вата" Способ теплоизоляции строительной поверхности и соответствующая ему теплоизоляционная плита
EP3564423B2 (de) * 2018-04-30 2023-07-12 Betek Boya ve Kimya Sanayi A.S. Verfahren zur herstellung von mineralwollepaneelen aus zwei oder mehr schichten mit unterschiedlicher dichte

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EP0600106A1 (de) † 1991-04-16 1994-06-08 The C.A. Lawton Company Verfahren und Gegenstand zur Herstellung von Matten
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PT1456444E (pt) 2010-01-15
DK1456444T3 (da) 2010-03-01
PL200843B1 (pl) 2009-02-27
ATE448345T1 (de) 2009-11-15
DK1456444T4 (en) 2014-03-03
PL370360A1 (en) 2005-05-16
SI1456444T1 (sl) 2010-03-31
SI1456444T2 (sl) 2014-04-30
WO2003054264A1 (en) 2003-07-03
ES2334776T5 (es) 2014-03-06
AU2002356778A1 (en) 2003-07-09
ES2334776T3 (es) 2010-03-16
EP1456444B1 (de) 2009-11-11
EP1456444A1 (de) 2004-09-15
DE60234383D1 (de) 2009-12-24

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