EP1559845B1 - Process for manufacturing an insulating mat of mineral fibres and insulating mat - Google Patents

Abstract

The thermal insulation panel (1), of mineral fibers (2) and a bonding agent and especially mineral and/or glass wool, has projecting ribs (10) on at least one main axis direction at the large surfaces (3,4), on the contact zones (5,6) between the insulation and the outer surfaces. The ribs are at equal intervals, with a semi-circular cross section. The core zone (9) is composed of compressed loops (11) of a primary nonwoven felt, with their deflections bonded together in at least one contact zone. The bonding agent is a mixture of phenol, formaldehyde and urea resins.

Description

The invention relates to a method for producing an insulating element made of binders bound mineral fibers, in particular rockwool and / or glass wool, wherein the mineral fibers are produced from a melt and deposited on a conveyor as a primary web, the primary web stabilized perpendicular to its longitudinal extent and as a secondary web with a core region having a course of mineral fibers substantially perpendicular or steep to the large surfaces, and at least one edge zone with a course of Mineralfasem substantially parallel to the large surfaces deposited on a second conveyor and fed to a curing oven for curing of the binder and subsequently dividing the secondary nonwoven by a separating cut parallel to the large surfaces of the secondary nonwoven into at least two insulating material webs and applying a carrier layer to at least one large surface becomes. The invention further relates to an insulation web made of mineral fibers bound with a binder, in particular of mineral wool and / or glass wool, prepared by the process consisting of a large surface having secondary nonwoven with a core region of a course of mineral fibers substantially at right angles or steeply to the large Having surfaces, with a large surface area and a resulting in dividing a secondary nonwoven web in two insulating material separating surface, wherein the Mineralfasem in the region of the separation surface perpendicular to the separation surface and in the region of the surface at an angle deviating from 90 ° to the large surface, in particular parallel to the large surface are arranged running, and with a lamination

Insulating materials made of vitreous solidified mineral fibers are classified according to the chemical composition commercially available in glass wool and rock wool insulation materials. Both varieties differ in the chemical composition of the mineral fibers. The glass wool fibers are made from silicate melts that contain high levels of alkalis and boron oxides that act as fluxes. These melts have a wide processing range can be and with the help of rotating bowls whose walls have holes, take off to relatively smooth and long Mineralfasem, which are usually at least partially bound with mixtures of thermosetting phenol-formaldehyde and urea resins. The proportion of these binders in the glass wool insulating materials is for example about 5 to about 10% by mass and is also limited by the fact that the character of a non-combustible insulating material is to be preserved. The bond can also be made with thermoplastic binders such as polyacrylates. The pulp is added to other substances such as oils in amounts below about 0.4% by mass for hydrophobing and dust binding. The impregnated with binders and other additives mineral fibers are collected as fiber web on a slow-speed conveyor. In most cases, the mineral fibers of several fiberizing devices are deposited one after the other on this conveyor. The mineral fibers are oriented largely directionless in one plane. But they store very flat on top of each other. By slight vertical pressure, the fiber web is compressed to the desired thickness and the conveying speed of the conveyor simultaneously to the required density and the binder cured in a curing oven by means of hot air, so that the structure of the fiber web is fixed.

In the production of rock wool insulation impregnated Mineralfasem are collected as thin as possible and lightweight mineral fiber fleece, a so-called primary fleece and carried away at high speed from the field of Zerfaserungsvorrichtung to keep required coolant low, which otherwise in the course of further manufacturing process with additional energy would be removed from the fiber web. From the primary nonwoven an endless fiber web is built, which has a uniform distribution of Mineralfasem.

The primary nonwoven consists of relatively coarse fiber flakes, in the core areas of which higher binder concentrations are present, while in the peripheral areas weaker or non-bonded mineral fibers predominate. The mineral fibers are aligned in the fiber flakes approximately in the transport direction. Stone wool insulation have contents of binders of about 2 to about 4.5% by mass. With this small amount of binders, only part of the mineral fibers are in contact with the binders. The binders used are predominantly mixtures of phenol, formaldehyde and urea resins. Some of the resins are already substituted by polysaccharides. Inorganic binders are used as for the glass wool insulating materials only for special applications of insulating materials, as they are much more brittle than the largely elastic to plastic plastic reacting organic binder, which meets the desired character of insulating materials from Mineralfasem as elastic-springy building materials. The additives used are mostly high-boiling mineral oils in proportions of 0.2% by mass, in exceptional cases also about 0.4% by mass.

Usually, the primary nonwovens are deposited by means of a pendulum-suspended conveyor transversely across another conveyor, which allows the production of an endless fibrous web consisting of a plurality of obliquely superimposed individual layers. By a horizontally directed in the conveying direction and a simultaneous vertical compression, the fiber web can be unfolded more or less intense. The axes of the main folds are aligned horizontally and thus run transversely to the conveying direction.

The forces acting on the fiber web cause binder-rich core zones are compacted and unfolded into narrow lamellae, resulting in main folds with folds in flanks. At the same time, the less bound or binder-free mineral fibers in the interstices of the folds and between the lamellae are slightly rolled and slightly compressed. The fine structure thus consists of relatively stiff slats, which have a certain flexibility due to their numerous folds, but are relatively stiff parallel to the folding axes and form spaces which are easily compressible. As a result of the build-ups and dislocations, the compressive strength and the transverse tensile strength of the fibrous web clearly increase in comparison with a normal, in particular extremely flat, arrangement of the mineral fibers. The flexural strength of the fibrous web or of the sections separated from it in the form of plates or Dämmfilzen is therefore significantly higher in the transverse direction than in the production direction. at Roof insulation panels with densities of about 130 to 150 kg / m ³ , the bending strength in the transverse direction on the order of three to four times as high as the bending strength in the production direction.

This dependence of the mechanical properties of the orientation of the mineral fibers in the insulating material is used for the production of lamellae for lamellar plates and commercially available lamellar sheets called products.

Lamellae are usually 50 mm to 200 mm wide and 10 mm to 140 mm thick insulating material elements that are cut off in the direction of production by an at least correspondingly thick fiber web. The mineral fibers in the fiber web or in the particularly solid lamellae are oriented at right angles to the cut surfaces, which are now the large surfaces of the lamellae. Slats with densities of more than about 75 kg / m ³ are therefore suitable as tensile and pressure resistant insulating layer on the outer walls of buildings and can be glued on the outer wall and then plastered with a reinforced plaster layer. Such insulation is referred to as a thermal insulation composite system. The pressure-resistant lamella is sufficiently flexible in the longitudinal direction so that it can also be glued onto curved components. At the same time, it is still so compressible at right angles to the side surfaces that deviations from the respective length and width (dimensional tolerances) between the individual lamellas can be compensated with a small contact pressure. This can be used to produce joint-tight insulation layers. Several lamellae who further assembled to slat plates or lamellae.

Slat plates in the bulk density range of about 30 to about 100 kg / m ³ , preferably <60 kg / m ³ are separated in the desired thickness in the production direction as lamellae of between about 75 to 250 mm thick fiber web lying flat transverse be glued to a closed carrier material. The individual slats are pressed together only under slight pressure and usually form no closed insulation layer. In order to have low combustible substance in the lamellar plate for reasons of fire safety, the specific amounts of, for example, dispersion adhesives are very low. process engineering Bonding foils, for example, can be even more easily connected to the surface of the lamellae by heating a foil layer, which in many cases is only about 0.03 to 0.06 mm thick.

In the same way, slat plates can also be made from glass wool fiber webs with mineral fibers extending at right angles to the large surfaces. The smooth Mineralfasem are directed in these lamellae pronounced parallel to each other and very easy to compress against lateral forces, especially since the bulk densities are generally lower than that of the lamella plates made of rock wool insulation materials.

Lamellae can also be used to produce lamellar webs having widths of, for example, 500 mm or 1000 mm, thicknesses of approximately 20 mm to approximately 100 mm and lengths of several meters. Due to the orientation of the Mineralfasem perpendicular to the large surfaces can be flat surfaces, for example, provided by large ventilation ducts with a flat and relatively strong insulation layer. The lamella webs are compressible and can therefore in the direction of the width of the slats, i. in the longitudinal direction of the slat webs are easily performed around pipelines with small diameters and there give a uniform sheath. This behavior is favored by the joints between the individual lamellae, since here the transverse stiffening of the insulating material is interrupted. The lamellae of the lamellar webs are arranged on a carrier layer and connected to the carrier layer, in particular adhesively bonded. As a carrier layer in particular metal, metal-plastic composite or metal-paper-plastic composite films are used, which may be supplemented by mesh scrims of different types of fibers.

The slat webs that can be produced from individual slats are limited in terms of their material thickness by the weight of the slats and, among other things, by the weight of the slats, limited adhesive strength on the carrier layer and by the maximum material thickness of the secondary web. The lamellae are disc-wise of a mineral fiber web prepared in the usual way, in particular separated a secondary non-woven and adhered with one of the two cut surfaces on the support layer, so that the lamellae and thus the lamellae have a course of the individual Mineralfasem exactly right angles or at steep angles to the cut surfaces of the lamellae and thus the large surfaces of the lamella web. Depending on the bulk density and the binder contents, the lamellae have a comparatively high transverse tensile strength and at the same time a high compressive strength, so that the lamellae are compressible and in particular compressible in the longitudinal direction of the lamella web. Laminated sheets with gross densities of up to approx. 60 kg / m ³ are therefore also used to insulate round components such as pipes, containers and other shaped surfaces. Due to their sufficiently high compressive strength, even roundness or flatness, lamellar sheets can also wear clothing, for example made of thin sheets, free of thermal bridges, without further support structures.

Slat trajectories and slat plates with a small width allow for larger deformations at constant force than slat trays and slat plates with larger width. The possible bending radius of these lamellar sheets and lamellar plates decreases with increasing insulation thickness and bulk density. The increasing with decreasing bending radius compression of the inner zones of the lamellae or lamellar plate leads to a considerable compression, but also to increase the compressive strength in these zones. Laminated webs are therefore just like solid, but much more expensive to produce pipe shells as a supporting layer for the sheathing of pipes, for example, with smooth or profiled sheets of steel, aluminum, plastic films, gypsum or mortar layers. The mineral fibers oriented at right angles or radially in the case of pipes to the insulated surfaces lead to an increase in the thermal conductivity of the insulating materials compared with insulating materials which have a laminar fiber structure or against pipe shells in which the mineral fibers are arranged concentrically around the central axis of the pipeline.

The production of lamellae is complicated in terms of process engineering and leads to a low throughput speed of the production plants. The bonding technique is also substantially unsuitable for the partly heavy weight slats. An adhesive bond between adjacent lamellae can also be weakened by loose mineral fibers or mineral fiber fragments (dust) being present in the region of the adhesive surfaces.

Laminated lanes are rolled up tightly for storage and transport and wrapped in a covering. Here, the lamellae are stressed at the beginning and at the end of a role strong on shear. After unrolling these slats fall off easily. The lamellae are even thrown off when the lamella web is allowed to unroll itself after removal of the sheaths by the action of the large restoring forces. In this uncontrolled Austrollvorgang the end of the role whipping like a whip through the air, so that already partially detached lamellae are completely replaced by the acceleration or the strong impact of the end on the ground.

Furthermore, there is a risk that individual lamellae detach from the lamellar web if the lamellae are inadvertently folded outwards. Because of the initially inadequate strength of the connection of the lamellae and the negative effects in the handling of the lamellae webs, carrier layers which are only partially glued to the lamellae are largely eliminated. These include, for example, mesh fabric made of glass fibers or similar planar structures.

The lamella plates glued as individual elements have the processing technology advantage that necessary separating cuts can either be performed along the transverse joints between adjacent lamellae or at least serve as an auxiliary line for the guidance of a cutting tool. The transverse joints can also be marked as a kink on the carrier layer to adapt by folding the slats, the slats in size with respect to the installation conditions.

A much more economical method for the production of insulating materials with the characteristic of lamellae, lamellar plates or lamellar sheets orientation of the mineral fibers is in the EP 0 741 827 B1 described. In this method, a thin primary nonwoven is unfolded by an up and down moving conveyor and placed endlessly and looped on a second conveyor. This creates individual layers which are pressed against each other in the horizontal direction and are compressed differently depending on the desired density of density. For this purpose, the primary fleece is guided between two pressure-resistant bands, which initially limit only the height of the primary fleece. Already hereby, the mineral fibers are aligned in the arcuately deflected tracks of the primary web parallel to boundary surfaces. To obtain largely flat surfaces, the primary nonwoven can also be actively compressed in the vertical direction.

This orientation of the mineral fibers in the primary non-woven can be done in a separate device, but is suitably made in conjunction with a curing oven. In the curing oven, the endless fibrous web between two pressure belts, of which at least one is movable in the vertical direction, flows through hot air in the vertical direction. The printing tapes have pressure-resistant elements with holes in which surface areas of the fiber web press, whereby the surfaces are profiled. In the two surfaces of the fiber web may lead to a further alignment of the mineral fibers, a further compression compared to the underlying areas and possibly to a slight binder enrichment.

With the aid of the thermal energy transmitted through the hot air, the fibrous web with the binding and / or impregnating agents contained therein is heated, so that moisture present in the fibrous web is expelled and the binders cure, in which they form connecting films or solids. After fixation of the fibrous web by solidification of the binder is shown in longitudinal section a structure in which the mineral fibers are oriented in the core of the primary web predominantly perpendicular to the large surfaces of the endless fiber web.

In the near-surface areas, the mineral fibers are aligned parallel to the large surfaces. Because of the relatively high stiffness of the core of the primary web, the mineral fibers can also be compressed in a mushroom-like manner with correspondingly large vertical pressures and / or pressed downwards between the zones having mineral fibers running at right angles to the large surfaces. Between the arcuately deflected paths of the primary web generally remain small gussets that occur as different widths and different depths transverse grooves in the two major surfaces of the endless fiber web.

In the horizontal section, the higher-density zones with the mineral fibers running at right angles to the large surfaces differ significantly from the intermediate zones with a flat arrangement of the mineral fibers. In cross-section, the structure is less uniform than in insulation boards used to make fins. For example, the bending tensile strength is lower because of the inhomogeneity of the structure at a comparable density.

From the EP 0 741 827 B1 Furthermore, the production of laminated Dämmfilzen is known in which the endless loop-shaped unfolded fiber web are glued on both large surfaces with support layers of aluminum foil and the fiber web is then cut centrally and parallel to their large surfaces, so that ultimately two equally thick and laminated fiber webs arise which are then rolled up. In the fibrous webs produced in this way and referred to as insulating felts, only a partial bonding with the carrier layer is possible. This partial bonding and the low transverse tensile strength of the Mineralfasem leads to a low-strength composite, the connection is much less solid compared to a slat plate or a lamellar mat of fins. However, this difference does not play a significant role in a continuously bonded fiber web, in particular when detaching the carrier layers at the two ends. However, the outer, unbacked compressible zones lead to bumps.

The EP 0 867 572 A2 further describes an insulating element made of mineral fibers, consisting of a mineral fiber fleece and / or a plurality of interconnected lamellae and at least one applied on a main surface lamination in the form of a film. This insulating element thus consists of a thin uniform fiber web of flat superimposed and interconnected individual mineral fibers with a thickness of less than 15 mm and a lamination and several interconnected slats. The lamination can be applied both on the thin fiber web and on the lamellae.

From the DD 248 934 A3 and in this known as the prior art EP 1 152 094 A1 as well as the DE 197 58 700 C2 Methods are known in which a impregnated with binding and other additives fiber web is divided into slats, which are rotated by 90 ° and then pressed together horizontally and compressed vertically, so that slat webs arise. It is also envisaged that the individual slats are densified differently and formed of different materials. After joining the individual lamellae, the mineral fibers are oriented more or less at right angles to the large surfaces depending on the orientation in the original fiber web. Due to the indispensable vertical pressure, the mineral fibers present in the two near-surface zones are also bent over and fixed in a flat bearing.

Strength increase may be in the in the EP 0 741 827 B1 as well as in the DD 248 934 A3 described method that the passing of the curing oven, the topmost, a few microns to millimeters thick zone of the fiber web is more compacted and enriched with binders, as the immediately underlying zones. Thus, a firmer contact with the lamination can be made, although the decisive for the use of transverse tensile strength of the fiber web is primarily influenced by the lower-lying zones.

From the US 4,128,678 a device and a method for producing an insulating material from a strip-shaped nonwoven material is known in which the non-woven fibers are provided with a curable binder. In the preparation of the insulating material, the strip-shaped nonwoven material is first wave-compacted and then heated to cause the compound of the fibers of the non-woven material. Subsequently, the nonwoven material is divided centrally by means of a band saw arranged transversely to a conveying direction, so that two nonwoven strips are formed, each with adjacently arranged, U-shaped fiber arrangements. On a surface formed by connecting legs of the U-shaped fiber arrangements, a carrier material is glued in a subsequent step, which ensures the mechanical strength necessary for the use of the insulating material. Thus, the insulating material can be preferably used for the isolation of pipes and other curved components with almost any diameter.

Starting from this prior art, the invention has the object of developing a method for producing an insulating element, and an insulating element such that, in a simple and inexpensive manner an insulating element can be manufactured which has improved strength characteristics as well as improved thermal conductivity so that the insulating element can be used both in the field of insulation of building facades as well as in the range of curved surfaces.

To solve this problem, it is provided in a method according to the invention that the large surface to be joined to the carrier layer is made flat by removing protrusions and / or unevenness after passing through the curing oven before applying the carrier layer. On the part of an insulating element according to the invention is provided for solving the problem that a support layer is disposed on a smooth formed large surface of the secondary web and that the support layer is mounted on the large surface.

With a method according to the invention insulating elements can be produced, which has a profile of a portion of Mineralfasem parallel to the large surfaces, whereby the heat transfer is reduced by the insulating material in the direction perpendicular to the large surfaces. On the other hand, mineral fibers aligned at right angles to these mineral fibers, ie mineral fibers oriented in the main direction of the transmission heat losses, increase the thermal conductivity. These mineral fibers running at right angles to the large surfaces increase the transverse tensile and compressive strength of the insulating material and reduce the rigidity parallel to the large surfaces. These properties, which are dependent on the orientation of the mineral fibers, can be combined in a suitably oriented mineral fiber structure of an insulating element according to the invention, whereby this structure proves to be advantageous, particularly in the case of a rollable insulation web, in that the insulating web in an outer zone connected to the carrier layer has the structure and properties an insulating felt, while the adjoining this zone areas of the insulating material web to an oppositely arranged and unbacked formed large surface due to the orientation of the mineral fibers perpendicular to the large surfaces have the beneficial properties of lamellar sheets.

According to the invention, the secondary web is machined after passing through the curing oven in the region of its with the support layer, for example, by the surface is abraded to eliminate protrusions and / or bumps. At the same time, mineral fibers whose orientation is not parallel or perpendicular to the large surface are removed. Alternatively, in order to remove larger quantities of mineral fibers it may be provided that mineral fibers are cut away to a predetermined depth with at least one cut parallel to the large surfaces. Subsequently, a grinding process can be provided, with which the required surface roughness is set.

The process according to the invention can be carried out immediately after the passage of the curing oven. In this case, both large surfaces of the secondary nonwoven fabric are processed and provided with a carrier layer before the secondary nonwoven fabric is subsequently divided into sections parallel and perpendicular to the large surfaces.

In an alternative continuous production, the secondary nonwoven fabric can first be divided into sections by cuts made parallel to and at right angles to the large surfaces, in particular with saws or lasers, which sections are subsequently machined and adhesively bonded to carrier layers and then rolled up or stored flat on, for example, pallets.

In machining, protrusions or protuberances caused at least by perforated hardening furnace tapes are removed. This contact zones are maintained in which the mineral fibers are arranged absolutely parallel to the large surfaces running.

According to one embodiment of the invention, it is provided that the region of the edge zone in which the mineral fibers are arranged flat or running at small angles to the large surface, are partially or completely removed. As a result, the bending ability and compressibility of the secondary web or of the insulating element produced therefrom is increased in its longitudinal axis direction.

With a different depth of erosion of Mineralfasem in the area adjacent to the surface of the edge zone Mineralfasem be exposed with a steeper orientation to the large surface, whereby the transverse tensile strength of the secondary web or of the insulating material produced therefrom in the area of the large surface increases, so that the Adhesive bond between the large surface and the carrier layer arranged thereon is substantially improved, the carrier layer is laminated to the surface.

With the removal of the mineral fibers oriented essentially parallel to the large surface area and thus an increased proportion of mineral fibers oriented steeply to at right angles to the large surface, the heat transfer through the insulating element increases.

An insulating element produced according to this invention is preferably suitable for insulating smooth curved surfaces, such as, for example, pipelines, due to the fact that, in the region of the large surface opposite the large surface area formed with the carrier layer, generally unclad large surface perpendicularly oriented mineral fibers. The compressibility of the insulating element in the region of the large surface with an orientation of the mineral fibers perpendicular to the large surface can be increased according to a further feature of the invention in that the secondary nonwoven or the insulating element is pre-compressed during rolling and thereby elasticized.

The insulating element according to the invention can be covered with a lining, for example with a cover made of a thin sheet metal, wherein the cladding preferably on the large surfaces with the parallel thereto Mineral fibers is arranged so that the slightly compressible outer edge zone below the support layer can elastically resiliently adapt to the inner surface of the panel. In the same way, the elasticity of the insulating element can be used to isolate for the arrangement of insulating elements in a small distance from each other arranged pipes. In this application, the elasticity of the insulation elements according to the invention is used in the contact areas.

According to a further feature of the invention, it is provided that in at least one large surface, in particular in the surface connected to the carrier layer are preferably introduced prior to winding, in particular at right angles to the longitudinal axis of the secondary web incisions and / or recesses. Such trained insulating elements have the advantage that their elasticity is improved, so that they are rollable or windable even with larger material thicknesses and associated greater rigidity. Also, this insulation elements could be used by this design for the insulation of objects with highly curved surfaces.

Figur 1

einen ersten Abschnitt einer schematisch dargestellten Anlage zur Herstellung eines Dämmstoffelementes aus Mineralfasern;

Figur 2

einen zweiten Abschnitt der Anlage zur Durchführung des Verfahrens zur Herstellung eines Dämmstoffelementes aus Mineralfasem gemäß Figur 1,

Figur 3

einen Abschnitt eines Dämmstoffelementes in verschiedenen Bearbeitungsstufen im Längsschnitt und

Figur 4

ein in mehrere Abschnitte unterteiltes Dämmstoffelement in Seitenansicht.

Further feature and advantages of the invention will become apparent from the following description of the accompanying drawings in which preferred embodiments of an insulating element and a device for producing an insulating element are shown. In the drawing show:

FIG. 1

a first portion of a schematically illustrated plant for producing an insulating element made of mineral fibers;

FIG. 2

a second section of the plant for carrying out the method for producing a mineral fiber insulating element according to Figure 1,

FIG. 3

a section of an insulating element in different processing stages in longitudinal section and

FIG. 4

a subdivided into several sections insulation element in side view.

FIG. 1 shows the first section of a plant 1 for producing a sheet-like insulating element 2 (FIG. 2) from mineral fibers 3. The mineral fibers 3 are produced from a silicate material, for example natural and / or artificial stones, by melting the silicate material in a cupola 4 and the melt 5 is fed to a fiberizing unit 6. The fiberizing unit 6 has a plurality of spinning wheels 7 driven in rotation, of which only one spinning wheel 7 is shown in FIG.

The cupola 4 has on the output side a spout 8, via which the melt 5 flows from the cupola 4 onto the spinning wheels 7.

Due to the rotational movement of the spinning wheels 7, the mineral fibers 3 are formed from the melt 5 and collected on a first conveyor belt 9. On this first conveyor belt 9, a primary nonwoven fabric 10 is formed in which the mineral fibers 3, which are mixed with binder in the fiberising aggregate 6, are aligned in substantially the same direction and arranged in a laminar manner. The primary nonwoven 10 is then transferred to a downstream processing station 12 via a second conveyor belt 11 which, in contrast to the first conveyor belt 9, is not a collecting conveyor belt but a transport conveyor belt.

In the processing station 12, the general transport direction of the primary web 10 is changed. This change takes place from the original longitudinal direction into a transport in the original transverse direction of the primary web 10. The conveying direction is shown in FIG. 1 by an arrow 13.

The primary web 10 is transported over a roller 14 whose purpose is to change the transport direction of the primary web 10 from a substantially horizontal direction in a substantially vertical direction to supply the primary web 10 to another processing station 15. This further processing station 15 has two parallel conveyor belts 16, 17 on, between which the primary web 10 is guided. The conveyor belts 16, 17 are arranged to oscillate and oscillate the primary web 10 at right angles to its longitudinal extent as a secondary web 18 on a further conveyor, not shown, which runs parallel to the conveyor belts 9 and 11.

The thus suspended secondary web 18 is then fed to a compression station 19, in which the secondary web 18 is compressed. The compacting station 19 has an upper conveyor belt 20 and a lower conveyor belt 21, between which the secondary web 18 runs. The two conveyor belts 20 and 21 of the compression station 19 are arranged in a pendulous manner and, in addition to the function of compacting the secondary web 18, also function to aufzupreln the compacted secondary web 18 in the longitudinal direction meandering. This floating of the secondary web 18 causes the secondary web 18 in its central region has an orientation of the mineral fibers 3, which is aligned at right angles to the large surfaces 22, 23. In edge zones 101 immediately below the large surfaces 22, 23, the secondary web 18 has an orientation of the mineral fibers 3 which are at an angle other than the orthogonal to the large surfaces 22, 23 to a parallel orientation relative to these large surfaces 22, 23 varies. This arrangement and orientation of the mineral fibers 3 in the secondary web 18 results from the swaying of the secondary web 18 following the compression station 19.

The suspended secondary web 18 is fed immediately after the swaying of a processing station 24, which has an upper conveyor belt 25 and a lower conveyor belt 26 and their conveying speeds compared to the conveying speed of the compression station 19 is lower, so that the suspended Sekundärvlies 18 compressed in its longitudinal direction and the individual meander of the suspended Sekundärvlieses 18 are pushed together.

The processing station 24 is followed by a further processing station 27, which also has an upper conveyor belt 28 and a lower conveyor belt 29, between which the suspended secondary web 18 is conveyed. The processing station 27 has a further reduced conveying speed of the secondary web 18 in order to continue the compaction and the homogenization of the suspended secondary web 18.

The thus prepared secondary web 18 forms an end product that can be further processed to form certain insulating elements 2 of mineral fibers 3, such as insulation boards or insulation panels, as will be described below with reference to Figure 2.

The meandering unfolded and compressed secondary web 18 is fed to a curing oven 30 by two parallel conveyor belts 31 and 32 are arranged. In the hardening furnace 30 hot air is conveyed through the conveyor belts 31, 32 and thus also through the secondary web 18, which hot air cures the binder contained in the secondary web 18 for connecting the individual mineral fibers 3. As a result of the curing of the binder, the secondary nonwoven 18 is fixed in its geometric shape, which it obtained in front of the curing oven through the processing stations 12, 15, 19 and 24 and 27. At the same time, the secondary web 18 is compressed between the conveyor belts 31, 32 of the curing oven 30.

The distance between the two conveyor belts 31, 32 in the curing oven 30 is set to the material thickness of the secondary web 18 and limited by the conveying speed of the conveyor belts 31, 32 in relation to the amount of hot air required to cure the binder.

Subsequent to the curing oven 30, the secondary web 18 passes through a first sawing station 33, which has a band saw 34 with a band-shaped saw blade 35, with which saw blade 35 divides the secondary web 18 by a separating cut parallel to the large surfaces 22, 23 into two insulating elements 2 each having a large surface 22, 23 and a substantially coextensive, the respective large surface 22, 23 opposite separating surface.

The secondary web 18 having a width of 2,400 mm is subsequently subdivided into four part webs by a circular saw with a circular saw blade 37 in the longitudinal direction, each sub web ultimately forming an insulating element 2 and having a width of 1,200 m.

The insulation elements 22 separated in the longitudinal direction by the separating cut parallel to the large surfaces 22, 23 of the secondary nonwoven 18 are lifted apart and fed to a laminating station, in which a carrier layer 39 is applied to a large surface 22, 23 separating surfaces of the insulating elements 2. The carrier layers 39 are hereby stored for each insulating material web 2 in each case a laminating roll, wherein the carrier layers 39 withdrawn with the promotion of the insulating elements 2 of the Kaschierungsrolle and the same surface is glued to the insulating elements 2. Following the laminating station, the insulating elements 2 are wound up and packed. For this purpose, the insulation elements 2 are cut to length in a predetermined length of the secondary web 18 by a section perpendicular to the longitudinal direction of the secondary web 18.

The carrier layer 39 is formed as an aluminum-polyethylene composite film and forms an outer reinforcement, protective and / or decorative layer. The connection of the support layer 39 with the insulating element 2 in the laminating station is effected by a sprayed onto the insulating element 2 highly viscous dispersion adhesive which is sprayed over the entire surface, selectively or in strips depending on the required connection between the support layer 39 and the insulating element 2 and its adhesive effect. The carrier layer 39 is arranged on the large surface 22, 23 of the insulating element 2, in the region of which the mineral fibers 3 are arranged parallel to the large surface 22, 23. It is additionally provided that prior to winding of the insulating element 2 in the region of the large surfaces 22, 23 existing Mineralfasem 3, which differ from a rectangular orientation to the large surfaces 22, 23 are partially removed by cutting or grinding, and also projections from mineral fibers 3 or bumps in the large surface 22, 23 are removed to provide a flat and smooth surface for attachment of the support layer 39.

It can be seen in FIG. 3 that with the cutting tools 114 either a part of the edge zones 101 or the entire edge zones 101 can be removed, so that the secondary nonwoven 18 can have different fiber progressions. In particular, the insulation elements 2 according to FIG. 4 can be produced from a secondary nonwoven 18 according to FIG. 3, or the secondary nonwoven 18 can have an exclusively orthogonal course of the mineral fibers 2 to the large surfaces 22, 23 before the secondary nonwoven 18 is connected to the carrier layer 39.

The insulating elements 2 according to FIG. 4 are thus characterized in that the edge zones 101 in the area of the large surfaces 22, 23 have been partially removed and that the cut surface 115 is designed to achieve a high transverse tensile strength in a core region 109 of the insulating element 1 according to FIG.

The insulating elements 2 may be formed as insulating panels and produced in many different dimensions depending on the width of the production facilities.

The insulating material elements 2 shown in Figure 4 are formed web-shaped, wherein the carrier layer 39 is disposed on a smooth-formed large surface 22, 23. The carrier layer 39 is arranged on the large surface 22, 23 in the region of the edge zone 101, which edge zone the mineral fibers 3 are arranged to extend substantially parallel to the large surface 22, 23.

The connection between the carrier layer 39 and the edge zone 101 takes place in the case of a carrier layer 39 made of an aluminum-polyethylene composite film in that the aluminum-polyethylene composite film is heated, so that the plastic content in the composite film softens and with the large surface 22, 23 bonded in the region of the edge zone 101.

The insulating elements 2 according to Figure 4 are formed from a secondary web 18 by a division of the secondary web 18 according to the above description, wherein in the secondary web, the primary web 10 is arranged meandering. In the deflection areas between the meanders arise gussets, in which mineral fibers 3 are displaced.

It can be seen in FIG. 4 that the edge zone 101 can be removed starting from the large surface 22, 23 in different material thickness. As a result, the material thickness of the edge zone is influenced in order to adapt the insulating element 2 to the application.

Claims (16)

1. Method for producing an insulating element from binder-bound mineral fibers, in particular from rock wool and/or glass wool, wherein the mineral fibers are produced from a melt and are deposited as a primary non-woven web on a conveyor device, wherein the primary non-woven web is arranged by means of pendulums in overlapping folds at right angles to its longitudinal extension and is deposited as a secondary non-woven web having a core area in which the mineral fibers are oriented substantially at right angles or steeply inclined with respect to the major surfaces and having at least one fringe in which the mineral fibers are oriented substantially parallel to the major surfaces on a second conveyor device and are fed to a hardening furnace for the curing of the binder, and wherein the secondary non-woven web is subsequently divided in at least two insulating material webs by a split cut parallel to the major surfaces of the secondary non-woven web, and wherein a supporting layer is applied to at least one major surface,
   characterized in
   that after passing through the hardening furnace (30) and prior to the applying of the supporting layer (39) the major surface (22, 23) that is to be connected to the supporting layer (39) is made even by removing protrusions and/or irregularities.
2. Method according to claim 1,
   characterized in
   that the protrusions and/or irregularities are removed by abrasion and/or by at least one cut parallel to the major surface (22, 23).
3. Method according to claim 1
   characterized in
   that the protrusions and/or irregularities together with the mineral fibers (3) are removed up and into a region of the fringe (101) in which the mineral fibers (3) are predominantly, namely at least 80%, oriented parallel to the major surface (22, 23).
4. Method according to claim 1,
   characterized in
   that as a supporting layer (39) an air-permeable and/or thermally resistant non-woven web, woven fabric or non crimp fabric, especially from glass and/or natural fibers or organic chemical fibers, like for instance carbon, aramid, terephthalate, polyamide, polypropylene or mixtures thereof, or a film, for example an aluminium polyethylene composite film is applied at least in one layer and especially in the form of webs that are resistant to extension.
5. Method according to claim 3,
   characterized in
   that the mineral fibers which in the region of the fringe (101) are not oriented parallel to the major surfaces (22, 23) are displaced to gussets between adjacent meanders (3) of the secondary non-woven web (18).
6. Method according to claim 1,
   characterized in
   that the secondary non-woven web (18) which is connected to the supporting layer (18) is wound up.
7. Method according to claim 1,
   characterized in
   that the secondary non-woven web (18) which is connected to the supporting layer (18) is compressed in the direction of the surface normal of the major surfaces (22, 23) prior to being wound up.
8. Method according to claim 1,
   characterized in
   that the supporting layer (18) is glued to the secondary non-woven web (18).
9. Method according to claim 1,
   characterized in
   that preferably prior to the winding-up operation incisions and/or recesses that preferably extend at right angles to the longitudinal axis of the secondary non-woven web (18) are made in at least one major surface (22, 23), especially in that surface (22, 23) which is connected to the supporting layer.
10. Method according to claim 1,
    characterized in
    that prior to applying the supporting layer (39) the secondary non-woven web (18) is subdivided in sections in parallel and/or at right angles to its longitudinal direction.
11. Method according to claim 1,
    characterized in
    that the mineral fibers (3) of the major surface (22, 23) to be connected to the supporting layer (39) are removed up to the core area (109) after passing through the hardening furnace (30) before applying the supporting layer (39).
12. Web of insulating material made of binder-bound mineral fibers, particularly of mineral wool and/or glass wool, produced by the method according to one of the claims 1 to 11, which web of insulating material consists of a secondary non-woven web having major surfaces with a core area which has an orientation of the mineral fibers substantially at right angles or steeply inclined with respect to the major surfaces, with one major surface and a separation plane that is produced at the division of the secondary non-woven web in two webs of insulating material, with the mineral fibers in the region of the separation plane being arranged to have an orientation at right angles to the separation plane and in the region of the surface at angle deviating from 90° with respect to the major surface, especially parallel to the major surface, and with a lamination,
    characterized in
    that a supporting layer (39) is arranged on one major surface (22, 23) of the secondary non-woven web (18) that is made even by removing protrusions and/or irregularities and that the supporting layer (39) is fixed on the major surface (22, 23).
13. Web of insulating material according to claim 12,
    characterized in
    that between the supporting layer (39) and the major surface (22, 23) at least one fringe (101) with an orientation of the mineral fibers (3) substantially parallel to the major surface (22, 23) is arranged.
14. Web of insulating material according to claim 12,
    characterized in
    that the supporting layer (39) is formed as an air-permeable and/or thermally resistant non-woven web, woven fabric or non crimp fabric, especially from glass and/or natural fibers or organic chemical fibers, like for instance carbon, aramid, terephthalate, polyamide, polypropylene or mixtures thereof, or a film, for example an aluminium polyethylene composite film is applied at least in one layer and especially in the form of webs that are resistant to extension.
15. Web of insulating material according to claim 12,
    characterized in
    that the supporting layer (39) is glued to the secondary non-woven web (18).
16. Web of insulating material according to claim 12,
    characterized in
    that incisions and/or recesses that preferably extend at right angles to the longitudinal axis of the secondary non-woven web (18) are arranged in at least one major surface (22, 23), especially in that surface (22, 23) which is connected to the supporting layer.

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