EP2791434B1

EP2791434B1 - Mineral wool panel

Info

Publication number: EP2791434B1
Application number: EP12808741.8A
Authority: EP
Inventors: Gorazd Sebenik; Gregor KEJZAR; Jure Smolej; Miha Kese
Original assignee: Knauf Insulation SPRL
Current assignee: Knauf Insulation SPRL
Priority date: 2011-12-12
Filing date: 2012-12-10
Publication date: 2018-02-07
Anticipated expiration: 2032-12-10
Also published as: RU2638211C2; PL2791434T3; GB201121252D0; WO2013087560A1; EP2791434A1; UA112333C2; ES2662415T3; RU2014128463A

Description

This invention relates to a mineral wool insulation panel, in particular for use in fire rated doors.
EP1533462A relates to a construction for a fire rated door and discloses the use of a plurality of mineral wool insulation panels within the door cavity, each mineral wool panel having a different density and/or quantity of fire retardants. This is intended to optimise the insulation to correspond to the varying temperature stresses over the height of the door. A disadvantage with this arrangement is the need to supply and assemble different individual mineral wool panels.
One aim of the present invention is to facilitate the supply and assembly of mineral wool panels, particularly for fire rated doors. Another aim is to alleviate the risk of weak points of prior arrangements of insulations panels for fire rated doors whilst optimising material useage.
According to one aspect, the present invention provides a mineral wool insulation panel as defined in claim 1. Other aspects are defined in other dependent claims whilst the dependent claims define preferred and/or alternative embodiments.
The provision of a single piece mineral wool insulation panel having a height of at least 160 cm and a width of at least 60cm allows the panel to be used without requiring additional panels to fill the cavity of a fire rated door. Handling and assembling a single panel is easier and more efficient than dealing with multiple different panels. In addition, the provision of a single or unitary panel having dimensions that can fill the entire cavity of a door avoids the risk of a point of weakness or a thermal bridge in the insulation that would occur at the abutments of separate but adjoining panels. The panel may be substantially rectangular; it may be provided with preformed cuts and/or cut-outs to facilitate its assembly in a door cavity.
The dimensions of the panel may be:

height ≥ 160 cm, optionally ≥ 180 cm or ≥ 200 cm and/or ≤ 260 cm, optionally ≤ 240 cm or ≤ 230 cm;
width ≥ 60 cm, optionally ≥ 70 cm or ≥ 80 cm and/or ≤ 150 cm, optionally ≤ 120 cm or ≤ 100 cm;
thickness preferably ≥ 1,5 cm, optionally ≥ 3 cm or ≥ 4 cm and/or preferably ≤ 12 cm, optionally ≤ 10 cm or ≤ 8 cm

The thermal stresses to which a door is subjected during a fire or fire test are not constant over the height of the door. The configuration of lower, central and upper bands in the insulation panel allows the upper and/or lower bands to be arranged with a desired higher density of mineral wool insulation for achieving a desired fire resistance and/or thermal performance without the use of the same high density at the central band. This reduces the total weight and thus cost of the mineral wool panel compared to a single panel having a homogeneous density of the density of the upper and/or lower bands. In one preferred embodiment, the density at the upper and lower bands is substantially the same and/or the mineral wool panel is substantially symmetrical about its central horizontal axis; this allows the panel to be used in a door cavity either way up and thus facilitates assembly. The most critical portion of a door for its fire resistance or performance is generally a band across the width of the door at or towards its top edge and/or a band across the width of the door at or towards its bottom edge. The panel according to the present invention thus provides for a high density of mineral wool insulation to be provided at these areas whilst using a lower density of mineral wool at a central band across the width of the door at which such a high density would be unnecessary.
In another preferred embodiment, the density at the lower band is less than the density at the central band, and the density at the central band is less than the density at the upper band; this provides a useful optimisation of the quantity of mineral wool insulation use in the panel whilst providing for a desired density of mineral wool insulation at the upper band, for example to achieve a desired fire class. Each of the upper and lower bands may have a height ≥ 5 cm, preferably ≥ 10 cm, more preferably ≥ 15 cm and/or ≤ 60 cm, preferably ≤ 40 cm, more preferably ≤ 30 cm. One edge of each of the upper and/or lower bands may be situated respectively at the upper and lower edge of the panel. The density of mineral wool over each or any of the upper, central and lower bands need not be homogeneous. Indeed, transition in density between the upper and/or lower bands and the central band is preferably gradual as opposed to being a step change in density.
The density at each of the upper and lower bands may be ≥ 100 kg/m³, preferably ≥ 120 kg/m³, more preferably ≥ 140 kg/m³ and/or ≤ 220 kg/m³, preferably ≤ 250 kg/m³, more preferably ≤ 300 kg/m³. In respect of the invention defined in claim 1, the density of the mineral wool insulation at each of the upper and lower bands is within the range 100 to 300 kg/m³. The density at the central band may be ≥ 60 kg/m³, preferably ≥ 80 kg/m³, more preferably ≥ 100 kg/m³ and/or ≤ 180 kg/m³, preferably ≤ 210 kg/m³, more preferably ≤ 250 kg/m³. Since the density throughout each band need not be homogeneous, the density for a band may be determined by taking three samples each having dimensions of about 10 cm x 10 cm at locations along a single line substantially parallel to the top or bottom edge of the panel across the width of the panel and determining the average density of these three samples.
The density at the upper band and/or central band and/or lower band may be substantially constant across the entire width of the panel at that band. For example, the density at such band(s) across the entire width of the panel may be within the range of ± 10 kg/m³ or ± 5 kg/m³ with respect to the average density at the band in question, such average density and variation in density at a band being determined by taking a representative number of samples each having dimensions of about 10 cm x 10 cm at locations along a single line within the band substantially parallel to the top or bottom edge of the panel across the width of the panel.
The density of the mineral wool insulation at each of the upper and lower bands may be greater than the density of the mineral wool insulation at the central band by at least 8 %, more preferably by at least 12 % and even more preferably by at least 15 %.
One position at a fire rated door which may be considered critical in terms of its fire performance is the position towards a corner of the door spaced 10 cm from each of the adjacent edges at that corner. Consequently, it is preferred that each such position of the mineral wool insulation panel is situated within one of the upper or lower bands.
The mineral wool is preferably stone wool; alternatively it may be glass wool. Where the mineral wool comprises a binder, this may be present at a quantity of ≥ 0,5 wt % preferably ≥ 0,8 wt %, and/or ≤ 4 wt %, preferably ≤ 3 wt % expressed a % weight with respect to the mineral wool including the binder and measured, for example, by loss on ignition. Such a binder is preferably a thermally cured organic binder, for example a phenol formaldehyde binder, a urea formaldehyde binder or a binder based on carbohydrates, applied to the mineral fibre between their formation and their collection together as a primary mat. In some embodiments the panel is free of binder or substantially free of binder. The mineral wool may account for at least 85%, at least 90%, at least 94%, at least 96% or at least 98% by weight of the mineral wool insulation panel.
The panel is particularly suited for use in doors, particularly in fire rated doors and even more particularly in doors meeting a Ei 30, Ei40, Ei 60, Ei90 or Ei120 fire class. The doors may comprise a peripheral skin, preferably comprising sheet metal, notably steel, which define an internal door cavity in which the mineral wool panel is arranged.
Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings of which:

Fig 1 is a schematic plan view of a mineral wool insulation panel;
Fig 2 is a schematic side view of the panel of Fig 1;
Fig 3 is a schematic perspective representation of part of a production process by which such a panel may be manufactured;
Fig 4 and Fig 5, Fig 6 and Fig 7, and Fig 8 and Fig 9 are pairs of view similar to Fig 1 and Fig 2, each pair of views illustrating an alternative mineral wool insulation panel.

The single piece stone wool insulation panel 10 illustrated in Figs 1 and 2 has a height h of about 200 cm, a width w of about 80 cm and a thickness t of about 6cm. It is substantially rectangular having a top edge 11, bottom edge 12, and first 13 and second 14 side edges.
An upper band 21, a central band 23 and a lower band 22 each extend across the width of the panel 10. In the embodiment illustrated in Fig 1 and Fig 2, the upper 21 and lower bands 22 each have a higher density of mineral wool than the central band 23. The density of the mineral wool insulation in the height direction h is not homogeneous by varies gradually and transition zones 24, 25 also of gradually varying density separate each of the upper and lower bands 21,22 from the central band 23. A representative density of each band may be taken as the average density along imaginary upper 31, lower 32 and central 33 sample lines situated respectively within each band and running across the width w of the panel parallel to the top and bottom edges 11,12, the central sample line preferably being situated mid-way between the top edge 11 and the bottom edge 12 of the panel, the upper sample line 31 preferably being situated at a distance of about 15 cm from the top edge 11 and the lower sample line 32 preferably being situated at a distance of about 15 cm from the bottom edge 12.
Each of four near corner positions 41, 42, 43, 44, each of which is situated proximate a corner of the panel 10 at a distance of 10 cm from each edge of the mineral wool insulation panel at that corner, is situated within one of the upper or lower bands 21, 22.
Fig 3 illustrates part of an apparatus which may be used to manufacture a mineral wool panel 10. Mineral wool fibres, to which a thermally curable binder has preferably been applied, are transferred in the form of a primary mat 61 having a substantially homogeneous weight per unit area across its width w₁ from a collection belt 62 to a primary mat conveyor 63 advancing in a first direction 64. A swinging pendulum mechanism 66 is used to transfer the primary mat 61 to a secondary mat conveyer 68 advancing in a direction 69 substantially perpendicular to the primary mat conveyer 63 so as to form a secondary mat 70 by reciprocal folding of the primary mat 61. The speed of the pendulum towards at least one of its apexes of its movement is arranged to be different, for example lower, than the speed of the pendulum at its central position; in this way, with the secondary mat conveyer 68 advancing at a substantially constant speed, a different, for example, greater quantity (weight per unit area) of the primary mat 61 is deposited at one or both side edges 71, 72 at the extremities of the width w₂ of the secondary mat 70 than is deposited at the central position 73 across the width w₂ of the secondary mat 70.
In a subsequent step (not illustrated) the secondary mat is compressed, its binder (when present) is cured in a curing oven ant its edges 71, 72 are preferably trimmed.
Advantageously, the width w₂ of the secondary mat 70 is arranged to be substantially the same as the desired height h of the mineral wool insulation panel 10 so that after any edge trimming of the mat, the mat is cut across its width w₂ to form the mineral wool insulation panel 10, the width w₂ of the mat thus becoming the height h of the panel. In this way, there is little or no waste generated from cutting of the mat to form the panels 10.
The following tables sets out a number of different embodiments:

Example 1 (illustrated in Figs 1 and 2)

	Density	Comments
Mineral wool density at upper band	160 kg/m³ to 200 kg/m³, preferably about 180 kg/m³ ± 10 kg/m³
Mineral wool density at central band	120 kg/m³ to 170 kg/m³, preferably about 140 kg/m³ to 150 kg/m³ ± 10 kg/m³	Density at central band lower than density at each of the upper and lower bands
Mineral wool density at lower band	160 kg/m³ to 200 kg/m³, preferably about 180 kg/m³ ± 10 kg/m³	Density at lower band preferably substantially similar (e.g. ± 10 kg/m³) with respect to density at upper band

Example 2 (illustrated in Figs 4 and 5)

	Density	Comments
Mineral wool density at upper band	160 kg/m³ to 200 kg/m³, preferably about 180kg/m³ ± 10 kg/m³
Mineral wool density at central band	120 kg/m³ to 170 kg/m³, preferably about 140 kg/m³ to 150 kg/m³ ± 10 kg/m³	Density at central band lower than density at upper band
Mineral wool density at lower band	120 kg/m³ to 170 kg/m³, preferably about 140 kg/m³ to 150 kg/m³ ± 10 kg/m³	Density at lower band preferably substantially similar (e.g. ± 10 kg/m³) with respect to density at central band

Example 3 (illustrated in Figs 6 and 7)

	Density	Comments
Mineral wool density at upper band	160 kg/m³ to 200 kg/m³, preferably about 180kg/m³ ± 10 kg/m³
Mineral wool density at central band	120 kg/m³ to 170 kg/m³, preferably about 140 kg/m³ to 150 kg/m³ ± 10 kg/m³	Density at central band lower than density at upper band
Mineral wool density at lower band	100 kg/m³ to 140 kg/m³, preferably about 120 kg/m³ ± 10 kg/m³	Density at lower band lower than density at central band

Example 4 (illustrated in Figs 8 and 9)

	Density	Comments
Mineral wool density at upper band	120 kg/m³ to 170 kg/m³, preferably about 140 kg/m³ to 150 kg/m³ ± 10 kg/m³
Mineral wool density at central band	160 kg/m³ to 200 kg/m³, preferably about 180 kg/m³ ± 10 kg/m³	Density at central band higher than density at each of the upper and lower bands
Mineral wool density at lower band	120 kg/m³ to 170 kg/m³, preferably about 140 kg/m³ to 150 kg/m³ ± 10 kg/m³	Density at lower band preferably substantially similar (e.g. ± 10 kg/m³) with respect to density at upper band

Claims

A mineral wool insulation panel having a height of at least 160 cm and a width of at least 60cm comprising an upper band located towards an upper edge of the panel, a lower band located towards the lower edge of the panel and a central band positioned between the upper and lower bands, each of the bands extending substantially across the width of the panel, characterized in that the mineral wool panel is a single piece mineral wool insulation panel and in that the density of the mineral wool at the central band is different from the density at the upper band and/or the lower band and in which the density of the mineral wool insulation at each of the upper and lower bands is within the range 100 to 300 kg/m³.
A single piece mineral wool insulation panel in accordance with claim 1, in which the density of the mineral wool insulation at the central band is less than the density at the upper band and/or the lower band.
A single piece mineral wool insulation panel in accordance with any preceding claim, in which the density of the mineral wool insulation at the central band is less than the density at both the upper band and the lower band.
A single piece mineral wool insulation panel in accordance with any preceding claim, in which the difference in density of the mineral wool insulation at bands having different densities is at least 8%, preferably at least 10%.
A single piece mineral wool insulation panel in accordance with any preceding claim, in which the difference in density of the mineral wool insulation at bands having different densities is at least 10 kg/m³, preferably at least 20 kg/m³, more preferably at least 25 kg/m³.
A single piece mineral wool insulation panel in accordance with any preceding claim, in which the density of the mineral wool insulation at the central band is within the range 60 to 250 kg/m³.
A single piece mineral wool insulation panel in accordance with any preceding claim, in which the mineral wool insulation panel has four corners, two corners at extremities of a lower edge and two corners at extremities of an upper edge, each of these corners having an associated near corner position which is proximate that corner and spaced from each edge of the mineral wool insulation panel at that corner by a distance of 10 cm, and in which each of the four near corner positions of the mineral wool insulation panel is situated within one of the upper or lower bands.
A single piece mineral wool insulation panel in accordance with any preceding claim, in which:
the upper band comprises a band located towards an upper edge of the panel which extends substantially across the width of the panel, which has a height of 10cm and is centred on a line which is substantially parallel to a top edge of the panel, the said line being spaced from the top edge of the panel by 10 cm;

the lower band comprises a band located towards a lower edge of the panel which extends substantially across the width of the panel, which has a height of 10cm and is centred on a line which is substantially parallel to a lower edge of the panel, the said line being spaced from the lower edge of the panel by 10 cm; and

the central band comprises a band located towards the centre of the panel which extends substantially across the width of the panel, which has a height of 10cm and is centred on a line which is substantially parallel to and equidistant from the upper and lower bands.
A single piece mineral wool insulation panel in accordance with any preceding claim, in which:
the upper band has a density in the range 160 kg/m³ to 200 kg/m³; and

the central band has a density which is less than the density of the upper band and which is in the range 120 kg/m³ to 170 kg/m³.
A single piece mineral wool insulation panel in accordance with any preceding claim, in which:
the lower band has a density which is less than the density of the upper band and which is selected from (i) a density which in the range 120 kg/m³ to 170 kg/m³ and which differs from the density of the central band by less than 5% and (ii) a density which is less than the density of the central band and which is in the range 100 kg/m³ to 140 kg/m³.
A single piece mineral wool insulation panel in accordance with any of claims 1 to 9, in which:
the upper band has a density in the range 160 kg/m³ to 200 kg/m³;

the central band has a density which is less than the density of both the upper and the lower bands and which is in range 120 kg/m³ to 170 kg/m³; and

the lower band has a density in the range 160 kg/m³ to 200 kg/m³.
A door comprising a mineral wool insulation panel in accordance with any preceding claim.
A method of manufacturing a single piece mineral wool insulation panel having a height of at least 160 cm and a width of at least 60cm comprising an upper band located towards an upper edge of the panel, a lower band located towards the lower edge of the panel and a central band positioned between the upper and lower bands, each of the bands extending substantially across the width of the panel and the density of the mineral wool at the central band being different from the density at the upper band and/or the lower band, the method comprising the steps of:
a) producing a primary mat of mineral fibres having a weight per cm² which is substantially homogeneous across its width;

b) transporting the primary mat along a primary mat conveyer in a first direction at a substantially constant speed;

c) producing a secondary mat of mineral fibres from the primary mat, the secondary mat being produced by using a pendulum mechanism to continuously fold the primary mat on a secondary mat conveyer advancing in a direction substantially perpendicular to the primary mat conveyer at a substantially constant speed whilst arranging for the speed of the pendulum towards one or each of the apexes of its movement to be lower than the speed of the pendulum at its central position so as to deposit a greater weight per cm² of mineral fibres at one or each of the edges of the secondary mat compared with the weight per cm² of mineral fibres at a central position of the secondary mat;

d) compressing, optionally curing and optionally trimming the edges of the secondary mat to form a tertiary mat having a first side band located towards a first side edge of the mat, a second side band located towards the other edge of the mat and a central band positioned between the two edges of the mat, the density of the mineral wool at the central band being less that the density at one or each of the side bands ; and

e) cutting the tertiary mat across its width to form a mineral wool insulation panel having a height corresponding substantially to the width of the tertiary mat.
The method of claim 13 in which the single piece mineral wool insulation panel is a single piece mineral wool insulation panel in accordance with any one of claims 1 to 11.
Use of a mineral wool insulation panel in accordance with any of claims 1 to 11 in a door having a fire class of at least Ei30.