SK160494A3 - Process and device for manufacturing mineral fiber products - Google Patents

Abstract

When manufacturing mineral fiber products with compressed surface areas made of mineral fiber webs, in which the fibers extend substantially parallel, perpendicular or obliquely to the large surfaces of the mineral fiber web, which contains an uncured binder, it is very important to achieve a high tearing resistance and a strong fiber connection between the compressed surface areas or layers and the remaining part of the mineral fiber web. It is therefore proposed to expose at least one surface area to needling down to a predetermined penetration depth, in order to felt the fibers and at the same time to compress the surface area.

Description

The invention relates to a method for producing mineral fiber products with compacted surface areas of mineral fiber webs, wherein the fibers extend within the mineral fiber web substantially parallel to or extend perpendicularly or obliquely to the large surfaces of the mineral fiber web, and wherein the mineral web The fibers comprise an uncured _r binder.

BACKGROUND OF THE INVENTION

The method of the above type and the apparatus for carrying out the method have been known, in particular, from Canadian Patent No. 1,057,183. In order to produce a densified surface area or surface layer, a partial cut is cut by cutting horizontally parallel to the large surfaces. section. This sub-section is then separated from the remaining mineral fiber web and compressed between the press trains and thereby compacted. This compacted sub-belt is then returned to the remaining mineral fiber web. They are then passed together through a quenching furnace in which the binder contained in the mineral fiber belt in the partial belt is cured until previously unhardened. In practice, however, it has been shown that the fibers in a separate partial belt are crushed as a result of the large statically acting forces causing compression and, in addition, the partial belt is still compressed, in the form of a bread dough that is rolled out. This results in relatively inhomogeneously compacted areas within the partial web. The teaching disclosed in the Canadian patent has also been developed somewhat, although a relatively thin subbase has been cut, compressed and then finally applied with a pendulum device in the folds again onto the remaining mineral fiber strip. In all cases, however, it turned out that no reliable permanent bonding of the fibers between the two differently treated layers could be achieved. Mineral fiber boards, manufactured finally as a finished product, with different apparent densities in both layers have in practice always had insufficient tear resistance. For example, when laying such boards or even partial strips on a flat, roof, or wall-mounting, the compacted surface layers have separated from the underlying non-compacted mineral fiber web, and have been partially undulated because the compacted material has tried, albeit slightly, stretch again. In principle, nothing would have changed if the idea were to introduce between the two subbands of different apparent densities, a layer of adhesive without taking into account that this would result in a considerable additional cost and curing in the hardening the furnace would lead to considerable difficulties.

The simplest and closest solution for forming a compacted surface area or surface layer would be not to cut the mineral fiber web into sub-webs, but to apply pressure directly to the surface. However, in the case of a mineral fiber web in which the binder is not yet cured, the surface area or surface layer cannot be compacted because the material escapes the compressive stress due to considerable deformation and in all cases the fiber is crushed in the direct vicinity of the surface.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method for producing mineral fiber products with compacted surface areas or surface layers, by means of which high tear resistance and intensive fiber bonding can be achieved.

According to the invention, this object is achieved by at least the surface area being subjected to the impact of the needles up to a predetermined depth of penetration, so that the surface area becomes dense and at the same time thickened.

In this way, a substantial advantage is achieved in that the surface area or the surface layer can be compacted to a certain depth in a simple and targeted manner without affecting the remaining part of the mineral fiber web, but at the same time obtaining both high tear resistance and high tear resistance. high flexural strength. The finished product is most often boards, which after passing the processed strip.z. The mineral fibers are cut to a predetermined length by a quenching furnace.

The stroke frequency of the needles in relation to the normal conveying speed of the mineral fiber web is an important factor both for the degree of compaction and for felting. Thus, a change in the strength properties of the end product can be achieved by making the stroke frequency of the impacting needles variable and adjustable. At a high stroke frequency, the advantage is that the mineral fiber layer not affected by the needles cannot deform or even compact at all due to the inertia of the mass.

It goes without saying that even the density of the needles, i.e. their distance to each other and / or standing needles, has an important effect on the end product, but the number of needles to be chosen and their distance to each other must be determined However, a change in the strength properties of the finished product can be achieved simply by making the stroke and depth of penetration of the needles variable and adjustable.

One further preferred embodiment is achieved by continuously moving the terminated mineral fiber web, subjecting it to a first mechanical pre-compaction, then compacting in a predetermined surface area by needle impacts and felting, and in a second compaction the binder is cured,

When a finished board product is to be obtained, it is preferable that the impacts of the needles for compaction and felting are evenly distributed over the entire surface area.

In practice, there are numerous: examples of the use of a mineral fiber board product in which both sides or both large surfaces are to be compacted, or possibly contain hard layers, for example for free-standing building partitions or for thermal and acoustic insulation of external walls, In this latter case, one side of the panel should be attached to the wall of the building and a plaster should be applied to the outside. In order to achieve such products, it is advantageous if the impact treatment of the needles is carried out on both parallel surfaces of the mineral fiber web running parallel to one another.

The production of the board material can be increased at the conveying contact speed by cutting the mineral fiber web after curing of the binder parallel to the large surfaces, so that two mineral fiber boards with a one-side compacted layer are formed.

There is a great need for mineral fiber products which have to be fixed on bent surfaces, for example around pipes. It is then recommended to perform the method such that the impact of the needles takes place in the longitudinal and / or transverse direction of the mineral fibers, so that the finished plates are flexible or can be bent in the shape of polygons. In this way, a product is obtained which, in addition to the flexibility and the bendability, also exhibits a high resistance to pressure on the sections.

The felting between the densified surface layer and the non-densified mineral fiber layer can be favorably affected by this, and the tear resistance can be increased by processing with different kinds or different needle shapes. In this connection, it is advantageous to make the surface area felted and compacted by means of short needles, and with longer needles a portion of the fibers from the outer compacted surface area is punched into the inner non-compacted region of the mineral fiber web.

Without requiring a time-consuming reconstruction of the manufacturing machine, numerous variants of the end product can be achieved by determining the thickness of the layer compaction in the surface area by selecting the penetration depth of the needles, the stroke frequency and the shape of the needles. strokes and large cross-section needles provided thin, highly compacted layers and, on the other hand, large penetration depths, low stroke frequencies and low cross-section needles provided thick, less compacted layers.

When a board-shaped end product is desired to have a surface coating which is as hard and pressure-resistant as possible, this can be achieved simply by introducing additional adhesives by means of hollow needles to further strengthen the surface area. These adhesives may, to some extent, act as small punches after curing. However, these can also be introduced through the nozzle so that they penetrate into the region between adjacent fibers and thereby create an even greater cohesion within the densified surface layer. However, the additives can also reach the non-compacted mineral fiber layer so that numerous additional anchors are formed in addition to the felt in the region between the compacted and non-compacted layers. For these products, as well as for all other products manufactured according to the invention, the advantage that steam can diffuse well through them is retained.

For a sheet material to be provided with a plaster, paint or other coating, it is advantageous if the thin web of fibrous material, preferably glass fibers, is laid on the surface of the mineral fiber web and then the needle impact process is performed, the web is placed in a mineral fiber web.

In an alternative method, the fabric is laid on the surface of the mineral fiber web and then the needle impact process is performed so that part of the tissue is deposited in the mineral fiber web. The nonwoven web or fabric may also be composed of a fibrous material other than mineral fibers, such as plastic fibers or metal fibers.

Overview of the figures in the drawing

In the drawing, exemplary embodiments of the device according to the invention are shown as a diagram, and these figures show:

Fig. 1 shows the principle of the conveying path of a mineral fiber web with conveying devices and a compaction and felting device;

Fig. 2 shows an example of a needle implementation,

Fig. 3 illustrates another embodiment of a needle

Fig. 4 shows an enlarged side view of a cut-out on both sides of a felted mineral fiber web.

Fig. 5 shows the principle of the representation according to FIG. 1 but with double-sided compaction and felting devices.

DETAILED DESCRIPTION OF THE INVENTION

In the embodiment shown in FIG. 1, the mineral fiber web X is fed in the direction of the arrow 22 between endless conveyor belts X and X with a certain thickness. The mineral fiber web β comes from a collection chamber (not shown), which is known per se, in which the mineral fibers produced, after the addition of a binder, settle on an air permeable conveyor belt and form a layer therefrom. The mineral fiber web χ is then initially maintained in a relatively loose state between the two conveyor belts 2 and X which are guided around the deflection rollers 4 and 5. This is followed by some, somewhat exaggerated, pre-compacting of the mineral fiber web between the pressure rollers 6, 2 to β and? Or between suitably arranged and guided conveyor belts. Since the binder inside the mineral fiber web X is not yet cured and the mineral fibers are essentially parallel to the large surfaces of the web 1 as a result of the previous manufacturing process, the mineral web 1 can be very homogeneously mechanically pre-compacted in this first conveying section. until a pre-compacted mineral fiber web 10 of a predetermined thickness is formed.

The pre-compacted mineral fiber web 10 then enters a densifying and felting device, which is shown in simplified form in FIG. It has a large number of needles 13 which are connected in groups or connected to a lifting device which performs high frequency stroke movements in the direction of the arrow 15. Such a lifting device is arranged on at least one side of the surface, either on the upper or on the lower side of the mineral fiber belt 10, 17 and is provided with a stroke drive (not shown). In this embodiment, the needles 13 are attached to the plate carrier 11. This plate carrier 11 is coupled to the lifting device and to the drive, such that the needles 13 penetrate to a predetermined penetration depth at the bar area of the mineral strip 10, 17. The fibers are compacted in a preselected surface area and felted at the same time.

The lift of the lifting device is preferably adjustable and adjustable to a certain height, and the frequency of the strokes can be controlled by the drive. It is further preferred that the impact forces of the needles 13 are adjustable. By limiting the impact forces, the compaction needle 13 can be prevented from being deformed when undesirable wool spikes occur within the mineral fiber web 10, 17 so that the risk of breakage of the needles 13 is thereby reduced. In practice, these explained adjustments and adjustments can be easily accomplished in that the lifting device can be operated pneumatically or hydraulically.

The needles 13, in particular the compacting needle for compacting, have a chisel head 27 or 10, which according to FIG. 2 and 3 formed at the end of the shank 26 and 29 of the needle 13, respectively. «The head 27 of the needle 13 has a blade 28 at the lower end which forces the threads to assume the shape of a loop. In the embodiment of the needles 13 of FIG. 3, a downwardly projecting tip 31 of the needle 13 is disposed on the hub 30 of the needle 13. Instead, several needle tips 31 may also be provided. Preferably, the needle tips 13 have small side hooks 32 and 33 which result in further deformation and felting the fiber region, in particular in the boundary region between the compacted region and the non-compacted region of the mineral fiber web. For the same purpose of felting and bonding between the two layers mentioned above, there are other constructional arrangements in which at least two different groups of needles are arranged, namely a group of short front needles and a group of longer rear needles. In order to obtain the effect of good entanglement, the needles U and / or the slide have a larger diameter and, as shown in FIG. 2 with 3, shapes other than those known in the multi-needle sewing machines in the textile industry The arrangement of the compacting needles should be sufficient to arrange the non-oriented punctures so that the outer surface areas or surface layers are as uniform as possible and consistent with the set stroke frequency. by division predzhutovali. It is important that the impact stresses of the U needles are concentrated on an area that is in comparison with the surface of the entire mineral fiber web, that the impact forces compact the outer areas of interest and that, as a result of the force distribution layers with little strain. Suitable choices of compaction needles, for example with short front needles, are the fibers of the outer pre-compacted layers being pressed into the non-compacted layers of the underlying fibers, so that further connections are formed which affect the other _: favorable bending behavior and tear off of finished products. The compaction needles themselves are preferably composed of a light abrasion resistant material. In contrast, the aim is to reduce the moving mass of the needles and the moving parts as much as possible so that the highest possible frequencies of the strokes are possible. This is particularly important at high uniform speeds in the production of mineral fiber strips.

The compaction and felting may optionally be performed on the top or bottom side of the mineral fiber web or, if shown in FIG. 5 and in particular FIG. 4 on an enlarged scale, on both sides. Two-sided P ^ compacted ^with 27 mineral fiber is then compacted and felted two surface areas 34 and 35 and between lying and uncompressed nesplstenú middle layer 17 possibly being 37 but guaranteed a good bond between the layers. If, in accordance with the practical use of the final board product, only one unilaterally compacted and felt layer is required, the cutting device (not shown) for cutting the double-felt and compacted mineral fiber web 17 or 21 in accordance with the separating cut 36 (FIG. 4) can be arranged. in two subbands.

As further shown in FIG. 1 and 5, a densified mineral fiber web 17 exiting the piercing or felting device is fed via conveyor rollers 18, X9 or suitable endless conveyor belts into a quenching furnace 20 in which the mineral fiber web 21 may be between, for example, endless conveyor belts (not shown). bands even more compacted to smooth the surfaces. The hardening binder 20 is then finally cured in the hardening furnace 20. The mineral fiber web 17 extends in the direction of the arrow 23 from the quenching furnace 20 and can be divided into suitable pieces of sheets and processed into the final product, or the described cutting section 36 of FIG. 4 due to the division into parts of boards.

Fig. 1 and 5 show an even further construction of the device according to the invention, that is, on one side (FIG. 1) or on both sides (FIG. 5), between the plate carriers 11 and 12 needles 1,3 on one side and the mineral fiber web 10, 17 on the other hand, a further plate 24 and 25 is now provided in which the needles 13a are guided. These plates 24 and 2p can also be connected to the trimming device. They may induce some surface compaction, but in particular these plates 24 and 25 may serve to re-push eventually hardened fibers back into the surface.

Both sides of FIG. 5, the arranged lifting devices are preferably driven in the direction of the arrow 15 and 16 with the same stroke frequency and back pressure, i.e. when the upper lifting device moves downwards, the lower lifting device moves simultaneously upwards and vice versa at the return pressure. Since the device of FIG. 5 is substantially symmetrical or mirror-image with respect to the median plane, the same reference numerals have been used for the same or equally acting parts.

Further embodiments of the invention are achieved in that the needles are in the form of hollow needles and are connected to an additive supplying device, preferably a liquid additive. In particular, at higher conveying speeds of the mineral fiber web, it is preferable that the needles are now mounted movably, preferably pivotably, on the lifting device in order to adapt to the conveying speeds of the mineral fiber web during the stroke. In this way, the needles are spared, friction and the resulting heating are avoided, and the risk of breakage is virtually eliminated. These movements of the needles during needling into the mineral fiber web, in its direction of transport, and the backward movements of the needles after exiting the mineral fiber web to their original position can be produced by simple mechanical drive devices, for example by eccentrics.

As far as the material is concerned, mineral fibers have always been mentioned in general, and mineral fiber materials in general. Here, however, it is particularly important to point out that both the device and the method are particularly suitable for the manufacture of mineral wool products. Furthermore, not only strips of material where the fibers run parallel to the large surfaces are processed, but also lamellar strips or lamellar plates in which the fibers extend perpendicularly under another needle to the large surfaces.

Claims (27)

A method for producing mineral fiber products with ± surface areas of mineral fiber webs, wherein the fibers extend within the mineral fiber web substantially parallel or perpendicular or oblique to the large surfaces of the mineral fiber web and wherein the mineral fiber web comprises an uncured binder characterized in that at least one surface area is exposed to the needles up to a predetermined penetration depth such that the fibers are felted and at the same time the surface area is compacted. Method according to claim 1, characterized in that the frequency of the impact strokes is variable and adjustable. Method according to claim 1 or 2, characterized in that the stroke and depth of penetration of the needles are variable and adjustable. Method according to one of the preceding claims, characterized in that the continuous mineral fiber web is continuously moved, subjected to mechanical pre-compaction, then compacted and felt by the impact of the needles in a predetermined surface area, and cured by a heat treatment. Method according to one of the preceding claims, characterized in that the needle impacts are distributed evenly over the entire surface area for compaction and felting. Method according to one of the preceding claims, characterized in that the needle impact treatment is carried out on the two surfaces of the mineral fiber strip running parallel to one another. Method according to claim 6, characterized in that after the binder has cured the mineral fiber web is cut in a plane of cut parallel to the large surfaces, so that two mineral fiber boards with a single-side compacted layer are formed. Method according to one of Claims 1 to 4, characterized in that the needle impacts are carried out in rows in longitudinal and / or transverse section to the mineral fiber web, so that the finished board products are bendable or mono-angular metal-bendable. Method according to one of the preceding claims, characterized in that the processing is carried out with different types of needles or needle shapes. Method according to claim 9, characterized in that compacting and felting of the surface area is carried out by means of short front needles and by means of longer rear needles a part of the fibers from the outer compacted surface area is pressed into the inner non-compacted region of the mineral fiber web. Method according to one of the preceding claims, characterized in that the thickness of the compacted layer in the surface area is selected by selecting the penetration depth of needles, stroke frequencies and needle shape such that both small penetration depths, high stroke frequencies and needles with large effective cross-section high densified layers and high penetration depths, low stroke frequency 15 and needles with a small cross-section provide less compacted layers. Method according to one of the preceding claims, characterized in that other additives add hollow needles to further strengthen the surface area. Method according to one of the preceding claims, characterized in that a thin web of fibrous material, preferably glass fibers, is laid on the surface of the mineral fiber web and then a needle impacting process is carried out by placing a portion of the web fibers in the web. mineral fiber. Method according to one of Claims 1 to 12, characterized in that a fabric is laid on the surface of the mineral fiber web and then a needle bumping process is carried out so that part of the fabric is deposited in the mineral fiber web. Device for carrying out the method according to one of the preceding claims, characterized in that a plurality of needles (13, 14) are connected in groups or together with a lifting device (15, 16) which is arranged at least on the side of the belt surface (10). And 17) mineral fiber-reinforced and propelled, so that the needles penetrate at a predetermined depth of penetration into the mineral fiber web (10, 117) and felts and at the same time compact these in the surface area. Device according to claim 15, characterized in that the stroke of the lifting device (15, 16) is adjustable and adjustable and the stroke frequency is adjustable by the drive. 17th Device according to claim 15 or 16, characterized in that the cutting forces of the needles (13, 14) are controllable. Device according to one of Claims 15 to 17, characterized in that the needles (13, 14), in particular the compacting needles, for compacting, have a chisel head (27, 30). Device according to claim 18, characterized in that at least one protruding needle tip (31) is arranged on the chisel-shaped head (27, 30). Device according to one of Claims 15 to 19, characterized in that the needles (13, 14, 26, 29) are designed as hollow needles and are connected to an additive supplying device, preferably a liquid additive. Device according to one of Claims 15 to 20, characterized in that the needles are mounted on a plate carrier (11, 12) which is connected to the lifting device and the drive. Apparatus according to claim 21, characterized in that between the plate carriers (11, 12) and the mineral fiber web (10, 17) there is another plate (24, 25) in which the needles (13, 14) are guided. ) and which is also associated with a lifting device. Device according to one of Claims 15 to 22, characterized in that at least two different groups of needles, a group of short front needles and a group of longer rear needles are arranged. Apparatus according to one of Claims 15 to 23, characterized in that it has conveyor rollers (6, 16, 17). 7, 8, 9) or conveyor belts (2, 3) on both sides of a continuously moving continuous strand (1, 10, 17) of mineral fibers for pre-compacting, single or double-sided lifting devices with a large number of needles (13, 14) for the layered felting and compacting of the surface area (34, 35) of the surface of the mineral fiber web (17), and other conveyor rollers (18, 19) or conveyor belts for feeding to the quenching furnace (20). Apparatus according to one of claims 15 to 24, characterized in that it has a cutting device for cutting the double-felt and compacted mineral fiber web (21) into two partial webs. Apparatus according to one of Claims 15 to 25, characterized in that the needles (13, 14) are mounted in the conveying direction (22, 23) in order to adapt to the conveying speed of the mineral fiber web (10, 17). movable, preferably pivotable, on a lifting device. Device according to one of Claims 15 to 26, characterized in that the lifting device can be operated pneumatically or hydraulically.