SK280293B6 - Process and apparatus for manufacturing mineral fiber products - Google Patents

Abstract

When manufacturing mineral fiber products with compressed surface areas, or compressed surface layers, it is 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. An apparatus contains a great amount of needles (13, 14) which are put in series or are coupled to a lifting device (15, 16). The lifting device (15, 16) is arranged upon an upper or lower side of mineral fibre web (10, 17) surface. Said apparatus is further provided with a drive so the needles penetrate into the web (10, 17) in a cycle, till said predetermined penetration depth is achieved.

Description

SK 280293-6

Technical field

The invention relates to a process for the manufacture of mineral fiber products having 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 binder.

BACKGROUND OF THE INVENTION

A method of this type and 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 section is cut by means of a cut running horizontally parallel to the large surfaces of the mineral fiber web. . This sub-section is then separated from the remaining mineral fiber web and compressed between the press rolls 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 further developed, although a relatively thin sub-web has been cut, compressed and then finally applied by a pendulum device in the folds again onto the remaining mineral fiber web. In all cases, however, it turned out that no reliable permanent fiber bond could be achieved between the two differently treated layers. Mineral fiber boards, manufactured finally as an end product, with different apparent densities in both layers, have in practice always had insufficient tear resistance. For example, when laying such boards or sub-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 as the compacted material has tried, albeit little, again to expand . In principle, there would be no change in principle if it were an idea to insert a layer of glue between the two subbands of different apparent densities without taking into account the higher costs and curing in the quenching furnace. difficulties.

The simplest and closest solution to the formation of 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 has not yet been cured, the surface area or surface layer cannot be compacted, since the material escapes the compressive stress by considerable deformation and in all cases the fibers are crushed in the direct vicinity of the surface.

SUMMARY OF THE INVENTION

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.

The object according to the invention 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 is felted and simultaneously thickened.

In this way, a substantial advantage is achieved in that the surface area or 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 a high resistance to tear-off as well as high flexural strength. The end products are most often plates which are cut to a predetermined length after passing the treated mineral fiber web through the 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.

Obviously, the density of the needles, i.e. their spacing and / or standing needles, also has an important effect on the end product, but the number of needles to be selected and their spacing must be determined by a single test for larger product groups. . However, a change in the strength properties of the end product can be achieved simply by making the stroke and depth of needle penetration variable and adjustable.

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

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

In practice, there are many examples of the use of a mineral fiber board product in which both sides or both large surfaces are to be compacted, or they may also contain hard layers, for example for free-standing building partitions or for thermal and acoustic insulation of external walls. in the latter case, one side of the board is to be fixed 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 the two parallel running surfaces of the mineral fiber web.

The production of the board material can be increased at the contact conveying speed by cutting the mineral fiber web after curing 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 mounted on bent surfaces, for example around pipes. It is then recommended to carry out the method in such a way that the impact of the needles takes place in the longitudinal and / or transverse direction of the mineral fibers, so that the finished boards

SK 280293 Β6 are flexible or can be bent in the shape of polygons. In this way, a product is obtained which, in addition to being flexible and / or bendable, also has a high pressure resistance on the sections.

The felting between the densified surface layer and the non-densified mineral fiber layer can be favorably influenced by this, and the tear resistance can also be increased by processing with different kinds or different shapes of needles. In this context, it is advantageous if the surface area is felted and compacted by means of short needles, and by 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 the time-consuming reconstruction of the machine, numerous variants of the finished product can be achieved by determining the thickness of the compacted layer in the surface area by selecting needles formation, stroke frequency and needle shape such that both low penetration depths, high stroke frequencies and high effective cross-section needles provided thin, highly compacted layers and, on the other hand, large penetration depths, low stroke frequency, and low cross-section needles provided thick, less compacted layers.

When a board-like end product is desired to be as hard and pressure-resistant as possible, this can be achieved simply by introducing additional adhesives with hollow needles to further strengthen the surface area. Once cured, these adhesives may act to some extent as small punches. 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 preferable that a thin web of fibrous material, preferably glass fibers, is laid on the surface of the mineral fiber web and then a needle impact march is performed so that a portion of the webs of fibers 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 fabric is deposited in the mineral fiber web. The thin web or fabric may also be composed of other fibrous material 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, in which FIG. 1 shows the principle of the conveying path of a mineral fiber web with conveying devices and a compacting and felting device; FIG. 2 shows an example of an embodiment of a needle, FIG. 3 shows another embodiment of the needle, and FIG.

shows a side view of the cut-out of a double-sided compacted mineral fiber web in an enlarged view, and FIG.

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 1 is fed in the direction of the arrow 22 between the endless conveyor belts 2 and 3 with a certain thickness. The mineral fiber web 1 comes from a well-known, not shown, collection chamber in which the mineral fibers produced, after the addition of a binder, settle on the air permeable conveyor belt and form a layer thereon. The mineral fiber web 1 is then initially maintained in a relatively loose state between the two webs 2 and 3, which are guided around the deflection rollers 4 and 5. This is followed by a somewhat exaggerated depiction of the pre-compacting of the mineral fiber web between the pressure rollers 6, 7 8 and 9 or between suitably arranged and guided conveyor belts. Since the binder inside the mineral fiber web 1 is not yet cured and the mineral fibers, as a result of the previous manufacturing process, run substantially parallel to the large surfaces of the web 1, the mineral web 1 can be mechanically pre-compacted in this first conveying section until a pre-compacted mineral fiber web 10 with a predetermined thickness is formed.

The pre-compacted mineral fiber web 10 then enters a compaction and entanglement 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 lower side of the mineral fiber web 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 in the bar area of the mineral fiber web 10, 17 and this is compacted in a pre-selected area of the surface and at the same time felted.

The lift of the lifting device is preferably adjustable and adjustable to a certain height, and the stroke frequency 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 occurring when the undesirable wool residue occurs within the mineral fiber web 10, 17, so that the risk of breakage of the needles 13 is thereby reduced. In practice, these explained melts and adjustments can be easily accomplished in that the lifting device can be operated pneumatically or hydraulically.

The needles 13, in particular the compaction needles used for the compaction, have a chisel head 27 or 30, 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, when encountered with the fibers, compels them to assume a loop shape. 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, a plurality of needle tips 13 may also be provided. Preferably the needle tips 13 have small side hooks 32 and 33 which result in further deformation and felting of the mineral fibers. 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, other constructional embodiments serve to arrange at least two different groups of needles, namely a group of short

2806 needles and a group of longer rear needles. In order to achieve the effect of good felting, the needles 13 or slides have a larger diameter and as shown in FIG. 2 and 3, other shapes such as those known in 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 areas of the surface and / or the surface layers are pre-compacted evenly and with uniform distribution according to the set stroke frequency. It is important that the impact stress of the needles 13 is 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 the following layers are underneath little stressed. By a suitable choice of compacting needles, for example with short front needles, the fibers of the outer pre-compacted layers are pressed into the non-compacted layers of the underlying fibers, so that further connections are formed which further favor the bending behavior and tear-off of the finished products. The compaction needles themselves are preferably composed of a lightweight abrasion-resistant material. Then the aim is to reduce the moving mass of the needles and the moving parts as much as possible so that the stroke frequencies are as high as 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 upper or lower side of the mineral fiber web or, if shown in FIG. 5 and in particular FIG. 4 on an enlarged scale, on both sides. The mutually compacted mineral fiber web 17 then has two compacted and felted surface regions 34 and 35 and a non-compacted and non-compacted intermediate layer 17 or 37 lying therebetween, but a good bond between the layers is guaranteed. If only one unilaterally compacted and felt layer is required in accordance with the practical use of the finished board product, the cutting devices for cutting the double-felt and compacted mineral fiber web 17 or 21 in accordance with the separating section 36 (Fig. 4) may not be shown. Arrange in two subbands.

As further shown in FIG. 1 and 5, a compacted mineral fiber web 17 emerging from the piercing or felting device via conveyor rollers 18, 19, or suitable endless conveyor belts, is fed to a quenching furnace 20, in which the mineral fiber web 21 may be between, for example, not shown Conveyor belts are even slightly 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 cut-off 36 of FIG. 4 due to division into board parts.

Fig. 1 and 5 show yet another 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 of needles 13 on one side and the mineral fiber web 10, 17 on the other a further plate 24 and 25 is now provided in which the needles 13, 14 are guided. These plates 24 and 25 can also be connected to the lifting 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 counter-pressure, i.e. when the upper lifting device moves down, the early lower lifting device moves up and vice versa at the return pressure. Since the device of FIG. 5, the same reference numerals have been used for the same or equally acting parts with respect to the median plane in a substantially symmetrical or mirror-like manner.

Further embodiments of the invention are achieved by the needles being hollow and connected to an additive supplying device, preferably a liquid additive. Especially at higher conveying speeds of the mineral fiber web, it is preferable that the needles are now mounted movably, preferably pivotable, on the lifting device in order to adapt to the conveying speed of the mineral fiber web during stroke. In this way, the needles are saved, the 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 or mineral fiber materials have always been mentioned in general. However, it should first of all be pointed out that both the apparatus 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 large surfaces are processed, but also lamellar strips or lamellar plates in which the fibers run perpendicularly at different angles to the large surfaces are processed.

Claims (27)

PATENT CLAIMS 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 or perpendicular to, or inclined 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 any 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 impact of the needles in a predetermined surface area, and in the second compaction the binder cures. Method according to one of the preceding claims, characterized in that the impact of the needles is 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. SK 280293-6 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 one-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 flexible or polygonally 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 the area of the surface is compacted and felted with short front needles and part of the fibers from the outer compacted surface area are pressed into the inner non-compacted region of the mineral fiber web by means of longer rear needles. Method according to one of the preceding claims, characterized in that the thickness of the densified layer in the surface area is achieved by selecting the penetration depth of the needles, the stroke frequencies and the shape of the needles such that low penetration depths, high stroke frequencies and needles with high effective cross section thin, highly compacted layers as well as large penetration depths, low stroke frequencies and small cross-section needles provide less compacted layers. Method according to one of the preceding claims, characterized in that further additives are introduced by 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 so that a portion of the fibers of the web is deposited in the mineral web. fibers. Method according to one of Claims 1 to 12, characterized in that a fabric is placed on the surface of the mineral fiber web and then a needle bumping process is performed 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 large number of needles (13, 14) are connected in groups or connected to a lifting device (15, 16) which is arranged at least on the side of the belt surface. (10, 17) of mineral fibers and equipped with a drive for penetrating the needles in tact up to a predetermined depth into the mineral fiber web (10, 17), for felting and at the same time compacting 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. Device according to claim 15 or 16, characterized in that the impact 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 the 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. Device according to one of Claims 15 to 23, characterized in that it has conveyor rollers (6, 7, 8, 9) or conveyor belts (2, 3) on both sides of a continuously moving continuous belt (1, 10, 17). ) of mineral fibers for pre-compacting, one-sided or double-sided lifting devices with a large number of needles (13, 14) for layered sp. Fusing and compacting the surface area (34, 35) of the mineral fiber web (17) and other conveyor rollers ) 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-sided and compacted mineral fiber web (21) into two partial webs. Device according to one of Claims 15 to 25, characterized in that the needles (13, 14) are movably mounted in the conveying direction (22, 23) to adapt to the conveying speed of the mineral fiber web (10, 17). , preferably pivotable on the lifting device. Device according to one of Claims 15 to 26, characterized in that the lifting device can be operated pneumatically or hydraulically.