Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4209—Inorganic fibres
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/593—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives to layered webs
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H13/00—Other non-woven fabrics
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
  • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
  • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
  • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
  • E04C2/296—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and non-metallic or unspecified sheet-material

Definitions

• the present invention relates to a process for the preparation of an insulating board having at least one high density layer, wherein a primary web of mineral fibre material is provided, where the primary web is compressed m at least one longitudinally extending zone in which the primary web is made to overlap itself under formation of a secondary web, and where the secondary web is cured and optionally compressed.
• Boards of mineral fibre material for insulation purposes can be prepared with various properties depending on the desired field of application.
• the mineral fibre material will often comprise an amount of binding agent, e.g. in the form of phenol formaldehyde urea which is cured when the secondary web passes through a curing owen.
• the inner wall is erected first, whereafter it is clad with a layer of insulating material before the outer wall is erected.
• the insulating material will typically be secured to the inner wall by means of wall ties which are anchored in the wall and extend throughout and beyond the insulating material.
• the wall ties retain the insulating material secured to the wall by means of retaining clips in the form of plate shaped end pieces which urge against the outer layer of the insulating material.
• retaining clips in the form of plate shaped end pieces which urge against the outer layer of the insulating material.
• the outer wall with the insulating material mounted thereon may risk being exposed to weathering conditions for a prolonged period until the outer wall is erected. Consequently, it is desirable to be able to prepare an insulating board which also has a suitably weather-resistant surface, i.e. a hard or high density layer.
• the insulating board may be prepared on a dual-density apparatus, e.g. as described in US 4 950 355, and according to the utility model the insulating board may contain 0.5-15 weight-% binding agent, and preferably 0.5- 5 weight-%.
• an object of the present invention to provide a process of the kind stated in the preamble of claim 1, wherein an insulating board comprising at least one hard, easy-to-handle and weather-resistant layer, and at least one soft and conformable layer, may easily be prepared and without the use of excessive pre-compression.
• a compression aid is supplied to the longitudinally extending pre- compression zone.
• the invention is based on the recognition that by supplying a compression aid to the zones of the primary web to be pre-compressed, it is possible to essentially maintain the pre-compression until the product is cured, thus resulting in the pre-compressed zones forming layers having a significantly higher density relative to the degree of pre-compression, than corresponding layers not having been subjected to the application of such compression aid.
• the high density layers may be produced thinner using less mineral fibres and thus enabling that the average density of the insulating board may be lowered. Accordingly both costs of production and transport may be reduced.
• the compression aid is preferably substantially in the form of a liquid, which is added to the pre-compression zones of the primary web before, during and/or shortly after the pre-compression force is applied.
• the amount of such liquid necessary to obtain the desired effect depends on the nature of the liquid in question.
• the practical lower limit is determined by the minimum amount where an actual effect can be noticed, and the upper limit is more or less determined by whether and/or to which extent compression aid is to be removed at a later stage.
• Applicable substantially liquid compression aids comprises most organic and inorganic based liquids, comprising e.g. oils (organic as well as preferably silicon-based oil) , water, surfactants, suspension or solutions comprising dye or one or more coloring agents, suspensions of binding agents (e.g. phenol formaldehyde resin or mela me resin), colloidal suspensions and/or the like, or any mixture thereof.
• oils organic as well as preferably silicon-based oil
• surfactants e.g. phenol formaldehyde resin or mela me resin
• suspensions of binding agents e.g. phenol formaldehyde resin or mela me resin
• colloidal suspensions e.g. phenol formaldehyde resin or mela me resin
• Water in terms of pre-compression aid, is preferably added in an amount of about 0,2-2 we ⁇ ght-%, or added m an amount so that the total amount of water m the pre- compression zones is about 0,8-3 we ⁇ ght-%.
• an oil is used as compression aid.
• Applicable oils comprise any oil capable of keeping the fibers together, i.e. maintaining the pre-compression effect.
• the used oil is preferably silicon-based.
• the oil is preferably added to the pre-compression zone of the primary web in a total amount of about 0,2-2 weight- percent.
• the entire primary web may for other reasons comprise an amount of oil in which case, the oil is added to the pre-compression zone is preferably added in an amount corresponding to about 0,4-1 weight-percent- points more than the average amount of oil in the zones of the primary web not to be pre-compressed.
• the excess part of the applied liquid compression aid may be removed from the product or transformed immediately before, during and/or at any time after the curing of the product.
• the compression aid may be e.g. evaporated, combusted, hardened or cured.
• substantially non-liquid compression aids may be applied.
• Such substantially non-liquid compression aids may comprise adhesives, derivatives of cellulose or acrylates, water-soluble polymers, thermoplastic polymers, surfactants, colloidal substances, diatomite, gels (e.g. silicagel or water glass) , dye or coloring agents, or mixtures thereof.
• the here-mentioned substances may also be applied in combination with one or more substantially liquid substances, e.g. in the form of one of the above mentioned substantially liquid substances.
• the amount of binding agent in weight-% of the cured end-product can be the same in all layers requiring an amount of binding agent.
• the binding agent in an essentially uniform amount across the entire primary web or to those of the primary web zones requiring binding agent.
• This latter embodiment gives the advantage of only having to handle one type of composition, which is supplied in different amounts and/or concentrations to the different zones of the primary web.
• a further advantage of this particular embodiment of the process according to the invention is that an increased level of binding agent in the pre-compression zones eventually will result in the high density layers being even harder and more weather- resistant.
• compositions applicable as both binding agent and compression aid comprise any composition comprising a curable binding agent in a liquid suspension, any curable binding agent being a liquid at the supply-temperature and any substantially non-liquid composition having an adhesive effect at the supply-temperature and being curable.
• a double-functioning composition is an aqueous suspension of phenol- formaldehyde-urea .
• the applied binding agent may be supplied before, under or after appliance of the compression a d and/or the compression force.
• 1-3 weight-o binding agent are added to the zones of the primary web which are to constitute the low density layers of the insulating board, and 1.3-5 weight-" binding agent to the zones of the primary web which are to constitute the high density layers of the insulating board, i.e. the pre-compression zones. All binding agent weight-percentages is relative to the cured end-product.
• an average amount of binding agent of 2-3 we ⁇ ght-% is added to the primary web.
• the process according to the invention to prepare the above insulating boards by first preparing a mineral fibre web having an easy-to- handle and weather-resistant layer on both sides, whereafter the web is divided symmetrically or asymmetrically in the vertical direction so as to obtain two webs having one easy-to-handle and weather-resistant side and one soft and conformable side, respectively.
• Fibre webs may also be prepared where the primary web is compressed at another site or several other sites than along the edges, and the web may be divided into one or more planes parallel to the upper and lower surface in a suitable way so as to obtain insulating boards having the desired combinations of layers with different properties.
• the pre-compression of the primary web may be performed using any known means of compression, e.g. rollers, continuous bands and the like.
• the surface of the pre- compression means may be smooth or curved or having a pattern.
• the applied pressure may be constant or varied over time and/or the pre-compression zone.
• rollers are used for applying a constant pressure to the entire pre-compression zone.
• the invention also relates to an insulating board obtainable by the process according to the invention.
• the insulating board according to the invention offers the advantage that it can be packed more densely than conventional insulating boards without suffering damage. Hereby transport and handling of the final packaged products are facilitated. Further, the insulating boards might be prepared using a lower amount of binding agent than similar conventional boards.
• the insulating boards according to the invention exhibit an improved tensile strength over conventional insulating boards.
• An insulating board according to the invention having a high density layer positioned at one surface of the board, and a low density layer positioned at the other surface of the board, is particularly suited for cavity wall insulation where the insulating board is secured with the soft and conformable surface of the insulating board to the outer side of the inner wall by means of wall ties, and where the outer wall is erected at a distance from the insulating boards so as to establish a cavity between the insulating material and the inner side of the outer wall.
• a particularly preferred embodiment of the insulating board according to the invention comprises a low density layer positioned at one surface of the board, and a high density layer positioned at the other surface of the board.
• Another particularly preferred embodiment of the insulating board according to the invention is prepared by dividing m the vertical direction a mineral fibre web having several hard and/or low density layers.
• an insulating board having two hard surfaces with a soft core, or two soft surfaces with one hard core.
• Yet another particularly preferred embodiment of the insulating board according to the invention is characterized by having a high density layer on both surfaces.
• Still another preferred embodiment of the insulating board according to the invention has a low density layer on both surfaces. In this way the insulating board is conformable to uneven surfaces on both sides, simultaneously with it still being easy-to-handle due to a firm core in the form of a high density layer.
• insulating board as used herein comprises any board or sheet formed insulating material intended for thermal insulation, sound insulation or sound regulation, fire retardant purposes, or the like.
• mineral fibre as used herein comprises all types of man-made mineral fibres, such as rock, glass or slag fibres, in particular fibres used in materials for the above purposes, and as filler in cement, plastics or other substances, or which are used as culture medium for plants .
• binding agent as used herein comprises any material which is suited as binding agent in mineral fibre materials for the above products, e.g. phenol formaldehyde urea, acrylic-copolymer, resorsinole, furan or melamine resin. Such binding agents are preferably supplied to the mineral fibre material in the form of aqueous suspensions.
• layer denotes areas which essentially exhibit uniform characteristics within the area; but the term comprises both layers which are sharply delimited, and areas in which there is a stepwise or continuous transition to any neighboring layers.
• high density layer denotes a layer which has a density which is higher than the average density of the product, i.e. high density layers are hard layers .
• low density layer denotes a layer which has a density which is lower than the average density of the hard layers, i.e. low density layers are softer layers.
• substantially liquid and substantially non-liquid is meant in combination to denote the hole continuous range of states from liquid state to solid state. Accordingly the expression substantially liquid denotes compositions being primarily liquid, and the expression substantially non-liquid denotes compositions being primarily solid.
• building surface denotes any surface of a building, comprising e.g. inner and outer walls, the inside of cavity walls, roofs and ceilings.
• Mineral fibres are obtained by spinning in a spinning chamber, and are made to deposit on a conveyor belt under formation of a primary web having a width of about 1.8 m, and a surface weight of about 500 g/ ⁇ r.2.
• a binding agent comprising phenol formaldehyde urea in aqueous suspension is continuously distributed to the fibres in the air in the spinning chamber prior to the fibres settling on the conveyor belt, the binding agent being added in an amount corresponding to a final concentration of phenol formaldehyde urea in the primary web of about 2.1 % of the weight of the web.
• a zone along both edges of the primary web having a width of about 30 cm is sprayed with a further amount of pure water corresponding to a final concentration of water of app .
• 1,8 we ⁇ ght-% m the sprayed zones, and the zones are rolled by means of 2 rollers each urging against the web at a pressure of 1600 kg.
• the primary web is laid out by pendulum distribution under formation of a secondary web having a width of about 2 m, the secondary web as seen m cross-section comprising about 12 layers of primary web.
• the secondary web obtained is compressed to a height of 200 mm, and cured in a curing owen, whereafter the secondary web is divided symmetrically in the vertical direction into 2 webs having a height of 100 mm.
• the insulating boards are provided by cutting off in the desired sizes from the divided secondary web.
• Insulating boards prepared by the process according to the example have a high density layer of about 15 mm positioned at one surface, and a low density layer of about 85 mm positioned at the other surface.
• the high density layer has a density of about 60 kg/m 3
• the low density layer has a density of about 26 kg/m 3 , the average density of the insulating board being about 29.9 kg/m 3 .
• Mineral fibres are obtained by spinning in a spinning chamber, and are made to deposit on a conveyor belt under formation of a primary web having a width of about 1.8 m, and a surface weight of about 500 g/m 2 .
• a binding agent comprising phenol formaldehyde urea m aqueous suspension is continuously distributed to the fibres in the air in the spinning chamber prior to the fibres settling on the conveyor belt, the binding agent being added m an amount corresponding to a final concentration of phenol formaldehyde urea in the primary web of about 2 we ⁇ ght-% of the weight of the web.
• a zone along one edge of the primary web having a width of about 30 cm is sprayed with a further amount of an aqueous suspension comprising phenol formaldehyde urea corresponding to a final concentration of binding agent of app. 3 we ⁇ ght-% in the sprayed zone, and the zone is rolled by means of 2 rollers each urging against the web at a pressure of 1600 kg.
• the primary web is laid out by pendulum distribution under formation of a secondary web having a width of about 2 m, the secondary web as seen in cross-section comprising about 12 layers of primary web.
• the secondary web obtained is compressed to a height of 200 mm, and cured m a curing owen.
• the insulating boards are provided by cutting off in the desired sizes from the divided secondary web.
• insulating boards prepared by the process according to the invention exhibit better properties than conventional insulating boards.

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Architecture (AREA)
• Inorganic Chemistry (AREA)
• Structural Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Civil Engineering (AREA)
• Laminated Bodies (AREA)
• Nonwoven Fabrics (AREA)
• Building Environments (AREA)
• Dry Formation Of Fiberboard And The Like (AREA)
• Thermal Insulation (AREA)
• Application Of Or Painting With Fluid Materials (AREA)
• Chemical Or Physical Treatment Of Fibers (AREA)
• Insulating Bodies (AREA)

Priority Applications (7)

Applications Claiming Priority (2)

Publications (1)

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ID=8100206

Family Applications (1)

Country Status (10)

Cited By (2)

Families Citing this family (3)

Citations (4)

Family Cites Families (3)

• 1996
  • 1996-10-09 GB GB9621079A patent/GB2317403B/en not_active Expired - Lifetime
• 1997
  • 1997-09-22 AT AT97918926T patent/ATE191528T1/de not_active IP Right Cessation
  • 1997-09-22 CZ CZ99942A patent/CZ94299A3/cs unknown
  • 1997-09-22 AU AU42956/97A patent/AU4295697A/en not_active Abandoned
  • 1997-09-22 DE DE69701638T patent/DE69701638T2/de not_active Expired - Fee Related
  • 1997-09-22 ES ES97918926T patent/ES2144855T3/es not_active Expired - Lifetime
  • 1997-09-22 EP EP97918926A patent/EP0927287B1/en not_active Expired - Lifetime
  • 1997-09-22 PL PL97332457A patent/PL332457A1/xx unknown
  • 1997-09-22 HU HU9904721A patent/HU221918B1/hu not_active IP Right Cessation
  • 1997-09-22 WO PCT/DK1997/000400 patent/WO1998012395A1/en not_active Application Discontinuation

Patent Citations (4)

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