Note: Descriptions are shown in the official language in which they were submitted.
~ WO 94/16164 215 :~ 6 7 0 PCT/DK94/00029
A METHOD OF PRODUCING A MINERAL FIBER-INSULATING WEB, A PLANT FOR
PRODUCING A MINERAL FIBER WEB, AND A MINERAL FIBER-INSULATED PLATE.
The present invention generally relates to the technical field of
producing mineral fiber-insulating plates. Mineral fibers generally
comprise fibers such as rockwool fibers, glass fibers, etc. More pre-
cisely, the present invention relates to a novel technique of producing
a mineral fiber-insulating web from which mineral fiber-insulating
plates are cut. The mineral fiber-insulating plates produced from the
mineral fiber-insulating web produced in accordance with the present in-
vention exhibit advantageous characteristics as to mechanical perfor-
mance, such as modulus of elasticity and strength, low weight and good
thermal-insulating property.
Mineral fiber-insulating webs are normally hitherto produced as ho-
mogeneous webs, i.e. webs in which the mineral fibers of which themineral fiber-insulating web is composed, are generally orientated in a
single predominant orientation which is mostly determined by the orien-
tation of the production line on which the mineral fiber-insulating web
is produced and transmitted during the process of producing the mineral
fiber-insulating web. The product made from a homogeneous mineral fiber-
insulating web exhibits characteristics which are determined by the in-
tegrity of the mineral fiber-insulating web and which are predominantly
determined by the binding of the mineral fibers within the mineral
fiber-insulating plate produced from the mineral fiber-insulating web,
and further predominantly determined by the area weight and density of
the mineral fibers of the mineral fiber-insulating plate.
The advantageous characteristics of mineral fiber-insulating plates
of a different structure has to some extent already been realized as
techniques for the production of mineral fiber-insulating plates in
which the mineral fibers are orientated in an overall orientation diffe-
rent from the orientation determined by the production line, has been
devised, vide Published International Patent Application, International
Application No. PCT/DK91/00383, International Publication No.
W092/10602, US patent No. 4,950,355, and US patent No. 3,493,252.
Reference is made to the above patent applications and patents, and the
above US patents are hereby incorporated in the present specification by
reference.
2153~70
WO 94/1616~ PCTADK91/00029
~ ,~ 2
From the above published international patent application,
International Publication No. W092/10602, a method of producing an
insulating mineral fiber plate composed of interconnected rod-shaped
mineral fiber elements is known. The method includes cutting a
continuous mineral fiber web in the longitudinal direction thereof in
order to form lamellae, cutting the lamellae into desired lengths,
turning the lamellae 90 about the longitudinal axis and bonding the
lamellae together for forming the plate. The method also includes a step
of curing the continuous mineral fiber web, or alternatively the plate
composed of the individual lengths of lamellae bonded together for the
formation of the plate.
From US patent No. 3,493,452, a method of producing a fibrous sheet
structure including filaments or fibers of a polymeric material such as
polyethylene trephtalate or polyhexamethyleaditamide is known. The
method includes producing the polymeric material filaments or fibers by
means of a carting machine from a supply of filaments or fibers
constituted by a porous resilient bat of filaments or fibers, collecting
the polymeric material filaments or fibers on a belt for the formation
of a continuous web of polymeric material filaments or fibers,
compressing the web, cutting the web into a series of parallel fiber
strips including polymeric material filaments or fibers and turning the
fiber strips 90 about the longitudinal axis and adjoining the strips
together as the strips are caused to effect unification solely through
the release of a compression effect which has been applied to the strips
during the process of turning the strips. The web produced in accordance
with the technique described in the above US patent is suitable for
manufacturing fabrics such as carpets, blankets, bed spreads, bathrobes
etc.
An object of the present invention is to provide a novel method of
producing a mineral fiber-insulating web from which mineral fiber-insu-
lating plates may be cut which method renders it possible in an online
production plant to produce mineral fiber-insulating plates which are of
a composite and complex structure providing distinct advantages as com-
pared to the prior art homogeneous single direction orientated mineral
fiber-containing plates.
A particular advantage of the present invention relates to the no-
vel mineral fiber-insulating plate according to the present invention
~ WO 94/16164 215 3 6 7 0 PCT/D~94/00029
and produced in accordance with the method according to the present in-
vention which as compared to prior art mineral fiber-insulating plates
contains less mineral fibers and is consequently less costly than the
prior art mineral fiber-insulating plates, still exhibiting advantages
as compared to the prior art mineral fiber-insulating plates relating to
mechanical performance and thermal-insulating properties.
A further advantage of the present invention relates to the fact
that the amount of material wasted by producing mineral fiber-insulating
plates in accordance with the method according to the present invention
is basically non-existing, or at least reduced to a very low percentage,
such as the percentage of 0-2% of the amount of material used for produ-
cing the mineral fiber-insulating plate.
A particular feature of the present invention relates to the fact
that the novel mineral fiber-insulating plate according to the present
invention and produced in accordance with the method according to the
present invention is produceable from less mineral fibers or less mate-
rial as compared to the prior art mineral fiber-insulating plate still
providing the same properties as the prior art mineral fiber-insulating
plate regarding mechanical performance and thermal-insulating proper-
ties, thus, providing a more lightweight and more compact mineral fiber-
insulating plate product as compared to the prior art mineral fiber-in-
sulating plate product reducing transport, storage and handling costs.
The above object, the above advantage and the above feature to-
gether with numerous other objects, advantages and features which will
be evident from the below detailed description of present preferred em-
bodiments of the invention are obtained by a method according to the
present invention comprising the following steps:
a) producing a first non-woven mineral fiber web defining a first
longitudinal direction parallel with the mineral fiber web and a second
transversal direction parallel with the first mineral fiber web, the
first mineral fiber web containing mineral fibers arranged generally in
the second transversal direction and including a first heat-curable
bonding agent, the first non-woven mineral fiber web defining a first
mineral fiber web height,
b) moving the first mineral fiber web in the first longitudinal
direction of the first mineral fiber web,
c) cutting the first mineral fiber web parallel with the first
W O 94/16164 . PCT~DK94100029 ~
21~3670 . 4
..
longitudinal direction and perpendicular to the second transversal di-
rection so as to produce a plurality of mutually parallel mineral fiber
strips extending in the first longitudinal direction, the mutually pa-
rallel mineral fiber strips being of identical width,
d) tilting each of the mutually parallel mineral fiber strips so as
to turn the mineral fibers of each of the mutually parallel mineral
fiber strips from the arrangement generally in the second transversal
direction to the arrangement generally perpendicular to the first lon-
gitudinal direction and the second transversal direction,
e) adjoining the tilted mineral fiber strips in abutting
relationship so as to produce a second non-woven mineral fiber web
defining a second mineral fiber web height identical to the width of the
mutually parallel mineral fiber strips, the second mineral fiber web
containing mineral fibers arranged generally perpendicular to the first
longitudinal direction and the second transversal direction,
f) moving the second mineral fiber web in the first longitudinal
direction,
g) producing a third non-woven mineral fiber web defining a third
direction parallel with the third mineral fiber web, the third mineral
fiber web containing mineral fibers arranged generally in the third di-
rection and including a second heat-curable bonding agent, the third
mineral fiber web being a mineral fiber web of a higher compactness as
compared to the second mineral fiber web,
h) adjoining the third mineral fiber web to the second mineral
fiber web in facial contact therewith for producing a fourth composite
mineral fiber web, and
i) curing the first and second curable bonding agents so as to
cause the mineral fibers of the fourth composite mineral fiber web to
bond to one another, thereby forming the mineral fiber-insulating web.
The third non-woven mineral fiber web which is adjoined to the se-
cond mineral fiber web in step f) may constitute a separate mineral
fiber web. Thus, the first and the third mineral fiber webs may be pro-
duced by separate production lines which are joined together in step f).
In accordance with the presently preferred embodiment of the method
according to the present invention, the third non-woven mineral fiber
web is produced by separating a surface segment layer of the first
mineral fiber web therefrom and by compacting the surface segment layer
~ WO 94/16164 21 S 3 ~ 7 0 PCT/DK94/00029
for producing the third mineral fiber web.
The method according to the present invention preferably further
comprises the additional step similar to step g) of producing a fifth
non-woven mineral fiber web simiiar to the third mineral fiber web, and
the step of adjoining in step h) the fifth mineral fiber web to the se-
cond mineral fiber web in facial contact therewith and so as to sandwich
the second mineral fiber web between the third and fifth mineral fiber
web in the fourth mineral fiber web. By producing a fifth non-woven
mineral fiber web an integral composite mineral fiber structure of the
fourth mineral fiber web is accomplished in which structure, the central
body originating from the second mineral fiber web is sandwiched between
opposite compacted surface layers constituted by the third and the fifth
mineral fiber webs.
The method according to the present invention further preferably
comprises the introduction step of producing a first mineral fiber web
from a basic non-woven mineral fiber web by arranging the basic mineral
fiber web in overlapping layers so as to provide a more homogeneous and
compact mineral fiber web as compared to the basic mineral fiber web
which additionally contains mineral fibers generally orientated along
the longitudinal direction of the basic mineral fiber web. By producing
the first mineral fiber web from the basic non-woven mineral fiber web
by arranging the basic mineral fiber web in overlapping layers, the ge-
neral orientation of the mineral fibers of the basic non-woven mineral
fiber web is shifted from the longitudinal direction of the basic
mineral fiber web to the transversal direction of the first non-woven
mineral fiber web. The basic non-woven mineral fiber web is preferably
arranged in overlapping relation generally in the second transversal di-
rection.
In accordance with the technique described in the above-mentioned
published international patent application, application No.
PCT/DK91/00383, publication No. W0 92/10602, the first and second non-
woven mineral fiber webs are preferably exposed to compacting and com-
pression in order to provide more compact and more homogeneous mineral
fiber webs. The compacting and compression may include heigt compres-
sion, longitudinal compression, transversal compression and combinations
thereof. Thus, the method according to the present invention preferably
further comprises the additional step of height-compressing the first
WO 94/16164 ~ PCT/DK9~/00029 ~
215367~
non-woven mineral fiber web produced in step a) and preferably produced
from the basic non-woven mineral fiber web as described above.
Further preferably, the method according to the present invention
may comprise the additional step of longitudinally compressing the first
non-woven mineral fiber web produced in step a) and additionally or al-
ternatively the additional step of longitudinally compressing the second
non-woven mineral fiber web produced in step e). By performing a longi-
tudinal compression, the mineral fiber web exposed to the longitudinal
compression is made more homogeneous, resulting in an overall improve-
ment of the mechanical performance and, in most instances, the thermal-
insulating property of the longitudinally compressed mineral fiber web
as compared to a non-longitudinally compressed mineral fiber web.
As will be evident from the detailed description below of presently
preferred embodiments of the present invention, the mineral fiber-insu-
lating plates produced in accordance with the method according to thepresent invention exhibit surprisingly improved mechanical properties
and mechanical performance, provided the second non-woven mineral fiber
web produced in step e) is exposed to transversal compression, producing
a homogenization of the mineral fiber structure of the second non-woven
mineral fiber web. The transversal compression of the second non-woven
mineral fiber web results in a remarkable improvement of the mechanical
properties and performance of the final mineral fiber-insulating plates
produced from the second non-woven mineral fiber web, which improvement
is believed to originate from a mechanical repositioning of the mineral
fibers of the second non-woven mineral fiber web, as the second non-
woven mineral fiber web is exposed to the transversal compression, by
which repositioning the mineral fibers of the second non-woven mineral
fiber web are evenly distributed throughout the uncured mineral fiber
web.
The method according to the present invention may further pre-
ferably and advantageously comprise the step of applying a foil to a
side surface of both side surfaces of the first non-woven mineral fiber
web and/or applying a foil to a side surface or both side surfaces of
the second non-woven mineral fiber web. The foil may be a foil of a
plastics material, such as a continuous foil, a woven or non-woven mesh,
or alternatively a foil of a non-plastics material, such as a paper or
cloth material. The mineral fiber-insulating web produced in accordance
~ WO 94/16164 215 3 6 7 0 PCT/DK94/()O029
with the method according to the present invention may, as discussed
above, be provided with two oppositely arranged mineral fiber webs sand-
wiching a central body of the composite mineral fiber-insulating web.
Provided the mineral fiber-insulating web is produced as a ~hree-layer
assembly, one or both outer side surfaces may be provided with similar
or identical surface coverings.
The method according to the present invention may further comprise
the additional step of compressing the fourth composite mineral fiber
web prior to introducing the fourth composite mineral fiber web into the
curing oven. The compressing of the fourth composite mineral fiber web
may comprise height compression, longitudinal compression and/or trans-
versal compression. By compressing the fourth composite mineral fiber
web, the homogenity of the final product is believed to be improved as
the compressing of the fourth composite mineral fiber web produces a ho-
mogenizing effect on the central body of the fourth composite mineralfiber web, which central body is constituted by the central body of the
second non-woven mineral fiber web.
The step i) of curing the first curable bonding agent and optional-
ly the second and third curable bonding agents as well may, dependent on
the nature of the curable bonding agent or bonding agents, be carried
out in numerous diffent ways, e.g. by simply exposing the curable
bonding agent or bonding agents to a curing gas or a curing atmosphere,
such as the atmosphere, by exposing the curable bonding agent or bonding
agents to radiation, such as UV radiation or IR radiation. Provided the
curable bonding agent or bonding agents are a heat-curable bonding
agents, such as conventional resin-based bonding agents normally used
within the mineral fiber industry, the process of curing the curable
bonding agent or bonding agents includes the step of introducing the
mineral fiber web to be cured into a curing oven. Consequently, the
curing process is performed by means of a curing oven. Further
alternative curing appliances may comprise IR radiators, microwave
radiators, etc.
From the cured mineral fiber-insulating web produced in step i),
plate segments are preferably cut by cutting the cured fourth composite
mineral fiber web into plate segment in a separate production step.
The above object, the above advantage and the above features to-
gether with numerous other objects, advantages and features is further-
WO 94/16164 PCT/DK94/00029 ~
21~3~70 ~ 8
more obtained by means of a plant for producing a mineral fiber-insula-
ting web, comprising:
a) first means for producing a first non-woven mineral fiber web
defining a first longitudinal direction parallel with the mineral fiber
web and a second transversal direction parallel with the first mineral
fiber web, the first mineral fiber web being produced containing mineral
fibers arranged generally in the second transversal direction and
including a first heat-curable bonding agent, the first non-woven
mineral fiber web being produced defining a first mineral fiber web
height,
b) second means for moving the first mineral fiber web in the first
longitudinal direction of the first mineral fiber web,
c) third means for cutting the first mineral fiber web parallel
with the first longitudinal direction and perpendicular to the second
transversal direction so as to produce a plurality of mutually parallel
mineral fiber strips extending in the first longitudinal direction, the
mutually parallel mineral fiber strips being of identical width,
d) fourth means for tilting each of the mutually parallel mineral
fiber strips so as to turn the mineral fibers of each of the mutually
parallel mineral fiber strips from the arrangement generally in the se-
cond transversal direction to the arrangement generally perpendicular to
the first longitudinal direction and the second transversal direction,
e) fifth means for adjoining the tilted mineral fiber strips in
abutting relationship so as to produce a second non-woven mineral fiber
web defining a second mineral fiber web height identical to the width of
each of the mutually parallel mineral fiber strips, the second mineral
fiber web being produced containing mineral fibers arranged generally
perpendicular to the first longitudinal direction and the second
transversal direction,
f) sixth means for moving the second mineral fiber web in the first
longitudinal direction,
g) seventh means for producing a third non-woven mineral fiber web
defining a third direction parallel with the third mineral fiber web,
the third mineral fiber web being produced containing mineral fibers
arranged generally in the third direction and including a second heat-
curable bonding agent, the third mineral fiber web being a mineral fiber
web of a higher compactness as compared to the second mineral fiber web,
~ W o 94/16164 2 1 ~ 3 6 7 0 PC~ IDK94/00029
h) eight means for adjoining the third mineral fiber web to the
second mineral fiber web in facial contact therewith for producing a
fourth composite mineral fiber web, and
i) ninth means for curing the first and second curable bonding
agents so as to cause the mineral fibers of the fourth composite mineral
fiber web to bond to one another, thereby forming the mineral fiber-
insulating web.
The plant according to the present invention may advantageously
comprise any of the above features of the method according to the
present invention.
The above object, the above advantage and the above features to-
gether with numerous other objects, advantages and features is further-
more obtained by means of a mineral fiber-insulating plate according to
the present invention, which mineral fiber-insulating plate defines a
longitudinal direction and comprises:
a central body containing mineral fibers,
a surface layer containing mineral fibers,
the central body and the surface layer being adjoined in facial contact
with one another,
the mineral fibers of the central body being arranged generally
perpendicularly to the longitudinal direction and perpendicularly to the
surface layer,
the mineral fibers of the surface layer being arranged generally in
a direction parallel with the longitudinal direction,
the surface layer being of a higher compactness as compared to the
central body, and
the mineral fibers of the central body and the mineral fibers of
the surface layer being bonded together in an integral structure solely
through cured bonding agents cured in a single curing process and
initially present in non-woven mineral fiber webs from which the central
body and the surface layer are produced.
The mineral fiber-insulating plate according to the present inven-
tion preferably comprises opposite surface layers of similar structure
sandwiching the central body in the integral structure of the mineral
fiber-insulating plate.
The present invention will now be further described with reference
to the drawings, in which
~ ~ 5 3 Go
7 o PCT~DK94/00029
Fig. 1 is a schematic and perspective view illustrating a first
production step of p~roducing a mineral fiber-insulating web from a
mineral fiber forming melt,
Fig. 2 is a schematic and perspective view illustrating a produc-
tion step of compacting a mineral fiber-insulating web,
Fig. 3 is a schematic and perspective view illustrating a produc-
tion step of separating a surface layer of the mineral fiber-insulating
web produced in accordance with the production steps shown in Fig. 1 and
optionally compacted in accordance with the production step shown in
Fig. 2
Fig. 4a is a schematic and perspective view illustrating a produc-
tion step of cutting a mineral fiber-insulating web into longitudinally
extending strips and of turning the strips 90 and furthermore illustra-
ting a production step of adjoining the strips,
Fig. 4b is a schematic and perspective view illustrating a produc-
tion step of transversely compacting the strips out, turned and adjoined
in the production step shown in Fig. 4a,
Fig 4c is a schematic and perspective view illustrating a produc-
tion step of simultaneously transversally compressing, height-compress-
ing and longitudinally compressing a mineral fiber-insulating web,
Fig. 5 is a schematic and perspective view illustrating the produc-
tion step of adjoining a surface layer, preferably a compacted surface
layer to a mineral fiber-insulating web produced in accordance with the
production steps shown in Figs. 3, 4a and 4b, and of curing the mineral
fiber-insulating web and furthermore illustrating a production step of
separating the cured mineral fiber-insulating web into plate segments,
Fig. 6a is a schematic and perspective view illustrating a first
embodiment of a mineral fiber-insulating plate segment produced in
accordance with the techniques disclosed in Figs. 1-5,
Fig. 6b is a schematic and perspective view illustrating a second
embodiment of a mineral fiber-insulating plate segment produced in
accordance with the techniques disclosed in Figs. 1-5,
Figs. 7 and 8 are diagrammatic views illustrating production para-
meters of an online production plant producing general building-insula-
ting plates from a mineral fiber-insulating web produced in accordance
with the teachings of the present invention, and
Figs. 9 and 10 are diagrammatic views similar to the views of Figs.
~ WO 94/16164 215 3 6 7-~ PCT/DK94/00029
11
7 and 8, respectively, illustrating production parameters of an online
production plant producing mineral fiber heat-insulating roofing plates
from a mineral fiber-insulating web produced in accordance with the
teachings of the present invention.
In Fig. 1, a first step of producing a mineral fiber-insulating web
is disclosed. The first step involve the formation of mineral fibers
from a mineral fiber forming melt which is produced in a furnace 30 and
which is supplied from a spout 32 of the furnace 30 to a total of four
rapidly rotating spinning-wheels 34 to which the mineral fiber forming
melt is supplied as a mineral fiber forming melt stream 36. As the
mineral fiber forming melt stream 36 is supplied to the spinning-wheels
34 in a radial direction relative thereto, a cooling gas stream is
simultaneously supplied to the rapidly rotating spinning-wheels 34 in
the axial direction thereof causing the formation of individual mineral
fibers which are expelled or sprayed from the rapidly rotating spinning-
wheels 34 as indicated by the reference numeral 38. The mineral fiber
spray 38 is collected on a continuously operated first conveyer belt 42
forming a primary mineral fiber-insulating web 40. A heat-curable
bonding agent is also added to the primary mineral fiber-insulating web
40 either directly to the primary mineral fiber-insulating web 40 or at
the stage of expelling the mineral fibers from the spinning-wheels 34,
i.e. at the stage of forming the individual mineral fibers. The first
conveyer belt 42 is, as is evident from Fig. 1, composed of two conveyer
belt sections. A first conveyer belt section which is sloping relative
to the horizontal direction and relative to a second substantially hori-
zontal conveyer belt section. The first section constitutes a collector
section, whereas the second section constitutes a transport section by
means of which the primary mineral fiber-insulating web 40 is transfer-
red to a second and a third continuously operated conveyer belt designa-
ted the reference numeral 44 and 46, respectively, which are operated insynchronism with the first conveyer belt 42 sandwiching the primary
mineral fiber-insulating web 40 between two adjacent surfaces of the se-
cond and third conveyer belts 44 and 46, respectively.
The second and third conveyer belts 44 and 46, respectively, com-
municate with a fourth conveyer belt 48 which constitutes a collector
conveyer belt on which a secondary mineral fiber-insulating web 50 is
collected as the second and third conveyer belts 44 and 46, respective-
WO 94/16164 PCT/DK94/00029
2153670 12
ly, are swung across the upper surface of the fourth conveyer belt 48 inthe transversal direction relative to the fourth conveyer belt 48. The
secondary mineral fiber-insulating web 50 is cGnsequently produced by
arranging the primary minëral fiber-insulating web 40 in overlapping re-
5 lation generally in the transversal direction of the fourth conveyerbelt 48.
By producing the secondary mineral fiber-insulating web 50 from the
primary mineral fiber-insulating web 40 as disclosed in Fig. 1, a more
homogeneous secondary mineral fiber-insulating web 50 is produced as
10 compared to the less homogeneous primary mineral fiber-insulating web
40.
It is to be realized that the overall orientation of the mineral
fibers of the primary mineral fiber-insulating web 40 is parallel with
the longitudinal direction of the web 40 and the direction of transpor-
15 tation of the first conveyer belt 42. Contrary to the primary mineralfiber-insulating web 40 the overall orientation of the mineral fibers of
the secondary mineral fiber-insulating web 50 is substantially perpendi-
cular and transversal relative to the longitudinal direction of the se-
condary mineral fiber-insulating web 50 and the direction of transporta-
20 tion of the fourth conveyer belt 48.
In Fig. 2, a station for compacting and homogenizing an inputmineral fiber-insulating web 50' is shown, which station serves the
purpose of compacting and homogenizing the input mineral fiber-
insulating web 50' for producing an output mineral fiber-insulating web
25 50", which output mineral fiber-insulating web 50" is more compact and
more homogeneous as compared to the input mineral fiber-insulating web
50'. The input mineral fiber-insulating web 50' may constitute the
secondary mineral fiber-insul ating web 50 produced in the station shown
in Fig. 1.
The compacting station comprises two sections. The first section
comprises two conveyer belts 52" and 54", which are arranged at the up-
per side surface and the lower side surface, respectively, of the
mineral fiber web 50'. The first section basically constitutes a section
in which the mineral fiber web 50' input to the section is exposed to a
35 height compression, causing a reduction of the overall height of the
mineral fiber web and a compacting of the mineral fiber web. The
conveyer belts 52" and 54" are consequently arranged in a manner, in
~ WO 94/16164 215 3 ~ 7 0 PCT/DK94/00029
13
which they slope from an input end at the left-hand side of Fig. 2, at
which input end the mineral fiber web 50' is input to the first section,
towards an output end, from which the height-compressed mineral fiber
web is delivered to the second section of the compacting station.
The second section of the compacting station comprises three sets
of rollers 56' and 58', 56" and 58", and 56''' and 58'''. The rollers
56', 56" and 56' " are arranged at the upper side surface of the mineral
fiber web, whereas the rollers 58', 58" and 58''' are arranged at the
lower side surface of the mineral fiber web. The second section of the
compacting station provides a longitudinal compression of the mineral
fiber web, which longitudinal compression produces a homogenization of
the mineral fiber web, as the mineral fibers of the mineral fiber web
are caused to be rearranged as compared to the initial structure into a
more homogeneous structure. The three sets of rollers 56' and 58', 56"
15 and 58", and 56''' and 58''' of the second section are rotated at the
same rotational speed, which is, however, lower than the rotational
speed of the conveyer belts 52" and 54" of the first section, causing
the longitudinal compression of the mineral fiber web. The height-com-
pressed and longitudinally compressed mineral fiber web is output from
the compacting station shown in Fig. 2, designated the reference numeral
50" .
It is to be realized that the combined height-and-longitudinal-
compression compacting station shown in Fig. 2 may be modified by the
omission of one of the two sections, i.e. the first section constituting
25 the height-compression section, or alternatively the second section
constituting the longitudinal-compression section. By the omission of
one of the two sections of the compacting station shown in Fig. 2, a
compacting section performing a single compacting or compression opera-
tion is provided, such as a height-compressing station or alternatively
30 a longitudinally-compressing station. Although the height-compressing
section has been described including conveyer belts, and the longitudi-
nally-compressing section has been described including rollers, both
sections may be implemented by means of belts or rollers. Also, the
height-compressing section may be implemented by means of rollers, and
35 the longitudinally-compressing section may be implemented by means of
conveyer belts.
In Fig. 3, a further production station is shown, in which station
WO 94/16164 PCT/DK91/00029 ~
215~7~ 14
a surface layer 24 is separated from the mineral fiber-insulating web
50", providing a remaining part of the mineral fiber-insulating web 50",
the remaining part being designated the reference numeral 50'''. The
mineral fiber-insulating web 50" may constitute the output mineral
5 fiber-insulating web 50" shown in Fig. 2, or alternatively the mineral
fiber-insulating web 50 produced in the station shown in Fig. 1. The
separation of the surface layer 24 from the remaining part 50'" of the
mineral fiber-insulating web is accomplished by means of a cutting tool
72 as the remaining part 50''' of the mineral fiber-insulating web 50"
10 is supported and transported by means of a conveyer belt 70. The cutting
tool 72 may be constituted by a stationary cutting tool or knife or al-
ternatively be constituted by a transversely reciprocating cutting tool.
The surface layer 24 separated from the mineral fiber-insulating web is
derived from the path of travel of the remaining part 50''' of the
15 mineral fiber-insulating web by means of a conveyer belt 74 and is
transferred from the conveyer belt 74 to three sets of rollers
comprising a first set of rollers 76' and 78', a second set of rollers
76" and 78", and a third set of rollers 76''' and 78''', which three
sets of rollers together constitute a compacting or compressing section
20 similar to the second section of the compacting station described above
with reference to Fig. 2.
In Fig. 4a, a production station is illustrated, which involves
four separate productions steps, a first production step involving
applying a continuous foil to an upper side surface of a mineral fiber-
25 insulating web, a second step involving cutting the mineral fiber-
insulating web into longitudinally extending strips, a third step invol-
ving turning the longitudinally extending strips 90- and adjoining the
turned, longitudinally extending strips together, and a fourth step in-
volving applying a surface covering constituted by a woven, mesh foil to
30 an upper side surface of the adjoined and turned, longitudinally extend-
ing strips.
In the left-hand part of Fig. 4a, the mineral fiber-insulating web
is shown. The mineral fiber-insulating web 50'" shown in Fig. 4a may
constitute the remaining part 50 ''' of the mineral fiber-insulating web
35 50", or may constitute the mineral fiber-insulating web 50" output from
the compacting station shown in Fig. 2, or may alternatively constitute
the mineral fiber-insulating web 50 produced in the station shown in
~ WO 94/16164 215 3 6 7 ~ PCT/DK94/00029
Fig. 1. The mineral fiber-insulating web to be processed in the station
shown in Fig. 4a, however, preferably constitutes the remaining part
50''' of the mineral fiber-insulating web 50" shown in Fig. 3. In a
first substation shown in Fig. 4a, the mineral fiber-insulating web
50''' is brought into contact with a pressing roller 68, by means of
which a continuous foil 67 of a thermoplastic material is applied to the
upper side surface of the mineral fiber-insulating web 50'''. The
continuous foil of the thermoplastic material is supplied from a roll
66. After the continuous foil 67 has been applied to the upper side
surface of the mineral fiber-insulating web 50''', the mineral fiber-
insulating web 50''' and the continuous foil 67 applied thereto are
brought into contact with a total of seven mutually parallel, rotatable
cutting knives, one of which is designated the reference numeral 60.
The knives 60 are arranged equidistantly spaced apart and cut the
mineral fiber-insulating web 50''', the upper side surface of which is
provided with the continuous foil 67, into a total of eight mutually pa-
rallel, longitudinally extending strips, each having a surface foil
strip. The longitudinally extending strips are thereupon brought into
contact with a total of eight turning plates 62 which serve the purpose
of turning the mutually parallel strips 90 relative to the longitudinal
direction of the mineral fiber-insulating web 50'''. One of the mutually
parallel strips is designated the reference numeral 64, and one of the
foil strips is designated the reference numeral 69.
The mineral fiber-insulating web 50''' shown in Fig. 3 is produced
from the mineral fiber-insulating web 50 shown in Fig. 1. Consequently,
the mineral fibers of the mineral fiber-insulating 50''' shown in Fig. 3
are generally orientated along the transversal direction of the mineral
fiber-insulating web 50'''. As the strips 64 of the mineral fiber-
insulating web 50''', which strips are cut by means of the knives 60,
are turned 90 relative to the longitudinal direction of the mineral
fiber-insulating web 50''', the mineral fibers of the strips 64 are
turned 90.
As the strips 64 of the mineral fiber-insulating web 50''' are
turned 90 relative to the longitudinal direction of the mineral fiber-
insulating web 50''', the foil strips 69 are also turned 90- and except
for the outermost surface foil strip embedded between two adjacent
strips 64 of the mineral fiber-insulating web 50'''. Consequently, the
w2~ 7 ~ PCT/DK94/00029 ~
16
r
mineral fibers of the strips 64 which are adjoined one another through
the foil strips 69 for the formation of an integral mineral fiber-insu-
lating web 50"" are generally orientated perpendicular to the longitudi-
nal direction of the mineral fiber-insulating web and also perpendicular
to the transversal direction of the mineral fiber-insulating web. Conse-
quently, the mineral fibers of mineral fiber-insulating web 50n" com-
posed of the strips 64 are generally orientated perpendicular to the
outer surfaces of the mineral fiber-insulating web 50"" constituted by
the adjoined strips 64.
After the integral mineral fiber-insulating web 50"" has been pro-
duced, in which mineral fiber-insulating web the foil strips 69 are em-
bedded within the strips 64, the mineral fiber-insulating web 50"" is
moved to a further foil application station, in which a woven mesh foil
99, which is supplied from a roll 98, is applied to one of the side sur-
faces, the upper side surface of the mineral fiber-insulating web 50""
by means of a press roller 97. The woven mesh foil 99 may be applied to
the upper side surface of the mineral fiber-insulating web 50"" and
fixated relative thereto by means of an adhesive layer, such as a glue
layer, or simply be pressed against the mineral fiber top surface of the
mineral fiber-insulating web.
Similarly, the continuous foil 67 may be applied to the upper side
surface of the mineral fiber-insulating web 50''' and adhered thereto by
means of an adhesive layer constituted by e.g. a glue layer, in a manner
well-known in the art per se.
It is to be realized that, in accordance with a preferred, alterna-
tive embodiment, the contiuous foil 67 and the woven mesh foil 99 are
omitted, as the mineral fiber-insulating web 50"" is simply produced
from the mineral fiber strips 64, which are produced by means of the
knives 60 from the mineral fiber-insulating web 50''' and turned by
30 means of the plates 62 and thereupon adjoined one another, producing a
mineral fiber-insulating web including mineral fibers, and the heat-
curable bonding agent exclusively.
In Fig. 4b, a transversally-compressing station is shown, which is
designated the reference numeral 80 in its entirety. In the station 80,
35 the mineral fiber-insulating web 50"" produced in accordance with the
above-described, preferred, alternative embodiment, comprising mineral
fibers and the heat-curable bonding agent exclusively, is brought into
2153~70
WO 94/16164 PCTIDK94/00029
17
r
contact with two conveyer belts 85 and 86, which define a constriction
in which the mineral fiber-insulating web is caused to be transversally
compressed and into contact with a total of four surface-agitating
rollers 89a, 89b, 89c and 89d, which togetner with similar rollers, not
shown in the drawing, arranged opposite to the rollers 89a, 89b, 89c and
89d serve the purpose of assisting in providing a transversal com-
pression of the web 50"". The conveyer belts 85 and 86 are journalled on
rollers 81, 83 and 82, 84, respectively.
From the transversally-compressing station 80, a transversally
10 compressed and compacted mineral fiber-insulating web 50''''' is sup-
plied. As the mineral fiber-insulating web 50"" is transmitted through
the transversally-compressing station 80 and transformed into the trans-
versally compressed mineral fiber-insulating web 50''''', the web is
supported on rollers constituted by an input roller 87 and an output
15 roller 88.
Although the mineral fiber-insul ating web 50"" input to the trans-
versally-compressing station 80 is preferably constituted by the above-
described, preferred and alternative embodiment, the mineral fiber-insu-
lating web 50"" may alternatively comprise integral foil strips similar
20 to the foil strips 69 discussed above.
Provided the mineral fiber-insulating web 50"" to be transversally
compressed within the station 80 is provided with a top surface layer,
such as the woven mesh foil 99 described above with reference to Fig.
4a, the foil has to be of a structure compatible with the transversal
25 compression of the web and foil assembly. Thus, the foil applied to the
upper side surface of the mineral fiber-insulating web 50"" has to be
compressable and adaptable to the reduced width of the mineral fiber-in-
sulating web 50''''' output from the transversally-compressing station
80.
In Fig. 4c, an alternative technique of compressing the mineral
fiber-insulating web 50"" is shown. According to the technique disclosed
in Fig. 4c, a station 60"" is employed, which station constitutes a
combined height-compressing, longitudinally-compressing and transver-
sally compressing station. Thus, the station 60"" comprises a total of
35 six sets of rollers, three sets of which are constituted by the three
sets of rollers 56', 58'; 56", 58"; and 56'", 58"' discussed above
with reference to Fig. 2, and constitutes an alternative to the combi-
W O 94tl6164 PCT~DK94/00029 ~
2~3670 18
nation of the stations discussed above with reference to Figs. 2 and 4b.
The station 60"" shown in Fig. 4c further comprises three sets of
rollers, a first set of which is constituted by two rollers 152' and
154', a second set of which is constituted by two rollers 152" and 154",
and third set of which is constituted by two rollers 152''' and 154'''.
The rollers 152', 152" and 152'''~re arranged at the upper side surface
of the mineral fiber-insulating`web 50" like the rollers 56', 56" and
56'''. The three rollers 154', 154" and 154"' are arranged at the lower
side surface of the mineral fiber-insulating web 50" like the rollers
58', 58" and 58'''. The three sets of rollers 152', 154'; 152", 154n;
and 152''', 154''' serve the same purpose as the belt assemblies 52",
54" discussed above with reference to Fig. 2, viz. the purpose of height
compressing the mineral fiber-insulating web 50" input to the station
60"".
The three sets of height-compressing rollers 152', 154'; 152",
154"; and 152''', 154''' are like the above-described belt assemblies
52", 54" operated at a rotational speed identical to the velocity of the
mineral fiber-insulating web 50n" input to the height-compressing
section of the station 60"". The three sets of rollers constituting the
longitudinally-compressing section, i.e. the rollers 56', 58'; 56", 58";
and 56''', 58''', are operated at a reduced rotational speed determining
the longitudinal compression ratio.
For generating the transversal compression of the mineral fiber-in-
sulating web 50"" input to the station 60"", shown in Fig. 4c, four
crankshaft assemblies designated the reference numerals 160', 160",
160''', and 160"" are provided. The crankshaft assemblies are of identi-
cal structures, and in the below description a single crankshaft assem-
bly, the crankshaft assembly 160", is described, as the crankshaft as-
semblies 160', 160"' and 160"" are identical to the crankshaft assembly
30 160" and comprise elements identical to the elements of the crankshaft
assembly 160", however, designated the same reference numeral s added a
single, a double and a triple mark, respectively.
The crankshaft assembly 160" includes a motor 162", which drives a
gear assembly 164", from which an output shaft 166" extends. A total of
35 six gearwheels 168" of identical configurations are mounted on the out-
put shaft 166". Each of the gearwheels 168" meshes with a corresponding
gearwheel 170". Each of the gearwheels 170" constitutes a drivewheel of
WO 91/16164 215 31~ 7 0 PCT/DK94/00029
19
a crankshaft lever system further comprising an idler wheel 172" and a
crankshaft lever 174". The crankshaft levers 174" are arranged so as to
be lifted from a retracted position to an elevated position between two
adjacent rollers at the righ-hand, lower side of the mineral fiber-insu-
lating web 50"" input to the station 60"" and are adapted to cooperate
- with crankshaft levers of the crankshaft lever system 160' positioned at
the right-hand, upper side of the mineral fiber-insulating web 50n"
input to the station 60"".
Similarly, the crankshaft levers of the crankshaft lever systems
160''' and 160"", arranged at the left-hand, upper and lower side, re-
spectively, of the mineral fiber-insulating web 50"" input to the
station 60"", are adapted to cooperated in a manner to be described
below.
As is evident from Fig. 4c, a first set of crankshaft levers 174',
174", 174''', 174"" of the crankshaft lever systems 160', 160", 160 " '
and 160"" are positioned between the first and second sets of rollers
152', 154' and 152", 154". Similarly, a second set of crankshaft levers
are positioned between the second and third sets of rollers 152", 154"
and 152''', 154'''.
The crankshaft levers of each of the total of six crankshaft lever
sets are of identical widths. Within each of the crankshaft lever sy-
stems 160', 160", 160''' and 160"", the first crankshaft lever is the
widest crankshaft lever, and the width of the crankshaft lever within
each crankshaft lever system is reduced from the first crankshaft lever
to the sixth crankshaft lever positioned behind the sixth set of rollers
56''', 58'''.
By means of the motors of the crankshaft assemblies 160', 160",
160''' and 160"", the crankshaft levers of a specific crankshaft set are
rotated in synchronism with the remaining three crankshaft levers of the
crankshaft lever set in question. The crankshaft levers of all six sets
of crankshaft levers are moreover operated in synchronism and in
synchronism with the velocity of the mineral fiber-insulating web 50""
input to the station 60"". The widest or first set of crankshaft levers
is adapted to initiate the transversal compression of the mineral fiber-
insulating web 50"", as the crankshaft levers 174" and 174"" of the
crankshaft lever systems 160" and 160"", respectively, are raised from
positions below the lower side surface of the mineral fiber-insulating
WO 94/16164 PCT/DK94100029 ~
2~3~7~ 20
web 50"" and are brought into contact with the lower side surface of the
mineral fiber-insulating web 50"", and as the crankshaft levers 174' and
174''' of the crankshaft lever systems 160' and 160' " , respectively,
are simultaneously lowered from positions above the upper side surface
of the mineral fiber-insulating web 50n" and brought into contact with
the upper side surface of the mineral fiber-insulating web 50n".
Further rotation of the output shafts 166', 166", 166''' and 166""
causes the crankshaft levers of the first set of crankshaft levers to be
moved towards the center of the mineral fiber-insulating web 50nn,
providing a transversal compression of a central area of the mineral
fiber-insulating web 50"". As the crankshaft levers of the first set of
crankshaft levers reach the central position, the crankshaft levers of
the crankshaft lever systems 160' and 160''' are raised, whereas the
crankshaft levers of the crankshaft lever systems 160" and 160"" are
lowered and consequently brought out of contact with the upper and lower
side surface, respectively, of the mineral fiber-insulating web 50"".
As the mineral fiber-insulating web 50" is moved further through
the station 60"", the next or second set of crankshaft levers provides
an additional transversal compression of areas of the mineral fiber-in-
sulating web 50"", which areas are positioned at opposite sides of theabove-mentioned central area, whereupon the third, the fourth, the
fifth, and the sixth sets of crankshaft levers provide additional trans-
versal compression of the mineral fiber-insulating web, producing an
overall, homogeneous, transversal compression of the mineral fiber-in-
sulating web.
The width of the crankshaft levers of each set of crankshaft le-
vers, the gear ratio of the gear assemblies 164', 164", 164''' and
164"", the gear ratio of the gearwheels 168 and 170, and the velocity of
the mineral fiber-insulating web 50"" input to the station 60"" are a-
dapted to one another and further to the rotational speed of the heightcompression and the longitudinally-compressing sections of the station
for producing the height-, longitudinally-compressed and transversally-
compressed mineral fiber-insulating web 50'''''.
The integration of the height-compressing section, the longitudi-
nally-compressing section and the transversally compressing section into
a single station, as described above with reference to Fig. 4c, is, by
no means, mandatory to the operation of the crankshaft systems described
23312~HN/LN/13.01 .94
WO 94/16164 215 3 6 7 0 PCTtDK94/00029
21
r
above with reference to Fig. 4c. Thus, the height-compressing section,
the longitudinally-compressing section and the transversally-compressing
sections may be separated, however, the integration of all three func-
tions reduces the overall size of the production plant. The station de-
scribed above with reference to Fig. 4c may preferably be completed byan additional longitudinally-compressing section similar to the longitu-
dinally-compressing section described above with reference to Fig. 2.
The additional longitudinally-compressing section may constitute an ad-
ditional or second longitudinally-compressing section or an alternative
longitudinally-compressing section, provided the station described above
with reference to Fig. 4c constitutes a height-compressing section and a
transversally-compressing section exclusively. Additionally or alterna-
tively, the height-compressing section of the station described above
with reference to Fig. 4c may be substituted by a separate height-com-
pressing section, such as a height-compressing section similar to the
height-compressing section described above with reference to Fig. 2.
As the mineral fiber-insulating web 50''''' has been produced as
described above with reference to Figs. 4a and 4b or 4c, and as the
surface layer 24 has been compacted as described above with reference to
Fig. 3, the compacted surface layer 24 is returned to the mineral fiber-
insulating web 50'' " ' and adjoined in facial contact with the upper
surface of the mineral fiber-insulating web 50'''''.
In Fig. 5, a set of rollers comprising a roller 79' and a roller
79" arranged at the upper and lower side surface of the surface layer
24, respectively, constitutes a set of rollers by means of which a sur-
face foil 99' supplied from a roll 98' is applied to the upper side sur-
face of the compacted surface layer 24. From the rollers 79' and 79",
the surface layer 24 which constitutes an integral mineral fiber-insula-
ting web of higher compactness as compared to the mineral fiber-insula-
ting web 50''''', is shifted towards the upper side surface of themineral fiber-insulating web 50''''' by means of two rollers 77' and
77". The roller 77" is positioned below the surface layer 24 and
constitutes a turning roller, whereas the roller 77', which is
- positioned above the upper side surface of the surface layer 24, serves
the purpose of pressing the compacted surface layer 24 into facial
contact with the upper side surface of the mineral fiber-insulating web
50''''', which is supported and transported by means of the conveyer
WO 91/16164 PCT/DK91/00029 ~
2~53~7 22
belt 70 also shown in Fig. 3. After the compacted surface layer 24 has
been arranged in facial contact with the upper side surface of the
mineral fiber-insulating web 50''''', a mineral fiber-insulating web
assembly is provided, which assembly is designated the reference numeral
90 in its entirety.
In Fig. 5, a further foil 99"~is shown in dotted line. This foil is
supplied from a roll 98". The fo~il 99" may constitute a continuous foil
or alternatively a mesh foil, i.e. a foil similar to the foil 67 and the
foil 99, respectively, described above with reference to Fig. 4a. It is,
however, to be emphasized that the foils 67, 99, 99' and 99" constitute
optional features which may be omitted, provided an integral mineral
fiber web structure is to be produced. Alternatively, one or more of the
above-listed foils, or all foils, may be provided in various embodiments
of the mineral fiber-insulating web produced in accordance with the
teachings of the present invention.
It is to be realized that the compacted surface layer 24 which is
separated from the mineral fiber-insulating web 50" as shown in Fig. 3,
may alternatively be provided from a separate production line as the
production station shown in Fig. 1 is communicating directly with the
production station shown in Fig. 4a, optionally through the production
station shown in Fig. 2, thus, eliminating the production station shown
in Fig. 3. Preferably, the production station shown in Fig. 3 is adapted
to separate two surface layers from the mineral fiber-insulating web 50"
for producing two separated surface layers separated from opposite side
surfaces of the mineral fiber-insulating web 50", which surface layers
are processed in accordance with the technique described above with re-
ference to Fig. 3 for the formation of two high compactness surface
layers which in accordance with the technique described above with refe-
rence to Fig. 5 are adjoined with the mineral fiber-insulating web
50''''' at opposite side surfaces thereof producing a sandwiching of the
mineral fiber-insulating web 50''''' between two opposite surface layers
similar to the surface layer 24 shown in Fig. 5.
In Fig. 5, the mineral fiber-insulating web assembly 90 is finally
moved through a curing station constituting a curing oven or curing fur-
nace comprising oppositely arranged curing oven sections 92 and 94,which generate heat for heating the mineral fiber-insulating web assem-
bly 50 to an elevated temperature so as to cause the heat-curable
~ Wo 94tl6164 215 3 6 7 0 PCT~DK94/00029
23
bonding agent of the mineral fiber-insulating web assembly to cure and
cause the mineral fibers of the central core or the body of the assembly
and the mineral fibers of the compacted surface layer or surface layers
to be bonded together so as to form an integral bonded mineral fiber-
insulating web which is cut into plate-like segments by means of a knife
- 96. Provided the foil strips 67, and optionally the continuous foil 99",
are provided, the thermoplastic mater;al of the foil strip 67 and the
continuous foil 99" is also melted, providing an additional bonding of
the mineral fibers of the mineral fiber-insulating web.
In Fig. 5, a single plate-like segment 10' is shown comprising a
central core 12 and a top layer 14. The top layer 14 is made from the
compacted surface layer 24, whereas the core 12 is made from the mineral
fiber-insulating web 50''''' shown in Fig. 5.
In Fig. 6a, a fragmentary and perspective view of a first embodi-
ment of a plate segment of a mineral fiber-insulating web according to
the present invention is shown, designated the reference numeral 10 in
its entirety. The plate segment 10 comprises the central core 12 and the
top layer 14 and further a bottom layer 16 made from a surface layer of
the mineral fiber-insulating web 50". The reference numeral 18 desig-
nates a segment of the core 12 of the plate segment 10 which segment 18is made from one of the strips 64 of the mineral fiber-insulating web
50"".
In Fig. 6b, a fragmentary and perspective view of a second embodi-
ment of a plate segment of a mineral fiber-insulating web according to
the present invention is shown, designated the reference numeral 10' in
its entirety. Like the plate segment 10, described above with reference
to Fig. 6a, the plate segment 10' comprises the central core 12, the top
layer 14 and the bottom layer 16. Moreover, a top surface covering 15 is
provided, which is constituted by the foil 99' described above with re-
ference to Fig. 5. The top surface covering 15 may constitute a web of aplastics material, a woven or non-woven plastic foil, or alternatively a
- covering made from a non-plastics material, such as a paper material
serving design and architectural purposes exclusively. The top surface
layer 15 may alternatively be applied to the mineral fiber-insulating
web after the curing of the heat-curable bonding agent, i.e. after the
exposure of the mineral fiber-insulating web 90 to heat generated by the
oven sections 92 and 94 shown in Fig. 5.
WO 94/16164 PCTADK94/00029 ~
21536~ 24
Example 1
A central core or boidy of a heat-insulating plate made from a
mineral fiber-insulating web produced in accordance with the method
according to the present invention as described above with reference to
Figs. 1-5, is produced in accordance with the specifications listed
below:
The method comprises a sequence of steps similar to the steps
described above w;th reference to Figs. 2, 4a, 4c, 2 and the right-hand
part of Fig. 5. The production output of the plant is 5000 kg/h. The
area weight of the primary web is 0.5 kg/m2, and the width of the
primary web is 2850 mm. The rate of the first longitudinal compression
produced in the station dis-closed in Fig. 2 is 1:1.5; the rate of
transversal compression produced in the station disclosed in Fig. 4c is
also 1:1.5, and the rate of the second longitudinal compression produced
in the station disclosed in Fig. 2 is 1:1.5. The mineral fiber strips
produced in the station dis-closed in Fig. 4a are of a quadratic cross-
sectional configuration measuring 50 mm x 50 mm. The density of the
final plate disclosed in Fig. 5 is 110 kg/m3. The width of the final
mineral fiber-insulating web is 1800 mm.
The production parameters used are listed in tables A and B below:
2i~67~
WO 94/16164 PCT/DK94/00029
Table A
Total thickness A B C D E
- mm m/min x 10 m/min m/min m/min m/min
- 50 9.26 28.41 18.94 12.63 8.42
9.26 18.94 12.63 8.42 5.61
100 9.26 14.20 9.47 6.31 4.21
125 9.26 11.36 7.58 5.05 3.37
150 9.26 9.47 6.31 4.21 2.81
175 9.26 8.12 5.41 3.61 2.41
200 9.26 7.10 4.73 3.16 2.10
225 9.26 6.31 4.21 2.81 1.87
250 9.26 5.68 3.79 2.53 1.68
275 9.26 5.17 3.44 2.30 1.53
A = Velocity of belt 42
B = Velocity of belt 48
C = Velocity of belt 70 after first longitudinal compression (Fig. 2)
D ~ Velocity of belt 70 after transversal compression (Fig. 4c)
E = Velocity of belt 70 after second longitudinal compression and before
curing oven (Fig. 5)
-
WO 94/1616~ PCT/DK9~/00029 ~
21~367 0 26
Table B
Total thickness F G H I J K
mm kg/m kg/m2 kg/m2 kg/m2 k / 2
1.63 2.44 3.67 3.67 5.50 5.56
2.44 3.67 5.50 5.50 8.25 6.94
100 3.26 4.89 7.33 7.33 11.00 8.33
125 4.07 6.11 9.17 9.17 13.75 6.94
10 150 4.89 7.33 11.00 11.00 16.50 11.11
175 5.70 8.56 12.83 12.83 19.25 9.72
200 6.52 9.78 14.67 14.67 22.00 13.89
225 7.33 11.00 16.50 16.50 24.75 15.28
250 8.15 12.22 18.33 18.33 27.50 13.89
15 275 8.96 13.44 20.17 20.17 30.25 9.72
F = Area weight of mineral fiber-insulating web on belt 48
G = Area weight of mineral fiber-insulating web after first
longitudinal compression (Fig. 2)
H = Area weight of mineral fiber-insulating web after transversal
compression (Fig. 4c)
I = Area weight of mineral fiber-insulating web before second lon-
gitudinal compression (Fig. 2)
J = Area weight of mineral fiber-insulating web after second lon-
gitudinal compression (Fig. 2)
K = Amount of material recycled
In Fig. 7, a diagramme is shown, illustrating the correspondence
between the parameters listed in Table A. The reference signs used in
Fig. 7 refer to the parameters listed in Table A.
In Fig. 8, a diagramme is shown, illustrating the correspondence
between the parameters listed in Table B. The reference signs used in
Fig. 8 refer to the parameters listed in Table B.
2153~70
WO 94/16164 PCT/DK94/00029
Z7
Example 2
A central core or body of a roofing plate, made from a mineral
- fiber-insulating web produced in accordance with the method according to
the present invention as described above with reference to Figs. 1-5, is
- produced in accordance with the specifications listed below:
The method comprises a sequence of steps similar to the steps de-
scribed above with reference to Figs. 2, 4a, 4c, 2 and the right-hand
part of Fig. 5. The production output of the plant is 5000 kg/h. The
area weight of the primary web is 0.5 kg/m2, and the width of the pri-
mary web is 2850 mm. The rate of the first longitudinal compression pro-
duced in the station disclosed in Fig. 2 is 1:1.5; the rate of transver-
sal compression produced in the station disclosed in Fig. 4c is also
1:1.5, and the rate of the second longitudinal compression produced in
the station disclosed in Fig. 2 is 1:2. The mineral fiber strips pro-
duced in the station disclosed in Fig. 4a are of a quadratic cross-sec-
tional configuration measuring 50 mm x 50 mm. The density of the final
plate disclosed in Fig. 5 is 200 kg/m3. The width of the final mineral
fiber-insulating web is 1800 mm.
The production parameters used are listed in tables C and D below:
Table C
Total thickness A B C D E
25 mm m/min x 10 m/min m/min m/min m/min
9.26 20.83 13.89 9.26 4.63
9.26 13.89 9.26 6.17 3.09
100 9.26 10.42 6.94 4.63 2.31
30 125 9.26 8.33 5.56 3.70 1.85
150 9.26 6.94 4.63 3.09 1.54
- 175 9.26 5.95 3.97 2.65 1.32
200 9.26 5.21 3.47 2.31 1.16
- 225 9.26 4.63 3.09 2.06 1.03
35 250 9.26 4.17 2.78 1.85 0.93
275 9.26 3.79 2.53 1.68 0.84
WO 94/16164 PCT/DK94/00029 ~
2153~7~ 28
A = Velocity of belt 42
B ~ Velocity of belt 48
C = Velocity of belt 70 after first longitudinal compression (Fig. 2)
D = Velocity of belt 70 after transversal compression (Fig. 4c)
E = Velocity of belt 70 after second longitudinal compression and
before curing oven (Fig. 5)
In Fig. 9, a diagramme similar to the diagramme of Fig. 7 is shown,
illustrating the correspondance between the parameters listed above in
table C.
Table D
15 Total thickness F G H I J K
mm kg/m kg/m2 kg/m2 kg/m2 k / 2
2.22 3.33 5.00 5.00 10.00 5.5~
3.33 5.00 7.50 7.50 15.00 6.94
100 4.44 6.67 10.00 10.00 20.00 8.33
125 5.56 8.33 12.50 12.50 25.00 6.94
150 6.67 10.00 15.00 15.00 30.00 11.11
175 7.78 11.67 17.50 17.50 35.00 9.72
200 8.89 13.33 20.00 20.00 40.00 13.89
225 10.00 15.00 22.50 22.50 45.00 15.28
250 11.11 16.67 25.00 25.00 50.00 13.89
275 12.22 18.33 27.50 27.50 55.00 9.72
F = Area weight of mineral fiber-insulating web on belt 48
G = Area weight of mineral fiber-insulating web after first
longitudinal compression (Fig. 2)
H = Area weight of mineral fiber-insulating web after transversal
compression (Fig. 4c)
I = Area weight of mineral fiber-insulating web before second lon-
gitudinal compression (Fig.2)
~ WO 94/16164 215 3 6 7 0 PCT~DK94/00029
29
J = Area weight of mineral fiber-insulating web after second lon-
gitudinal compression (Fig. 2)
K = Amount of material recycled
In Fig. 10, a diagramme similar to the diagramme of Fig. 8 is
- shown, illustrating the correspondance between the parameters listed above in table D.
Example 3
A central core or body of a heat-insulating plate made from a
mineral fiber-insulating web produced in accordance with the method
according to the present invention as described above with reference to
Figs. 1-5, iS produced in accordance with the specifications listed
below:
The method comprises a sequence of steps similar to the steps de-
scribed above w;th reference to Figs. 2, 4a, 4c, 2 and the right-hand
part of Fig. 5. The production output of the plant is 5000 kg/h. The
area weight of the primary web is 0.4 kg/m2, and the width of the pri-
mary web is 2280 mm. The rate of the first longitudinal compression pro-
duced in the station disclosed in Fig. 2 is 1:1.1; the rate of transver-
sal compression produced in the station disclosed in Fig. 4c is also
1:1.2, and the rate of the second longitudinal compression produced in
the station disclosed in Fig. 2 is 1:1.2. The mineral fiber strips pro-
duced in the station disclosed in Fig. 4a are of a quadratic cross-sec-
tional configuration measuring 50 mm x 50 mm. The density of the final
plate disclosed in Fig. 5 is 20 kg/m3. The width of the final mineral
fiber-insulating web is 1800 mm.
The production parameters used are listed in tables A and B below:
WO 91/16164 PCT/DK9~/00029 ~
2~67a
Table E
Total thickness A B C D E
mm m/min x 10 m/min m/min m/min m/min
t -- -- _ _ _ _ _ _ _ _ _ _ _ _ _
1~1 . 57 73.33 66.67 55.56 46.30
11.57 48.89 44.44 37.04 30.86
100 11.57 36.67 33.33 27.78 23.15
125 11.57 29.33 26.67 22.22 18.52
150 11.57 24.44 22.22 18.52 15.43
175 11.57 20.95 19.05 15.87 13.23
200 11.57 18.33 16.67 13.89 11.57
225 11.57 16.30 14.81 12.35 10.29
250 11.57 14.67 13.33 11.11 9.26
275 11.57 13.33 12.12 10.10 8.42
A = Velocity of belt 42
B = Velocity of belt 48
C = Velocity of belt 70 after first longitudinal compression (Fig. 2)
D = Velocity of belt 70 after transversal compression (Fig. 4c)
E = Velocity of belt 70 after second longitudinal compression and before
curing oven (Fig. 5)
In Fig. 11, a diagramme similar to the diagramme of Fig. 7 is
shown, illustrating the correspondance between the parameters listed
above in table E.
~ WO 94/16164 215 3 6 7 0 PCT/I~K94/00029
31
Table F
Total thickness F G H I J K
mm kg/m2 kg/m2 kg/m2 kg/m2 kg/m %
_ _ _ _ _ _ _ _
0.63 0.69 0.83 0.83 1.00 5.56
0.95 1.04 1.25 1.25 1.50 6.94
100 1.26 1.39 1.67 1.67 2.00 8.33
125 1.58 1.74 2.08 2.08 2.50 6.94
10 150 1.89 2.08 2.50 2.50 3.00 11.11
175 2.21 2.43 2.92 2.92 3.50 9.72
200 2.53 2.78 3.33 3.33 4.00 13.89
225 2.84 3.13 3.75 3.75 4.50 15.28
250 3.16 3.47 4.17 4.17 5.00 13.89
15 275 3.47 3.82 4.58 4.58 5.50 9.72
F = Area weight of mineral fiber-insulating web on belt 48
G = Area weight of mineral fiber-insulating web after first
longitudinal compression (Fig. 2)
H = Area weight of mineral fiber-insulating web after transversal
compression (Fig. 4c)
I = Area weight of mineral fiber-insulating web before second lon-
gitudinal compression (Fig. 2)
25 J = Area weight of mineral fiber-insulating web after second lon-
gitudinal compression (Fig. 2)
K s Amount of material recycled
In Fig. 12, a diagramme similar to the diagramme of Fig. 8 iS
30 shown, illustrating the correspondance between the parameters listed
above in table F.
Example 4
The importance of exposing the mineral fiber-insulating web to a
longitudinal and transversal compression is illustrated in the data in
table G given below:
WO 94/16164 PCT/DK94/00029 _
21~3~7~ _
32
c a~v~ _ c
cC ~ o
_ C _
o^ ~ ~ ~ ~ ~ ~
` ~ ~ ~U _ y y y
~ C ~
C cn O _ G 0~ O O O
-- c -- cn E m ~ o
_ ~ C O ' --I N O
C O U ' et
O
-- U C O
4-- U _ ~~n
;
~ ~ " O C
c ~
_ ~ _ X ~ I I I I
C ~ ~ ~
O
a~ ,._
cr~ ~ _v~
_ ,c
~ ~ O ~ ~ ~ 1~5 ~
-- ~ E C~- y y y
c o u ~ ~n o o
C ~ O _ C~JCo o
_ C _ _ _I
-- ~ o ~5
C
o
_ U C~)
U _ ~ V~
~ o C
CD I _ ~ C 115
nJ v~ ~ X
c ~a~ ~n _ I , ,
_ _ s_ C
- Q ~ -- C
y y y y
o
Q c.'~ c _
C cn
-- CV~
E _ cas c
~ _
C ~
o ~ o o
_ c a) a
C
c ~ a~~:s ~ ~
o _ ~o o
~_~ ," ta --~ E
--~ -- E _ --
~7 Y
C _ ~ Y
-- ~ ~ o _ ~U~
C o
_ ~ ~ o
I ~ o o c~ o o
~ WO 94/16164 215 3 6 7 0 PCT/DK94/00029
33
The mineral fiber-insulating plates according to the present
invention clearly demonstrate increased pressure strength and modulus of
elasticity as compared to a conventional heat-insulating plate. The
mechanical performance of the mineral fiber-insulating plates according
to the present invention, is, however, further increased by exposing the
- mineral-insulating web, from which the insulating plates are produces,
to longitudinal and transversal compression as discussed above with
reference to Fig. 2 and Fig. 4b.
