Note: Descriptions are shown in the official language in which they were submitted.
WO 94/16163 215 3 ~ 71 PCT/DK9~/00028
r
A METHOD OF PRODUCING A MINERAL FIBER-INSULATING WEB, A PLANT FOR
PRODUCING A MINERAL FIBER WEB, AND A MINERAL FIBER-INSULATED PLATE.
t The present invention generally relates to the technical field of
5 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
10 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-
15 mogeneous webs, i.e. webs in which the mineral fibers of which the
mineral 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
20 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,
25 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
30 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.
WO92/10602, US patent No. 4,950,355, Swedish patent No. 441,764, US
patent No. 2,546,230 and US patent No. 3,493,452. Reference is made to
the above patent applications and patents, and the above US patents are
hereby incorporated in the present specification by reference.
WO 91/16163 .. PCT/DK9~/00028 ~
21~3~71 ` 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 Swedish patent No. 441,764, a technique of producing mineral
fiber boards or plates composed of rod-shaped elements is known, which
technique is similar to the technique described in the above mentioned
international patent application. Thus, according to the technique
described in the above Swedish patent, a web of a mineral fiber material
is cut into rod-shaped elements of a specific length which are thereupon
turned and reassembled into a composite rod-shaped mineral fiber plate
structure in which the rod-shaped elements are glued together by means
of strands of bonding material which are introduced into through-going
apertures of the composite rod-shaped mineral fiber plate structure in a
separate production step.
From US patent No. 2,546,230, a technique of producing mineral
fiber boards or plates composed of rod-shaped elements are known. Thus,
the technique described in US patent No. 2,546,230 is very much similar
to the techniques known from the above-mentioned international patent
application and the above-mentioned Swedish patent and involves a
separate step of bonding the rod-shaped lamellae together by means of an
appropriate bonding agent.
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 batt 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,
WO 94/16163 215 ~ ~ 71 PCT/DK94/00028
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
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 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
30 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-
WO 94/16163 ~ , PCT/DK94/00028 ~
2~53~71 `i
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 curable bonding
agent,
b) moving the first mineral fiber web in the first longitudinal
direction of the first mineral fiber web,
c) folding the first mineral fiber web parallel with the first
longitudinal direction and perpendicular to the second transversal di-
rection so as to produce a second non-woven mineral fiber web, the se-
cond mineral fiber web comprising a central body and opposite surface
layers sandwiching the central body, the central body containing mineral
fibers arranged generally perpendicular to the first longitudinal
direction and the second transveral direction, and the surface layers
containing mineral fibers arranged generally in the second transversal
direction,
d) moving the second mineral fiber web in the first longitudinal
direction,
e) 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 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,
f) 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
g) 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).
WO 94/16163 21~ ~ 8 71 PCT/DE~94/00028
- 5
In accordance with a first 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 for producing the
5 third mineral fiber web.
The third mineral fiber web may additionally be produced by com-
pacting the surface segment layer comprising the step of folding the
surface segment layer so as to produce the third mineral fiber web con-
taining mineral fibers arranged generally orientated transversely rela-
tive to the longitudinal direction of the third mineral fiber web.
According to a further, presently preferred embodiment of the me-
thod according to the present invention, the third non-woven mineral
fiber web is produced by separating one of the surface layers of the se-
cond mineral fiber web produced in step c) from the central body thereof
15 and by compacting the surface layer for producing the third mineral
fiber web. Provided the third mineral fiber web is produced by
separating the surface layer from the second mineral fiber web, the
mineral fibers of the third mineral fiber web maintain the general
orientation of the mineral fibers of the second mineral fiber web, i.e.
20 the orientation generally in the second transversal direction.
The method according to the present invention preferably further
comprises the additional step similar to step e) of producing a fifth
non-woven mineral fiber web similar to the third mineral fiber web, and
the step of adjoining in step f) the fifth mineral fiber web to the se-
25 cond mineral fiber web in facial contact therewith and so as to sandwichthe 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 step of folding the first mineral fiber web is preferably car-
ried out so as to produce continuous ondulation extending in the first
35 longitudinal direction of the first mineral fiber web in order to pro-
duce an accurately structured, folded second mineral fiber web from
which the surface layer(s) are easily separated.
WO 91/16163 PCT/DK94/00028 ~
2153~71
Provided the third mineral fiber web is provided as surface layers
separated from the second mineral fiber web, the mineral fibers of the
third mineral fiber web are as discussed above generally orientated
along the second transversal direction. Consequently, the third direc-
tion may coincide with the second transversal direction and consequentlybe perpendicular to the first longitudinal direction.
Provided the third non-woven mineral fiber web is produced by a se-
parate production line, the third direction may be of any arbitrary o-
rientation, e.g. be identical to the first longitudinal direction and
consequently, be perpendicular to the second transversal direction.
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 mineralfiber 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
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
21~3671
WO 94/16163 PCT/DK94/00028
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 c). By performing a longi-
tudinal compression, the mineral fiber web exposed to the longitudinalcompression is made more homogeneous, resulting in an overall improve-
ment of the mechanical performance and, in most cases, 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 the
present invention exhibit surprisingly improved mechanical properties
and mechanical performance, provided the second non-woven mineral fiber
web produced in step c) is exposed to transversal compression, producing
a homogenization of the mineral fiber structure of the second non-woven
mineral f;ber 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
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.
WO 94/16163 ' : ' PCT/DK94/0002~ ~
21~3671 8
Provided the mineral fiber-insulating web is produced as a three-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 mineral
fiber web, which central body is constituted by the central body of the
second non-woven mineral fiber web.
In order to provide a more homogeneous and compact mineral fiber
web to be introduced into the curing oven in step g), the method accor-
ding to the present invention preferably further comprises the additio-
nal step of compacting the fourth composite mineral fiber web prior to
introducing the fourth composite mineral fiber web into the curing oven.
By compacting the fourth composite mineral fiber web, the homogenity of
the final product is improved as the compacting of the fourth composite
mineral fiber web produces a homogenizing effect on the central body of
the fourth composite mineral fiber web, which central body is consti-
tuted by the central body of the second non-woven mineral fiber web.
The step g) 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 agents, be carried out in nu-
merous diffent ways, e.g. by simply exposing the curable bonding agent
or agents to a curing gas or a curing atmosphere, such as the atmos-
phere, by exposing the curable bonding agent or agents to radiation,
such as UV radiation or IR radiation. Provided the curable bonding agent
or 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 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,
WO 94/16163 21~ 3 6 71 I'CT/DK94/00028
microwave radiators, etc.
From the cured mineral fiber-insulating web produced in step g),
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-
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 d;rection 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 curable bonding agent,
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 folding the first mineral fiber web parallel
with the first longitudinal direction and perpendicular to the second
transversal direction so as to produce a second non-woven mineral fiber
web, the second mineral fiber web comprising a central body and opposite
surface layers sandwiching the central body, the central body containing
mineral fibers arranged generally perpendicular to the first
longitudinal direction and the second transveral direction, and the
surface layers containing mineral fibers arranged generally in the se-
cond transversal direction,
d) fourth means for moving the second mineral fiber web in thefirst longitudinal direction,
e) fifth 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 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,
- f) sixth 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
g) seventh means for curing the first and second curable bonding
WO 94/16163 ~ PCT/DK94/00028 ~
2153~7~ ~o
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 pre-
sent 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 uncured, 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
Fig. 1 is a schematic and perspective view illustrating a first
~5 production step of producing a mineral fiber-insulating web from a
mineral fiber forming melt,
Fig. 2 is a schematic and perspective view illustrating a produc-
WO 91/16163 215 3 ~ 71 PCT/DK94/00028
11
tion step of compacting a mineral fiber-insulating web,
Figs. 3, 4, 5 and 6 are schematic and perspective views illustra-
ting four alternative techniques of folding a mineral fiber-insulating
web parallel with the longitudinal direction of the mineral fiber-insu-
lating web,
Fig. 7 is a schematic and perspective view illustrating a produc-
tion step of separating a surface layer of the folded mineral fiber-in-
sulating web produced in accordance with the techniques disclosed in
Figs. 3-6, and a production step of compacting the surface layer,
Fig. 8 is a schematic and perspective view illustrating a produc-
tion step of transversely compressing a mineral fiber-insulating web
produced in the production step shown in Fig. 7,
Fig. 9 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, or preferably a remaining part
of a mineral fiber-insulating web produced in accordance with the
techniques disclosed in Figs. 3-6, and from which a surface layer has
been separated in accordance with the technique disclosed in Fig. 7,
Fig. 10 is a schematic and perspective view illustrating a produc-
tion step of curing a mineral fiber-insulating web and a production step
of separating the cured mineral fiber-insulating web into plate seg-
ments,
Fig. 11 is a schematic, sectional and perspective view illustrating
the folded mineral fiber-insulating web produced in accordance with the
techniques disclosed in Figs. 3-6,
Fig. 12 is a schematic and perspective view illustrating a first
embodiment of a mineral fiber-insulating plate segment produced in ac-
cordance with the techniques disclosed in Figs. 1-10,
Fig. 13 is a schematic and perspective view illustrating a second
embodiment of a mineral fiber-insulating plate segment produced in ac-
cordance with the techniques disclosed in Figs. 1-10,
Figs. 14 and 15 are diagrammatic views illustrating production pa-
rameters of an online production plant producing general building-insu-
- lating plates from a mineral fiber-insulating web produced in accordance
with the teachings of the present invention, and
Figs. 16 and 17 are diagrammatic views similar to the views of
Figs. 14 and 15, respectively, illustrating production parameters of an
WO 94/16163 ~` ' PCT/DK9~/00028 ~
~1~3~7~ 12
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 fiberspray 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 collectorsection, whereas the second section constitutes a transport section by
means of which the primary mineral fiber-insulating web 40 is trans-
ferred to a second and a third continuously operated conveyer belt de-
signated the reference numeral 44 and 46, respectively, which are opera-
ted in synchronism with the first conveyer belt 42 sandwiching the pri-
mary mineral fiber-insulating web 40 between two adjacent surfaces of
the second 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-
ly, are swung across the upper surface of the fourth conveyer belt 48 in
WO 9~/16163 21 S 3 6 71 PCT/DK94/00028
13
the transversal direction relative to the fourth conveyer belt 48. The
secondary mineral fiber-insulating web 50 is consequently produced by
arranging the primary mineral fiber-insul ating web 40 in overl apping re-
lation generally in the transversal direction of the fourth conveyer
5 belt 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
compared to the less homogeneous primary mineral fiber-insulating web.
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-
tation of the first conveyer belt 42. Contrary to the primary mineral
fiber-insul ating web 40 the overall orientation of the mineral fibers of
15 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-
tion of the fourth conveyer belt 48.
In Fig. 2, a station for compacting and homogenizing an input
20 mineral 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
50", which output mineral fiber-insulating web 50" is more compact and
more homogeneous as compared to the input mineral fiber-insulating web
25 50'. The input mineral fiber-insulating web 50' may constitute the
secondary mineral fiber-insulating 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-
30 per side surface and the lower side surface, respectively, of themineral 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
height compression, causing a reduction of the overall height of the
- mineral fiber web and a compacting of the mineral fiber web. The
35 conveyer belts 52" and 54" are consequently arranged in a manner, in
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,
WO 94/16163 PCT/DK94/00028 ~
2153~71 14
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
10 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"
and 58", and 56''' and 58''' of the second section are rotated at the
same rotational speed, which is, however, lower than the rotational
15 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
the height-compression section, or alternatively the second section
constituting the longitudinal-compression section. By the omission of
25 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
a longitudinally-compressing station. Although the height-compressing
section has been described including conveyer belts, and the longitudi-
30 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
the longitudinally-compressing section may be implemented by means of
conveyer belts.
In Figs. 3, 4, 5 and 6, four alternative techniques of folding a
mineral fiber-insulating web in the longitudinal direction of the
mineral fiber-insulating web are disclosed. In Figs. 3, 4, 5 and 6, the
21S3~71
WO 94/16163 PCT/DK94/00028
mineral fiber-insulating web 50" may constitute the output mineral
fiber-insulating web 50" shown in Fig. 2, or alternatively the mineral
fiber-insulating web 50 produced in the staticn shown in Fig. 1.
In Fig. 3, the mineral fiber-insulating web 50" is brought into
5 contact with a pressing roller 51, by means of which a continuous foil
99 of a thermoplastic material is applied to the upper side surface of
the mineral fiber-insulating web 50". The continuous foil of the ther-
moplastic material is supplied from a roll 98. After the continuous foil
99 has been applied to the upper side surface of the mineral fiber-insu-
10 lating web 50", the mineral fiber-insulating web 50 n and the continuous
foil 67 applied thereto are forced through a corrugated gate 60' which
gate comprises two oppositely arranged, corrugated guide plates 64' and
66' and two oppositely arranged end walls, one of which is designated
the reference numeral 62'. As will be readily understood, the foil 99
15 has to be of an elasticity allowing that the foil 99 and the mineral
fiber-insulating web 50" are folded. The end walls of the corrugated
gate 60' and the corrugations of the corrugated gate plates 64' and 66'
taper from an input end of the corrugated gate 60' to an output end
thereof. As the mineral fiber-insulating web 50" and the foil 99 applied
20 thereto are forced through the corrugated gate 60', the mineral fiber-
insulating web is folded in its longitudinal direction providing a cor-
rugated and l ongitudinally folded mineral fiber-insul ating web 50'''.
In Fig. 4, an alternative technique of producing the corrugated and
longitudinally folded mineral fiber-insulating web 50''' from the plane
25 mineral fiber-insulating web 50" is disclosed. The technique disclosed
in Fig. 4 differs from the technique described above with reference to
Fig. 3 in that a gate 60" is used, which gate 60" differs from the cor-
rugated gate 60" shown in Fig. 3 in that the gate 60" comprises plane
oppositely arranged walls one of which is designated the reference nume-
30 ral 64" and curved end walls one of which is designated the referencenumeral 62".
In Fig. 5, a further alternative technique of producing a longitu-
dinally folded mineral fiber-insulating web 50''' from the plane mineral
- fiber-insulating web 50" is shown. The corrugated and longitudinally
35 folded mineral fiber-insulating web 50''' is in accordance with the
technique shown in Fig. 5 produced by means of a roller assembly 60'''
comprising plane end walls 62''' serving the same purpose as the plane
WO 91/16163 PCT/DK94/00028 ~
21~3~7~ ~ 16
end walls 62' and curved end walls 62" shown in Figs. 3 and 4, respec-
tively, viz. the purposè of guiding the outer edges of the plane mineral
fiber-insulating web 50" to the corrugated and longitudinally folded
configuration of the mineral fiber-insulating web 50'''. The roller as-
5 sembly 60''' further comprises a total of eight sets of rollers, eachset of rollers containing two rollers arranged at opposite sides of the
mineral fiber-insulating web. In Fig. 5, two rollers are designated the
reference numeral 68. The sets of rollers define a tapered configuration
tapering from an input end of the roller assembly 60''' to an output end
10 thereof from which output end the corrugated and longitudinally folded
mineral fiber-insulating web 50''' is supplied. The tapered configura-
tion serves the purpose of assisting the plane mineral fiber-insulating
web 50" to corrugate and longitudinally fold into the configuration of
the folded mineral fiber-insulating web 50''' shown in Fig. 5.
In Fig. 6, a further alternative technique of producing a longitu-
dinally folded mineral fiber-insulating web 50''' is shown. According to
the technique disclosed in Fig. 6, a station 60"" iS employed, which
station constitutes a combined height/longitudinally-compressing station
and a transversally-folding station. Thus, the station 60"" comprises a
20 total of 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.
The station 60"" shown in Fig. 6 further comprises three sets of
rollers, a first set of which is constituted by two rollers 152' and
25 154', 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''' are 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
30 side surface of the mineral fiber-insulating web 50" like the rollers
58', 58" and 58'''. The three sets of rollers 152', 154'; 152", 154";
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
35 60"".
The three sets of height-compressing rollers 152', 154'; 152",
154"; and 152''', 154''' are like the above-described belt assemblies
WO 94/16163 21~ 3 6 71 PCT/DK94/00028
17
52", 54" operated at a rotational speed identical to the velocity of the
mineral fiber-insulating web 50" input to the height-compressing section
of the station 60"". The three sets of rollers constituting the longitu-
dinally-compressing section, i.e. the rollers 56', 58'; 56", 58"; and
5 56''', 58''', are operated at a reduced rotational speed determining the
longitudinal compression ratio.
For generating the longitudinal folding of the mineral fiber-insu-
lating web 50" input to the station 60"", shown in Fig. 6, four crank-
shaft assemblies designated the reference numerals 160', 160", 160''',
10 and 160"" are provided. The crankshaft assemblies are of identical
structures, and in the below description a single crankshaft assembly,
the crankshaft assembly 160", is described, as the crankshaft assemblies
160', 160''' and 160"" are identical to the crankshaft assembly 160" and
comprise elements identical to the elements of the crankshaft assembly
15 160", however, designated the same reference numerals 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
six gearwheels 168" of identical configurations are mounted on the out-
20 put shaft 166". Each of the gearwheels 168" meshes with a correspondinggearwheel 170". Each of the gearwheels 170" constitutes a drivewheel of
a crankshaft lever system further comprising an idler wheel 172" and a
crankshaft 1 ever 174". The crankshaft levers 174" are arranged so as to
be lifted from a retracted position to an elevated position between two
25 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 50" 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. 6, 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
WO 94/16163 . ~ i PCT/DK94/00028 ~
21~3~7~ 18
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 folding of the mineral fiber-insulating web
50", as the crankshaft levers 174" and 174"" of the crankshaft lever sy-
stems 160" and 160"", respectively, are raised from positions below the
lower side surface of the mineral fiber-insulating 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 simul-
taneously lowered from positions above the upper side surface of the
mineral fiber-insulating web 50" and brought into contact with the upper
side surface of the mineral fiber-insulating web 50".
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 50", produ-
cing a central fold of the mineral fiber-insulating web 50". As the
crankshaft levers of the first set of crankshaft levers reach the cen-
tral position, the crankshaft levers of the crankshaft lever systems
160' and 160''' are raised, whereas the crankshaft levers of the crank-
shaft 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
WO 94/16163 2 1 5 3 6 71 PCT/DK94/00028
the station 60"", the next or second set of crankshaft levers generates
a second and a third fold of the mineral fiber-insulating web 50", which
second or third fold is positioned at opposite sides of the first fold,
whereupon the third, the fourth, the fifth, and the sixth sets of crank-
shaft levers produce additional folds of the mineral fiber-insulating
web, producing an overall, longitudinal folding of the mineral fiber-in-
sulating web.
The width of the crankshaft levers of each set of crankshaft
levers, 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 height
compression and the longitudinally-compressing sections of the station
for producing the longitudinally-folded, and height- and longitudinally-
compressed mineral fiber-insulating web 50'''.
The integration of the height-compressing section, the longitudi-
nally-compressing section and the longitudinally-folding section into a
single station, as described above with reference to Fig. 6, is, by no
means, mandatory to the operation of the longitudinally-folding crank-
shaft systems described above with reference to Fig. 6. Thus, theheight-compressing section, the longitudinally-compressing section and
the longitudinally-folding section may be separated, however, the inte-
gration of all three functions reduces the overall size of the produc-
tion plant. Furthermore, it is to be realized that the folding of the
mineral fiber web as discussed above with reference to Figs. 4, 5 and 6
provides a transversal compacting and compression of the web, further
providing a homogenization of the web as compared to the unfolded input
web.
In Fig. 11, a vertical sectional view of the corrugated and longi-
tudinally folded mineral fiber-insulated web 50''' is shown. The corru-
gated and longitudinally folded mineral fiber-insulating web 50''' com-
prises a central core or body 28 and two oppositely arranged surface
layers 24 and 26, which surface layers 24 and 26 are separated from the
- central core or body 28 of the corrugated and longitudinally folded
mineral fiber-insulating web 50''' along imaginary lines of separation
20 and 22, respectively. The surface layers 24 and 26 of the corrugated
and longitudinally folded mineral f;ber-insulating web 50''' are
WO 94/16163 PCT/DK94/00028
21536~1 20
composed of segments of the folded mineral fiber-insulating web which
segments contain mineral fiibers which are orientated substantially
transversally relative to the longitudinal direction of the corrugated
and longitudinally folded mineral fiber-insulating web 50'''. The
corrugated and longitudinally folded mineral fiber-insulating web 50'''
is produced from the secondary mineral fiber-insulating web 50 by
folding the secondary mineral fiber-insulating web 50, optionally after
compacting the secondary mineral fiber-insulating web 50, as will be
described below with reference to Fig. 8, and the overall orientation of
the mineral fibers of the secondary mineral fiber-insulating web 50 is
consequently maintained within the segments of the corrugated and
longitudinally folded mineral fiber-insulating web 50''' which segments
together constitute the surface layers 24 and 26.
The central core or body 28 of the corrugated and longitudinally
folded mineral fiber-insulating web 50''' is composed of segments of the
folded mineral fiber-insulating web 50''' which segments are folded per-
pendicular to the segments of the surface layers 24 and 26 of the
mineral fiber-insulating web 50'''. The mineral fibers of the central
core of body 28 of the corrugated and longitudinally folded mineral
fiber-insulating web 50''' are consequently orientated substantially
perpendicular to the longitudinal direction as well as the transversal
direction of the corrugated and longitudinally folded mineral fiber-
insulating web 50'''.
The corrugated and longitudinally folded mineral fiber-insulating
web 50''' shown in Fig. 9 and produced in accordance with the techniques
discussed above with reference to Figs. 3, 4, 5 and 6 is further pro-
cessed in a station illustrated in Fig. 7, in which station the surface
layer 24 is separated from the central core or body 28 of the corrugated
and longitudinally folded mineral fiber-insulating web 50''' along the
imaginary line of separation 20, shown in Fig. 9. The separation of the
surface layer 24 from the remaining part of the mineral fiber-insulating
web is accomplished by means of a cutting tool 72 as the remaining part
of the mineral fiber-insulating web 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 alternatively 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
2153~71
WO 94/16163 PCT/DK94/00028
21
r
of the remaining part of the 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'",
5 which three set of rollers together constitute a compacting or com-
pressing section similar to the second section of the corresponding sta-
tion described above with reference to Fig. 2.
In Fig. 8, a transversally-compressing station is shown, which is
designated the reference numeral 80 in its entirety. In the station 80,
10 the central core or body 28 or alternatively the corrugated and longitu-
dinally folded mineral fiber-insulating web 50'", produced in one of
the stations described above with reference to Figs. 3, 4, 5 and 6, is
brought into contact with two conveyer belts 85 and 86, which define a
constriction in which the mineral fiber-insulating web is caused to be
15 transversally compressed and into contact with a total of four surface-
agitating rollers 89a, 89b, 89c and 89d which together 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 transver-
sal compression of the central core or body 28. The conveyer belts 85
20 and 86 are journalled on rollers 81, 83 and 82, 84, respectively.
From the transversally-compressing station 80, a transversally
compressed and compacted central core or body 28' is supplied. As the
central core or body 28 is transmitted through the transversally-com-
pressing station 80 and transformed into the transversally compressed
25 central core or body 28', the core or body is supported on rollers con-
stituted by an input roller 87 and an output roller 88.
Although the central core or body 28 input to the transversally-
compressing station 80 is preferably constituted by the above-described
central core or body separated from the mineral fiber-insulating web
30 50", as described above with reference to Fig, 7, the mineral fiber-in-
sulating web 50" may alternatively be processed in the station 80 shown
in Fig. 8.
Provided the central core or body 28 or the mineral fiber-insula-
ting web 50''' to be transversally compressed within the station 80 is
35 provided with a top surface layer, such as the foil 99 described above
with reference to Fig. 3, the foil has to be of a structure compatible
with the transversal compression of the web and foil assembly. Thus, the
~93/~6j6~ 22 PCT/DK94/00028
foil applied to the upper side surface of the mineral fiber-insulating
web 50", as shown in Fig. 3, has to be compressable and adaptable to the
reduced width of the transversal-ly compressed central core or body 28'
or the transversally compressed mineral fiber-insulating web output from
the transversally-compressing station 80.
As the compacting of the separate surface layer 24 has been accom-
plished, as described above with reference to Fig. 7, the compacted sur-
face layer 24 is returned to the remaining part of the mineral fiber-in-
sulating web or the central core or body, which has preferably been
transversally compressed as described above with reference to Fig. 8,
and adjoined in facial contact with the upper surface of the central
core or body 28, as shown in Fig. 9.
In Fig. 9, 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 central core or body
28, is shifted towards the upper side surface of the central core or bo-
dy 28 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 sur-
face layer 24, serves the purpose of pressing the compacted surface
layer 24 into facial contact with the upper side surface of the central
core or body 28, which is supported and transported by means of the con-
veyer belt 70 also shown in Fig. 7. After the compacted surface layer 24
has been arranged in facial contact with the upper side surface of the
central core or body 28, a mineral fiber-insulating web assembly is pro-
vided, which assembly is designated the reference numeral 90 in its en-
tirety.
In Fig. 9, a further foil 99" is shown in dotted line. This foil is
supplied from a roll 98". The foil 99" may constitute a continuous foil
or alternatively a mesh foil, i.e. a foil similar to the surface foil
99' described above. It is, however, to be emphasized that the foils 99,
99' and 99" constitute optional features which may be omitted, provided
an integral mineral fiber web structure is to be produced. Alternative-
WO 94/16163 215 3 6 71 PCT/DK94/00028
23
ly, 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.
- 7, may alternatively be provided from a separate production line, as one
of the production stations shown in Fig. 3, 4, 5 and 6 may communicate
directly with the production station shown in Fig. 9, optionally through
the production station shown in Fig. 8, thus, eliminating the production
station shown in Fig. 7. Preferably, the production station shown in
Fig. 7 is adapted to separate two surface layers from the central core
or body 28 for producing two separated surface layers separated from op-
posite side surfaces of the central core or body 28, which surface
layers are processed in accordance with the technique described above
with reference to Fig. 7 for the formation of two high compactness sur-
face layers which, in accordance with the technique described above with
reference to Fig. 9, are adjoined with the central core or body 28 at
opposite side surfaces thereof, producing a sandwiching of the central
core or body 28, which has preferably been transversally compressed as
described above with reference to Fig. 8, between two opposite surface
layers similar to the surface layer 24 shown in Fig. 9.
In Fig. 10, the mineral fiber-insulating web assembly 90 is moved
through a curing station constituting a curing oven or curing furnace
comprising oppositely arranged curing oven sections 92 and 94, which ge-
nerate heat for heating the mineral fiber-insulating web assembly 50 to
an elevated temperature so as to cause the heat-curable 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 to-
gether 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 99 and optionally the continuous foils 99' and 99" are pro-
vided, the thermoplastic material of the foils 99, 99' and 99" is also
melted, providing an additional bonding of the mineral fibers of the
mineral fiber-insulating web. In Fig. 10, 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
WO 94/16163 PCT/DK94/00028 ~
21~3~ 1 24
12 is made from the central core or body 28 of the corrugated and
longitudinally folded mineral fiber-insulating web 50''' shown in Fig.
9.
In Fig. 12, 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 the central core or body 28 of the corrugated and longitu-
dinally folded mineral fiber-insulating web 50''', which central core or
body has preferably been transversally compressed as described above
with reference to Fig. 8.
In Fig. 13, 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. 12, 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. 9. The top surface covering 15 may constitute a web of a
plastics 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. 10.
Example 1
A heat-insulating plate of a structure similar to the plate shown
in Fig. 12, made from a mineral fiber-insulating web produced in accor-
dance with the method according to the present invention as describedabove with reference to Figs. 1-10, is produced in accordance with the
specifications listed below:
21~3671
WO 94/16163 PCT~DK94/00028
The method comprises steps similar to the steps described above
with reference to Figs. 1, 2, 6, 7, 8, 9 and 10. The production output
of the plant is 5000 kg/h. The area weight of the primary web produced
in the station disclosed in Fig. 1 is 0.4 kg/m2, and the width of the
primary web is 3600 mm. The density of the central core or body 28 iS 20
- kg/m3. The rates of longitudinal compression produced in two separate
stations similar to the station disclosed in Fig. 2 are 1:1 and 1:2, re-
spectively, and the rate of transversal compression produced in the sta-
tion disclosed in Fig. 8 iS 1:2. The final plate comprises a single
surface layer of an area weight of 1 kg/m2. The rate of longitudinal
compression of the surface layer is 1:2. The thickness of the surface
layer 10.00 mm, and the density of the surface layer is 100 kg/m3. The
width of the mineral fiber-insulating web produced in Fig. 1 is 1800 mm.
The production parameters used are listed in tables A and B below:
Table A
Total thickness A B C D E F
mm m/min x 10 m/minm/min m/min m/min m/min
- - - - - - - - - _ _ _ _ _ _ _ _
11.57 51.4451.44 51.44 15.72 25.72
11.57 40.2640.26 40.26 20.13 20.13
100 11.57 33.0733.07 33.07 16.53 16.53
125 11.57 28.0628.06 28.06 14.03 14.03
25150 11.57 24.3724.37 24.37 12.18 12.18
175 11.57 21.5321.53 21.53 10.77 10.77
200 11.57 19.2919.29 19.29 9.65 9.65
225 11.57 17.4717.47 17.47 8.74 8.74
250 11.57 15.9615.96 15.96 7.98 7.98
30275 11.57 14.7014.70 14.70 7.35 7.35
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
- A = Velocity of belt 42 of spinning chamber
B = Velocity of belt 48
C = Velocity of belt 70 after first longitudinal compression (Fig. 2)
35 D = Velocity of belt 70 after transversal compression (Fig. 8)
E = Velocity of belt 70 after second longitudinal compression (Fig. 2)
F = Velocity of belt 70 before curing oven (Fig. 5)
WO 94/16163 PCT/I~K91/00028
26
21536~ 1
Table B
Total thickness G H ` I J K L
mm kg/m kgjm2 kg/m2 kg/m2 k / 2 kg/m2
0.45 0.45 0.90 0.40 0.80 1.80
0.58 0.58 1.15 0.65 1.30 2.30
100 0.70 0.70 1.40 0.90 1.80 2.80
10 125 0.83 0.83 1 .65 1.15 2.30 3.30
150 0.95 0.95 1.90 1.40 2.80 3.80
175 1.08 1.08 2.15 1.65 3.30 4.30
200 1.20 1.20 2.40 1.90 3.80 4.80
225 1.33 1.33 2.65 2.15 4.30 5.30
15 250 1.45 1.45 2.90 2.40 4.80 5.80
275 1.58 1.58 3.15 2.65 5.30 6.30
G = Area weight of mineral fiber-insulating web on belt 42
20 H = Area weight of mineral fiber-insulating web after first
longitudinal compression (Fig. 2)
I = Area weight of mineral fiber-insulating web after transversal
compression (Fig. 8)
J = Area weight of mineral fiber-insulating web before second lon-
9 i tudinal compression (Fig. 2)
K = Area weight of mineral fiber-insulating web aber second lon-
gitudinal compression (Fig. 2)
L = Area weight of mineral fiber-insulating web before curing oven
In Fig. 14, a diagramme is shown, illustrating the correspondence
between the parameters listed in Table A. The reference signs used in
Fig. 14 refer to the parameters listed in Table A.
In Fig. 15, a diagramme is shown, illustrating the correspondence
between the parameters listed in Table B. The reference signs used in
35 Fig. 15 refer to the parameters listed in Table B.
~ w o 94/16163 21~ 3 6 71 PCT~DK94/00028
Example 2
A composite roofing plate of a structure similar to the plate shown
in Fig. 12, made from a mineral fiber-insulating web produced in accor-
- dance with the method according to the present invention as described
above with reference to Figs. 1-10, is produced in accordance with the
specifications listed below:
The method comprises steps similar to the steps described above
with reference to Figs. 1, 2, 6, 7, 8, 9 and 10. The production output
of the plant is 5000 kg/h. The area weight of the primary web produced
in the station disclosed in Fig. 1 is 0.6 kg/m2, and the width of the
primary web is 3600 mm. The density of the central core or body 28 is
110 kg/m3. The rates of longitudinal compression produced in two sepa-
rate stations similar to the station disclosed in Fig. 2 are 1:3 and1:2, respectively, and the rate of transversal compression produced in
the station disclosed in Fig. 8 is 1:2. The final plate comprises a
single surface layer of an area weight of 3.57 kg/m2. The rate of longi-
tudinal compression of the surface layer is 1:2. The thickness of the
surface layer is 17.00 mm, and the density of the surface layer is 210
kg/m3. The width of mineral fiber-insulating web produced in Fig. 1 is
1800 mm.
The production parameters used are listed in tables C and D below:
WO 94/16163 PCT~DK94/00028 ~
21536~1 28
Table C
Total thickness A B C D E F
mm m/min x 10 m/min m/min m/min m/min m/min
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ r _ _ _ _ _ _ _ _ _ _
7.72 38.58 12.~6 12.86 6.43 6.43
11.57 27.92 9.31 9.31 4.65 4.65
100 11.57 21.87 7.29 7.29 3.65 3.65
10125 11.57 17.98 5.99 5.99 3.00 3.00
150 11.57 15.26 5.09 5.09 2.54 2.54
175 11.57 13.26 4.42 4.42 2.21 2.21
200 11.57 11.72 3.91 3.91 1.95 1.95
225 11.57 10.50 3.50 3.50 1.75 1.75
15250 11.57 9.51 3.17 3.17 1.59 1.59
275 11.57 8.69 2.90 2.90 1.45 1.45
A = Velocity of belt 42 of spinning chamber
20 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. 8)
E = Velocity of belt 70 after second longitudinal compression (Fig. 2)
F = Velocity of belt 70 before curing oven (Fig. 5)
WO 94/16163 215 3 6 71 PCT/DK94/00028
29
Table D
.
Total thickness G H I J K L
mm kg/m2 kg/m2 kg/m2 kg/m2 kg/m2 kg/m2
0.60 1.80 3.60 1.82 3.63 7.20
0.83 2.49 4.98 3.19 6.38 9.95
10 100 1.06 3.18 6.35 4.57 9.13 12.70
125 1.29 3.86 7.73 5.94 11.88 15.45
150 1.52 4.55 9.10 7.32 14.63 18.20
175 1.75 5.24 10.48 8.69 17.38 20.95
200 1.98 5.93 11.85 10.07 20.13 23.70
15 225 2.20 6.61 13.23 11.44 22.88 26.45
250 2.43 7.30 14.60 12.82 25.63 29.20
275 2.66 7.99 15.98 14.19 28.38 31.95
G = Area weight of mineral fiber-insulating web on belt 42
H = Area weight of mineral fiber-insulating web after first
longitudinal compression (Fig. 2)
I = Area weight of mineral fiber-insulating web after transversal
compression (Fig. 8)
J = Area weight of mineral fiber-insulating web before second lon-
gitudinal compression (Fig. 2)
K = Area weight of mineral fiber-insulating web aber second lon-
gitudinal compression (Fig. 2)
L = Area weight of mineral fiber-insulating web before curing oven
In Fig. 16, a diagramme similar to the diagramme of Fig. 14 is
shown, illustrating the correspondance between the parameters listed
above in table C.
In Fig. 17, a diagramme similar to the diagramme of Fig. 15 is
shown, illustrating the correspondance between the parameters listed
above in table D.
WO 94/16163 t - PCT/DK94/00028 ~
2~536~1 30
Example 3
The importance of exposing the mineral fiber-insulating web to a
longitudinal and transversal compression is illustrated in the data in
table E given below: -
WO 94/16163 21~ 3 6 71 PCT/DK94/00028
31
~n ~
~ a) ~ _ c
_ ,c C ~ o
_ C _
o ~ ~ V~
V7 ~ ~ ~
~ ~ o _ ~ o- o o o
-- C -- CJ~ E U~ _I o
_ ~ C O ~ N O
C O
O >
_~.) ~ o n~
~n c
O ~
-- _ X L
Q a~ ~
c
I _
~ ~ _
c a~
_ c ~ ~ a~
O
C -- C~ ~ ~ ~ ~
O ~:1) E `' ~ `'`'
^ C t~ O O
~ ~O _ C~ O
_ C._ _
_ ~ O
c5 C
O >
c a~ -
O C
Q nJ
X
_ ~~ CL _ C
o o
_I ~ O
a~ .. ..
- -
a~ c _ c _
.C ~ ~J7 V~V~ V)
E
o ~n O O
_ C ~ 10
-- V
C I ~ ~ ~ ~
a~ ~n _ ~,7 _
~ 8 a~
O _ O ~ O
r
a~
E
_ J ~ cn ~
o _ ~
~ C O
a~ _ ~ ~ o
o o ~ o O
WO 94/16163 PCT/DK94/00028 ~
2153671 32
The mineral fiber-insulating plates according to the present inven-
tion clearly demonstrate increased pressure strength and modulus of e-
lasticity as compared to a conventional heat-insulating plate. The me-
chanical 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 re-
ference to Fig. 2 and Fig. 8.
