DE4222207C2 - Process for producing mineral fiber products and device for carrying out the process - Google Patents

Abstract

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

Description

The invention relates to a method for manufacturing of mineral fiber products with compacted surfaces areas of mineral fiber webs, with the fibers inside half of the mineral fiber web essentially parallel or perpendicular or oblique to the large surfaces of the Mineral fiber web run and being the mineral fiber web contains an uncured binder.

A method of the aforementioned type and a device to carry out the procedure is mainly through the Canadian Patent 1,057,183 became known. For Production of a compacted surface area or a surface layer is here a scales right, parallel to the large surfaces of the mineral cut a partial web. This sublane is then the remaining one Mineral fiber web lifted off and together between pressure rollers squeezed and thus compressed. This densified partial web will then return to the remaining mineral fiber web guided. Then there is a common run through a hardening furnace, in which the hitherto inconsistent Detected in the mineral fiber web and also in the partial web holding binder is cured. In practice it has however, it has been found that the fibers in the off-set Partial web due to the high static compression forces crushed and the web apart is pressed, comparable to a bread dough made from is rolled. This creates within the partial web relatively inhomogeneous densified zones. The in the Teaching taught by Canadian patent was also already developed further, and that was a relationship moderately thin partial web cut open, compressed and  then wrinkled using a pendulum device applied again to the remaining mineral fiber web. In all cases, however, it has been shown that none is reliable permanent fiber composite between the two below differently treated layers could be achieved. The mineral fiber boards ultimately produced as the end product with different bulk densities in the two aforementioned Layers have always been completely inadequate in practice adequate tear resistance. For example when laying the like plates or longer tracks on a flat roof of a building or when attached to building walls have the densified surface layers of the underneath undissolved mineral fiber web solved and sometimes even waveform assumed because the ver poetry material sought to come back when to expand even slightly. This would Principle also change nothing if you came up with the idea between the two partial webs of different bulk densities to apply an adhesive layer, apart from the fact that this would incur considerable additional costs and one Hardening in a hardening furnace is too difficult leads.

The easiest and most obvious way to condense one th surface area or a surface layer the mineral fiber web would not be in part cut open webs, but directly pressure on the Exercise surface. With a mineral fiber web in which however, the binder is still uncured no surface area or a surface layer ver seal because the material is under pressure through significant deformations and at most the Fibers are crushed in the immediate vicinity of the surface.  

DE 37 01 592 A1 describes a further method for Manufacture of mineral fiber products with compacted Surface areas known from mineral fiber webs, wherein the fibers within the mineral fiber web essentially parallel or perpendicular or oblique to the large upper surfaces of the mineral fiber web run and the Mineral fiber web contains an uncured binder. The densification of surface areas is done in the way made a primary fleece in two or more parts webs is split and that partial webs are lifted off and be subjected to pressure treatment so that they are in their entire height can be compressed. After this ver The lifted partial webs will not seal the rest compressed primary fleece fed back and in one the subsequent hardening furnace is then jointly hardened of the binder.

Furthermore, EP 03 88 062 A2 describes a needle treatment surface areas up to a predetermined Depth of penetration known for a material that serves medical or surgical purposes. It works So here is a material of the textile area, which should be suitable to injure body fluids or operated person. By needling becomes a densification of the surface of this material sought, but at the same time the receptivity of the Fluid conveyed through the numerous needle sticks.

Furthermore, DE-Z Melliand textile reports 12/1982, page 855, "Needling of inorganic Fibers "known, a mechanical consolidation by means of Ver needling with glass fibers or rock wool. The Designs also refer to rock fibers, too  Isolation purposes are used. He should required strength of mats by needling can be achieved. Furthermore, the use of binders be reduced by the needling process. It will but said nothing about whether the needling over Surface areas or rather over the entire thickness the mat in question should extend. But above all it will in this state of the art the needling in one Made of material in which the binder is already made is hardened. With such a material made of glass and Rock fibers occur due to the action of needles Broken fiber, and therefore there are numerous measures be taken to the disadvantages of the emerging fine To avoid fiber dust. The specialist is therefore at one such material prevented a needling process to make, because the formation of fine fiber dust must be avoided under all circumstances.

In another state of the art according to DE-OS 19 47 789 is about the production of nonwovens with increased Strength, whereby these nonwovens have a pronounced textile character, such as soft feel and smooth fall, should have. The materials listed are here Nonwovens are not comparable to mineral fiber products. To increase the overall strength of the nonwoven, binder is introduced into the fleece via hollow needles.

Finally, a distinction is made from DE 30 29 333 A1 Liche constructions of felting needles known.

In contrast, the invention is based on the object Process for producing mineral fiber products with ver to create sealed surface areas or layers, through which high tear resistance and an intensive Connection between the matted and compacted upper area on the one hand and the rest of the mineral fiber web on the other hand can be achieved.  

The object is achieved by the Features of claim 1.  

In this way, the main advantage is that a surface area or ver a surface layer to a certain depth can be sealed without the remaining part of the mineral to influence fiber web, but at the same time both high tear resistance as well as great flexural strength of the end product is obtained. The end product are mostly Slabs after the treated mineral fiber has passed Cut the path through the hardening furnace in the specified length be.

The stroke frequency of the needles in relation to the usual Conveying speed of the mineral fiber web is one important factor for both the degree of compaction as well also for matting. A change in the strength The properties of the end product can therefore be reduced achieved that the stroke frequency of the needle strokes is changeable and adjustable. At a high stroke frequency there is the advantage that the needles do not mineral fiber layer hit due to the masses inertia is not deformed or even compressed.

It goes without saying that the tightness of the needles, d. H. the distance of side by side and / or one behind the other the standing needles, an important influence on the end product, but the number of needles and their distance from each other for a larger product group through one-off attempts. A change in  Strength properties of an end product can, however can be easily achieved in that the stroke and the Penetration depth of the needles are changeable and adjustable.

An advantageous further development of the method is further achieved by an endless mineral fiber web is moved continuously, a first mechanical pre compression is then subjected to needle shots in the given surface area further compacted and matted and under a second compression of a heat treatment tion for curing the binder is supplied.

If a plate-shaped end product is to be obtained, it is appropriate that the needle shots for compression and Matting evenly in the entire surface area be shared.

In practice there are numerous use cases for a plate-shaped mineral fiber product in which both sides or the two large surfaces compressed and given should also have hard layers, e.g. B. for freestanding building partitions or for the outer wall Thermal and acoustic insulation, if in the latter case one Panel side is to be attached to the building wall and on a plaster should be applied to the outside. To educate development of such products, it is advantageous that the Verification of needle impact on both parallel to each other running surface areas of the mineral fiber web is made.

The production for plate material can be done at the same time Increase the remaining conveying speed by the fact that the mineral fiber web after the binder has hardened in a cutting plane parallel to the large surfaces is cut so that two mineral fiber boards with one layer compacted on the side.  

There is a great need for mineral fiber products that on curved surfaces, e.g. B. attached to pipes have to. It is then recommended to follow the procedure in the manner to design that the needle joints in rows in longitudinal and / or transverse direction of the mineral fiber web be so that the finished product plates are flexible or poly are bendable gonally. This way you get one Product which, in addition to flexibility or kinkability also shows great compressive strength in zones.

A matting between the compacted surfaces layer and the uncompressed mineral fiber layer can still favored by this and increased the tear resistance that treatment with different needle types or needle shapes. In this context it is advantageous that by means of short needles a Verdich treatment and matting of the surface area and that by means of longer needles a part of the Fibers from the outer compressed surface area in the inner undensified area of the mineral fiber web is encountered.

Without time-consuming redesigns on the manufacturing machine, there are numerous variations Achieve ten in the end product by the fact that the thickness of the compacted layer in the surface area by choosing the Penetration depth of the needles, by the stroke frequency and by the needle shape is determined in such a way that on the one hand shallow depths of penetration, high stroke frequencies and needles large effective cross section thin high density layer results and on the other hand great depths of penetration, low Stroke frequency and needles with small cross section thick, result in less densified layers.

If a plate-shaped end product is desired - which one the hardest and most pressure-resistant surface layer possible sitting, you can achieve this in a simple way  chen that additional additives through hollow needles to additional reinforcement of the surface area introduced become. These additives can be certain after hardening measure like small stamps. But you can also in the way that they are injected into the area between penetrate the neighboring fibers and thus one more greater cohesion within the condensed upper provide surface layer. The additives can also up to into the uncompressed mineral fiber layer be brought so that in addition to the matting in Area between the compressed and the non-compressed layer achieved numerous additional anchorages become. It remains with these products as well all others according to the inventive method adjustable products get the advantage that good Vapor diffusibility is given.

For a board material that is covered with a plaster, a coat of paint or another coating should be provided it is advantageous that a thin fleece is made of a fiber material, preferably made of glass fibers, on the surface laid on the mineral fiber web and then the pin joint process is made so that part of the nonwoven fibers is embedded in the mineral fiber web.

An alternative to this results from the fact that a fabric placed on the surface of the mineral fiber web and then the needle pushing operation is carried out so that a Part of the tissue is embedded in the mineral fiber web. The thin fleece or the fabric can also be made from another Fiber material exist as mineral fibers, such. B. from Plastic fibers, textile fibers or metal fibers.

In the drawing, embodiments of the inventions are device according to the invention shown in the diagram, namely demonstrate:  

Fig. 1 a schematic diagram of the conveyance path a mineral fiber web with conveyor devices and a compaction Guidance and Verfilzungsmaschine,

Fig. 2 shows an embodiment of a needle,

Fig. 3 shows another embodiment of a needle and

Fig. 4 is a side view of a detail of a mineral fiber web compressed and matted on both sides in an enlarged view and

Fig. 5 is a schematic diagram of FIG. 1, but with compression and felting machines on both sides.

In the embodiment according to the invention a pre direction of FIG. 1, a mineral fiber web 1 in the direction of arrow 22 is fed continuously between endless conveyor belts 2 and 3 with a certain thickness. The mineral fiber web comes from a known, unsigned collecting chamber, in which the mineral fibers produced are deposited into a layer on an air-permeable conveyor belt after the addition of a binder. The mineral fiber web 1 is then initially held in a relatively moderately loose state between the two conveyor belts 2 , 3 , which are guided around pulleys 4 and 5 . There is then a certain somewhat exaggerated pre-compression of the mineral fiber web 1 between pressure rollers 6 , 7 to 8 , 9 or between appropriately arranged and guided conveyor belts. Since the binding medium within the mineral fiber web 1 , 10 , 17 is not yet hardened and the mineral fibers run essentially parallel to the large surfaces of the web due to the previous manufacturing process, the mineral fiber web 1 can be mechanically precompressed very homogeneously in this first conveying section until a pre-compressed mineral fiber web 10 of a predetermined thickness is formed.

The mineral fiber web 10 pre-compressed in this way finally arrives in a compression and felting device, which is shown in simplified form in FIG. 1. It has a plurality of needles 13 which are connected in groups or together with a lifting device which carries out a high-frequency lifting movement in the direction of arrow 15 . Such a lifting device is arranged on at least one surface side, either on the upper or lower side, of the mineral fiber web 10 , 17 and is provided with a lifting drive, not shown. In this exemplary embodiment, the needles 13 are attached to a plate-like carrier 11 . This plate-like carrier is connected to the lifting device and the drive, in such a way that the needles penetrate into the surface area of the mineral fiber web 10 , 17 up to a predetermined depth of penetration and compress it in the preselected surface area and simultaneously matt it.

The stroke of the lifting device is advantageously adjustable and adjustable to a certain height, and the stroke frequency can be regulated via the drive. It is also advantageous if the impact forces of the needles 13 can be regulated. By limiting the impact forces the Ver 13 can be prevented from fibrous web upon the occurrence of unwanted wool inclusions within the mineral to deform, so that thereby the risk of breakage is reduced at the needles 13 seal needles. In practice, these previously explained settings and controls can be accomplished in a simple manner by the fact that the lifting device can be actuated pneumatically or hydraulically.

The needles 13 , in particular the compression needles used for compression, have a chisel-like widened head 27 or 30 which, according to FIGS. 2 and 3, are molded onto the end of the needle shaft 26 and 29, respectively. The needle head 27 has a cutting edge 28 at the lower end, which when the fibers meet, force them into a loop shape and thus give them a matting with the adjacent fibers. In the embodiment of the needle according to FIG. 3, a needle tip 31 which projects downward is provided on the chisel head 30 . Instead, several needle tips can be arranged. The needle tips expediently have small lateral hooks 32 and 33 , which lead to further deformation and matting of mineral fibers, particularly in the boundary region between the compressed surface region on the one hand and the non-compressed region of the mineral fiber web. The same goal of matting and connection between the two layers mentioned above serves a different constructive embodiment, according to which at least two different needle groups, namely a group of short front needles and a group of longer post needles, are provided. In order to achieve the effect of good felting, the needles or plungers have a larger diameter and, as shown in FIGS. 2 and 3, other shapes than are known from the textile industry, for example in the case of multi-needle sewing machines. The arrangement of the compression needles should suffice for a random stitch arrangement so that the outer surface areas or layers are pre-compressed as uniformly and evenly as possible in a punctiform manner and according to the stroke frequency to be set. It is important to concentrate the impact stress from the needles on a small area in relation to the surface of the entire mineral fiber web, so that the impact forces compress the outer zones explained and due to the force distribution at point loads, the layers below are only subjected to minor stresses. By a corre sponding choice of compaction needles, e.g. B. with a short front needle, the fibers from the outer compressed layers in the underlying undensified fiber layers are forced, so that additional connections are created, which continue to influence the bending and tear-off behavior of the finished product favorably. The compression needles themselves are advantageously made of light and abrasion-resistant material. The goal is to move de mass of the needles and the components to be moved to reduce as possible, so that correspondingly higher Hubfre frequencies are possible. This is particularly important at high line speeds in the production of mineral fiber webs.

The compression and matting can be carried out either on the top or bottom of the mineral fiber web or, as shown in FIG. 5 and in particular FIG. 4 on an enlarged scale, on both sides. The mineral fiber web 17 compressed on both sides then sits two compressed and matted surface areas 34 and 35 and an intermediate non-compacted and non-matted middle layer 17 and 37 , however, a good connection between the layers is ensured. If, in accordance with the practical application of the end product plates, only a one-sided compacted and felted layer is desired, a slicing device, not shown, for cutting a mineral fiber web 17 or 21 felted and compressed on both sides, corresponding to the separating cut 36 ( FIG. 4), in two parts tracks are provided.

As shown in FIGS. 1 and 5 also illustrate the emerging from the needle punching or Verfilzungsmaschine compacted mineral fiber web 17 by conveying rollers 18, 19 or corresponding endless conveyor belts is fed to a curing oven 20 in which the mineral fiber web 21, for example between non-drawn endless belts have a can receive further slight post-compaction, especially to smooth the surfaces. In the curing oven 20 , the previously uncured binder is then finally cured. The mineral fiber web emerges in the direction of arrow 23 from the hardening furnace and can be separated into suitable plate pieces and processed into the end product, or the described cut 36 according to FIG. 4 can cause the separation into plate parts.

FIGS. 1 and 5 show yet another embodiment of the device according to the invention, namely that on one side (Fig. 1) or both sides (Fig. 5) type between the plates needle carriers 11 and 12 on the one hand and the mineral fiber web 10, 17 on the other hand in each case a further Plate 24 and 25 is provided, in which the needles 13 , 14 are guided. These plates 24 and 25 can also be connected to the lifting device. They can bring about a certain additional surface compaction, but above all these plates can be used to push fibers that may have been torn out of the surface back into the surface.

The 5 mutually arranged Hubvorrichtun FIG. Are gen advantageously operated in the direction of arrows 15 and 16 with the same stroke frequency and in opposite phase, that is when the upper lifting device moves downward, the lower lifting device upwards simultaneously moved and vice versa during the return stroke. Since the device according to FIG. 5 is essentially symmetrical or a mirror image of the horizontal central plane, the same reference numerals have been used for the same or equivalent parts.

A further embodiment of the invention is thereby aims that the needles are designed as hollow needles and a feed device for additives, preferably liquid additives. Especially at higher conveyor speeds of the mineral fiber web, is it is advantageous that the needles to adapt to the conveyor speed of the mineral fiber web during the penetration can be moved in cycles in the conveying direction, preferably pivotable, are mounted on the lifting device. To this In this way, the needles are protected, friction and thus one  Preventing warming avoided and a risk of termination practically completely excluded. These movements of the Needles during the insertion into the mineral fiber web in their direction of conveyance and the back movements of the needles after leaving the mineral fiber web in the Original position can be determined by simple mechanical Gear arrangements, such. B. generated by eccentrics become.

In terms of material, mineral fibers have always been common at the top or mineral fiber material spoken. But it is still here particularly emphasized that both the method and the device is particularly suitable for the production of Rockwool products are. Furthermore, not only material run with a fiber path parallel to the large upper machined surfaces, but also lamellar webs or -plates where the fibers are vertical or under one other angles to the large surfaces.

Claims (19)

1. Process for making mineral fiber products from an endless, continuously moving mineral fiber web, with the fibers within the mineral fiber web essentially parallel or perpendicular or oblique to whose large surfaces run, and the Mineral fiber web, which is an uncured binder first contains a first subjected to mechanical pre-compression closing at least one surface area needle bumps, their stroke frequency, stroke and penetration depth of the Needles are changeable and adjustable up to one predetermined depth of penetration is exposed so that the Matting fibers in the surface area and at the same time the surface area is compacted, and what the Mineral fiber web under a second compaction Heat treatment for curing the binder added leads. 2. The method according to claim 1, characterized in that that the needle bumps for compacting and felting in evenly distributed over the entire surface area become. 3. The method according to claim 1 or 2, characterized records that the needle punch treatment on both parallel surface areas the mineral fiber web is made and that the Mineral fiber web after the binder has hardened in a sectional plane parallel to the large waiters is cut open so that two minerals fiberboard with a compacted layer on one side stand.   4. The method according to claim 1, characterized in that the needle joints in rows in longitudinal and / or Transverse direction of the mineral fiber web are made, so that the finished product plates are flexible or poly are bendable gonally. 5. The method according to any one of the preceding claims, characterized in that the treatment with such different types of needles or shapes, that by means of short needles a compression and Ver felting of the surface area is made, and that by means of longer needles a part of the fibers from the outer compressed surface area into the inner undensified area of the mineral fiber web is encountered. 6. The method according to any one of the preceding claims, characterized in that the thickness of the compacted Layer in the surface area is determined in such a way that on the one hand shallow depths of penetration, high stroke fre sequences and needles with a large effective cross-section result in thin, highly compressed layers and others large penetration depths, low stroke frequency and Small cross-section needles thicker, less compact layers. 7. The method according to any one of the preceding claims, characterized in that additional additives by Hollow needles for additional reinforcement of the surface area. 8. The method according to any one of the preceding claims, characterized in that a thin fleece from a Fiber material, preferably made of glass fibers, on the Surface of the mineral fiber web laid on and then the needle pushing operation is done so that part  of the nonwoven fibers embedded in the mineral fiber web becomes. 9. The method according to any one of claims 1 to 7, characterized characterized in that a fabric on the surface of the Mineral fiber web laid on and then the pin joint operation is done so that part of the fabric is embedded in the mineral fiber web. 10. Device for performing the method according to one of the preceding claims, characterized in that conveyor rollers ( 6 , 7 , 8 , 9 ) or belts ( 2 , 3 ) on both sides of the continuously moving endless mineral fiber web ( 1 , 10 , 17 ) for their pre-compression it is provided that a plurality of needles ( 13 , 14 ) are connected in groups or together with a lifting device ( 15 , 16 ) which is arranged at least on an upper surface side of the mineral fiber web ( 10 , 17 ) and is provided with a drive , so that the needles penetrate to a predetermined depth of penetration into the mineral fiber web ( 10 , 17 ) and matt them in the surface area and at the same time compress that the stroke of the lifting device is adjustable and adjustable and the stroke frequency is adjustable via the drive and that others Conveyor rollers ( 18 , 19 ) or belts for feeding to a hardening furnace ( 20 ) are provided. 11. The device according to claim 10, characterized in that the needles ( 13 , 14 ), in particular the compression needles serving the United, have a chisel-like widened head ( 27 , 30 ). 12. The apparatus according to claim 11, characterized in that at least one protruding needle tip ( 31 ) is provided on the chisel head ( 27 , 30 ). 13. Device according to one of claims 10 to 12, characterized in that the needles ( 13 , 14 ) are designed as hollow needles and are connected to a feed device for additives, preferably liquid additives. 14. Device according to one of claims 10 to 13, characterized in that the needles are attached to a plate-like carrier ( 11 , 12 ) which is connected to the lifting device and the drive. 15. The apparatus according to claim 14, characterized in that between the plate-like carrier ( 11 , 12 ) and the mineral fiber web ( 10 , 17 ) a further plate ( 24 , 25 ) is provided, in which the needles ( 13 , 14 ) are guided and which is also connected to the Hubvor direction. 16. The device according to one of claims 10 to 15, characterized in that at least two under different groups of needles, a group of short front needles and a group of longer needles are seen. 17. Device according to one of claims 10 to 16, characterized by a slicing device for slicing a matted and densified mineral fiber web ( 21 ) in two partial webs. 18. Device according to one of claims 10 to 17, characterized in that the needles ( 13 , 14 ) to adapt to the conveying speed of the mineral fiber web ( 10 , 17 ) during the puncture each cycle in the conveying direction ( 22 , 23 ) before moving are preferably pivotable, are mounted on the lifting device. 19. Device according to one of claims 10 to 18, characterized in that the lifting device pneu is actuated matically or hydraulically.