APPARATUS AND METHOD FOR MANUFACTURING MINERAL WOOL AS WELL AS A MINERAL WOOL PRODUCT

Abstract

An apparatus for manufacturing mineral wool includes means for producing molten mineral material, and a fiberizing device for forming fibers, into which fiberizing device the molten mineral material is fed and by which fibers are formed. The fiberizing device has, rotationally arranged around a vertical axis, at least one fiberizing plate with a vertical peripheral edge, into which are formed numerous small-sized holes, through which the molten material is led by centrifugal force to form fibers. Into the fiberizing device are arranged elements to produce a vertical flow of blowing medium to be led around the fiberizing plate, the flow causing the fibers to turn downwards and, at the same time, to thin. Downstream the fiberizing device is arranged a collection device, into which the formed fibers are led and collected into a mat-like material. In connection with said at least one fiberizing plate is arranged a substantially horizontal, relatively narrow channel, through which the fibers are brought into the chamber space of the collection device. A method for manufacturing mineral wool and a mineral wool product manufactured by the method are also disclosed.

Claims

1. An apparatus for manufacturing mineral wool, the apparatus comprising: means for producing molten mineral material; at least one fiberizing device for forming fibers, into which fiberizing device the molten mineral material is fed and by which fibers are formed, the fiberizing device comprising, rotationally arranged around a vertical axis, at least one fiberizing plate having a vertical peripheral edge, into which are formed a plurality of holes through which the molten material is led by centrifugal force to form fibers, wherein to the fiberizing device are arranged elements to produce a vertical flow of blowing medium to be led around the fiberizing plate, the flow causing the fibers to turn downwards and, at the same time, to thin; a collection device arranged downstream of the fiberizing device, into which the formed fibers are led and collected into a mat-like material; wherein the apparatus includes at least a first fiberizing device and a second fiberizing device; wherein a first channel having a length L1 is arranged between at least one fiberizing plate of the first fiberizing device and the collection device, the first channel for conveying fibers formed by the first fiberizing device to the collection device; wherein a second channel having a length L2 is arranged between at least one fiberizing plate of the second fiberizing device and the collection device, the second channel for conveying fibers formed by the second fiberizing device to the collection device; and wherein L1L2.

2. The apparatus according to claim 1, wherein a height H1 of the first channel decreases along the length L1.

3. The apparatus according to claim 1, wherein a height H2 of the second channel decreases along the length L2.

4. The apparatus according to claim 1, wherein the first channel includes at least one curved portion along the length L1.

5. The apparatus according to claim 1, wherein the second channel includes at least one curved portion along the length L2.

6. The apparatus according to claim 1, wherein a height H1 of the first channel decreases along the length L1; and wherein a height H2 of the second channel is uniform along the length L2.

7. The apparatus according to claim 1, wherein the first channel includes at least one curved portion along the length L1; and wherein the second channel is straight along the length L2.

8. The apparatus according to claim 1, wherein the first channel has a different shape than the second channel.

9. The apparatus according to claim 1, wherein the first channel has a different size than the second channel.

10. The apparatus according to claim 1, wherein the first fiberizing device is positioned at a first height level and the second fiberizing device is positioned at a second height level, and wherein the first height level is different from the second height level.

11. The apparatus according to claim 1, wherein 1 mL110 m.

12. The apparatus according to claim 1, wherein 1 mL210 m.

13. The apparatus according to claim 1, wherein the apparatus further includes a third fiberizing device; wherein a third channel having a length L3 is arranged between at least one fiberizing plate of the third fiberizing device and the collection device, the third channel for conveying fibers formed by the third fiberizing device to the collection device; and wherein L3=L1.

14. The apparatus according to claim 1, wherein the apparatus includes at least five fiberizing devices, each fiberizing device having a corresponding channel extending between the fiberizing device and the collection device.

15. The apparatus according to claim 1, wherein the apparatus includes at least ten fiberizing devices, each fiberizing device having a corresponding channel extending between the fiberizing device and the collection device.

16. The apparatus according to claim 1, wherein the collection device comprises a collection chamber, a collection drum having a perforated surface, and a suction box arranged inside of the collection drum.

17. The apparatus according to claim 16, wherein the collection device further comprises an inlet port through which the fibers pass to enter the collection chamber; and wherein the inlet port comprises a first opening for interfacing with the first channel and a second opening for interfacing with the second channel.

18. The apparatus according to claim 1, further comprising a first blower arranged with the first channel to create a first air flow that conveys fibers formed by the first fiberizing device to the collection device, and a second blower arranged with the second channel to create a second air flow that conveys fibers formed by the second fiberizing device to the collection device.

19. The apparatus according to claim 1, wherein the at least one fiberizing plate of the first fiberizing device includes holes having a diameter of 0.3 mm to 2 mm; and wherein the at least one fiberizing plate of the second fiberizing device includes holes having a diameter that is different from the diameter of the holes of the at least one fiberizing plate of the first fiberizing device.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In the following, the invention is described in more detail with reference to the accompanying figures, in which:

[0016] FIG. 1 shows a schematic illustration of an embodiment of an apparatus according to the invention;

[0017] FIG. 2 shows a schematic illustration viewed from above of one possible embodiment of the placement of fiberizing devices with their channels;

[0018] FIG. 3 shows a schematic illustration of an embodiment of the placement of the channels in the mouth of the collection device, the channels being connected to the fiberizing devices;

[0019] FIG. 4 shows a schematic illustration of an embodiment of the apparatus according to the invention where the conveying device is a belt;

[0020] FIG. 5 shows a schematic illustration of an embodiment of the apparatus according to the invention where the conveying device comprises a curved channel; and

[0021] FIG. 6 shows a schematic illustration of an embodiment of the apparatus according to the invention where the conveying device comprises an inclined channel.

DETAILED DESCRIPTION

[0022] Reference numeral 1 in FIG. 1 denotes a melting furnace, from which the molten material is led along a trough 2 into a fiberizing device 3. The fiberizing device 3 is equipped with a blower 4, which produces a flow 17 of blowing air, which transports the fibers 12 formed by the fiberizing device into the channel 5 and further into the collection device 6. The collection device 6 has a collection chamber 7 and collector elements 8, which, in this embodiment, comprise a collection drum 9 equipped with a perforated peripheral surface, inside which is a suction box 10. The blowing air moves through the holes of the drum 9 into the suction box and further away from the collection apparatus. This contributes to the collecting of the fibers 12 onto the surface of the drum 9 to form a primary fiber mat or web, which is then transported, for example, by a conveyor 11, to the pendulum device (not shown), in which it is formed into a secondary mat, which is then brought for further processing, for example, hardening. The collection chamber can as such be according to known art, or it can differ from known art. The feeding of binder is not shown in the figure. For example, the collection device can be a foraminous or perforated belt conveyor having suction boxes inside the belt loop.

[0023] The fiberizing device 3 comprises, rotating around a vertical axis 15, a cup-like plate 13, on the periphery of which are numerous small holes 14, through which the molten mass moves under the influence of centrifugal force forming fibers 12, which are stretched around the plate by vertically led blowing air 16, annularly surrounding the plate. In connection with the feeding of blowing air and the stretching of the fibers, binder and other necessary chemicals can be fed. Such a fiberizing plate and the production of blowing air, surrounding it annularly, in the manufacture of glass wool is prior known to the skilled person in the art, for example, from U.S. Pat. No. 4,759,974. The advantage in using such a fiberizing plate is that the majority of the mass can be fiberized. The disadvantage is that through one fiberizing device can be fed only approx. 400-500 kg molten mass per hour, which is significantly less than in solutions implemented with spinner discs, in which the fed amount of molten mass can be, for example, 5000-7000 kg per hour. In the solution according to the invention, in connection with the fiberizing device 3, preferably below it, is arranged a relatively small-diameter, horizontal channel 5 leading to the collection device, the length of which channel can be several metres, for example, in the range of approx. 1 m-approx. 10 m. In connection with the channel 5 is arranged a blower 4, which creates a horizontal air flow in the channel 5 directing the fibers 12, oriented downwards by the vertical blowing air 16 in the fiberizing device, horizontally along the channel 5 towards the collection device 6. By means of this channel solution, it is possible to place several fiberizing devices 3 to feed one collection device 6, wherein the production output can be increased to a desired level. The fiberizing devices can be placed at different height levels with each other and at different horizontal distance from the collection device 6, wherein only the channels 5 need to be adapted to the inlet port of the collection device. The channels 5 do not need to all be the same shape or size, and their location in relation to the collection apparatus can also be modified.

[0024] FIG. 2 shows as a schematic illustration viewed from above of one placement of the fiberizing devices 3 in relation to each other, as well as in relation to the collection chamber 7 and the collector elements 8. FIG. 3 shows schematically an example of one manner of placing the channels 5 in the mouth of the collection device 6 as viewed from the direction of the collection drum 9.

[0025] FIG. 4 shows a schematic illustration of the apparatus wherein the conveying device comprises a belt 20 on which the fibers are deposited. The belt can be provided with suction boxes inside the belt loop to assist depositing of the fibers on the certain portion of upper run of the belt. For releasing the fibers into a collection device the belt is preferably without any suction means in the discharging area of the belt loop or there can be blower means for directing an air flow from inside the belt loop through the belt in the discharging area of the belt 20 to assist releasing of the fibers.

[0026] FIG. 5 shows a schematic illustration of the apparatus wherein the conveying device 5 comprises a curved channel 5 through which the fibers are transported from a fiberizing device 3 to a collection device 6 by means of the blowing air directed vertically downwards around the fiberizing plate and/or by means of suction means arranged in the channel in the vicinity of the collection device.

[0027] FIG. 6 shows a schematic illustration of the apparatus wherein the conveying device 5 comprises an inclined channel 5 through which the fibers are transported from a fiberizing device 3 to a collection device by means of the blowing air directed vertically downwards around the fiberizing plate and/or by means of suction means arranged in the channel in the vicinity of the collection device.

[0028] One or more fiberizing plates can be equipped with perforations of different size in relation to the other fiberizing plates, wherein different fiberizing plates can be used to produce fibers of different size. Furthermore, different fiberizing plates can be used to produce different fiberizing parameters, such as, for example, the rotation speed of the plate, the feeding rate of the molten material and/or the flow rate of the vertical blowing air, to vary in a desired manner the characteristics of the intermediate product and/or final product to be manufactured by the apparatus.

[0029] In the solution according to the invention, the fiberizing plates can be similar to or different from each other, i.e. their dimensions, such as, for example, the diameters of the fiberizing plates may differ from each other, and the fiberizing plates may also differ in their design (for example, the height and shape of the edges of the fiberizing plate).

[0030] By using the method according to the invention, it is possible to create a mineral wool product having a fiber content in excess of 90%, preferably in excess of 95%, based on the following standards or specifications: [0031] 1. Eurima 5 (10.5.1967), Determination of the content of non-fibrous material in mineral wool [0032] 2. BS 2972:1975, Method of test for inorganic thermal insulating material, Section 14 [0033] 3. ASTM C 612-83, Annex, Shot content of unorganic fibrous thermal insulation [0034] 4. JIS A 9504-1984, Heat insulation made of Rockwool.

[0035] The method according to the invention enables the manufacture of a mineral wool product having the desired tensile strength characteristics, i.e. the transverse tensile strength of which is greater than the linear tensile strength.