Low volume density mineral wool mat containing thermally bonded fibers

Abstract

The present invention relates to a mineral wool mat (1), which has at least a plurality of mineral fibers (2) stacked adjacent to and overlapping each other within the mineral wool mat (1), and the mineral wool mat (1) has a volume density of 40 kg m -3 and the thickness of the mineral wool mat (1) is more than 50 mm.

Description

[Technical Field]

[0001] The present invention relates to the field of building materials, more particularly to the field of building materials for buildings formed from mineral wool mats, for example of the glass wool type, which are used in particular to provide heat and / or sound insulation. [Background technology]

[0002] Mineral wool mats are commonly used as insulating materials configured for heat and / or sound insulation, for example in building construction, etc. The insulating properties of mineral wool mats are obtained in particular by the ability of the mineral wool mats to trap air within their interior in a stable and immobile manner.

[0003] The mineral wool mat is obtained by passing a mineral fiber carpet through an oven, which is formed and intertwined with a mixture of virgin or recycled mineral fibers on a conveyor device upstream of the oven, with adhesive elements configured to bond the fibers together as they pass through the oven. This mineral fiber carpet can be produced by various types of equipment, for example by a fiber drawing station and a spreading station, which spreads a liquid binder on the mineral fibers previously obtained, so that the rings of mineral fibers sized in this way fall onto a conveyor device that guides the assembly towards the oven. Alternatively, but not limiting to the invention, a mineral fiber carpet formed before the oven can be obtained in a station, in which the mineral fibers and adhesive elements are blown into a housing and sucked onto a conveyor device that guides the assembly towards the oven.

[0004] The heat and / or sound insulation properties of the mineral wool mat, made of nonwoven fibrous material and obtained after passing through the oven, depend in particular on the arrangement of the fibers in the finished product, thereby avoiding the formation of conductive bridges from one side of the mat to the other by groups of mineral fibers. This insulation property depends in particular on the thickness and volume density of the mineral fiber mat, as well as on the interaction of the mineral fibers with the binder before passing through the oven.

[0005] These mineral wool mats, which are particularly designed for building construction, have a thickness of at least 50 mm, thereby making their structural properties different from mineral wool materials that may be used in other applications, such as the automotive industry. The inventors have found that prior art mineral wool mats used in the building industry, while effective, do not perform optimally. Some of these mineral wool mats are obtained by manufacturing equipment that uses a housing into which mineral fibers are blown and then sucked, thereby forcing them onto a conveyor device. The distribution of the mineral fibers on the conveyor device by such equipment is not satisfactory, and other manufacturing equipment has been developed that forms a mineral fiber carpet by mechanically depositing the mineral fibers on top of each other. Summary of the Invention [Problem to be solved by the invention]

[0006] The present invention falls within this context and aims to provide a mineral wool mat with improved heat and / or sound insulation using a production installation in which mineral fibers are mechanically deposited on a conveyor device of the installation. [Means for solving the problem]

[0007] Therefore, the present invention relates to a mineral wool mat, which comprises at least a plurality of mineral fibers that are stacked one on top of the other and adjacent to each other in the mineral wool mat, the mineral fibers being fixed to each other by thermally bonded fibers, and the mineral wool mat has a volume density of 40 kg m -3 and the thickness of the mineral wool mat is more than 50 mm.

[0008] This type of mineral wool mat is configured for building construction. These panels are produced using equipment that agitates the mineral fibers and mechanically deposits them on a conveyor system that feeds them into a furnace, thereby obtaining an optimal configuration of the mineral fibers in the mineral wool mat. The inventors have determined that this optimal configuration occurs when the mineral wool mat has a thickness of 50 mm or more and a load of 40 kg m -3 It has been found that this can be achieved by combining the following volume densities and by using thermally bonded fibers: The mineral wool mat according to the invention is advantageously obtained in an installation for producing mineral fibers by mechanical deposition on a conveyor device which transports the mineral fiber carpet towards a heated oven. The thermally bonded fibers play an important role in reducing the costs of producing the mineral wool mat by reducing maintenance and repairs.

[0009] One feature of the present invention is that the mineral fibers are glass fibers.

[0010] According to one feature of the invention, the thickness of the mineral wool mat is greater than 100 mm.

[0011] According to one feature of the invention, the thickness of the mineral wool mat is greater than 250 mm.

[0012] The thickness of the mineral wool mat considered here is the nominal thickness of the mat, i.e. the thickness that is visible to the user when the article is used, in particular for insulating buildings.

[0013] According to the practices known in the prior art, the mineral wool mat according to the present invention is obtained by passing a preformed mineral fiber carpet through an oven set at a specific firing temperature, and, if necessary, on a conveyor device directing the mineral fiber carpet towards the oven, by mixing virgin or recycled intertwined mineral fibers with adhesive elements configured to bond the fibers as they pass through the oven, here the thermal adhesive fibers according to the present invention.

[0014] In particular, the nominal thickness can be measured after packaging, for example when the product is purchased. For example, the above-mentioned nominal thickness is determined during application of the product through various successive steps in the industrial manufacturing process, including after the mineral fiber carpet has passed through an oven, cutting the mineral wool mat obtained after passing through the oven into panels or rollers of appropriate dimensions, compressing these panels or rollers before packaging, and packaging and storage before sale.

[0015] According to one feature of the present invention, the mineral fiber carpet is produced continuously in a single pass, with the fibers involved in the formation of the mineral fiber carpet passing through the oven being deposited one on top of the other in order. In other words, by stacking the mineral fiber carpets produced on equipment operating in parallel in front of the oven, or by stacking several mineral wool mats one on top of the other, it is not a problem to obtain a mineral wool mat with a nominal thickness greater than a predetermined value.

[0016] According to one aspect of the present invention, the mass per unit area of ​​the mineral wool mat is 4000 g m -2 It is understood that obtaining a mineral wool mat with a lower density and a greater thickness than known in the prior art means a greater mass, or grams, per unit area than known. The inventors have found that a density of 40 kg m -3 less than 50 mm thick, and the mass per unit area is 4000 g m -2We were able to target a particularly advantageous value range combination: ultra.

[0017] One feature of the present invention is that the volume density of the mineral wool mat is 7 kg m -3 ~40kg m -3 That is to be.

[0018] One feature of the present invention is that the volume density of the mineral wool mat is 10 kg m -3 ~35kg m -3 That is to be.

[0019] Another feature of the present invention is that the volume density of the mineral wool mat is 20 kg m -3 ~30kg m -3 That is to be.

[0020] One feature of the present invention is that the mineral fibers are fixed to each other by a dry process. This method has the advantage of not contaminating the mechanical elements of the production equipment, such as rollers through which the mineral fibers pass. Using a liquid binder means that the mechanical elements of the equipment are covered with the binder, which then needs to be removed. This means that the production equipment must be shut down, thereby increasing the cost of producing the mineral wool mat.

[0021] According to one aspect of the present invention, the mineral wool mat contains 2% to 30% thermally bonded fibers, which ensures that each mineral fiber is bonded to at least one other mineral fiber while maintaining maximum insulation properties of the mineral wool mat.

[0022] According to one aspect of the present invention, the mineral wool mat includes 3% to 15% thermally bonded fibers.

[0023] According to one aspect of the present invention, the mineral wool mat includes 4% to 10% thermally bonded fibers.

[0024] According to one aspect of the present invention, the proportion of mineral fibers present in the mineral wool mat is complementary to the proportion of thermally bonded fibers. In other words, the mineral wool mat is essentially made of mineral fibers and thermally bonded fibers, with the proportion of mineral fibers being approximately 90% when the proportion of thermally bonded fibers is approximately 10%. It should be noted that the terms "essentially made of" or "approximately" are intended to provide for a margin of approximately 0.1 to 2% in addition to the mineral fibers and thermally bonded fibers, particularly the presence of a coupling agent in the composition.

[0025] According to one aspect of the present invention, a thermally bonded fiber includes a core and a sheath, the core having a melting temperature different from the melting temperature of the sheath.

[0026] According to an optional feature of the invention, the adhesive elements are obtained by melting thermally bonded fibers, which are to be distinguished from mineral fibers insofar as melting a portion of the sheath of the thermally bonded fibers or partially melting the thermally bonded fibers themselves serves to form the adhesive elements associated with these mineral fibers.

[0027] An optional feature of the present invention is that the mineral fibers are uniformly distributed throughout the mineral wool mat.

[0028] In the mineral wool mat according to the invention, a homogeneous distribution of the mineral fibers is achieved in particular by orienting each of the mineral fibers in substantially the same direction and / or in several successive layers. As a result of such orientation of the mineral fibers, air is trapped in the mineral wool mat between successive rows of mineral fibers. Such orientation significantly limits the formation of thermal bridges. Furthermore, such a distribution of the mineral fibers creates a resistance to the passage of air, which tends to immobilize the air in the mineral wool mat, thereby improving the thermal and / or sound insulation properties of the mineral wool mat. The inventors have found that, in particular by controlled arrangement of the mineral fibers, a homogeneous distribution of the mineral fibers in the mineral wool mat, i.e. a homogeneous density, can be achieved, for example, in a mineral wool mat with a density of 40 kg m -3 It has been found that for a variety of articles of less than 1000 densities, it is possible to obtain articles that exceed the known performance of mineral wool mats of a similar given density.

[0029] According to one feature of the invention, at least the mineral fibers are uniformly distributed within the mineral wool mat, the uniform distribution of the mineral fibers being considered in the transverse direction and / or the vertical direction, each of which is perpendicular to the main longitudinal direction of extension of the mineral wool mat.

[0030] According to one aspect of the present invention, the coefficient of variation of the distribution of mineral fibers within the mineral wool mat is less than 5% between at least a first lateral region of the mineral wool mat and a second lateral region of the mineral wool mat, the first and second lateral regions being offset from each other in a transverse direction perpendicular to the main longitudinal direction of stretching. It should be noted that these regions form strips of identical dimensions, more specifically, ranging from 10 cm to 30 cm, depending on the protocol being implemented. It should also be noted that the mineral wool mat may be cut into any number of strips, and their widths or thicknesses may be used to measure the coefficient of variation between each strip.

[0031] According to one feature of the invention, the coefficient of variation of the distribution of mineral fibers within the mineral wool mat between at least a first lateral region of the mineral wool mat and a second lateral region of the mineral wool mat is less than 3%.

[0032] According to one feature of the invention, the coefficient of variation of the distribution of mineral fibers within the mineral wool mat between at least a first vertical region of the mineral wool mat and a second vertical region of the mineral wool mat is less than 10%, the first and second vertical regions being offset from each other in a vertical direction perpendicular to the transverse direction and to the main longitudinal direction of extension. The coefficient of variation is understood to be determined between each strip of the mineral wool mat relative to each other. In other words, the coefficient of variation in one region is the same for all other regions within the mineral wool mat.

[0033] According to one feature of the invention, the coefficient of variation of the distribution of mineral fibers within the mineral wool mat between at least a first vertical region of the mineral wool mat and a second vertical region of the mineral wool mat is less than 5%.

[0034] The present invention also relates to a method for producing the aforementioned mineral wool mat, which comprises at least one first step of mixing thermally bonded fibers and mineral fibers together, at least one second step of depositing the previously mixed mineral fibers and thermally bonded fibers on a conveyor device by a mechanical guide means to form a mineral fiber carpet, and at least one third step of transporting the mineral fiber carpet to a furnace by the conveyor device, and heating the mineral fibers and thermally bonded fibers in the furnace to form a mineral wool mat.

[0035] According to one feature of the present invention, the mineral fiber carpet is produced continuously in a single pass during the second step, in which the fibers participating in forming the mineral fiber carpet are deposited sequentially on top of each other as they pass through the furnace.

[0036] Other characteristics, details and advantages of the invention will become clearer on the one hand from the description that follows and on the other hand from the examples of embodiments that are shown in an illustrative and non-limiting manner with reference to the attached schematic drawings. [Brief explanation of the drawings]

[0037] [Figure 1] FIG. 1 is a graph showing the mass per unit area as a function of volume density for various mineral wool mats according to the prior art and showing the areas of interest for mineral wool mats according to the invention.

[0038] [Figure 2] FIG. 2 shows a schematic overview of a mineral wool mat according to the invention.

[0039] [Figure 3] FIG. 3 shows a mineral wool mat, such as that represented in FIG. 2, divided into a schematic manner into regions, making it possible to illustrate the homogeneous distribution of the fibers within the mat according to the invention.

[0040] [Figure 4] FIG. 4 shows a topographical view of the mineral fibers and thermally bonded fibers present in the mineral wool mat shown in FIGS.

[0041] [Figure 5] FIG. 5 shows a manufacturing facility suitable for forming mineral wool mats according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0042] First, it should be noted that although the drawings explain the invention in detail with respect to its implementation, these drawings can of course be used to better define the invention if necessary, and it should also be noted that these drawings only show examples of embodiments of the invention.

[0043] The features, variants, and different embodiments of the invention may be associated with one another in various combinations, provided they are not contradictory or mutually exclusive. In particular, it is possible to envisage variants of the invention having only a selection of the features described below, provided that this selection of features is sufficient to provide a technical advantage or to differentiate the invention from the prior art.

[0044] In the figures, elements common to multiple figures are numbered the same.

[0045] In the following description, orientation will be referred to as a function of longitudinal, vertical, and transverse axes arbitrarily defined by the L, V, and T trihedrons shown in Figures 2 to 5. The choice of names for these axes does not limit the possible orientations of the mineral wool mat.

[0046] Again, the present invention is based on a volume density of 40 kg m -3 The present invention relates to a mineral wool mat 1, which has a thickness of less than 50 mm and a thickness of more than 50 mm and comprises thermally bonded fibers. It should be noted that in the present invention and in its description, a distinction is made between the mineral wool mat and the mineral fiber carpet, which form the object of the present invention, in that the mineral wool mat is obtained by passing a mineral fiber carpet through an oven. Before passing through the oven, the mineral fiber carpet is formed by stacking mineral fibers interwoven with thermally bonded fibers one on top of the other, and this assembly is fired in the oven, and various subsequent steps, including, if necessary, compression before packaging, form the mineral fiber carpet.

[0047] Figure 1 shows the kg m of different mineral wool mats tested by us using different weighing procedures. -3 as a function of volume density, expressed as g m -2 Graph 7 shows the mass per unit area, expressed in (grams per square meter), or commonly known as grams.

[0048] As can be seen from Graph 7, the volume density is 40 kg m -3 The first mineral wool mat 5 of the prior art, which has a volume density of less than 40 kg m -3 The mass per unit area is smaller than that of the second mineral wool mat 51 of the prior art, which exceeds 2000 g m. All of the known polymerized mineral wool mats shown in FIG. 1 have a mass per unit area of ​​2000 g m. -2 Please keep in mind that we are referring to mineral wool mats, which contain, for example, glass wool fibers, and not wood wool, which is known to have a relatively high mass, or gram count, per unit area. -2 In this context of mineral wool less than 5, 51 of the prior art mineral wool mats, the mass per unit area increases as their volume density increases.

[0049] The mass per unit area of ​​the mineral wool mat is equal to the product of the volume density and the thickness of the mineral wool mat. In various mineral wool mats that form the known prior art, the thickness of the first and second mineral wool mats 5, 51 of the prior art is less than 200 mm.

[0050] The inventors have found that the first mineral wool mat 5 of the prior art has a compressive strength of 20 kg m -3 ~35kg m -3 It has a very low bulk density of 700 g m -2 ~1000g·m -2 It has been confirmed that the second mineral fiber mat 51 of the prior art has a mass per unit area of ​​35 kg m -3 ~50kg m -3 It has a volume density of 1000 g m -2 ~2000g·m -21. It can be seen that for the prior art mineral wool mats 5, 51, an increase in mass per unit area leads to an increase in volume density. As a result, the first and second prior art mineral wool mats 5 and 51 have a low thickness, which limits the immobilized air volume and thus the thermal performance of these mineral wool mats.

[0051] In this context, in order to apply the mineral wool mat to the structure that one wishes to insulate and to obtain satisfactory insulation properties, it may be necessary to double the mineral wool mat, for example by cutting it into panels that are laminated one on top of the other.

[0052] 4000g·m -2 Mass per unit area of ​​more than 40 kg m -3 Area of ​​interest 6, which includes volume densities less than 40 kg m, is also shown in Graph 7. Such mineral wool mats have a uniform distribution of mineral fibers and a volume density of less than 40 kg m. -3 Volume density less than 7 kg m -3 ~40kg m -3 , more preferably 10 kg m -3 ~35kg m -3 , more preferably 20 kg m -3 ~30kg m -3 Furthermore, according to the invention, such mineral wool mats have a thickness of more than 50 mm, preferably more than 100 mm, more preferably more than 300 mm, more preferably more than 400 mm.

[0053] The mineral wool mats are formed from a homogeneous distribution of mineral fibers that can inhibit the formation of thermal bridges within the mineral wool mat and thus provide better resistance to the passage of air than the first and second mineral wool mats 5 and 51 of the prior art. These mineral wool mats can be obtained by various manufacturing methods, including passing an assembly of mineral fibers and thermally bonded fibers forming a mineral fiber carpet through a furnace at least once, and firing the mineral fiber carpet to form a homogeneous bulk density of 40 kg m -3 A mineral wool mat according to the invention having a thickness of less than 50 mm is obtained. Such a mineral wool mat is also advantageously thicker than 50 mm. One of these manufacturing methods is explained in more detail in connection with FIG.

[0054] It should be noted that a mineral wool mat according to the invention can be obtained without the additional step of doubling the thickness of the mineral wool mat by stacking it on itself at the oven inlet. In other words, the mineral wool mat according to the invention is obtained by depositing the mineral fibers one on top of the other to form a mineral fiber carpet of sufficient thickness, which, when passed through the oven, results in a mineral wool mat thicker than a predetermined value, in particular a mineral wool mat thicker than 50 mm, preferably more than 100 mm, more preferably more than 250 mm, which is measured in grams or mass per unit area of ​​4000 g m -2 It's super.

[0055] 2 shows a mineral wool mat 1 according to the invention, which extends in its main longitudinal direction of extension, i.e. in a direction substantially parallel to the axis L. Furthermore, the mineral wool mat 1 has a thickness of more than 50 mm, more precisely in the embodiment shown it has a thickness of about 400 mm. It should be noted that the thickness of the mineral wool mat 1 is measured in a vertical direction, perpendicular to the axis L and parallel to the axis V.

[0056] The mineral wool mat 1 is formed from an intertwining of mineral fibers 2, in the embodiment shown glass fibers, which are bonded together by adhesive elements formed by thermally bonded fibers. More precisely, these mineral fibers 2 are stacked one on top of the other and next to each other within the mineral wool mat 1 with an orientation substantially parallel to the main longitudinal direction of extension of the mineral wool mat 1. It should be noted that the adhesive elements used to bond the mineral fibers 2 together will be explained in more detail below in connection with FIG. 4.

[0057] As can be seen from Figure 2, the mineral fibres 2 are arranged in the mineral wool mat 1 substantially longitudinally, i.e. in a direction parallel to the main longitudinal direction of extension of the mineral wool mat 1. This longitudinal orientation of the mineral fibres 2 in the mineral fibre carpet and in the mineral wool mat 1 after passing through the oven represents one embodiment of the present invention; in alternative embodiments, without departing from the context of the present invention, the mineral fibres 2 may be oriented differently and in different directions, as long as the distribution of the mineral fibres in each area of ​​the mineral wool mat is homogeneous, as will be explained in more detail in connection with Figure 3, which shows that the volume density of this mineral wool mat is 40 kg m -3 is less than.

[0058] As mentioned above, this mineral wool mat has a volume density of 40 kg m -3 and a homogeneous distribution of the mineral fibers 2, which may in particular be obtained by a mineral wool mat production installation, which is explained more precisely in connection with Figure 5. Furthermore, this production installation also ensures a homogeneous longitudinal distribution of the mineral fibers 2 in the mineral wool mat 1, and in particular prevents the formation of agglomerates of the mineral fibers 2 in the mineral wool mat 1.

[0059] It should be noted that the mineral fibers 2 are uniformly distributed within the mineral wool mat 1 in the thickness of the mineral wool mat 1, i.e. in a direction parallel to the axis V, and in a transverse direction perpendicular to the main longitudinal extension direction of the mineral wool mat 1 and perpendicular to the axis V.

[0060] FIG. 3 shows the mineral wool mat 1 shown in FIG. 2, and more particularly the homogeneous distribution of the mineral fibers 2 within the mineral wool mat 1.

[0061] As shown in FIG. 3, the mineral wool mat 1 has a first lateral region 11, a second lateral region 12 and a third lateral region 13.

[0062] These lateral regions 11-13 have similar dimensions and extend longitudinally and vertically from one longitudinal end to the opposite longitudinal end of the mineral wool mat 1. Furthermore, each lateral region 11, 12, 13 is offset relative to the adjacent lateral region 11, 12, 13 in a transverse direction, which is parallel to the axis T and perpendicular to the main longitudinal direction of extension of the mineral wool mat 1.

[0063] The mineral wool mat 1 also has a first vertical region 14, a second vertical region 15, and a third vertical region 16. These vertical regions 14-16 have similar dimensions and extend longitudinally and transversely from one transverse end to the opposite transverse end of the mineral wool mat 1. Furthermore, each vertical region 14, 15, 16 is offset relative to the adjacent vertical regions 14, 15, 16 in a vertical direction perpendicular to the main longitudinal direction and transverse direction of extension of the mineral wool mat 1.

[0064] It should be noted that this division into several lateral and vertical regions is arbitrary, and a different number of lateral or vertical regions is possible. This number of three lateral and three vertical regions represents an arbitrary division, made during calculations and subsequent testing by the inventors to ensure accuracy of the calculations and a homogeneous distribution of fibers within the resulting mat. For example, each mineral wool mat may be cut into two to six regions of 10 cm to 30 cm.

[0065] The mineral fiber carpet has a coefficient of variation in the distribution of fibers from one lateral region 11-13 to another of less than 5%, preferably less than 3%. In other words, the homogeneity of the mineral fibers 2 is such that the amount of fibers present in one lateral region is substantially equal to the amount of fibers present in the other lateral region, with a difference of less than 5%, preferably less than 3%. For this homogeneity of lateral distribution, as for the homogeneity of vertical distribution described below, the coefficient of variation is calculated by weighing and measuring the thickness of each relevant region, depending on the lateral or vertical division considered, for example, according to standard EN 1602. The average density and standard deviation are then calculated based on the difference between the average density and the density of each region. The coefficient of variation is obtained by dividing the standard deviation by the average density.

[0066] Similarly, the inventors have been able to determine by calculation and verify by tests that the mineral fiber carpet has a homogeneous fiber distribution from one vertical region 14-16 to the next, with a coefficient of variation of less than 10%, preferably less than 5%. In other words, the homogeneity of the glass fibers 2 is such that the amount of mineral fibers present in one vertical region is substantially equal to the amount of fibers present in another vertical region, with the difference in amounts being less than 10%. This homogeneous distribution of the mineral fibers in the regions 11-16 means that the mineral wool mat 1 has similar heat and / or sound insulation properties in each region, thereby enhancing the insulation effect.

[0067] 4 shows a topographical view of a mineral wool mat 1. More specifically, this view of the mineral wool mat 1 shows the mineral fibers 2 fastened together by a dry process. The use of dry adhesive elements as a means of fastening the mineral fibers 2 together helps to ensure homogeneity of the mineral fibers 2 within the mineral wool mat 1. The use of dry adhesive elements in this way also helps to achieve thicknesses and grams in line with those recommended for mineral wool mats according to the present invention.

[0068] In contrast to liquid sizing techniques, which involve spraying a liquid binder from suitable spray nozzles, the dry process makes it relatively easy to maintain the production equipment and minimizes damage to it. The liquid binder sprayed onto the mineral fibers accumulates on the rollers in the production equipment. This binder accumulation must be removed to ensure optimal operation of the production equipment during the next operation. However, roller maintenance requires the shutdown of the production line, which increases the production costs of mineral wool mats. Furthermore, this dry process does not form mineral fiber aggregates, which could result in multiple mineral fibers becoming trapped in the liquid binder.

[0069] As can be seen from Figure 4, the mineral fibres 2 are, according to the invention, fixed together by adhesive elements which are thermally bonded fibres 3. These thermally bonded fibres 3 are deposited together with the mineral fibres 2 to form the mineral wool mat 1 so that the content of thermally bonded fibres 3 in the mineral wool mat 1 is between 2% and 30%, preferably between 3% and 15%, more preferably between 4% and 10%.

[0070] In the example shown, the thermal bond fibers 3 are oriented in the same direction of extension as the mineral fibers 2. In other words, the thermal bond fibers 3 and the mineral fibers 2 are each oriented in a direction of extension parallel to the main longitudinal extension direction of the mineral wool mat 1.

[0071] Furthermore, the thermally bonded fibre 3 is formed by a core 31 and a sheath 32. The core 31 forms the rigid part of the thermally bonded fibre 3 and provides the mineral wool mat 1 with mechanical strength, while the sheath 32 ensures that the mineral fibres 2 are fixed together. For this purpose, the core 31 and the sheath 32 have different melting points, more particularly the sheath 32 has a lower melting temperature than the core 31.

[0072] In this way, when the mineral fiber carpet is passed through an oven to obtain the mineral wool mat according to the present invention, the sheath 32 can encase adjacent mineral fibers 2 and resolidify when it leaves the oven and cools, thereby fixing these mineral fibers together. It should be noted that the melting temperature of the core 31 is designed so that the core 31 maintains its rigidity even when the mineral fiber carpet made of a mixture of mineral fibers and adhesive passes through an oven, which ensures the mechanical strength of the mineral wool mat 1 after the oven.

[0073] Figure 5 shows part of a production installation 4 for a mineral fibre carpet 10 suitable for forming a mineral wool mat 1 according to the invention. The production installation 4 as described in relation to Figure 5 does not exclude any embodiment of the form that the production installation may take, as long as it is possible to obtain a mineral wool mat 1 according to the invention, i.e. in which the mineral fibres 2 are fixed together by thermally bonded fibres 3, the thickness of the mineral wool mat is more than 50 mm, and the volume density is 40 kg m -3 As long as it is less than

[0074] This manufacturing facility 4 has a distribution station 8 on the upstream side, taking into consideration the circulation direction of the mineral fibers 2, and although not shown, there is a supply device for the conveyor belt 42. In the supply device, the mineral fibers 2 and the thermally bonded fibers 3 are mixed so that the mineral fiber carpet 10 contains 2% to 30% of the thermally bonded fibers 3 and 70% to 98% of the mineral fibers 2.

[0075] The conveyor belt 42 is configured to move at a speed that can be modified by appropriate control commands. The conveyor belt 42 has a fiber dispensing end that is located above the dispensing station 8 described above.

[0076] The distribution station 8 has at least one roller train 81 with rollers 811 and a conveyor device 82 by which the mineral fiber carpet 10 can be formed when the mineral fibers 2 and the thermally bonded fibers 3 are deposited on the roller device 82. The roller train 81 is arranged in the path of the mineral fibers 2 between the conveyor belt 42 and the conveyor device 82.

[0077] The roller row 81 consists of a plurality of rollers 811 arranged parallel to one another and capable of swinging about parallel rotation axes 800. These rollers 811 are configured, on the one hand, to separate the mineral fibers 2 and prevent agglomerated mineral fibers 2 from depositing on the conveyor device 82, and, on the other hand, to orient these mineral fibers 2 substantially longitudinally and perpendicularly to the roller rotation axes 800 within the mineral fiber carpet 10.

[0078] The roller train includes a proximal roller located at a first end of the roller train closest to the conveyor belt 42 and its fiber-distribution end, a distal roller located at the opposite end of the roller train, and a number of central rollers located consecutively between the proximal and distal rollers. The distribution station 8 has mechanical guide means 19 for guiding the mineral fibers reaching the fiber-distribution end toward the roller train, and more particularly toward the proximal rollers. These mechanical guide means 19 can take various forms, including flexible ducts, rigid trays forming a funnel, or guide ramps, as shown in FIG. 5. These mechanical guide means 19 guide the mineral fibers, which fall by gravity, toward the proximal and immediately adjacent rollers in an environment where they will not be blown or sucked.

[0079] In this context, the distribution station 8 is configured to separate the mineral fibers 2 from one another, so that the mineral fibers 2 that were not completely separated in the feeding device are separated from one another, in particular by the arrangement of rollers 811 in the roller row 81, the rollers 811 rotating in the same direction serving to guide a portion of the mineral fibers 2 between two adjacent rollers 811 towards the conveyor device 82, and to guide another portion of the mineral fibers 2 towards the adjacent roller 811, to advance along the roller row 81 and further discharge onto the conveyor device 82.

[0080] The distribution station 8 serves to ensure the transverse and vertical homogeneity of the mineral fibers 2 in the mineral fiber carpet 10. This homogeneity, especially the transverse homogeneity, is made possible by scattering means, not visible in FIG. 5, provided at the end of the conveyor belt 42 closest to the distribution station 8. These scattering means enable the mineral fibers 2 and the thermally bonded fibers 3 to be scattered over the entire transverse direction of the rollers 811 of the roller train 81, which transverse direction is parallel to the transverse direction of the mineral fiber carpet 10.

[0081] It should also be noted that the manufacturing facility 4 is configured to form a mineral wool mat 1 of a desired thickness, at least above 50 mm, by adjusting the thickness of the mineral fiber carpet at the furnace outlet, in particular at the outlet of the distribution station 8. For example, it is possible to increase the thickness of the mineral fiber carpet 10, and therefore the thickness of the mineral wool mat 1, by increasing the inclination of the roller train 81. This makes it easier to continuously deposit the mineral fibers 2 and the thermally bonded fibers 3 one on top of the other over a relatively large-sized roller.

[0082] The conveyor device 82 transports the mineral fiber carpet 10, which is made of mineral fibers 2 and thermally bonded fibers 3, towards an oven (not shown), where the mineral fibers 2 and the thermally bonded fibers 3 are heated to cross-link the sheaths 32 of the thermally bonded fibers 3. In other words, in the oven, the mineral fibers 2 and the thermally bonded fibers 3 are heated, thereby fixing the mineral fibers 2 together. The mineral fiber carpet 10, in which the mineral fibers are fixed to each other by the thermally bonded fibers and which has a predetermined density and thickness, is converted into a mineral wool mat according to the present invention by passing through at least an oven, and then compressing and cutting it, if necessary, before packaging.

[0083] As is clear from the above description, the present invention proposes a mineral wool mat with improved heat and / or sound insulation by fixing mineral fibers together with thermally bonded fibers, and has a thermal insulation capacity of 40 kg m -3 For a range of articles having a volume density of less than 1000 mm and a thickness of more than 50 mm, this objective is achieved, making it possible to provide a mineral wool mat with relatively good insulating properties by improving resistance to air passage and limiting the formation of thermal bridges.

[0084] However, the invention as described is not limited exclusively to the means and arrangements described and illustrated, but applies to any equivalent means or arrangements and to any combination of these means or arrangements.

Claims

1. A mineral wool mat (1) comprising at least a plurality of mineral fibers (2) that overlap and are laminated adjacent to each other within the mineral wool mat (1), wherein the mineral fibers (2) are fixed to each other by adhesive elements formed by heat-bonded fibers (3), and the volume density of the mineral wool mat (1) is 40 kg·m³. －３ A mineral wool mat (1) having a thickness of more than 50 mm, where the mineral wool mat (1) is less than 50 mm.

2. The mineral wool mat (1) according to claim 1, wherein the mineral fiber (2) is a glass fiber.

3. The volume density of the mineral wool mat (1) is 7 to 40 kg·m³. －３ The mineral wool mat (1) according to claim 1 or 2.

4. The mineral wool mat (1) according to claim 1 or 2, wherein the thickness of the mineral wool mat (1) is greater than 100 mm.

5. The mineral wool mat (1) according to claim 1 or 2, wherein the mineral fibers (2) are fixed to each other by a dry process.

6. The mineral wool mat (1) according to claim 1 or 2, comprising 2% to 30% of the heat-bonded fibers (3).

7. The mineral wool mat (1) according to claim 1 or 2, wherein the heat-bonded fiber (3) has a core (31) and a sheath (32), and the core (31) has a melting temperature different from that of the sheath (32).

8. The mineral wool mat (1) according to claim 7, wherein the adhesive element is obtained by melting the heat-bonding fibers.

9. The mineral wool mat (1) according to claim 8, wherein at least the mineral fibers are uniformly distributed within the mineral wool mat, and the uniform distribution of the mineral fibers is considered in transverse and / or vertical directions, each of which is perpendicular to the main longitudinal direction of the stretching of the mineral wool mat.

10. A method for producing the mineral wool mat (1) according to claim 1 or 2, wherein the method comprises the following steps: - At least one first step of mixing the heat-bondable fiber (3) and the mineral fiber (2) together, - At least one second step of depositing the previously mixed mineral fibers (2) and heat-bonded fibers (3) onto a conveyor device (82) using mechanical guide means (19) to form a mineral fiber carpet (10), and, - At least one third step of transporting the mineral fiber carpet (10) to a furnace by the conveyor device (82), and heating the mineral fibers (2) and the heat-bonded fibers (3) to form the mineral wool mat (1), A method for carrying out this.

11. A method for producing a mineral wool mat (1) according to claim 10, wherein the mineral fiber carpet (10) is continuously produced in a single pass during the second step, and during the single pass, the fibers involved in the formation of the mineral fiber carpet (10) passing through the furnace are stacked and deposited in order.

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