Device and method for forming of insulation boards

Abstract

Device and method for forming of insulation boards solves problem of forming insulation boards during curing process by providing of at least one perforated slat designed for gas preferably hot air blow-through during the polymerization of a binder in a product, such as glass wool. The slat includes a height-adjustable, narrower section that imprints preferably rectangular profile into the product during polymerization - solidifying the product into its final shape. This final shape may resemble shiplap design of wood taking advantage of its labyrinth-like overlapping positioning of adjacent boards during assembly.

Description

[0001] DEVICE AND METHOD FOR FORMING OF INSULATION BOARDS

[0002] Technical field

[0003] Mineral wool production; glass wool production; fibers.

[0004] Technical problem

[0005] Current glass and mineral wool

[0006] State of the art

[0007] US 11952779B2 discloses an insulation system comprising: a first insulation board having four edges, wherein a first shiplap is formed on at least one of the edges of the first insulation board; and a second insulation board having four edges, wherein a second shiplap is formed on at least one of the edges of the second insulation board; wherein the first shiplap has a width ai; wherein the second shiplap has a width a2; wherein the first shiplap has a thickness bi; wherein the second shiplap has a thickness b2; wherein the first insulation board has a thickness ei; wherein the second insulation board has a thickness e2; wherein the ai = a2; wherein bi = b2; wherein bi < ei; wherein b2 < e2; wherein ei = e2; and wherein the first shiplap is operable to interface with the second shiplap to form an insulated joint between the first insulation board and the second insulation board.

[0008] US2013343818A1 discloses a subsurface thermal insulation product for reducing ground disturbance during a freeze-thaw cycle comprising: a plurality of thermal insulation panels each comprising: a foam board and a water wicking sheet attached to one of the top surface or the bottom surface of the foam board. Each foam board has a top surface and a bottom surface and four peripheral shiplap edges each with a notch that permits multiple thermal insulation panels to be placed in adjacent overlapping engagement. US2005221061A1 discloses a method for forming a shiplap edge in a duct board comprising the steps of: molding a shiplap edge in a first duct made of mineral fiber or mineral wool, so that the molded shiplap edge has a molded edge thickness, and machining the molded shiplap edge to a desired machined edge thickness that is less than the molded edge thickness.

[0009] US2013133277A1 discloses an insulating panel to be used in a panelized insulation system for insulating and finishing walls, including basement walls having a foam core made of inorganic materials. The system incorporates a capillary break, an integrated water drainage system and an electrical wire chase system within an insulating wall panel. Vertical slots are provided for insertion of metal studs for use in attaching the interior finish panel, such as inorganic fiber cement board with a vinyl laminate finish, onto the insulating panels. Embedding metal studs in the panel core reduces the sound transmission though the panel and eliminates thermal bridging between warm and cold surfaces. Steps on the edges and the top / bottom surfaces of the insulating panel allow more panels to join together with shiplap joints.

[0010] Description of new invention

[0011] Device and method for forming of insulation boards solves problem of forming insulation boards during curing process by providing of at least one perforated slat designed for gas preferably hot air blow-through during the polymerization of a binder in a product, such as glass wool. The slat includes a height-adjustable, narrower section that imprints preferably rectangular profile into the product during polymerization - solidifying the product into its final shape. This final shape may resemble shiplap design of wood taking advantage of its labyrinth-like overlapping positioning of adjacent boards during assembly.

[0012] US 11952779B2 defines the general inventive concepts relating to a rigid insulation board having at least one interlocking shiplap edge. As used herein, the term “shiplap” is intended to encompass any shaping imparted to the edges of the insulation boards that allows the edges of adjacent boards to overlap with one another to form a substantially flush joint. The shaping can occur during formation of the boards of after formation thereof.

[0013] For purposes of these specifications, the overlapping portions of the insulation board can be flat, or grooved, or enabling different forms of interlocking one insulation board with adjacent. All of these variations are described as “grooves”.

[0014] One of the aims of this device and process is providing shapes of insulation product to provide for continuous surface of several pieces of insulation products. In glass or mineral wool production, perforated slats are integrated into the curing oven where the binder between the fibers polymerizes, defining the product's final shape. Some products require interlocking edges that allow forming a continuous surface by stacking of boards, using so-called Shiplap joints. Such products are formed by pressing the slat's perforation section of non-base height into the wool layer during polymerization.

[0015] The problem encountered is in inflexible setups not allowing for different shapes and / or thicknesses of depressed portions of the board. For adjustments (if at all possible), one must undertake halting of the conveyers and adjusting the height.

[0016] For purposes of these specifications, “conveyer” refers not only to customary way understanding conveyers but also to collection of slats which are independent one to another but bound together on some sort of chain, rope, belt or somesuch arrangement allowing for coordinated movement of said slats around the driving wheels, so in fact this arrangement behaves as a conveyer, or a pair thereof (Figure 1).

[0017] In order to form the final product, i.e. shiplap insulation board, a continuous process is envisioned whereby continuous stream of uncured or partially cured layer of mineral or glass wool enters space between two conveyer belts (each made of plurality of slats)

[0018] It is important for at least some slats to be perforated. These slats are not only meant to shape the product but also to provide for curing of such product which is in case of mineral wool exposing the product to warm or hot air completing the polymerization process. The device according to these specifications comprises:

[0019] - Slat Frame: A rigid frame, fixed between conveyor pull chains, providing sufficient bending stiffness. The frame has a perforated surface in non-adjustable areas and supports other components;

[0020] - Height- Adjustable Perforation Sections: These sections can be adjusted vertically to imprint specific profiles into the product during polymerization;

[0021] - Height Adjustment Mechanism: A mechanism built into the slat allows for adjusting the height of the narrower perforated section. During operation, this mechanism interacts with an external activation element;

[0022] - Activation Element: Located externally, typically beneath the slat, this element enables the operator to select the desired height for the adjustable perforation section, thus controlling the shape imprinted on the product.

[0023] The new invention comprises one or more of these features.

[0024] The perforated slat's primary function is to work in tandem with an opposing slat to define the product's thickness during the hardening process, which is achieved by curing the binder at elevated temperatures with forced air flow. The slat’s height-adjustable perforation sections create the desired groove patterns in the product.

[0025] The advantage against state of the art lies in the ability to customize groove depths, directly influencing the product's final shape. Imprinting these grooves optimizes the product's structural integrity by improving mechanical properties, particularly in areas of geometric transitions where stress concentrations often occur.

[0026] The method according to these specifications comprises the following steps:

[0027] Providing for device according to these specifications;

[0028] Introducing insulation product during curing into said device, said product comprising mineral and / or glass wool mixed with binder;

[0029] Positioning of said product in proximity of slat forming part of said device; Optionally, positioning second slat forming part of said device;

[0030] Adjusting height according to preset conditions.

[0031] To achieve desired grooves depths, slats future narrower, height-adjustable sections that are attached to internal height adjustment mechanisms within the slat frame. When the operator modifies its height using the actuator, the perforation section moves up or down to imprint the chosen profile height into the product.

[0032] The subject of these specifications is therefore device for forming of insulation boards wherein said device comprises:

[0033] A plurality of slats, comprising upper slats forming the upper part of the conveyor pair and lower slats forming the lower part of the conveyor pair, for moving a layer of mineral or glass wool that requires shaping and / or curing;

[0034] A driving means for propelling the conveyor pair, said driving means chosen from a group consisting of rope, belt, chain, or a connection mechanism linking the slats to form a self-propelling group;

[0035] At least one slat with at least one partially perforated section allowing the passage of gas, preferably hot air, for curing the mineral or glass wool;

[0036] At least one slat with at least one part capable of moving relative to the rest of the slat, forming a height-adjustable section;

[0037] At least one activation element for adjusting the height of the height-adjustable section.

[0038] Device according to these specifications can further comprise:

[0039] - At least one conveyer pull chain for moving of at least one part of said conveyer pair;

[0040] - A rigid frame, attached to said at least one conveyor pull chain, providing sufficient bending stiffness, said frame having a perforated surface in non- adjustable areas;

[0041] - Height- adjustable perforation sections, said sections to be adjusted vertically to imprint specific profiles into the product during polymerization; - Height adjustment mechanism, said mechanism built into the slat allowing for adjusting the height of said height-adjustable perforated section; during operation, this mechanism interacts with an external activation element;

[0042] - Activation element located externally, typically beneath the slat, this element enabling the operator to select the desired height for the adjustable perforation section, thus controlling the shape imprinted on the product.

[0043] The subject of these specifications is also method for forming of insulation boards with the following steps:

[0044] - Providing of device according to these specifications;

[0045] - Introducing layer of mineral or glass wool in need of shaping and / or curing between upper and lower parts of conveyer pair;

[0046] - Adjusting of height of at least one of slats forming said conveyer pair by activation element;

[0047] - Imprinting of shape by means of said height-adjusted slat into said mineral or glass wool layer;

[0048] - Curing of said mineral or glass wool layer by means of gas, preferably hot air, passing through perforations in at least one of said slats.

[0049] Method according to these specifications can further comprise step of moving upper part of conveyer pair, and lower part of said conveyer pair with different velocity relative to one another.

[0050] Method according to these specifications can further comprise step of providing of at least one part of said conveyer comprised of at least one pair of slats not adjacent next to each other.

[0051] After exiting from said conveyer pair, at least partially cured layer of mineral or glass wool with imprinted grooves (thinner parts of said layer) including simple rectangular shape having all surfaces essentially flat or smooth is cut into insulation boards, said insulation boards preferably used as insulation for building insulation or similar purposes. Figure 6 shows such a insulation board as a result of device and method for forming of insulation boards according to these specifications.

[0052] Detailed description of new invention

[0053] The invention is further described with help of the figures, said figures forming part of these specifications:

[0054] Figure 1 shows pair of conveyers for curing product, comprising of lower slats (1) and upper slats (2), forming the product (3) while curing.

[0055] Figure 2 shows conveyors section of two lower slats (1) and two upper slats (2), transparently shown product (3) passing through the conveyor, activation elements (4) for changing or setting the height adjustable pucks with mechanism (5) height and consequently grooves depth. This figure shows the essential part of the method wherein said layer of mineral or glass wool thickness is adjusted to form cross-section of shiplap formed layer of mineral or glass wool to be cut into shiplap formed insulation boards.

[0056] Figure 3 shows cross section showing lower slat (1), upper slat (2), product (3) being cured, activation elements (4) and slat height adjustable pucks with mechanisms (5).

[0057] Figure 4 shows lower conveyor slat (1) with single height adjustable puck with mechanism (5).

[0058] Figure 5 shows upper conveyor slat (2) with two height adjustable pucks with mechanisms (5).

[0059] Figure 6 shows example of final product, that has been cut into a desired shiplap board (6).

[0060] According to preferred embodiment insulation product arrives in front of conveyer pair as layer of mineral / glass wool. It is introduced between both parts of the conveyer pair, said insulation product comprised of mineral or glass wool mixed with binder, said binder preferably polymer, undergoing curing.

[0061] This conveyer pair transports said layer of insulation product by being propelled by upper and lower slats, at least some of said slats being perforated, said slats part of said conveyer pair. Each of said slats is formed as a negative of form of surface of said insulation - upper slat negative of upper surface, lower slat negative of lower surface.

[0062] Upon contact with said layer of mineral / glass wool, said layer is being transformed into desired shape, in this embodiment forming continuous shiplap form. Upon curing, said continuous shiplap form is cut into individual boards.

[0063] Forming of said layer of mineral / glass wool is similar to imprinting patterns into said layer, so it will be referred as such. While in preferred embodiment the imprinted form is simple shiplap form with smooth surfaces, different surfaces can be imprinted such as grooved surfaces or similar in order to improve labyrinth like properties of said boards when interlocked into position during assembly.

[0064] The imprints are in this particular case formed in such a way that the upper slat (1) imprints rectangular shape into said layer of mineral or glass wool from above, and the lower slat (2) imprints rectangular shape into layer of mineral or glass wool from below, in order to form a layer of mineral or glass wool with two portions of said layer of mineral or glass wool which are thinner than the rest of the layer of mineral or glass wool.

[0065] As said, after at least partial curing said layer of mineral or glass wool is cut into insulation boards

[0066] During assembly of such products, said insulation boards can be stacked one on top another in order to form continuous surface with labyrinth-type of joint comprised of two thinner parts of the insulation boards interlocking. The operator can predefine depth of such imprint. Based on such depth, different outcomes are achieved.

[0067] For example, the operator can adjust height of imprint in such a fashion that interlocking insulation products have flush surfaces. In such case each thinner section of the insulation board is approximately half of full thickness of the insulation board.

[0068] At least few of said slats forming of said conveyer pair are perforated allowing for passage of gas, preferably hot air, in direction transverse to direction of said layer of mineral / glass wool moving to allow for curing of said insulation.

[0069] Method can provide also for different velocity of upper and lower slats. In such a case, there will be effect of dragging of said insulation layer through the conveyer pair providing particularly smooth surface.

[0070] Device and method according to these specifications can provide for having at least one of conveyer pair (either upper, or lower) not being comprised of slats adjacent next to each other. This would have effect of rugged surface, aid rugged surface (on one or both sides) having better interlocking properties in direction normal to board main surface - for cases where same boards are used for different thicknesses of final facade.

[0071] In another example, the thickness of thinner parts of the insulation board is larger that approximately one half of full thickness of the insulation board. This results in partially raised interlocking surface giving impression of planks overlapping one another, with impression that the planks are overlapping on exterior of said interlocking surface.

[0072] In third example, the thickness of thinner parts of the insulation board is smaller that approximately one half of full thickness of the insulation board. This results in partially depressed interlocking surface giving impression of planks overlapping one another, with impression that the planks are overlapping on interior of said interlocking surface. The same effect is obtained if sum of thicknesses of both thinner parts are approximately same as insulation board.

[0073] In fourth example, the sum of thicknesses is such that one side of interlocking surface is flush while another can be varied to achieve overlapping planks .

[0074] Adjusting the heights can be done either generally, or for each insulation board differentially, hence achieving architectural effects.

Claims

CLAIMS1. Device for forming insulation boards, wherein said device comprises:- A plurality of slats, comprising upper slats forming the upper part of the conveyor pair and lower slats forming the lower part of the conveyor pair, for moving a layer of mineral or glass wool that requires shaping and / or curing;- A driving means for propelling the conveyor pair, said driving means chosen from a group consisting of rope, belt, chain, or a connection mechanism linking the slats to form a self-propelling group;- At least one slat with at least one partially perforated section allowing the passage of gas, preferably hot air, for curing the mineral or glass wool;- At least one slat with at least one part capable of moving relative to the rest of the slat, forming a height-adjustable section;- At least one activation element for adjusting the height of the height-adjustable section.

2. Device according to claim 1, wherein the device comprises:- At least one conveyor pull chain for moving at least one part of the conveyor pair;- A rigid frame, attached to the conveyor pull chain, providing sufficient bending stiffness, with a perforated surface in non-adjustable areas;- Height- adjustable perforated sections, which can be adjusted vertically to imprint specific profiles into the product during polymerization;- A height adjustment mechanism built into the slat, allowing the height of the height- adjustable perforated section to be adjusted. During operation, this mechanism interacts with an external activation element;- An activation element located externally (typically beneath the slat), enabling the operator to select the desired height for the adjustable perforated section, thus controlling the shape imprinted on the product.

3. Method for forming insulation boards, comprising the following steps:- Providing the device according to any of the preceding claims;- Introducing a layer of mineral or glass wool, requiring shaping and / or curing, between the upper and lower parts of the conveyor pair;- Adjusting the height of at least one of the slats forming the conveyor pair by the activation element;- Imprinting a shape into the mineral or glass wool layer by means of the height- adjusted slat;- At least partially curing the mineral or glass wool layer by means of gas, preferably hot air, passing through the perforations in at least one of the slats;- Cutting the mineral or glass wool layer into insulation boards, essentially perpendicular to the direction of movement of the conveyor pair.

4. Method according to claim 3, wherein the upper part and the lower part of the conveyor pair move at different velocities relative to one another.

5. Method according to any of claims 3 to 4, comprising providing at least one part of the conveyor comprising at least one pair of slats that are not adjacent to each other.

6. Method according to any of claims 3 to 5, wherein the height of at least one height- adjustable slat is adjusted so that the thickness of the thinner parts of the insulation board is greater than approximately half of the total thickness of the insulation board.

7. Method according to any of claims 3 to 6, wherein the height of at least one height- adjustable slat is adjusted so that the thickness of the thinner parts of the insulation board is less than approximately half of the total thickness of the insulation board.

8. Method according to any of claims 3 to 7, wherein the height of at least one height- adjustable slat is adjusted so that the sum of the thicknesses is such that one side of the interlocking surface of the insulation boards produced by this method is flush, while the other side can be varied to achieve an overlapping plank effect.

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