Annular Spray Nozzle Flat Jet Biosourced Mineral Wool Binder
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Solution Overview
Problem
Conventional mineral wool manufacturing processes using phenolic-based binders face ecological concerns due to the release of toxic volatile organic compounds, and the use of biosourced 'green binders' is complicated by their higher viscosity, leading to evaporation issues and jet interference during spraying.
Innovation Solution
An annular device with spray nozzles producing a flat jet of biosourced binder is used, allowing for controlled orientation and distribution around the fibers, eliminating the need for additional cooling stages and preventing jet interference by varying the inclination of nozzles to ensure uniform coverage and efficient evaporation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phenolic-based binders are used for bonding mineral fibers, then the bonding efficiency and manufacturing control are improved, but toxic volatile organic compounds are released causing ecological harm
Solution Approach 1:
The invention changes the chemical composition parameters of the binder by using biosourced products (vegetable oils, fatty acids, starches) instead of phenolic compounds. This substitution maintains the binder's functional properties for bonding mineral fibers while eliminating the release of toxic volatile organic compounds, thus resolving the contradiction between bonding efficiency and ecological harm.
2Object-generated harmful factors
If biosourced green binders are used to replace phenolic binders, then ecological safety is improved, but the higher viscosity of green binders causes evaporation issues and spraying complications
Solution Approach 1:
The invention introduces a dynamic adjustment mechanism for the binder composition, allowing the viscosity and water content of the green binder to be optimized during the spraying process. This enables adaptation to the higher viscosity of biosourced binders while maintaining proper spray characteristics and preventing evaporation issues, thus resolving the contradiction between ecological safety and spraying control.
3Ease of operation
If water is added to green binder to reduce viscosity for spraying, then sprayability is improved, but water evaporation problems occur in subsequent stations
Solution Approach 1:
The invention optimizes the water-to-binder ratio parameter to achieve the minimum necessary water content for adequate sprayability while avoiding excess water that would cause evaporation problems. This precise parameter control allows the use of green binders with improved spray characteristics without suffering from excessive water evaporation in subsequent processing stations.
4Device complexity
If conventional spray nozzles are used for green binder, then the spraying mechanism is simple, but jet interference occurs and uniform distribution is not achieved
Solution Approach 1:
The invention modifies the spray nozzle geometry by introducing a slot-shaped orifice instead of a conventional circular opening. This dimensional change in the spray outlet creates a flat jet pattern that prevents jet interference between adjacent nozzles and ensures uniform binder distribution across the fiber torus, resolving the contradiction between device simplicity and distribution precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables the use of eco-friendly biosourced binders without phenolic components, improving the manufacturing process by reducing water evaporation issues and ensuring consistent binder distribution, resulting in high-quality mineral wool production.
Implementation Method 1
at least one spray nozzle communicating fluidly with the distribution circuit and arranged on the periphery of the annular projection device to project the sizing composition onto the fibers intended to pass inside the annular projection device
Implementation Method 2
the use of a nozzle of spray allowing the formation of a flat jet allows good distribution of the binder around the periphery of the torus of fibers passing through the gluing station
Implementation Method 3
The spray nozzles are oriented towards the inside of the annular projection device with an angle of inclination determined relative to a plane of revolution of the annular projection device
Data Source
Figure 1~2
Figure 3~4b
Figure 5~7
AI summary
An annular device (20) for spraying a sizing composition onto mineral fibres (3) comprises at least one circuit (24, 26) for distributing the sizing composition and at least one spray nozzle (22) in fluid communication with the distribution circuit and arranged on the periphery of the annular spray device in order to spray the sizing composition onto the fibres that pass through the annular spray device defined by an axis of revolution (X-X). According to the invention, the sizing composition is a binder based on biosourced products, and at least one spray nozzle comprises a spray head (36) having a slot (50) through which the biosourced-product-based binder leaves the annular spray device, said slot having a rectangular cross-section such as to form a flat jet of biosourced-product-based binder.