Method for manufacturing insulation products based on mineral wool using a solid thermosetting binder
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing insulation products based on mineral wool bound by organic binders involve applying a binder composition to still-hot fibers, leading to sticky fibers that soil equipment and require costly washing systems.
Innovation Solution
Applying a water-soluble and thermosetting binder powder to mineral wool fibers at room temperature, followed by humidification to retain the binder particles and prevent them from gathering at the bottom of the mixture, ensuring even distribution and uniform mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an aqueous binder composition is sprayed onto still-hot mineral fibers, then the binder sets effectively, but the fibers become sticky and soil the equipment
Solution Approach 1:
The invention changes the temperature parameter from hot to room temperature when applying the binder composition. This parameter change prevents the binder from becoming sticky while still allowing it to set effectively, thereby eliminating the soiling problem without compromising binder setting effectiveness
Solution Approach 2:
The invention extracts the harmful stickiness property from the binder-fiber mixture by changing the application temperature. The binder composition is applied at room temperature where it remains non-sticky, and only later does it undergo setting, thus separating the sticky phase from the binding phase
2Object-generated harmful factors
If a washing system is installed to clean soiled equipment, then equipment cleanliness is maintained, but production costs increase significantly
Solution Approach 1:
The invention extracts and eliminates the source of soiling by changing the binder application temperature to room temperature. This removes the need for the washing system entirely, reducing both equipment complexity and production costs while maintaining equipment cleanliness
Solution Approach 2:
The invention replaces the expensive washing system with a simple temperature control approach. By applying binder at room temperature, the process becomes inherently cleaner, making complex washing equipment unnecessary
3Ease of manufacture
If binder particles are simply mixed with mineral fibers, then the process is simple, but the binder particles gather at the bottom due to gravity
Solution Approach 1:
The invention introduces humidified air as an intermediary medium to carry the binder particles uniformly through the mineral wool fibers. This intermediary prevents direct gravitational settling while maintaining simple processing, achieving both ease of manufacture and uniform distribution
Solution Approach 2:
The invention uses a stream of humidified air (pneumatic approach) to distribute binder particles uniformly throughout the mineral fibers. The air stream counteracts gravitational settling, ensuring even distribution while keeping the process simple and efficient
4Productivity
If mineral fibers are conveyed by a stream of hot air, then the fibers are transported efficiently, but the sticky sized fibers soil the walls and equipment
Solution Approach 1:
The invention changes the temperature parameter of the air stream from hot to room temperature when applying the binder. This parameter change prevents fiber stickiness while maintaining transport efficiency, thereby eliminating soiling without sacrificing productivity
Solution Approach 2:
The invention inverts the conventional approach by applying binder at room temperature instead of hot temperature. This inversion prevents the stickiness issue that occurs with hot binder application, while still achieving effective fiber binding after setting
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 method eliminates the need for costly washing systems by preventing fiber stickiness and ensures a uniform distribution of binder particles, resulting in insulation products with improved mechanical performance and reduced production costs.
Implementation Method 1
humidification to retain the binder particles and prevent them from gathering at the bottom of the mixture
Implementation Method 2
heating the mixture obtained thereby at a temperature sufficient to cause the reagents of the binder to react and thereby form an insoluble and infusible binder
Data Source
AI summary
The present invention relates to a method for manufacturing insulation products based on mineral wool bound by an organic binder, comprising the following successive steps:(a) providing a mineral wool,(b) humidifying the mineral wool,(c) placing the humidified mineral wool fibers in contact with particles of binder comprising a mixture of thermosetting reagents,(d) shaping the mixture of mineral wool and binder particles, and(e) heating the shaped mixture to a temperature and for a period sufficient to allow the condensation of the reagents and the formation of an insulation product based on mineral wool bound by an insoluble and infusible organic binder.