Multi-Layer Mineral Wool Insulation Using Compressed Recycled Surface Layers
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Solution Overview
Problem
Existing methods for manufacturing multilayer mineral wool insulation are complex and do not effectively utilize recycling materials, which are often surplus or returned from customers, to achieve a very rigid surface layer with high density.
Innovation Solution
A method where a mineral wool mat with fibers parallel to its surfaces is enhanced by adding a compressed layer of recycled crushed or pulverized mineral wool mixed with a binding agent, which is then further compressed and coated with fibreglass fabric before curing, allowing for a multi-layer insulation product with varying properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thin mineral wool sheet is cut and compressed between rollers into a denser form, then the surface layer rigidity is improved, but the manufacturing complexity increases due to additional cutting and compression steps
Solution Approach 1:
The insulation product is divided into multiple layers with different densities and functions: a less dense base layer for thermal insulation and a highly compressed surface layer for rigidity and strength. This segmentation allows each layer to be optimized independently for its specific function.
Solution Approach 2:
The surface layer is pre-compressed to the desired high density (at least 450 kg/m³) before being applied to the base layer. This preliminary compression ensures the surface layer achieves the required rigidity and density without requiring complex in-line compression equipment during the main manufacturing process.
2Strength
If loose material is spread to form a rigid surface layer with density of at least 450 kg/m³, then the surface layer strength is improved, but the manufacturing complexity increases due to additional spreading and compression steps
Solution Approach 1:
The surface layer material is pre-compressed to the target density of at least 450 kg/m³ in a separate operation before being applied to the base layer. This eliminates the need for complex in-line compression equipment and multiple processing steps during main production.
Solution Approach 2:
The method utilizes loose mineral wool material that would otherwise be waste or surplus, transforming it into a valuable high-density surface layer. This converts a discarded material into a functional component with high rigidity requirements.
3Loss of substance
If recycled crushed and pulverized mineral wool is used in the additional insulation layer, then material utilization is improved, but the manufacturing precision decreases due to variable composition of recycled material
Solution Approach 1:
The recycled material undergoes controlled crushing and pulverization to change its physical parameters, transforming it into a fine-grained material suitable for high-density compression. This parameter change enables the variable composition to be managed through controlled compression rather than requiring uniform raw material.
Solution Approach 2:
The method recycles crushed and pulverized mineral wool that would otherwise be waste material from production or customer returns. By applying high compression (50% or more), the variable composition of recycled material is transformed into a consistent high-density product suitable for the surface layer.
4Quantity of substance
If the additional insulation layer is compressed to 50% or more before being brought onto the mineral wool mat, then the surface layer density is improved, but the manufacturing complexity increases due to additional compression equipment
Solution Approach 1:
The additional insulation layer is pre-compressed to the desired density (50% or more compression) in a separate operation before being applied to the mineral wool mat. This preliminary compression simplifies the overall manufacturing process by eliminating the need for complex in-line compression equipment during the main production line.
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 simplifies the production process, integrates recycling materials efficiently, and achieves a high-density insulation product without requiring significant changes to existing manufacturing lines, enabling the creation of a rigid and effective insulation with desired properties.
Implementation Method 1
the binding agents in the mineral wool mat and the additional insulation layer harden under the influence of heat and the layers simultaneously adhere to each other
Data Source
Figure 1~2
AI summary
The invention relates to a method for manufacturing a double or multi-layer mineral wool insulation (1). In the method, on a mineral wool manufacturing line is continuously produced a mineral wool mat (2) having a bottom side and a top side defining the main surfaces of the mineral wool mat, in which the fibres are located substantially in levels parallel with said main surfaces. In the method, onto at least one of said main surfaces is brought an additional insulation layer (3, 3') containing recycled material, which contains shredded and/or crushed and/or pulverized mineral wool and into which recycled material is mixed binding agent in a powdered form before it is brought onto said at least one main surface of the mineral wool mat (2). The layer (3, 3') of recycled material is compressed into a mat-like layer before it is brought onto said at least one main surface of the mineral wool mat. Finally, the mineral wool insulation (1) formed from a mineral wool mat (2) and an additional insulation layer of recycled material (3, 3') added onto its at least one main surface is taken to a curing treatment (8).