Stock material or miscellaneous articles – Structurally defined web or sheet – Honeycomb-like
Reexamination Certificate
1999-06-25
2001-04-10
Zirker, Daniel (Department: 1771)
Stock material or miscellaneous articles
Structurally defined web or sheet
Honeycomb-like
C428S317100, C428S317900, C428S071000
Reexamination Certificate
active
06214438
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an insulation material comprising a basic material which is built up of cells and a filler which is present in said cells.
The invention furthermore relates to a method for producing such insulation material and to a device for carrying out the method in order to obtain the intended insulation material.
2. Discussion of the Background
From U.S. Pat. No. 4,271,876 it is known to use insulation material comprising a basic material built up of cells for producing prefabricated building components. The thermal and acoustic insulation value of such building components incorporating basic materials built up of cells can be further enhanced, however. The improvement of the thermal and acoustic insulation of such insulation material may take place by filling the cells with a filler of for example mineral wool fibres or cellulose fibres.
The term fibres used herein is understood to mean short, elongated particles, but also granular particles and the like.
Several experiments have been conducted within this framework, but it has become apparent that it is very difficult to fill the cells properly with such relatively light fibres. As a result of the problems involved in the filling of such basic material the use of this insulation material has not led to the expected large-scale use, because the increasingly stringent requirements with regard to the insulation value are not met.
SUMMARY OF THE INVENTION
The object of the invention is to provide an insulation material whereby fibres have been introduced into the cells of the basic material in a simple manner.
This objective is accomplished with the basic material according to the invention in that said filler is built up of separate fibres, which are bonded together by means of a foam-like bonding agent.
The foam will make the fibres heavier, as a result of which the fibres can be introduced into the cells of the basic material by the force of gravity. Fibres not bonded to bonding agent are relatively too light, and they exhibit a tendency to remain on top of the basic material.
A major advantage of the insulation material according to the invention is the fact that it has a high insulation value and that the filler can be introduced into the cells in a simple manner.
It has to be noted that from WO 93/25492 an isulation material is known comprising fibres which are bonded together by means of a foamlike bonding agent. However, this insulation material is used as such.
Another object of the invention is to provide a method wherein fibres can be introduced into the cells of the basic material in a simple manner.
This objective is accomplished with the method according to the invention in that first a mixture of separate fibres and a foam-like bonding agent is prepared, and that this mixture is introduced into the open cells of the basic material via a nozzle.
The fibres, which are weighted and bonded by the foam, can be introduced into the cells of the basic material in a simple manner, for example under the influence of the force of gravity.
One embodiment of the method according to the invention is characterized in that said filler is defibered into fibres, the fibres are subsequently bonded together by means of the bonding agent, after which the bonded fibres are defibered anew and introduced into the cells of the basic material.
By defibering the filler relatively small fibres or separate particles will be obtained. Said fibres are subsequently bonded to the bonding agent, as a result of which the specific weight of each fibre will increase. The fibres will also adhere together as a result of the presence of the bonding agent. When subsequently the fibres provided with the bonding agent are defibered, fibres weighted by the bonding agent will be obtained, which will fall into the cells of the basic material under the influence of the force of gravity. It is also possible, of course, to blow or suck the fibres into the cells of the basic material.
One embodiment of the method according to the invention is characterized in that upon providing the fibres with the bonding agent, the fibres are formed into a foam by means of the bonding agent, which foam is subsequently defibered.
Defibering the foam will result in the formation of separate fibres surrounded by bonding agent, which can be introduced into the cells of the basic material in a simple manner. The fibres will adhere together again once they are in the cell, to which adhering process the bonding agent will be conducive.
Another embodiment of the method according to the invention is characterized in that the basic material is vibrated while the fibres are being introduced into the cells.
The vibration of the basic material will cause the particles being introduced into the cells to move downward, thus creating space for additional fibres near the upper side of the cells. In this manner the cells will be entirely filled with fibres.
The invention also relates to a device suitable for carrying out the method, which comprises a filling station, which device is characterized in that said filling station is provided with a mixer for mixing said bonding agent and said fibres, so as to obtain said filler.
The fibres are bonded to the bonding agent by means of such a device before being introduced into the cells of the basic material.
One embodiment of the device according to the invention is characterized in that the device comprises a first defibering apparatus, a mixer connected to said first defibering apparatus via a pipe, which mixer is connected, via a further pipe, to a second defibering apparatus, which is provided with an outlet opening.
With such a device the first defibering apparatus is used for reducing the insulation material to fibres. The second defibering apparatus is used for separating the fibres, which adhere together as a result of the presence of the bonding agent.
REFERENCES:
patent: 4271876 (1981-06-01), Nash et al.
patent: 5455096 (1995-10-01), Toni et al.
patent: 5776579 (1998-07-01), Jessup et al.
patent: WO 93/25492 (1993-12-01), None
Oblon & Spivak, McClelland, Maier & Neustadt P.C.
Zirker Daniel
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