Methods for producing a mineral wool needle-felt and a mineral w

Details Methods for producing a mineral wool needle-felt and a mineral w Methods for producing a mineral wool needle-felt and a mineral w

1993-10-15

1997-09-30

Crowder, C. D.

Textiles: manufacturing

Textile product fabrication or treatment

Fiber entangling and interlocking

28107, D04H 148, D04H 106

Patent

active

056715188

DESCRIPTION:

BRIEF SUMMARY
BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention relates to an agent effective as a processing aid for processing mineral wool mats by subjecting the fibers to the influence of a force in order to cause new, stable positions of the fibers relative to each other, as well as a needle-punched felt and a crimped mineral wool product produced by utilizing this agent, and methods for producing them.
2. Description of Related Art
In needle-punching mineral wool felts a needling aid, a so-called finishing agent or avivage, must be applied to the fibers in the form of an additive. Such finishing agents are often produced on the basis of mineral oils or natural oils, fatty acid derivatives and the like. The finishing agent has the functions of making the fibers more supple and of reducing friction between the fibers during the needling process in order to prevent tearing or breaking of the fibers during needling as far as possible. The finishing agent must furthermore perform the function of a dust bonding agent in order to permit processing and use of the needle-felt without any additional dust protection measures.
These functions are performed best by a finishing agent having a low viscosity in the range of some hundreds or a few thousands of cP since such low-viscosity finishing agents, due to their low viscosity, can form a thin lubricating film to produce a good antifriction effect while requiring relatively small amounts. However the use of a needling aid having a low viscosity and thus a good "lubricating effect" also causes the fibers to easily slide out of their anchoring positions obtained in the needle-felt during the needling process. The felt just needled is thus undone and loses a major part of its inner cohesion.
Here it is known from DE-A 38 35 007 to add a certain amount of a finishing agent with an unusually high viscosity of up to 10,000 cP as a needling aid in order to consolidate rock wool with relatively small average fiber thicknesses of less than 6 .mu.m by needle-punching. The finishing agent renders the relatively thin rock-wool fibers so supple that they can be needled without breakage or rupture of the fibers occurring despite the high viscosity of the finishing agent, while the high viscosity of the finishing agent ensures that the fibers remain in their anchoring positions immediately after the needling process. It is a disadvantage that the high viscosity of the needling aid prevents needling of all kinds of mineral wool felts at a high speed. Another disadvantage is the relatively large amount of needling aid which must be added under practical conditions for the high-viscosity finishing agent to form a film; since the finishing agent is of an organic-chemical nature it volatizes under the influence of heat while causing a considerable annoying odor, or else the finishing agent must previously be expelled in an additional operation. If thorough baking is performed immediately after the needling process to avoid an odor for the customer, as well as for strainless stabilization of the needle-felt, then the finishing agent will no longer be available as a dust bonding agent during subsequent manipulation and processing of the needle-felt up to its final installation, so that additional dust protection measures will become necessary.
A similar set of problems presents itself in the production of crimped mineral wool products as known, for instance, from U.S. Pat. No. 2,409,066 or EP-A 0 133 083. Here, too, the objective is to shift single fibers relative to each other until they reach a new final position wherein they are then to be anchored stably inside the product in order to provide it with a desired mechanical strength and stability. The higher the viscosity of the utilized finishing agent, the more force is necessary to shift the fibers relative to each other. In the case of a laminar mat to be crimped, as this force has to be applied by means of transverse forces from the edges of the latter and therefore has a very indirect effect upon individual fibers

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McCutheon's Emulsifiers & Detergents, International Edition 1985, p. 223 Oct. 22, 1985.

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