Mineral wool acoustic panel and process for manufacturing such a panel

Patent metadata

Field	Value
Publication number	US-11788282-B2
Application number	US-201816755464-A
Country	US
Kind code	B2
Filing date	Oct 12, 2018
Priority date	Oct 13, 2017
Publication date	Oct 17, 2023
Grant date	Oct 17, 2023

Abstract

A mineral wool panel, intended to be used as an acoustic panel, has a surface density of greater than or equal to 3.2 kg/m2, an air flow resistivity of between 30 and 120 kPa·s/m2, and a Young's modulus of between 0.5 and 4 MPa.

First claim

The invention claimed is:

1. A mineral wool panel intended to be used as an acoustic panel and having:
a surface density of greater than or equal to 3.2 kg/m 2 ,
an air flow resistivity of between 30 and 120 kPa·s/m 2 , and
a Young's modulus of between 0.5 and 4 MPa,
and the mineral wool panel not being cut through the thickness along a plane substantially parallel to its two main faces, and wherein said mineral wool panel has a panel volume of mineral wool and results directly from manufacture of said mineral wool so that none of said two main faces is a face that results from cutting through a block of mineral wool of volume greater than said panel volume.

2. The panel as claimed in claim 1 , additionally having a micronaire of between 2.5/5 g and 6/5 g or a fasonaire of between 200 and 300.

3. The panel as claimed in claim 1 , additionally comprising a veil on each main face of the panel.

4. The panel as claimed in claim 3 , wherein the veil intended to be facing a side from where the sound to be absorbed originates having a specific air flow resistance of less than or equal to 1 kPa·s/m, and the opposite veil having a specific air flow resistivity of greater than or equal to 1 kPa·s/m.

5. The panel as claimed in claim 1 , comprising a weight content of binder of between 2% and 15% of the total weight.

6. The panel as claimed in claim 1 , having a sound absorption αw of greater than or equal to 0.9.

7. The panel as claimed in claim 1 , having a sound insulation D nfw of greater than or equal to 38 dB.

8. The panel as claimed in claim 1 , wherein the surface density is greater than or equal to 4.5 kg/m 2 , the air flow resistivity is between 50 and 90 kPa·s/m 2 , and the Young's modulus is between 1.2 MPa and 4 MPa.

9. The panel as claimed in claim 2 , wherein the micronaire is between 3.5/5 g and 6/5 g or the fasonaire is between 200 and 280.

10. The panel as claimed in claim 4 , wherein the veil intended to be facing the side from where the sound to be absorbed originates has a specific air flow resistance of less than or equal to 0.5 kPa·s/m, and the opposite veil has a specific air flow resistivity of greater than or equal to 10 kPa·s/m.

11. The panel as claimed in claim 5 , wherein the weight content of binder is between 2% and 10% of the total weight.

12. The panel as claimed in claim 7 , wherein the sound insulation D nfw is greater than or equal to 41 dB.

13. A process for manufacturing a mineral wool panel, comprising:
manufacturing a mat of mineral fibers by:
internal centrifugation for glass fibers, using equipment comprising:
at least one centrifuge capable of rotating about an axis X and a peripheral band of which is pierced by a plurality of orifices for delivering filaments of a molten material,
a high-temperature gas attenuating means in the form of an annular burner that attenuates the filaments into fibers, and
a receiving belt associated with suction means for receiving the fibers, or

external centrifugation for rock fibers, using equipment comprising:
at least three rotors capable of rotating about an axis Y and a contact of which with the molten material makes it possible to deliver fibers, and
a receiving belt associated with suction means for receiving the fibers, and

crimping the mat of mineral fibers with a degree of crimping of between 1.5 and 5, wherein the mineral wool panel is intended to be used as an acoustic panel and has
a surface density of greater than or equal to 3.2 kg/m 2 ,
an air flow resistivity of between 30 and 120 kPa·s/m 2 , and
a Young's modulus of between 0.5 and 4 MPa,
and the mineral wool panel not being cut through the thickness along a plane substantially parallel to its two main faces, and wherein said mineral wool panel has a panel volume of mineral wool and results directly from manufacture of said mineral wool so that none of said two main faces is a face that results from cutting through a block of mineral wool of volume greater than said panel volume.

14. The process as claimed in claim 13 , wherein, during the of manufacturing of the mat of glass fibers, a combination of parameters is regulated from among at least:
a viscosity of the molten glass, which is between 820 and 1500 poise,
a pressure of the burner, which is between 200 and 1000 mm WC,
a total daily output of glass per centrifuge, which is between 14 metric tonnes/day and 23 metric tonnes/day,
a number of holes of each centrifuge, which is between 5000 and 40 000, and
a rotational speed of the centrifuge at a speed greater than 2000 revolutions/minute.

15. The process as claimed in claim 13 , wherein a diameter of the orifices of each centrifuge is between 0.5 and 1.1 mm.

16. The process as claimed in claim 13 , wherein each centrifuge has a diameter of between 200 and 800 mm.

17. The process as claimed in claim 13 , wherein, during the of manufacturing of the mat of rock fibers, a combination of parameters is regulated from among at least:
a total daily output of rock, which is between 100 and 250 metric tonnes/day,
a rotational speed of the rotors, which is between 2000 and 4000 revolutions/min.

18. The process as claimed in claim 17 , wherein each rotor has a diameter of between 150 mm and 350 mm.

19. The process as claimed in claim 13 , wherein binder is projected onto the mineral fibers before the mineral fibers fall onto the receiving belt, with a content of between 2% and 15% of the total weight, the mat of mineral fibers being passed into a drying oven in order to polymerize the binder.

20. The process as claimed in claim 13 , wherein a veil is adhesively bonded to each of the main faces of the mineral wool panel.

Assignees

• Saint Gobain Isover
• Saint Gobain Placo

Inventors

• Jacqus Gary
• Berger Sylvain
• Leroy Pierre
• Nilsson Erling
• Dray Delphine

Classifications

• E04B1/8409 Primary

  sheet-shaped · CPC title

• C03B37/04

  by using centrifugal force {, e.g. spinning through radial orifices; Construction of the spinner cups therefor (bonder application C03C25/00)} · CPC title

• D04H1/4218

  Glass fibres · CPC title

• D10B2401/063

  high strength · CPC title

• G10K11/162

  Selection of materials · CPC title