Description of the problem During manufacturing of light building panels using continuous process one can experience interruptions due to manual (as opposed to automated) and/or un-optimized process (and devices) for preparation and delivering of insulation filling onto the line for manufacturing of light building panels. The interruptions may arise either during transport of pallets of mineral wool or other filling, or during actual processing on manufacturing line for manufacturing of band of mineral wool lamellas. One of time consuming operations is horizontal cutting of mineral wool and turning of each lamella into correct position for further processing. This problem could be successfully solved using set of tools on vertical axle with multiple cutting edges set apart or using horizontal sawing band with intermediate mechanism for leading during vertical slabs of mineral wool while the lamellas could be correctly turned with single turn of whole mineral wool slab. In this application mineral wool is used to describe insulation materials used for light building panels filling. Another problem arising is need to halt the process during exchange of cutting tool due to manufacturing of light building panels of different thickness or due to wear of the tool (or plurality thereof) itself. This problem could be solved using appropriate design of the device so the set of cutting tools could be exchanged during process provided that accumulation of already finished products of the line is sufficient, Further, another advantage would be use of mineral wool slabs of same dimensions for finished products of various thickness sizes therefore reducing need for covered warehouses, The cutting of slabs into lamellas on the manufacturing line itself reduces necessary manipulation of lamellas automatically reducing possibility of mechanical damages of the lamellas and has beneficial effect on tolerance of manufacturing as well as quantity of waste. One needs to take into account that un-optimized thickness of light building panels increases use of material and quantity of waste increasing manufacturing cost and presenting environmental problem.

State of the art There are two well known systems for continuous manufacturing of light building panels of mineral wool or similar materials filling.

First process developed in the 1980's uses cutting, turning, and sorting of mineral wool lamellas parallel to or during continuous manufacturing of light building panels. This process has been independently developed by Trimo and by Paroc, and has been used later by other manufacturers. The main characteristic of this process is step shift in larnellas. During actual manufacturing the equipment should be as simple as possible and therefore costs should be decreased. One needs to provide for as homogeneous input material (mineral wool or other insulation filling) as possible otherwise the manufacturing interruptions are expected which reduces productivity and increases waste. The dimensions of cut mineral wool should be as accurate as possible (i. e. the tolerances should be low) as the mineral woo ! cutting increases quantity of mineral wool waste which increases the overall cost of light building panels manufacturing.

Change of dimension of manufactured light building panels requires change of tools and consequently halting of the manufacturing process resulting in decreased productivity.

In addition, change of input material usually requires halting of whole manufacturing line. Use of glue between lamellas negatively influences characteristics of the panels such as flarnmability and fire resistance while non-use of glue between lamellas does not ensure constant mechanical characteristics along length and across cross section of the panel. Further, using non homogeneous mineral wool increases problems during sorting of lamellas without using a glue resulting in need for corrective actions or devices. The problems further arise because of need for narrow tolerances during cutting and providinD for lasnellas height tolerances between lamellas in lamella band during sorting and transport toward double belt, and this further increases need for corrective actions with additional devices or increased use of glue.

The second state of the art process is built around"pushed fibres"of mineral wool and is characterized in input of pre-forrned (i. e. ground and milled) mineral wool slabs during continuous manufacturing of light building panels. This process was developed at the end of 1990's. Well known member of this class is process introduced by Hoesch with Rockwool, This process requires the input material (i. e. mineral wool slabs) to be preformed (i. e. ground on both sides and milled at the sides) according to pre-set tolerances thus substantially increasing input material cost. For different building panels dimensions different dimensions of slabs need to be obtained which present logistical problem and increases suppliers cost (which needs to change its production line setting to provide slabs of different thickness). To provide for continuous panel production (of different thickness) one needs larger volume of input material and resulting larger covered warehouse area increasing manufacturing costs. The technology of"pushed fibres"is less advantageous regarding mechanical characteristics of panels as vertically oriented fibres and does not provide for uniform repeatability of these characteristics. At the same time there are less providers of mineral wool which could be subjected to such technology, technology for manufacturing of such wool is more technically demanding resulting in higher mineral wool cost. Actual delivering of these mineral wool slabs onto continuous production line for manufacturing of light building panels is either with slabs facing one another or with partial step shift. This arrangement presents weak spot as it requires gluing whereas facing glued slabs have poorer fire resistance and anti- flammability characteristics.

Description of new invention The subject of new invention is process and apparatus for preparation, cutting, and sorting of lamellas into band of insulation filling, preferably mineral wool used as light building panels filling- The main characteristic of this invention is that it comprises transport, loading of slabs, cutting of slabs of insulation material into lamellas, accumulation of lamellas, delivering of lamellas, forming repeated connections between lamellas, and transport of lamellas during various phases of manufacturing process of light building panels.

The process is characterized in that that with increase of dimensions of the slabs of the insulation material such as mineral wool the number of cut of insulation as well as number of lamellas on light building panel unit.

Further, the decrease in number of lamellas in particular light building panel results in increased simplification and reliability of transport and sorting of lamellas.

The cutting of insulation slabs, preferably of mineral wool is performed in vertical position whereby correct orientation of filling is ensured with one turn for multiple lamellas resulting in operation of the line using larger filling thickness and higher speed.

The system of transporters provides for creation accumulation of lamellas on the line resulting in ability to exchange of type of wool and change of cutting (sawing) tools during operation without interruptions (stopping) of the line.

The process and devices taking advantage of circular saw cutting provide for transporter, pre-reserve, and reserve (i. e. bank or accumulation of lamellas) to establish high enough accumulation of lamellas to allow for exchange of slab and panel thickness as well as saw set for cutting of lamellas without stopping the line. The lamellas are formed in the repository in separate compartment and are tfflereÇore simply separated by principle of descending. On the other hand, the process and devices taking advantage of band saw the accumulation is established on the band itself so the sawing band can be changed without stopping the manufacturing line. During manufacturing process the axial (i. e. lengthwise, in direction of longer axis) displacement (shift) of lamellas is important. This displacement takes place just before the lamellas are connected into the band while simultaneously time the lamellas are pressed from the side and transported using transporters with momentum regulation. This arrangement ensures uniform positioning of lamellas on the frontal coupling part therefore taking care of problem of corrective measures due to shift in position of frontal coupling shift in the axial (i. e. lengthwise, in direction of longer axis) direction. To facilitate this arrangement the band comprised of lamellas is pushed with regulated push force and/or comprises electronically regulated system of guidance over the inflection. This transport is basically combination of guiding of sides of lamellas and friction between lamellas. The band takes advantage of elastic deformation of lamellas (and hence the band comprised of lamellas) in order to obtain inflection of the band so no vertical displacement of one lamella as compared to another occurs, and no boundary shift in the area where the band is not supported by a structure due to spraying of glue. Regulation of process parameters ensures that the band (although not supported) does not collapse To ensure appropriate tolerance of the insulation filling a device for side profiling is used, said device comprised of saws and/or mills and/or other cutting tools. This device is regulation using mechanism capable of change of preset thickness (i. e. displacement of cutting tools) during operation of the line if different thickness of manufactured light building panel is desired.

The process and device shortly described above have been developed to ensure simple, flexible, and economical embodiment of equipment for cutting and sorting of insulation filling on continuous line for production of light building panels with mineral wool filling or filling of similar fibrous insulation materials and is describing the process and equipment, for operations starting with pallets loaded with insulation wool slabs, and ending with coupling of sorted band of lamellas attached to one another at the entrance to double belt conveyer in already described (WO 99/45218) published PCT patent application as part of line for continuous manufacturing of light building panels.

The device and process presented herein for preparation and delivering of insulation filling onto the line for manufacturing of light building panels comprise transport of pallets in insulation filling as well as line for production of band of lamellas of mineral wool.

The essence of the invention is presented below in more detail with description and attached figures whereas the figures are part of this patent application and are incorporated into this description by reference.

Figure 1 presents embodiment of transport of mineral wool pallets and transfer of slabs from said pallets toward the manufacturing line as follows : input transporter of line A (1), accumulation transporter of line B (2), accumulation transporter of line C (3), cart (4), transporter of line E (5), transporter of line D (6), cart (7), pallet palletizer (8), device for removal of the pallets (10), lifting mechanism (11), side belt conveyer (12), vertical transporter with rods (13), conveyer belt (14), tilting chute (20), input conveyer belt (21), directing conveyer belt (22), conveyer belt at the bottom of the chute (23), non satisfactory (over tolerance) insulation filling slabs repository (30), driving mechanism for lateral movements (31), belt conveyer (32).

Figure 2 presents schematic of the part of the line using advantage of circular saws for manufacturing of lamellas band of mineral wool as follows: device for cutting into lamellas (40), circular saw (41), conveyer belt (42), conveyer belt with side guides (50), conveyer belt for hand preparation/removal of lamella stack (60), conveyer belt- switch (70), separator of lamella stack (80), conveyer belt (S1), side clutch (82), repository (90), driving mechanism for step, movements (91), conveyer belt (92), mechanism for holding of lower lamellas (93), device for delivering of lamellas (100), repository (101), conveyer belt (102).

Figure 3 shows schematic of the part of the line using advantage of band saw for manufacturing of band of lamellas of mineral wool as follows: conveyer belt (24), cart with repository and compartments (150) for adding of slabs into the saw, device for turning of repository (151), mechanism for holding filling slabs in repository (152), saw for cutting of slabs into lamellas (160), band saw for upper leveling of the slabs (161) with guiding of saw band between each filling slab, lifting frame with insulation filling slab holders for holding from the top (162), cart for sawing of slabs into lamelhs (163), conveyer belt for cutting of lamellas (164) with guiding of saw band between each filling slab, numerically controlled driving mechanism for lifting frame (165), conveyer belt (166) for removal of cut lamellas from the saw and adding them into the conveyer belt.

Figure 4 shows schematics of the part of the line for guiding of lamellas into a band and transport of the band of lamellas as follows : guide of lamellas into the band (110), conveyer belt (111), upper conveyer belt (112), mechanism for formation of initial displacement (113), side conveyer belt (114), separating guide walls (115), conveyer belt (116), device for profiling of band sides (120), upper milling set (121), lower milling set transport system with inflection (130). The direction of movement of lamellas is from right to left, The process as described in this patent application starts with preparation of insulation filling slabs and with transport of pallets of insulation filling preferably mineral wool slabs and removal (transfer) of said slabs from the pallets. The insulation filling slabs (which are for the purposes of this application denoted also as mineral wool slabs whereas insulation filling and mineral wool can be used interchangeably) are manufactured in as large dimensions as feasible. The thickness of mineral wool slabs is increased co the point where the constant quality and structure of fibres contained therein can be maintained.

Suggested thickness of input material insulation filling slabs is between 120 and 200 mm. This invention also enables increase in widths of said slabs as a result of lower number of frontal couplings between lamellas in light building panel. Input material (mineral wool) density is in the cange of 80 to 150 kg/m3 whereby the data are not lining this invention and are given for informative purposes.

Mineral wool slabs are stacked on che pallets in the numbers that the overall height and width is swill logistically acceptab. 1e. The pallets are loaded onto the transporter of line A (1) using loading means (e.g. fork Said transporter (1) has guide for centering of the pallet at the loading point, A cart (4) transports the slabs of basic quality of the wool for desired product onto the accumulation transporter (2) of line B while the pallets with different wool quality (i.e. with different density) are loaded onto the accumulation transporter of line C (3). Transporter of line A (1) is dedicated for additional accumuRntinn of slabs with bic quality and for loading of special quality of the svool on pallets in cast of testing or smaller batches of finished product.

The pallet with appropriate wool quality is removed from one of the lines A, B, C, D and loaded onto the transporter of ime E (5) which then t sports the pallet onto the device for removal (transfer) of slabs of mineral wool from the pallet (10). Before the removal lifting rods of transporter of line E ($) lilts the pallet above the transport chain.

Empty pallet the transporter of line E (5) delivers to a care (7) which in turn transports the empty pallet 10 a pallet palletzier (8).

In case of change of program requiring change of mineral wool the pallet with rernamder of mineral wool slabs is transported with the cart (7) onto a transporter of line D (6) which transports it to rhe cart (4) returning it to appropriate accumulation line.

These pallets of mineral wool are e then first used when production with that quality is needed again.

A line for cutting and sorting lamellas into endless band of insulation filling preferably minera wool as filling of light building panels comprises : a device for removal of slabs, a device for cutting into lamellae, a separator of lamella a repository, a device for delivery of the lamellas, an equipment for forming lamellas into parquet- like arrangement, conveyer belts, and other equipment for connection between particular devices.

The device for removal of slabs (10) from the pallet comprises lifting mechanism (11) onto which au least two side conveyer belts (12) are attached in said side conveyer belts (12) removing the slabs from the pallet in rows from the top, i, e. row by row. This is achieved in such a manner that the lifting mechanism lowers side conveyer belts (12) <BR> <BR> <BR> into the level of top row. For the illustrative purpose, this description describe removal of two mineral wool slabs although different number of slabs of arbitrary dimensions can be handled. The side conveyer belts (12) first clutch both slabs of wool from their sides. Then, the lifting mechanism lifts for sufficient amount that the row comprised of both slabs is separated from the row in the stack below the handled row.

Then, the driving mechanism of both sidf conveyer belt$ (12) turns on, and said side conveyer belts (12) deliver each of both slabs to a vertical transporter with rods (13).

Said vertical transporter with rods (13) delivers said slabs to the conveyer belt (14).

After the delivery of both slabs said side conveyer belts (12) stop and separate (i.e. move apart from said slabs in lateral direction), the lifting mechanism lowers said side conveyer beRs (12) to the level of next row to bs transported, and said process repeats itself until the pallet is emptied. The process of delivering sajd slabs to the vertical transporter with rods (13) is described as follows as empty rods of the vertical transporter with rods (13) are varied on the level with side conveyer belts (12) said side convcyer belts (12) ¢ngage two (for illustrative purposes, any number can be handled in that manner) slabs from the pallet. Said two conveyer belts (12) deliver the first of both slabs in/onto empty rods following which the chain connected to rods moves for one step down (i. e. for one distance between rods) and takes over another slab. Conveyer belt (14) has also a pusher. After the slabs which are in the level of input conveyer belt (21) are in turn for removal from the pallet said conveyer belt (14) is elevated sufficiently so the slabs now coming from below are pushed from the rods onto the input conveyer belt (21) Each slab of mineral wool is transported into the tilting chute (20) in order to be set upright (vertically) for entering into the device for sawing (cutting) of lamellas. Said input conveyer belt (21) transports the slab onto the directing conveyer belt (22), and said directing conveyer belt (22) transports slab to the vertical position. Following that the slab slides onto the conveyer belt at the bottom of the chute (23).

The embodiment taking advantage of circular saws for cutting of lamellas said slab is delivered from said conveyer belt at the bottom of the chute (23) into a device for sawing (cutting) into lamellas (40) unless said slab falls outside preset tolerances in which case the slab is directed into non satisfactory (over tolerance) insulation filling slabs repository (30). Said slab is then taken over by conveyer belt (42) transporting vertically oriented wool slab through circular saw (41) cutting said slab into lamellas.

Quickly exchangeable axle comprising set of cutting disks circular saws) enables change of cutting height of the lamella without actually stopping the line for manufacturing of light building panels. The axis of saw set is vertical in order to cut lamellas already on the top of one another and with vertically oriented fibres in lamella.

Mineral wool slabs are cu. c into lamellas of appropriate heights according to desired thickness of manufactured light building panel. For each light building panel thickness there is prearranged appropriate axle comprising cutting disks. Set contains at least one saw more than necessary as the outside borders of the slab must be cut to ensure proper tolerances. Sufficiently accumulated quantity of lamellas in next stations provides an operator ample time to exchange the axle comprising cubing disks (circular saws) without actually stopping the manufacturing line of light building panels. Stack of lamellas is transported with conveyer belt with side guides (50) over conveyer belt- switch (70) into a separator of lamella stack (80). There is also a position on the conveyer belt (60) enabling hand extraction of lamellas for operations such as manually formation of lamella stack from lamellas of the remainder. Conveyer belt--switch (70) takes over from conveyer belt (60) manually formed stack and delivers it into the separator of lamella stack (80), this operation controlled with appropriate program notifying that the stack has been completed.

Conveyer belts (50), (60), and conveyer belt-switch (70) can accept several stacks whereby an accumulation of same number of stacks (in this particular embodiment 8) is ensured as capacity of a repository (90). With this operation part of accumulation needed for change of saw set or saw band is provided for.

Before entrance into repository the separator of lamella stack (SO) is situated, said separator of lamella stack (80) enabling at the end of particular lamella thickness said lamellas to be forwarded to conveyer belt (92) filling the repository (90) with appropriate number of lamellas of particular thickness, this in turn enabling optimization of number of lamellas and minimum oversupply of lamellas for particular order. The lamellas are separated with holding/opening of the side holding mechanism (93) and lowering/lifting of conveyer belt (92). For discharging of remainder of lamellas from the stack the conveyer belt reversibly transports the remainder onto the conveyer belt-switch (70) and consequently onto the conveyer belt (60). If the stack does not have to be separated the lamellas are simply transported through it.

The repository (90) moves laterally with driving mechanism for lateral step movements (91). Under the repository (90) there is the conveyer belt (92). Lateral movement of the repository (91) enables conveyer belt (81) to push stack of lamellas into each compartment. The conveyer belt (92) after the filling of the compartments waits until there is last row of lamellas turn to be delivered in a repository (101). Parallel to delivering of last row of lamellas conveyer belt (92) delivers all lamella stacks from the repository (90) into a device for delivering of lamellas (100). The compartments in the repository (90) and in the repository (101) of the device for delivering of lamellas (100) prevent attaching of lamellas one to another during direct contact of said lamellas.

Given modular width of light building panel actual number of compartments depends on thickness of mineral wool slab.

Number of compartments and thickness of mineral wool slab determine the width of band of mineral wool and therefore modular width of light building panel. Different modular widths and combinations of number of compartments result in various relations. Filling of only specific compartments results in band of mineral wool conforming to modular width of the light building panel.

After the repository (90) is completely (according to desired modular width) filled the whole contents of lamellas is transported using simultaneous movements of the conveyer belt (92) and conveyer belt (102), said conveyer belt (102) following conveyer belt (92) in the transport-direction, said content transported into the device for delivering of lamellas (100) into a band of lamellas (also called descending of lamellas). In said device for delivering of lamellas (100) said lamellas are separated along the rows as follows a mechanism of side holders in the compartments keeps the upper row of lamellas while the lower row of lameUas descends onto conveyer belt (102) which then delivers said descended lamellas onto a conveyer belt (111), and lamellas are transported in appropriate (so called transport) direction- In band saw embodiment the filling slabs in vertical position are pushed by conveyer belt (24) into a repository until all compartments are filled. For filling individual compartments a cart with repository (150) moves stepwise laterally past conveyer belt (24). After the repository on the cart (150) is filled a mechanism for holding said nnnera ! wool slabs (152) holds the slabs in order to prevent their movement during upper leveling by band saw (161) when the cart with the repository (150) transports the slabs onto the cart for sawing of slabs into lamellas (163). After the slabs are in position for delivering the lifting frame with insulation slab holders (162) descends on upper side of said slabs, following which the holders on said frame hold said slabs during sawing (cutting) operation. Lifting and lowering of said frame (162) with numerically controlled driving mechanism (165) enables change from one to another lamella's height without change of tools as well as change of lamellas height during cutting of slabs already in position for cutting. This solution also enables cutting of lamellas of arbitrary height. With presented approach the slabs are precisely positioned and clasped on the top. The band saw (164) features guide of sawing band between each slab which diminishes bending/curving of sawing band and thereby the lamella height tolerance can be achieved. The height of the cut according to the light building panel thickness is achieved via numerically controlled driving mechanism (165) of vertical movement of lifting frame (162) which automatically lowers held slabs after each cut for desired amount to achieve desired height of lamella. With the last cut of the batch undergoing sawing the next-to-last level of lamellas is produced. Level by level of lamellas is removed via conveyer belt (166) from under the lifting frame (162) following the cut by the band saw. Following the cut of next-to-last level of lamellas and their removal by said conveyer belt (166) the holders of said frame (162) release the last level oflamellas onto said conveyer belt (166). Said conveyer belt (166) is used to transport the lamellas onto to conveyer belt (111) which is used for both, circular saw, and band saw processes and is described below.

A guide of lamellas into a band (110) has built into a mechanism (113) for formation of initial displacement (shift) between adjacent lamellas at the end of the compartments.

One of possible form is parquet-like form, however, the embodiment can also be used for other forms (e. g. fish bone, non-symmetric form etc.). The parquet-like form is not novel as it has already been discussed in published PCT application WO 99/45218 and is hereby incorporated by reference. The process and device described herein further allow for non-symmetric step-like displacement (shift) of adjacent lamellas in order to achieve at most one frontal coupling across any given cross section of light building panel. At this point in the prod. uctioa line the aamellas are already adjacent one to another as the separating guide walls (115) (signifying compartments) have already ended just before this point in the production line. Over first lamellas (first to establish displacement/shife there are positioned separately driven conveyer belts (112) said conveyer belts (112) regulated for each row of lamellas in order to ensure repeatability of contour of frontal coupling between lamellas in axial (i. e. lengthwise, along the longer axis) direction achieved through controlled compression (controlled deformation) of lamellas engaged in frontal coupling. Number of said conveyer belts (112) equals number of lamellas across the width of the band of lamellas undergoing formation.

After formation and regulation of repeated system of frontal coupling (i. e. frontal coupling contour) in direction of band of lamellas movement side conveyer belts start to press lamellas into the band of lamellas from the side also.

If not all compartments are filled (according to desired modular width of light building panel) unnecessary separating guide walls (115) are removed and side conveyer belts are adjusted (moved closer) accordingly. In addition, mills are adjusted to modular width chosen.

At the end of separating guide walls using side conveyer belts (114) the band of pressed lamellas is formed by pressing, said band on lamellas formed on conveyer belt (116) carrying said band of pressed lamellas into a device for profiling band sides (i. e. formation using sawing and milling) (120) which forms side borders and at the same time ensures correct modular width of the band of lamellas taking into account necessary tolerance (i. e. larger width than width of final product). Said device comprises upper milling set (121) and lower milling set (122) resulting in expedient adjustment of milling tools using mechanism of said device (120) to change of thickness of light building panel during operation in case such change is desired.

The formed band of lamellas is then guided over transport system with inflection (130) from transport level onto level of lower metal sheet (or other material used for outside light building panel layer, see PCT appllcatiorl W0 99/4S218, at the entrance into the double belt conveyer. This system of guiding of band of lamellas provides for elastic deformation of lamellas linked in the band of lamellas in the axial (i. e. lengthwise, along longer axis) direction without significant displacement between adjacent lamellas or shift resulting in uneven height between lamellas. At the same time the velocities of all transporters of band of lamellas as well as pushing force of band of lamellas are regulated and/or controlled resulting in prevention of uncontrolled hoarding of lamellas or break-up of band of lamellas within the area where the band of lamellas is not supported due to glue application by glue sprayer head.

The areas of cutting and forming of mineral wool are equipped with suction system removing particles of mineral wool from the cutting area and transporting them past repository of so called"sawdust"to a filter.