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Патент USA US2409067

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0&8, 1946.
E. R. POWELL ETAL
2,409,066
MANUFACTURE OF‘ FELTED PRODUCT
Filed Jan. 25, 1943
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INVENTOR
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BY
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ATTORNEY
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Patented Oct. 8, 1946
UNTED
2,409,966
STATES * PATENT ' OFFICE
2,409,066
MANUFACTURE OF FELTED PRODUCTS
Edward R. Powell, North Plain?eld, N.
., and
Harry E. Holcomb, Stratford, Conn., assignors
to Johns -Manville Corporation, New York,
N. Y., a corporation of New York
Application January 23, 1943, Serial No. 473,368
g‘.
7 Claims.
The instant invention relates to improvements
in the manufacture of felted products and more
particularly to a method and apparatus for the
production of a felt or mat of mineral wool ?bers,
the felt having improved structural character
istics. The invention has found a principal ?eld
of use in connection with mineral wool ?bers, by
which term is included ?bers formed from rock,
(0]. 154-28)
2
Fig. 1 is a diagrammatic side elevational view of
an apparatus in accordance with the invention
and to be employed for carrying out the method;
and
Fig. 2 is a view similar to Fig. 1 illustrating a
modi?cation of the invention.
Referring now to the drawing, there is illus
trated at lil a portion of a conventional blow
slag, glass and the like, but may be employed with
chamber or other collecting apparatus for ?bers
other types of ?bers where similar problems are ll) such as ‘mineral wool fibers of the type previously
encountered.
referred to.‘ It will be understood that suitably
Conventionally mineral wool felts are formed
the ?bers may be those newly formed by disinte
by subjecting a molten stream of the selected
grating a molten stream of the material issuing
from a cupola or other melting furnace of conven
raw material to the action of a steam jet. The
jet disintegrates the stream into a great multi
tional type, the ?bers being carried into the blow
plicity of ?ne ?bers which are carried in air sus
pension into a blow chamber or other suitable
collecting means where they are gathered in inter
felted relationship. Usually a binder of a suit
chamber I9 in air suspension and falling onto a
continuously moving conveyor 12 forming the
?oor of the blow chamber. A binder of any suit
able type is employed, the binder being sprayed
into the suspension of ?bers adjacent their place
of formation, the binder particles settling with
the ?bers to become interspersed throughout the
felt. The felted material thus formed may be
conveyed to suitable treating means where it is
compressed and the binder set to form resilient
blocks or felts. Due to the settling of the ?bers
from the air suspension onto the blow chamber
floor, usualy a continuously traveling conveyor, a
able type may be applied to the ?bers. Due to
the falling movement of the ?bers and also to the
forward travel of the conveyor, a predominant
number of the ?bers will lie in planes parallel to
the faces of the felt. The parallel relationship
of the ?bers is accentuated by the compressing
action of a roll I 3 placed, as is conventional, ad
jacent the exit of the blow chamber.
_
,
Adjacent the end of conveyor 12 there is pro
videda transfer conveyor Id supported on rollers
16. The upper reach of conveyor I4 is driven in
resilient but relatively compressible mat is ob 30 the same direction as the upper reach of con
veyor l2 as indicated by the arrows and at the
tained in which the fibers lie predominantly in
same speed. Suitably conveyor It is inclined
planes parallel to the faces of the mat producing
a laminar type felted structure.
downwardly from conveyor !2 as illustrated in the
A principal object of the instant invention is
drawing. Located to extend below conveyor [4
the provision of a method and apparatus for mod 35 is a third conveyor l8 supported on rolls 20 and
ifying the aboVe-referred-to ?ber relationship to
adapted to be driven at a speed slower than that
obtain a felted material which will withstand
of conveyors l2 and [4 for a purpose later to be
greater loads without undue distortion and which
described. Between the forward roll it support
will be resistant to delamination. A more speci?c
ing conveyor l4 and the upper reach of conveyor
object of the invention is the provision of such
18, a plurality of freely rotatable rollers 22 are
apparatus and method which will provide a more
supported on suitable shafts (not shown). Roll
heterogeneous arrangement of the ?bers in the
ers 22 lie in substantially the plane of the upper
felt with a consequent reduction of the laminar
reach
of conveyor l4 as shown, and support the
characteristics and a higher resistance to com
felt in its travel from transfer conveyor id to
pression.
conveyor l8. Located above conveyor is is a
A further object of the invention is to provide
fourth conveyor '24 supported on rollers 26 and
a method and apparatus for the above purposes,
adapted to be driven at the same speed as con
adapted to be continuously operated in conjunc
veyor I8. Conveyor 25 is preferably supported in
tion with the normal ?ber-forming and felting
operations.
a plane parallel to the plane of conveyor is and
is spaced from conveyor [4 a distance approxi
Our invention will be more fully understood,
and further objects and advantages thereof will
mately equal tothe thickness‘ of the felt issuing
become apparent when reference is made to the
fromrthe blow chamber Ill. Conveyors l8 and 24
converge, the lower end of conveyor 24 approach
more detailed description thereof which is to fol
low, and to the accompanying drawing, in which: 55 ing conveyor l8 to’ provide a gap or bight 23 of
12,409,066
3
of the felt.
the scope of the invention as de?ned by the sub
joined claims.
Although no driving means for the several con
veyors has been shown in the drawing, it will be
appreciated that any conventional apparatus
may be employed for this purpose. Separate
?bers lie predominantly in planes parallel to the
appreciably less width than the original thickness
What we claim is:
1. A method of reorienting the ?bers of a t_rlaV_
eling mat of felted mineral wool in which the
faces of the mat, said method comprising mov
ing said mat to means traveling in a plane at an
angle to the plane of such movement of said mat,
from one main drive. The belts are of wire
mesh or other suitable construction as normally 10 but in the same general direction as, and at a
slower speed than, such movement of said mat,
employed in mineral wool manufacture.
and substantially simultaneously therewith con
In the operation of the apparatus described
?ning the upper surface of said mat by means
above and in the carrying out of the method of
traveling in the plane of the upper surface of said
the invention, conveyors l8 and 24 are driven at
mat
and in the direction of movement of said
a relatively slower speed than conveyors l2 and 15
mat.
I4. Suitably a speed of 1.25 feet per minute may
2. A method of reorienting the ?bers of a trav
be employed for conveyors l2 and I4, and a speed
eling
mat of felted mineral wool in which the
of one foot per minutefor conveyors l3 and 24.
?bers lie predominantly" in planes parallel to the
It will be understood that the speed relationships
given are merely illustrative and that others may 20 faces of the mat, said method comprising pro
jecting the mat from the end of a traveling web
be employed depending upon the particular con
onto a conveyor traveling at a lower speed than
ditions of operation. The felt issuing from the
and located below said traveling web whereby
blow chamber is carried by conveyor 14 into the
said mat forms loops, and substantially simul
gap de?ned by the lower reach of conveyor 24
taneously with its formation compressing said
and rollers 22. When the felt comes into con 25
looped mat between converging surfaces.
tact with the belt I8 as well as belt 24, the lower
3. An apparatus comprising driven means for
speed of these belts, and hence of travel of the
conveying
a felted mat, a conveyor underlying an
felt, causes the felted material to jam together
end of said means, and a second conveyor overly
into small heterogeneously arranged noils and
lumps effectively breaking the continuity of the 30 ing said ?rst mentioned conveyor in a plane in
clined with respect to the plane of said ?rst men
laminations. In this way a uniform overall felted
tioned
conveyor and extending substantially to
structure is obtained with excellent delamination
said means, whereby said means conveys the
resistance.
felted mat directly between said ?rst and second
As the felt with the ?bers reoriented, as de
drives may be used or the different conveyors
may all be driven at the required relative speeds
scribed above, approaches and enters the bight
28 between roll 26 and conveyor I 8, it is sub
stantially compressed to consolidate the ?ber
35 conveyors, and means for driving said conveyors
at a slower speed than that of said ?rst men
tioned means.
4. An apparatus comprising a conveyor for
carrying
a felted mat, a second conveyor under
to any suitable ?nishing apparatus which, as il
lustrated, may comprise compression belts 30 and 40 lying an end of said ?rst conveyor and spaced
therefrom, a third conveyor overlying said sec
32 supported on rollers or drums 34 and 36 re
ond
mentioned conveyor in a plane inclined with
spectively. As the felt passes between belts 39
mass. The felt then passes from conveyor is to
and 32, it is compressed to a desired ?nish thick
ness, and the binder is set in any suitable man
ner, depending on the particular type of binder
employed. The felt may then be subdivided into
blocks or sheets of desired size by suitable means
not shown, or may be subjected to further ?n
ishing steps.
respect to the plane of said second mentioned
conveyor and extending substantially to said ?rst
a conveyor whereby said ?rst conveyor deposits the
mat directly between said second and third con
veyors, and means for driving said second and
third mentioned conveyors at a slower rate than
the rate of movement of said ?rst mentioned
Referring to Fig. 2, a modi?cation of the in 50
5. An apparatus comprising a conveyor carry
vention is illustrated. In this instance the blow
ing a felted mat, a second conveyor underlying an
chamber conveyor [2, transfer conveyor l4, and
end of said ?rst mentioned conveyor and spaced
conveyors l8 and 24 are provided as before. How
conveyor.
'
'
therefrom, a third conveyor overlying said sec
ever, rollers 22 are eliminated and the blow
chamber conveyor belt and transfer conveyor M 5 ond mentioned conveyor in a plane inclined with
respect to the plane of said second mentioned
are run at a considerably higher speed than con
conveyor to de?ne a restricted space between the
veyors l8 and 24. For example, the blow cham
ends thereof, said third conveyor extending sub
ber conveyor and the transfer coveyor may travel
stantially to said ?rst conveyor, non-driven
at a rate of three feet a minute, while conveyors
l8 and 24 are traveling at the rate of one foot 60 means for supporting the felted mat between the
end of said ?rst mentioned conveyor and a point
per minute. The felt drops over the end of con
adjoining the second mentioned conveyor, and
veyor l4 and forms large corrugations oi‘ loops
means
for driving such second and third men
on the slow moving conveyor 18. The corrugated
tioned conveyors at slower speeds than said ?rst
felt is compressed between the adjacent reaches
of conveyors l8 and 24 to a thickness as deter 65 mentioned conveyor.
6. An apparatus comprising a conveyor for
mined by the space or bight‘ between the lower
carrying a felted mat, a second conveyor under
end of conveyor 24 and conveyor l8. As before,
lying an end of said ?rst mentioned conveyor and
a heterogeneous arrangement of the ?bers in the
spaced therefrom, a third conveyor overlying said
-felt results, and delamination resistance and re
70 second mentioned conveyor in a plane inclined
sistance to compression are greatly increased.
with respect to the plane of said second men
Having thus described our invention in rather
tioned conveyor to de?ne a restricted space be
full detail, it will be understood that these de
tween the ends thereof, said third conveyor ex
tails need not be strictly adhered to, but that vari
tending substantially to said first conveyor, and
ous changes and modi?cations will suggest-them
selves to one skilled in the art, all falling within 75 means for driving said second and third men
2,409,066
5
tioned conveyors at such lower rate of speed than
6
second conveyor a zone of gradually decreasing
said ?rst mentioned conveyor that the felted mat
thickness through which said mat is carried,
is deposited on said second mentioned conveyor
means for driving said second and third convey
in the form of corrugations.
ors at slower speeds than said ?rst conveyor to
7. An apparatus for producing a compacted 5 accumulate additional material in said advanc
mat of mineral wool ?bers or the like comprising
ing mat, and means cooperating with said third
a conveyor, means for driving the same, a. sec
conveyor to support and con?ne said mat during
ond conveyor in advance of said ?rst conveyor for
a portion of its travel beneath said third convey»
receiving material discharged therefrom, a third
conveyor positioned above said second conveyor
and extending substantially to said ?rst conveyor
to overlie and con?ne said mat, against upward
movement, said third conveyor de?ning with said
or to facilitate the uniform forcing together of
the ?bers in the mat as it passes through said
zone of gradually decreasing thickness.
EDWARD R. POWELL.
HARRY E. HOLCOMB.
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