Патент USA US2409067код для вставки
0&8, 1946. E. R. POWELL ETAL 2,409,066 MANUFACTURE OF‘ FELTED PRODUCT Filed Jan. 25, 1943 Al A@ Q. MN, %\ INVENTOR iZwa/Fa 6’ Fame-AA. frémwy f, //O£CO/)//5~ BY . ATTORNEY ' 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.