US20050006808A1 - Method for inline production of smooth surface board - Google Patents
Method for inline production of smooth surface board Download PDFInfo
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- US20050006808A1 US20050006808A1 US10/606,988 US60698803A US2005006808A1 US 20050006808 A1 US20050006808 A1 US 20050006808A1 US 60698803 A US60698803 A US 60698803A US 2005006808 A1 US2005006808 A1 US 2005006808A1
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- Prior art keywords
- conveyor
- fibrous material
- speed
- board
- pulling apparatus
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
- D04H1/4218—Glass fibres
- D04H1/4226—Glass fibres characterised by the apparatus for manufacturing the glass fleece
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2317/00—Animal or vegetable based
- B32B2317/12—Paper, e.g. cardboard
- B32B2317/122—Kraft paper
Definitions
- This invention relates to a method for curing fibrous mineral material in an oven. More particularly, this invention relates to a method for the inline production of smooth surface board from fibrous mineral material.
- the uncured and therefore unhardened surfaces of the pack can be pressed into the openings in the foraminous flights.
- This pressing causes an undesirable embossing of the pattern of the flight surface onto the finished boards.
- composite boards having a smooth surface on one side can be provided by many known methods, including skidding, wherein upper and lower oven conveyors are run at slightly different speeds, and the faster conveyor skids over the surface of the pack, smoothing that surface.
- skidding wherein upper and lower oven conveyors are run at slightly different speeds, and the faster conveyor skids over the surface of the pack, smoothing that surface.
- This invention relates to an improved method for manufacturing smooth surface board from fibrous material.
- the method includes moving fibrous material through an oven on a first conveyor assembly to produce a board of fibrous material.
- the first conveyor assembly includes a first upper conveyor and a first lower conveyor.
- the board of fibrous material is then pulled from the oven with a pulling apparatus downstream of the oven.
- the board of fibrous material is preferably pulled at a speed different from the speed of at least one of the first upper conveyor and the first lower conveyor, causing the fibrous material to skid relative to the at least one of the first upper conveyor and the first lower conveyor, and thereby resulting in a smooth surface board.
- Another embodiment of the method for manufacturing smooth surface board from fibrous material includes moving fibrous material through an oven on a first conveyor assembly to produce a board of fibrous material.
- the first conveyor assembly includes a first upper conveyor and a first lower conveyor.
- One of the first upper conveyor and the first lower conveyor are driven at a speed faster relative to the other of the first upper conveyor and the first lower conveyor.
- the board of fibrous material is then pulled from the oven with a pulling apparatus downstream of the oven.
- the board of fibrous material is preferably pulled at a speed different from the speed of least one of the first upper conveyor and the first lower conveyor, causing the fibrous material to skid relative to the at least one of the first upper conveyor and the first lower conveyor, and thereby resulting in a smooth surface board.
- FIG. 1 is a schematic elevational view of an apparatus for forming smooth surface board from fibrous material according to the invention.
- FIG. 2 is a schematic elevational view of an alternate embodiment of the pulling apparatus illustrated in FIG. 1 .
- FIG. 1 an apparatus 10 for manufacturing a smooth surface board 12 according to the invention.
- molten glass is supplied from a furnace (not shown) via a forehearth (not shown) to a fiberizer 14 .
- Binder applicators 16 then apply, preferably by spraying, a binder on the veils of fibers 18 produced by the fiberizer 14 .
- the fibers are collected as pack 20 on a collection conveyor 22 .
- the binder can be a phenol-formaldehyde binder, or any other desired type of binder. It will be appreciated that the pack 20 can be produced by any desired alternate method, many of which are known in the art.
- the uncured pack 20 is then passed through an oven 24 on a first conveyor assembly 25 .
- the uncured pack 20 is passed through the oven 24 between a first lower conveyor 26 and a first upper conveyor 28 of the first conveyor assembly 25 , and emerges as the cured smooth surface board 12 .
- the cured fibrous material will be referred to as smooth surface board.
- the pack 20 is cured within the oven 24 by hot curing gases, such as hot air.
- the hot curing gases can be supplied to the oven 24 from a source of hot gas (not shown) via a supply duct 30 .
- the curing gases can be removed from the oven 24 via an exhaust duct 32 .
- the first lower conveyor 26 and the first upper conveyor 28 are preferably foraminous, such as foraminous belts, although such foraminous belts are not required. Any conveyor means suitable for carrying the uncured pack 20 through the oven 24 , while enabling the flow of curing gases through the pack 20 , can be used for the conveyors 26 and 28 .
- the first lower conveyor 26 and the first upper conveyor 28 are preferably moved in the direction of the arrow 33 by motors 34 and 36 , respectively.
- the uncured and therefore unhardened surfaces of the pack can be pressed into the openings in the foraminous belts of the conveyors 26 and 28 .
- This pressing can cause undesirable embossing of the pattern of belt surfaces 38 and 40 , respectively, onto the finished board 12 .
- skidding will refer to the process of moving or driving one conveyor, such as the first upper conveyor 28 , at a speed faster relative to the first lower conveyor 26 .
- the first upper conveyor 28 thereby also moves at a speed faster relative to the upper surface 20 A of the pack 20 .
- the surface 40 of the first lower conveyor 26 moves the pack 20 in the direction of the arrow 33
- the surface 38 of the first upper conveyor 28 moves faster, or skids, relative to an upper surface 20 A of the pack 20 .
- the surface 38 of the first upper conveyor 28 moves within the range of from about 0.4 to about 4.0 percent faster relative to the speed of the first lower conveyor 26 .
- Such skidding smoothes the upper surface 20 A of the pack 20 . It will be understood that such skidding can also be provided by driving the first lower conveyor 26 at a speed faster relative to the first upper conveyor 28 .
- the belt surfaces 38 and 40 are substantially non-gripping, such that either or both of the conveyors 26 and 28 can skid relative to the respective surfaces of the pack 20 .
- a mat facing 42 can enhance the smoothing effect caused by the relatively faster moving conveyor 28 .
- the mat facing 42 can be applied to the upper surface 20 A of the pack 20 , as shown in FIG. 1 .
- the mat facing 42 can be any desired mat facing such as polyester/glass mat.
- the mat facing 42 is shown only being applied to the upper surface 20 A of the pack 20 in FIG. 1 , it will be understood that the mat facing 42 can also be applied to a lower surface 20 B of the pack 20 , or can be applied to both the surfaces 20 A and 20 B of the pack 20 .
- a pulling apparatus or second conveyor assembly 46 is provided downstream of the oven 24 .
- the second conveyor assembly 46 includes a second lower conveyor 48 and a second upper conveyor 50 .
- the second lower conveyor 48 and the second upper conveyor 50 are preferably moved in the direction of the arrows 52 and 54 by motors 56 and 58 , respectively.
- the second lower conveyor 48 and the second upper conveyor 50 of the second conveyor assembly 46 provide sufficient pressure and/or surface area relative to the smooth surface board 12 , so as to not skid or slip when engaging the smooth surface board 12 .
- the second lower conveyor 48 and the second upper conveyor 50 are preferably formed of any flexible belt material. More preferably, conveyor surfaces 60 and 62 , respectively, of the second lower conveyor 48 and the second upper conveyor 50 are gripping surfaces. As used herein, such a gripping surface is defined as having a coefficient of friction greater relative to the coefficient of friction of the surfaces 38 and 40 of the first lower conveyor 26 and the first upper conveyor 28 , respectively. It will be understood that the second conveyor assembly 46 can be positioned at any desired distance d from the oven 24 and the first conveyor assembly 25 to provide sufficient support to the smooth surface board 12 .
- the pack 20 enters an inlet end 64 of the oven 24 where the pack 24 is compressed and cured as herein described.
- the cured pack 20 then exits an outlet end 66 of the oven as the smooth surface board 12 .
- the smooth surface board 12 is relatively rigid and dense, such as for example, a board having a density within the range of from about 2 pounds per cubic foot to about 8 pounds per cubic foot.
- a second layer of material such as a foil-scrim-kraft (FSK) layer 44 , or a layer of any desired material (not shown), can be applied to the lower surface 20 B (as viewed in FIG. 1 ) of the smooth surface board 12 , as shown in FIG. 1 .
- Any desired conventional adhesive can be used to adhere the FSK layer 44 to the smooth surface board 12 .
- the FSK layer 44 can also be applied to the upper surface 20 A of the pack 20 , or can be applied to both the surfaces 20 A and 20 B of the pack 20 .
- the FSK layer 44 is illustrated in FIG. 1 as being applied to the smooth surface board 12 upstream of the second conveyor assembly 46 , it will be understood that the FSK layer 44 can also be applied downstream of the second conveyor assembly 46 .
- the second conveyor assembly 46 is driven at a speed different from the speed of the speed of at least one of the first lower conveyor 26 and the first upper conveyer 28 .
- the second conveyor is driven at a speed different from the speed of both the first lower conveyor 26 and the first upper conveyer 28 .
- the speed of the smooth surface board 12 with the second conveyor assembly 46 By controlling the speed of the smooth surface board 12 with the second conveyor assembly 46 , the speed of the pack 20 through the oven 24 and thereby the smoothing of the pack surfaces 20 A and 20 B, can also be controlled. For example, by driving the second conveyor assembly 46 at a speed substantially equal to the speed of the slowest conveyor (i.e., the first lower conveyor 26 ) of the first conveyor assembly 25 , the lower surface 20 B of the pack 20 is engaged by and carried on the first lower conveyor 26 , while the first upper conveyor 28 skids along the upper surface 20 A of the pack 20 .
- the slowest conveyor i.e., the first lower conveyor 26
- the second conveyor assembly 46 can be driven at a speed faster relative to both the speed of the first lower conveyor 26 and the first upper conveyor 28 .
- the first lower conveyor 26 and the first upper conveyor 28 are then caused to skid along the relatively faster moving lower and upper surfaces 20 A and 20 B of the pack 20 , respectively.
- the lower and upper surfaces 20 A and 20 B of the pack 20 are thereby both smoothed.
- the second conveyor assembly 46 can be driven at a speed slower relative to both the speed of the first lower conveyor 26 and the first upper conveyor 28 .
- the first lower conveyor 26 and the first upper conveyor 28 are then also caused to skid along the relatively slower moving lower and upper surfaces 20 A and 20 B of the pack 20 , respectively.
- the lower and upper surfaces 20 A and 20 B of the pack 20 are thereby both smoothed.
- the pulling apparatus 68 includes at least one wheel 70 having a plurality of spikes 72 for engaging at least one surface of the smooth surface board 12 .
- the method of operation of the pulling apparatus 68 is substantially identical to the method of operation of the pulling apparatus or second conveyor assembly 46 , and will not be described herein. It will be understood, however, that the method of the invention can be satisfactorily performed with any desired pulling apparatus.
Abstract
Description
- This invention relates to a method for curing fibrous mineral material in an oven. More particularly, this invention relates to a method for the inline production of smooth surface board from fibrous mineral material.
- It is common practice in the manufacture of formed composite boards, such as a ceiling tile or an acoustic panel, to pass mineral fiber insulation between a pair of foraminous conveyors, or belts, mounted for travel through the curing oven. Hot gases are passed through the insulation to more effectively cure the binder in the insulation. Associated with the oven are flows of hot curing gases, usually air, which travel generally upwardly or downwardly through the insulation. A common construction for the belts is that of foraminous flights connected in series and driven by a chain. The ends of the flights are mounted on wheels which ride in tracks running the length of the oven.
- At the beginning of the curing process, the uncured and therefore unhardened surfaces of the pack can be pressed into the openings in the foraminous flights. This pressing causes an undesirable embossing of the pattern of the flight surface onto the finished boards. In response to such embossing, composite boards having a smooth surface on one side can be provided by many known methods, including skidding, wherein upper and lower oven conveyors are run at slightly different speeds, and the faster conveyor skids over the surface of the pack, smoothing that surface. However, it is desired to provide an improved method for forming smooth surface board from fibrous mineral material.
- This invention relates to an improved method for manufacturing smooth surface board from fibrous material. The method includes moving fibrous material through an oven on a first conveyor assembly to produce a board of fibrous material. The first conveyor assembly includes a first upper conveyor and a first lower conveyor. The board of fibrous material is then pulled from the oven with a pulling apparatus downstream of the oven. The board of fibrous material is preferably pulled at a speed different from the speed of at least one of the first upper conveyor and the first lower conveyor, causing the fibrous material to skid relative to the at least one of the first upper conveyor and the first lower conveyor, and thereby resulting in a smooth surface board.
- Another embodiment of the method for manufacturing smooth surface board from fibrous material includes moving fibrous material through an oven on a first conveyor assembly to produce a board of fibrous material. The first conveyor assembly includes a first upper conveyor and a first lower conveyor. One of the first upper conveyor and the first lower conveyor are driven at a speed faster relative to the other of the first upper conveyor and the first lower conveyor. The board of fibrous material is then pulled from the oven with a pulling apparatus downstream of the oven. The board of fibrous material is preferably pulled at a speed different from the speed of least one of the first upper conveyor and the first lower conveyor, causing the fibrous material to skid relative to the at least one of the first upper conveyor and the first lower conveyor, and thereby resulting in a smooth surface board.
- Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.
-
FIG. 1 is a schematic elevational view of an apparatus for forming smooth surface board from fibrous material according to the invention. -
FIG. 2 is a schematic elevational view of an alternate embodiment of the pulling apparatus illustrated inFIG. 1 . - Referring now to the drawings, there is shown in
FIG. 1 anapparatus 10 for manufacturing asmooth surface board 12 according to the invention. In the illustrated manufacturing process, molten glass is supplied from a furnace (not shown) via a forehearth (not shown) to afiberizer 14.Binder applicators 16 then apply, preferably by spraying, a binder on the veils offibers 18 produced by thefiberizer 14. The fibers are collected aspack 20 on acollection conveyor 22. The binder can be a phenol-formaldehyde binder, or any other desired type of binder. It will be appreciated that thepack 20 can be produced by any desired alternate method, many of which are known in the art. - The
uncured pack 20 is then passed through anoven 24 on afirst conveyor assembly 25. Preferably, theuncured pack 20 is passed through theoven 24 between a firstlower conveyor 26 and a firstupper conveyor 28 of thefirst conveyor assembly 25, and emerges as the curedsmooth surface board 12. Since the apparatus of the invention is primarily used for manufacturing board products having a smooth surface, the cured fibrous material will be referred to as smooth surface board. Thepack 20 is cured within theoven 24 by hot curing gases, such as hot air. The hot curing gases can be supplied to theoven 24 from a source of hot gas (not shown) via asupply duct 30. The curing gases can be removed from theoven 24 via anexhaust duct 32. - The first
lower conveyor 26 and the firstupper conveyor 28 are preferably foraminous, such as foraminous belts, although such foraminous belts are not required. Any conveyor means suitable for carrying theuncured pack 20 through theoven 24, while enabling the flow of curing gases through thepack 20, can be used for theconveyors lower conveyor 26 and the firstupper conveyor 28 are preferably moved in the direction of thearrow 33 bymotors - At the beginning of the curing process, the uncured and therefore unhardened surfaces of the pack can be pressed into the openings in the foraminous belts of the
conveyors belt surfaces board 12. - To prevent such embossing, and to produce a
board 12 having at least one relatively smooth face, a smoothing process, herein after referred to as skidding, can be used. It will be understood that skidding will refer to the process of moving or driving one conveyor, such as the firstupper conveyor 28, at a speed faster relative to the firstlower conveyor 26. The firstupper conveyor 28 thereby also moves at a speed faster relative to theupper surface 20A of thepack 20. Accordingly, thesurface 40 of the firstlower conveyor 26 moves thepack 20 in the direction of thearrow 33, while thesurface 38 of the firstupper conveyor 28 moves faster, or skids, relative to anupper surface 20A of thepack 20. Preferably, thesurface 38 of the firstupper conveyor 28 moves within the range of from about 0.4 to about 4.0 percent faster relative to the speed of the firstlower conveyor 26. - Such skidding smoothes the
upper surface 20A of thepack 20. It will be understood that such skidding can also be provided by driving the firstlower conveyor 26 at a speed faster relative to the firstupper conveyor 28. Preferably, thebelt surfaces conveyors pack 20. - Applying a mat facing 42 to a surface of the
pack 20 can enhance the smoothing effect caused by the relatively faster movingconveyor 28. If desired, the mat facing 42 can be applied to theupper surface 20A of thepack 20, as shown inFIG. 1 . The mat facing 42 can be any desired mat facing such as polyester/glass mat. Although the mat facing 42 is shown only being applied to theupper surface 20A of thepack 20 inFIG. 1 , it will be understood that the mat facing 42 can also be applied to alower surface 20B of thepack 20, or can be applied to both thesurfaces pack 20. - A pulling apparatus or
second conveyor assembly 46 is provided downstream of theoven 24. As shown inFIG. 1 , thesecond conveyor assembly 46 includes a secondlower conveyor 48 and a secondupper conveyor 50. The secondlower conveyor 48 and the secondupper conveyor 50 are preferably moved in the direction of thearrows motors lower conveyor 48 and the secondupper conveyor 50 of thesecond conveyor assembly 46 provide sufficient pressure and/or surface area relative to thesmooth surface board 12, so as to not skid or slip when engaging thesmooth surface board 12. - The second
lower conveyor 48 and the secondupper conveyor 50 are preferably formed of any flexible belt material. More preferably,conveyor surfaces lower conveyor 48 and the secondupper conveyor 50 are gripping surfaces. As used herein, such a gripping surface is defined as having a coefficient of friction greater relative to the coefficient of friction of thesurfaces lower conveyor 26 and the firstupper conveyor 28, respectively. It will be understood that thesecond conveyor assembly 46 can be positioned at any desired distance d from theoven 24 and thefirst conveyor assembly 25 to provide sufficient support to thesmooth surface board 12. - In operation, the
pack 20 enters aninlet end 64 of theoven 24 where thepack 24 is compressed and cured as herein described. The curedpack 20 then exits anoutlet end 66 of the oven as thesmooth surface board 12. Preferably, thesmooth surface board 12 is relatively rigid and dense, such as for example, a board having a density within the range of from about 2 pounds per cubic foot to about 8 pounds per cubic foot. - After curing in the
oven 24, a second layer of material, such as a foil-scrim-kraft (FSK)layer 44, or a layer of any desired material (not shown), can be applied to thelower surface 20B (as viewed inFIG. 1 ) of thesmooth surface board 12, as shown inFIG. 1 . Any desired conventional adhesive can be used to adhere theFSK layer 44 to thesmooth surface board 12. It will be understood that theFSK layer 44 can also be applied to theupper surface 20A of thepack 20, or can be applied to both thesurfaces pack 20. Although theFSK layer 44 is illustrated inFIG. 1 as being applied to thesmooth surface board 12 upstream of thesecond conveyor assembly 46, it will be understood that theFSK layer 44 can also be applied downstream of thesecond conveyor assembly 46. - The
second conveyor assembly 46 is driven at a speed different from the speed of the speed of at least one of the firstlower conveyor 26 and the firstupper conveyer 28. Preferably, the second conveyor is driven at a speed different from the speed of both the firstlower conveyor 26 and the firstupper conveyer 28. - By controlling the speed of the
smooth surface board 12 with thesecond conveyor assembly 46, the speed of thepack 20 through theoven 24 and thereby the smoothing of the pack surfaces 20A and 20B, can also be controlled. For example, by driving thesecond conveyor assembly 46 at a speed substantially equal to the speed of the slowest conveyor (i.e., the first lower conveyor 26) of thefirst conveyor assembly 25, thelower surface 20B of thepack 20 is engaged by and carried on the firstlower conveyor 26, while the firstupper conveyor 28 skids along theupper surface 20A of thepack 20. - Alternately, the
second conveyor assembly 46 can be driven at a speed faster relative to both the speed of the firstlower conveyor 26 and the firstupper conveyor 28. By moving thesmooth surface board 12 at a speed faster than both the firstlower conveyor 26 and the firstupper conveyor 28, the firstlower conveyor 26 and the firstupper conveyor 28 are then caused to skid along the relatively faster moving lower andupper surfaces pack 20, respectively. The lower andupper surfaces pack 20 are thereby both smoothed. - Additionally, the
second conveyor assembly 46 can be driven at a speed slower relative to both the speed of the firstlower conveyor 26 and the firstupper conveyor 28. By moving thesmooth surface board 12 at a speed slower than both the firstlower conveyor 26 and the firstupper conveyor 28, the firstlower conveyor 26 and the firstupper conveyor 28 are then also caused to skid along the relatively slower moving lower andupper surfaces pack 20, respectively. The lower andupper surfaces pack 20 are thereby both smoothed. - An alternate embodiment of the pulling apparatus is shown generally at 68 in
FIG. 2 . The pullingapparatus 68 includes at least onewheel 70 having a plurality ofspikes 72 for engaging at least one surface of thesmooth surface board 12. The method of operation of the pullingapparatus 68 is substantially identical to the method of operation of the pulling apparatus orsecond conveyor assembly 46, and will not be described herein. It will be understood, however, that the method of the invention can be satisfactorily performed with any desired pulling apparatus. - The principle and mode of operation of this invention have been described in its preferred embodiments. However, it should be noted that this invention may be practiced otherwise than as specifically illustrated and described without departing from its scope.
Claims (29)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
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US10/606,988 US20050006808A1 (en) | 2003-06-26 | 2003-06-26 | Method for inline production of smooth surface board |
CA002467669A CA2467669A1 (en) | 2003-06-26 | 2004-05-19 | Method for in-line production of smooth surface board |
MXPA04005615A MXPA04005615A (en) | 2003-06-26 | 2004-06-10 | Method for inline production of smooth surface board. |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US10/606,988 US20050006808A1 (en) | 2003-06-26 | 2003-06-26 | Method for inline production of smooth surface board |
Publications (1)
Publication Number | Publication Date |
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US20050006808A1 true US20050006808A1 (en) | 2005-01-13 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US10/606,988 Abandoned US20050006808A1 (en) | 2003-06-26 | 2003-06-26 | Method for inline production of smooth surface board |
Country Status (3)
Country | Link |
---|---|
US (1) | US20050006808A1 (en) |
CA (1) | CA2467669A1 (en) |
MX (1) | MXPA04005615A (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2008145356A1 (en) * | 2007-05-30 | 2008-12-04 | Saint Gobain Isover | Method and apparatus for production of a mineral wool product, and mineral wool product produced therewith |
US20150232373A1 (en) * | 2014-02-14 | 2015-08-20 | Charles Douglas Spitler | System and method for continuous strand fiberglass media processing |
US9694510B2 (en) | 2015-03-27 | 2017-07-04 | Charles Douglas Spitler | Skin stiffness characteristics and loft control production system and method with variable moisture content in input fiberglass media |
US9695084B2 (en) | 2015-05-11 | 2017-07-04 | Charles Douglas Spitler | Preparation for fiberglass air filtration media |
US9968876B1 (en) | 2014-02-14 | 2018-05-15 | Superior Fibers, Llc | Method of manufacturing fiberglass filtration media |
US10106452B2 (en) | 2014-02-14 | 2018-10-23 | Superior Fibers, Llc | System and method of continuous glass filament manufacture |
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Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2008145356A1 (en) * | 2007-05-30 | 2008-12-04 | Saint Gobain Isover | Method and apparatus for production of a mineral wool product, and mineral wool product produced therewith |
US20150232373A1 (en) * | 2014-02-14 | 2015-08-20 | Charles Douglas Spitler | System and method for continuous strand fiberglass media processing |
US9446978B2 (en) * | 2014-02-14 | 2016-09-20 | Charles Douglas Spitler | System and method for continuous strand fiberglass media processing |
US9968876B1 (en) | 2014-02-14 | 2018-05-15 | Superior Fibers, Llc | Method of manufacturing fiberglass filtration media |
US10106452B2 (en) | 2014-02-14 | 2018-10-23 | Superior Fibers, Llc | System and method of continuous glass filament manufacture |
US10351462B1 (en) | 2014-02-14 | 2019-07-16 | Superior Fibers, Llc | Method of manufacturing fiberglass filtration media |
US10487427B2 (en) | 2014-02-14 | 2019-11-26 | Superior Fibers, Llc | System and method for continuous strand fiberglass media processing |
US9694510B2 (en) | 2015-03-27 | 2017-07-04 | Charles Douglas Spitler | Skin stiffness characteristics and loft control production system and method with variable moisture content in input fiberglass media |
US10046477B2 (en) | 2015-03-27 | 2018-08-14 | Superior Fibers, Llc | Skin stiffness characteristics and loft control production system and method with variable moisture content in input fiberglass media |
US9695084B2 (en) | 2015-05-11 | 2017-07-04 | Charles Douglas Spitler | Preparation for fiberglass air filtration media |
Also Published As
Publication number | Publication date |
---|---|
CA2467669A1 (en) | 2004-12-26 |
MXPA04005615A (en) | 2005-04-18 |
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AS | Assignment |
Owner name: OWENS-CORNING FIBERGLAS TECHNOLOGY, INC., ILLINOIS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:THOMAS, DAVID W.;REEL/FRAME:014555/0513 Effective date: 20030701 |
|
AS | Assignment |
Owner name: OWENS CORNING INTELLECTUAL CAPITAL, LLC, OHIO Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:OWENS-CORNING FIBERGLASS TECHNOLOGY, INC.;REEL/FRAME:019795/0433 Effective date: 20070803 Owner name: OWENS CORNING INTELLECTUAL CAPITAL, LLC,OHIO Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:OWENS-CORNING FIBERGLASS TECHNOLOGY, INC.;REEL/FRAME:019795/0433 Effective date: 20070803 Owner name: OWENS CORNING INTELLECTUAL CAPITAL, LLC, OHIO Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:OWENS-CORNING FIBERGLAS TECHNOLOGY, INC.;REEL/FRAME:019795/0433 Effective date: 20070803 |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- AFTER EXAMINER'S ANSWER OR BOARD OF APPEALS DECISION |