CA1244723A - Laminar block and method of and apparatus for producing the laminar block - Google Patents
Laminar block and method of and apparatus for producing the laminar blockInfo
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- CA1244723A CA1244723A CA000550524A CA550524A CA1244723A CA 1244723 A CA1244723 A CA 1244723A CA 000550524 A CA000550524 A CA 000550524A CA 550524 A CA550524 A CA 550524A CA 1244723 A CA1244723 A CA 1244723A
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- thread
- laminar
- laminar body
- needle
- sewing needle
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Abstract
Abstract:
The present invention is directed to an apparatus for manufacturing a laminar block. The apparatus comprises a sewing needle having an apparatus for a single chain stitch comprising: a sewing needle having a recess capable of engaging and disengaging a thread at a side wall portion on a top end thereof and adapted to be moved reciprocatingly along a longitudinal direction thereof;
and an auxiliary needle adapted to be moved to one outer surface of a laminar body along the sewing needle in a space on one side of the laminar body composed of a plur-ality of laminated sheet-like members made of inorganic fibers such that a first loop-like thread part of a sewing thread, engaged upon forward movement of the sewing needle to the recess of the sewing needle when the top end of the sewing needle inserted into the laminar body from the outer surface of a sheet-like member situated on one side thereof is protruded out of the outer surface of a sheet-like member situated on the other side of the laminar body, exposed, upon returning movement of the stitching needle, to said one side of the laminar body passing through the laminar body while being engaged in the recess, and disen-gaged from the recess of the sewing needle, is engaged with the auxiliary needle upon next forward movement of the sewing needle before the sewing needle is again inserted into the laminar body from said one side, and adapted to be moved apart from said one side of the laminar body in the space on said one side of the laminar body such that the engagement of the auxiliary needle with the first loop-like thread part is released when a second loop-like thread part, engaged to the recess upon the next forward movement of the sewing needle and passed through the laminar body and the first loop-like thread in the state engaged to the recess upon next returning movement of the sewing needle, is exposed to said one side of the laminar body. The laminar block is useful as an insulating material.
The present invention is directed to an apparatus for manufacturing a laminar block. The apparatus comprises a sewing needle having an apparatus for a single chain stitch comprising: a sewing needle having a recess capable of engaging and disengaging a thread at a side wall portion on a top end thereof and adapted to be moved reciprocatingly along a longitudinal direction thereof;
and an auxiliary needle adapted to be moved to one outer surface of a laminar body along the sewing needle in a space on one side of the laminar body composed of a plur-ality of laminated sheet-like members made of inorganic fibers such that a first loop-like thread part of a sewing thread, engaged upon forward movement of the sewing needle to the recess of the sewing needle when the top end of the sewing needle inserted into the laminar body from the outer surface of a sheet-like member situated on one side thereof is protruded out of the outer surface of a sheet-like member situated on the other side of the laminar body, exposed, upon returning movement of the stitching needle, to said one side of the laminar body passing through the laminar body while being engaged in the recess, and disen-gaged from the recess of the sewing needle, is engaged with the auxiliary needle upon next forward movement of the sewing needle before the sewing needle is again inserted into the laminar body from said one side, and adapted to be moved apart from said one side of the laminar body in the space on said one side of the laminar body such that the engagement of the auxiliary needle with the first loop-like thread part is released when a second loop-like thread part, engaged to the recess upon the next forward movement of the sewing needle and passed through the laminar body and the first loop-like thread in the state engaged to the recess upon next returning movement of the sewing needle, is exposed to said one side of the laminar body. The laminar block is useful as an insulating material.
Description
~4~7~:3 Laminar block and_method of_and ap~ratus for_~oducing the laminar block _ _______________ The present application is divided out of Canadian Patent Application Serial No. 454,699 filed May 18, 1984.
BACKGROUND OF THE ~NVENTION
_____ __~_____ ______ This invention relates to a novel apparatus for pro-ducing a laminar block having a plurality of integrallylaminated sheet-like members each of which is made of inorganic fibers.
Laminar blocks oE the parent application each comprising a plurality o~ integrally laminated sheet-like members, each of which is made of inorganic fibers are employed, for instance, as linings to the wall part of the main body of a kiln of furnace for use in the ceramic industry for heat-insulating or warm-keeping purpose.
In the drawings which illustrate aspects of the invention of the parent application:
Figure 1 is a perspective view of a conventional laminar block;
Figure 2 is a perspective view of one embodiment of a laminar block;
Figure 3 is a view showing thread details of the laminar block shown in Figure 2;
Figure 4 is a view showing other thread details of the laminar block shown in Figure 2;
Fiyure 5 i~s a perspective view of a further embodiment of a laminar block;
Figure 6 is a perspective view of the laminar blocks shown in Figure 2 as applied to the lining of a furnace wall; and Figure 7(a) through Figure 7(h) are views showing the production steps ~or the laminar block shown in Figure 3.
~2~47~3 One example of ~onventional laminar blocks used for the lining of the furnace wall is shown in Figure l. A
laminar block l in Figure 1 comprises blankets 2,2, each of which is made of inorganic Eibers. In the laminar block l illustrated in the figure, thirteen sheets of rectangular blankets 2 are laminated. A laminar body ~
composed of the thirteen laminated rectangular blankets 2 are integrated to form the block l by a single thread 5, which is inserted into the laminar body 4 of the thirteen blankets 2 and bound at both ends thereof so as to constitute a closed loop 3.
Upon using the laminar block l for the lining on the wall portion o~ the furnace main body, it is disposed and secured within the furnace main body such that a face of the laminar block l at which the laminated portion is exposed, or the side face 6 is in contact with the inner sur~ace of the wall portion of the furnace main body.
In the production of the laminar block l, the size of the block l or the size of the blanket 2 is often specified to a certain standard size in view of the productivity or the like. When the laminar block is used for the lining on the walls of furnaces with different sizes or shapes, the laminar block 1 is cut into an optimum shape at the working place of applying the lining corresoonding to the shape and the size of the applied portion.
However, in a case where the laminar block 1 illus-trated in Figure 1 is cut, for instance, into two sub-blocks 8 and 9 along the plane shown by an imaginary line 7 in Figure l, the loop 3 of the thread 5 is cut or dis-connected at two points 10 and 11 leaving each of the sub-blocks 8 and 9 in a state where the thread part 12 or 13 is merely inserted therein. Accordingly, the laminated blanket portions 2a and 2b of the laminar sub-blocks 8, 9 can no longer be kept integral.
~or th-e integral lamination of blankets made of inorganic ~ibers, it has also been known to apply adhesives between blankets laminated with each other and securing - ~2~4723 the blankets to each other to form a laminar block.
In the laminar block in which laminated blankets are fixed with each other by means of the adhesives, however, each blanket constituting the laminar block is likely to be separated because each blanket is made oE a stack of inorganic fibers.
Moreover, in the case where inorganic adhesives are used, for example, in order to provide the laminar block with a sufficient heat-resistance, it is difficult to cut the laminar block due to the high rigidity of the solidified adhesive layer~
Furtl-ermore, in the case where the inorganic adhesives are used between the blankets, there is fear that the adhesives may be Eirmly sintered with the fibers of the upper and lower blankets upon actual furnace operation, whereby intra-layer peeling may result within the blanket in parallel, with the plane of adhesion depending on the shrinkage of the Eibers.
In addition, upon using the adhesives between the blankets to be laminated, it is actually impossible to move the laminar body until the applied adhesives between the blankets are cured, as well intra-layer peeling has often occurred when external forces are applied to the blankets during so-called handling work such as transport-ation of the laminar block even after the adhesives have been cured.
In order to reduce at least a part of the disadvantage of the conventional laminar block, the parent invention provides a laminar block which can be cut relatively readily into a desired shape or siæe as required and in which the laminated state of the cut pieces formed by the cutting of the laminar block is likely to be maintained.
This is provided by a laminar block comprising:
a laminar body composed oE a plurality oE laminated sheet-like members, each member being made of inorganic fibers;
at least one first stitching thread parts, each having a first surface thread part extended along an outer surface of a sheet-like member situated at one surface side of the laminar body, a first penetrating thread part extended substantially continuously from one end of the first sur-face thread part so as to penetrate the laminar body in a direction of a thickness thereof and a second penetrating thread part extended substantially continuously from the other end of the first surface thread part so as to pene-trate the laminar body in the direction of the thickness thereof; and at least one second stitching thread parts, each having a second surface thread part extended along an outer surface of a sheet-like member situated at said one or the other surface side of the laminar body, a third penetrat-ing thread part extended substantially continuously from one end of the second surface thread part so as to pene-trate the laminar body in the direction of the thickness thereof, and a fourth penetrating thread part extended substantially continuously from the other end of the second surface thread part so as to penetrate the laminar body in the direction of the thickness thereof at a portion different from that wheee the first and second penetrating thread parts of adjacent one first stitching thread part penetrate the laminar body.
It is the object of the present invention to provide an apparatus ~or manufacturing the above laminar block.
Thus, the present invention relates to an apparatus ~or a single chain stitch comprising:
a sewing needle having a recess capable of engaging and disengaging a thread at a side wall portion on a top end thereof and adapted to be moved reciprocatingly along a longitudinal direction thereof; and an auxillary needle adapted to be moved to one outer surface of a laminar body along the sewing needle in a space on one side oE the laminar body composed of a plur-ality of laminated sheet-like members made of inorganic `` ~æ~723 fibers such that a Eirst loop-like thread portion of a sewing thread, engaged upon forward movement of the sewing needle to the recess of the sewing needle when the top end of the sewing needle inserted into the laminar body from the outer surface of a sheet-like member situated on one side thereof is protruded out of the outer surface of a sheet-like member situated on the other side of the laminar body, exposed, upon returning movement of the sewing needle, to said one side of the laminar body passing through the laminar body while being engaged in the recess, and disengaged from the recess of the sewing needle, is engaged with the auxiliary needle upon next forward movement of the sewing needle before the sewing needle is again inserted into the laminar body from said one side, and adapted to be moved apart from said one side of the laminar body in the space on said one side of the laminar body such that the engagement of the auxiliary needle with the first loop-like thread part is released when a second loop-like thread part, engaged to the recess upon the next forward movement of the sewing needle and passed through the laminar body and the ~irst loop-like thread in the state engaged to the recess upon next returning movement of the sewing needle, is exposed to said one side of the laminar body.
In the description of the drawings which follow~s, embodimer.ts of the parent application as well as the present application will be described.
In Figure 2, a preferred laminar block 20 is shown schematically.
The laminar block 20 comprises a plurality of rectang-ular blankets 21 as a sheet-like member, for instance, ceramic fiber blankets. A laminar body 22 consisting of ten blankets 21 laminated or stacked to each other is integrated by means of three lines of stitching or sewing threads 23, 24 and 25 made of vinylon ~Kuraray Vinymo~ #~).
In the laminar block 2n, the laminar body 22 may be or may not be compressed in its thickness direction (laminating ~Z~L7~3 direction). The structure o the stitching thread will be described in detail only with reference to the stitching thread 23 since the structure of the stitching threads 23, 24 and 25 is identical with each other.
The stitching thread 23 comprises a front side thread part 28 extended substantially continuously along the outer surface 27 of a blanket 26 situated on one surface side of the laminar body 22, a rear side thread part 31 extended substantially continuously along the outer surface 30 of a blanket 29 situated on the other surace side of the laminar block 22, and penetrating thread parts ~4, 45, 46, 47, 48 and 48a which are respectively connected at their ends 32, 33, 34, 35, 36 and 37 integrally with the front side thread part 28, and at their other ends 38, 39, 40, 41, 42 and 43 integrally with the rear side thread part 31, and extended substantially continuously between both of the ends thereof so as to penetrate the inside of the laminar body 22.
Each of "the thread parts which are extended substan-tially continuously" may be a single thread part extendedcontinuously or two or more thread parts extended continu-ously while being placed in parallel or twisted with each other. Furthermore, the thread part may comprise two or more relatively short thread parts which are firmly bound or connected to each other at their longitudinal end so as to constitute a long thread part as the whole capable of withstanding the tensile force.
The "integral connection" may be carried out by binding the thread parts, fusing the thread parts, and/or bonding these parts by means of adhesives.
The thread 23 itsel~ may comprise one or more threads.
In the laminar block 22, since the thread 23 Eorms five closed loops ~9, 50, 51, 52 and 53, the laminar block 20 can be more homogenous as a whole than a type oE conven-tional laminar block formed by the use o adhesive layers.Moreover, in a case where the block 20 is cut by means of a hand saw or the like along a line like the phantom line 7 ~44'723 shown in Figure 1 to disconnect, for instance, one of the loops 50, 51, 52, each of the two cut block pieces can be retained at least by one closed loop formed by a part of the thread 23 thereby preventing the blankets of the cut block pieces from being individually disintegrated. In the explanation above, for instance, the closed loop 49 comprises a surface thread part 28a between the integral connection parts 32 and 33 in the front side thread part 28, two penetrating thread parts 44 and 45 and a surface thread part 31c between the integral connection parts 3 and 39 in the rear side thread part 31. Similarly, the closed loop 50 comprises a surface thread part 28d between the integral connection parts 33 and 34 in the Eront side thread part 28, two penetrating thread parts 45 and 46, and a surface thread part 31a between the integral connec-tion parts 39 and 40 in the rear side thread part 31.
The closed loops 51 and the like are formed in a similar manner.
Since the threads 24 and 25 are disposed in addition to the thread 23 in parallel therewith in the laminar - block 20, if the block 20 is cut along various planes, cut block pieces or sub-blocks can be retained integrally.
The laminar body 22 may be integrated so as to form the laminar block 20, instead of using three lines of the threads 23, 24 and 25, by the use of a single line of thread, for instance, only the intermed;ate thread 24, bv two lines of threads, for instance, the threads 23 and 25 or, furthermore, by four or more lines of threads.
Although the threads 23, 24 and 25 are extended in parallel with each other in the illustrated embodiment, one or more threads may further be extended in the direc-tion crossing to the above-described threads 23, 24 and/or 25 so as to stitch the laminar body 22.
Referring ~urther to the thread 23 in the laminar block 20, each of the first surface thread parts comprises, for instance, the thread part 28a between the integral connec-tion parts 32 and 33 in the thread part 28, the thread 47;Z:;~
part 28b between the integral connection parts 34 and 35 in the thread part 28 or the thread part 28c between the integral connection parts 36 and 37 in the thread part 28. In this case, each of the second surface thread parts comprises, for example, the thread part 31a between the integral connection parts 39 and 40 in the thread part 31 or the thread part 31b between the integral connection parts 41 and 42 in the thread part 31. In the case mentioned above, each of the first stitching thread part comprises the thread parts 28a, 44 and 45, the thread parts 28b, 46 and 47 or the thread parts 28c, 48 and 48a.
Each of the second stitching thread parts comprises the thread parts 31a, 45 and 46 or the thread parts 31b, 47 and 48.
In the thread 23 of the laminar block 20, if each of the first surface thread parts comprises the thread part 28d between the integral connection parts 33 and 34 in the thread part 28 or the thread part 28e between the integral connection parts 35 and 36 in the thread part 28, each of the second surface thread parts comprises, for instance, the thread part 31c between the integral connection parts 38 and 39 in the thread part 31, the thread part 31d between the integral connection parts 40 and 41 in the thread part 31 or the thread part 31e between the integral connection parts 42 and 43 in the thread part 31.
Explanation will be made to the detailed structure of the thread 23 in the laminar block 20 shown in Figure 2 referring to an example shown in Figure 3.
In the embodiment shown in Figure 3, the thread 23 has such an arrangement in the form of a single chain stitch of a thread 54. Specifically, the thread parts 28, 31, 44, 45, 4fi, 47, 48 and 48a comprise a continuous single strand of thread 54, in which each of the surface thread parts 28a, 28d, 23b, 28e and 28c in the ~ront side thread oart 28 comprises two substantially parallel thread parts o~ the thread 54, each of the penetrating thread parts 44, g 45, 46, 47, 48 and 48a comprises two substantially parallel thread parts of the thread 54 and each of the surface thread parts 31c, 31a, 31d, 31b and 31e in the rear side thread part 31 comprises one thread part of the thread 54.
S Both ends 54a, 54b are left free. One end 54a of the thread 54 may, however, be bound to the thread part 31c at the integral connection part 38 and the other end 54b of the thread 54 may also be bound to the thread part 31e at the integral connection part 43. The turn back part 54c of the thread 54 is also left free. The part 54c may, however be bound to the thread part 28c at one end of the final penetrating thread part 48a of the single chain stitch. Further, adhesives 55 are preferably applied to the integral connection parts 33, 34, 35, 36, 37, 38, 39, 40, 41, 42 and 43 excepting for the integral connection part 32 for securing adjacent or crossin~ thread parts in order to form a plurality of closed loops so that the integration of the laminar body 22 or each cut pieces thereof with the thread 54 or 23 may not be degraded by the disconnection of the thread 54 or 23 at least in one point.
In order to maintain the block or sub-block substan-tially integrally, the adjacent thread parts constituting the respectively crossing parts or branching parts 32 to 43 may not be secured to each other in each oE these crossing parts or branching parts 32 to 43 of the thread parts, because there is relatively little Eear that the thread or penetrating thread portions may be drawn out of the laminated blankets due to the Erictional Eorces between the blankets and the penetrating thread parts.
More specifically, even if any one of the loops 49, 50, 51, 52 and 53 should be disconnected upon cutting of the block 22, other loops can still retain their configura-tion and prevent those blankets of the laminar block 20 constituting the cut pieces with the loops from being disintegrated individually.
~L~4~7~3 In the case where a relatively large number of surface thread parts 28a, 28b, 31a, etc and the penetrating thread parts 44, 45, 46, etc are formed, if a certain loop should be disconnected, it may cause relatively less slacking in the thread of other loops situated at relatively remote places in a shor~ time. Accordingly, securing of the connection parts 33, 34, 35, 36, 39, 40, 41, 42, etc with adhesives may not always be necessary.
The arran~ement of the thread 23 in the laminar block 20 shown in Figure 2 will be explained specifically refer-ring to another embodiment shown in Figure 4.
In the embodiment shown in Figure 4, the thread 23 has an arrangement in the form of a lock stitch of two threads 56 and 57 made, for instance, of rayon. Specifically, the upper portions 58, 59, 60, 61, 62 and 63 of the penetrating thread parts 44, 45, 46, 47, 48 and 48a, as well as the front side thread part 28 be formed by a continuous single strand of thread 56, while the lower portions 64, 65, 66, 67, 68 and 69 of the penetrating thread parts 44, 45, 46, 47, 48 and 48a, as well as the rear side thread part 31 comprise another continuous single strand of thread 57.
One or both of the threads 56 and 57 may comprise two or more threads. Æach of the surface thread parts 28a, 28d, 28b, 28e and 28c of the front side thread part 28 comprises one of the thread parts of the thread 56, while each of the surface thread parts 31c, 31a, 31d, 31b and 31e of the rear side thread part 31 comprises one of the thread parts of the thread 57. The penetratin~ thread part 44 comprises an upper thread portion 58 having two parallel turn back thread parts 58a and 58b of the thread 56 and a lower thread portion 64 having two parallel turn back thread parts 64b and 64c which are turned back so as to be engaged cross-wise at a turn back point 64a to the turn back point 58c of the upper thread portion 58 of the thread 57. That is, the upper thread portion 58 and the lower thread por-tion 64 constitute the penetrating thread part 44 which is 7~3 extended substantially continuously so as to withstand the tensile force as a whole. Other penetrating thread parts 45, 46, 47, 4~ and 48a have a similar constitution as that of the penetrating thread part 44.
Adhesives 70 are applied for securing a plurality of adjacent thread parts, each having one end at each of the connection parts 32 to 43, to each other in order to constitute integral connection parts. The adhesives 70 may not be used when the size of the block is relatively large. In the illustrated embodiment, both ends 56a and 56b of the thread 56 and both ends 57a and 57b o the thread 57 are secured at each of their connection parts 32 and 37 and connection parts 38 and 43 to the adjacent thread parts by means of the adhesives 70. The adhesives 70 are not always necessary when the size of the block is relatively large.
It will also be apparent in the laminar block 20 having thus been constituted as shown in Figure 4 that if the lam-inar block 20 is cut into sub-blocks, the sub-blocks can be retained integrally by t'ne closed loops contained in each of them. In a case where a larger number of stitches, that is, a large number of penetrating thread parts are present, it is not always necessary to integrate each of the connec-tion oarts with adhesives or the like also in this embodiment.
Although it is desirable for the thread parts consti-tuting the laminar block to form a plurality of closed loops as shown in Figures 2 through 4, such a plurality of closed loops may not always be necessary in a case where the number of stitches is relatively large. For instance, as shown in Figure 5, a laminar block 72 may comprise a laminar body 22 composed or consisting of a plurality of blankets 21 laminated to each other and a thread 71 stitching the laminar body 22 in the form of a "wave-like stitch". In the laminar block 72, surface thread parts 73, 74, 75 and 76 are formed on the surface 27 of the blanlcet 26 situated at one sur~ace side of the laminar ~a2~7~3 body 22, while surface thread parts 77, 78, 79, 80 and 81 are ~ormed on the surface 30 of the blanket 29 situated on the other surface side of the laminar body 22. The laminar block 72 contains ten penetrating thread parts 82, 83, 84, 85, a6, 87, 88, 89, 90 and 91 formed by the "wave-like stitch". In the laminar block 72, each of the first stitching thread parts comprises, for example, thread parts 83, 73 and 84, thread parts 85, 74 and 86, thread parts 87, 75 and 88 or thread parts 89, 76 and 90, while each of the second stitching thread parts comprises, for example, thread parts ~2, 77 and 83, thread parts 84, 7 and 85, thread parts 86, 79 and 87, thread parts 88, ~0 and 89 or thread parts 90, 81 and 91.
In this case, the ~riction between the blankets and the penetrating thread parts also serves for keeping the block integrated.
In a case where the laminar block 72 is cut along a plane shown by the imaginary line 94, the stitching thread part comprising parts 73, 78 and 85 or the stitching thread part comprising parts 87, 75 and 88, and the stitching thread part comprising parts 88, 80 and 89 can contribute to the integral retention for each cut block pieces or sub-blocks 72a or 72b within a relatively short period of time after the cutting when the sub-blocks 72a, 72b are not roughly handled as in the case of a general mounting operation.
Accordingly, in the case where the laminar block 72 is cut just prior to their use in a working place where the cut block pieces 72a and 72b are used, closed loops are not always necessary for the cut block pieces if a relatively large number of stitching thread parts are left in each of the cut block pieces.
In a case where the block 72 is formed with the laminar body 22 being integrated in substantially a non-com~ression state, the closed loops may not be ~ormed, if a relatively large number of stitching thread parts are provided.
~4723 It is of course possible, if desired, to constitute the laminar block by forming the independent closed loop respectively with each of a plurality of threads so that the laminar body can be retained as an integral block.
Figure 6 shows an example where the laminar blocks 20 shown in Figure 2 and sub-blocks thereof produced by cutting the block 20 are applied to the lining of a furnace wall.
In Figure 6, reference numeral 95 denotes the shell or wall portion of a furnace main body, that is, a part of the furnace wall, for instance, made of metal. Reerence numeral 97 represents a laminar block oE a standard size similar to the laminar block 20, and 98 represents a cut piece prepared by cutting the laminar block 20 into an appropriate size corresponding to the configuration of the wall portion 96.
The stack-lining of the blocks 97 and the block piece 98 are made by securing the blocks 97 and the sub-block 98 to the furnace wall 95 by means of adhesives or pins such that the end faces of the laminated blankets are in contact with the inner surface 99 of the furnace wall 95 and they are compressed in the laminated direction 100.
In a case where the block 97 (or 20) is cut into the sub-block 98 at a place of applying the lining work to the furnace wall by means of a hand saw or the like according to the shape of the wall portion 96 to be lined, there is little fear that the cut pieces 98 might be disintegrated individually. It is thus possible to apply the lining work by the use of the blocks 97 and 98 while preparing the block pieces 98 at the working place of the lining.
In the above-mentioned stack-lining, since the fibers are generally arranged perpendicular to the lining surface, degradation of the blanket due to exposure to a high temperature in the furnace occurs only at one end of the fibers and the blanket can withstand higher temperatures.
In addition, the heat shrinkage in the laminated direction ~ 47;23 can be compensated by utilizing the restoring or expanding force of the compressed blankets. In this way, the work-able or applicable temperature range of the blanket composed of inorganic fibers can be significantly extended.
Explanation will then be made to one example of a method for producing, from the laminar body 22, the laminar block 20 having a thread 23 (single chain stitch by a thread 5~) constituted as shown in Figure 3, as well as an apparatus therefor referring to Figures 7(a) through 7(h).
In Figure 7, a sewing needle denoted by 101 is adapted to be displaced in the vertical direction A or B, if desired, by drive means not illustrated and an auxiliary needle denoted by 102 is also displaced in the vertical direction A or B by another drive means not shown. The lS needle 101 is pointed at its top end 103 and has a recess 105 with a protrusion 104 on the side of the top end 103.
The intruding recess 105 capable of engaging and disengag-ing a thread 107 has an opening 106 on one side of the needle 101, a concave portion 108 capable of retaining a stitching thread 107 on the side of the top end 103 of the needle 101 and a slope 110 on the side oE a needle base end 109 along which the stitching thread 107 is readily detached or disengaged. The needle 101 while engaging nothing in the intruding recess 105 is caused to move to the laminar body 22 composed of the blankets 21 from below in the direction ~ and inserted into the laminar body 22 so that the top end 103 projects out of the laminar body 22. A thread 107 is engaged with an appropriate engaging means (not shown) if desired, to the top end 103 of the needle 101 protruded above the laminar body 22. The thread 107 can be delivered from a thread roll 111. After engaging the thread 107 on the top end 103, the needle 101 starts to move in the direction B relative to the laminar body 22 while engaging the thread 107 in the concave por-tion 108 of the recess 105. In this state, the top end 112 of the auxiliary needle 102 is situated substantially ~Z447~3 on or adjacent to the lower surface 27 o~ the laminar body lrefer to Figure 7(a)).
The needle 101 is further returned in the direction B
while enga~ing the stitching thread 107 to the recess 105 as shown in Figure 7(b).
In this state, the auxiliary needle 102 is still situated on the lower surface 27 of the laminar body 22.
~hen the needle 101 leaves the surface 27 of the laminated blanket 22 to which it was inserted initially, the auxili-ary needle 102 returns in the direction B to its lower endposition (Figure 7(c)).
When the needle 101 and the auxiliary needle 102 are lowered to the lower end position, both o them are caused to move rightwardly in the direction C relative to the laminar body 22. Instead of moving the needles 101 and 102, ~he laminar body 22 may be moved by a predetermined feed amount leftwardly (in the direction D) relative to the needles 100 and 102 and the roll 111. In this case, the roll 111 and the thread 107 take the positions as shown in the imaginary line in Figure 7(d). After or at the same time with the relative movement of the needles 101 and 102 in the direction C relative to the body 22 by an approp-riate feed means not illustrated, the needle 101 is dis-placed in the direction A relative to the body 22.
When the top end 103 of the needle 101 is in abutment against the lower surface 27 of the laminar body 22, the auxiliary needle 102 which is moved upwardly in the direction A engages a loop~ e thread part 107a o~ the stitching thread 107 detached ~rom the needle 101 along the slope 110 of the recess 105 of the needle 101 at the top end 112 thereof.
The auxiliary needle 102 engaging the thread 107 at the top end 112 thereof is moved upwardly in the direction A up to its upper end position where the top end 112 is substantially in abutment against the lower sur~ace 27 of the laminar hody 22 and then stopped at that position.
~2~4~2;3 Then, the needle 101 is inserted at its top end 103 into the laminar body 22 and continuously moved in the direction (refer to Figure 7(e)).
The stitching thread 107 is enga~ed by the adequate engaging means to the recess 105 of the needle 101 which is inserted in and penetrating through the laminar body 22 of blankets 21, in the same manner as in Figure 7(a) (if desired, after moving the roll 111 in the direction C
relative to the laminar body 22 by a moving means not illustrated). In this state, the auxiliary needle 102 is kept in abutment against the lower surface 27 of the laminar body 22 and still engages the loop-like thread part 107a of the stitching thread 107 as it is (refer to Figure 7(f)).
Then, ~hen the needle 101 moved in the direction B
leaves the laminar body 22 of the blankets ~1 as shown in Figure 7(g) or, specifically, when the recess 105 engaged with the next loop-like thread part 107b oE the thread 107 leaves the lower surface 27 of the blanket laminar body 22 passing through the loop-like part 107a the auxiliary needle 102 releases the previously engaged loop-like thread part 107a of the thread 107 and returns to the lowest position together with or independently from the movement of the needle 101 as shown in Figure 7(h)). In this case, the crossing portion 113 of the stitching thread 107 may be bound to secure by means of adhesives or the li'~e.
The auxillary needle 102 may be constructed in any optional manner as long as it moves vertically alollg the side of the needle 101 near the opening 106 of the recess 105 of the needle 101.
In this way, when the needle 101 and the auxiliary needle 102 are returned to the original lowest end position, the needles 101 and 102 move in the direction C
relative to the blanket laminar body 22, and the needle 101 is inserted through the laminar body 22 of the blankets 21, whereby the state shown in Figure 7(e) is again attained.
7;~3 By repeating the steps shown in Figures 7(e) to 7(h), continuous stitching or sewing (single chain stitch) of the laminar body 22 with the thread 107 can be carried out to produce the laminar block 20.
Embodiments of this invention and the parent applica-tion will now be described referring to Examples.
Ex_m~e 1 A blanket 25 mm in thickness and 0.13 g/cm3 in bulk density prepared from raw material composed of A12O3 - SiO2 by melting in an electric furnace, and blowing and then gathering the same and further applying a needling treat-ment (DURABLANKET* made by Toshiba Monofrax Co., L,td.) was cut into blanket pieces 21 each sized in 25 mm x 300 mm.
Sixteen sheets of such blankets were laminated to form a laminar body 22 and compressed to reduce the thickness by about 25 ~ in the laminated direction into a size of 25 mm x 300 mm x 300 mm. Then, the laminar block kept in the compressed state was sewn using a stainless steel needle 101 having 5 mm in diameter and with a pointed top end and by the steps of inserting the needle 101 through the laminar body, engaging an industrial sewing-machine thread 107 (VINYMO* #4 having 100 ~ vinylon content manufactured by Ruraray Co., Ltd.) to the intruding recess 105 formed at about 6 mm from the top end 103, returning the needle 101 while engaging the thread 107 at the recess 105, dis-placing the needle 101 together with the engaged thread 107 by about 25 mm in the direction C shown in Figure 7 where the thread 107 was detached from the intruding recess 105 of the needle 101 and engaged by an auxiliary needle 102, then inserting only the needle 101 again into the laminar body 22, engaging the thread 107 to the intruding recess 105, returning the needle 101 again and then lowering the needle 101 through the loop 107a of the thread 107 engaged to the auxiliary needle 102. Hereinafter, the above * Trade mark 7~3 described steps were repeated to stitch, the laminar body was stitched at about 25 mm pitch (feeding amount). The laminar block thus stitched had 0.16 g/cm3 of bulk density and retained the size of 25 mm x 300 mm x 300 mm which was substantially the same as the initial size.
~hen the stitched block was bisected along the diagonal direction with a sharp knife, none of the cut pieces or sub-blocks showed change in the bulk density and none of the cut pieces disintegrated individually.
Exam~le 2 A laminar body 22 was formed by laminating sixteen sheets of the same blankets as used in Example 1 each sized 25 mm in thickness, 150 mm in width and 600 mm in length. The laminar body ?.2 was sewn or stitched in the same manner as in Example 1 and each of the stitches was secured using instantaneous adhesives at the parts 33, 34, etc. shown in Figure 3 to form individual loops. In Example 2, two stitch lines (for instance, two lines 23 and 25 in Figure 3) were formed, with a distance between the two lines being 75 mm, and a large laminar block of 300 mm x 150 mm x 600 mm (compressed to reduce the thick-ness by about 25 % in the laminated direction) was thus prepared. The block was bisected each in longitudinal and lateral directions (in the direction of 150 mm size and 600 mm size) by using a sharp knife into four cut pieces or sub-blocks each of 75 mm x 300 mm x 300 mm in size. In a similar manner to Example 1, the sub-blocks kept the bulk density of about 0.16 g/cm3 and each of the sub-blocks retained their gathered condition with no individual disintegration.
BACKGROUND OF THE ~NVENTION
_____ __~_____ ______ This invention relates to a novel apparatus for pro-ducing a laminar block having a plurality of integrallylaminated sheet-like members each of which is made of inorganic fibers.
Laminar blocks oE the parent application each comprising a plurality o~ integrally laminated sheet-like members, each of which is made of inorganic fibers are employed, for instance, as linings to the wall part of the main body of a kiln of furnace for use in the ceramic industry for heat-insulating or warm-keeping purpose.
In the drawings which illustrate aspects of the invention of the parent application:
Figure 1 is a perspective view of a conventional laminar block;
Figure 2 is a perspective view of one embodiment of a laminar block;
Figure 3 is a view showing thread details of the laminar block shown in Figure 2;
Figure 4 is a view showing other thread details of the laminar block shown in Figure 2;
Fiyure 5 i~s a perspective view of a further embodiment of a laminar block;
Figure 6 is a perspective view of the laminar blocks shown in Figure 2 as applied to the lining of a furnace wall; and Figure 7(a) through Figure 7(h) are views showing the production steps ~or the laminar block shown in Figure 3.
~2~47~3 One example of ~onventional laminar blocks used for the lining of the furnace wall is shown in Figure l. A
laminar block l in Figure 1 comprises blankets 2,2, each of which is made of inorganic Eibers. In the laminar block l illustrated in the figure, thirteen sheets of rectangular blankets 2 are laminated. A laminar body ~
composed of the thirteen laminated rectangular blankets 2 are integrated to form the block l by a single thread 5, which is inserted into the laminar body 4 of the thirteen blankets 2 and bound at both ends thereof so as to constitute a closed loop 3.
Upon using the laminar block l for the lining on the wall portion o~ the furnace main body, it is disposed and secured within the furnace main body such that a face of the laminar block l at which the laminated portion is exposed, or the side face 6 is in contact with the inner sur~ace of the wall portion of the furnace main body.
In the production of the laminar block l, the size of the block l or the size of the blanket 2 is often specified to a certain standard size in view of the productivity or the like. When the laminar block is used for the lining on the walls of furnaces with different sizes or shapes, the laminar block 1 is cut into an optimum shape at the working place of applying the lining corresoonding to the shape and the size of the applied portion.
However, in a case where the laminar block 1 illus-trated in Figure 1 is cut, for instance, into two sub-blocks 8 and 9 along the plane shown by an imaginary line 7 in Figure l, the loop 3 of the thread 5 is cut or dis-connected at two points 10 and 11 leaving each of the sub-blocks 8 and 9 in a state where the thread part 12 or 13 is merely inserted therein. Accordingly, the laminated blanket portions 2a and 2b of the laminar sub-blocks 8, 9 can no longer be kept integral.
~or th-e integral lamination of blankets made of inorganic ~ibers, it has also been known to apply adhesives between blankets laminated with each other and securing - ~2~4723 the blankets to each other to form a laminar block.
In the laminar block in which laminated blankets are fixed with each other by means of the adhesives, however, each blanket constituting the laminar block is likely to be separated because each blanket is made oE a stack of inorganic fibers.
Moreover, in the case where inorganic adhesives are used, for example, in order to provide the laminar block with a sufficient heat-resistance, it is difficult to cut the laminar block due to the high rigidity of the solidified adhesive layer~
Furtl-ermore, in the case where the inorganic adhesives are used between the blankets, there is fear that the adhesives may be Eirmly sintered with the fibers of the upper and lower blankets upon actual furnace operation, whereby intra-layer peeling may result within the blanket in parallel, with the plane of adhesion depending on the shrinkage of the Eibers.
In addition, upon using the adhesives between the blankets to be laminated, it is actually impossible to move the laminar body until the applied adhesives between the blankets are cured, as well intra-layer peeling has often occurred when external forces are applied to the blankets during so-called handling work such as transport-ation of the laminar block even after the adhesives have been cured.
In order to reduce at least a part of the disadvantage of the conventional laminar block, the parent invention provides a laminar block which can be cut relatively readily into a desired shape or siæe as required and in which the laminated state of the cut pieces formed by the cutting of the laminar block is likely to be maintained.
This is provided by a laminar block comprising:
a laminar body composed oE a plurality oE laminated sheet-like members, each member being made of inorganic fibers;
at least one first stitching thread parts, each having a first surface thread part extended along an outer surface of a sheet-like member situated at one surface side of the laminar body, a first penetrating thread part extended substantially continuously from one end of the first sur-face thread part so as to penetrate the laminar body in a direction of a thickness thereof and a second penetrating thread part extended substantially continuously from the other end of the first surface thread part so as to pene-trate the laminar body in the direction of the thickness thereof; and at least one second stitching thread parts, each having a second surface thread part extended along an outer surface of a sheet-like member situated at said one or the other surface side of the laminar body, a third penetrat-ing thread part extended substantially continuously from one end of the second surface thread part so as to pene-trate the laminar body in the direction of the thickness thereof, and a fourth penetrating thread part extended substantially continuously from the other end of the second surface thread part so as to penetrate the laminar body in the direction of the thickness thereof at a portion different from that wheee the first and second penetrating thread parts of adjacent one first stitching thread part penetrate the laminar body.
It is the object of the present invention to provide an apparatus ~or manufacturing the above laminar block.
Thus, the present invention relates to an apparatus ~or a single chain stitch comprising:
a sewing needle having a recess capable of engaging and disengaging a thread at a side wall portion on a top end thereof and adapted to be moved reciprocatingly along a longitudinal direction thereof; and an auxillary needle adapted to be moved to one outer surface of a laminar body along the sewing needle in a space on one side oE the laminar body composed of a plur-ality of laminated sheet-like members made of inorganic `` ~æ~723 fibers such that a Eirst loop-like thread portion of a sewing thread, engaged upon forward movement of the sewing needle to the recess of the sewing needle when the top end of the sewing needle inserted into the laminar body from the outer surface of a sheet-like member situated on one side thereof is protruded out of the outer surface of a sheet-like member situated on the other side of the laminar body, exposed, upon returning movement of the sewing needle, to said one side of the laminar body passing through the laminar body while being engaged in the recess, and disengaged from the recess of the sewing needle, is engaged with the auxiliary needle upon next forward movement of the sewing needle before the sewing needle is again inserted into the laminar body from said one side, and adapted to be moved apart from said one side of the laminar body in the space on said one side of the laminar body such that the engagement of the auxiliary needle with the first loop-like thread part is released when a second loop-like thread part, engaged to the recess upon the next forward movement of the sewing needle and passed through the laminar body and the ~irst loop-like thread in the state engaged to the recess upon next returning movement of the sewing needle, is exposed to said one side of the laminar body.
In the description of the drawings which follow~s, embodimer.ts of the parent application as well as the present application will be described.
In Figure 2, a preferred laminar block 20 is shown schematically.
The laminar block 20 comprises a plurality of rectang-ular blankets 21 as a sheet-like member, for instance, ceramic fiber blankets. A laminar body 22 consisting of ten blankets 21 laminated or stacked to each other is integrated by means of three lines of stitching or sewing threads 23, 24 and 25 made of vinylon ~Kuraray Vinymo~ #~).
In the laminar block 2n, the laminar body 22 may be or may not be compressed in its thickness direction (laminating ~Z~L7~3 direction). The structure o the stitching thread will be described in detail only with reference to the stitching thread 23 since the structure of the stitching threads 23, 24 and 25 is identical with each other.
The stitching thread 23 comprises a front side thread part 28 extended substantially continuously along the outer surface 27 of a blanket 26 situated on one surface side of the laminar body 22, a rear side thread part 31 extended substantially continuously along the outer surface 30 of a blanket 29 situated on the other surace side of the laminar block 22, and penetrating thread parts ~4, 45, 46, 47, 48 and 48a which are respectively connected at their ends 32, 33, 34, 35, 36 and 37 integrally with the front side thread part 28, and at their other ends 38, 39, 40, 41, 42 and 43 integrally with the rear side thread part 31, and extended substantially continuously between both of the ends thereof so as to penetrate the inside of the laminar body 22.
Each of "the thread parts which are extended substan-tially continuously" may be a single thread part extendedcontinuously or two or more thread parts extended continu-ously while being placed in parallel or twisted with each other. Furthermore, the thread part may comprise two or more relatively short thread parts which are firmly bound or connected to each other at their longitudinal end so as to constitute a long thread part as the whole capable of withstanding the tensile force.
The "integral connection" may be carried out by binding the thread parts, fusing the thread parts, and/or bonding these parts by means of adhesives.
The thread 23 itsel~ may comprise one or more threads.
In the laminar block 22, since the thread 23 Eorms five closed loops ~9, 50, 51, 52 and 53, the laminar block 20 can be more homogenous as a whole than a type oE conven-tional laminar block formed by the use o adhesive layers.Moreover, in a case where the block 20 is cut by means of a hand saw or the like along a line like the phantom line 7 ~44'723 shown in Figure 1 to disconnect, for instance, one of the loops 50, 51, 52, each of the two cut block pieces can be retained at least by one closed loop formed by a part of the thread 23 thereby preventing the blankets of the cut block pieces from being individually disintegrated. In the explanation above, for instance, the closed loop 49 comprises a surface thread part 28a between the integral connection parts 32 and 33 in the front side thread part 28, two penetrating thread parts 44 and 45 and a surface thread part 31c between the integral connection parts 3 and 39 in the rear side thread part 31. Similarly, the closed loop 50 comprises a surface thread part 28d between the integral connection parts 33 and 34 in the Eront side thread part 28, two penetrating thread parts 45 and 46, and a surface thread part 31a between the integral connec-tion parts 39 and 40 in the rear side thread part 31.
The closed loops 51 and the like are formed in a similar manner.
Since the threads 24 and 25 are disposed in addition to the thread 23 in parallel therewith in the laminar - block 20, if the block 20 is cut along various planes, cut block pieces or sub-blocks can be retained integrally.
The laminar body 22 may be integrated so as to form the laminar block 20, instead of using three lines of the threads 23, 24 and 25, by the use of a single line of thread, for instance, only the intermed;ate thread 24, bv two lines of threads, for instance, the threads 23 and 25 or, furthermore, by four or more lines of threads.
Although the threads 23, 24 and 25 are extended in parallel with each other in the illustrated embodiment, one or more threads may further be extended in the direc-tion crossing to the above-described threads 23, 24 and/or 25 so as to stitch the laminar body 22.
Referring ~urther to the thread 23 in the laminar block 20, each of the first surface thread parts comprises, for instance, the thread part 28a between the integral connec-tion parts 32 and 33 in the thread part 28, the thread 47;Z:;~
part 28b between the integral connection parts 34 and 35 in the thread part 28 or the thread part 28c between the integral connection parts 36 and 37 in the thread part 28. In this case, each of the second surface thread parts comprises, for example, the thread part 31a between the integral connection parts 39 and 40 in the thread part 31 or the thread part 31b between the integral connection parts 41 and 42 in the thread part 31. In the case mentioned above, each of the first stitching thread part comprises the thread parts 28a, 44 and 45, the thread parts 28b, 46 and 47 or the thread parts 28c, 48 and 48a.
Each of the second stitching thread parts comprises the thread parts 31a, 45 and 46 or the thread parts 31b, 47 and 48.
In the thread 23 of the laminar block 20, if each of the first surface thread parts comprises the thread part 28d between the integral connection parts 33 and 34 in the thread part 28 or the thread part 28e between the integral connection parts 35 and 36 in the thread part 28, each of the second surface thread parts comprises, for instance, the thread part 31c between the integral connection parts 38 and 39 in the thread part 31, the thread part 31d between the integral connection parts 40 and 41 in the thread part 31 or the thread part 31e between the integral connection parts 42 and 43 in the thread part 31.
Explanation will be made to the detailed structure of the thread 23 in the laminar block 20 shown in Figure 2 referring to an example shown in Figure 3.
In the embodiment shown in Figure 3, the thread 23 has such an arrangement in the form of a single chain stitch of a thread 54. Specifically, the thread parts 28, 31, 44, 45, 4fi, 47, 48 and 48a comprise a continuous single strand of thread 54, in which each of the surface thread parts 28a, 28d, 23b, 28e and 28c in the ~ront side thread oart 28 comprises two substantially parallel thread parts o~ the thread 54, each of the penetrating thread parts 44, g 45, 46, 47, 48 and 48a comprises two substantially parallel thread parts of the thread 54 and each of the surface thread parts 31c, 31a, 31d, 31b and 31e in the rear side thread part 31 comprises one thread part of the thread 54.
S Both ends 54a, 54b are left free. One end 54a of the thread 54 may, however, be bound to the thread part 31c at the integral connection part 38 and the other end 54b of the thread 54 may also be bound to the thread part 31e at the integral connection part 43. The turn back part 54c of the thread 54 is also left free. The part 54c may, however be bound to the thread part 28c at one end of the final penetrating thread part 48a of the single chain stitch. Further, adhesives 55 are preferably applied to the integral connection parts 33, 34, 35, 36, 37, 38, 39, 40, 41, 42 and 43 excepting for the integral connection part 32 for securing adjacent or crossin~ thread parts in order to form a plurality of closed loops so that the integration of the laminar body 22 or each cut pieces thereof with the thread 54 or 23 may not be degraded by the disconnection of the thread 54 or 23 at least in one point.
In order to maintain the block or sub-block substan-tially integrally, the adjacent thread parts constituting the respectively crossing parts or branching parts 32 to 43 may not be secured to each other in each oE these crossing parts or branching parts 32 to 43 of the thread parts, because there is relatively little Eear that the thread or penetrating thread portions may be drawn out of the laminated blankets due to the Erictional Eorces between the blankets and the penetrating thread parts.
More specifically, even if any one of the loops 49, 50, 51, 52 and 53 should be disconnected upon cutting of the block 22, other loops can still retain their configura-tion and prevent those blankets of the laminar block 20 constituting the cut pieces with the loops from being disintegrated individually.
~L~4~7~3 In the case where a relatively large number of surface thread parts 28a, 28b, 31a, etc and the penetrating thread parts 44, 45, 46, etc are formed, if a certain loop should be disconnected, it may cause relatively less slacking in the thread of other loops situated at relatively remote places in a shor~ time. Accordingly, securing of the connection parts 33, 34, 35, 36, 39, 40, 41, 42, etc with adhesives may not always be necessary.
The arran~ement of the thread 23 in the laminar block 20 shown in Figure 2 will be explained specifically refer-ring to another embodiment shown in Figure 4.
In the embodiment shown in Figure 4, the thread 23 has an arrangement in the form of a lock stitch of two threads 56 and 57 made, for instance, of rayon. Specifically, the upper portions 58, 59, 60, 61, 62 and 63 of the penetrating thread parts 44, 45, 46, 47, 48 and 48a, as well as the front side thread part 28 be formed by a continuous single strand of thread 56, while the lower portions 64, 65, 66, 67, 68 and 69 of the penetrating thread parts 44, 45, 46, 47, 48 and 48a, as well as the rear side thread part 31 comprise another continuous single strand of thread 57.
One or both of the threads 56 and 57 may comprise two or more threads. Æach of the surface thread parts 28a, 28d, 28b, 28e and 28c of the front side thread part 28 comprises one of the thread parts of the thread 56, while each of the surface thread parts 31c, 31a, 31d, 31b and 31e of the rear side thread part 31 comprises one of the thread parts of the thread 57. The penetratin~ thread part 44 comprises an upper thread portion 58 having two parallel turn back thread parts 58a and 58b of the thread 56 and a lower thread portion 64 having two parallel turn back thread parts 64b and 64c which are turned back so as to be engaged cross-wise at a turn back point 64a to the turn back point 58c of the upper thread portion 58 of the thread 57. That is, the upper thread portion 58 and the lower thread por-tion 64 constitute the penetrating thread part 44 which is 7~3 extended substantially continuously so as to withstand the tensile force as a whole. Other penetrating thread parts 45, 46, 47, 4~ and 48a have a similar constitution as that of the penetrating thread part 44.
Adhesives 70 are applied for securing a plurality of adjacent thread parts, each having one end at each of the connection parts 32 to 43, to each other in order to constitute integral connection parts. The adhesives 70 may not be used when the size of the block is relatively large. In the illustrated embodiment, both ends 56a and 56b of the thread 56 and both ends 57a and 57b o the thread 57 are secured at each of their connection parts 32 and 37 and connection parts 38 and 43 to the adjacent thread parts by means of the adhesives 70. The adhesives 70 are not always necessary when the size of the block is relatively large.
It will also be apparent in the laminar block 20 having thus been constituted as shown in Figure 4 that if the lam-inar block 20 is cut into sub-blocks, the sub-blocks can be retained integrally by t'ne closed loops contained in each of them. In a case where a larger number of stitches, that is, a large number of penetrating thread parts are present, it is not always necessary to integrate each of the connec-tion oarts with adhesives or the like also in this embodiment.
Although it is desirable for the thread parts consti-tuting the laminar block to form a plurality of closed loops as shown in Figures 2 through 4, such a plurality of closed loops may not always be necessary in a case where the number of stitches is relatively large. For instance, as shown in Figure 5, a laminar block 72 may comprise a laminar body 22 composed or consisting of a plurality of blankets 21 laminated to each other and a thread 71 stitching the laminar body 22 in the form of a "wave-like stitch". In the laminar block 72, surface thread parts 73, 74, 75 and 76 are formed on the surface 27 of the blanlcet 26 situated at one sur~ace side of the laminar ~a2~7~3 body 22, while surface thread parts 77, 78, 79, 80 and 81 are ~ormed on the surface 30 of the blanket 29 situated on the other surface side of the laminar body 22. The laminar block 72 contains ten penetrating thread parts 82, 83, 84, 85, a6, 87, 88, 89, 90 and 91 formed by the "wave-like stitch". In the laminar block 72, each of the first stitching thread parts comprises, for example, thread parts 83, 73 and 84, thread parts 85, 74 and 86, thread parts 87, 75 and 88 or thread parts 89, 76 and 90, while each of the second stitching thread parts comprises, for example, thread parts ~2, 77 and 83, thread parts 84, 7 and 85, thread parts 86, 79 and 87, thread parts 88, ~0 and 89 or thread parts 90, 81 and 91.
In this case, the ~riction between the blankets and the penetrating thread parts also serves for keeping the block integrated.
In a case where the laminar block 72 is cut along a plane shown by the imaginary line 94, the stitching thread part comprising parts 73, 78 and 85 or the stitching thread part comprising parts 87, 75 and 88, and the stitching thread part comprising parts 88, 80 and 89 can contribute to the integral retention for each cut block pieces or sub-blocks 72a or 72b within a relatively short period of time after the cutting when the sub-blocks 72a, 72b are not roughly handled as in the case of a general mounting operation.
Accordingly, in the case where the laminar block 72 is cut just prior to their use in a working place where the cut block pieces 72a and 72b are used, closed loops are not always necessary for the cut block pieces if a relatively large number of stitching thread parts are left in each of the cut block pieces.
In a case where the block 72 is formed with the laminar body 22 being integrated in substantially a non-com~ression state, the closed loops may not be ~ormed, if a relatively large number of stitching thread parts are provided.
~4723 It is of course possible, if desired, to constitute the laminar block by forming the independent closed loop respectively with each of a plurality of threads so that the laminar body can be retained as an integral block.
Figure 6 shows an example where the laminar blocks 20 shown in Figure 2 and sub-blocks thereof produced by cutting the block 20 are applied to the lining of a furnace wall.
In Figure 6, reference numeral 95 denotes the shell or wall portion of a furnace main body, that is, a part of the furnace wall, for instance, made of metal. Reerence numeral 97 represents a laminar block oE a standard size similar to the laminar block 20, and 98 represents a cut piece prepared by cutting the laminar block 20 into an appropriate size corresponding to the configuration of the wall portion 96.
The stack-lining of the blocks 97 and the block piece 98 are made by securing the blocks 97 and the sub-block 98 to the furnace wall 95 by means of adhesives or pins such that the end faces of the laminated blankets are in contact with the inner surface 99 of the furnace wall 95 and they are compressed in the laminated direction 100.
In a case where the block 97 (or 20) is cut into the sub-block 98 at a place of applying the lining work to the furnace wall by means of a hand saw or the like according to the shape of the wall portion 96 to be lined, there is little fear that the cut pieces 98 might be disintegrated individually. It is thus possible to apply the lining work by the use of the blocks 97 and 98 while preparing the block pieces 98 at the working place of the lining.
In the above-mentioned stack-lining, since the fibers are generally arranged perpendicular to the lining surface, degradation of the blanket due to exposure to a high temperature in the furnace occurs only at one end of the fibers and the blanket can withstand higher temperatures.
In addition, the heat shrinkage in the laminated direction ~ 47;23 can be compensated by utilizing the restoring or expanding force of the compressed blankets. In this way, the work-able or applicable temperature range of the blanket composed of inorganic fibers can be significantly extended.
Explanation will then be made to one example of a method for producing, from the laminar body 22, the laminar block 20 having a thread 23 (single chain stitch by a thread 5~) constituted as shown in Figure 3, as well as an apparatus therefor referring to Figures 7(a) through 7(h).
In Figure 7, a sewing needle denoted by 101 is adapted to be displaced in the vertical direction A or B, if desired, by drive means not illustrated and an auxiliary needle denoted by 102 is also displaced in the vertical direction A or B by another drive means not shown. The lS needle 101 is pointed at its top end 103 and has a recess 105 with a protrusion 104 on the side of the top end 103.
The intruding recess 105 capable of engaging and disengag-ing a thread 107 has an opening 106 on one side of the needle 101, a concave portion 108 capable of retaining a stitching thread 107 on the side of the top end 103 of the needle 101 and a slope 110 on the side oE a needle base end 109 along which the stitching thread 107 is readily detached or disengaged. The needle 101 while engaging nothing in the intruding recess 105 is caused to move to the laminar body 22 composed of the blankets 21 from below in the direction ~ and inserted into the laminar body 22 so that the top end 103 projects out of the laminar body 22. A thread 107 is engaged with an appropriate engaging means (not shown) if desired, to the top end 103 of the needle 101 protruded above the laminar body 22. The thread 107 can be delivered from a thread roll 111. After engaging the thread 107 on the top end 103, the needle 101 starts to move in the direction B relative to the laminar body 22 while engaging the thread 107 in the concave por-tion 108 of the recess 105. In this state, the top end 112 of the auxiliary needle 102 is situated substantially ~Z447~3 on or adjacent to the lower surface 27 o~ the laminar body lrefer to Figure 7(a)).
The needle 101 is further returned in the direction B
while enga~ing the stitching thread 107 to the recess 105 as shown in Figure 7(b).
In this state, the auxiliary needle 102 is still situated on the lower surface 27 of the laminar body 22.
~hen the needle 101 leaves the surface 27 of the laminated blanket 22 to which it was inserted initially, the auxili-ary needle 102 returns in the direction B to its lower endposition (Figure 7(c)).
When the needle 101 and the auxiliary needle 102 are lowered to the lower end position, both o them are caused to move rightwardly in the direction C relative to the laminar body 22. Instead of moving the needles 101 and 102, ~he laminar body 22 may be moved by a predetermined feed amount leftwardly (in the direction D) relative to the needles 100 and 102 and the roll 111. In this case, the roll 111 and the thread 107 take the positions as shown in the imaginary line in Figure 7(d). After or at the same time with the relative movement of the needles 101 and 102 in the direction C relative to the body 22 by an approp-riate feed means not illustrated, the needle 101 is dis-placed in the direction A relative to the body 22.
When the top end 103 of the needle 101 is in abutment against the lower surface 27 of the laminar body 22, the auxiliary needle 102 which is moved upwardly in the direction A engages a loop~ e thread part 107a o~ the stitching thread 107 detached ~rom the needle 101 along the slope 110 of the recess 105 of the needle 101 at the top end 112 thereof.
The auxiliary needle 102 engaging the thread 107 at the top end 112 thereof is moved upwardly in the direction A up to its upper end position where the top end 112 is substantially in abutment against the lower sur~ace 27 of the laminar hody 22 and then stopped at that position.
~2~4~2;3 Then, the needle 101 is inserted at its top end 103 into the laminar body 22 and continuously moved in the direction (refer to Figure 7(e)).
The stitching thread 107 is enga~ed by the adequate engaging means to the recess 105 of the needle 101 which is inserted in and penetrating through the laminar body 22 of blankets 21, in the same manner as in Figure 7(a) (if desired, after moving the roll 111 in the direction C
relative to the laminar body 22 by a moving means not illustrated). In this state, the auxiliary needle 102 is kept in abutment against the lower surface 27 of the laminar body 22 and still engages the loop-like thread part 107a of the stitching thread 107 as it is (refer to Figure 7(f)).
Then, ~hen the needle 101 moved in the direction B
leaves the laminar body 22 of the blankets ~1 as shown in Figure 7(g) or, specifically, when the recess 105 engaged with the next loop-like thread part 107b oE the thread 107 leaves the lower surface 27 of the blanket laminar body 22 passing through the loop-like part 107a the auxiliary needle 102 releases the previously engaged loop-like thread part 107a of the thread 107 and returns to the lowest position together with or independently from the movement of the needle 101 as shown in Figure 7(h)). In this case, the crossing portion 113 of the stitching thread 107 may be bound to secure by means of adhesives or the li'~e.
The auxillary needle 102 may be constructed in any optional manner as long as it moves vertically alollg the side of the needle 101 near the opening 106 of the recess 105 of the needle 101.
In this way, when the needle 101 and the auxiliary needle 102 are returned to the original lowest end position, the needles 101 and 102 move in the direction C
relative to the blanket laminar body 22, and the needle 101 is inserted through the laminar body 22 of the blankets 21, whereby the state shown in Figure 7(e) is again attained.
7;~3 By repeating the steps shown in Figures 7(e) to 7(h), continuous stitching or sewing (single chain stitch) of the laminar body 22 with the thread 107 can be carried out to produce the laminar block 20.
Embodiments of this invention and the parent applica-tion will now be described referring to Examples.
Ex_m~e 1 A blanket 25 mm in thickness and 0.13 g/cm3 in bulk density prepared from raw material composed of A12O3 - SiO2 by melting in an electric furnace, and blowing and then gathering the same and further applying a needling treat-ment (DURABLANKET* made by Toshiba Monofrax Co., L,td.) was cut into blanket pieces 21 each sized in 25 mm x 300 mm.
Sixteen sheets of such blankets were laminated to form a laminar body 22 and compressed to reduce the thickness by about 25 ~ in the laminated direction into a size of 25 mm x 300 mm x 300 mm. Then, the laminar block kept in the compressed state was sewn using a stainless steel needle 101 having 5 mm in diameter and with a pointed top end and by the steps of inserting the needle 101 through the laminar body, engaging an industrial sewing-machine thread 107 (VINYMO* #4 having 100 ~ vinylon content manufactured by Ruraray Co., Ltd.) to the intruding recess 105 formed at about 6 mm from the top end 103, returning the needle 101 while engaging the thread 107 at the recess 105, dis-placing the needle 101 together with the engaged thread 107 by about 25 mm in the direction C shown in Figure 7 where the thread 107 was detached from the intruding recess 105 of the needle 101 and engaged by an auxiliary needle 102, then inserting only the needle 101 again into the laminar body 22, engaging the thread 107 to the intruding recess 105, returning the needle 101 again and then lowering the needle 101 through the loop 107a of the thread 107 engaged to the auxiliary needle 102. Hereinafter, the above * Trade mark 7~3 described steps were repeated to stitch, the laminar body was stitched at about 25 mm pitch (feeding amount). The laminar block thus stitched had 0.16 g/cm3 of bulk density and retained the size of 25 mm x 300 mm x 300 mm which was substantially the same as the initial size.
~hen the stitched block was bisected along the diagonal direction with a sharp knife, none of the cut pieces or sub-blocks showed change in the bulk density and none of the cut pieces disintegrated individually.
Exam~le 2 A laminar body 22 was formed by laminating sixteen sheets of the same blankets as used in Example 1 each sized 25 mm in thickness, 150 mm in width and 600 mm in length. The laminar body ?.2 was sewn or stitched in the same manner as in Example 1 and each of the stitches was secured using instantaneous adhesives at the parts 33, 34, etc. shown in Figure 3 to form individual loops. In Example 2, two stitch lines (for instance, two lines 23 and 25 in Figure 3) were formed, with a distance between the two lines being 75 mm, and a large laminar block of 300 mm x 150 mm x 600 mm (compressed to reduce the thick-ness by about 25 % in the laminated direction) was thus prepared. The block was bisected each in longitudinal and lateral directions (in the direction of 150 mm size and 600 mm size) by using a sharp knife into four cut pieces or sub-blocks each of 75 mm x 300 mm x 300 mm in size. In a similar manner to Example 1, the sub-blocks kept the bulk density of about 0.16 g/cm3 and each of the sub-blocks retained their gathered condition with no individual disintegration.
Claims
1. An apparatus for a single chain stitch comprising:
a sewing needle having a recess capable of engaging and disengaging a thread at a side wall portion on a top end thereof and adapted to be moved reciprocatingly along a longitudinal direction thereof; and an auxiliary needle adapted to be moved to one outer surface of a laminar body along the sewing needle in a space on one side of the laminar body composed of a plur-ality of laminated sheet-like members made of inorganic fibers such that a first loop-like thread part of a sewing thread, engaged upon forward movement of the sewing needle to the recess of the sewing needle when the top end of the sewing needle inserted into the laminar body from the outer surface of a sheet-like member situated on one side thereof is protruded out of the outer surface of a sheet-like member situated on the other side of the laminar body, exposed, upon returning movement of the stitching needle, to said one side of the laminar body passing through the laminar body while being engaged in the recess, and disen-gaged from the recess of the sewing needle, is engaged with the auxiliary needle upon next forward movement of the sewing needle before the sewing needle is again inserted into the laminar body from said one side, and adapted to be moved apart from said one side of the laminar body in the space on said one side of the laminar body such that the engagement of the auxiliary needle with the first loop-like thread pact is released when a second loop-like thread part, engaged to the recess upon the next forward movement of the sewing needle and passed through the laminar body and the first loop-like thread in the state engaged to the recess upon next returning movement of the sewing needle, is exposed to said one side of the laminar body.
a sewing needle having a recess capable of engaging and disengaging a thread at a side wall portion on a top end thereof and adapted to be moved reciprocatingly along a longitudinal direction thereof; and an auxiliary needle adapted to be moved to one outer surface of a laminar body along the sewing needle in a space on one side of the laminar body composed of a plur-ality of laminated sheet-like members made of inorganic fibers such that a first loop-like thread part of a sewing thread, engaged upon forward movement of the sewing needle to the recess of the sewing needle when the top end of the sewing needle inserted into the laminar body from the outer surface of a sheet-like member situated on one side thereof is protruded out of the outer surface of a sheet-like member situated on the other side of the laminar body, exposed, upon returning movement of the stitching needle, to said one side of the laminar body passing through the laminar body while being engaged in the recess, and disen-gaged from the recess of the sewing needle, is engaged with the auxiliary needle upon next forward movement of the sewing needle before the sewing needle is again inserted into the laminar body from said one side, and adapted to be moved apart from said one side of the laminar body in the space on said one side of the laminar body such that the engagement of the auxiliary needle with the first loop-like thread pact is released when a second loop-like thread part, engaged to the recess upon the next forward movement of the sewing needle and passed through the laminar body and the first loop-like thread in the state engaged to the recess upon next returning movement of the sewing needle, is exposed to said one side of the laminar body.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000550524A CA1244723A (en) | 1983-05-20 | 1987-10-28 | Laminar block and method of and apparatus for producing the laminar block |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP88888/83 | 1983-05-20 | ||
| JP58088888A JPS59213692A (en) | 1983-05-20 | 1983-05-20 | Inorganic fiber heat insulating block |
| CA000454699A CA1237891A (en) | 1983-05-20 | 1984-05-18 | Laminar block and method of and apparatus for producing the laminar block |
| CA000550524A CA1244723A (en) | 1983-05-20 | 1987-10-28 | Laminar block and method of and apparatus for producing the laminar block |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000454699A Division CA1237891A (en) | 1983-05-20 | 1984-05-18 | Laminar block and method of and apparatus for producing the laminar block |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1244723A true CA1244723A (en) | 1988-11-15 |
Family
ID=25670393
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000550524A Expired CA1244723A (en) | 1983-05-20 | 1987-10-28 | Laminar block and method of and apparatus for producing the laminar block |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1244723A (en) |
-
1987
- 1987-10-28 CA CA000550524A patent/CA1244723A/en not_active Expired
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