MXPA97002106A

MXPA97002106A - Method and apparatus for packing material compresiblede aislamie

Info

Publication number: MXPA97002106A
Application number: MXPA/A/1997/002106A
Authority: MX
Inventors: W Scott James; Magy Gabor; M Johnson Kenneth; V Monnin Raymond
Original assignee: Owens Corning Fiberglas Technology Inc
Priority date: 1994-09-21
Filing date: 1995-09-15
Publication date: 1997-06-01

Abstract

A method for packaging compressible insulation material (10), which includes feeding this insulation material (10) in contact with a mandrel (14), winding this insulation material (10) over the mandrel (14) to form a roll ( 50) of insulation material, apply pressure on the insulation material (10), during the winding thereof, with a pair of opposite strips (16, 18), which are adapted for contact with the roll (50) that is form, with an area of increasing contact as the diameter of the roll (50) increases, and increase the tension on the bands (16, 18) as the diameter of the roll (50) increases, in order to maintain a substantially constant pressure on the insulation material (1

Description

METHOD AND APPARATUS FOR PACKAGING COMPLETE INSULATION MATERIAL TECHNICAL FIELD This invention relates to the packaging of compressible insulation material for transport and storage. More particularly, this invention relates to the winding of compressible insulation material to a highly compressed condition, for efficient transport and storage. PREVIOUS TECHNIQUE The insulation products are usually compressed from a fibrous or cellular matrix, which inhibits heat transfer by conduction of solids and radiation, and also supplies or defines cells or voids to limit convective heat transfer. Therefore, these products necessarily contain a high percentage of air. In order to efficiently transport and store the insulation products from the manufacturing site to the final destination, it is convenient to significantly compress the insulation material. Care should be taken not to over-compress the insulation, since it would lead to the loss of the ability to recover the necessary thickness for the value of the insulation when the package is removed. Fiberglass insulation products are traditionally packaged either as flat sheets or folded into bags, or as rolls of long insulation blankets. The existing glass fiber insulation packing machines, for winding fibrous insulation products in rolls, are of two general types. The first uses a mandrel to which the guide edge of the insulation blanket joins for winding. These machines are somewhat deficient in that they typically overcompress the guide portion of the blanket, resulting in loss of insulation value. The other machine for insulating rolls is the band winding machine, which uses a band that wraps around the insulation roll as it is wound. The web winding has a series of rollers that define the path of the web, and allow the loop of the web to expand to accommodate the roller that grows during the packing process. The web winding is deficient in that it is difficult to exactly control the compressive forces applied to the insulation material during winding, which results in insulation rolls compressed not appropriately, ie either overcompressed or subcompressed. In addition, both the web and mandrel winding machines are limited in the amount of compression and thus the density in the final roll insulation package.

EXPOSITION OF THE INVENTION The invention provides an insulation winding machine, which overcomes the defects of conventional machines, by applying a compressive force, generally constant, during the winding of the insulation material. This insulation material is wound onto a mandrel and brought into contact by a traveling band, and preferably a pair of opposed bands, whose tension is increased during the winding process. According to this invention, a method for packaging compressible insulation material is provided, this method comprises feeding the insulation material in contact with a mandrel, winding the insulation material in the mandrel to form an insulation roll, applying pressure to the material of insulation, during the winding of the insulation material, with a traveling band, which is adapted for contact with the roll that is formed, with an increasing area of contact as the diameter of the roll increases, and increase the tension on the band as the diameter of the roll increases, in order to maintain a substantially constant pressure in the insulation material. Preferably, there are two opposed bands, whose tension is increased to maintain a substantially constant pressure in the insulation material.

The use of two opposing bands helps to drive the insulation in a roll around the mandrel, while controlling the pressure in the roll. By increasing the tension on the bands, as the diameter of the roll increases, this roll of insulation will be highly compressed without an overcompression of the guide portion of the insulation blanket. It is convenient to supply a constant pressure or ring tension on the insulation material, as the roll grows in size. By increasing the tension in the band in a manner approximately proportional to the diameter of the roll, the ring tension can be maintained substantially constant. In a specific embodiment of the invention, the bands are mounted for travel around at least three rolls, and the tension in the bands is controlled by the movement of at least one of the rolls. The controlled movement of the movable roller changes the trajectory of the bands, thus modifying the tension in the bands. In general, the pressure applied to the insulation material by the bands is proportional to the tension in the bands. In a specific embodiment of the invention, the tension is increased from the initial tension to the final tension, this final tension is within the range of 1.2 to 2.0 times the initial tension as the diameter of the roll increases. Preferably, the final tension is about 1.7 times the initial tension. In another embodiment of the invention, the bands are coupled by the deflecting rollers to increase the angle of winding of the band around the insulation material. The deflecting rollers change the trajectory of the bands, so that they are forced to travel a greater distance around the circumference of the roll formed on the mandrel. Preferably, the deflector roller is brought into contact with the web for less than half the length of the time period, during which the insulating material is rolled up. After this time, the roll has reached a size so that the roll angle is sufficient to make possible the tension of the band to control the pressure in the roll formed on the mandrel. In a preferred embodiment of the invention, the contacting step of the deflector roller is carried out during the first 1/2 packing cycle. More preferably, the contacting step of the deflector roller is carried out during the first 1/3 of the packing cycle. According to this invention, an apparatus for packaging compressible insulation material is also provided, comprising a mandrel mounted for rotation and adapted to wind the insulation material in a roll, a pair of opposite strips, adapted for contacting the roll that is formed in the mandrel to apply pressure to this roll, the bands are placed so that they make contact with the roll that is formed with a growing contact area, as the diameter of the roll increases, and elements to increase the tension of the rolls. bands as the diameter of the roll increases, in order to maintain a substantially constant pressure in the insulation material. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic view in cross section, in elevation, of the apparatus for packing compressible insulation material, according to the invention. Figure 2 is a schematic, elevational view of a portion of the apparatus of Figure 1, with the deflector roller engaged, prior to the start of the winding process. Figure 3 is a view similar to Figure 2, in which the insulation material is being rolled up. Figure 4 is a view similar to Figure 3, in which the roll is almost complete. Figure 5 is a schematic view, in elevation, of the mandrel and ejection ring, of the apparatus shown in Figure 1.

Figure 6 is a view similar to Figure 4, in which the upper and lower bands have been removed from contact with the completed roll to remove this roll from the apron. Figure 7 is a schematic elevational view of an alternative apparatus having an upper band and a lower clamping ring for packaging compressible insulation material according to the invention. THE BEST WAY TO CARRY OUT THE INVENTION The invention will be described in terms of the packing of glass fiber insulation material. It will be understood that the method and apparatus of the invention can be used to pack insulation material from other fibrous material, such as mineral wool fibers or polymers, or other non-fibrous insulation material, such as compressible foams. The most suitable insulation material for use with the invention is the insulation of low density glass fiber constructions, having a density in the range of 4,806 to 22,213 kg / m 3. This invention can be employed using rolls of rolled sheets, as well as rolls of continuous blankets of insulation. Referring to Figure 1, it can be seen that the insulation material, such as the glass fiber mat 10, can be introduced to the apparatus of the invention by means of any suitable conveying system, such as the compression conveyors 12 previous. These pre-compression conveyors can gradually converge to slowly evacuate air from the blanket. The primary apparatus for rolling the blanket is a mandrel 14 rotatably mounted and the opposite strips 16 and 18. The bands, upper and lower, are mounted to travel in opposite directions as they make contact with the insulation blanket, and to press on the blanket of insulation to ensure that the roll has the proper compression. The upper band is mounted to travel around three rollers, 20, 22 and 24, of the upper band, respectively, while the lower band is mounted to travel around three rollers, 30, 32 and 34, of the lower band, respectively . The roller 24 of the upper band is mounted for vertical movement and can be moved vertically by the action of any suitable element, such as a pneumatic apparatus 36. It will be understood that numerous other orientations or methods can be used to control the tension in the bands Similarly, the roller 34 of the lower band can be adapted to move vertically downwardly by the pneumatic cylinder 38. The bands can be of any type suitable for continuously applying force and direction to the insulation material, such as a wire mesh, canvas and perforated rubber bands.

As the insulation roll grows in size, the increasing angle of winding around the insulation roll increases the force applied to all the rolls and, therefore, tends to increase the tension in the band. The upper and lower band rollers are mounted for movement to accommodate changes in the belt path, and the amount of resistance to the force applied to the rollers, upper and lower, is controlled by placing these rollers, upper and lower. lower, by pneumatic cylinders 36 and 38. The amount of resistance to movement controls the tension and thus the pressure on the insulating material that is wound. Mounted within the travel path of the two bands are the deflector rollers, upper and lower, 40 and 42, respectively. These are mounted for movement in and out of contact with the bands, and are adapted with elements, such as pneumatic cylinders, 44 and 46, respectively, to move them in contact with the bands. As shown in Figure 2, the contact of the upper deflector roller 40 causes the upper band to deviate from the straight path between the rollers, 20 and 22, of the upper band. The deflector roller contact also increases the tension in the bands, and also applies additional pressure on the insulation blanket that is rolled. As shown in Figure 3, this deviation in the straight line path causes the upper band to increase the roll angle around the insulation roll 50 (shown in Figure 4), which is wound on the mandrel. Similarly, the contact of the lower baffle 42 causes the lower band to deviate from the straight path, between the lower band rollers, 30 and 32, and increases the winding angle around the insulation roll. As shown in Figure 4, during the last winding stages, the deflector rollers, upper and lower, can be retracted out of contact with the bands, primarily because the angle of winding of the bands is increased by virtue of the increase in the size of the roll. During the start-up phase of the operation, the baffle rollers come into contact before the guide end of the insulation blanket is attached to the mandrel. Although the baffle rollers may be contacted during the entire packing cycle, preferably, the baffle rolls are disconnected after a quarter of the insulation blanket is wound onto the mandrel. As shown in Figure 5, the mandrel can be adapted with openings or air doors 52, which are operatively connected to a source of vacuum or air pressure, not shown, by the duct 54. During the start phase of the In the winding process, the air gates are preferably connected to a source of negative pressure gauge to facilitate the attachment of the start end of the insulation blanket to the mandrel. The starting phase of the process will be facilitated by the rotary impulse of the mandrel. After the insulation blanket has been completely rolled up, the air doors are connected to a manometric positive air pressure source, not shown, to enable the roller to slide out more easily or be removed from the mandrel. It has been found that the insulation roll can be removed even without lubrication or the use of a core tube. Ejection of the roll from the mandrel is preferably achieved by movement of the ejection ring 56 along the mandrel. This ejection ring can be operated by any element, such as the pistons 58. It will be understood that any other suitable element for removing the completed roll from the mandrel can be used. The rolls can also be removed manually. Preferably, a wrapping material or other suitable packing or restriction material is applied to the roll before the pressure from the upper and lower bands is removed. Using two bands (upper and lower) the rolling material can be inserted and rolled up. around the completed insulation roll, while it is still within the confines of the upper and lower bands.

The removal of the rolls from the mandrel will be facilitated if the upper and lower bands are mounted to disconnect from the mandrel and the roll. Preferably, the upper and lower bands are mounted for an open jaw type movement, as shown in Figure 6, to enable easy roll removal. Preferably, the wrapping material or other suitable packing material is applied to the roll before removing the pressure from the upper and lower bands. As shown in Figure 7, the invention can be carried out just by using a band and a backing device, such as backing roller 60. This backing roller provides a surface on which the package can be pressed by the upper band. The backing roller can be mounted to allow vertical movement to increase the size of the package, as the insulation material is rolled up. Two or more backup rollers can also be used. It will be apparent from the foregoing that various modifications to this invention can be made. However, they are considered to be within the scope of the invention. INDUSTRIAL APPLICABILITY This invention has been found useful in packaging compressible materials of the type used for thermal and acoustic insulation.

Claims

CLAIMS 1. A method for packing compressible insulation material, this method comprises: feeding the insulation material in contact with a mandrel; wind this insulation material over the mandrel, to form an insulation roll; apply pressure on the insulation material, during the winding of the same, with a pair of opposite bands, which are adapted for contact with the roll that is formed, with an area of increasing contact, as the diameter of the roll increases; and increasing the tension on the bands, as the diameter of the roll increases, in order to maintain a substantially constant pressure on the insulation material. The method of claim 1, wherein the bands are mounted for travel around at least three rollers, one of the rollers is mounted for movement, and the tension in the bands is controlled by controlling the movement of one of the rollers. the rollers. 3. The method of claim 2, wherein the voltage is increased from an initial voltage to a final voltage, which is within the approximate range of 1.2 to 2. Or sometimes the initial tension as the diameter of the roll increases. The method of claim 1, comprising contacting at least one of the bands with a baffle roller, to increase the roll angle of the band around the insulation material. The method of claim 4, wherein the deflector roller is co-jointed with the web for less than half the length of the time period, during which the insulation material is rolled. The method of claim 1, wherein the mandrel is adapted with openings, and includes the step of applying a negative gauge pressure to the openings, to facilitate attachment of the start end of the insulation blanket to the mandrel. The method of claim 1, wherein the mandrel is adapted with openings, and includes the step of applying a positive gauge pressure to the openings, to facilitate removal of the insulation roll from the mandrel. 8. The method of packing a fibrous, compressible, insulation material, this method comprises: feeding the fibrous insulation material in contact with a mandrel; wind this insulation material over the mandrel, to form an insulation roll; apply pressure on the insulation material, during the winding thereof, with a pair of opposite strips, which are adapted for contact with the roll formed with a growing contact area as the diameter of the roll increases; and increasing the tension on the bands, as the diameter of the roll increases, in order to maintain a substantially constant pressure on the insulation material. The method of claim 8, wherein the fibrous insulation material is compressed prior to the feeding step. The method of claim 8, wherein the deflector roller is brought into contact with the web for less than half the length of the time period, during which the insulating material is rolled up. The method of claim 8, wherein the mandrel is adapted with openings and includes the step of applying a negative gauge pressure to the openings to facilitate attachment of the start end of the insulation blanket to the mandrel. The method of claim 8, wherein the mandrel is adapted with openings, and includes the step of applying a positive gauge pressure to the openings to facilitate removal of the isolation roll from the mandrel. 13. The method of packing compressible insulation material, this method comprises: feeding the insulation material in contact with a mandrel; wind this insulation material over the mandrel, to form an insulation roll; apply pressure on the insulation material, during the winding of the same, with a traveling band, which is adapted for contact with the roll that is formed with a growing contact area as the diameter of the roll increases; and increasing the tension in the band, as the diameter of the roll increases, in order to maintain a substantially constant pressure on the insulation material. The method of claim 13, wherein the band is mounted for travel around at least three rollers, one of the rollers is mounted for movement, and the tension in the band is controlled by controlling the movement of one of the rollers. The method of claim 14, wherein the voltage is increased from the initial voltage to the final voltage, which is within the approximate range of 1.2 to
2. Or sometimes the initial tension as the diameter of the roll increases. 16. The method of claim 14, wherein it comprises contacting the web with a deflector roller to increase the angle of winding of the web around the insulating material. 17. Apparatus for packaging a compressible insulation material, this apparatus comprises: a mandrel mounted for rotation and adapted to wind the insulation material in a roll; a pair of opposite bands, adapted for the contact of the roll formed in the mandrel, to apply pressure to the roll, the bands are placed so that they make contact with the roll formed with a growing contact area as the roll diameter; and elements for increasing the tension on the bands, as the diameter of the roll increases, in order to maintain a substantially constant pressure on the insulation material. The apparatus of claim 17, wherein each band is mounted for travel around at least three rollers, and wherein at least one of the rollers is mounted for movement to control web tension. The apparatus of claim 17, wherein a baffle roller is mounted for contact with at least one of the bands, to increase the roll angle of the band around the roll of the insulation material that is formed on the mandrel. . The apparatus of claim 17, wherein the mandrel is adapted with openings, which are operatively connected to a source of negative pressure gauge, to facilitate attachment of the start end of the insulation blanket to the mandrel. The apparatus of claim 17, wherein the mandrel is adapted with openings, which are operatively connected to a manometric positive pressure source to facilitate the removal of the roll of insulation material from the mandrel.