US2989775A - Apparatus for producing fiber reinforced sponge sheeting - Google Patents

Apparatus for producing fiber reinforced sponge sheeting Download PDF

Info

Publication number
US2989775A
US2989775A US810474A US81047459A US2989775A US 2989775 A US2989775 A US 2989775A US 810474 A US810474 A US 810474A US 81047459 A US81047459 A US 81047459A US 2989775 A US2989775 A US 2989775A
Authority
US
United States
Prior art keywords
conveyor
face
band
along
run
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US810474A
Inventor
Pekarek Frank
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nylonge Corp
Original Assignee
Nylonge Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nylonge Corp filed Critical Nylonge Corp
Priority to US810474A priority Critical patent/US2989775A/en
Application granted granted Critical
Publication of US2989775A publication Critical patent/US2989775A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length

Definitions

  • 'lhin sheets of artificial sponge material have been generally employed for cleaning and polishing purposes.
  • Such sheets particularly when they are formed of viscose produced regenerated cellulose are provided with reinforcing fibers to increase the strength and useful life thereof.
  • the thin sheets have been fabricated by cutting. them from a block of the sponge or they are directly-extruded as a thin sheet or cloth.
  • the process is expensive and the end product lacks uniformity, strength and other desired physical properties.
  • the cost of the end product is relatively low, it possesses a drawback and disadvantage.
  • the strength of the extruded sponge cloth is satisfactory in the direction of extrusion, the strength thereof transverse to the direction of the extrusion is very low and entirely inadequate and the result is an unacceptable product.
  • the reason for the lack of strength across the direction of extrusion is that the reinforcing fibers are oriented in the direction of extrusion providing little reinforcing across the direction of extrusion.
  • Another object of the present invention is to provide an improved apparatus for the production of fiber reinforced sponge cloth or sheeting.
  • Still another object of the present invention is to provide an improved apparatus for the production of fiber reinforced sponge cloth or sheeting characterized by the high uniform strength of the end product substantially independent of the direction of stress.
  • a further object of the present invention is to provide an improved apparatus for the production of fiber reinforced sponge cloth or sheet wherein a substantially random orientation is imparted to the reinforcing fibers.
  • Still a further object of the present invention is to provide an improved apparatus of the above nature characterized by its simplicity, ruggedness, low cost and high capacity.
  • FIGURE 1 is a top plan view of an improved apparatus embodying the present invention, shown partially broken away for convenience of illustration;
  • FIGURE 2 is a sectional view taken along line 2-2 in FIGURE 1;
  • FIGURE 3 is a sectional view taken along line 3-3 in FIGURE 2.
  • the present invention is based upon the discovery that when a flowable fi-ber carrying sponge forming mass is deposited on an advancing belt conveyor and continuously spread on the conveyor to the desired depth or thickness by a lip member extending diagonally across the conveyor and moving along its length with a component in'the direction of advance of the conveyor, which component should be approximately equal to the speed of the conveyor, the resulting sponge cloth produced thereby is characterized by its high uniform strength which is independent of direction. It is believed that the uniformity in strength which is independent of direction is achieved by reason of the random orientation of the reinforcing fibers in the resulting cloth as contrasted to sponge cloth produced with conventional extrusion apparatus.
  • an improved extrusion apparatus of the character described comprising an endless band conveyor having an upper advancing run provided with an upwardly directed face, means for depositing a flowable mass on said conveyor face, an endless second band extending diagonally across said conveyor face forward of said mass depositing means and having a bottom edge substantially parallel to and confronting and spaced above said conveyor face, and means driving said conveyor to have a component in the direction of advance of said conveyor.
  • the feed run of the conveyor band is upwardly forwardly inclined and travels across an underlying support plate.
  • An open bottom distributing chamber extends diagonally across the face of the conveyor and has a longitudinal forwardly directed opening in the front thereof directly above the conveyor face.
  • An endless second band registers with the chamber forwardly directed opening and extends therewith diagonally across the conveyor face and is slightly rearwardly upwardly inclined relative thereto. The lower edge of the second band is spaced a short distance above the conveyor face to define therewith an extrusion opening from the dis tributing chamber.
  • the conveyor and second band are so driven that the run of the band registering with the chamber opening is so driven that it has a component of movement in the direction of advance of conveyor, said component being of a speed approximately equal to the speed of advance of the conveyor belt, that is the speed of conveyor belt plus or minus less than about 20% thereof. It is believed, that in the aforesaid arrangement that the second hand not only effects the orientless extrusion of the sponge forming mass, but it also eifects a pumping mixing of the mass in the distributing chamber so as to disturb and avoid any orientation of the material therein.
  • the reference numeral 10 generally designates the improved apparatus which comprises a continuous conveyor system 11 and a fluid mass depositing and spreading system 12.
  • the conveyor system 11 includes a suitably mounted substantially planar support plate 13 of rectangular configuration and forwardly upwardly inclined an angle of several degrees.
  • the trailing and leading ends of the support plate 13 terminate in curved depending lips 14 and 15 respectively.
  • An endless flexible conveyor band or belt 16. has an upper run 17 extending longitudinally across the top face of the support plate 13 and advancing along a direction from the trailing lip 14 to the leading lip 15.
  • the trailing end of the conveyor belt 16 passes over and in engagement with a drum 18 and the portion .of' the upper run 17 thereof forward of the leading lip 15 passes over an idler roll 19, the top face of the support plate 13 lying along the plane tangent to the drum 18 and roll 19.
  • the conveyor belt 16 passes through a viscose coagulating zone which may be a tank containing a fluid at elevated temperatures; an infra-red heating zone, an electric current applying arrangement or the like and thence about a leading drum and along a return run to the trailing drum 18.
  • the trailing drum 18 is positively driven at a variable predetermined speed by means of an electric motor 20 coupled thereto through a variable speed reduction unit 21.
  • the belt 16 is suitably supported along its length and that the leading drum may be an idler or may be positively driven in the manner of the trailing drum in which latter case the drum 13 may idle.
  • the conveyor belt 16 is of any desired width, for example approximately four feet, and is narrower than and extends medially across the support plate 13 to leave uncovered laterally spaced longitudinally extending borders 22.
  • the belt 16 has a contoured, preferably checkered upper or outer conveying face 23 and is formed of any suitable reinforced flexible material such as a natural or synthetic rubber which is resistant to the ambient environment.
  • the mass depositing and spreading system 12 includes a suitably supported elongated hopper or distributing chamber 26 which extends diagonally across the upper face of the conveyor upper run 17 in the area supported by the plate 13 and between diagonally opposite corners of the plate 13.
  • the chamber 26 preferably extends at an angle of between 30 and 75 for example between 40" and 60 to the direction of advance of the conveyor belt 16 and its ends overlie the plate borders 22.
  • the distributing chamber 26 comprises a rear wall including a lower flat section projecting at an angle to, and upwardly and rearwardly from the top face of the belt upper nm 17 and terminating in a flat vertical top section 28. Projecting forwardly from the rear wall upper and lower sections 27 and 28 are substantially cylindrical end walls 29 and 30 whichextend beyond the corresponding edges of the conveyor belt 16.
  • An upper front vertical wall section 32 extends diagonally between the leading upper edges of the end walls 29 and 30 and parallel to the rear wall section 28.
  • a forwardly directed diagonally extending rectangular chamber opening 33 is delineated by the lower edge of the front wall 32, the front edges of the end walls 29 and 30 and the top face of the belt upper run 17, the opening 33 forming an angle to the belt face and being upwardly rearwardly inclined.
  • the end wall 29 extends to the support plate top face, its forward edge being disposed outside the conveyor edge and being provided with an inwardly projecting arm lying in the plane of the opening 33 and extending a short distance above the conveyor belt top face and terminating in a forwardly directed lip 34 along the outer edge of the belt upper run 17.
  • a second forwardly directed lip 36, of the same height as the lip 34 projects from the inner edge of the end wall 30 along the opposite longitudinal edge of the conveyor belt 16.
  • a top wall 37 covers the chamber 26 and is provided with an opening 38 at its trailing end.
  • a delivery conduit 39 is located directly above and discharges into the opening 38, and communicates with a source of sponge forming mass.
  • An elongated endless flat band 40 is disposed above and extends diagonally across the top trailing face of the conveyor belt upper run 17 and is supported by and between a pair of longitudinally offset drums 41 which are located adjacent opposite edges of the support plate 13.
  • the drums 41 are upwardly rearwardly inclined several degrees to a perpendicular to the surface of the conveyor belt upper run 17.
  • the endless band 40 includes a trailing advancing run 42 and a leading parallel return run 43.
  • the belt advance run 42 registers the chamber front opening 33 and extends beyond the edges of the conveyor belt upper run 17.
  • the upper edge 44 of the band 40 along its advance run 42 is disposed below and along the lower edge of the chamber front wall 32 and the bottom edge 46 of the band 40 along its advance run 42 is parallel to and a short distance above the confronting upper face of the conveyor belt 16 which distance is determined by the desired thickness of the end product and may be of the order of about A; inch to 34 inch.
  • the band advance run 42 defines the fiont wall of the chamber 26 and an elongated slot between the bottom edge 46 of the band advance run 42 and the confronting face of the conveyor belt 16, which slot extends between the lips 34 and 36 and defines an extrusion opening.
  • a backing plate 47 extends along the inner face of the band advance run 42 and is provided with a longitudinally extending medially located positioning slot which slidably engages a corresponding ridge 49 medially peripherally extending along the inner face of the band 40.
  • the band 40 may be formed of any suitable chemical resistant flexible material.
  • One or both of the drums 41 are positively driven by the electric motor 20 through a variable speed reduction unit 50 which is connected to the drum shafts in conventional fashion.
  • the band 40 is driven in such a sense that it moves along its advance run 42 forwardly along and laterally across the conveyor belt upper run 17 having a component of movement in the direction of advance of the conveyor belt 16. Furthermore it is highly desirable and advantageous to drive the band 40 at a speed whose component in the direction of the advance of the conveyor belt 16 is approximately equal to the advancing speed of the conveyor belt 16, that is between about plus and minus twenty percent of such speed. Furthermore, it has been found in practice, that the speed of the band 40 should preferably not exceed 100 inches per minute.
  • Examples of suitable linear speeds of the band 40 for various angles of the advance run 42 to the longitudinal direction of advance of the conveyor belt 16 whose speed is 30 inches per minute are as follows: at 45 -42 inches per minute; 50-47 inches per minute; 52 inches per minute; '60 inches per minute; 71 inches per minute; --82 inches per minute; and 75-ll5 inches per minute.
  • a fiber reinforced viscose sponge forming mass is produced by steeping sheets of cellulose containing between 40 and 50 pounds alpha cellulose, forexample, 45 pounds of alpha cellulose in an approximately 18 /2% sodium hydroxide solution for a time sufiicient to convert the cellulose into alkali cellulose.
  • the excess sodium hydroxide solution is then expressed from the resulting alkali cellulose in the conventional manner and the unaged alkali cellulose is admixed with between 15 and 35 pounds of carbon bisulfide, for example, approximately 27 pounds of carbon bisulfide, and the resulting mixture is tumbled in a suitable drum until cellulose xanthate is produced in accordance with the general practice.
  • the resulting cellulose xanthate is dissolved in a weak sodium hydroxide solution in an amount to produce approximately 600 pounds of viscose having an analysis of between 6% and 9% cellulose, for example, 7.6% cellulose, 5% to 7% of total alkalinity, for example, 7% and between 3.3% and 5% total sulfur, for example, 3.5%.
  • the conveyor belt 16 is driven at approximately 30 inches per minute and the band 40, which extends at an angle of about 69 to the longitudinal direction of the conveyor b'elt' is driven at a'linear speed of about 60 inches per minute.
  • the conveyor belt 16 carries a sheet of sponge forming mass of uniform thicknessfromthe open bottom of the chamber 26, the belt 16 entering the chamber 26 directly below the bottom edge of the rear wall section 27 and leaving-the chamber at the lower edge 46 of the band 40.
  • the depth of the sheet 51 is determined by the-height ofthe band of lower edge 46 above the conveyor belt confronting face and by the speed of the conveyor belt.
  • the sponge forming mass While carried by the belt 16 the sponge forming mass is transported through a coagulating zone, such as a coagulating liquid of well known composition at an elevated temperature where the viscose is coagulated, the cellulose regenerated and the pore forming crystals substantially leached out.
  • a coagulating zone such as a coagulating liquid of well known composition
  • the sponge sheet is then separated from the belt 16 and transported through washing, bleaching and plasticizing baths and a series of squeeze rolls to produce the finished sponge which may be cut to the desired sizes.
  • the resulting sponge cloth is characterized by its uniformly high strength along both its longitudinal. and transverse directions. This is in contrast to sponge cloth produced by conventional extrusion where the strength of the sponge sheet transverse to the extrusion direction is only a small fraction of its strength parallel to the direction of extrusion.
  • This highly desirable result is believed to be a consequence of the random orientation of the fibers in the sponge cloth as distinguished from the conventionally extruded sponge cloth where the fibers are oriented in a longitudinal direction. This random orientation appears to be accomplished primarily by the extrusion edge 46 advancing in the direction of advance of the extruded sheet 50 so that a minimum of stress or strain is applied to the extruded sheet in the direction along its surface.
  • Another contributing factor may be the mass mixing and agitating action of the inner surface of the band 40. It has been observed that the mass in the chamber 26 is carried by the band 40 forwardly and upwardly along the leading portion of the chamber where it moves toward the trailing portion of the chamber 26 and flows downwardly toward the bottom opposite end by gravity.
  • An improved extrusion apparatus of the character described comprising an endless first band conveyor having an upwardly directed face along an advancing run thereof, a distributing chamber extending transversely along said conveyor upwardly directed face and having a bottom opening formed therein and confronting said face, an endless second hand defining the front wall of said chamber and having a lower edge disposed above said conveyor face and means advancing said second hand.
  • An improve extrusion apparatus of the character described comprising an endless driven longitudinally extending first :band conveyor having an upwardly directed face along an advancing run thereof, a transversely extending distributing chamber disposed along said conveyor face and having formed therein a bottom opening confronting said conveyor face and a forwardly directed opening extending transversely along and upwardly from said conveyor face and a second driven endless band having a longitudinal run registering with and extending along said forwardly directed opening and having a bottom edge disposed above said conveyor face.
  • An improved extrusion apparatus of the character des'c'rib'e'd' comprising 'an endless driven longitudinallyextendirig first bandconveyor having an upwardly directed face along an advancing run thereof,'a transversely extending distributing chamber disposed along said conveyor "face and having formed therein a bottom opening confronting said conveyor face and a forwardly directed opening extending diagonally across and upwardly from said conveyor face, and a second driven endless band having a longitudinal run registering with and extending diagonally across said conveyor face and along said forwardly directed opening and having a bottom edge disposed above said conveyor face.
  • An improved extrusion apparatus of the character described comprising an endless driven longitudinally extending first band conveyor having an upwardly directed face along an advancing run thereof, a transversely extending distributing chamber disposed along said conveyor face and having formed therein a bottom opening confronting said conveyor face and a forwardly directed opening extending transversely along and upwardly and rearwardly from said conveyor face and a second driven endless band having a longitudinal run registering with and extending along said forwardly directed opening and having a bottom edge disposed above said conveyor face, and being upwardly, rearwardly inclined from said bottom edge.
  • An improved extrusion apparatus of the character described comprising an endless driven longitudinally extending first band conveyor having an upwardly directed forwardly upwardly inclined face along an advancing run thereof, a transversely extending distributing chamber disposed along said conveyor face and having formed therein a bottom opening confronting said conveyor face and a forwardly directed opening extending diagonally across and upwardly and rearwardly from said conveyor face and a second driven endless band having a longitudinal run registering with and extending along said forwardly directed opening and having a bottom edge disposed above said conveyor face and being upwardly and rearwardly inclined from said bottom edge.
  • An improved extrusion apparatus of the character described comprising a base plate having an upper face, an open bottom distributing chamber located above and extending across said base plate and having formed therein a forwardly directed opening, an endless driven first band conveyor having an upper run extending along said upper face between said distributing chamber and said base plate and advancing forwardly of said opening, said conveyor band being of a width substantially equal to the Width of said forwardly directed opening and a second driven endless band having a longitudinal run registering with and extending along said forwardly directed opening and having a bottom edge disposed above said conveyor upper run.
  • An improved extrusion apparatus of the character described comprising an endless first band conveyor having an upwardly directed face along an advancing run thereof, a distributing chamber extending transversely along said conveyor upwardly directed face and having formed therein a bottom opening confronting said conveyor face and a forwardly directed opening extending diagonally across and communicating with said conveyor face, an endless second band registering with said forwardly directed opening and having a bottom edge closely confronting said conveyor face to define therewith an extrusion opening and means driving said conveyor band and said second band whereby said second band has a component of movement in the direction of advance of said conveyor band.
  • An improved extrusion apparatus of the character described comprising an endless first band conveyor having an upwardly directed face along an advancing run thereof, a distributing chamber extending transversely along said conveyor upwardly directed face and having formed therein a bottom opening confronting said conveyor face and a forwardly directed opening extending diagonally across and communicating with said conveyor face, an endless second band registering with said for- ⁇ vardly directed opening and having a bottom edge closely confronting said conveyor face to define therewith an 8 extrusion opening and means driving said conveyor band and said second band whereby said second band has a component of velocity in the direction of advance of said conveyor band and approximately equal to the speed of advance of said conveyor band.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)

Description

June 27, 1961 F. PEKAREK 2,989,775
APPARATUS FOR PRODUCING FIBER REINFORCED SPONGE SHEETING Filed May 1, 1959 IN V EN TOR.- Frank Pkark.
AT TOP? N EY.
United States Patent 2,989,775 APPARATUS FOR PRODUCING FIBER REIN- FORCED SPONGE SHEETING Frank Pekarek, Cleveland, Ohio, assignor to Nylonge Corporation, Cleveland, Ohio, a corporation of Ohio Filed May 1, 1959, Ser. No. 810,474 11 Claims. (Cl. 18-'4) The present invention relates generally to an improved extrusion method and apparatus and it relates more particnlarly to an improved method and apparatus for the production of fiber reinforced sponge cloth.
'lhin sheets of artificial sponge material have been generally employed for cleaning and polishing purposes. Such sheets, particularly when they are formed of viscose produced regenerated cellulose are provided with reinforcing fibers to increase the strength and useful life thereof. The thin sheets have been fabricated by cutting. them from a block of the sponge or they are directly-extruded as a thin sheet or cloth. In the former case the process is expensive and the end product lacks uniformity, strength and other desired physical properties. In the latter case although the cost of the end product is relatively low, it possesses a drawback and disadvantage. While the strength of the extruded sponge cloth is satisfactory in the direction of extrusion, the strength thereof transverse to the direction of the extrusion is very low and entirely inadequate and the result is an unacceptable product. The reason for the lack of strength across the direction of extrusion is that the reinforcing fibers are oriented in the direction of extrusion providing little reinforcing across the direction of extrusion.
It is therefore a principal object of the present invention to provide an improved extrusion method and apparatus. I
Another object of the present invention is to provide an improved apparatus for the production of fiber reinforced sponge cloth or sheeting.
Still another object of the present invention is to provide an improved apparatus for the production of fiber reinforced sponge cloth or sheeting characterized by the high uniform strength of the end product substantially independent of the direction of stress.
A further object of the present invention is to provide an improved apparatus for the production of fiber reinforced sponge cloth or sheet wherein a substantially random orientation is imparted to the reinforcing fibers.
Still a further object of the present invention is to provide an improved apparatus of the above nature characterized by its simplicity, ruggedness, low cost and high capacity.
The above and other objects of the present invention will become apparent from a reading of the following description taken in conjunction with the accompanying drawing, wherein:
' FIGURE 1 is a top plan view of an improved apparatus embodying the present invention, shown partially broken away for convenience of illustration;
FIGURE 2 is a sectional view taken along line 2-2 in FIGURE 1; and
FIGURE 3 is a sectional view taken along line 3-3 in FIGURE 2.
The present invention is based upon the discovery that when a flowable fi-ber carrying sponge forming mass is deposited on an advancing belt conveyor and continuously spread on the conveyor to the desired depth or thickness by a lip member extending diagonally across the conveyor and moving along its length with a component in'the direction of advance of the conveyor, which component should be approximately equal to the speed of the conveyor, the resulting sponge cloth produced thereby is characterized by its high uniform strength which is independent of direction. It is believed that the uniformity in strength which is independent of direction is achieved by reason of the random orientation of the reinforcing fibers in the resulting cloth as contrasted to sponge cloth produced with conventional extrusion apparatus. In a sense, therefore, the present invention contemplates the provision of an improved extrusion apparatus of the character described comprising an endless band conveyor having an upper advancing run provided with an upwardly directed face, means for depositing a flowable mass on said conveyor face, an endless second band extending diagonally across said conveyor face forward of said mass depositing means and having a bottom edge substantially parallel to and confronting and spaced above said conveyor face, and means driving said conveyor to have a component in the direction of advance of said conveyor.
According to a preferred form of the present invention the feed run of the conveyor band is upwardly forwardly inclined and travels across an underlying support plate. An open bottom distributing chamber extends diagonally across the face of the conveyor and has a longitudinal forwardly directed opening in the front thereof directly above the conveyor face. An endless second band registers with the chamber forwardly directed opening and extends therewith diagonally across the conveyor face and is slightly rearwardly upwardly inclined relative thereto. The lower edge of the second band is spaced a short distance above the conveyor face to define therewith an extrusion opening from the dis tributing chamber. The conveyor and second band are so driven that the run of the band registering with the chamber opening is so driven that it has a component of movement in the direction of advance of conveyor, said component being of a speed approximately equal to the speed of advance of the conveyor belt, that is the speed of conveyor belt plus or minus less than about 20% thereof. It is believed, that in the aforesaid arrangement that the second hand not only effects the orientless extrusion of the sponge forming mass, but it also eifects a pumping mixing of the mass in the distributing chamber so as to disturb and avoid any orientation of the material therein.
Referring now to the drawing which illustrates a preferred embodiment of the present invention the reference numeral 10 generally designates the improved apparatus which comprises a continuous conveyor system 11 and a fluid mass depositing and spreading system 12. The conveyor system 11 includes a suitably mounted substantially planar support plate 13 of rectangular configuration and forwardly upwardly inclined an angle of several degrees. The trailing and leading ends of the support plate 13 terminate in curved depending lips 14 and 15 respectively. An endless flexible conveyor band or belt 16. has an upper run 17 extending longitudinally across the top face of the support plate 13 and advancing along a direction from the trailing lip 14 to the leading lip 15. The trailing end of the conveyor belt 16 passes over and in engagement with a drum 18 and the portion .of' the upper run 17 thereof forward of the leading lip 15 passes over an idler roll 19, the top face of the support plate 13 lying along the plane tangent to the drum 18 and roll 19. Following the idler roll 19 the conveyor belt 16 passes through a viscose coagulating zone which may be a tank containing a fluid at elevated temperatures; an infra-red heating zone, an electric current applying arrangement or the like and thence about a leading drum and along a return run to the trailing drum 18. The trailing drum 18 is positively driven at a variable predetermined speed by means of an electric motor 20 coupled thereto through a variable speed reduction unit 21. It should be noted that the belt 16 is suitably supported along its length and that the leading drum may be an idler or may be positively driven in the manner of the trailing drum in which latter case the drum 13 may idle. The conveyor belt 16 is of any desired width, for example approximately four feet, and is narrower than and extends medially across the support plate 13 to leave uncovered laterally spaced longitudinally extending borders 22. Further, the belt 16 has a contoured, preferably checkered upper or outer conveying face 23 and is formed of any suitable reinforced flexible material such as a natural or synthetic rubber which is resistant to the ambient environment.
The mass depositing and spreading system 12 includes a suitably supported elongated hopper or distributing chamber 26 which extends diagonally across the upper face of the conveyor upper run 17 in the area supported by the plate 13 and between diagonally opposite corners of the plate 13. The chamber 26 preferably extends at an angle of between 30 and 75 for example between 40" and 60 to the direction of advance of the conveyor belt 16 and its ends overlie the plate borders 22. The distributing chamber 26 comprises a rear wall including a lower flat section projecting at an angle to, and upwardly and rearwardly from the top face of the belt upper nm 17 and terminating in a flat vertical top section 28. Projecting forwardly from the rear wall upper and lower sections 27 and 28 are substantially cylindrical end walls 29 and 30 whichextend beyond the corresponding edges of the conveyor belt 16. An upper front vertical wall section 32 extends diagonally between the leading upper edges of the end walls 29 and 30 and parallel to the rear wall section 28. A forwardly directed diagonally extending rectangular chamber opening 33 is delineated by the lower edge of the front wall 32, the front edges of the end walls 29 and 30 and the top face of the belt upper run 17, the opening 33 forming an angle to the belt face and being upwardly rearwardly inclined. The end wall 29 extends to the support plate top face, its forward edge being disposed outside the conveyor edge and being provided with an inwardly projecting arm lying in the plane of the opening 33 and extending a short distance above the conveyor belt top face and terminating in a forwardly directed lip 34 along the outer edge of the belt upper run 17. A second forwardly directed lip 36, of the same height as the lip 34 projects from the inner edge of the end wall 30 along the opposite longitudinal edge of the conveyor belt 16.
The lower edge of the end wall 30 and the adjacent lower edge of the rear wall section 27 extend to the support plate top face. A top wall 37 covers the chamber 26 and is provided with an opening 38 at its trailing end. A delivery conduit 39 is located directly above and discharges into the opening 38, and communicates with a source of sponge forming mass.
An elongated endless flat band 40 is disposed above and extends diagonally across the top trailing face of the conveyor belt upper run 17 and is supported by and between a pair of longitudinally offset drums 41 which are located adjacent opposite edges of the support plate 13. The drums 41 are upwardly rearwardly inclined several degrees to a perpendicular to the surface of the conveyor belt upper run 17. The endless band 40 includes a trailing advancing run 42 and a leading parallel return run 43. The belt advance run 42 registers the chamber front opening 33 and extends beyond the edges of the conveyor belt upper run 17. The upper edge 44 of the band 40 along its advance run 42 is disposed below and along the lower edge of the chamber front wall 32 and the bottom edge 46 of the band 40 along its advance run 42 is parallel to and a short distance above the confronting upper face of the conveyor belt 16 which distance is determined by the desired thickness of the end product and may be of the order of about A; inch to 34 inch. The band advance run 42 defines the fiont wall of the chamber 26 and an elongated slot between the bottom edge 46 of the band advance run 42 and the confronting face of the conveyor belt 16, which slot extends between the lips 34 and 36 and defines an extrusion opening. By reason of the inclination of the belt 40, the lower edge along the return run thereof is disposed a greater distance above the belt top face than the edge 46. A backing plate 47 extends along the inner face of the band advance run 42 and is provided with a longitudinally extending medially located positioning slot which slidably engages a corresponding ridge 49 medially peripherally extending along the inner face of the band 40. The band 40 may be formed of any suitable chemical resistant flexible material.
One or both of the drums 41 are positively driven by the electric motor 20 through a variable speed reduction unit 50 which is connected to the drum shafts in conventional fashion. The band 40 is driven in such a sense that it moves along its advance run 42 forwardly along and laterally across the conveyor belt upper run 17 having a component of movement in the direction of advance of the conveyor belt 16. Furthermore it is highly desirable and advantageous to drive the band 40 at a speed whose component in the direction of the advance of the conveyor belt 16 is approximately equal to the advancing speed of the conveyor belt 16, that is between about plus and minus twenty percent of such speed. Furthermore, it has been found in practice, that the speed of the band 40 should preferably not exceed 100 inches per minute.
Examples of suitable linear speeds of the band 40 for various angles of the advance run 42 to the longitudinal direction of advance of the conveyor belt 16 whose speed is 30 inches per minute are as follows: at 45 -42 inches per minute; 50-47 inches per minute; 52 inches per minute; '60 inches per minute; 71 inches per minute; --82 inches per minute; and 75-ll5 inches per minute.
In accordance with an example of producing a sponge cloth, employing the present improved apparatus, a fiber reinforced viscose sponge forming mass is produced by steeping sheets of cellulose containing between 40 and 50 pounds alpha cellulose, forexample, 45 pounds of alpha cellulose in an approximately 18 /2% sodium hydroxide solution for a time sufiicient to convert the cellulose into alkali cellulose. The excess sodium hydroxide solution is then expressed from the resulting alkali cellulose in the conventional manner and the unaged alkali cellulose is admixed with between 15 and 35 pounds of carbon bisulfide, for example, approximately 27 pounds of carbon bisulfide, and the resulting mixture is tumbled in a suitable drum until cellulose xanthate is produced in accordance with the general practice. The resulting cellulose xanthate is dissolved in a weak sodium hydroxide solution in an amount to produce approximately 600 pounds of viscose having an analysis of between 6% and 9% cellulose, for example, 7.6% cellulose, 5% to 7% of total alkalinity, for example, 7% and between 3.3% and 5% total sulfur, for example, 3.5%.
To the 600 pounds of viscose in a green unripened condition is then added from 15 to 30 pounds, for example, 20 pounds of thoroughly opened hemp fibers having an average staple length. of approximately inch to 1 inch and thorough mixing is effected, preferably by means of a double delta blade mixing machine maintaining the mass at a temperature not exceeding 15 C. This initial mixing period is approximately 20 minutes. To the resulting mass is added between 1500 and 2500 pounds, for example, 2000 pounds sodium sulfate decahydrate crystals having an average particle size of about 1 to 2, millimeters. The mixing is continued for approximately 10, minutes while maintaining the temperature at about 15 C. or less. It should be noted that any other suitable methods may be employed, for producing viscose having the desired properties. An example of such a method is the so-called one step method which is set forth in the literature.
asserts 1 -The above viscose sponge forming mass is continuously introduced into the-chamber 26 to maintain the level therein at approximately the level of the band edge 44. The conveyor belt 16 is driven at approximately 30 inches per minute and the band 40, which extends at an angle of about 69 to the longitudinal direction of the conveyor b'elt' is driven at a'linear speed of about 60 inches per minute. The conveyor belt 16 carries a sheet of sponge forming mass of uniform thicknessfromthe open bottom of the chamber 26, the belt 16 entering the chamber 26 directly below the bottom edge of the rear wall section 27 and leaving-the chamber at the lower edge 46 of the band 40. The depth of the sheet 51 is determined by the-height ofthe band of lower edge 46 above the conveyor belt confronting face and by the speed of the conveyor belt. While carried by the belt 16 the sponge forming mass is transported through a coagulating zone, such as a coagulating liquid of well known composition at an elevated temperature where the viscose is coagulated, the cellulose regenerated and the pore forming crystals substantially leached out. The sponge sheet is then separated from the belt 16 and transported through washing, bleaching and plasticizing baths and a series of squeeze rolls to produce the finished sponge which may be cut to the desired sizes.
The resulting sponge cloth is characterized by its uniformly high strength along both its longitudinal. and transverse directions. This is in contrast to sponge cloth produced by conventional extrusion where the strength of the sponge sheet transverse to the extrusion direction is only a small fraction of its strength parallel to the direction of extrusion. This highly desirable result is believed to be a consequence of the random orientation of the fibers in the sponge cloth as distinguished from the conventionally extruded sponge cloth where the fibers are oriented in a longitudinal direction. This random orientation appears to be accomplished primarily by the extrusion edge 46 advancing in the direction of advance of the extruded sheet 50 so that a minimum of stress or strain is applied to the extruded sheet in the direction along its surface. Another contributing factor may be the mass mixing and agitating action of the inner surface of the band 40. It has been observed that the mass in the chamber 26 is carried by the band 40 forwardly and upwardly along the leading portion of the chamber where it moves toward the trailing portion of the chamber 26 and flows downwardly toward the bottom opposite end by gravity.
While there has been illustrated and described a preferred embodiment of the present invention it is apparent that numerous alterations, omissions and additions may be made Without departing fromthe spirit thereof.
What is claimed is:
1. An improved extrusion apparatus of the character described comprising an endless first band conveyor having an upwardly directed face along an advancing run thereof, a distributing chamber extending transversely along said conveyor upwardly directed face and having a bottom opening formed therein and confronting said face, an endless second hand defining the front wall of said chamber and having a lower edge disposed above said conveyor face and means advancing said second hand.
2. An improve extrusion apparatus of the character described comprising an endless driven longitudinally extending first :band conveyor having an upwardly directed face along an advancing run thereof, a transversely extending distributing chamber disposed along said conveyor face and having formed therein a bottom opening confronting said conveyor face and a forwardly directed opening extending transversely along and upwardly from said conveyor face and a second driven endless band having a longitudinal run registering with and extending along said forwardly directed opening and having a bottom edge disposed above said conveyor face.
3. An improved extrusion apparatus of the character des'c'rib'e'd' comprising 'an endless driven longitudinallyextendirig first bandconveyor having an upwardly directed face along an advancing run thereof,'a transversely extending distributing chamber disposed along said conveyor "face and having formed therein a bottom opening confronting said conveyor face and a forwardly directed opening extending diagonally across and upwardly from said conveyor face, and a second driven endless band having a longitudinal run registering with and extending diagonally across said conveyor face and along said forwardly directed opening and having a bottom edge disposed above said conveyor face.
l 4. Animproved extrusion apparatus in accordance with clairn 3 wherein said second band has a component of velocity in the direction of advance and approximately equal to the speed of said conveyor band.
5. An improved extrusion apparatus of the character described comprising an endless driven longitudinally extending first band conveyor having an upwardly directed face along an advancing run thereof, a transversely extending distributing chamber disposed along said conveyor face and having formed therein a bottom opening confronting said conveyor face and a forwardly directed opening extending transversely along and upwardly and rearwardly from said conveyor face and a second driven endless band having a longitudinal run registering with and extending along said forwardly directed opening and having a bottom edge disposed above said conveyor face, and being upwardly, rearwardly inclined from said bottom edge.
6. An improved extrusion apparatus of the character described comprising an endless driven longitudinally extending first band conveyor having an upwardly directed forwardly upwardly inclined face along an advancing run thereof, a transversely extending distributing chamber disposed along said conveyor face and having formed therein a bottom opening confronting said conveyor face and a forwardly directed opening extending diagonally across and upwardly and rearwardly from said conveyor face and a second driven endless band having a longitudinal run registering with and extending along said forwardly directed opening and having a bottom edge disposed above said conveyor face and being upwardly and rearwardly inclined from said bottom edge.
7. An improved extrusion apparatus of the character described comprising a base plate having an upper face, an open bottom distributing chamber located above and extending across said base plate and having formed therein a forwardly directed opening, an endless driven first band conveyor having an upper run extending along said upper face between said distributing chamber and said base plate and advancing forwardly of said opening, said conveyor band being of a width substantially equal to the Width of said forwardly directed opening and a second driven endless band having a longitudinal run registering with and extending along said forwardly directed opening and having a bottom edge disposed above said conveyor upper run.
8. An apparatus in accordance with claim 7 wherein said second band along said longitudinal run is upwardly rearwardly inclined.
9. An apparatus in accordance with claim 7 wherein said chamber forwardly directed opening extends diagonally across said conveyor.
10. An improved extrusion apparatus of the character described comprising an endless first band conveyor having an upwardly directed face along an advancing run thereof, a distributing chamber extending transversely along said conveyor upwardly directed face and having formed therein a bottom opening confronting said conveyor face and a forwardly directed opening extending diagonally across and communicating with said conveyor face, an endless second band registering with said forwardly directed opening and having a bottom edge closely confronting said conveyor face to define therewith an extrusion opening and means driving said conveyor band and said second band whereby said second band has a component of movement in the direction of advance of said conveyor band.
11. An improved extrusion apparatus of the character described comprising an endless first band conveyor having an upwardly directed face along an advancing run thereof, a distributing chamber extending transversely along said conveyor upwardly directed face and having formed therein a bottom opening confronting said conveyor face and a forwardly directed opening extending diagonally across and communicating with said conveyor face, an endless second band registering with said for- \vardly directed opening and having a bottom edge closely confronting said conveyor face to define therewith an 8 extrusion opening and means driving said conveyor band and said second band whereby said second band has a component of velocity in the direction of advance of said conveyor band and approximately equal to the speed of advance of said conveyor band.
References Cited in the file of this patent UNITED STATES PATENTS 1,888,376 Duty Nov. 22, 1932 2,778,086 Wilcox Jan. 22, 1957 FOREIGN PATENTS 1,081,925 France June 16, 1954
US810474A 1959-05-01 1959-05-01 Apparatus for producing fiber reinforced sponge sheeting Expired - Lifetime US2989775A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US810474A US2989775A (en) 1959-05-01 1959-05-01 Apparatus for producing fiber reinforced sponge sheeting

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US810474A US2989775A (en) 1959-05-01 1959-05-01 Apparatus for producing fiber reinforced sponge sheeting

Publications (1)

Publication Number Publication Date
US2989775A true US2989775A (en) 1961-06-27

Family

ID=25203935

Family Applications (1)

Application Number Title Priority Date Filing Date
US810474A Expired - Lifetime US2989775A (en) 1959-05-01 1959-05-01 Apparatus for producing fiber reinforced sponge sheeting

Country Status (1)

Country Link
US (1) US2989775A (en)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3142714A (en) * 1961-12-20 1964-07-28 Nylonge Corp Method for the production of cleaning devices
US3163886A (en) * 1960-08-09 1965-01-05 Wilke Kiaus Dieter Apparatus for manufacturing light construction panels
US3357044A (en) * 1966-04-06 1967-12-12 American Excelsior Corp Production of shaped articles
US3399426A (en) * 1964-10-05 1968-09-03 Advance Ind Inc Method of and apparatus for extruding thermoplastic material
US3526927A (en) * 1965-11-22 1970-09-08 Novacel Sa Method and apparatus for making artificial skins
US4219524A (en) * 1979-01-10 1980-08-26 Owens-Corning Fiberglas Corporation Method and apparatus for producing sheet molding compound

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1888376A (en) * 1929-07-18 1932-11-22 Spencer C Duty Process of and apparatus for forming face brick
FR1081925A (en) * 1953-05-13 1954-12-23 Saint Gobain Process for the production of plasterboard or the like by rolling or continuous pressing
US2778086A (en) * 1953-02-20 1957-01-22 Alliance Clay Product Company Apparatus for scoring column from which bricks are made

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1888376A (en) * 1929-07-18 1932-11-22 Spencer C Duty Process of and apparatus for forming face brick
US2778086A (en) * 1953-02-20 1957-01-22 Alliance Clay Product Company Apparatus for scoring column from which bricks are made
FR1081925A (en) * 1953-05-13 1954-12-23 Saint Gobain Process for the production of plasterboard or the like by rolling or continuous pressing

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3163886A (en) * 1960-08-09 1965-01-05 Wilke Kiaus Dieter Apparatus for manufacturing light construction panels
US3142714A (en) * 1961-12-20 1964-07-28 Nylonge Corp Method for the production of cleaning devices
US3399426A (en) * 1964-10-05 1968-09-03 Advance Ind Inc Method of and apparatus for extruding thermoplastic material
US3526927A (en) * 1965-11-22 1970-09-08 Novacel Sa Method and apparatus for making artificial skins
DE1753693B1 (en) * 1965-11-22 1972-06-29 Novacel Sa Method and device for the production of artificial leather
US3357044A (en) * 1966-04-06 1967-12-12 American Excelsior Corp Production of shaped articles
US4219524A (en) * 1979-01-10 1980-08-26 Owens-Corning Fiberglas Corporation Method and apparatus for producing sheet molding compound

Similar Documents

Publication Publication Date Title
US3080688A (en) Scouring device
US2989775A (en) Apparatus for producing fiber reinforced sponge sheeting
US3142714A (en) Method for the production of cleaning devices
US2678081A (en) Apparatus for making carpet underlay material
ES412620A1 (en) Fibrous materials
US2450847A (en) Apparatus for treating rubberreinforcing cord fabric
US3109703A (en) Method for the production of cleaning devices
US2463289A (en) Method and apparatus for producing cellular rubber material
US3032828A (en) Process of making fabric-foam laminates
US2047395A (en) Film extruding press
US2573952A (en) Apparatus for depositing strips of adhesive upon a base material
US2665450A (en) Method and apparatus for continuous production of absorbing material
US2540195A (en) Method for mixing rubber and the like
US2882327A (en) Process of producing rubber latex dispersion containing rubber crumb granules
US1660924A (en) Sheet material
US3632258A (en) Confectionery bar extruding machine
US2502361A (en) Method for making fibrous materials
US3377652A (en) Apparatus for the production of artificial sponge
US1619210A (en) Apparatus for forming articles from sheets of material
US3816204A (en) Process for preparing mats having cushion
US2571760A (en) Apparatus for forming colloidized plastics
US3031325A (en) Underlay for rugs and carpets
US2230074A (en) Tile manufacture
US1500209A (en) Felting and recessing machine
US2655895A (en) Flocking machine