US3133319A - Process and apparatus for cleaning, separating and felting fibrous materials - Google Patents

Process and apparatus for cleaning, separating and felting fibrous materials Download PDF

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US3133319A
US3133319A US107788A US10778861A US3133319A US 3133319 A US3133319 A US 3133319A US 107788 A US107788 A US 107788A US 10778861 A US10778861 A US 10778861A US 3133319 A US3133319 A US 3133319A
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fibrous material
air
felting
chamber
aeration chamber
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US107788A
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Thomas R Gould
Charles D Simmers
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Johns Manville Corp
Johns Manville
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Johns Manville
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    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01GPRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
    • D01G9/00Opening or cleaning fibres, e.g. scutching cotton
    • D01G9/08Opening or cleaning fibres, e.g. scutching cotton by means of air draught arrangements

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  • This invention relates to process and apparatus for opening, cleaning and felting fibrous materials. Although particularly directed to the opening and cleaning of a fibrous material containing fibers and unwanted particles and tufts of fibrous material and unwanted particles, such as mineral wool, the invention also may be effectively utilized to separate any fibrous material containing relatively lighter material and heavier unwanted particles.
  • Mineral wool being composed of relatively brittle vit reous fibers cannot be satisfactorily processed in the usual textile fiber opening equipment, for opening up the tufts or clumps of fiber and separating the unwanted particles, commonly identified as shot, and other unfiberized particles from the fiber. There is too great a loss of fiber and the cleaned fiber is reduced to an undesirably short length when processed in such equipment.
  • the mineral wool largely in the form of clumps or tufts with adhering unfiberized glass-like particles, generally referred to as shot, is subjected to aeration by small blasts of air, sufficient to open up the bundles of fiber and separate most of the shot from the fibers, but insuificient to destroy the fibers or unduly reduce their length.
  • the apparatus of the instant invention comprises an aeration chamber having side walls and an enclosed base with a foraminous member extending generally transversely of the chamber adjacent one end thereof.
  • a duct adjacent the other end of the aeration chamber connects the aeration chamber to a felting zone and comprises a separation section having a substantially greater cross-sectional area than the other sections of the duct means for reducing the velocity of the air flow therethrough.
  • the fibrous material to be cleaned, separated and felted is introduced into said aeration chamber between said foraminous member and said duct means.
  • At least one air stream moving in generally angular relationship to the Walls of said aeration chamber is introduced into said aeration chamber so as to create a highly turbulent air suspension of said fibrous material.
  • Means are provided in said felting zone to cause a flow of volume air from said aeration chamber through said duct means and said separating section to said felting zone so that said fibrous material containing fibers and unwanted particles and tufts of fibrous material and unwanted particles intermixed therewith tends to flow with said volume air toward said felting zone.
  • the velocity of the air flow therethrough is reduced to cause the unwanted 3,133,319 Patented May 19, 1964 particles and tufts of fibrous materials and unwanted particles to be separated from the opened and cleaned fibers of said fibrous material so that the unwanted particles and tufts of fibrous materials and unwanted particles settle back into the air chamber to be deposited on the foraminous member therein while the opened and cleaned fibers flow With said volume air to said felting zone.
  • Means are provided adjacent said foraminous material for agitating said tufts of said fibrous materials to separate said tufts into fibers and unwanted particles with the agitating means providing sufficient impetus to the cleaned fibers to introduce these fibers to said air stream to be carried to and through said separating section to said felting zone.
  • FIG. 1 is a side elevational view, parts being broken away, illustrating the aeration chamber for opening and cleaning the fibers, the enlarged separation section, the transfer horn and felting tower;
  • FIGS. 2 and 3 are horizontal sectional views on the lines 2-2 and 3-3, respectively, of FIG. 1, looking in the direction of the arrows;
  • FIG. 4 is an elevational view of the devices for feeding the raw, uncleaned mineral wool to a transport conduit;
  • FIG. 5 is a vertical sectional view therethrough, on the line 55 of FIG. 4;
  • FIG. 6 is an elevational view of the fiber feeding devices, on a reduced scale, showing the relation of these devices to the blower supplying transporting air;
  • FIG. 7 is a fragmentary view illustrating a modified form of air jet which may be employed adjacent the supporting screen in the aeration chamber.
  • FIG. 8 is a vertical sectional view illustrating a modification of the fiber feeding devices.
  • FIGS. 1 to 6 the form of the invention illustrated in FIGS. 1 to 6 comprises an aeration chamber 10, a duct 11 thereabove, formed with an enlarged separation section 12 and a transfer horn 14, leading to the upper section 15 of a felting tower 16.
  • the duct 11 serves for guiding the cleaned air-borne fiber from the aeration chamber to the felting tower and is especially formed to perform an important function in connection with the fiber opening and cleaning operation, as described below.
  • the equipment is designed for processing a large volume of mineral wool, in a continuous operation, there being sufficient capacity to accommodate the output of a standard mineral wool cupola and fiberizing equipment, for example, 2,000 pounds to 3,000 pounds or more of raw or uncleaned mineral wool per hour. However, it has been found equally effective in smaller sizes, processing a few hundred pounds of mineral wool'per hour.
  • the felting tower 16 may be of any preferred type or size, capable of handling the quantity of cleaned fiber supplied.
  • the tower includes an upper section 15 motor 38.
  • the conveyor is of the open meshscreen or plate type permitting the air and suspended fibers to be drawn downwardly through the felting chamber and onto the upper reach of the conveyor as the air is evacuated from the suction chamber 40 evacuated by vacuum fan or fans 41.
  • the construction of the vacuum felting equipment is well known in this art.
  • the evacuating fan or fans in the present invention are of greater capacity than the usual vacuum felting fans in that they are effective, at least in part, to elevate fibrous material upwardly from the aeration chamber, through the duct work 11 and then onto the felting conveyor, as appears below.
  • the aeration chamber may be of any crosssectional configuration
  • the aeration chamber in FIG. 1 is illustrated as being substantially square in cross section, from 6 feet to feet square and approximately 6 feet in height.
  • a transverse screen 19 suitably formed of Woven wire cloth, of relative open mesh, for example, from2and /2 x2and /zupto 4and- /2 x4and /z mesh, desirably being approximately 3 and /2 x 3 and /2 mesh.
  • This screen constitutes a floor for the mass of fibrous material but permits shot to pass readily through into the base of the chamber where a suitable disposal system is installed.
  • this disposal system is indicated as a pan 21 inserted through a suitable side opening in the base, the pan being periodically removed and emptied.
  • the base portion of the aeration chamber including any access doors for the removal of the heavy particles, sealed during normal operation of the equipment.
  • the uncleaned mass of fibrous material is introduced into the chamber 10 through the conduit in which the uncleaned mass of fibrous material is suspended in an air stream.
  • This conduit 20 is carefully placed so that the mass of fibrous material carried therein will be distributed around the chamber by the substantially circulatory motion of the suspending air stream.
  • the conduit 20 which may be of any necessary size, up to 16 inches or more in diameter, enters the chamber 10 near one corner thereof as at 27 and preferably so as to direct said air stream in a direction substantially parallel to the plane of the screen 18. Also, it is preferred that the conduit be directed at an angle of around 65 or 70 from the entering side, to direct the air and mass of fibrous material slightly toward the adjacent side wall directly ahead of the conduit.
  • conduit 22 diagonally opposite the conduit 20 and similarly positioned and angled to direct the air stream toward the adjacent side wall of the chamber 10 opposite to the aforesaid adjacent side.
  • the two air streams thus cooperate in building up a substantially circular air flow in the chamber.
  • the conduit 22 should be smaller than conduit 20, for example, one-half to three-fourths the diameter of conduit 20, for the best results. It is not necessary to add a mass of fibrous material with the air stream supplied by conduit 22 although obviously this conduit could be employed as a supplemental source of fibrous material to be processed.
  • the velocities of the incoming air stream through conduits 20 and 22 are preferably maintained substantially equal.
  • the jets are rotated slowly and continuously so that the fibrous clumps are agitated sufficiently to be caught up by the volume air introduced through conduits 2t) and 22.
  • the air jets shown as four in number, symmetrically spaced around the chamber 10, may be rotated by any suitable means shown as a belt or chain 24 driven by bevel gears 25, reduction gear box 26 and motor 28.
  • bafile strips 29 around the perimeter of the screen, angled upwardly and outwardly, preferably about 45 from the screen to the side walls.
  • the baffles extend entirely around the screen, except at the discharge ends of conduits 2t) and 22.
  • the conduits being directed toward angular baflles of adjacent side walls, assist the air from jets 23 and the volume air from conduits 20 and 22 in elevating any mineral wool tufts collected on the screen adjacent the baffles.
  • volume air introduced through conduits 20 and 22 is sufficient, when combined with the effect of the suction fan 41 and the air blasts from the jets, to maintain the mass of fibrous material in the chamber 10 in a state of constant agitation and to lift lighter fibers and fibrous tufts out of the aeration chamber and into the separation zone 12.
  • the term, volume air is that air passing through the screen 19, separation zone 12 and the duct 14 to the felting tower 16.
  • the lighter, well cleaned fibers pass through the separation chamber 12 and are carried away through the duct 11 to the felting tower while the heavier particles hesitate and are buffeted about so that they either lose some of their adhered heavier particles and are carried to the felting tower or else they drop back toward or into the aeration chamber for further processing.
  • the constant movement of the mass of fibrous material over and around the screen 19 facilitates the discharge of heavier particles, by gravity, through the screen.
  • separation section 12 has a much larger cross-sectional area than the aeration chamber and that the remainder of the duct leading to the felting tower is considerably reduced in the cross-sectional area.
  • Section 12 may have, for example, from one and one-half to two times the cross-sectional area of the aeration chamber.
  • the separation section 12 should be 11 to 16 feet square, desirably 13 and /2 feet square.
  • the transfer horn is of gradually reduced cross-sectional area to provide for increased air speed so that all fiber passing into the horn will be discharged into the felting tower. At the throat or point of introduction into the felting tower the horn may have a cross-sectional area of 2 and /2 feet square or even less for smaller volume of fibers.
  • the mass of fibrous material containing fibers and unwanted particles and tufts of fibrous material and unwanted particles is fed into the conduit 20 in any way which will not interfere with the air flow through the conduit nor with the operation of the cleaning, separating or felting equipment.
  • FIGS. 4-6 There is illustrated in FIGS. 4-6 a method of introducing the mass of fibrous material, which may be preformed and stored fiber or fibrous material directly from the forming equipment, into the conduit 20.
  • the fibrous material is withdrawn at a regulated rate from a fiber supply, as by a suitable picker roll (not shown), and transported on conveyor 42 to the rotary valve 44 mounted on conduit 20.
  • the mass of fibrous material mainly in the form of fiber with adhering shot-like particles and clumps of fibrous material with shot-like particles intermixed therewith, is discharged into the hopper 45 between the blades 46.
  • the blades are rotated slowly, discharging the mass of fibrous material gradually into the conduit 20, while preventing escape of air pressure through the valve.
  • Compressed air is supplied to the conduit 20 from any suitable source, shown as a centrifugal air compressor 47.
  • the air flow from compressor 47 carries the mass of fibrous material through conduit 20 and projects it into the aeration chamber 10.
  • a similar compressor (not shown) supplies compressed air to conduit 22.
  • any usual type mineral wool binder may be employed in the present invention, such as phenolic, resinous or other heat setting or thermoplastic binders. These are well known in the art.
  • the binder is preferably introduced by being added to the mineral wool as it enters the hopper 45, as by means of suitable tubing, not shown, or it may be sprayed over the fibers on the conveyor 42 as shown at 66 in FIG. 8, or it may be added in the felting tower 15.
  • FIG. 8 This construction is illustrated in FIG. 8.
  • the duct 11, with separation section 12 and transfer horn 14, felting tower and vacuum felting equipment shown in FIGS. 1 to 3 are used with the fiber feeding mechanism and aeration chamber of FIG. 8, their function being as hereinabove described.
  • the aeration chamber is of the same shape and size as in FIG. 1 except that one side wall 48 is broken away just above the transverse screen 1921 to form an opening 50' for receiving the housing 52 for the conveyor 54, carrying the newly formed mass of fibrous material from the vicinity of the fiberizing equipment.
  • the conveyor 54 is preferably supported at its forward end by a series of rolls, as shown, the forward upper roll being of reduced diameter to facilitate discharge of its burden into the chamber 100.
  • the rearward end may be supported by the usual large roll (not shown).
  • the upper reach of the conveyor traveling in the direction of the arrow, carries a bed of fibrous material up to the edge of the aeration chamber. At this point, it is picked olf of the conveyor and projected into the aeration chamber by a picker roll 56 rotated at a relatively high rate of speed, for example, around 1,000 r.p.m., to cause the projected mineral wool tufts to be broken up and shot and other unfiberized material to be released from adherence to the fibers.
  • a shield 58 encircling the upper rearward portion of the picker roll maintains the housing 52 separate from the aeration chamber 10a.
  • the shield 58 extends from the top of the opening 50 to a point a short distance above the upper surface of thefibrous material on conveyor 54.
  • the binder if desired may be added to the fibrous material by being sprayed onto the wool on the conveyor, as by spray pipe 66.
  • volume air can be admitted to the chamber Illa-by providing conduits, such as those shown at 20 and 22. If the conduits 20 and 22 are used in this form of the invention they will preferably be placed in the same position and at the same angles indicated in FIG. 2, and as described above.
  • the air flow is thus primarily produced in this form of the invention, by the suction created at the vacuum felting equipment, supplemented where required by the volume or type of fibrous material being processed, by air introduced through conduits 20 and/or 22, or blown in through housing 52.
  • the aeration chamber may have vertical side walls throughout or the base of the chamber, below screen 19a, may have two opposed converging side walls, as shown at 62, to form a trough from which shot and other waste material passing through the screen may be removed.
  • legs 64 are provided to help support the aeration chamber and overlying duct work.
  • the screen 19a similar to screen 19, extends entirely across the aeration chamber and is formed of open mesh to permit shot and heavy particles to drop downwardly through the screen.
  • the baffle plates 29, shown in FIGS. 1 and 2 are preferably supplied for the three sides of the screen, other than the side in which the fibrous material is introduced.
  • baffle plate 59 Adjacent and in front of the picker roll 56 there is provided a baffle plate 59 which is relatively flat and serves as an apron to ease the fibrous material into the aeration chamber. It is preferred to provide an air pipe 60, connected with a supply (not shown) of air under pressure, near the upper edge of baffie plate 59, with upwardly directed air jets, to provide a lift to the fibrous material entering the chamber 10a. This will permit the immediate removal of light weight fibers and fiber clumps upwardly from the aeration chamber for separation in the separating section. A guard 61 placed in front of the return bend of the conveyor 54 prevents the fibrous material from being blown against the conveyor.
  • High pressure, rotatable air jets 2312 are provided, as in the first form of the invention and for the purpose stated above.
  • the air jets shown in FIGS. 7 and 8 comprise double ended jets having opposed rounded nozzles 63 with small discharge passages, one-eighth to one fourth inch in diameter, for each nozzle.
  • the jets are carried by rotatable tubes extending upwardly through the screen, the tubes being rotated and supplied with compressed air as in the first form of the invention.
  • the rounded configuration shown in FIGS. 7 and 8 is for the purpose of preventing the nozzles from picking up and winding the deposited fibrous material about the jets. With double ended jets as shown they may be rotated more slowly, thereby further avoiding entanglement with the fibrous material.
  • a small quantity of any standard grade of textile lubricant (0.1% is generally sufiicient) may be sprinkled on the fibers on the conveyor carrying them to the rotary valve 44 of FIG. 5 or on the conveyor 54 of FIG. 8, by means of a spray pipe similar to pipe 66.
  • the operation of the fiber cleaning, separating and felting apparatus will be clear from the above description.
  • the mass of fibrous material containing fiber and unwanted particles and tufts of fibrous material and unwanted particles is passed into the aeration chamber by one of the methods shown.
  • the volume air produced by the cooperation of the suction fans at the felting conveyor and the air supplied under pressure through the conduits 20 and 22 flowing from the aeration chamber through the separating section 12 and duct 14 serves to elevate and agitate the mass of fibrous material and to clean the mass of fibrous material so that the unwanted particles become disengaged from the fiber and escape downwardly through the transverse screen in the aeration chamber.
  • the high pressure blasts of air from the rotating jets directed across the screen, just above the screen, agitate and break up the tufts in the mass of fibrous material to release the fiber and separate therefrom shot and heavier particles.
  • the jet blasts also elevate the fibrous masses sufiiciently so that the lighter fibrous tufts and fibers are caught up by the volume air and lifted into the separation section 12 of the duct.
  • the lighter materials are carried away to the felting zone and the heavier materials fall back into the aeration chamber for further processing.
  • Apparatus for cleaning, separating and felting a fibrous material containing fibers and unwanted particles and tufts of fibrous material and unwanted particles comprising, an aeration chamber formed with side walls and an enclosed base, a foraminous member extending generally transversely of said chamber, means for suspending said fibrous material in an air stream, means for introducing said air stream containing said fibrous material into said chamber above said screen, said air stream moving in generally angular relationship to the walls of said aeration chamber so as to create a highly turbulent air suspension of said fibrous material, a duct connecting said aeration chamber to a felting zone, means imparting an upwardly directed force to said air stream so that said fibrous material will move through said duct means, a separation section in said duct means, said separation section having substantially greater cross-sectional area than the other sections of said duct means for reducing the velocity of the air flow therethrough to cause said unwanted particles and said tufts of fibrous material to be separated from the fibers of said fibrous material and to settle back
  • Apparatus as defined in claim 1 wherein said means for introducing said air stream containing said fibrous material into said aeration chamber comprises at least one conduit, said conduit opening into said chamber adjacent one corner thereof.
  • said agitating means comprises a plurality of air jets positioned in said aeration chamber and provided with nozzles for direoting blasts of air generally in a direction substantially parallel to the plane of said foraminous member and in close proximity thereto, means for rotating said air jets, and means for supplying compressed air thereto.
  • Apparatus for cleaning, separating and felting a fibrous material containing fibers and unwanted particles and tufts of fibrous material containing fibers and unwanted particles comprising, an aeration chamber formed with side walls and an enclosed base, a foraminous member extending generally transversely of said chamber, a duct connecting said aeration chamber to a felting zone, means for introducing an air stream into said aeration chamber between said screen and said duct means, means for introducing a fibrous material containing fibers and unwanted particles and tufts of fibrous material containing fibers and unwanted particles in said aeration chamber, said air stream moving in generally angular relationship to the walls of said aeration chamber so as to create a high turbulent air suspension of said fibrous material, means imparting an upwardly directed force to said air stream so that said fibrous material will.
  • a separation section in said duct means said separation section having substantially greater cross-sectional area than the other sections of said duct means for reducing the velocity of the air flow therethrough to cause said unwanted particles and said tufts of fibrous material to be separated from the fibers of said fibrous material and to settle back into said aeration chamber to be deposited on said foraminous member as said fibers move through said duct means to said felting zone, means adjacent said foraminous member for agitating said tufts of said fibrous material to separate said tufts of fibrous material into fibers and unwanted particles, said agitating means transferring said fibers to said air stream to be carried to and through said separation section to said felting zone, said agitating means maintaining said foraminous member clean so that said unwanted particles may be passed therethrough to be collected, and means for felting said fibers in said felting zone.
  • said agitating means comprises a plurality of air jets positioned in said aeration chamber and provided with nozzles for directing blasts of air generally in a direction substantially parallel to the plane of said foraminous member and in close proximity thereto, means for rotating said air jets, and means for supplying compressed air thereto.
  • Apparatus as defined in claim 9 wherein said jets have a plurality of outlet passages for simultaneously directing air blasts in different directions.

Description

May 19, 1964 Filed May 4, 1961 T. R. PROCESS AND APPARAT AND FELTIN N 2 Sheets-Sheet 1 INVENTORS T M/W510. 60010 arm BY C/MKLAS'SD. SIM/7596' ATTORNEY y 1954 T. R. GOULD ETAL 3,133,319
PROCESS AND APPARATUS FOR CLEANING, SEPARATING AND FELTING FIBROUS MATERIALS 2 Sheets-Sheet 2 Filed May 4, 1961 INVENTOR MOM/45? 60010 and BY amusa .s/Mvses E; ATTORNEY United States Patent York Filed May 4, 1961, Ser. No. 107,788 Claims. (Cl. 19205) This invention relates to process and apparatus for opening, cleaning and felting fibrous materials. Although particularly directed to the opening and cleaning of a fibrous material containing fibers and unwanted particles and tufts of fibrous material and unwanted particles, such as mineral wool, the invention also may be effectively utilized to separate any fibrous material containing relatively lighter material and heavier unwanted particles.
Mineral wool being composed of relatively brittle vit reous fibers cannot be satisfactorily processed in the usual textile fiber opening equipment, for opening up the tufts or clumps of fiber and separating the unwanted particles, commonly identified as shot, and other unfiberized particles from the fiber. There is too great a loss of fiber and the cleaned fiber is reduced to an undesirably short length when processed in such equipment.
By the use of the process and apparatus of the present invention the mineral wool, largely in the form of clumps or tufts with adhering unfiberized glass-like particles, generally referred to as shot, is subjected to aeration by small blasts of air, sufficient to open up the bundles of fiber and separate most of the shot from the fibers, but insuificient to destroy the fibers or unduly reduce their length.
It is a primary object of this invention to provide process and apparatus for the cleaning, separating, and felting of a fibrous material to eliminate or greatly reduce the unwanted particles present in the fibrous material.
It is a further object of this invention to provide process and apparatus for the separating of opened and cleaned fibers from unopened tufts thereof.
The foregoing objects are attained by the process and apparatus of the instant invention, wherein the fibrous material to be cleaned, separated and felted is subjected generally to turbulent air suspensions to accomplish the cleaning and separating action. The apparatus of the instant invention comprises an aeration chamber having side walls and an enclosed base with a foraminous member extending generally transversely of the chamber adjacent one end thereof. A duct adjacent the other end of the aeration chamber connects the aeration chamber to a felting zone and comprises a separation section having a substantially greater cross-sectional area than the other sections of the duct means for reducing the velocity of the air flow therethrough. The fibrous material to be cleaned, separated and felted is introduced into said aeration chamber between said foraminous member and said duct means. At least one air stream moving in generally angular relationship to the Walls of said aeration chamber is introduced into said aeration chamber so as to create a highly turbulent air suspension of said fibrous material. Means are provided in said felting zone to cause a flow of volume air from said aeration chamber through said duct means and said separating section to said felting zone so that said fibrous material containing fibers and unwanted particles and tufts of fibrous material and unwanted particles intermixed therewith tends to flow with said volume air toward said felting zone. In the separating section, the velocity of the air flow therethrough is reduced to cause the unwanted 3,133,319 Patented May 19, 1964 particles and tufts of fibrous materials and unwanted particles to be separated from the opened and cleaned fibers of said fibrous material so that the unwanted particles and tufts of fibrous materials and unwanted particles settle back into the air chamber to be deposited on the foraminous member therein while the opened and cleaned fibers flow With said volume air to said felting zone. Means are provided adjacent said foraminous material for agitating said tufts of said fibrous materials to separate said tufts into fibers and unwanted particles with the agitating means providing sufficient impetus to the cleaned fibers to introduce these fibers to said air stream to be carried to and through said separating section to said felting zone.
The invention will be more fully understood and furtherobjects and advantages thereof will become apparent when reference is made to the following detailed description of a preferred embodiment of the invention and the accompanying drawings in which:
FIG. 1 is a side elevational view, parts being broken away, illustrating the aeration chamber for opening and cleaning the fibers, the enlarged separation section, the transfer horn and felting tower;
FIGS. 2 and 3 are horizontal sectional views on the lines 2-2 and 3-3, respectively, of FIG. 1, looking in the direction of the arrows;
FIG. 4 is an elevational view of the devices for feeding the raw, uncleaned mineral wool to a transport conduit;
FIG. 5 is a vertical sectional view therethrough, on the line 55 of FIG. 4;
FIG. 6 is an elevational view of the fiber feeding devices, on a reduced scale, showing the relation of these devices to the blower supplying transporting air;
FIG. 7 is a fragmentary view illustrating a modified form of air jet which may be employed adjacent the supporting screen in the aeration chamber; and
FIG. 8 is a vertical sectional view illustrating a modification of the fiber feeding devices.
Referring to the details of the drawing, the form of the invention illustrated in FIGS. 1 to 6 comprises an aeration chamber 10, a duct 11 thereabove, formed with an enlarged separation section 12 and a transfer horn 14, leading to the upper section 15 of a felting tower 16. The duct 11 serves for guiding the cleaned air-borne fiber from the aeration chamber to the felting tower and is especially formed to perform an important function in connection with the fiber opening and cleaning operation, as described below. The equipment is designed for processing a large volume of mineral wool, in a continuous operation, there being sufficient capacity to accommodate the output of a standard mineral wool cupola and fiberizing equipment, for example, 2,000 pounds to 3,000 pounds or more of raw or uncleaned mineral wool per hour. However, it has been found equally effective in smaller sizes, processing a few hundred pounds of mineral wool'per hour.
The felting tower 16 may be of any preferred type or size, capable of handling the quantity of cleaned fiber supplied. Thus the tower includes an upper section 15 motor 38. The conveyor is of the open meshscreen or plate type permitting the air and suspended fibers to be drawn downwardly through the felting chamber and onto the upper reach of the conveyor as the air is evacuated from the suction chamber 40 evacuated by vacuum fan or fans 41. The construction of the vacuum felting equipment is well known in this art. The evacuating fan or fans in the present invention are of greater capacity than the usual vacuum felting fans in that they are effective, at least in part, to elevate fibrous material upwardly from the aeration chamber, through the duct work 11 and then onto the felting conveyor, as appears below.
Although the aeration chamber may be of any crosssectional configuration, the aeration chamber in FIG. 1 is illustrated as being substantially square in cross section, from 6 feet to feet square and approximately 6 feet in height. At a point well above the floor 18 and preferably at a point about 2 feet above the floor and about 4 feet below the top of the chamber there is provided a transverse screen 19, suitably formed of Woven wire cloth, of relative open mesh, for example, from2and /2 x2and /zupto 4and- /2 x4and /z mesh, desirably being approximately 3 and /2 x 3 and /2 mesh. This screen constitutes a floor for the mass of fibrous material but permits shot to pass readily through into the base of the chamber where a suitable disposal system is installed. As shown in FIG. 1 this disposal system is indicated as a pan 21 inserted through a suitable side opening in the base, the pan being periodically removed and emptied. On account of the air currents and pressures in the aeration chamber, described below, it is necessary to maintain the base portion of the aeration chamber, including any access doors for the removal of the heavy particles, sealed during normal operation of the equipment.
The uncleaned mass of fibrous material is introduced into the chamber 10 through the conduit in which the uncleaned mass of fibrous material is suspended in an air stream. This conduit 20 is carefully placed so that the mass of fibrous material carried therein will be distributed around the chamber by the substantially circulatory motion of the suspending air stream. As shown, the conduit 20, which may be of any necessary size, up to 16 inches or more in diameter, enters the chamber 10 near one corner thereof as at 27 and preferably so as to direct said air stream in a direction substantially parallel to the plane of the screen 18. Also, it is preferred that the conduit be directed at an angle of around 65 or 70 from the entering side, to direct the air and mass of fibrous material slightly toward the adjacent side wall directly ahead of the conduit.
It has been found best to provide a second conduit 22 diagonally opposite the conduit 20 and similarly positioned and angled to direct the air stream toward the adjacent side wall of the chamber 10 opposite to the aforesaid adjacent side. The two air streams thus cooperate in building up a substantially circular air flow in the chamber. The conduit 22 should be smaller than conduit 20, for example, one-half to three-fourths the diameter of conduit 20, for the best results. It is not necessary to add a mass of fibrous material with the air stream supplied by conduit 22 although obviously this conduit could be employed as a supplemental source of fibrous material to be processed. The velocities of the incoming air stream through conduits 20 and 22 are preferably maintained substantially equal.
With a large volume of fibrous material being introduced into the chamber 10, and despite the elevating effect of the volume air introduced into the lower portion of chamber 10 through conduits 20 and 22, there is a tendency for the mass of fibrous material to settle down onto the screen, but more troublesome is the tendency of fibrous clumps therein and shot to settle on parts of the screens and to spread and to ultimately cover the entire screen. This difficulty has been overcome in the present construction by providing a plurality of jets 23 for supplying high pressure air blasts at or near the upper surface of the screen, for example, approximately 1 inch above the screen, with the high pressure blasts directed substantially parallel to the plane of the screen. The jets are rotated slowly and continuously so that the fibrous clumps are agitated sufficiently to be caught up by the volume air introduced through conduits 2t) and 22. The air jets, shown as four in number, symmetrically spaced around the chamber 10, may be rotated by any suitable means shown as a belt or chain 24 driven by bevel gears 25, reduction gear box 26 and motor 28.
The tendency for fibrous clumps to settle in the corners and at the edges of the screen is further avoided by placing bafile strips 29 around the perimeter of the screen, angled upwardly and outwardly, preferably about 45 from the screen to the side walls. The baffles extend entirely around the screen, except at the discharge ends of conduits 2t) and 22. The conduits, being directed toward angular baflles of adjacent side walls, assist the air from jets 23 and the volume air from conduits 20 and 22 in elevating any mineral wool tufts collected on the screen adjacent the baffles.
The volume air introduced through conduits 20 and 22 is sufficient, when combined with the effect of the suction fan 41 and the air blasts from the jets, to maintain the mass of fibrous material in the chamber 10 in a state of constant agitation and to lift lighter fibers and fibrous tufts out of the aeration chamber and into the separation zone 12. The term, volume air, is that air passing through the screen 19, separation zone 12 and the duct 14 to the felting tower 16. The lighter, well cleaned fibers pass through the separation chamber 12 and are carried away through the duct 11 to the felting tower while the heavier particles hesitate and are buffeted about so that they either lose some of their adhered heavier particles and are carried to the felting tower or else they drop back toward or into the aeration chamber for further processing. The constant movement of the mass of fibrous material over and around the screen 19 facilitates the discharge of heavier particles, by gravity, through the screen.
It will be noted that separation section 12 has a much larger cross-sectional area than the aeration chamber and that the remainder of the duct leading to the felting tower is considerably reduced in the cross-sectional area. Section 12 may have, for example, from one and one-half to two times the cross-sectional area of the aeration chamber. Thus, for example, if the aeration chamber 10 is 8 feet square, the separation section 12 should be 11 to 16 feet square, desirably 13 and /2 feet square. The transfer horn is of gradually reduced cross-sectional area to provide for increased air speed so that all fiber passing into the horn will be discharged into the felting tower. At the throat or point of introduction into the felting tower the horn may have a cross-sectional area of 2 and /2 feet square or even less for smaller volume of fibers.
The mass of fibrous material containing fibers and unwanted particles and tufts of fibrous material and unwanted particles is fed into the conduit 20 in any way which will not interfere with the air flow through the conduit nor with the operation of the cleaning, separating or felting equipment. There is illustrated in FIGS. 4-6 a method of introducing the mass of fibrous material, which may be preformed and stored fiber or fibrous material directly from the forming equipment, into the conduit 20. The fibrous material is withdrawn at a regulated rate from a fiber supply, as by a suitable picker roll (not shown), and transported on conveyor 42 to the rotary valve 44 mounted on conduit 20. The mass of fibrous material, mainly in the form of fiber with adhering shot-like particles and clumps of fibrous material with shot-like particles intermixed therewith, is discharged into the hopper 45 between the blades 46. The blades are rotated slowly, discharging the mass of fibrous material gradually into the conduit 20, while preventing escape of air pressure through the valve. Compressed air is supplied to the conduit 20 from any suitable source, shown as a centrifugal air compressor 47. The air flow from compressor 47 carries the mass of fibrous material through conduit 20 and projects it into the aeration chamber 10. A similar compressor (not shown) supplies compressed air to conduit 22.
Any usual type mineral wool binder may be employed in the present invention, such as phenolic, resinous or other heat setting or thermoplastic binders. These are well known in the art. The binder is preferably introduced by being added to the mineral wool as it enters the hopper 45, as by means of suitable tubing, not shown, or it may be sprayed over the fibers on the conveyor 42 as shown at 66 in FIG. 8, or it may be added in the felting tower 15.
Instead of processing a mass of fibrous material previously produced and stored, the present process is applicable to processing a newly formed mass of fibrous material as it is removed from the fiberizing zone on a standard conveyor. This construction is illustrated in FIG. 8. The duct 11, with separation section 12 and transfer horn 14, felting tower and vacuum felting equipment shown in FIGS. 1 to 3 are used with the fiber feeding mechanism and aeration chamber of FIG. 8, their function being as hereinabove described.
The aeration chamber is of the same shape and size as in FIG. 1 except that one side wall 48 is broken away just above the transverse screen 1921 to form an opening 50' for receiving the housing 52 for the conveyor 54, carrying the newly formed mass of fibrous material from the vicinity of the fiberizing equipment.
The conveyor 54 is preferably supported at its forward end by a series of rolls, as shown, the forward upper roll being of reduced diameter to facilitate discharge of its burden into the chamber 100. The rearward end may be supported by the usual large roll (not shown). The upper reach of the conveyor, traveling in the direction of the arrow, carries a bed of fibrous material up to the edge of the aeration chamber. At this point, it is picked olf of the conveyor and projected into the aeration chamber by a picker roll 56 rotated at a relatively high rate of speed, for example, around 1,000 r.p.m., to cause the projected mineral wool tufts to be broken up and shot and other unfiberized material to be released from adherence to the fibers. A shield 58 encircling the upper rearward portion of the picker roll maintains the housing 52 separate from the aeration chamber 10a. The shield 58 extends from the top of the opening 50 to a point a short distance above the upper surface of thefibrous material on conveyor 54. In this form of the invention the binder, if desired may be added to the fibrous material by being sprayed onto the wool on the conveyor, as by spray pipe 66. a
It will be understood that volume air can be admitted to the chamber Illa-by providing conduits, such as those shown at 20 and 22. If the conduits 20 and 22 are used in this form of the invention they will preferably be placed in the same position and at the same angles indicated in FIG. 2, and as described above.
The air flow is thus primarily produced in this form of the invention, by the suction created at the vacuum felting equipment, supplemented where required by the volume or type of fibrous material being processed, by air introduced through conduits 20 and/or 22, or blown in through housing 52.
The aeration chamber may have vertical side walls throughout or the base of the chamber, below screen 19a, may have two opposed converging side walls, as shown at 62, to form a trough from which shot and other waste material passing through the screen may be removed. In this case legs 64 are provided to help support the aeration chamber and overlying duct work. The screen 19a, similar to screen 19, extends entirely across the aeration chamber and is formed of open mesh to permit shot and heavy particles to drop downwardly through the screen. The baffle plates 29, shown in FIGS. 1 and 2, are preferably supplied for the three sides of the screen, other than the side in which the fibrous material is introduced. Adjacent and in front of the picker roll 56 there is provided a baffle plate 59 which is relatively flat and serves as an apron to ease the fibrous material into the aeration chamber. It is preferred to provide an air pipe 60, connected with a supply (not shown) of air under pressure, near the upper edge of baffie plate 59, with upwardly directed air jets, to provide a lift to the fibrous material entering the chamber 10a. This will permit the immediate removal of light weight fibers and fiber clumps upwardly from the aeration chamber for separation in the separating section. A guard 61 placed in front of the return bend of the conveyor 54 prevents the fibrous material from being blown against the conveyor.
High pressure, rotatable air jets 2312 are provided, as in the first form of the invention and for the purpose stated above. The air jets shown in FIGS. 7 and 8 comprise double ended jets having opposed rounded nozzles 63 with small discharge passages, one-eighth to one fourth inch in diameter, for each nozzle. The jets are carried by rotatable tubes extending upwardly through the screen, the tubes being rotated and supplied with compressed air as in the first form of the invention. The rounded configuration shown in FIGS. 7 and 8 is for the purpose of preventing the nozzles from picking up and winding the deposited fibrous material about the jets. With double ended jets as shown they may be rotated more slowly, thereby further avoiding entanglement with the fibrous material.
It has been found desirable although not essential to supply a small quantity of lubricant to the fibers at some point before they enter the aeration chamber. Thus, a small quantity of any standard grade of textile lubricant (0.1% is generally sufiicient) may be sprinkled on the fibers on the conveyor carrying them to the rotary valve 44 of FIG. 5 or on the conveyor 54 of FIG. 8, by means of a spray pipe similar to pipe 66.
The operation of the fiber cleaning, separating and felting apparatus will be clear from the above description. The mass of fibrous material containing fiber and unwanted particles and tufts of fibrous material and unwanted particles is passed into the aeration chamber by one of the methods shown. The volume air produced by the cooperation of the suction fans at the felting conveyor and the air supplied under pressure through the conduits 20 and 22 flowing from the aeration chamber through the separating section 12 and duct 14 serves to elevate and agitate the mass of fibrous material and to clean the mass of fibrous material so that the unwanted particles become disengaged from the fiber and escape downwardly through the transverse screen in the aeration chamber. The high pressure blasts of air from the rotating jets, directed across the screen, just above the screen, agitate and break up the tufts in the mass of fibrous material to release the fiber and separate therefrom shot and heavier particles. The jet blasts also elevate the fibrous masses sufiiciently so that the lighter fibrous tufts and fibers are caught up by the volume air and lifted into the separation section 12 of the duct. The lighter materials are carried away to the felting zone and the heavier materials fall back into the aeration chamber for further processing.
While the invention has been described in rather full detail, it will be understood that these details need not be strictly adhered to and that various changes and modi fications may suggest themselves to one skilled in the art, all falling within the scope of the invention as defined by the snbjoined claims.
What we claim is:
1. Apparatus for cleaning, separating and felting a fibrous material containing fibers and unwanted particles and tufts of fibrous material and unwanted particles, comprising, an aeration chamber formed with side walls and an enclosed base, a foraminous member extending generally transversely of said chamber, means for suspending said fibrous material in an air stream, means for introducing said air stream containing said fibrous material into said chamber above said screen, said air stream moving in generally angular relationship to the walls of said aeration chamber so as to create a highly turbulent air suspension of said fibrous material, a duct connecting said aeration chamber to a felting zone, means imparting an upwardly directed force to said air stream so that said fibrous material will move through said duct means, a separation section in said duct means, said separation section having substantially greater cross-sectional area than the other sections of said duct means for reducing the velocity of the air flow therethrough to cause said unwanted particles and said tufts of fibrous material to be separated from the fibers of said fibrous material and to settle back into said aeration chamber to be deposited on said foraminous member as said fibers move through said duct means to said felting zone, means adjacent said foraminous member for agitating said tufts of fibrous material to separate said tufts of fibrous materials into fibers and unwanted particles, said agitating means transferring said fibers to said air stream to be carried to and through said separation section to said felting zone, said agitating means maintaining said foraminous member clean so that said unwanted particles may be passed therethrough to be collected, and means for felting said fibers in said felting zone.
2. Apparatus as defined in claim 1 wherein said means for introducing said air stream containing said fibrous material into said aeration chamber comprises at least one conduit, said conduit opening into said chamber adjacent one corner thereof.
3. Apparatus as defined in claim 2 wherein said conduit is positioned to direct said air stream containing said fibrous material toward an adjacent side wall in the interior of said chamber.
4. Apparatus as defined in claim 3 and further comprising at least a second conduit opening into said aeration chamber for supplying an additional air stream, said second conduit being positioned to direct air toward another adjacent side wall within said chamber other than the first named adjacent side wall, and means for providing an air flow through said supplemental air conduit.
5. Apparatus as defined in claim 1 and further comprising angularly disposed baffies extending around the outer portion of the interior of said aeration chamber and angled inwardly and downwardly from the side walls of said chamber to said foraminous member.
6. Apparatus as defined in claim 5 wherein said agitating means comprises a plurality of air jets positioned in said aeration chamber and provided with nozzles for direoting blasts of air generally in a direction substantially parallel to the plane of said foraminous member and in close proximity thereto, means for rotating said air jets, and means for supplying compressed air thereto.
7. Apparatus as defined in claim 6 wherein said jets have a plurality of outlet passages for simultaneously directing air blasts in different directions.
8; Apparatus for cleaning, separating and felting a fibrous material containing fibers and unwanted particles and tufts of fibrous material containing fibers and unwanted particles, comprising, an aeration chamber formed with side walls and an enclosed base, a foraminous member extending generally transversely of said chamber, a duct connecting said aeration chamber to a felting zone, means for introducing an air stream into said aeration chamber between said screen and said duct means, means for introducing a fibrous material containing fibers and unwanted particles and tufts of fibrous material containing fibers and unwanted particles in said aeration chamber, said air stream moving in generally angular relationship to the walls of said aeration chamber so as to create a high turbulent air suspension of said fibrous material, means imparting an upwardly directed force to said air stream so that said fibrous material will. move through said duct means, a separation section in said duct means, said separation section having substantially greater cross-sectional area than the other sections of said duct means for reducing the velocity of the air flow therethrough to cause said unwanted particles and said tufts of fibrous material to be separated from the fibers of said fibrous material and to settle back into said aeration chamber to be deposited on said foraminous member as said fibers move through said duct means to said felting zone, means adjacent said foraminous member for agitating said tufts of said fibrous material to separate said tufts of fibrous material into fibers and unwanted particles, said agitating means transferring said fibers to said air stream to be carried to and through said separation section to said felting zone, said agitating means maintaining said foraminous member clean so that said unwanted particles may be passed therethrough to be collected, and means for felting said fibers in said felting zone.
9. Apparatus as defined in claim 8 wherein said agitating means comprises a plurality of air jets positioned in said aeration chamber and provided with nozzles for directing blasts of air generally in a direction substantially parallel to the plane of said foraminous member and in close proximity thereto, means for rotating said air jets, and means for supplying compressed air thereto.
10. Apparatus as defined in claim 9 wherein said jets have a plurality of outlet passages for simultaneously directing air blasts in different directions.
References Cited in the file of this patent UNITED STATES PATENTS 23,903 Crist May 10, 1859 2,362,965 Berkman Nov. 21, 1944 2,450,511 Harner et al. Oct. 5, 1948 2,697,439 Davis Dec. 21, 1954 2,833,412 Ahlmann May 6, 1958 2,874,840 Simpson Feb. 24, 1959 2,968,069 Powell Jan. 17, 1961

Claims (1)

1. APPARATUS FOR CLEANING, SEPARATING AND FELTING A FIBROUS MATERIAL CONTAINING FIBERS AND UNWANTED PARTICLES AND TUFTS OF FIBROUS MATERIAL AND UNWANTED PARTICLES, COMPRISING, AN AERATION CHAMBER FORMED WITH SIDE WALLS AND AN ENCLOSED BASE, A FORAMINOUS MEMBER EXTENDING GENERALLY TRANSVERSELY OF SAID CHAMBER, MEANS FOR SUSPENDING SAID FIBROUS MATERIAL IN AN AIR STREAM, MEANS FOR INTRODUCING SAID AIR STREAM CONTAINING SAID FIBROUS MATERIAL INTO SAID CHAMBER ABOVE SAID SCREEN, SAID AIR STREAM MOVING IN GENERALLY ANGULAR RELATIONSHIP TO THE WALLS OF SAID AERATION CHAMBER SO AS TO CREATE A HIGHLY TURBULENT AIR SUSPENSION OF SAID FIBROUS MATERIAL, A DUCT CONNECTING SAID AERATION CHAMBER TO A FELTING ZONE, MEANS IMPARTING AN UPWARDLY DIRECTED FORCE TO SAID AIR STREAM SO THAT SAID FIBROUS MATERIAL WILL MOVE THROUGH SAID DUCT MEANS, A SEPARATION SECTION IN SAID DUCT MEANS, SAID SEPARATION SECTION HAVING SUBSTANTIALLY GREATER CROSS-SECTIONAL AREA THAN THE OTHER SECTIONS OF SAID DUCT MEANS FOR REDUCING THE VELOCITY OF THE AIR FLOW THERETHROUGH TO CAUSE SAID UNWANTED PARTICLES AND SAID TUFTS OF FIBROUS MATERIAL TO BE SEPARATED FROM THE FIBERS OF SAID FIBROUS MATERIAL AND TO SETTLE BACK INTO SAID AERATION CHAMBER TO BE DEPOSITED ON SAID FORAMINOUS MEMBER AS SAID FIBERS MOVE THROUGH SAID DUCT MEANS TO SAID FELTING ZONE, MEANS ADJACENT SAID FORAMINOUS MEMBER FOR AGITATING SAID TUFTS OF FIBROUS
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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2603907A1 (en) * 1986-09-13 1988-03-18 Hollingsworth Gmbh DEVICE FOR SEPARATING A FIBER-LIKE MATERIAL FROM AN AIRFLOW
US20120181361A1 (en) * 2011-01-13 2012-07-19 Frank Levy System and method for separating carpet fibers
EP2670902B1 (en) 2011-01-31 2016-08-17 Rockwool International A/S Method and apparatus for removing shot from mineral fibre material

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US23903A (en) * 1859-05-10 Grain-separator
US2362965A (en) * 1942-05-15 1944-11-21 Milkweed Products Dev Corp Method of ginning milkweed
US2450511A (en) * 1945-01-24 1948-10-05 Eagle Picher Co Apparatus for diverting mineral wool from blow rooms
US2697439A (en) * 1951-07-06 1954-12-21 American Machine Dev Corp Tobacco separating and tearing apparatus
US2833412A (en) * 1954-07-28 1958-05-06 Smidth & Co As F L Method and apparatus for screening
US2874840A (en) * 1954-09-24 1959-02-24 Columbian General Blacks Ltd Methods of separating or classifying materials
US2968069A (en) * 1956-01-30 1961-01-17 Johns Manville Method and apparatus for cleaning and felting fibrous material

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Publication number Priority date Publication date Assignee Title
US23903A (en) * 1859-05-10 Grain-separator
US2362965A (en) * 1942-05-15 1944-11-21 Milkweed Products Dev Corp Method of ginning milkweed
US2450511A (en) * 1945-01-24 1948-10-05 Eagle Picher Co Apparatus for diverting mineral wool from blow rooms
US2697439A (en) * 1951-07-06 1954-12-21 American Machine Dev Corp Tobacco separating and tearing apparatus
US2833412A (en) * 1954-07-28 1958-05-06 Smidth & Co As F L Method and apparatus for screening
US2874840A (en) * 1954-09-24 1959-02-24 Columbian General Blacks Ltd Methods of separating or classifying materials
US2968069A (en) * 1956-01-30 1961-01-17 Johns Manville Method and apparatus for cleaning and felting fibrous material

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2603907A1 (en) * 1986-09-13 1988-03-18 Hollingsworth Gmbh DEVICE FOR SEPARATING A FIBER-LIKE MATERIAL FROM AN AIRFLOW
US20120181361A1 (en) * 2011-01-13 2012-07-19 Frank Levy System and method for separating carpet fibers
US8870104B2 (en) * 2011-01-13 2014-10-28 Frank Levy Method for separating carpet fibers
EP2670902B1 (en) 2011-01-31 2016-08-17 Rockwool International A/S Method and apparatus for removing shot from mineral fibre material
EP2670902B2 (en) 2011-01-31 2019-12-18 Rockwool International A/S Method for removing shot from mineral fibre material

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