US3549738A - Method for producing fibrous products having integral tongue and groove edges - Google Patents

Method for producing fibrous products having integral tongue and groove edges Download PDF

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Publication number
US3549738A
US3549738A US763655A US3549738DA US3549738A US 3549738 A US3549738 A US 3549738A US 763655 A US763655 A US 763655A US 3549738D A US3549738D A US 3549738DA US 3549738 A US3549738 A US 3549738A
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United States
Prior art keywords
binder
fibers
groove
tongue
density
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Expired - Lifetime
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US763655A
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English (en)
Inventor
Richard Lloyd Troyer
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Johns Manville Corp
Johns Manville
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Johns Manville
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    • 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
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/0044—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for shaping edges or extremities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/08—Moulding or pressing
    • B27N3/18—Auxiliary operations, e.g. preheating, humidifying, cutting-off
    • B27N3/183—Forming the mat-edges, e.g. by cutting
    • 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
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/248—Moulding mineral fibres or particles bonded with resin, e.g. for insulating or roofing board
    • B29C67/249—Moulding mineral fibres or particles bonded with resin, e.g. for insulating or roofing board for making articles of indefinite length
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
    • B29K2309/08—Glass

Definitions

  • ABSTRACT OF THE DISCLOSURE Method of consolidating, shaping and fixing the consolidated density and shape of a body of loose mass of fibers containing binders throughout to produce products of fixed configuration and density, which includes the concerted forming of integral tongue and/ or groove longitudinal edges for effective complementary uniting of components with a like adjacent component, and the resulting tongue and/ or groove fibrous product.
  • This invention relates to the manufacture of bonded fibrous products, and in particular to the forming and curing of loose mases of fibrous material, containing throughout thermally activable binder material, into coherent, permanently shaped, semi-rigid but resilient and flexible, or rigid fibrous products, typically of low density structures but of substantially increased densities and integrity over the initial loose mass of fibrous material.
  • While this invention is primarily concerned with the manufacture of products from glass fibers, the means thereof are also applicable to the formation of products from fibrous materials of other compositions for sources of a substantially stiff and resilient nature including common inorganic fibers such as rock, mineral, or slag wools and related siliceous fibers, and even organic fibers exhibiting sufficiently stiff resilient characteristics such as relatively coarse wood fibers.
  • common inorganic fibers such as rock, mineral, or slag wools and related siliceous fibers
  • organic fibers exhibiting sufficiently stiff resilient characteristics such as relatively coarse wood fibers.
  • the low density products of this invention are primarily designed for use in thermal insulation applications, the method is amenable to the manufacture of panels, tiles, sections, etc., for other or combined utilities such as decorative wall or ceiling construction units alone or of composite functions providing effective thermal and/ or sound insulations.
  • Typical means of forming conventional tongue and groove edges comprise cutting away or routing out of material with saws, knives, or other blade devices to effect this conventional joint substantially similar to the forming of tongue and grooved lumber.
  • the removal of substantial amounts of the material mass along the more vulnerable edges to form either a conventional tongue or groove structure further extensively weakens the already fragible edge portions.
  • This invention comprises a combination of sequential steps or forming operations, and a combination of means for carrying out the same, which enables the effective manufacture on an economical continuous basis of relatively low density, semi-rigid but flexible, or rigid shapes of permanently bonded fibrous products having integrally formed therein typical tongue and/or grooved edges of increased density and in turn strength and durability.
  • the invention constitutes a continuous method of forming low density fibrous products such as insulation sections or wall and ceiling finishing panels by consolidating and shaping a body of a loose mass of fibers containing binder and fixing the consolidation or density and shape imparted thereto by curing the binder while substantially simultaneously therewith or during the foregoing continuous operation additionally forrning typical tongue and/ or groove structures continuing along one or both longitudinal edges of the product.
  • FIG. 1 is a schematic side view illustrating the steps and means thereof of this invention for producing fibrous products having integral tongue and/or groove edges;
  • FIG. 2 is a schematic top View of the procedure and means of FIG. 1, further illustrating the steps and arrangement of means of the invention
  • FIG. 3 is an end view of the heated press taken on a plane along line 33 of FIGS. 1 and 2, looking into the entrance of the heated press and showing the tongue and groove forming mold units; and,
  • FIG. 4 is a perspective view of a typical low density 3 product of this invention illustrating the integrally molded tongue and groove longitudinal edges.
  • a semi-rigid but resilient and flexible, or rigid, relatively low density, bonded fibrous product suitable for thermal or sound insulation utility, or for panel or tile finishing application is formed by continuously passing a moving body of loose mass of fiber containing binder throughout, through compressing and heating means comprising a cooperating pair of spaced-apart opposing, smooth surface, heated platens which compress and form the two major surfaces of the body of loose mass of fiber to the approximate shape or thickness and density of the designed final product while heating the compressed and/or shaped mass sufficiently to set the binder content therein and permanently fix the imparted consolidation or density, thickness and shape.
  • the invention additionally constitutes in combination with the foregoing continuous operation of forming by consolidation and shaping and thus securing the binder to fix the consolidated density and shape, and substantially simultaneous therewith, the forming of integral tongue or groove longitudinal edges extending the length of the continuously formed product.
  • FIG. 1 a manufacturing operation and means therefor for the production of semi-rigid, relatively low density insulating board, or the like products, from glass or other equivalent stifily resilient fibers and thermally activatable binder, having a generally rectangular transverse cross-sectional configuration from a body of loose, random intermingled mass of fibrous material containing the binder throughout.
  • body of a loose mass or bed of binder containing fibrous material such as common glass fibers produced as disclosed in US. Letters Pat. No. 3,129,084 to Labino, is carried by conveyor 11, or any appropriate transporting means, and continuously fed to the compressing, shaping and thermal setting means 12.
  • An integral groove is formed in one side of the product between its major surfaces by cutting a marginal slit 13 in one longitudinal edge of the moving body 10 of loose mass of fibers with a revolving circular knife 14, or other equivalent means such as a revolving saw or reciprocating knife or saw, extending along the length thereof and generally intermediate and parallel to the two major surfaces of the moving body 10.
  • the depth of the cut forming the marginal slit is such as to exceed the designed depth of the final groove.
  • the cut surfaces of the slit be heated to a temperature sufiicient to substantially activate the binder in the immediate area and set the same to prevent fibrous material from tearing loose and breaking away during subsequent forming and curing operations, and thereby fouling or clogging the mold, disrupting the operation and/ or the consistency of the product leaving voids or areas of under density.
  • This expedient preliminary precuring of the cut surfaces of the marginal slit can be achieved by means of an appropriate heated plate 15, inserted into position within the slit 13, cut into the moving body 10 by revolving knife 14 whereby the cut surface of the slit comes into passing contact with the heated plate as the body moves to the compressing, shaping and thermal setting means 12.
  • the body of loose mass of binder containing fibers enters the compacting, shaping, thermal setting means 12, comprising a pair of heated opposed platens 16 and 17, each having tapered portions 18 and 19, respectively, providing an entrance thereto and facilitating compression of the loose mass of unbonded fibers.
  • the heated opposing platens 16 and 17 each comprise a broad surface of substantially fiat plane and 21, respectively, of suflicient area or length in relation to forming speed and product thickness to enable adequate heating through the low density body 10 of loose fibers containing binder to substantially complete the cure of the thermally activatable binder at least to the point of permanently fixing the imposed shape and density, and of such width as to accommodate the fiber mass and form the product dimensions.
  • Each platen 16 and 17 is provided with suitable heating means, not shown, such as electrical resistance heaters, induction coils, or internal steam conduits or other appropriate sources to produce adequate heat to effect the thermal activation and curing of the binder.
  • the two major surfaces of the fibrous body 10 are compressed upon entering the gradually tapered sections 18 and 19 of the spaced-apart, generally parallel opposing heating platens 16 and 17, respectively, to approximately the ultimate thickness and shape and density of the desired product, which, of course, is governed by the distance spaced between the substantially parallel platens 16 and 17. While thus compressed and conformed to shape, the moving body is permanently fixed to the imparted shape and density by the substantially simultaneous application of heat which thermally activates and sets the heat curable binder.
  • a mold form 22 in combination with the means 12, is positioned generally intermediate the platens 16 and 17, and so as to penetrate the slit 13 cut in the margin of the body 10 to an extent at least to the depth of the desired edge groove in the ultimate product, and of a thickness to expand the slit 13 to the width of the groove of the desired ultimate product.
  • the mold 22 is interposed within the marginal portion of the moving body 10 of fiber for a length preferably substantially corresponding to the length of the generally parallel section of platens 16 and 17, and at least for a duration sufiicient for the curing of the binder of the fibers to permanently fix the edge groove.
  • mold form 22 may be independently heated to facilitate activation of the cure.
  • the heating of the mold form 22 is not usually necessary since the heat transmitted from platens 16 and 17 normally more readily penetrates the reduced portions of the body forming the walls of the groove.
  • the opposite longitudinal edge of the body 10 of loose binder containing fiber is correspondingly provided with a complementary edged tongue with a forming mold which may be provided by continuing the sloped tapered sections 18 and 19 of platens 16 and 17, respectively, in a limited marginal area of these platens extending inwardly at least equivalent to the length of the tongue of the designed product and such as to effectively mate with the corresponding groove.
  • the marginal continuations of platens 16 and 17 continue to approach each other to the point of providing secondary or minor spaced-apart platen mold surfaces 23 and 24, spaced a distance from each other, generally intermediate surfaces 20 and 21, approximately equivalent to the width of the tongue of the designed products and such as to effectively mate with the corresponding grooves.
  • the tongueforming mold surfaces can be constructed of separate or a unitary cooperating pair of opposing mold faces, which are mechanically combined with primary consolidating, shaping, and heating platens 16 and 17.
  • products of this invention may be produced with both longitudinal edges each having a grooved marginal area as shown 25 or with both edges each provided with a tongue as shown in 26 to cooperate with independent appropriately corresponding mounting frames or means.
  • This invention is particularly directed to the manufacture of insulating products from resin binder containing fibrous materials compirsing a loose random mass of glass fibers having densities of up to about pounds per cubic foot but typically less than about 1 or 2 pounds per cubic foot, and containing dispersed throughout between about 3 and of resinous binder material such as a thermosetting resin of the phenol formaldehyde type, although the means of the invention are also applicable with the use of thermoplastic or other thermally activatable binders.
  • resinous binder material such as a thermosetting resin of the phenol formaldehyde type
  • a vapor barrier comprising metal foil or plastic sheet, etc.
  • the insulation section when joined with like abutting units, forms a continuous vapor barrier with the cooperating tongue and groove joints conveniently forming a seal between the sections.
  • the tongue 26 and cooperating groove 25 should be correspondingly tapered to enable a force fit which is easily achieved with the resilient compressible materials of this invention.
  • Method of forming permanently shaped and bonded low density fibrous products of generally rectangular transverse cross-sectional configuration having two major surfaces and two opposite longitudinal edges extending the length thereof with integral tongue and groove formed therein, comprising:
  • Method of forming permanently shaped and bonded low density fibrous products of' generally rectangular transverse cross-sectional configurations having two major surfaces and two opposing longitudinal edges extending the length thereof with integral tongue and groove formed therein; comprising:
  • the moving body of loose mass of fibers containing binders throughout comprises mineral fibers with between about 3 to 25% by weight thereof of resin binder material in a density of less than about 10 pounds per cubic foot and which is consolidated to a shaped product of a density of about 0.5 to 20 pounds per cubic foot.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Composite Materials (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Forests & Forestry (AREA)
  • Nonwoven Fabrics (AREA)
  • Moulding By Coating Moulds (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
  • Producing Shaped Articles From Materials (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
US763655A 1968-09-30 1968-09-30 Method for producing fibrous products having integral tongue and groove edges Expired - Lifetime US3549738A (en)

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US76365568A 1968-09-30 1968-09-30

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US (1) US3549738A (enrdf_load_stackoverflow)
JP (1) JPS4926102B1 (enrdf_load_stackoverflow)
BR (1) BR6912813D0 (enrdf_load_stackoverflow)
CA (1) CA939466A (enrdf_load_stackoverflow)
DE (1) DE1949652A1 (enrdf_load_stackoverflow)
FR (1) FR2019246A1 (enrdf_load_stackoverflow)
GB (1) GB1260175A (enrdf_load_stackoverflow)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4115498A (en) * 1976-02-27 1978-09-19 Owens-Corning Fiberglas Corporation Method and apparatus for molding articles from fibrous material
US4589832A (en) * 1985-02-26 1986-05-20 Thetford International Products, Ltd. Briquette making machine
US5486401A (en) * 1994-05-09 1996-01-23 Owens-Corning Fiberglas Technology, Inc. Insulation assembly and method of making
WO2002099213A1 (de) 2001-06-02 2002-12-12 Deutsche Rockwool Mineralwoll Gmbh & Co. Ohg Verfahren zur herstellung von dachdämmplatten, dachdämmplatten und vorrichtung zur durchführung des verfahrens
US20030099812A1 (en) * 2001-11-28 2003-05-29 Vaders Dennis H. Method of manufacturing contoured consolidated cellulosic panels with variable basis weight
US20030098117A1 (en) * 2001-11-28 2003-05-29 Vaders Dennis H. Method of manufacturing consolidated cellulosic panels with contoured surfaces and variable basis weight
CN108340526A (zh) * 2017-01-23 2018-07-31 上海联净复合材料技术有限公司 模块化发泡板的加工系统及方法
CN114250094A (zh) * 2022-01-02 2022-03-29 罗利芳 一种生物质燃料制备装置

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4038356A (en) * 1976-04-14 1977-07-26 Johns-Manville Corporation Method and apparatus for making a fibrous board-like product having a male edge and a female edge
GB2148779B (en) * 1982-11-25 1986-09-24 Thetford Int Prod Briquette making machine
DE9314391U1 (de) * 1993-09-23 1993-12-09 Heidelberger Dämmsysteme GmbH, 69115 Heidelberg Mehrlagige Dämmplatte
DE4417970C2 (de) * 1994-05-21 1996-12-12 Odenwald Faserplatten Deckenelement und damit hergestellte Zwischendecke

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2165280A (en) * 1936-06-03 1939-07-11 Owens Corning Fiberglass Corp Method and apparatus for forming a fibrous mat
US2527628A (en) * 1944-09-16 1950-10-31 American Viscose Corp Process for producing a matrix containing particulate fillers
US2854230A (en) * 1955-10-31 1958-09-30 Vibradamp Corp Glass fiber spring unit and method of making same
US2938566A (en) * 1956-04-26 1960-05-31 Ohio Commw Eng Co Apparatus for forming solid structural members of glass fiber reinforced resin
US3071805A (en) * 1958-12-29 1963-01-08 Allwood Inc Method and means for producing wood-composition panels

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2165280A (en) * 1936-06-03 1939-07-11 Owens Corning Fiberglass Corp Method and apparatus for forming a fibrous mat
US2527628A (en) * 1944-09-16 1950-10-31 American Viscose Corp Process for producing a matrix containing particulate fillers
US2854230A (en) * 1955-10-31 1958-09-30 Vibradamp Corp Glass fiber spring unit and method of making same
US2938566A (en) * 1956-04-26 1960-05-31 Ohio Commw Eng Co Apparatus for forming solid structural members of glass fiber reinforced resin
US3071805A (en) * 1958-12-29 1963-01-08 Allwood Inc Method and means for producing wood-composition panels

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4115498A (en) * 1976-02-27 1978-09-19 Owens-Corning Fiberglas Corporation Method and apparatus for molding articles from fibrous material
US4589832A (en) * 1985-02-26 1986-05-20 Thetford International Products, Ltd. Briquette making machine
US5486401A (en) * 1994-05-09 1996-01-23 Owens-Corning Fiberglas Technology, Inc. Insulation assembly and method of making
US5578258A (en) * 1994-05-09 1996-11-26 Owens Corning Fiberglas Technology, Inc. Method of making an insulation assembly
WO2002099213A1 (de) 2001-06-02 2002-12-12 Deutsche Rockwool Mineralwoll Gmbh & Co. Ohg Verfahren zur herstellung von dachdämmplatten, dachdämmplatten und vorrichtung zur durchführung des verfahrens
US20030099812A1 (en) * 2001-11-28 2003-05-29 Vaders Dennis H. Method of manufacturing contoured consolidated cellulosic panels with variable basis weight
US20030098117A1 (en) * 2001-11-28 2003-05-29 Vaders Dennis H. Method of manufacturing consolidated cellulosic panels with contoured surfaces and variable basis weight
US6743318B2 (en) 2001-11-28 2004-06-01 Masonite Corporation Method of manufacturing consolidated cellulosic panels with contoured surfaces and variable basis weight
US20040213987A1 (en) * 2001-11-28 2004-10-28 Vaders Dennis H. Method of manufacturing consolidated cellulosic panels with contoured surfaces and variable basis weight
US6866740B2 (en) 2001-11-28 2005-03-15 Masonite Corporation Method of manufacturing contoured consolidated cellulosic panels with variable basis weight
US20050140043A1 (en) * 2001-11-28 2005-06-30 Masonite Corporation Method of manufacturing contoured consolidated cellulosic panels with variable basis weight
US7096916B2 (en) 2001-11-28 2006-08-29 Masonite Corporation Method of manufacturing consolidated cellulosic panels with contoured surfaces and variable basis weight
US7314585B2 (en) 2001-11-28 2008-01-01 Masonite Corporation Method of manufacturing contoured consolidated cellulosic panels with variable basis weight
CN108340526A (zh) * 2017-01-23 2018-07-31 上海联净复合材料技术有限公司 模块化发泡板的加工系统及方法
CN114250094A (zh) * 2022-01-02 2022-03-29 罗利芳 一种生物质燃料制备装置
CN114250094B (zh) * 2022-01-02 2024-05-28 罗利芳 一种生物质燃料制备装置

Also Published As

Publication number Publication date
DE1949652A1 (de) 1970-04-09
CA939466A (en) 1974-01-08
BR6912813D0 (pt) 1973-06-05
FR2019246A1 (enrdf_load_stackoverflow) 1970-06-26
JPS4926102B1 (enrdf_load_stackoverflow) 1974-07-05
GB1260175A (en) 1972-01-12

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