US3865566A

US3865566A - Method and apparatus for producing and collecting fibers

Info

Publication number: US3865566A
Application number: US425592A
Authority: US
Inventors: Dale Kleist
Original assignee: Owens Corning Fiberglas Corp
Current assignee: Owens Corning
Priority date: 1972-03-21
Filing date: 1973-12-17
Publication date: 1975-02-11
Anticipated expiration: 1992-02-11
Also published as: GB1397025A; NL7303155A; LU67250A1; DE2313376A1; FR2176935B1; CA991409A; FR2176935A1; BE797045A

Abstract

The disclosure embraces a method of and apparatus for producing fibers from heat-softenable materials by centrifuging streams of heat-softened material, such as glass, delivered from one or more centrifuging devices or spinners disposed for rotation about an axis or axes disposed at an acute angle with respect to a horizontal plane, engaging the centrifuged streams by annular high velocity gaseous blasts for attenuating the centrifuged streams to discrete fibers, collecting the fibers, and controlling the distribution of the fibers to attain a desired orientation of the fibers as they are collected.

Description

United States Patent Kleist Feb. 11, 1975 [5 METHOD AND APPARATUS FOR 3,265,477 8/1966 PRODUCING AND COLLECTING FIBERS 3,372,011 3/1968 3,372,0l3 3/1968 [75] Inventor: Dale Kleist, Saint Louisville, Ohio 3. 7 310 972 [73] Assignee: Owens-Corning Fiberglas Corporation, Tol d Ohi Primary Examiner-Robert L. Lindsay, Jr. Attorney, Agent, or Firm-Carl G. Staelin; John W. [22] Flled' 1973 Overman; Harry 0. Ernsberger [2]] Appl. N0.: 425,592

Related US. Application Data [57] ABSTRACT [63] Continuation of Ser. No. 236,623, March 2l. l972, The disclosure embraces a method of and apparatus abandoned' for producing fibers from heat-softenable materials by centrifuging streams of heat-softened material. such as [52] US. Cl 65/6, 65/9, 65/l4, glass delivered from one or more centrifuging devices 264/8 425/8 or spinners disposed for rotation about an axis or axes [51] hit. d p at an acute angle with respect to a horizontal Fleld of Search 5, 6, 8, 9,.l4l6, p g gi g the centrifuged Streams annular 264/8 425/8 high velocity gaseous blasts for attenuating the centrifuged streams to discrete fibers. Collecting the fibers, [56] References C'ted and controlling the distribution of the fibers to attain a UNITED STATES PATENTS desired orientation of the fibers as they are collected.

2,317,895 4/1943 Drill 65/9 X 3,250,602 5/1966 Stalego 65/8 14 Clam, 13 Drawmg Flgms PATENTEU FEBI H975 SHEET 1 OF 5 1 METHOD AND APPARATUS FOR PRODUCING AND COLLECTING FIBERS This application is a continuation of my copending application, Ser. No. 236,623, filed Mar. 21, 1972, now abandoned.

The invention relates to a method of and apparatus for producing attenuated fibers from heat-softenable material wherein centrifuged streams of the material are attenuated to fibers by engaging gaseous blasts with the centrifuged streams whereby to direct the attenuated fibers downwardly at an angle of about 45 with respect to a horizontal plane and controlling the distribution of the blast-attenuated fibers whereby the fibers may be collected in a desired pattern of orientation on a collecting surface.

Rotary processes have been used extensively in producing fibers, such as glass fibers, wherein the spinner is usually disposed for rotation about a vertical axis and the streams of glass, centrifuged from the spinner, engaged by a vertically downwardly directed annular gaseous blast for attenuating the centrifuged streams to fibers and the fibers collected upon a moving conveyor wherein the fibers are impinged generally vertically onto the conveyor. In such processes the vertically moving fibers are collected in random disposition in a mass upon the conveyor. The mass of fibers processed into a mat results in a mat having comparatively low parting strength, low tensile strength and a low recovery characteristic. In the use of such rotary processes, difficulties are encountered in endeavoring to control distribution of the fibers impinged vertically onto the collecting conveyor and hence there is a tendency for the density of the fibers in the central region of the col lected mass to be higher than the density at the edge regions of the mass.

Another method that has been used in forming fibers from heat-softenable material, such as glass, involves attenuating primary filaments from streams of heatsoftened glass and feeding the primary filaments into horizontally directed attenuating blasts of intensely-hot high-velocity gases of combustion from combustion burners and collecting the blast-attenuated fibers upon a substantially horizontal conveyor or collecting surface. One form of this method of fiber attenuation and collection is disclosed in Stalego et al. U.S. Pat. No 3,002,224. The fibers attenuated by the burner-blast method and collected on a horizontal surface and processed into a mat provide a mat having good parting strength and tensile strength characteristics. However, the throughput of glass in the latter method, that is, the number of primary filaments which can be attenuated to fibers by a single burner blast is limited and, by reason of reheating the primary filaments by a blast of intensely hot gases of combustion, the production of fibers by such process involves high cost particularly because of the heat energy required to reheat the cooled primary filaments to an attenuating temperature.

The present invention embraces a method of and apparatus for forming fibers of heat-softened material, such as glass, by a rotary process wherein the attenuated fibers are directed downwardly at an angleof about 45 with respect to a horizontal plane and onto a fiber-collecting surface in a manner wherein distribution of the fibers on the collecting surface may be readily controlled.

Another object of the invention embraces a method of forming fibers of heat-softened material by a rotary process wherein streams of the heat-softened material are delivered from one or more spinners rotating about axes disposed at acute angles with respect to a horizontal plane, the centrifuged streams attenuated to fine fibers by gaseous attenuating blasts disposed to direct the attenuated fibers in directions generally parallel with the axes of rotation of the spinners toward a fiber collecting surface, and the fibers engaged by forces effective with the gases of the blasts to impart a sweeping action to the fibers lengthwise of the collecting surface and to provide controlled distribution of the fibers and small groups of the fibers as they are delivered onto the collecting surface whereby the pattern of deposition of the fibers may be controlled and the collected fibers arranged in generally parallel laminar-like orientation, the method providing a high throughput of fiber forming material with a minimum expenditure of energy whereby the cost of producing a mat of fibers having high strength and other desirable characteristics is greatly reduced. V V V Another object of the invention embraces a method of forming and collecting fibers of heat-softened fiberforming material wherein streams of the material are delivered from one or more spinners rotating about the axes disposed at about 45 to a horizontal plane and the streams attenuated by annular gaseous blasts to long fine fibers and the fibers conveyed by the blasts in directions generally parallel with the axes of rotation of the spinners toward a foraminous conveyor surface, and a subatmospheric or reduced pressure environment established beneath the conveyor surface and the extent of reduced pressure varied and controlled at different zones adjacent the conveyor surface whereby to promote deposition of the fibers on the conveyor surface in generally parallel, laminar-like orientation with a minimum of fiber spread whereby a mat formed of the collected fibers is endowed with high parting strength and tensile strength and having the characteristic of recovery to a high percentage of its original thickness after being compressed for a period of time.

Another object of the invention involves a method of forming fibers of heat-softened material, such as glass, wherein a stream of glass is delivered directly onto a surface of a spinner rotating on an axis disposed at about 45 to a horizontal plane and streams of glass centrifuged from the spinner engaged by an annular gaseous blast and attenuated to fine fibers conveyed generally in directions parallel with the axis of rotation of the spinner toward a moving foraminous conveyor and directing jets of gas or other fluid into engagement with the fibers effective to control lateral distribution of the attenuated fibers as the fibers move toward a collecting conveyor to control the pattern of orientation of the fibers deposited upon the conveyor.

Another object of the invention resides in a method of forming fibers utilizing a plurality of rotary fiber forming units mounted in juxtaposed relation wherein a stream of glass is delivered into a spinner of each fiber forming unit, each spinner rotating on an axis arranged at an acute angle with respect to a horizontal plane, centrifuging streams of the material from each spinner and engaging the centrifuged streams by an annular high velocity gaseous blast adjacent each of the spinners for attenuating the streams to fibers and engaging the attenuated fibers from the units by controlled forces to effect desired distribution of the fibers as they are collected on the conveyor.

Another object of the invention resides in an apparatus for forming fine fibers of glass or other heatsoftened material wherein a stream of molten glass from a supply is flowed directly into contact with a surface of a hollow spinner rotating about an axis disposed at an acute angle with respect to a horizontal plane wherein rotation of the spinner projects the glass through perforations in the spinner wall as fine streams into an annular attenuating gaseous blast for attenuating the streams to fine fibers conveyed by the blast toward a foraminous fiber collecting conveyor, the arrangement having means directing jets of fluid, such as a gas or air, toward the fibers for distributing the fibers on the conveyor.

Another object of the invention resides in an apparatus for forming and collecting fibers attenuated from heat-softenable material wherein a plurality of centrifugal fiber forming units are employed which may be disposed in transverse side-by-side relation or in tandem relation lengthwise of a fiber-collecting conveyor, each unit including a spinner rotating about an axis angularly disposed with respect to a horizontal plane and provided with openings through which streams of the fiberforming material are projected, a blower means being associated with each spinner and arranged to deliver a high velocity annular gaseous blast into engagement with the streams for attenuating the streams to fibers which are conveyed by the annular blasts in directions parallel to the axes of the spinners toward a foraminous fiber collecting surface or conveyor, and the fibers engaged by jets of air or other fluid for controlling the transverse distribution of the fibers on the conveyor, the jets being adjustable for modifying transverse distribution of the fibers to attain a desired pattern or orientation of the fibers on the conveyor.

Further objects and advantages are within the scope of this invention such as relate to the arrangement, operation and function of the related elements of the structure, to various details of construction and to combinations of parts, elements per se, and to economies of manufacture and numerous other features as will be apparent from a consideration of the specification and drawing of a form of the invention, which may be preferred, in which:

FIG. 1 is a side elevational view of an apparatus for forming and collecting fibers according to the method of the invention;

FIG. 2 is a view taken substantially on the line-22 of FIG. 1;

FIG. 3 is a view taken substantially on the line 33 of FIG. 1;

FIG. 4 is a side elevational view of one of the fiberforming units, portions thereof being shown in section;

FIG. 5 is a view similar to FIG. 2 illustrating a group of more than two fiber-forming units;

FIG. 6 is a side elevational view illustrating a modified position of the fiber collecting conveyor with respect to the path of traverse of the fibers from a fiberforming unit;

FIG. 7 is a top plan view illustrating two fiberforming units in side-by-side relation and a regionally controlled reduced pressure environment beneath the fiber collecting conveyor;

FIG. 8 is a side elevational view of the arrangement shown in FIG. 7 illustrating partitions shown in section providing controlled reduced pressure zones or chambers;

FIG. 9 is a transverse sectional view taken substantially on the line 9-9 of FIG. 7;

FIG. 10 is a schematic side elevational view illustrating two rows of fiber-forming units spaced lengthwise in tandem relation;

FIG. 11 is a top plan view of the arrangement shown in FIG. 10 illustrating the two rows of fiber-forming units in lengthwise spaced tandem relation;

FIG. 12 is a schematic elevational view illustrating a row of fiber-forming units in lengthwise spaced tandem relation, and

FIG. 13 is a top plan view illustrating transversely arranged groups of fiber-forming units for producing a fibrous mass or mat of substantial width.

While the method and apparatus of the invention are particularly usable for forming and processing fibers of glass, it is to be understood that the method and apparatus may be used for forming and processing other heat-softenable fiber-forming materials.

Referring to the drawings in detail and initially to FIGS. 1 through 3, there is illustrated a pair or group of fiber-forming instrumentalities or units disposed whereby the fibers are collected on a surface or moving conveyor in combination with an arrangement for effecting or influencing distribution of the fibers and pattern of deposition in respect to the fiber collecting surface or conveyor. The apparatus illustrating the invention is particularly adapted for forming and processing fibers from heat-softened mineral materials such as heat-softened glass. The apparatus is preferably disposed in an elongated rectangular-shaped chamber 10, the chamber comprising a floor 12, side walls 14 and 15, end walls 16 and 17 and a roof or ceiling 18.

The arrangement is inclusive of a forehearth or receptacle means 20 containing a supply 22 of heatsoftened fiber-forming material, such as glass, the forehearth or receptacle being connected with a melting facility or furnace 24 in which glass batch or other fi ber-forming material is reduced to a heat-softened or flowable condition by the application of heat. The heatsoftened or molten material is delivered from the melting facility to the forehearth or receptacle 20 providing a supply of the molten fiber-forming material for a plurality of fiber-forming instrumentalities or units.

In the embodiment illustrated in FIGS. 1 through 3, two fiber-forming units 25 and 25' are disposed beneath the forehearth or receptacle means 20, the units being arranged in adjacent side-by-side relation, as shown in FIGS. 2 and 3. A stream 27 of heat-softened fiber-forming material or glass from a stream feeder means 28 associated with a forehearth 20 flows into each spinner or centrifuge of each of the fiber-forming

units

25 and 25.

A frame structure 29 is provided for mounting the fiber-forming units 25 and 25'. The frame structure is inclusive of horizontal structural members 30. Secured to and depending from the horizontal members 30 are members or bars 31, arranged in pairs as shown in FIGS. 2 and 3. The pairs of depending members 31 support the fiber-forming units 25 and 25'. Each of the fiber-forming units, shown in FIGS. 1 through 4, is inclusive of a generally cylindrically shaped housing or casing 32, each of the housings 32 being provided with pins or trunnions 33 which extend into bores provided at the lower end regions of the depending frame members 31.

Through the provision of the trunnion-type mounting, the angularity of each fiber-forming unit may be adjusted to a limited extent rotating a unit about the axis of the trunnion pins 33. Each fiber-forming unit includes a plate-like means or member 34 secured to the housing 32, each plate 34 having an opening 37 accommodating a glass stream 27. Mounted at the central region of each plate 34 is a cylindrically shaped member or enclosure 35 and reinforcing struts or members 36, particularly shown in FIG. 4. The member 35 encloses antifriction bearings 38 in which is journally mounted a spindle or shaft 40 which is preferably tubular. Secured to the member 35 is a means or bracket 42 on which is mounted a motor 44 for rotating the shaft or spindle 40.

Mounted on the lower end of each of the shafts 40 is a centrifuge, rotor or hollow spinner 48 comprising a floor 50 which is secured to the shaft by suitable means. The floor 50 is fashioned with a central planar portion 5] and preferably with an annular region 52 inclined upwardly and outwardly from the central planar region 51 of the floor 50, the annular region 52 being integral with or joined to a peripheral wall portion 54, particularly shown in FIG. 4. Joined with the upper region of the peripheral wall portion 54 is an annular flange 56. The peripheral wall 54 of the spinner is fashioned with a plurality of rows of small orifices, openings or perforations 58.

In the embodiment illustrated, each of the fiberforming units is adapted to be mounted in an angular position with respect to a horizontal plane, the angle of the spinner axis being about 45 to a horizontal plane as indicated at angle A in FIG. 4. The vertically falling glass stream 27 delivered into the spinner of each fiber forming unit is offset or spaced from the axis of the fiber-forming unit as illustrated in FIGS. 2 and 3 and, as shown in FIG. 4, and may engage the planar floor portion 51 of the spinner 48 at an angle of incidence of about 45 with respect to a horizontal plane as indicated by the angle A, shown in FIG. 4.

In the angularity of the spinner is adjusted to a position wherein the falling glass stream engages the annular sloping or frusto-conically shaped floor portion 52 of the spinner, then the angle of incidence of the glass stream with the floor portion 52 will be modified to the extent of the angularity of the annular sloping floor portion 52 with respect to the planar floor portion 50.

Under the influence of centrifugal forces of rotation of the spinner the glass of the stream, upon engaging the floor of the spinner, is rapidly moved radially of the spinner and distributed throughout the inner surface of the peripheral wall 54 of the spinner. The spinner is rotated at a speed at which the heat-softened glass at the interior surface of the peripheral wall 54 is extruded or projected by centrifugal forces through the openings or orifices 58 in the spinner wall providing streams or primary filaments of glass which are engaged by a high velocity gaseous blast and attenuated by the blast to discrete fibers 60. Each spinner may be of a diameter of up to inches or more and the number of openings 58 in the peripheral wall 54 may be in a range of three thousand to twelve thousand or more. the number of orifices being dependent in a measure upon the size of the spinner, and the throughput of glass and quality of fiber desired.

A high velocity gaseous attenuating blast for each fiber-forming unit is provided by blower means 62, and

an annular combustion burner construction 64 provides heat at the region of the peripheral wall 54 of the spinner to maintain the centrifuged streams or primaries of glass in an attenuable condition. The blower construction 62 surrounds the peripheral wall of the spinner construction 48 and is inclusive of an annularly shaped body or member 66 configurated to form an annular manifold or chamber 68, a top or cover plate 69 being secured to the body 66.

The blower construction or means 62 is preferably supported from the housing 32 by circumferentially spaced brackets 71. The cover member 69 has a circular depending lip portion 70 which is spaced from a portion 72 of the blower body 66, the portion 72 being configurated to provide a plurality of circumferentially spaced slots or orifices 74, the depending portion 70 of the cover 69 overlying the portion 72 forming an upper wall of each of the slots 74.

The manifold or chamber 68 is supplied with gas under pressure, such as compressed air or steam, from a supply through a tubular member or pipe 76. The compressed air or steam in the manifold chamber 68 is delivered through the slots 74 and provides a highvelocity gaseous fiber-attenuating blast of a temperature lower than that of the glass centrifuged through the orifices 58. A valve means 78 associated with the pipe 76 provides means for regulating the admission of gas to the manifold chamber 68 for controlling the velocity of the fiber-attenuating blast.

The burner construction 64 includes an annularly shaped manifold 80 providing a chamber 81 which receives combustible fuel and air mixture from a supply (not shown) through a tube or pipe 82, a valve means 84 being associated with the tube or pipe 82 for regulating flow of combustible mixture to the manifold chamber 81. The burner construction includes an inner cylindrically shaped wall 86, the outer circular wall portion of the housing or casing 32 providing an outer wall of the burner construction. Disposed within the burner walls is a lining 88 of high temperature resistant refractory shaped to provide an annular confined combustion zone or chamber 90, the latter having an annular throat or discharge passage 92.

An upper wall 94 of the burner construction and the adjacent refractory lining are provided with openings accommodating circumferentially spaced fittings 96, one of which is shown in FIG. 4. Each of the fittings 96 is fashioned with a plurality of small passages 97 through which the combustible gas and air mixture from the manifold chamber 81 is delivered under comparatively low pressure into the combustion chamber 90.

The combustible mixture is substantially completely burned within the combustion chamber and the flames or intensely hot gases of combustion and radiant heat are delivered through the annular throat 92 and downwardly along the exterior of the peripheral wall 54 of the spinner 48, this arrangement providing heat to maintain the centrifuged streams or primary filaments in a softened attenuable condition. The small passages 97 in the fittings 96 form a fire screen means to avoid ignition of the mixture in the manifold chamber 81. The cover member 69 of the blower construction 62 is spaced from the lower wall of the burner providing a passage or region 98 through which air induced by the high velocity of the gases of the blast is admitted to the blast.

In the operation of the fiber-forming units 25 and 25' in producing fibers, the motor 44 of each unit is energized and rotates the spinner, rotor or centrifuge at a speed whereby centrifugal forces project streams or primary filaments of glass from the orifices in the peripheral wall 54 into the gaseous attenuating blast, the gases of the blast flowing through the circumferentially spaced slots 74 of the blower construction.

The hot gases from the burning mixture in the combustion burner 90 are delivered along the exterior of the spinner wall 54 to maintain the centrifuged streams or primaries in condition for attenuation. The attenuated fibers 60 from each of the fiber-forming units are in a generally cylindrically-shaped hollow column, the fibers being directed downwardly and angularly with respect to a horizontal plane as hereinbefore described and illustrated in FIG. 1. Due to turbulence of the gases of the blasts, some of the fibers are formed into small elongated groups which with discrete fibers are directed toward the upper flight 104 of the conveyor.

Means may be provided for deliverying binder or adhesive onto the discrete fibers and elongated groups of fibers moving angularly and downwardly. Disposed adjacent each of the fiber-forming

units

25 and 25 and embracing the column or group of fibers moving away from each unit is a frusto-conically shaped member 99, shown in FIGS. 1 and 2, each member 99 being supported by suitable means (not shown). The axis of each frusto-conically shaped member 99 is aligned with the axis of the spinner of the adjacent fiber-forming unit. Mounted on each of the members 99 is a manifold 100 provided with a plurality of nozzles 101 for delivering binder or adhesive onto the fibers. Adhesive or binder from a supply (not shown) is conveyed to the manifold 100 by a tube 102.

In the embodiment illustrated, a moving conveyor means is provided for collecting the fibers delivered from the. fiber-forming units 25. With particular reference toFIGS. l and 2, there is illustrated a foraminous or reticulated endless belt conveyor 103, the upper flight of which may be horizontal, or as illustrated in FIG. 1, may be inclined slightly upwardly in a direction away from the region of the fiber-forming units. The foraminous conveyor 103 is supported by

rolls

106, 107 and 108, one of the rolls being driven by a motor (not shown) in a conventional manner.

As illustrated in FIG. 1, the fibers from the fiberforming units 25 and 25' are collected or deposited upon the collecting surface provided by the upper flight 104 of the conveyor 103 as a mass M of fibers. The mass of fibers may be conveyed through an oven 110 between the adjacent flights of foraminous conveyors 112 and 114 supported by

rolls

116 and 118 driven by means (not shown). The conveyors 112 and 114 are disposed to receive and compress the mass M of fibers into a mat 120 of desired density and thickness. The oven 110 may be of conventional character establishing a heated environment of sufficient temperature to set or cure the binder or adhesive in the mat 120.

Disposed beneath the upper flight 104 of the foraminous conveyor 103 is a sheet metal receptacle 124 fashioned or configurated to provide a chamber 126. The chamber 126 is connected with a suction blower (not shown) by a pipe or tube 128 for establishing reduced pressure or suction in the region beneath the upper flight of the conveyor, the reduced pressure assisting in the deposition or collection of the fibers from the

fiberforming units

25 and 25 on the conveyor surface and disposing of the spent gases of the attenuating blasts.

With reference to FIG. 2, the fiber-forming units 25 and 25' are disposed adjacent but in spaced transverse relation with respect to the lengthwise movement or dimension of the conveyor 103. In such arrangement there is a tendency for the two groups of fibers from the two fiber-forming units to be deposited on the upper flight 104 of the conveyor 103 in ridges, that is, the fibers being deposited generally in two rows lengthwise of the conveyor with the lesser quantities of fibers in parallel planes through the respective axes of the fiberforming units.

The invention includes a method and means for influencing the movement of fibers of each of the groups of fibers from the fiber-forming units by forces acting in directions to control the pattern of deposition or orientation of the fibers on the upper flight 104 of the conveyor. While it is usually desirable to effect deposition of the fibers on the collecting conveyor in a manner to promote the formation of a mass of fibers of substantially uniform thickness and density, the method and means for controlling the distribution and deposition of the fibers may be utilized to vary the density and thickness of the mass of fibers in different zones or regions of the mass as the fibers are collected on the fibercollecting conveyor or collecting surface.

Referring to FIGS. 1 and 2, there is disposed a plurality of fluid delivery means or nozzle constructions for directing streams or jets of gas, such as air or steam, into engagement with the lower regions of the groups of attenuated fibers in advance of the region of deposition of the fibers on the conveyor flight 104. As particularly shown in FIG. 2, there is provided two groups of fluid delivery means or nozzles, there being three nozzles in each group delivering streams of gas for engaging fibers from each unit. The nozzle or jet constructions of one group for projecting streams of air or other gas into engagement with the fibers from the left-hand fiber-forming unit 25, as viewed in FIG. 2, are designated 134, 136 and 138.

The corresponding nozzle or jet constructions of the second group for projecting streams of air or other gas into engagement with the fibers delivered from the right-hand fiber-forming unit 25' are designated 134', 136 and 138'. The nozzles or jets of each group are mounted for adjustment by means (not shown) whereby the individual nozzles or jets may be adjusted vertically and angularly to promote the deposition of the fibers on the collecting conveyor flight 104 in a desired pattern. Supply pipes 140 and 140' are provided for conveying gas, such as compressed air or steam, from a supply to the groups of nozzles. Each of the supply pipes is equipped with conventional valve means (not shown) for regulating the delivery of air or other gas from the individual nozzles.

It is usually desired to collect the fibers from the units in a mass on the conveyor wherein the thickness of the mass and density thereof are substantially uniform throughout the width of the collected mass. The positions and angularities of the nozzles as illustrated in FIG. 2 promote the transverse distribution of both groups of fibers to form a mass of fibers of substantially uniform density and thickness on the conveyor.

In the arrangement shown in FIG. 1, the fluid delivery jets or nozzles are disposed slightly rearwardly and above the left end region of the conveyor flight 104, the

nozzles being of a shape or configuration and adjusted so that the streams of fluid, such as air or steam, engage and entrain or deflect the fibers moving away from each of the fiber-forming units in a manner to influence the transverse distribution of the fibers as the fibers are deposited on the conveyor flight. With the fluid delivery jets disposed in the positions illustrated in FIG. 1, the streams of fluid engage fibers and entrain them for movement above the conveyor flight 104 for an appreciable lengthwise distance or region indicated at B in FIG. 1 in which region substantially no fibers are deposited on the conveyor.

At the region B of the foraminous or reticulated conveyor, the reduced pressure or suction established in the chamber 126 is unimpeded by fibers and is highly effective to convey away spent gases of the attenuating blasts and spent gases of the streams of gas delivered from the fiber distributing jets or nozzles. This method of disposing of spent gases enables a substantial reduction in the amount of reduced pressure or suction required for the purpose of collecting the fibers and hence effects substantial savings in energy in the opera tion of collecting the fibers.

The group of fibers delivered from each of the fiberforming units is of a generally hollow column forma tion, the fibers moving angularly downwardly in a direction generally parallel with the axis of rotation of the spinner or centrifuge. The jets 134 and 134' disposed substantially horizontally, as shown in FIG. 2, deliver or project gas streams lengthwise of the conveyor flight 104 and engage the lower region of the fibers of each column of fibers and deflect the engaged fibers to flatten the column of fibers which action tends to spread some of the fibers transversely of the conveyor flight 104.

A substantial portion of the fibers spread in a lefthand direction from the left-hand fiber-forming unit 25, as viewed in FIG. 2, is engaged by the gas stream delivered from the nozzle or jet 136 which is angularly adjusted with respect to the direction of movement of the spreading fibers to direct this region of the fibers onto the left-hand edge region of the conveyor flight 104 to effect deposition of sufficient fibers at the conveyor edge region to provide a thickness of the mass at this region substantially equal to the thickness of the mass of fibers collected forwardly of the gas delivery jet or nozzle 134.

The fibers that are spread in a right-hand direction delivered from the fiber-forming unit 25 are engaged by the gas stream from the angularly disposed jet or nozzle 138 and are directed toward the central region of the conveyor flight to effect deposition of a portion of the fibers near the central lengthwise region of the conveyor flight. The streams of gas from the jets or nozzles 134, 136 and 138' engaging and entraining or de fleeting fibers from the right-hand fiber-forming unit 25', as viewed in FIG. 2, provide for a similar transverse distribution of fibers delivered from the fiberforming unit 25'.

The gas stream from the horizontal elongated nozzle 134 disposed centrally of the column of fibers from the fiber-forming unit 25 engages and entrains a lower region of the column of fibers and deflects and flattens portions of the fiber group causing a spreading of some of the fibers laterally of the moving column of fibers. The gas stream delivered from the angularly disposed jet or nozzle 136 directs or deflects some of the fibers spread in a right-hand direction from the unit 25' for deposition along the right-hand edge region of the conveyor flight 104.

The gas stream from the angularly disposed jet or nozzle 138 engages some of the fibers spread in a lefthand direction from the column of fibers delivered from the unit 25 and redirects them toward the central region of the conveyor in a manner similar to the redirection of fibers by the gas stream from the jet 138. Thus, by reason of the entrainment and deflection of fibers under the influence of the gas streams from the several jets or nozzles, the fibers from the two units may be distributed so that the collected mass on the conveyor belt may be of substantially uniform thickness transversely of the conveyor flight 104. The gas streams from the several jets or nozzles convey the fi-' bers and elongated groups of fibers in directions generally parallel with the fiber collecting surface or conveyor flight.

By adjusting the height and angularities of the nozzles delivering the fiberdistributing gas streams, the thickness and density of the fibrous mass at various regions transversely of the conveyor flight may be regulated and controlled to attain other patterns of density and thickness of the mass. In addition to the advantage of directing and controlling the deposition of the fibers on the conveyor flight to provide the uninhibited region B to facilitate conveying away the spent gases of the at tenuating blasts and the gases of the fiber-distributing means, the discrete fibers and small elongated groups of fibers move generally lengthwise of the conveyor and are deposited in generally parallel relation with re spect to the conveyor flight 104 and in laminar-like orientation.

The collected fibers in this pattern of orientation formed into a mat provide a mat of high strength and good compression recovery characteristics. The method of fiber formation and collection enables a high rate of production of fibers at a low cost. Furthermore, turbulence that may result from the attenuating blasts is substantially reduced by reason of the rapid removal of substantial amounts of the gases of the blasts and fiber distributing gases at the unimpeded reduced pressure region B.

The invention embraces the employment of more than two rotary fiber-forming units operating concomitantly for delivering fibers onto a collecting surface or conveyor to produce a mat of substantial width. FIG. 5 illustrates an arrangement wherein more than two fiber-forming units are operated concomitantly in producing fibers in conjunction with fiber-distributing forces or means for distributing the fibers transversely onto a comparatively wide conveyor to product a fibrous mass or mat of substantial width.

Each of the fiber-forming units is supported from pairs of depending structural members or bars 31a upon trunnions or pins 33a in the manner hereinbefore described in reference to the mounting of the fiberforming units illustrated in FIGS. 1 and 2. Each of the fiber-forming

units

25a, 25b and 250 are of the character illustrated in FIG. 4 and are arranged in an angular position of about 45 with respect to a horizontal plane in the same manner as the unit 25 illustrated in FIG. 4.

Disposed in a position to receive and collect the fibers delivered from the fiber-forming units is a foraminous or reticulated conveyor 144 of substantial width which is supported upon rolls in the manner illustrated in FIG. 1, one of the rolls 106a being illustrated in FIG. 5, the rolls being of a sufficient length to support the conveyor 144. The upper flight 145 of the conveyor 144 provides a surface on which the fibers are collected.

A receptacle 124a is disposed beneath the upper flight 145 of the fiber-collecting conveyor 144 and provides a chamber 126a connected with a source of reduced pressure such as a suction blower (not shown) for providing a region of reduced pressure or suction beneath the upper flight of the conveyor. The reduced pressure provided in the chamber 126a assists in collecting the fibers on the conveyor and conveying away the spent gases of the attenuating blasts and fiber distributing gases in the manner hereinbefore described in connection with the arrangement shown in FIGS. 1 and 2.

The arrangement shown in FIG. embraces a method and means for influencing the movement of f1- bers of each of the groups of fibers from the fiberforming units by forces acting in directions to control the pattern of deposition of the fibers on the upper flight 145 of conveyor 144. In the arrangement illustrated in FIG. 5, groups of nozzles are provided for directing streams of fluid, such as air or steam, into engagement with fibers moving away from each fiberforming unit in advance of the region of deposition of the fibers for distributing the fibers on the conveyor.

In the arrangement shown in FIG. 5, a group of gas delivery nozzles is provided for each group of fibers and each group of nozzles is of the character shown in FIG. 2 and hereinbefore described. The nozzles 134a, 136a and 138a correspond with the

nozzles

134, 136 and 138 illustrated in FIG. 2. This group of nozzles, disposed adjacent the fiber-forming unit 25a, delivers streams of fluid such as gas or air streams into engagement with the fibers to influence distribution of the fibers delivered from the unit 25a transversely of a region of the conveyor flight 145 in the zone forwardly of the nozzles.

The streams of fluid delivered from nozzles 134b, l36b and 138b comprising the second group engage and deflect or redirect some of the fibers delivered from the fiber-forming unit 25b transversely over the adjacent region of the conveyor flight 144. The streams of fluid delivered from nozzles 134e, 1360 and l38c comprising the third group of nozzles engage and deflect or redirect some fibers delivered from the fiberforming unit 250 transversely over the adjacent region of the conveyor flight 144. If more than three fiberforming units are employed, an additional group or groups of fiber-distributing nozzles may be utilized for deflecting, redirecting or distributing fibers from each additional fiber-forming unit.

If it is desired to collect the fibers on the conveyor flight in a pattern or orientation wherein the thickness and density of the mass or pack of fibers are substantially uniform transversely of the conveyor flight 144, the nozzles of the groups adjacent each fiber-forming unit are disposed substantially in the positions illustrated in FIG. 5. If it is desired to collect the fibers in a mass or pack wherein certain regions of the mass or pack are to be of increased thickness, the nozzles of the groups may be adjusted to obtain such a pattern of orientation of the collected fibers.

The nozzles of the groups illustrated in FIG. 5 are disposed with respect to the columns of fibers delivered from the fiber-forming units and the chamber 126a whereby the streams of gas from the nozzles entrain the fibers in the manner illustrated in FIG. 1 whereby the fibers are deposited on the conveyor downstream of the conveyor so that an area of the conveyor, such as that illustrated at B in FIG. 1, is unimpeded or uninhibited to facilitate conveying away the spent gases of the blasts and spent gases from the fiber-distributing nozzles, thus reducing turbulence of the fibers.

FIG. 6 is a semischematic side elevational view illustrating a fiber-forming unit with the axis of the spinner disposed at about 45 to a horizontal plane in combination with a fiber-collecting foraminous conveyor having its upper or fiber-collecting flight disposed at an angle less than 45 from a horizontal plane. In the arrangement shown in FIG. 6, the fiber-forming unit 25d is in clusive of a housing 32d enclosing a hollow spinner 48d mounted for rotation on an axis disposed at about a 45 angle with respect to a horizontal plane D-D as in the other forms of the invention.

The hollow spinner 48d receives a stream 27d of heat-softened glass or other heat-softened fiberforming material. The hollow spinner is rotated by means such as a motor illustrated at 44 in FIGS. 1 and 4. A blower means or manifold 624 provides an annular gaseous attenuating blast which engages the streams of glass centrifuged from the spinner and attenuates the I streams to fibers 60d. The fibers entrained in the blast are discrete fibers or small elongated bundles or groups of fibers and are conveyed by the gases of the blast in directions generally parallel with the axis of rotation of the spinner.

Disposed adjacent the fiber-forming unit and embracing the fibers moving away from the unit is a frusto-conically shaped member d, the axis of the member 100d being substantially coincident with the axis of rotation of the spinner. The member 100d supports a plurality of nozzles 101d for delivering binder or adhesive onto the fibers. Disposed in a position to receive the fibers 60d is the upper flight 148 of an endless belt type foraminous conveyor 149 supported on rolls 150, one of which is illustrated in FIG. 6, the conveyor arrangement being similar to that illustrated in FIG. 1 but in a forwardly inclined or angular position. The upper flight 148 of the conveyor is disposed at an angle C of less than 45 with respect to a horizontal plane indicated at DD.

In the embodiment illustrated in FIG. 6 the flight 148 is shown as being at about a 30 angle with respect to the plane DD but the angularity of the flight 148 with respect to the horizontal plane may be varied dependent upon the character of fiber deposition and orientation desired in the mass of pack M2 of fibers. A receptacle 124d is disposed beneath the upper flight 148 of the conveyor and is connected by means of a pipe or duct 154 with a suction blower for establishing subatmospheric or reduced pressure in the chamber 126d provided by the receptacle 124d.

The arrangement shown in FIG. 6 is inclusive of a plurlaity of fluid delivery means or nozzle constructions for directing streams or jets of gas, such as air or steam, into engagement with some of the fibers of the group of fibers in advance of the region of deposition of the fibers on the conveyor flight 148. A group of three nozzles is preferably employed for each group of fibers,

nozzles

134d and 136d being shown in FIG. 6, and a third nozzle (not shown) of the group corresponds to the nozzle 138 shown in FIG. 2.

While only one fiber-forming unit is shown in FIG. 6, it is to be understood that additional units may be employed disposed in side-by-side relation as shown in FIGS. 2 and 5, a group of air or steam delivery nozzles being employed fordelivery of jets or streams of air or steam in engagement with fibers of each of the groups. The streams of gas from the nozzles engage and entrain the fibers for an appreciable distance so that substantially no fibers are deposited on the region of the conveyor adjacent the end region of the suction chamber 126d to provide an uninhibited region of the conveyor flight 148 for conveying away some of the spent gases of the attenuating blast.

The velocity and turbulence of the gases of the attenuating blasts and the forces of the jets or streams of gas from the nozzles have a sweeping effect on the fibers and small elongated bundles of fibers to enhance and promote their deposition on the conveyor flight in generally parallel relation with the conveyor flight providing a laminar-like orientation.

A mat formed by compressing the mass of fibers and setting the binder is endowed with improved strength characteristics as compared with the strength characteristics of a mat formed from fibers impinged vertically onto a substantially horizontal conveyor flight as in rotary processes heretofore employed.

FIGS. 7, 8 and 9 illustrate a method and apparatus for regulating or controlling the degree or effectiveness of reduced pressure or suction existent at different re gions beneath the fiber-collecting conveyor flight. In the arrangement shown in FIGS. 7 and 8, two rotary fiber-forming units or fiberizers 256 and 252' are arranged in adjacent side-by-side relation, the attenuated fibers formed from these units being delivered toward and collected in a mass Me upon the upper flight 158 of a foraminous endless belt-type conveyor 160.

Each of the fiber-forming

units

25e and 25e is of the character illustrated in FIG. 4 and is inclusive of a housing 32e enclosing a hollow spinner 48c mounted for rotation on an axis disposed at about a 45 angle with respect to a horizontal plane. Each of the hollow spinners receives a stream 27e of heat-softened glass or other heat-softened fiber-forming material. Each hollow spinner is rotated by means, such as a motor, illustrated at 44 in FIGS. 1 and 4.

A blower means or manifold 62e for each fiberizing unit provides a gaseous attenuating blast which engages the streams of glass centrifuged from the spinner and attenuates the glass to fibers 602. The fibers entrained in the blasts are conveyed in two groups or hollow columns in directions generally parallel with the axis of rotation of the spinner. Disposed adjacent each fiberforming unit and embracing the fibers moving away from each unit is a frusto-conically shaped member 1002 supporting a plurality of nozzles 101e for delivering binder or adhesive onto the fibers.

Disposed in a position to receive the fibers 60a is the upper flight 158 of an endless belt type foraminous conveyor 160 supported on rolls 162, one of which is illustrated in FIGS. 7 and 8, the conveyor flight 158 being inclined slightly upwardly from a horizontal plane in a direction away from the fiber-forming units in the manner illustrated in FIG. 1.

In the arrangement illustrated in FIGS. 7 through 9, means is provided for establishing reduced pressure or suction beneath the upper flight 158 of the conveyor in several regions or zones, the degree or effectiveness of the reduced pressure or suction being controlled in each of the several regions or zones to vary or modify the pattern of deposition or collection of the fibers on the conveyor flight 158.

Disposed beneath the conveyor flight 158 is a receptacle 166 having a floor portion 167. Centrally disposed and extending lengthwise of the receptacle 166 is a partition means or wall 169 as shown in FIGS. 7 and 9. Extending transversely of the receptacle 166 and spaced lengthwise are partitions or

walls

172, 173, and 174 as particularly shown in FIGS. 7 and 8. The transverse walls, with the central lengthwise partition or wall 169 provide individual zones or

chambers

176, 177, I78, 179, I80, I81, I82 and 183.

Each of the chambers identified by numerals 176 through 183 provides an individual zone or region in which the extent or degree of reduced pressure or suction may be regulated in order that the regions of reduced pressure may be utilized in promoting desired distribution of the fibers collected upon the conveyor flight 158. Means is provided for regulating or controlling the degree of reduced pressure or suction in each of the zones or chambers.

In the embodiment illustrated in FIGS. 7 through 9, an individual suction blower means is provided for the pairs of partitioned chambers or zones. As shown in FIG. 7 the re are four

suction blowers

186, 187, 188 and 189 of conventional character, each of the blowers being independently driven by a motor 192. The suction blower 186 is in communication with the chamber by a pipe or duct 196, an adjustable damper or valve member I98 being provided in the pipe 196 for varying the effective suction or reduced pressure in the chamber 180.

A pipe 200 has one end in communication with the pipe 196, the other end being in communication with the chamber 176, a damper or valve l98e being disposed in the pipe 200 near its region ofjuncture with the chamber 176 as shown in FIG. 9. The reduced pressure or suction in the

respective chambers

180 and 176 may be controlled by the dampers or valve members 198 and 198:: which are individually adjustable for the purpose.

By regulating the degree or extent of suction or reduced pressure in

chambers

176 and 180, the reduced pressures effective to assist inthe deposition or collection of fibers on the conveyor at the regions of the chambers may be adjusted to attain more uniform distribution of fibers. By adjusting the dampers or

valves

198 and 198e, more fibers may be collected on the conveyor adjacent one of the chambers than adjacent the other chamber. In this manner the thickness of the mass offibers at the regions of influence of the reduced pressure in the chambers may be modified depending upon the character desired for the end product.

A similar arrangement is provided for controlling the extent or effectiveness of suction in

chambers

177 and 181. The suction blower 187 is in communication with a chamber 181 by a pipe or duct 202, a damper or valve 203 in the pipe 202 may be adjusted to vary the degree or extent of suction or reduced pressure in chamber 181. A pipe 205 has one end in communication with the pipe 202, the other end on communication with the chamber 177. A valve or damper 203:: is disposed in the pipe 205 near its juncture with the chamber 177 and is adjustable for controlling the degree or extent of reduced pressure in the chamber 177.

Through the method of regulating the reduced pressure or suction in

chambers

177 and 181 through adjustment of the

valves

203 and 203e, the suction may be varied to influence the deposition of fibers on the regions of the conveyor flight in

registration withthe chambers

181 and 177 whereby the thickness or amount of the mass of fibers at these regions may be controlled.

The suction blower 188 is connected by a pipe or duct 207 with the chamber 182. An adjustable damper or valve 209 is provided in the pipe 207 for varying the suction or reduced pressure in the compartment or chamber 182. The pipe 207 is connected by a pipe or duct 210 with the chamber 178, a valve or damper 209e for controlling the suction or reduced pressure in the chamber 178. By adjusting the valves or

dampers

209 and 209e the suction or reduced pressure may be individually controlled in each of the

chambers

178 and 182 to influence the deposition of fibers on the regions of the conveyor in registration with the chambers or

compartments

182 and 178.

The suction blower 189 is in communication with the compartment or chamber 183 by a pipe or duct 212, a damper or valve 214 in the pipe 212 and being adjustable to control the degree or extent of the suction or reduced pressure in the chamber 183. A pipe 216 has one end in communication with the pipe 212, the other end being in communication with the chamber 179. A damper or valve member 214e in the pipe 216 near its region of juncture with the chamber 179 is adjustable for varying the suction or reduced pressure in the chamber 179. The suction or reduced pressure in

chambers

183 and 179 influences the distribution and deposition of fibers on the region of the conveyor flight 158 in registration with the

chambers

179 and 183.

Each of the blower constructions is fashioned with an exhaust pipe 220, as shown in FIGS. 7 and 9, which may be connected with a vent stack arrangement (not shown) for conveying the air or other gases from the several compartments or chambers disposed beneath the regions of the conveyor flight 158.

his to be understood that while eight chambers or compartments providing reduced pressure or suction zones are illustrated in FIG. 7, a lesser or greater number of compartments or chambers may be provided depending upon the length and width of the fibercollecting flight or surface, the number of fiber-forming units delivering fibers onto a conveyor flight and the transverse distribution of the fibers for collection at the various regions of reduced pressure or suction.

The arrangement shown in FIGS. 7 and 8 is inclusive of means for exerting forces against the columns of fibers delivered from the fiber-forming units for deflecting or redirecting the fibers and thereby modifying the distribution and orientation pattern of the fibers on the conveyor flight 158. An arrangement of nozzles 134e and 136e of a group of nozzles as disclosed in FIG. 2 may be provided for the purpose.

Fluid under pressure, such as compressed air or steam, may be delivered from the nozzles, the nozzles being disposed and adjusted to engage the fibers of a lower region of the column of fibers to flatten the column of fibers and deflect the fibers into a more nearly parallel relation with respect to the conveyor flight 158 as well as to provide a region of the conveyor 158 adjacent the

chambers

178 and 182 that is uninhibited by fibers to promote flow of some of the gases of the attenuating blasts and gases from the nozzles l34e and 136e into the

chambers

178 and 182 in the manner hereinbefore described in reference to the construction illustrated in FIGS. 1 and 2.

The arrangement shown in FIGS. 7 through 9 carries out the method of efficient and effective control over the distribution and collection of fibers occurring at the various regions of the collecting conveyor flight 158 in registration with the several chambers so that various regions of the collected mass of fibers may be maintained uniform or varied in thickness if desired.

FIGS. 10 and 11 illustrate a modified arrangement utilizing a plurality of angularly disposed fiber-forming units operating concomitantly and the fibers collected on a moving foraminous collecting surface or conveyor. As shown in FIG. 11, there are five pairs of fiberforming units 25f disposed in transverse relation and the pairs arranged in tandem in lengthwise spaced relation, each of the units being of the character illustrated in FIG. 4. The axis of the rotating spinner 48f in each of the units 25f is angularly disposed with respect to a horizontal plane of approximately 45, that is, the same as angle A shown in FIG. 4.

A stream 27fof glass from a forehearth or other supply flows into the interior of each of the hollow spinners in each of the fiber-forming units 25f. The fibercollecting arrangement may be of the general character illustrated in FIGS. 7 through 9. A foraminous or reticulated endless belt type conveyor 160f is mounted on suitable rolls, one of which is illustrated at 162]", one of the conveyor supporting rolls being driven by a motor (not shown) in a conventional manner. The supper flight l58f of the conveyor is disposed in a position whereby the fibers from the several fiber-forming units 25f are collected or deposited in a mass Mf upon the conveyor flight 158f.

The reduced pressure or suction establishing means provided beneath the upper flight 158fof the conveyor is of the character illustrated in FIGS. 7 through 9 and includes a receptacle 166f having transverse partitions 172f, 173fand 174fand a centrally disposed lengthwise partition l69f. Suction blower or reduced pressure establishing means of the character illustrated in FIG. 9 may be utilized in the arrangement shown in FIGS. 10 and 11, the blowers being in communication with the chambers provided by the transverse and lengthwise partitions by pipes or ducts (not shown). The reduced pressure or suction in each of the chambers or zones provided by the partitions may be regulated or controlled by suitable valves or dampers of the character illustrated in FIG. 9.

The arrangement illustrated in FIGS. 10 and 11 is inclusive of means for exerting forces against the lower regions of the columns of fibers delivered from the fiber-forming units 25f for deflecting or redirecting the fibers of the columns into a flattened pattern in a more nearly parallel relation with the fiber collecting conveyor flight 158f so that the fibers are deposited or collected in laminar-like orientation.

An arrangement of groups 224 of nozzles, two of the nozzles of each group being illustrated at 134fand 136f of a, group of nozzles is provided for each column of fibers, the arrangement of nozzles being of the character shown in FIG. 2. Fluid under pressure, such as compressed air or steam, is projected from the nozzles of the several groups into engagement with fibers of a lower region of each of the columns of fibers to deflect and distribute the fibers on the conveyor flight 158f in the manner hereinbefore described.

FIG. 12 is a semischematic elevational view, partly in section, illustrating a plurality of angularly disposed fiber-forming units 253 disposed in spaced relation in a single row lengthwise of a fiber-collecting conveyor or surface. As illustrated in FIG. 12, there are nine fiberforming units but it is to be understood that a lesser or greater number of units may be employed if desired. Each of the units g is of the character illustrated in FIG. 4. The axis of the rotating spinner 48g in each of the units is preferably angularly disposed with respect to a horizontal plane of about as illustrated by the angle A shown in FIG. 4.

A stream 27g of molten glass from a forehearth or other supply flows into each of the hollow spinners of each of the fiber-forming units 25g. The fibercollecting arrangement may be of the general character illustrated in FIGS. 7 through 9. A foraminous or reticulated endless belt type conveyor 1603 is mounted on suitable rolls, one of which is illustrated at 162g, one of the conveyor supporting rolls being driven by a motor (not shown) in a conventional manner. The upper flight 158g of the conveyor is disposed as shown in FIG. 12 whereby the fibers from the several fiber-forming units 25g are collected forming a mass Mg upon the conveyor flight 158g.

As illustrated in FIG. 12, the upper flight 1583 may be inclined from a horizontal plane slightly upwardly in a right-hand direction. A reduced pressure or suction establishing means of the character illustrated in FIGS. 7 through 9 may be provided beneath the upper flight 158g of the conveyor to facilitate control of the deposition of the fibers on the conveyor. Disposed beneath the conveyor flight 158g is a receptacle 166g having transversely extending partitions 172g, 173g and 174g providing individual suction or reduced pressure chambers or zones beneath the conveyor.

The blowers may be in communication with the chambers by pipes or ducts (not shown). The reduced pressure or suction in each of the chambers or zones may be regulated or controlled by suitable valves or dampers (not shown) of the character illustrated in FIG. 9. In the use of a plurality of fiber-forming units arranged in a single row lengthwise of the conveyor flight, the use of a lengthwise extending central partition in the receptacle 166g is optional depending upon the spread ofthe fibers and the width ofthe mass of the collected fibers.

The arrangement illustrated in FIG. 12 is inclusive of means for exerting forces against the lower regions of the columns or veils of fibers and elongated groups of fibers moving away from the fiber-forming units 25g for deflecting and redirecting the fibers of the columns or veils by a sweeping action into a flattened pattern and in more nearly parallel relation with the fiber-collecting conveyor flight 158g so that the fibers and groups of fibers are collected in laminar-like orientation.

An arrangement of groups 224g of nozzles is provided, there being one group of nozzles for each column of fibers, the arrangement of a group of nozzles being of the general character shown in FIG. 2. Fluid under pressure, such as compressed air or steam, is projected from the nozzles of the several groups into engagement with the fibers of a lower region of each of the columns of fibers. The nozzles of each group 224g are adjustable so as to deflect and distribute the fibers on the conveyor flight 158g to provide a desired pattern of collection.

The jets or streams of fluid engage the columns of fibers and tend to flatten the columns so that the fibers move in a more nearly parallel relation with the conveyor flight 158g. By regulating the amplitude or degree of suction or reduced pressure in the chambers provided by the partitions 172g, 173g and 174g, the distribution of the fibers may be further controlled.

FIG. 13 illustrates in plan view a further modification of an arrangement of fiber-forming units and a fiber collecting conveyor for collecting fibers in a mass of substantial width. The conveyor is of the foraminous or reciculated endless-belt type and is supported in the manner illustrated in FIGS. 10 and 11, one of the supporting rolls 162h being shown in FIG. 13. In the ar rangement illustrated, there are five-fiber-forming units 2511 arranged in a single row in transversely spaced relation with respect to the lengthwise direction of a conveyor flight 228 and preferably adjacent an end region of the conveyor flight.

Four fiber-forming units 25hh are arranged in a second row, the fiber-forming units 25hh being in spaced transverse relation with respect to the lengthwise direction of the conveyor flight. The fiber-forming units 25hh of the second row are in staggered relation with respect to the fiber-forming units 25h of the first row in the manner illustrated in FIG. 13. Through the use ofa substantial number of fiber-forming units arranged in two or more rows, a mass Mh of fibers may be formed of substantial width of several feet.

Each of the fiber-forming units 25h is disposed with the axis of its spinner at approximately a 45 angle with respect to a horizontal plane, the positioning of each unit being subtantially as illustrated in FIG. 4. A stream of glass from a supply flows into the hollow spinner of each unit and fibers formed from the projection of primaries or streams of glass from orfices in the spinner wall attenuated to fibers by a gaseous blast from a blower of the character shown in FIG. 4.

The columns of fibers are directed at about a 45 angle with respect to a horizontal plane downwardly toward the conveyor flight 228 for collection on the conveyor flight. A reduced pressure or suction establishing means is provided beneath the conveyor flight 228, the suction establishing means including a receptacle 230 which may be of the general character of the receptacle 166 shown in FIGS. 7 and 8 but of a width substantially that of the conveyor flight in order to convey away gases from the attenuating blasts of the fiberforming units 25h and 251111.

The receptacle 230, connected with a suction blower or blowers may, if desired, be partitioned into a plurality of suction zones, such as shown in FIG. 7, to facilitate collection of the fibers on the conveyor flight 228. Groups of nozzles (not shown) such as the nozzles 224 shown in FIG. 12 may be provided for projecting streams of air or other gas into engagement with the fibers for deflecting or redirecting fibers from each of the fiber-forming units 2511 and 25hh to control the distribution of the fibers both lengthwise and transversely of the conveyor flight.

While it has been found preferable to mount the fiber-forming units with the axes of the spinners disposed at about a 45 angle with respect to a horizontal plane as indicated by the angle A in FIG. 4, the spinners may be mounted with their axes at an acute angle in a range of from about 30 to 60 with respect to a horizontal plane. Each of the nozzles of the groups of nozzles providing jets or streams of air or other gas engaging the fibers of the descending columns of fibers may be adjusted to control the distribution of fibers both lengthwise and transversely of the fiber-collecting conveyor or surface and promote collection of the fibers in a desired pattern or orientation.

The streams or jets of gas from the nozzles and the gases of the attenuating blasts provide a sweeping action or movement of the fibers or elongated groups of fibers in generally parallel relation with respect to the fiber-collecting surface to obtain a laminar-like mass of fibers which, when formed into a mat, provide high strength characteristics and a good recovery factor. The streams of air or other gas from the nozzles cause a flattening of the veil or column of fibers to obtain a more uniform transverse distribution of the fibers and to substantiallyeliminate the formation of ridges of fibers lengthwise of the conveyor.

As illustrated in FIG. 3, each glass stream 27 is offset transversely from the axis of the spinner and engages the floor region ofa spinner rotating in a direction generally opposed to the direction of flow of the glass stream as shown by the arrows in FIG. 3. By engaging the glass stream with a spinner surface moving toward the stream, the moving glass stream maintains a more stabilized position.

It has been found that where the streams of glass are delivered into the spinners at opposite sides of the spinner axes from those shown in FIG. 3, the glass tends to follow the direction of rotation of the spinners and the glass streams tend to wander and are less stable than when the streams are delivered into the spinners in the manner illustrated in FIG. 3.

The method of delivering fibers from an angularly disposed fiber-forming unit in an acute angular direction with respect to a fiber-collecting surface, the fibers and elongated groups of fibers move downstream of the collecting surface in a sweeping action and are collected in more nearly parallel relation whereby the fibers in the collected mass are in laminar-like formation. Mats formed from the mass of fibers are endowed with high strength characteristics and other advantageous properties hereinbefore mentioned. The control of the deposition of the fibers is enhanced through the use of independently controlled reduced pressure or suction zones beneath the reticulated or foraminous collecting surface or conveyor flight.

It is apparent that, within the scope of the invention, modifications and different arrangements may be made other than as herein disclosed, and the present disclosure is illustrative merely, the invention comprehending all variations thereof.

I claim:

1. The method of forming and collecting fibers of heat-softened fiber-forming material including rotating a spinner having an orificed peripheral wall region and an imperforate floor region about an axis disposed at an acute angle with respect to a horizontal plane, feeding heat-softened material from a supply onto the imper-,

forate floor region of the rotating spinner, projecting streams of the material from the orificed wall region of the spinner under the influence of centrifugal forces of rotation of the spinner, attenuating the streams to fibers whereby the attenuated fibers in column formation move downwardly away from the spinner and generally parallel with the axis of the spinner, engaging fibers of the moving column by jets of gas to deflect the fibers in directions generally parallel with, and downstream of a moving fiber-collecting surface, and collecting the fibers on the moving .surface.

2. The method of forming and collecting fibers of heat-softened fiber-forming material including rotating a spinner having an orificed wall region and an imperforate floor region about an axis disposed at an acute angle with respect to a horizontal plane, feeding a stream of heat-softened material onto the floor region of the rotating spinner, projecting the heat-softened material from the orificed region of the spinner forming primary filaments under the influence of centrifugal forces of rotation of the spinner, engaging the primary filaments by an annular gaseous blast, attenuating the primary filaments to fibers whereby the attenuated fibers in column formation move downwardly away from the spinner and generally parallel with the axis of the spinner, projecting jets of air directed downstream of the angularly moving column of fibers, engaging the fibers by the jets of air to deflect the fibers in directions generally parallel with a moving fiber-collecting surface, and collecting the fibers on the moving surface.

3. The method according to claim 2 wherein the stream of heat-softened material offset from the axis of the spinner engages the floor region of the spinner rotating in a direction generally opposed to the direction of flow of the stream of the material.

4. The method of forming and collecting fibers of heat-softened glass including rotating a spinner having an orificed wall region and an imperforate floor portion about an axis disposed at an acute angle with respect to a horizontal plane, feeding heat-softened glass onto the floor portion of the spinner, projecting streams of the glass from the orificed region of the spinner under the influence of centrifugal forces of rotation of the spinner,'attenuating the streams to fibers whereby the attenuated fibers in column formation move downwardly away from the spinner and generally parallel with the axis of the spinner, directing jets of gas substantially horizontally and beneath the angularly moving column of fibers and downstream of the moving column of fibers, engaging the fibers by the jets of gas to deflect the fibers in directions generally parallel with a moving fiber-collecting surface, and collecting the fibers on the moving surface.

5. The method of forming and collecting fibers of heat-softened glass including rotating a spinner having an orificed peripheral wall region and a nonorificed region about an axis disposed at an acute angle with respect to a horizontal plane, feeding heat-softened glass onto the nonorificed region of the spinner, projecting streams of the glass from the orificed region of the spinner under the influence of centrifugal forces of rotation of the spinner, attenuating the streams to fibers whereby the attenuated fibers in column formation move downwardly away from the spinner and generally parallel with the axis of the spinner, directing jets of gas substantially horizontally and beneath the angularly moving column of fibers and downstream of the moving column of fibers, engaging the fibers by the jets of gas to deflect the fibers in directions generally parallel with a moving fiber-collecting surface, and collecting the fibers on the moving surface.

6. The method according to claim wherein the jets of gas are jets of compressed air.

7. The method of forming and collecting fibers of heat-softened fiber-forming material from at least two fiber-forming instrumentalities including rotating a spinner of each instrumentality having an orificed peripheral wall region and an imperforate floor region about an axis disposed at an acute angle with respect to a horizontal plane, feeding the heat'softened material onto the imperforate floor regions of the rotating spinners, projecting streams of the material through orifices at the orificed wall region of each of the spinners under the influence of centrifugal forces of rotation of the spinners, attenuating the streams from each spinner to fibers whereby the attenuated fibers in column formation from each spinner move downwardly and generally parallel with the axes of the spinners, directing jets of gas substantially horizontally and beneath the angularly moving columns of fibers, engaging the fibers of the columns by the jets of gas to deflect the fibers in directions generally parallel with and downstream of a moving fiber-collecting surface, distributing the fibers by the forces of the jets of gas lengthwise and transversely of the moving surface, and collecting the fibers on the moving surface.

8. A method of forming and collecting fibers of heatsoftened glass including rotating a spinner having an orificed wall region and an imperforate floor portion about an axis disposed at an acute angle with respect to a horizontal plane, feeding a stream of the heatsoftened glass onto the floor portion of the spinner. projecting primary filaments of the glass from the orificed wall region of the spinner under the influence of centrifugal forces of rotation of the spinner, attenuating the primary filaments to fibers, impinging jets of air into engagement with the attenuated fibers distributing the fibers lengthwise and laterally of a lengthwise moving fiber-collecting surface, establishing a plurality of partitioned zones arranged lengthwise of and beneath the collecting surface, withdrawing gases from each of the partitioned zones providing reduced pressure in each of said zones to influence the collection of fibers on the moving surface, and regulating the rate of withdrawal of gases from each of the partitioned zones for varying the amplitude of reduced pressure in each individual zone.

9. Apparatus for forming fibers of heat-softened fiber-forming material including, in combination, support means, a hollow spinner having an imperforate floor portion and an orificed peripheral wall mounted by the support means, the axis of the spinner being disposed at an acute angle with respect to a horizontal plane, means for delivering a stream of the heatsoftened material into the spinner, the acute angle of the spinner axis being such that the heat-softened material engages the imperforate floor portion of the spinner, means for rotating the spinner to project primary filaments of the material from the orifices in the spinner wall, means attenuating the primary filaments to fibers whereby the attenuated fibers move downwardly in column formation and generally parallel with the axis of the spinner, a moving fiber-collecting conveyor, and nozzle means disposed beneath the column of fibers, said nozzle means delivering streams of gas into engagement with the fibers for entraining and conveying the fibers downstream of the moving conveyor for collection on the moving conveyor, said nozzle means being adjustable for varying the distribution of the fibers transversely of the moving conveyor.

10. The combination according to claim 9 wherein the gas delivered from the nozzle means is compressed air.

11. Apparatus for forming and collecting fibers of heat-softened glass including, in combination, support means, a hollow spinner having an orificed peripheral wall region and an imperforate floor portion mounted on the support means for rotation about an axis at an acute angle with respect to a horizontal plane, means for delivering a stream of heat-softened glass into the spinner onto the imperforate floor portion of the spinner, means for rotating the spinner to project primary filaments of the glass from the orifices in the spinner wall region, means delivering an annular gas stream into engagement with the primary filaments attenuating the filaments to fibers and conveying the fibers away from the spinner in directions generally parallel with the axis of the spinner, a moving conveyor means for collecting the fibers, and nozzle means disposed beneath the spinner projecting air streams into engagement with the moving fibers entraining and conveying the fibers lengthwise and downstream of the conveyor means and distributing the fibers laterally of the conveyor means.

12. Apparatus for forming and collecting fibers of heat-softened glass including, in combination, support means, a plurality of fiber-forming intrumentalities mounted by the support means, each instrumentality including a rotatable spinner having an orificed peripheral wall region and an imperforate floor portion, each of the spinners being rotatable about an axis disposed at an acute angle with respect to a horizontal plane, ma sfqrrg atinsthe winaetsamsaastet q irerins a stream of heat-softened glass onto the imperforate floor portion of each of the rotating spinners, project ing primary filaments of the glass through orifices at the orificed wall region of each of the spinners under the influence of centrifugal forces of rotation of the spinners, means attenuating the primary filaments from each spinner to fibers whereby the attenuated fibers in column formation from each spinner move downwardly and generally parallel with the axes of the respective spinners, a moving foraminous fiber-collecting conveyor, nozzle means projecting jets of compressed air substantially horizontally and beneath the angularly moving columns of fibers in directions downstream of the columns of the fibers whereby the jets of compressed air engage the fibers of the columns to deflect the fibers in directions generally parallel with and downstream of the moving fiber-collecting surface, said nozzle means being arranged whereby the jets of compressed air distribute the fibers lengthwise and transversely of the moving conveyor on which the fibers are collected.

13. The combination according to claim 12 wherein the axis of each of the spinners is disposed at an acute angle of about 45 with respect to a horizontal plane.

14. Apparatus for forming and collecting fibers of heat-softened glass including, in combination, support means, a plurality of fiber-forming instrumentalities mounted by the support means, each instrumentality including a rotatable spinner having an orificed peripheral wall region and an imperforate floor portion, each of the spinners being rotatable about an axis disposed at an acute angle with respect to a horizontal plane,

means for rotating the spinners, means for delivering a stream of heat-softened glass onto the imperforate floor portion of each of the rotating spinners, projecting primary filaments of the glass through orifices at the orificed wall region of each of the spinners under the influence of centrifugal forces of rotation of the spinners, means attenuating the primary filaments from each spinner to fibers whereby the attenuated fibers in column formation from each spinner move downwardly and generally parallel with the axes of the respective spinners, a moving foraminous fiber-collecting conveyor, nozzle means projecting jets of compressed air substantially horizontally and beneath the angularly moving columns of fibers in directions downstream of the columns of the fibers whereby the jets of compressed air engage the fibers of the columns to deflect the fibers in directions generally parallel with and downstream of the moving fiber-collecting surface, said nozzle means being arranged whereby the jets of compressed air distribute the fibers lengthwise and transversely of the moving conveyor on which the fibers are collected, a receptacle disposed beneath and extending lengthwise of the foraminous conveyor, transverse partitions disposed in the receptacle providing a plurality of individual chambers, suction blower means, tubular means establishing communication of the suction blower means with each of the chambers providing reduced pressure in each of the chambers effective to collect the fibers on the conveyor, and valve means associated with the tubular means for individually regulating the amplitude of reduced pressure in each chamber.

Claims

1. The method of forminG and collecting fibers of heat-softened fiber-forming material including rotating a spinner having an orificed peripheral wall region and an imperforate floor region about an axis disposed at an acute angle with respect to a horizontal plane, feeding heat-softened material from a supply onto the imperforate floor region of the rotating spinner, projecting streams of the material from the orificed wall region of the spinner under the influence of centrifugal forces of rotation of the spinner, attenuating the streams to fibers whereby the attenuated fibers in column formation move downwardly away from the spinner and generally parallel with the axis of the spinner, engaging fibers of the moving column by jets of gas to deflect the fibers in directions generally parallel with and downstream of a moving fiber-collecting surface, and collecting the fibers on the moving surface.

4. The method of forming and collecting fibers of heat-softened glass including rotating a spinner having an orificed wall region and an imperforate floor portion about an axis disposed at an acute angle with respect to a horizontal plane, feeding heat-softened glass onto the floor portion of the spinner, projecting streams of the glass from the orificed region of the spinner under the influence of centrifugal forces of rotation of the spinner, attenuating the streams to fibers whereby the attenuated fibers in column formation move downwardly away from the spinner and generally parallel with the axis of the spinner, directing jets of gas substantially horizontally and beneath the angularly moving column of fibers and downstream of the moving column of fibers, engaging the fibers by the jets of gas to deflect the fibers in directions generally parallel with a moving fiber-collecting surface, and collecting the fibers on the moving surface.

6. The method according to claim 5 wherein the jets of gas are jets of compressed air.

7. The method of forming and collecting fibers of heat-softened fiber-forming material from at least two fiber-forming instrumentalities including rotating a spinner of each instrumentality having an orificed peripheral wall region and an imperforate floor region about an axis disposed at an acute angle with respect to a horizontal plane, feeding the heat-softened material onto the imperforate floor regions of the rotating spinners, projecting streams of the material through orifices at the orificed wall region of each of the spinners under the influence of centrifugal forces of rotation of the spinners, attenuating the streams from each spinner to fibers whereby the attenuated fibers in column formation from each spinner move downwardly and generally parallel with the axes of the spinners, directing jets of gas substantially horizontally and beneath the angularly moving columns of fibers, engaging the fibers of the columns by the jets of gas to deflect the fibers in directions generally parallel with and downstream of a moving fiber-collecting surface, distributing the fibers by the forces of the jets of gas lengthwise and transversely of the moving surface, and collecting the fibers on the moving surface.

8. A method of forming and collecting fibers of heat-softened glass including rotating a spinner having an orificed wall region and an imperforate floor portion about an axis disposed at an acute angle with respect to a horizontal plane, feeding a stream of the heat-softened glass onto the floor portion of the spinner, projecting primary filaments of the glass from the orificed wall region of the spinner under the influence of centrifugal forces of rotation of the spinner, attenuating the primary filaments to fibers, impinging jets of air into engagement with the attenuated fibers distributing the fibers lengthwise and laterally of a lengthwise moving fiber-collecting surface, establishing a plurality of partitioned zones arranged lengthwise of and beneath the collecting surface, withdrawing gases from each of the partitioned zones providing reduced pressure in each of said zones to influence the collection of fibers on the moving surface, and regulating the rate of withdrawal of gases from each of the partitioned zones for varying the amplitude of reduced pressure in each individual zone.

9. Apparatus for forming fibers of heat-softened fiber-forming material including, in combination, support means, a hollow spinner having an imperforate floor portion and an orificed peripheral wall mounted by the support means, the axis of the spinner being disposed at an acute angle with respect to a horizontal plane, means for delivering a stream of the heat-softened material into the spinner, the acute angle of the spinner axis being such that the heat-softened material engages the imperforate floor portion of the spinner, means for rotating the spinner to project primary filaments of the material from the orifices in the spinner wall, means attenuating the primary filaments to fibers whereby the attenuated fibers move downwardly in column formation and generally parallel with the axis of the spinner, a moving fiber-collecting conveyor, and nozzle means disposed beneath the column of fibers, said nozzle means delivering streams of gas into engagement with the fibers for entraining and conveying the fibers downstream of the moving conveyor for collection on the moving conveyor, said nozzle means being adjustable for varying the distribution of the fibers transversely of the moving conveyor.

12. Apparatus for forming and collecting fibers of heat-softened glass including, in combination, support means, a plurality of fiber-forming intrumentalities mounted by the support means, each instrumentality including a rotatable spinner having an orificed peripheral wall region and an imperforate floor portion, each of the spinners being rotatable about an axis disposed at an acute angle with respect to a horizontal plane, means for rotating the spinners, means for deivering a stream of heat-softened glass onto the imperforate floor portion of each of the rotating spinners, projecting primary filaments of the glass through orifices at the orificed wall region of each of the spinners under the influence of centrifugal forces of rotation of the spinners, means attenuating the primary filaments from each spinner to fibers whereby the attenuated fibers in column formation from each spinner move downwardly and generally parallel with the axes of the respective spinners, a moving foraminous fiber-collecting conveyor, nozzle means projecting jets of compressed air substantially horizontally and beneath the angularly moving columns of fibers in directions downstream of the columns of the fibers whereby the jets of compressed air engage the fibers of the columns to deflect the fibers in directions generally parallel with and downstream of the moving fiber-collecting surface, said nozzle means being arranged whereby the jets of compressed air distribute the fibers lengthwise and transversely of the moving conveyor on which the fibers are collected.

13. The combination according to claim 12 wherein the axis of each of the spinners is disposed at an acute angle of about 45* with respect to a horizontal plane.

14. Apparatus for forming and collecting fibers of heat-softened glass including, in combination, support means, a plurality of fiber-forming instrumentalities mounted by the support means, each instrumentality including a rotatable spinner having an orificed peripheral wall region and an imperforate floor portion, each of the spinners being rotatable about an axis disposed at an acute angle with respect to a horizontal plane, means for rotating the spinners, means for delivering a stream of heat-softened glass onto the imperforate floor portion of each of the rotating spinners, projecting primary filaments of the glass through orifices at the orificed wall region of each of the spinners under the influence of centrifugal forces of rotation of the spinners, means attenuating the primary filaments from each spinner to fibers whereby the attenuated fibers in column formation from each spinner move downwardly and generally parallel with the axes of the respective spinners, a moving foraminous fiber-collecting conveyor, nozzle means projecting jets of compressed air substantially horizontally and beneath the angularly moving columns of fibers in directions downstream of the columns of the fibers whereby the jets of compressed air engage the fibers of the columns to deflect the fibers in directions generally parallel with and downstream of the moving fiber-collecting surface, said nozzle means being arranged whEreby the jets of compressed air distribute the fibers lengthwise and transversely of the moving conveyor on which the fibers are collected, a receptacle disposed beneath and extending lengthwise of the foraminous conveyor, transverse partitions disposed in the receptacle providing a plurality of individual chambers, suction blower means, tubular means establishing communication of the suction blower means with each of the chambers providing reduced pressure in each of the chambers effective to collect the fibers on the conveyor, and valve means associated with the tubular means for individually regulating the amplitude of reduced pressure in each chamber.