Fiber insertion device for continuous 3d foaming machine and method

Abstract

A method and apparatus are described for the making of a three dimensional filament reinforced foam insulation member. Generally parallel arrays of vertically stacked fabric or cloth having filaments running in an X-Y axis are reinforced by third axis Z directional filaments pre-cut to a desired length and inserted down through openings referred to as vertical columns hereinafter through the said array. The Z filaments are air directed through the stack of open weave. After the formation of the filament reinforced weave the assembly is impregnated with foam to form a unitary member. The apparatus to form the article and carry out the method above consists of a conveyor carrying stacked open weave fabric through an open ended enclosure wherein there are provided first vertical tubes and second vertical tubes. The second vertical tubes are injected into the stack or array of open weave. The first vertical tubes are telescopically inserted into the tops of the said second vertical tubes. A filament is fed vertically downwardly into the first vertical tube and cut to a predetermined length. Compressed air in a chamber surrounding the said first vertical tube assists in forcing the filaments into the said second vertical tube. The said second vertical tube may be vibrated to prevent hang up of the desired Z directional filament. The said second set of vertical tubes are retracted from the array after the array is completely reinforced with Z directional filament. Thereafter foam insulating may fill the reinforced array. Additional cutters may be provided for trim purposes to remove excess Z directional filaments extending above the array.