Method and apparatus for producing blankets of mineral fibers

Abstract

A machine for forming mineral fibers into mats or blankets comprising a plurality of modules each including primary fiber formers, fiber attenuation means, binder applicators, and fiber collectors to produce continuous lengths of mat. A common conveyor is adapted to receive the mats of each module at spaced mat receiving stations along its length. The common conveyor receives the uncured mats in juxtaposition to each other and conveys them to stations for further processing. Each module is adapted to operate and be taken off or put on line without disruption of the operation of the other modules. Each includes a scrap conveyor for primary fibers, a fiber collection conveyor cleaning means for the conveyor and a suction box all of which are shielded from the common conveyor to avoid contamination of the mat on the common conveyor. Flexibility is afforded by the modules since combined fiber layers of different fiber characteristic, with different additives and binders, with interlayers or septa including septa which is gas impermeable, and in a wide range of densities and thickness can be produced on an in-line basis. Output can be split so that one or more modules are arranged to produce a mat for a first product while one or more other modules are producing a mat for a second product. A split, bidirectional common conveyor is utilized to optionally issue mat from one or both ends of the machine. Fiber attenuation by gas blast is preferred for the modules and is arranged to direct the fibers vertically downward to a horizontal fiber collection conveyor at a low velocity and low enough temperature to avoid curing the binder for the fibers on the collection conveyor. A liquid reverse flush of the collection conveyor removes fibers and binder which adhere to the conveyor surface.