Fiber mat forming method

Abstract

A fiber mat as well as its method of fabrication and forming machine are described. The fiber mat comprises a plurality of fibers which are limitations bound together and distributed throughout the mat, and wherein some of the fibers are inclined towards a central horizontal plane of the mat. The inclined fibers on opposed sides of the mat have opposed angles of inclination whereby the mat, when used as insulation, can be easily separated substantially along the central horizontal plane by applying a pulling force on one side or opposed sides of the mat in the direction of the inclined fibers. The forming machine is characterized by having two forming surfaces, one disposed horizontally and the other vertically whereby the mat is formed with higher density towards the opposed flat horizontal surfaces of the mat and the lower density is distributed along the central horizontal plane. By having these opposed forming surfaces there is provided a former which provides double formation capacity capable of providing a mat with improved density profile, provides higher air flow, less shingling effect, and the production of a mat which can be easily split substantially in the middle along the central horizontal plane when used as an insulating mat. Because the former doubles the capacity of fibers and also the thickness of the formed mat, it is possible to compress the mat to form fiber boards.