Process and machine for manufacturing insulation modules

Claim 2

A PROCESS FOR THE MANUFACTURING OF INSULATED ENCLOSURE LINEAR MODULES, SAID PROCESS COMPRISING: SEVERING FROM A STACK OF SHEETS OF FIBROUS INSULATION MATERIAL A PLURALITY OF GENERALLY RETANGULAR BATTENS OF SUBSTANTIALLY SIMILAR SIZE AND DISPOSED IN SIDE TO SIDE RELATIONSHIP, EACH OF SAID BATTENS BEING COMPOSED OF A THICKNESS OF FIBROUS INSULATION MATERIAL AND HAVING SIDE AND EDGE SURFACES, SAID EDGE SURFACES BEING OF SMALLER DIMENSION THAN THE DIMENSION OF SAID SIDE SURFACES, SAID BATTENS COOPERATING TO DEFINE A PAD OF INSULATING MATERIAL; FORMING A FIBROUS PAD OF GENERALLY RETANGULAR CONFIGURATION, THE EDGE SURFACES OF SAID BATTENS BEING EXPOSED AT THE SIDE SURFACES OF SAID PAD; PROVIDING A SUBSTRATE OF A DIMENSION CORRESPONDING TO THE DIMENSION OF SAID PAD AND SUPPORTING SAID SUBSTRATE; COATING AT LEAST ONE OF THE SIDE SURFACES OF SAID SUBSTRATE WITH AN ADHESIVE MATERIAL; SECURING A CONNECTING MEMBER TO SAID SUBSTRATE PRIOR TO ASSEMBLY OF SAID SUBSTRATE AND SAID FOBROUS PAD, SAID CONNECTING MEMBER EXTENDING FROM A COATED SURFACE OF SAID SUBSTRATE; PROTECTING SAID CONNECTING MEMBER FROM SAID ADHESIVE MATERIAL DURING COATING OF SAID SUBSTRATE; BRINGING SAID PAD UNIT INTO INTIMATE ENGAGEMENT WITH SAID COATED SURFACE OF SAID SUBSTRATE; AND RETAINING SAID PAD UNIT AND SUBSTRATE IN A STATE OF COMPRESSION DURING CURING OF SAID ADHESIVE MATERIAL.

Claim 3

A process as recited in claim 1, wherein said coating includes coating the side edges of said substrate with said adhesive and said process includes: providing a plurality of edge battens of fibrous insulation material; securing said edge battens of fibrous insulation material to each of the edge surfaces of said fibrous pad by bringing the same into assembly in the presence of said adhesive material; and maintaining said pad, said substrate and said edge battens under mechanical pressure during curing of said adhesive material.

Claim 4

A process as recited in claim 1, wherein: said substrate comprises a block of material having side surfaces of substantially the same size as the side surfaces of said fibrous pad; and at least substantially enclosing said module with a protective wrapper, said wrapper maintaining said module under mechanical compression.

Claim 5

A process as recited in claim 3, wherein said module is enclosed in a protective wrapper by: locating protective wrapping material relative to a module assembly station prior to assembly of said pad and said block; placing said pad at said module assembly station on top of at least a portion of said wrapping material; bringing said block into assembly with said pad thus forming said module; forcing said module and wrapping material into a folding receiver thus simultaneously folding portions of said wrapping material about said module and mechanically compressing said module; and securing said folded portions of said wrapping material about said module.

Claim 6

A process as recited in claim 3, wherein: said securing of said folded portions of said wrapping material is accomplished by forcing staples through said wrapping material into said block to retain said wrapping material in assembly with said module.

Claim 7

A process as recited in claim 1 wherein said adhesive is grout applied in a substantially viscous liquid form and is applied by providing a contained quantity of grout; securing said substrate to a movable fixture prior to assembly of said module; and lowering said substrate by movement of said fixture sufficiently into said contained quantity of grout to coat one of the side surfaces and substantially all of said edge surfaces of said substrate with grout.

Claim 8

A process as recited in claim 6, wherein assembly of said substrate and said pad is accomplished after coating of said substrate with grout by: bringing said grout coated side surface of said substrate into assembly with one of the side surfaces of said pad; and applying mechanical pressure during at least part of the curing period of the grout.

Claim 9

A process as recited in claim 7, including: providing a plurality of edge battens of fibrous insulation material having side surfaces of a width substantially equaling the combined thickness of said fibrous pad and said substrate; bringing said edge battens of fibrous insulation material into engagement with said grout coated edges of said substrate; and applying mechanical force to said edge battens of fibrous insulation material and to said substrate during at least a portion of the curing period of the grout.

Claim 10

A process as recited in claim 8, including: at least partially enclosing said module in a protectivE wrapper, said protective wrapping maintaining said module under mechanical compression during complete curing of the grout.

Claim 11

A process as recited in claim 8, including: at least partially enclosing said module in a protective wrapper, said protective wrapper maintaining said module under mechanical compression during complete curing of the grout.

Claim 12

A process for the manufacture of insulated furnace liner modules, said process comprising: arranging a plurality of layers of fibrous insulating material into a multi-layer stack; imparting incremental linear movement to said stock; severing a portion of said stack at each increment of movement of said stack, thereby defining a generally rectangular pad composed of a plurality of battens of fibrous insulating material, said pad having side surfaces defined by exposed edge surfaces of said battens; providing a generally rigid block of insulating material, said block having side surfaces corresponding to the configuration and dimension of said pad and having a plurality of edge surfaces; providing a quantity of uncured adhesive material having a curing period; bringing one of said side surfaces of fibrous insulation material having side surfaces of a width and said block into engagement with said adhesive material therebetween, defining a pad/block assembly having side surfaces and edge surfaces; providing a plurality of edge battens of a width substantially equaling the combined thickness of said assembled pad and block; securing said edge battens of fibrous insulation material to each of the edge surfaces of said pad block assembly by bringing the side surfaces of each of said edge battens into assembly with respective ones of the edge surfaces of said pad block assembly in the presence of a quantity of said adhesive and defining an assembled insulating module; and applying mechanical force to said assembled module during at least a portion of the curing period of said adhesive material.

Claim 13

A process for the manufacture of insulated furnace liner modules, said process comprising: arranging a plurality of layers of fibrous insulating material into a multi-layer stack; imparting incremental linear movement to said stock; severing a portion of said stack at each increment of movement of said stack, thereby defining a generally rectangular pad composed of a plurality of battens of fibrous insulating material, said pad having side surfaces defined by exposed edge surfaces of said battens; providing a generally rigid block of insulating material, said block having side surfaces corresponding to the configuration and dimension of said pad and having a plurality of edge surfaces; providing a quantity of uncured adhesive material having a curing period; bringing one of said side surfaces of fibrous insulation material having side surfaces of a width and said block into engagement with said adhesive material therebetween, defining a pad/block assembly having side surfaces and edge surfaces; providing a plurality of edge battens of a width substantially equaling the combined thickness of said assembled pad and block; securing said edge battens of fibrous insulation material to each of the edge surfaces of said pad block assembly by bringing the side surfaces of each of said edge battens into assembly with respective ones of the edge surfaces of said pad block assembly in the presence of a quantity of said adhesive and defining an assembled insulating module; and applying mechanical force to said assembled module during at least a portion of the curing period of said adhesive material.

Claim 14

A process as recited in claim 11, including: at least partially enclosing said module in a protective wrapping in such manner as to maintain said module under mechanical compression during at least a part of the curing period of said adhesive material.

Claim 15

A process as recited in claim 12, wherein wrapping said module comprises: locating protective wrapping material relative to a module assembly station prior to assembly of said pad and said block; placing said pad at said mocule assembly station on top of at least a portion of said wrapping material; bringing said block into assembly with said pad thus forming said module; folding portions of said wrapping material about said module; and securing said folded portions of said wrapping material about said module.

Claim 16

A process as recited in claim 13, wherein: said securing of said folded portions of said material is accomplished by stapling said wrapping material to said block.

Claim 17

A process as recited in claim 11, wherein said adhesive material is grout, applied in substantially viscous liquid uncured form and is applied by: providing a contained quantity of grout; placing said block into a movable fixture prior to formation of said pad block assembly; lowering said block by movement of said fixture sufficiently into said contained quantity of grout to coat one of the side surfaces and substantially all of the edge surfaces of said block with grout.

Claim 18

A process as recited in claim 15, wherein assembly of said block and pad is accomplished after coating of said block with grout by: bringing said grout coated side surface of said block into assembly with one of the side surfaces of said pad; and applying mechanical pressure to said block and pad during at least part of the curing of grout.

Claim 19

A process as recited in claim 16, including: providing a plurality of edge battens of fibrous insulation material having side surfaCes of a width substantially equaling the combined thickness of said fibrous pad and said block of insulation material; bringing said edge battens of fibrous insulation material into engagement with said grout coated edges of said block; and applying mechanical force to said edge battens of fibrous material and to said block during at least a portion of the curing time of grout.

Claim 20

A process as recited in claim 11, including: severing said stacked layers of fibrous insulation material longitudinally prior to incremental severing of said stack and defining at least two elongated stacks of fibrous insulation material; and said incremental severing defining a plurality of said generally rectangular pads of insulation material at each incremental severing operation, each of said pads being separately handled in assembly of separate modules.

Claim 21

A process as recited in claim 11, wherein said arranging of said plurality of layers of fibrous material into a stack comprises: arranging the trailing extremity of each of said layers in such manner that each of the layers is staggered the width of one of said battens, whereby a similar succeeding stack of such layers may be formed to enable the fibrous material to be fed continuously without encountering a vertical joint extending through all of the layers.

Claim 22

A machine for the manufacture of insulated modules for lining enclosures such as furnaces and the like, said machine comprising: means for retaining a supply of elongated sheets of fibrous insulation material; means for severing from said supply of elongated sheets a pad of insulating material comprised of a plurality of battens of said insulation material arranged in side to side relation; means for locating said insulating pad of insulation material with the edge surfaces of the battens exposed and cooperating to define side surfaces of said insulating pad; means defining a module assembly station; means for retaining said pad of insulating material at said module assembly station; means for coating a mineral block of insulating material with an adhesive material; means for transporting said coated mineral blocks to said module assembly station and bringing said coated mineral blocks into assembly with said pad of insulating material, thereby defining an insulation module assembly; and means for placing said insulation module assembly under mechanical compression during at least a part of the curing period of said adhesive material.

Claim 23

A machine for the manufacture of insulated modules for lining enclosures such as furnaces and the like, said machine comprising: means for retaining a supply of elongated sheets of fibrous insulation material; means for severing from said supply of elongated sheets a pad of insulating material comprised of a plurality of battens of said insulation material arranged in side to side relation; means for locating said insulating pad of insulation material with the edge surfaces of the battens exposed and cooperating to define side surfaces of said insulating pad; means defining a module assembly station; means for retaining said pad of insulating material at said module assembly station; means for coating a mineral block of insulating material with an adhesive material; means for transporting said coated mineral blocks to said module assembly station and bringing said coated mineral blocks into assembly with said pad of insulating material, thereby defining an insulation module assembly; and means for placing said insulation module assembly under mechanical compression during at least a part of the curing period of said adhesive material.

Claim 24

A MACHINE AS RECITED IN CLAIM 20, INCLUDING: MEANS FOR AT LEAST PARTIALLY ENCLOSING SAID INSULATION MODULE ASSEMBLY IN A PROTECTIVE WRAPPING, SAID WRAPPING MAINTAINING SAID MODULE UNDER A DEGREE OF COMPRESSION DURING FULL CURING OF SAID ADHESIVE MATERIAL.

Claim 25

A machine as recited in claim 20, including: a supply of edge battens of fibrous material; a plurality of said edge battens of fibrous material being placed about the exposed edges of said pad of insulation material and the coated mineral block by manual operation, said edge battens of fibrous material cooperating with said pad and said block to define said insulation module; and means for at least partially enclosing said insulation module assembly in a protective wrapping and maintaining said module under a degree of compression during curing of said adhesive material.

Claim 26

A machine as recited in claim 20, wherein said means for retaining a supply of elongated sheets of fibrous insulation material comprises: elongated conveyor means defining a stack support, said fibrous material being positioned in layers on said conveyor means and defining a multi-layer stack, said stack being moved incrementally by said conveyor means by an increment distance equaling the thickness of said pad of insulation material.

Claim 27

A machine as recited in claim 23, wherein said means for severing battens of said insulation material from said supply comprises: a cross cut saw mechanism being Disposed in movable relation to said conveyor means; and means for causing transverse movement of said cross cut saw mechanism and causing a cut across the leading extremity of said multi-layer stack of insulating material following each increment of movement of said stack by said conveyor means, said battens and said pad of battens of insulating material resulting from said transverse movement of said crosscut saw mechanism.

Claim 28

A machine as recited in claim 24, wherein said means for arranging said battens of insulation material in side-by-side relationship comprises: means for applying said plurality of sheets of insulation material in said multi-layer stack on said conveyor means, together with said means for severing battens of insulation material from said multi-layer stack.

Claim 29

A machine as recited in claim 20, wherein said means for positioning said pad of insulating material at a module assembly station comprises: fixture means for engaging the leading extremity of the multi-layer stack of insulating material prior to severing battens of insulation material from said stack, said engaging means being capable of retaining each of the various layers of said stack of insulating material in substantially immovable relation with the other layers, said fixture means being manually movable from the leading extremity of said stack to said module assembly station, transporting said pad therewith; and insulating pad ejector means being provided on said fixture means and being operative to eject said pad of insulating material from said fixture after said pad has been properly positioned at said assembly station of said machine.

Claim 30

A machine as recited in claim 26, wherein said fixture means includes: impaling means being disposed for receiving and retaining relationship within the various layers of fibrous insulating material of said stack, said impaling means retaining said battens of said pad of insulating material in substantially immovable relation one with the other during movement of said pad to said module assembly station.

Claim 31

A machine as recited in claim 27, wherein said fixture includes: locking means for retaining said fixture mechanism in a static position during transporting and positioning of said pad at said module assembly station; and said insulating pad ejector means being operative upon release of said locking means for ejecting said pad of insulating material from said impaling means.

Claim 32

A machine as recited in claim 28, wherein said pad ejector means comprises: an ejector plate disposed in movable relation to said fixture and having a plurality of apertures formed therein, said impaling means extending through said apertures; an ejector and locking shaft being movably carried by said fixture, said shaft being connected to said ejector plate; and means for imparting movement to said ejector plate and causing said impaling means to be separated from said pad of insulation material.

Claim 33

A machine as recited in claim 29, wherein said means for imparting movement to said ejector plate comprises a compression spring carried by said fixture and imparting a force to said shaft for movement of said shaft in one direction thereof.

Claim 34

A machine as recited in claim 20, wherein said means defining said assembly station comprises: pad locating means; and means for maintaining said module under mechanical compression during at least a portion of the curing time of said adhesive material.

Claim 35

A machine as recited in claim 31, wherein said pad locating means comprises: a module support plate; and a plurality of pad locating fingers projecting upwardly from said module support plate.

Claim 36

A machine as recited in claim 32, wherein said pad locating means also comprises: sheet locator means that extend through apertures formed in a sheet of protective wrapping material; and said module assembly station includes means for at least partially enclosing said module in said sheet of protective wrapping material during assembly of said module.

Claim 37

A machine as recited in claim 20, wherein said module assembly station of said machine comprises: receptacle means; a module support plate being disposed in receiving alignment with said receptacle means and being adapted for lowering into said receptacle means; and a linear fluid motor being disposed at the lower portion of said receptacle means and being operatively connected to said module support plate, said linear fluid motor yielding responsive to application of sufficient force to said module to achieve predetermined compression of said module and allowing said module to be forced into said receptacle along with said module support plate.

Claim 38

A machine as recited in claim 34, wherein said module assembly station includes: wrapper folding means disposed in movable assembly with said receptacle and being operative responsive to predetermined movement of said module support plate and said module into said receptacle to cause folding of a protective wrapper about at least a portion of said module.

Claim 39

A machine as recited in claim 20, wherein said means for coating a mineral block of insulating material with an adhesive material comprises: means for providing a quantity of uncured adhesive material; means for retaining a mineral block of insulating material to be coated; means for lowering said mineral block into said adhesive material sufficiently to coat one of the side surfaces and substantially all of the edge surfaces of the block with a coating of said adhesive material and for raising said coated mineral block from said adhesive material following coating thereof; and means for transporting said coated mineral block to said module assembly station and for placing said mineral block in assembly with said pad of insulating material.

Claim 40

A machine as recited in claim 36, wherein said means providing a quantity of uncured adhesive material comprise: a bin having an outlet opening defined at the lowermost portion thereof, said ben containing a quantity of adhesive material; adhesive containing means being disposed adjacent said bin; means for continuously transporting adhesive material from said bin to said adhesive containing means, said adhesive containing means receiving said mineral blocks for coating the same with said adhesive.

Claim 41

A machine as recited in claim 37, wherein said means for continuously transporting adhesive material comprises: pump means having the suction side thereof in communication with said outlet opening of said bin and having the discharge side thereof disposed in communication with said adhesive containing means; and said adhesive containing means discharging overflow of adhesive material therefrom into said bin.

Claim 42

A machine as recited in claim 36, wherein said means for retaining a mineral block of insulating material comprises: block support plate means; a plurality of spike means adapted for retaining engagement into a mineral block to be supported thereby; and means for ejecting said mineral block from said spike means of said mineral block support plate means.

Claim 43

A machine as recited in claim 39, wherein said ejecting means comprises: ejector housing means being connected to said block support plate means, said connector housing being received by said block transporting means; hydraulic block ejection cylinder means being disposed within said ejector housing means and having an operating stem disposed for ejecting engagement with said mineral block and ejecting said mineral block from said spike means upon actuation of said hydraulic block ejection cylinder.

Claim 44

A machine as recited in claim 36, wherein said means for transporting and placing said mineral block comprises: hydraulic cylinder means being said means for lowering and raising said mineral block; and means pivotally mounting said hydraulic cylinder means fOr movement through an arc comprising the arcuate distance between said means for coating said mineral block and said module assembly station.

Claim 45

A machine as recited in claim 20, wherein said means for severing battens of insulation material comprises: means for causing incremental linear movement of said supply of elongated sheets of fiberous insulation material; a transverse saw mechanism; means for raising and lowering said saw mechanism relative to said supply of elongated sheets of fiberous insulation material, said saw mechanism being lowered following each increment of linear movement of said supply of elongated sheets.

Claim 46

A machine as recited in claim 42, wherein said means for severing battens of insulation material includes: a dividing saw mechansim being disposed in alignment with the linear axis of said supply of said sheets of insulation material, said dividing saw mechanism dividing said sheets into linear strips upon linear movement of said supply of elongated sheets of insulation material.

Claim 47

A machine as recited in claim 43, wherein said supply of elongated sheets of insulation material comprises: a multi-layer stack of elongated sheets of said insulation material; and conveyor means supporting said stack and being operative to cause incremental movement of said stack toward said transverse and dividing saw mechanisms, said dividing saw mechanism severing said stack into a plurality of elongated stacks and said transverse saw mechanism causing a transverse cut through said stack simultaneously severing a plurality of battens defining a pad of insulation material from each of said plurality of elongated stacks.