Manufacturing a laminated pack of mineral fibers and resulting product

Claim 2

Apparatus for producing a laminated pack of mineral fibers comprising (a) a first forming conveyor, a plurality of sources of mineral fibers positioned to successively deposit mineral fibers onto said first forming conveyor to form a first layer of mineral fibers, and first vacuum means to provide suction to said mineral fibers through said first forming conveyor, said first vacuum means being adapted to provide sufficient suction to force substantially all of the mineral fibers downwardly onto the first forming conveyor, thereby crushing the bottom portion of said first layer and forming a first bottom surface on said first layer which is smooth relative to the top surface of said first layer (b) a second forming conveyor, a plurality of sources of mineral fibers positioned to successively deposit mineral fibers onto said second forming conveyor to form a second layer of mineral fibers, second vacuum means to provide suction to said mineral fibers through said second forming conveyor, said second vacuum means being adapted to provide sufficient suction to force substantially all of the mineral fibers downwardly onto the second forming conveyor, thereby crushing the bottom portion of said second layer and forming a second bottom surface on said second layer which is smooth relative to the top surface of said second layer, and means for changing the path of said second layer to a generally downward direction while maintaining the suction on said second layer; and (c) means for joining said top surfaces of said first and second layers to produce a laminated pack having as its outer surfaces of said first and second bottom surfaces.

Claim 3

The apparatus of claim 1 in which said means for changing the path of said first layer comprises a rotatable slot roll around which said first forming conveyor travels.

Claim 4

The apparatus of claim 2 in which said means for joining comprises said first forming conveyor and said second forming conveyor.

Claim 6

The apparatus of claim 4 comprising means for moving the first rotatable slot roll in a direction toward or away from said second forming conveyor.

Claim 7

Apparatus for producing a laminated pack of mineral fibers comprising (a) a first forming conveyor, a plurality of sources of mineral fibers positioned to successively deposit mineral fibers onto said first forming conveyor to form a first layer of mineral fibers, first vacuum means to provide suction to said mineral fibers through said first forming conveyor, said first vacuum means being adapted to provide sufficient suction to force substantially all of the mineral fibers downwardly onto the first forming conveyor, thereby crushing the bottom portion of said first layer and forming a first bottom surface on said first layer which is smooth relative to the top surface of said first layer, and means for changing the path of said first layer to a generally downward direction while maintaining the suction on said first layer; (b) a second forming conveyor, a plurality of sources of mineral fibers positioned to successively deposit mineral fibers onto said second forming conveyor to form a second layer of mineral fibers, second vacuum means to provide suction to said mineral fibers through said second forming conveyor, said second vacuum means being adapted to provide sufficient suction to force substantially all of the mineral fibers downwardly onto the second forming conveyor, thereby crushing the bottom portion of said second layer and forming a second bottom surface on said second layer which is smooth relative to the top surface of said second layer, and means for changing the path of said second layer to a generally downward direction while maintaining the suction on said second layer; and where (c) said first forming conveyor is positioned adjacent said second forming conveyor so that after the paths of said first and second layers are turned downward said top surfaces of said first and second layers are joined to produce a laminated pack having as its outer surfaces said first and second bottom surfaces.

Claim 8

Apparatus for producing a laminated pack of mineral fibers comprising (a) a first forming conveyor, a plurality of sources of mineral fibers positioned to successively deposit mineral fibers onto said first forming conveyor to form a first layer of mineral fibers, first vacuum means to provide suction to said mineral fibers through said first forming conveyor, said first vacuum means being adapted to provide sufficient suction to force substantially all of the mineral fibers downwardly onto the first forming conveyor, thereby crushing the bottom portion of said first layer and forming a first bottom surface on said first layer which is smooth relative to the top surface of said first layer, and means for changing the path of said first layer to a generally downward direction while maintaining the suction on said first layer; (b) a second forming conveyor, a plurality of sources of mineral fibers positioned to successively deposit mineral fibers onto said second forming conveyor to form a second layer of mineral fibers, second vacuum means to provide suction to said mineral fibers through said second forming conveyor, said second vacuum means being adapted to provide sufficient suction to force substantially all of the mineral fibers downwardly onto the second forming conveyor, thereby crushing the bottom portion of said second layer and forming a second bottom surface on said second layer which is smooth relative to the top surface of said second layer, and means for changing the path of said second layer to a generally downward direction while maintaining the suction on said second layer; and where (c) said first forming conveyor is positioned adjacent said second forming conveyor so that after the paths of said first and second layers are turned downward said top surfaces of said first and second layers are joined to produce a laminated pack having as its outer surfaces said first and second bottom surfaces.

Claim 9

The apparatus of claim 6 comprising means for moving one of said forming conveyors in a direction toward or away from the other of said forming conveyors.

Claim 12

The method of claim 8 comprising joining said top surfaces by directing said first and second layers between said first and second forming conveyors.

Claim 13

The method of claim 9 comprising changing the paths of said first and second layers by turning said first and second layers downwardly around first and second slot rolls, respectively.

Claim 14

The method of claim 8 comprising changing the path of said first layer to a generally downward direction while maintaining the suction on said first layer.

Claim 15

A mineral fiber insulation pack made by the method of claim 8.

Claim 16

A mineral fiber insulation pack made by the method of claim 11.

Claim 17

A mineral fiber insulation pack made by the method of claim 9.

Claim 20

Apparatus for producing a laminated pack of mineral fibers comprising (a) a first forming conveyor, a plurality of sources of mineral fibers positioned to successively deposit mineral fibers onto said first forming conveyor to form a first layer of mineral fibers, and first vacuum means to provide suction to said mineral fibers through said first forming conveyor, said first vacuum means being adapted to provide sufficient suction to force substantially all of the mineral fibers downwardly onto the first forming conveyor, thereby crushing the bottom portion of said first layer and forming a first bottom surface on said first layer which is smooth relative to the top surface of said first layer; (b) a second forming conveyor, a plurality of sources of mineral fibers positioned to successively deposit mineral fibers onto said second forming conveyor to form a second layer of mineral fibers, second vacuum means to provide suction to said mineral fibers through said second forming conveyor, said second vacuum means being adapted to provide sufficient suction to force substantially all of the mineral fibers downwardly onto a second forming conveyor, thereby crushing the bottom portion of said second layer and forming a second bottom surface on said second layer which is smooth relative to the top surface of said second layer; (c) means for changing the path of either said first layer or said second layer or both to join said top surfaces of said first and second layers to produce a laminated pack having as its outer surfaces said first and second bottom surfaces; and (d) means for maintaining the suction on said layer or layers as its path is being changed.

Claim 21

Apparatus for producing a laminated pack of mineral fibers comprising (a) a first forming conveyor, a plurality of sources of mineral fibers positioned to successively deposit mineral fibers onto said first forming conveyor to form a first layer of mineral fibers, and first vacuum means to provide suction to said mineral fibers through said first forming conveyor, said first vacuum means being adapted to provide sufficient suction to force substantially all of the mineral fibers downwardly onto the first forming conveyor, thereby crushing the bottom portion of said first layer and forming a first bottom surface on said first layer which is smooth relative to the top surface of said first layer; (b) a second forming conveyor, a plurality of sources of mineral fibers positioned to successively deposit mineral fibers onto said second forming conveyor to form a second layer of mineral fibers, second vacuum means to provide suction to said mineral fibers through said second forming conveyor, said second vacuum means being adapted to provide sufficient suction to force substantially all of the mineral fibers downwardly onto a second forming conveyor, thereby crushing the bottom portion of said second layer and forming a second bottom surface on said second layer which is smooth relative to the top surface of said second layer; (c) means for changing the path of either said first layer or said second layer or both to join said top surfaces of said first and second layers to produce a laminated pack having as its outer surfaces said first and second bottom surfaces; and (d) means for maintaining the suction on said layer or layers as its path is being changed.