Feeder assembly for insulation blowing machines

A feeder assembly for particulate matter blowing machines including a cylindrical member with an opening along its upper surface through which particulate matter is inserted. A drive shaft is positioned longitudinally through the member and a cylindrical drum mounted around the drive shaft. A vane assembly attached to the drum engages the inner surface of the member at a plurality of locations thereby defining a plurality of airlocks. An inlet cover is attached to one end of the member and it has an inlet opening through which gases are forced into the airlocks. An outlet cover is attached to the opposite end of the cylindrical member and the outlet cover has an outlet opening aligned with the inlet opening through which the particulate matter is blown out of the airlocks. A motor turns the drive shaft whereby the airlocks pass adjacent the opening and particulate matter fills the airlocks, and then the airlocks are rotated until adjacent the openings when the material is blown out.

BACKGROUND OF THE INVENTION 
This invention relates to an apparatus for producing particulate material 
from compact masses of material. More particularly the present invention 
is concerned with an apparatus for producing particulate material from 
compressed or compacted masses of material such as insulation materials 
and then pneumatically blowing or spraying such materials. This invention 
further relates to an improved feeder assembly for such an apparatus which 
pneumatically blows such materials to the desired location. 
In general the types of insulation materials with which the present 
invention is concerned include loose insulating material that is 
generally, but not exclusively, fibrous such as granulated rock wool, 
granulated mineral fiber wool, glass fiber materials, cellulose fibers, 
expanded mica, etc. This insulation material may be in particulate form 
and may be either blown dry or sprayed through a nozzle with liquid added 
to form an insulating and sealing coating on any surface. The insulation 
material has been blown on conven-tional ceilings of places of habitation 
or working areas as well as in mine shafts, tunnels and the like. 
The insulating material used in conventional insulation spraying and 
blowing machines is in a relatively loose condition but it is usually 
packed under high compression in bags or sacks for shipment to the user. 
Upon being opened these bags or sacks usually yield compressed masses of 
the insulation material that render the insulation material difficult to 
use in conventional apparatus that require feeding through an air hose to 
the area to be insulated. Because of the very low density of the material 
there is usually formed under the compaction in the bags or sacks large 
masses that are perhaps up to a foot or more in diameter and cannot be 
easily separated into the individual particulate material. Even smaller 
masses in the form of nodules that may be up to several inches in diameter 
are unsuitably large to be fed through an air hose or to be effective in 
providing the desired insulation. These large masses as well as the 
nodules must be separated into particulate materials, although they may be 
to some extent intertwined with each other and not be discrete. The 
fibrous material forming the majority of the insulating materials is 
typically the most difficult to handle unless it is kept in a 
semi-fluidized state which desirably relies upon the material being 
particulate. The term "particulate" includes not only particles but also 
one or more intertwined or overlapping fibers and for convenience the term 
"particulate material" will therefore include materials formed as 
particles as well as such fibers. 
The parent application over which this invention is an improvement 
discloses an apparatus for producing preselected and consistent density of 
particulate material from compact masses of insulation materials and then 
pneumatically dispensing the material in a uniform flow. The apparatus 
includes a hopper for receiving the compact masses, an outlet positioned 
in the bottom of the hopper and a shredding zone located within the upper 
portion of the hopper for shredding large compact masses into smaller 
masses or nodules. A shredding means including a plurality of 
counterrotating shafts and having a plurality of radially extending bars 
extend through the hopper and have orbits that mutually overlap. An auger 
is positioned below the shredding means and above the outlet for moving 
the material along the hopper. Below the auger is a tearing and separating 
zone that receives the material from the outlet and operates to tear and 
separate any of the nodules of the material into particulate material. The 
tearing and separating zone includes means having a plurality of 
counterrotating brush elements through which the material passes to be 
torn and separated. The particulate material is then received and 
dispensed by a pneumatic trans-port means, which includes a rotating air 
lock having an inlet at one end and an end plate at the other or exhaust 
end of the air lock. An exhaust metering port is formed in the end plate 
with a graduated opening enlarged towards the direction of rotation of the 
air lock to permit the particulate material to be progressively 
discharged. 
The particulate matter was not, however, being completely discharged in the 
above-described apparatus. In particular, the material was getting stuck 
in the narrow part of the discharge airlock and around the bolts holding 
the sealing strips to the long support members. Also, insufficient 
pressure was being developed in the airlock cells to blow or spray the 
materials resulting in inconsistent and incomplete filling and dumping of 
the airlock chambers. 
It was also found that to replace the rubber seals as they wore out 
required that the rotor be removed from the feeder barrel. This meant that 
more skilled repair personnel were needed and that the machine would be 
out of use for longer periods of time. 
OBJECTS OF THE INVENTION 
The principal object of the present invention is to provide for an improved 
apparatus for producing particulate material from compact masses of such 
material and pneumatically conveying and dispensing such materials. 
Another object of the present invention is to provide for an improved 
assembly for blowing or spraying particulate material. 
A further object of the present invention is to provide for an improved 
apparatus for blowing or spraying particulate material which more 
completely sprays the material out of the chambers. 
A still further object of the present invention is to provide for an 
improved apparatus for blowing or spraying particulate material which has 
an easier, smoother, and more consistent filling and dumping of the 
airlock chambers. 
Another object is to provide for a particulate material blowing assembly 
having more sealing surface on its vanes and thus having greater pressure 
to blow the materials to the desired location. 
A further object is to provide for a smoother flow of the particulate 
material with less pulsations. 
A still further object is to provide for a more thorough discharge from 
each of the chambers as it passes the air stream. 
Another object is to provide for a particulate blowing assembly including 
sealing strips which are easy to replace when worn. 
A further object is to provide for an apparatus which does not require that 
the rotor be removed from the feeder barrel when the sealing strips are 
being replaced. 
Other objects and advantages of the present invention will become more 
apparent to those persons having ordinary skill in the art to which the 
present invention pertains from the following description taken in 
conjunction with the accompanying drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
As may be best seen in FIG. 1 the present invention, shown generally at 10, 
is the complete apparatus for producing particulate material from compact 
masses and uniform and preselected density. As shown, the apparatus may be 
sized for different purposes but generally it is to be expected that the 
apparatus will be mobile and permit transportation to various job 
locations where insulation is to be applied. 
The apparatus includes a base 12 to support the drive mechanisms 14 and 15 
securely attached to base 12. Upright frame members 16 are positioned to 
rise from the corners of the base 12 and along with cross members 18 
provide support for the hopper 20. Hopper 20 is provided with vertical end 
walls 22 and 24 that depend from the cross members 18. The hopper is 
provided with downwardly extending side walls 26 and 28 secured to the 
cross members 18. Side wall 28 only extends part way down the hopper to a 
point at 30 where it converges to form lower inclined wall 32. At the 
bottom of the hopper 20 is arcuate trough 36 formed from side wall 26 and 
lower wall 32. The trough extends the length of the hopper and forms a 
bottom 38. 
The arcuate trough 36 is cut away at one end of the hopper to form a 
material outlet 40. The outlet is of preselected length and width and 
sufficiently large to accommodate the highest volume flow of material that 
would be desired. The outlet 40 is made adjustable however to control the 
flow rate of the material through the outlet by means of a sliding gate. 
To permit ease of adjustability, and to indicate the position of the 
sliding gate, a manual indicator and adjustor is provided for use by the 
operator. It is then a simple matter to move the adjustor longitudinally 
of the trough to open or close the outlet 40. 
As best shown in FIGS. 2 and 3, the contents of the hopper 20 are kept in 
motion by means of an agitator shown generally at 46 which is positioned 
high in the hopper and extends longitudinally to rotate about shaft 48. 
The agitator is provided with a plurality of rods 50 secured to the shaft 
48 in any suitable manner. The rods are positioned to be in pairs at right 
angles to each other as best shown in FIG. 3. The pairs of rods 50 are 
spaced along the shaft in any convenient interval. 
Positioned below the agitator 46 and mounted on shafts 52 and 54, which are 
preferably counterrotating, is a shredding means 56 positioned within the 
shredding zone 58 as illustrated by the vertical line between the arrows. 
This initial shredding is important to achieve the uniformity in density 
that is produced by the present invention. Each of the counter-rotating 
shafts 52 and 54 is provided with pairs of bars 60 and 62. The bars 60 and 
62 are suitably secured to their respective shafts 52 and 54. The 
shredding bars 60 and 62 are coupled in pairs and spaced at various 
intervals along the respective shafts 52 and 54 as best shown in FIG. 2. 
It is seen in FIG. 3, that the shafts 52 and 54 are closely adjacent such 
that the orbit of the shredding bars 60 and 62 substantially overlap. 
While there is no actual physical contact between the shredding bars on 
one shaft with the shredding bars on the other shaft, it can be seen that 
the orbits of the shredding bars on the adjacent shafts substantially 
overlap and intermesh. 
Positioned immediately below the shredding bars 60 and 62 to receive the 
material passing through the shredding zone is a conveying means of any 
type such as an auger 64 mounted for rotation within the trough 36. The 
auger is provided with a shaft 66 extending through the end walls 22 and 
24 of the hopper. The auger screw 68 extends along the auger shaft 66 from 
the end wall 24 up to approximately the beginning of the outlet 40 as best 
shown in FIG. 2. From that point through the full longitudinal extent of 
the outlet 40 the auger shaft 66 is provided with radial paddles 70. The 
direction of rotation of the auger shaft and the auger screw spiral are 
constructed such that material dropping from the shredding zone into the 
auger and falling to the bottom of the hopper will be moved towards the 
outlet 40. The radial paddles 70 positioned at right angles to adjacent 
paddles help to move the material through the outlet 40. 
As the material falls through outlet 40 it enters a tearing and separating 
zone shown generally at 72 in which are included the tearing and 
separating means 74. The tearing and separating means 74 is retained in 
the brush housing 76 which bridges the outlet 40 and is connected to the 
drum feeder shown generally at 78 positioned below. Within brush housing 
76 and mounted for rotation are a pair of shafts 80 and 82 that preferably 
counterrotate. Secured to each of the shafts 80 and 82 are wire brushes 84 
and 86. It is preferred that the brushes 84 and 86 extend the full length 
of the shafts 80 and 82 and rotate freely within brush housing 76. It is 
also preferable that the orbit of the brushes on the adjacent shafts 80 
and 82 be such that the spacing 88 between the brushes be relatively 
small, preferably less than a quarter of an inch. The shafts 80 and 82 may 
be rotated at different speeds such as by endless belt 90 which wraps 
around ordinary but different sized pulleys 92 and 94. Due to the 
different rotational speeds of the brushes 84 and 86 material passing 
through the spacing 88 is torn apart. This is particularly evident in the 
event that nodules of insulating material drop from the outlet into the 
tearing and separating zone and it is here that the tips of the brushes 
tear away the individual fibers leaving the particulate material to pass 
through the tearing and separating zone into drum feeder 78. The density 
of the product entering the air lock is thus made more uniform. 
Drum feeder 78 includes a feeder barrel 96 having opposing support legs 98 
and 100 and horizontal plates 102 and 104 on which brush housing 76 is 
mounted. A lengthwise opening 105 along its upper surface allows the 
material to pass from spacing 88 of the tearing and separating zone into 
drum feeder. WDdrive shaft 106 is positioned in feeder barrel 96 along its 
longitudinal axis. Cylindrical drum rotor 108 is attached to drive shaft 
106 and extends generally the length of feeder barrel 96. A plurality of 
vanes shown generally at 110 are attached to rotor 108 by metal brackets 
112. Brackets 112 include a first leg 114 positioned against rotor 108 and 
secured thereto by screws 116 and a second leg 118 extending generally 
radially from rotor 108. Pliable seal strips 120 are attached by glue or 
similar adhesive means to second legs 118. The strips engage the inner 
surface of the barrel thereby defining a plurality of cavities, including 
cavities 122, 124 and 126. As can be readily seen from the drawings, the 
cavities define a more rectangular shape than the previous triangular 
shape. The omitted small pie-shaped portion in prior machines frequently 
did not discharge completely as it passed the air stream. This problem 
does not exist according to the present invention and the result is a 
smoother flow of material with fewer pulsations. 
The present design including drum rotor 108 provides a greater surface to 
which the vanes may be attached. Thus, a greater number of vanes (for 
example, eight are illustrated in the drawings) can be used. The greater 
number of vanes used means the greater number of cavities defined thereby 
and thus, the greater pressure that may be thereby generated. It has 
further been found that the rubber seals wear out and must frequently be 
removed and replaced. The design according to the present invention 
permits the seals to be more readily changed without removing the rotor 
from the feeder barrel. 
Inlet plate 128 as best shown in FIG. 6, is attached to one end of the 
barrel and a fiber seal placed therebetween. A corresponding outlet plate 
130 is attached to the opposing end and a fiber seal 132 placed 
therebetween. An oblong shaped air inlet 134 is positioned in inlet plate 
128, offset in the direction of rotation of the vanes and disposed at an 
angle to the horizontal as best shown in FIG. 7. A suitable inlet hood 136 
is attached to the inlet cover about air inlet 134. Air outlet 138 in 
outlet plate 130, although disposed generally parallel to inlet 134, can 
have a tapered, material-metering shape as best described in the parent 
application. This parallel alignment of the holes provides a feeder which 
delivers the particulate material faster than that of prior machines. 
Outlet hood 140, as shown in FIG. 5, is attached to outlet plate 130 and 
houses the air outlet. Thus, when the filled cavities are aligned with the 
holes the air stream blows or sprays the particulate matter out in a 
rapid, even spray. 
From the foregoing detailed description, it will be evident that there are 
a number of changes, adaptations and modifications of the present 
invention which come within the province of those persons having ordinary 
skill in the art to which the aforementioned invention pertains. However, 
it is intended that all such variations not departing from the spirit of 
the invention be considered as within the scope thereof as limited solely 
by the appended claims.