PARTICLE DISPLACEMENT

Abstract: A method and an apparatus for displacing of particles on and into a loose layer of material, for instance a mineral wool layer (2) by means of an apparatus comprising means, for instance one or more conveyors (4, 10) for continuously advancing the layer of material and means for subjecting the layer of material to a constant force and concurrently therewith an oscillation energy within the acoustic area. The constant force may be applied in that the conveyor is mounted sloping downwards in the advancing direction whereby the gravety force is the constant force, or it may be a flow of air which is blowing against and which is allowed to pass through the layer of material. The oscillation energy may be provided by means of one or more sound emitting means (9, 14) mounted above the layer of material and preferably co-operating with a collection means (7, 12) mounted underneath the layer of material. By the method and the apparatus particles may be expelled from the layer of material or particles supplied to the surface of the layer of material may be forced into and distributed in the interior of the layer of material or both operations may be carried through concurrently.

Description: Particle displacement. The present invention relates to a method and an apparatus for displacement of particles on and in a loose layer of material, and the invention is more particularly directed to a method and an apparatus for treating a layer of mineral wool. By displacement of particles is meant either removal of not wanted particles from the layer of mineral wool, or introduction and distribution of other particles of the layer of mineral wool, or both alternatives at the same time. When manufacturing mineral wool, especially so called stone wool and slag wool, particles of non-fibrated material, so called shots or pearls, are formed concurrently with the fibres. Such particles may be more or less ball formed and provide a basically non-wanted part of the material and they make the mineral wool heavy and may, when becoming released as the mineral wool is mounted on the intended place, drop out of the mineral wool and cause skin irritation and littering problems. Further they often give the mineral wool a dark colour, what is considered a disadvantageous from the esthetical viewpoint. In order to reduce or eliminate the existance of said non-wanted particles it has been an ambition to improve both the fibrating process and the subsequent process of separating the fibres from the nonfibrated material. In this respect great success has been achieved. It has not, however, been possible to eliminated all of said particles. Attempts also have made to remove the said particles after the mineral wool has been collected to a layer. Among the suggested ways of removing the particles may be mentioned the method of sucking the particles away by means of nozzles located adjacent, possibly very close to the wool layer. In order to prevent the particles from becoming released attemts also have been made to bind the particles harder to the rest of the mineral wool by spraying an oil or a surface covering onto the mineral wool. Another problem which has since long been actual in the mineral wool industry is the need of adding particles. In this respect it is question of particles giving the mineral wool new or improved qualities. Such particles may be a binder in dry form but they may also be particles giving the mineral wool a better ability of preventing infra red radiation. In both cases there is a question of improving the qualities and the isolation property. It may, however, also be of interest to give the mineral wool new qualities. An addition of the above mentioned type of active carbon in fine grain form may give the mineral wool an adsorption ability for gases that the mineral wool otherwise does not possess. Such an absorption ability might be of value in sorie connections, for instance when the mineral wool is used as a filter. There has, however, been great difficulties in making such supplementary particles penetrate into the mineral wool, The fibre structure of the mineral wool with very short mutual fibre distances give the wool good filtrating properties and this may of course be desirable in some cases. The said structure, however, prevents the powder particles from penetrating into the mineral wool. Therefore attempts have been made to supply the powder in connection to the fibrating process, so that the powder and the particles deposite concurrently to a powder-enriched mineral wool layer. A disadvantage in such a method is that it is difficult to supply the powder so that the powder content is relatively evenly distributed in the mineral wool. Further it often has been difficult to avoid losses of powder, and this may be an important disadvantage since the powder is often a qualitified type of material. Now it has surprisingly shown that both the above mentioned problems, which may seem different from each other, can be solved by a single new method. The invention lies is said method. According to the invention a layer of mineral wool is subjected to a constant force acting at an angle to the plane of the mineral wqol layer. The force may be the gravity force or it may be the froce from a flow of air which is brought to pass the mineral wool layer. Concurrently with said constant force the mineral wool layer is subjected to oscillation energy within the acoustic area. The phenomena thereby occuring is very difficult to study in detail. It is thought that the acoustic energy give the particles and/or the mineral wool fibres such mutual movements that the particles by means of the constant force can move in relation to the fibres to a degree which is much higher than the previously observed degree. The possibility of the particles to move in relations to the fibre structure now can be utilized so that particles of the fibre structure is thereby caused to move out of the fibre structure. It thereby shows that the invention has a limited effect on large particles but a sufficiently great effect on particles lying close the surface of the mineral wool layer. Therefore the method of the invention makes it possible to remove from the greatest part of the particles from the mineral wool, which particles would otherwise shake out when handling the mineral wool, and which particles might cause skin irritation and which would give the mineral wool a dark colour. It is also possible to cause a powder which is spread out over the the mineral wool layer to move into the mineral wool layer. It is quite possible to make use of both phenomena at the same time. As mentioned above it is possible to have the gravity force act as the constant force. Said force alternatively can be executed by a flow of air which is created for instance in that the mineral wool layer is moved over a suction box in which there is a sub-pressure. It has, however, shown that the combination of said two steps gives a constant force which can be dimensioned very freely. By utilizing the gravity for having the powder enter the mineral wool and having the particles leave the mineral wool respectively the process is also simplified in other respects. The particles leaving the mineral wool are then removed from the mineral wool layer and it is easy to intitially distribute a powder over the surface of the mineral wool, which powder by the method is brough to penetrate into the mineral wool layer. As evident the method only can be effected in one direction, viz. in the direction of the constant force. Often it is a wish to remove particles from both surface layers of the mineral wool and in such case it is advantageous to first execute the method in one direction, then in the opposite direction. By this method the powder formed material can be distributed more evenly in the mineral wool layer than would otherwise have been possible. The frequency and the intensity that the oscillation energy should have to give the best effect is to a high degree depending on the tightness, the orientation and the diameter of the fibrous material and the shape, size and density of the powder and the separate shot particles respectively. To some extent also the forces acting between the particles, for instance the adhession has a role. It has, however, been observed that a substantially better effect can sometimes be obtained if frequencys of two distinctly different frequency intervals are used at the same time. It has shown that as a rule infrasound or infralight of very low frequencies are most effective. In most cases a frequency of between 10 and 200 Hz is suitable, and in connection to mineral wool a frequency of between 20 and 60 Hz is especially preferable. The intensity also is of treat importance. At a sound strength below a certain level hardly any effects can be observed. Effects above 70 dB are useful provided that the frequency or the frequencies respectively are correctly chosen. At sound strengths over 130 dB the helth view points are of determining importance for the practical use of the method. There is also a risk that the separate fibres get such large movements that the entire fibre structure collapses. To summerize the invention relates to a method and an apparatus of the above mentioned type in which the mineral wool layer including the particles are subjected to oscillation energy within the acoustic area and concurrently therewith to a constant force directed at an angle, preferably blunt angle to the plane of the mineral wool layer. The invention now will be described more closely in connection to accompanying drawings. It is, however, to be understood that the embodiments of the invention described and shown in the drawings are only of illustrating type and that many different modifications may be presented within the scope of the appended claims. In the drawings figure 1 diagrammatically shows a vertical cross section through an apparatus for executing the method according to the invention. Figure 2 is a diagram illusrating how the distribution of present particles of a mineral wool layer is changed by the method according to the inention. Figure 3 is a similar diagram showing the distribution of a powder which is supplied to one surface of the mineral wool layer, and figure 2 correspondingly shows the situation when the powder is supplied to both sides of the mineral wool layer. Figure 5 shows an embodiment of an apparatus for executing the method according to the invention modified as compared with that of figure 1. In the apparatus shown in figure 1 a mineral wool layer 2 is fed on a conveyor 1. The conveyor extends over a turning roll 3 thereby delivering the mineral wool layer 2 to a second conveyor 4 extending over rolls 5. The upper part 6 of said second conveyor 4 is sloping slightly downwards and provides a plane against which a constant force, in this case the gravety force, is acting on the mineral wool layer. The force is meeting the surface of the mineral wool layer under a blunt angle. Above the said upper part 6 of the conveyor there is a funnel formed collection means 7 at the bottom of which there is a worm. Above the conveyor the sound emitting means 9 is mounted. The conveyor 4 is perforated and may for instance be a metal wire net. When the mineral wool layer 2 passes the sound emitting means 9 and is subjected to acoustic energy of a suitable frequency and strength loose particles from the mineral wool layer, especially from the lower part thereof are released and drop through the conveyor and down to the collection means 7 and are removed therefrom by the worm 8. After this treament the mineral wool layer 2 leaves the second conveyor 4 and is transferred to a corresponding third coneyer 10 extending over rolls 11. Also said third conveyor 10 is perforated. Underneath the upper sloping part of the third conveyor 10 there is a collction means 12 having a worm 13, and above the conveyor 10 there is a sound emitting means 14. When the mineral wool layer 2 passes under the sound emitting means 14 particles likewise become loosened from the mineral wool layer and drop down into the collection means 12. The said particles mainly come from the former upper part, now the lower part of the mineral wool layer. After the treatment on the third conveyor 10 the layer 2 is transmitted to a fourth conveyor 15 extending over a turning roll 16. Above the first conveyor and in advance of the sound emitting means 9 there is a vibration feeder 17 comprising a flute 18 and a vibrator 19. The vibration feeder 17 in turn is connected to and fed from a silo 20 comprising a fine grain powder. The powder may be a binde that can e hardened, for instance a powder formed thermosetting resin which after a further treatment like melting and solidifying binds the fibres of the mineral wool layer together. The powder alternatively may be particles of substances which adds qualities to or changes the properties of the mineral wool layer, for instance the opacity thereof. Or especially the properties as concerns heat radiation, the absobtion property or the fertilizing properties. By the action of the vibration feeder 17 a flow 21 of the fine grain powder will be distributed over the mineral wool layer 2. Under the action of gravety and the sound energy from the sound emitting means 9 the powder penetrates into the mineral wool layer 2. Likewise there is a vibration feeder 22 comprising a flute 23 and a vibrator 24 above the third conveyor 10. By means of a conveyor 25 the second vibration feeder 22, feeds a fine grain powder 26 from a silo 27 to the upper surface of the mineral wool layer 2 after said layer has been turned when being transferred from the second conveyor 4 to the third conveyor 10. Under the action of the sound emitting means 14 the powder will penetrate into the mineral wool layer. Figure 2 is a diagram showing the effect of the invention when the mineral wool layer subjected to treatment contains loose particles. The vertical axis of the diagram represents the thickness of the mineral wool layer and the lower part of the diagram represents the part of the mineral wool layer which is facing down at the beginning of the treatment. The horizontal axis represents the amount of loose particles and the line A represents the original state. At the original state the amount of loose particles consequently are the same throughout the entire mineral wool layer. This is not always the case, but for the sake of simplicity this presumption has been made in the present case. The line B represents the amount of loose particles after the mineral wool layer has been subjected to a double side treatment according to the invention. As evident from the diagram the reduction in amount of loose particles is substantial only at the two outermost part of the mineral wool layer. The loose particles, so called shots or pearls, which are normally present in the mineral wool layer are generally so large, the typical diameter is 0.1 mm, that they cannot be moved any substantial distance through the mineral wool structure without becoming definitively caught in the fibre grid. Figure 3 is a similar diagram showing the amount of added powder, for instance added finder. If the binder is choosen with a sufficient fine grain the line a may represent the amount after the binder has been supplied to the upper surface of the mineral wool layer and thereafter has been entered to the mineral wool layer by treament according to the invention. The line "a" represents an optimum position in that the powder reaches the surface of the mineral wool layer at the same time as the powder from the upper surface is just starting to sink. The line "b" represents an earlier stage in which the amount of powder at the upper surface of the mineral wool layer is still very high and no powder has not yet reached the lower surface thereof. The line "c" on the contrary represents a late stage characterized in both that the powder in the upper surface of the mineral wool layer has started becoming reduced depending on a continued transportation of powder into the mineral wool layer, and in that the amount of powder at the lower surface of the mineral wool layer is substantial and indicates that powder the conditions for a fairly well executed double side application of powder and treatment according to the invention. Later than the mineral wool layer has been turned and is subjected to a renewed treatment the powder which has already been introduced into the mineral wool layer will move in the opposite direction, and the amount of said powder is represented by the line "f". At the same time additional powder has been supplied to the opposite surface in the diagramme the lower side, and said powder has been introduced in the mineral wool layer. The amount of said powder is represented by the line "g". The line "h" shows the sum of the amounts represented by the lines "f" and "g". By chosing the parameters, for intance the treating times, the grain size of the powder, the thickness of the layer etc. The line "h" may get different character. Figure 5 shows an apparatus in which the removal of free particles is made separately from the transportation of powder into the mineral wool layer. The figure shows a first conveyor 30 extending over a roll 31. A layer 32 of mineral wool is supportedon the conveyor 30. By means of the conveyor 30 the mineral wool layer 32 is transferred to a second conveyor 32 is transferred to a second conveyor 33 extending over rolls 34. The conveyor 33 consists of a metal net. Close to the receiving end of the conveyor 33 a sound emiting means is mounted over the conveyor and on the opposite end thereof underneath the conveyor there is a collection means 36 at the bottom of which a worm 37 is mounted. By the action of the sound emitting means 35 and the gravety force a part of the free particles of the mineral wool layer are brought to leave same and drop down through the conveyor 3 and into the collection means 36 from the bottom of which the particles are removed by the worm 37. In the down streem direction of the sound emitting means 35 a vibration feeder 38 is mounted over the conveyor 33 and the mineral wool layer 32. The feeder 38 comprises a flute 39 and a vibrator 40. A silo 41 comprising fine grain powder is mounted in communication with the flute 39. When the conveyor 39 is moving and the vibration feeder 38 is operating a layer of a powder 42 is spread over the mineral wool layer 32. Under the action of the gravety force and sound emitting means 43 and 44 the powder 42 now enters the mineral wool layer 32. A part of the powder may pierce the minf l wool layer 32 and leave at the bottom side thereof, whereby the powder passes through the meshes of the conveyor 33 and drops down in a collection means 45 from which it is removed by a worm 46. The action of the gravety force is supported by the action of an air flew which is introduced by a fan which is not shown in the drawings. The fan is connected to an opening 47 of the collection means 45 and it causes air flow from the ambient through the mineral wool layer 32 and the conveyor 33. The air leaving through the opening 47 may contain powder, and this powder is filtered away by a filter which is not shown in the drawings and which is preferably mounted between the collection means and the fan. The mineral wool layer 32 from which free particles have now been revmoved and which has been supplied with a powder leaves the conveyor 33 at the outlet end thereof and is laid down on a third conveyor 48. ROCKWOOL AKTIEBOLAGET, "Displacement of particles" List of reference numerals 1 conveyor, 1:st 30 conveyor, 1:st 2 mineral wool layer 31 roll 3 turning roll 32 mineral wool layer 4 conveyor, 2:nd 33 conveyor, 2:nd 5 rolls 34 rolls 6 upper part (of 4) 35 sound emitting means 7 collection means 36 collection means 8 worm 37 worm 9 sound emitting means 38 vibration feeder 10 conveyor, 3rd 39 flute 11 rolls 40 vibrator 12 collection means 41 silo 13 worm 42 layer of powder 14 sound emitting means 43 sound emitting means 15 conveyor, 4:th 44 sound emitting means 16 turning roll 45 collection means 17 vibration feeder 46 worm 18 flute 47 opening (of 45) 19 vibrator 48 conveyor, 3:rd 20 silo 21 flow 22 vibration feeder 23 flute 24 vibrator 25 conveyor 26 powder 27 silo

Claims: CLAIMS 1. Method of displacing particles on or in a loose layer of material, for instance a mineral wool layer (2) in relation to said layer, characterized in that the layer (2) of material comprising the particles is subjected both to oscillation energy (by 9, 14) within the acoutic area and concurrently therewith to a force directed at an angle, preferably a blunt angle, to the plane of the layer. 2. Method according to claim 1, c h a r a c t e r i z e d in that a constant force is the gravety force. 3. Method according to claim 1, c h a r a c t e r i z e d in that the constant force at least partly consists of a flow of air (L) which is moved towards and through the layer (2) of material. 4. Method according to any of claims 1-3, in which the particles originally are located inside the layer of material, c h a r a c t er i z e d in that the constant force and the oscillation energy are utlized for moving the particles out of the layer (2) of material. 5. Method according to any of claims 1-4, c h a r a c t e r i z e d in that particles are supplied to the surface of the layer of material and in that the constant force and the oscillation energy are utlized for moving the particles from said surface to the interior of the layer of material (2). 6. Method according to claim 4 or 5, c h a r a c t e r i z e d in that the layer (2) of material is treated with the constant force acting on the layer first in one direction and thereafter in the opposite direction. 7. Method according to claim 5 or 6, c h a r a c t e r i z e d in that the particles consists of a substance, for instance a powder formed synthetic resin, which after further treatment, for instance melting and solidifying, acts as a binder between the fibres of the layer (2) of material. 8. Method according to claim 5 or 6, c h a r a c t e r i z e d in that the particles consists of substances which add qualities to the layer (2) of material or changes the qualities thereof, for instance the opacity, espcialy the opacity for heat radiation, its absorbtion ability and its fertilizing properties. 9. Method according to any of the preceding claims, c h a r a ct e r i z e d in that oscillation energy within the acoustic area has a frequency of 10-200 or preferably 20-60 Hz and a sound level between 70 and 130 dB. 10. Method according to any of the preceding claims, c h a r a ct e r i z e d in that the oscillation energy within the acoustic area lies within two distinctly separated frequency areas. 11. Apparatus for executing the method according to any of the preceding claims for displacement of particles on or in a loose layer of material, for instance a mineral wool layer (2) in relation thereto, c h a r a c t e r i z e d in that the apparatus comprises means (4) for feeding the layer (2) of material, means for subjecting the layer (2) of material to a constant force and means (9, 14) for subjecting the layer of material both to the constant force and to oscillation energy within the acoustic area. 12. Apparatus according to claim 11, c h a r a c t e r i z e d in that the constant force is the gravety force, and in that said gravety force is acting at an angle, peferably a blunt angle as seen in the feeding direction of the layer of material (2) and in that said layer of material is sloping downwards. 13. Apparatus according to claim 11, c h a r a c t e r i z e d in that the constant force acting on the layer of material is a flow of air which is directed to and is allowed to pass through said layer of material (2). 14. Apparatus according to claim 11, 12 or 13, c h a r a c t er i z e d in that the means for subjecting the layer of material to oscillation energy is a sound emitting means (9, 14; 35, 43, 44) mounted aboe the layer of material on one or more places. 15. Apparatus according to claim 14, c h a r a c t e r i z e d in that a collection means (7, 12; 36, 45) is mounted underneath the layer of collecting particles which have been forced out of the layer of material. 16. Apparatus according to claim 15, c h a r a c t e r i z e d in that the collection means (45) is connected to a suction means for providing a sub-pressure in said collection means. 17. Apparatus according to any of claims 11-16, c h a r a c t er i z e d in that it is formed with means (for instance 17-21) for supplying particles to the surface of the layer of material. 18. Apparatus according to any of claims 11-17, c h a r a c t er i z e d in that it is formed for double sided treatment of the layer of material and comprises two sloping conveyors (4, 10) mounted underneath each other and on which the layer of material (2) successively and after having been turned upside down is treated firstly from one side and thereafter from the opposite side. 19. Apparatus according to any of claims 11-18, c h a r a c t er i z e d in that is is designed for providing both an expelling of particles present in the layer of material and concurrently therewith an entering and distribution from outside of other particles in the interior of the layer of material. 20. Apparatus according to any of claims 11-18, c h a r a c t er i z e d in that it is designed for providing an expelling of particles present in the layer of material in a first stage and thereafter providing an introduction and distribution of other particles in the layer of material in a second stage.

Inventors: ANKERSSON, BILL, LINDQVIST, ARNE
Applicants: ROCKWOOL AKTIEBOLAGET
Application year: 1985
Main classification: B07B13
IPC codes: B07B9, B01F13, D04H1, C04B41, B07B1, B07B13, B07B4, C04B30, C03B37