Apparatus for continuous production of a mattress comprising agglomerated mineral fibers

Abstract

An apparatus for the continuous production of a mattress of agglomerated mineral fibres is disclosed, comprising: a mineral fibre receiving or forming chamber; an accumulation conveyor comprising adjacent drums for receiving and accumulating fibres between the drums to form a mattress comprising mineral fibres; an air extraction device in fluid communication with the perforated or air-permeable circumferential surface of the drums and with the lower space between the drums for unloading the mattress of mineral fibres formed between the drums, characterised in that the drums each comprise first and second half-drums movable along a rotation axis (X) between first and second end-of-travel positions, in the first end-of-travel position the first and second half-drums are juxtaposed or in contact with each other, in the second end-of-travel position the first and second half-drums are spaced apart from each other by a predetermined maximum distance in the direction of the rotation axis (X) of the drums, further provided is an annular band overlapping the relative end portions of the half-drums with at least one of the first and second half-drums.

Description

Technical Field

[0001] In a broader sense, the present invention relates to the production of insulating mattresses comprising agglomerated mineral fibers (nonwoven fabrics), such as glass fibers or rock wool fibers.

[0002] Specifically, the present invention relates to an apparatus for the continuous production of agglomerated mineral fiber mattresses, comprising: a mineral fiber receiving chamber or forming chamber; an accumulation conveyor disposed below the receiving chamber or forming chamber and including adjacent drums having perforated or breathable surfaces for receiving and accumulating fibers to form an agglomerated mineral fiber mattress between the drums; and an air extraction device in fluid communication with the perforated or breathable surfaces of the drums and a lower space for unloading the mattress formed between the drums.

[0003] This invention represents, in particular, an improvement over prior art for receiving (collecting) so-called insulating mineral fibers containing a liquid binder and for separating gases from the fiberizing machine and introducing air to produce mattresses having said mineral fibers. Background Technology

[0004] As is known in the art, the production of mattresses containing agglomerated mineral fibers (e.g., glass fibers) involves separating fibers produced by a fiber forming machine (fiberizing machine) from gases generated by the burners of these machines and introduced air, as well as collecting and shaping (accumulating) the separated fibers to form a felt containing agglomerated mineral fibers, essentially in the form of a mattress.

[0005] To perform these operations, it is well known to use equipment comprising: a receiving or collecting chamber designed to be fed from above by a flow containing mineral fibers from a fiberizing machine, gas, and introduced air; an accumulation conveyor arranged below the fiber receiving or collecting chamber and including adjacent drums provided with perforated or breathable surfaces for receiving and accumulating fibers to form a mattress containing agglomerated mineral fibers between the drums; and an air extraction device fluidly communicating with the perforated or breathable surfaces of the drums and with the lower space for unloading the mattress containing agglomerated mineral fibers formed between the drums.

[0006] Specifically, according to known methods, a stream of mineral fibers containing gas, introduced air, and impregnated with a binder mixture (resin) output from a fiberizing machine is introduced into a fiber receiving chamber or collection chamber and guided to a breathable or perforated surface of a drum disposed below the receiving or collection chamber. These surfaces are breathable, or they have pores sized to allow gas to pass through but not mineral fibers. They are subjected to suction by an air extraction device and function as a filter, allowing fibers to accumulate thereon to form a mineral fiber-containing mattress, while the suctioned gas is released to the outside. Thus, the mineral fiber-containing mattress formed is unloaded through a lower space formed between the drums, which is appropriately predetermined according to the desired thickness of the mattress.

[0007] Typically, the fiber receiving chamber or forming chamber includes an upper part having a first vertical wall extending longitudinally along the direction of the rotation axis of the drum and a second vertical wall extending laterally relative to the rotation axis of the drum, the first and second walls laterally defining the receiving chamber or forming chamber, and also includes a lower element equipped with an arc-shaped recess, under which the drum is housed.

[0008] The first and second vertical walls of the chamber typically consist of rotating pads or belts, usually made of polyvinyl chloride (PVC), with their outward-facing portions in contact with cleaning devices (such as scrapers). They are arranged to keep the surfaces of these walls clean and free from fiber clumps impregnated with adhesive mixtures, which would otherwise form on the walls if they were fixed and could fall between the drums, thus damaging the quality of the produced mineral fiber mattress.

[0009] Furthermore, the first vertical walls have a greater height because they laterally cover the lower element, terminate below, and are tangentially juxtaposed with the ventilated or perforated surface of the drum, while the second vertical walls of the sloping groove terminate above the lower element and are movable above the drum along its axis of rotation, moving away from or close to each other, to adjust the width of the fiber receiving chamber or forming chamber (i.e., the chamber size in the direction of the drum's axis of rotation) according to the width or lateral width of the mineral fiber mattress to be obtained.

[0010] The lower element of the chamber is fixed, and its width or amplitude in the direction of the rotation axis of the drum substantially corresponds to the width of the receiving chamber or forming chamber obtained by adjusting the mutual distance between the second vertical walls.

[0011] While the aforementioned device is generally satisfactory from a functional standpoint, it is not without its drawbacks. One such drawback involves the formation of resin-impregnated fiber clumps on the fixed lower element during operation. These clumps tend to settle between the drums, thus compromising the properties and quality of the resulting mineral fiber mattress, especially when the device is used for extended periods.

[0012] In such a situation, it may be necessary to shut down the equipment to perform cleaning operations, which would subsequently extend production time and reduce production output.

[0013] To compensate for this drawback, it has been suggested that the second vertical wall be extended downwards to approximately the same height as the first vertical wall, so that when using the device, the second vertical wall and its lower portion are arranged laterally alongside the drum, rather than above the lower element. This makes it possible to remove the fixed lower element.

[0014] However, even though this scheme can reduce the formation of impregnated fiber clumps in the receiving or forming chamber, it also brings significant limitations, namely, the width of the aforementioned chambers can no longer be adjusted by moving the second vertical wall away from or closer to each other along the direction of the drum's rotation axis, and therefore the width or amplitude of the mineral fiber mattress obtained by the equipment cannot be changed according to production needs.

[0015] Therefore, the main objective of this invention is to provide an apparatus for the continuous production of mattresses containing agglomerated mineral fibers, the apparatus having structural features that allow for adjustment of the width of the produced mattresses as needed, while avoiding or minimizing the formation of impregnated fiber clumps in the fiber receiving chamber or forming chamber during equipment operation, thereby overcoming the disadvantages of the prior art described above.

[0016] Another object of the present invention is to provide a device as described above, which has a simple structure, thereby making the manufacture of the product obtained therefrom simple and economical. Summary of the Invention

[0017] These objectives are achieved by an apparatus for the continuous production of agglomerated mineral fiber mattresses, the apparatus comprising: a mineral fiber receiving chamber or forming chamber; an accumulation conveyor disposed below the receiving chamber or forming chamber and including adjacent drums having perforated or breathable circumferential surfaces for receiving and accumulating fibers between the drums to form a mineral fiber-containing mattress; and an air extraction device in fluid communication with the perforated or breathable surfaces of the drums and a lower space between the drums for unloading the mineral fiber-containing mattress formed between the drums. The apparatus is characterized in that each of the drums comprises a first half-drum and a second half-drum that are telescopically connected to each other, and the first and second half-drums are movable along a rotational axis between a first stroke end position and a second stroke end position, in which the first and second half-drums are juxtaposed or in contact with each other, and in which the first and second half-drums are spaced apart by a predetermined maximum distance from each other, and a breathable or perforated annular belt is provided, which overlaps at least one of the first and second half-drums at opposite ends of the half-drums.

[0018] In one embodiment, the breathable or perforated annular band consists of a circumferentially extending breathable or perforated plate that is fixed to the end of the circumferential surface of one of the first and second half-drums and partially overlaps to the opposite end of the circumferential surface of the other of the first and second half-drums.

[0019] In another embodiment, the breathable or perforated annular band consists of a breathable or perforated ring integrally formed at one end of one of the first and second half-drums and having a larger diameter than the latter, the breathable ring further partially overlapping the opposite end of the circumferential surface of the other of the first and second half-drums.

[0020] In an embodiment, the fiber receiving chamber or forming chamber includes: a first vertical wall that extends longitudinally in the direction of the rotation axis of the drum and terminates below in a manner tangentially juxtaposed with the circumferential surface of the first half-drum or the second half-drum; and a second vertical wall that extends laterally relative to the rotation axis of the drum and terminates below in a manner laterally juxtaposed with the first half-drum or the second half-drum.

[0021] In an embodiment, the first and second vertical walls of the fiber receiving chamber or forming chamber are substantially the same height.

[0022] In one embodiment, the second vertical wall moves between the first vertical walls along the longitudinal axis of the drum, moving away from or closer to each other, so as to adjust the width of the receiving chamber or forming chamber by an amount substantially equal to the sum of the width of the circumferential surface of the drum and the distance determined by the mutual positioning of the first half-drum and the second half-drum along the rotation axis of the drum.

[0023] In an embodiment, the breathable or perforated annular band has a reduced thickness between 1 mm and 5 mm, preferably about 3 mm.

[0024] In an embodiment, the circumferential surface of the drum is perforated, and the overlapping annular band is perforated. In the overlapping region of at least one of the first and second half-drums, the ratio of solid to hollow portions is greater than the ratio of solid to hollow portions in half-drums 4a and 4b, and the size of the holes is smaller than the size of the holes in the half-drums. In other words, in the region overlapping with or exceeding the circumferential surface of at least one half-drum, the number of holes in the annular band is greater than the number of holes present in the lower half-drum.

[0025] Advantageously, since the solid portion of the overlapping band may overlap the hole below the drum, this minimizes the loss of effective surface area on the drum for gas suction during equipment operation, especially in cases of wear or when the rotational movements of these drums are not perfectly synchronized.

[0026] In an embodiment, the first vertical wall extending longitudinally along the rotation axis of the drum has a rotation direction substantially parallel to the rotation axis of the drum, i.e., along the width direction of the fiber receiving chamber or forming chamber, while the second vertical wall extending laterally relative to the rotation axis of the drum has a vertical rotation direction (from bottom to top or vice versa), which is substantially perpendicular to the rotation axis of the drum, or in other words, along the height direction of the fiber receiving chamber or forming chamber.

[0027] Advantageously, this design allows for the avoidance of potential damage to the edges of the fiber mattress formed between drums 4. Furthermore, the aforementioned design allows for reduced fiber loss in the receiving chamber, thereby increasing subsequent output across the entire production line.

[0028] In an embodiment, the suction device includes suction chambers disposed within each drum below its ventilated or perforated surface. Each suction chamber includes a first half-chamber disposed within a first half-drum and a second half-chamber disposed within a second half-drum. The first and second half-chambers are movable along a rotation axis between a first end position and a second end position of the first and second half-drums. A belt is also provided that overlaps at opposite ends of the half-chambers with at least one of the first and second half-chambers.

[0029] The features and advantages of the present invention will become more apparent from the following description, given by way of indicative and non-limiting example with reference to the accompanying drawings. Attached Figure Description

[0030] In the attached diagram:

[0031] Figure 1 A side view of an apparatus for the continuous production of mattresses containing agglomerated mineral fibers, according to the prior art, is shown.

[0032] Figure 2 It shows Figure 1 Side views of the equipment from different angles in an operating configuration with a narrow fiber receiving chamber or forming chamber;

[0033] Figure 3 It shows Figure 1 Side views of the equipment from different angles in an operating configuration with a relatively wide fiber receiving chamber or forming chamber;

[0034] Figure 4 A side view of an apparatus for the continuous production of mattresses containing agglomerated mineral fibers, according to an embodiment of the present invention, is shown.

[0035] Figure 5 shows Figure 4 Side views of the equipment from different angles in an operating configuration with a narrow fiber receiving chamber or forming chamber;

[0036] Figure 6 shows an enlarged view of the details of the device shown in Figure 5;

[0037] Figure 7 shows Figure 4 Side views of the equipment from different angles in an operating configuration with a relatively wide fiber receiving chamber or forming chamber;

[0038] Figure 8 shows an enlarged view of the details of the device shown in Figure 7;

[0039] Figure 9 shows an enlarged view of another detail of the device shown in Figure 7;

[0040] Figure 10 shows a side view of an apparatus for the continuous production of mattresses containing agglomerated mineral fibers according to another embodiment of the present invention;

[0041] Figure 11 shows a side view of the second vertical wall of the device in Figure 10;

[0042] Figure 12 shows a top view of the first vertical wall of the device in Figure 10. Detailed Implementation

[0043] refer to Figures 1-3 The apparatus for the continuous production of mattresses containing agglomerated mineral fibers, according to the prior art, is generally indicated by reference numeral 1 in the accompanying drawings.

[0044] The equipment 1 includes a fiber receiving chamber or forming chamber 2, an accumulator conveyor 3 arranged below the receiving chamber or forming chamber 2, the accumulator conveyor 3 including an adjacent drum 4 provided with a circumferential perforated surface 5, and an air extraction device 6 (not shown in detail) arranged inside the drum 4 and communicating with the perforated surface 5 of the drum.

[0045] The receiving chamber or forming chamber 2 includes a first vertical wall 7 extending longitudinally along the rotation axis X of the drum 4 and a second vertical wall 8 extending laterally relative to the rotation axis X of the drum 4. The first and second walls 7 and 8 define the receiving chamber or forming chamber 2 from above. Below, the receiving chamber or forming chamber 2 is closed by a lower element 9, which is equipped with an arc-shaped recess, below which the drum 4 is accommodated.

[0046] The first vertical wall 7 and the second vertical wall 8 of chamber 2 consist of an infinitely movable rotating pad or belt (e.g., PVC), the outward portion of which is in contact with at least one scraper 10 arranged to keep the surfaces of these walls clear of any fiber clumps that may form thereon on the walls, which are impregnated with an adhesive mixture.

[0047] The first vertical wall 7 is laterally juxtaposed with the lower element 9 and terminates below it in a manner tangential to the perforated circumferential surface 5 of the corresponding drum 4. The second vertical wall 8 terminates above the lower element 9, thus having a smaller height than the first vertical wall 7, and is movable between the first vertical walls 7 and above the drum 7 along its axis of rotation X, moving away from or closer to each other to adjust the width W (i.e., the dimension of the chamber 2 in the direction of the axis of rotation X of the drum 4) of the receiving chamber or forming chamber 2, depending on the width or lateral width of the mineral fiber-containing mattress to be obtained. An exemplary configuration of device 1 is as follows... Figure 2 As shown, the second vertical wall 8 is closer together to allow for a smaller width W of the receiving chamber or forming chamber 2, while another exemplary configuration of the device 1 is as follows: Figure 3 As shown, the second vertical walls 8 are spaced further apart, thus having a larger width W for the receiving chamber or forming chamber.

[0048] The lower element 9 of chamber 2 is fixed, and its width or amplitude in the direction of the rotation axis X of drum 4 substantially corresponds to the width W of chamber 2 obtained by adjusting the mutual distance between the second vertical walls 8.

[0049] The juxtaposition of the second vertical wall 8, which contacts the lower element 9 above, and the overlap of the first vertical wall 7, which contacts the side of the lower element 9 and tangentially on the circumferential surface 5 of the perforation of the drum 4, essentially allow the receiving chamber or forming chamber 2 to be “sealed”.

[0050] In terms of the operation of device 1, the fiber bundle 12 impregnated with the adhesive mixture, output from the corresponding fiberizing unit 13, along with gas and introduced air, are introduced into the receiving chamber or forming chamber 2 and directed toward the perforated circumferential surface 5 of the drum 4, which rotates in the opposite direction to that shown by arrow B. Fibers accumulate on the circumferential surface 5 of the drum 4, forming a mattress 14 containing agglomerated mineral fibers, while gas is appropriately drawn out to the outside by an extraction device 6 (e.g., a suction device capable of generating a vacuum) through holes 5a on the circumferential surface 5 (arrow A).

[0051] In fact, it should be noted that the size of the hole 5a on the circumferential surface 5 is reduced to a size sufficient to allow gas to pass through but not fibers.

[0052] Therefore, the mattress 14, carried by the rotating motion of the drum 4 in opposite directions, is conveyed to the lower space between the drums 4, where the mattress is unloaded and collected on the conveyor belt 16 for delivery to the next processing station, storage or other purpose.

[0053] As previously stated, although the device 1 allows the width of the mattress 14, which includes mineral fibers, to be varied according to a predetermined width W in the fiber receiving chamber or forming chamber 2, the presence of the fixed lower element 9 promotes the formation of impregnated fiber clumping on it during device operation. In the long run, these clumping tend to fall between the drums 4, thereby jeopardizing the quality of the mattress 14.

[0054] Now for reference Figure 4 Figure 9 illustrates an apparatus according to the invention for the continuous production of mattresses comprising agglomerated mineral fibers. The apparatus is generally indicated by reference numeral 20.

[0055] Elements of device 20 that are structurally and / or functionally equivalent to corresponding elements of device 1 described above will be given the same reference numerals as the latter.

[0056] The device 20 includes: a fiber receiving chamber or forming chamber 2; an accumulation conveyor 3 arranged below the fiber receiving chamber or forming chamber 2 and including an adjacent drum 4 having a circumferential surface 5 with a hole 5a; and an air extraction device 6 having an output opening 11 arranged inside the drum 4 and in fluid communication with the perforated surface 5 of the drum 4.

[0057] The receiving chamber or forming chamber 2 includes a first vertical wall 7 extending longitudinally along the rotation axis X of the drum 4 and a second vertical wall 8 extending laterally relative to the rotation axis X of the drum 4. The first and second walls 7 and 8 are above and laterally define the receiving chamber or forming chamber 2.

[0058] The first vertical wall 7 and the second vertical wall 8 of the receiving or collecting chamber 2 consist of an infinitely movable rotating pad or belt, the outward portion of which is in contact with at least one scraper 10 arranged to keep the surfaces of these walls clear of fiber clumps impregnated with an adhesive mixture that may form thereon.

[0059] According to a first aspect of the invention, a first vertical wall 7 terminates at the bottom and is tangentially juxtaposed with the circumferential surface 5 of the perforation of the corresponding drum 4, while a second vertical wall 8 is above the output opening 11 of the extraction device 6 and is laterally juxtaposed with it in the upper region of the drum 4, so as to laterally close a portion of the circumferential surface 5 of the perforation located above the lower space between the drums 4 for unloading the mattress 14 during rotation of the drum 4.

[0060] In an alternative embodiment of the invention, device 20 may further include a third vertical wall 15. Figure 4 (shown in dashed lines), it is arranged below the second vertical wall 8 and has a smaller size so as to be laterally juxtaposed with the drum 4, and laterally closes a portion of the circumferential surface 5 of the perforation of the drum 4, which, during the rotation of the drum, substantially reaches the height of the lower space for unloading the mattress 14 from the smaller end of the second vertical wall 8, the mattress being substantially located at the minimum distance between the drums 4 in the lateral direction of the rotation axis X of the drum 4.

[0061] These third walls 15 are of the same type as the second vertical walls 8, and their outward portions can come into contact with a scraper (not shown) to remove fiber clumps impregnated with an adhesive mixture that may form thereon.

[0062] In this embodiment, the second vertical wall 8 has substantially the same height as the first vertical wall 7. Furthermore, the second vertical wall 8 can move away from or closer to each other outside the drum 4 along its rotation axis X in order to adjust the width W of the chamber 11 of the receiving chamber or forming chamber 2 (i.e., the size of the chamber 2 in the direction of the rotation axis X of the drum).

[0063] According to the present invention, each drum 4 consists of a first half-drum 4a and a second half-drum 4b that are telescopically connected to each other. They are movable along the rotation axis X between a first stroke end position and a second stroke end position. At the first stroke end position, the first half-drum 4a and the second half-drum 4b are placed side by side or in contact with each other (Figs. 5-6). At the second stroke end position, the first half-drum 4a and the second half-drum 4b are spaced apart from each other by a maximum distance along the direction of the drum's rotation axis X. This maximum distance is appropriately predetermined based on the receiving chamber or forming chamber 2 and the maximum width W required for the final product (Figs. 7 and 8).

[0064] In other words, the mutual movement of the first half-drum 4a and the second half-drum 4b along the rotation axis X of the drum 4, together with the movement of the second vertical wall 8 in the same direction, allows them to be laterally juxtaposed with the drum 4, enabling the width W of the receiving chamber or forming chamber 2 to be adjusted to be substantially equal to the sum of the width of the circumferential surface of the drum 4 and the distance determined by the mutual positioning of the first half-drum 4a and the second half-drum 4b along the rotation axis of the drum.

[0065] The telescopic connection itself can be made in a conventional manner, for example, the first half-drum 4a and the second half-drum 4b can be provided with coaxial tubular rods that extend along the rotation axis X of the drum 4 and slide into each other.

[0066] The telescopic movement of the first half-drum 4a and the second half-drum 4b of each drum 4 can be performed by at least one corresponding bracket 21, the lower region of which is connected to the first half-drum 4a or the second half-drum 4b and can move back and forth along the rotation axis X of the drum 4.

[0067] Furthermore, according to another aspect of the invention, for each drum 4, the device 20 includes a circumferentially extending perforated plate 22, which is fixed to the end of the circumferential surface 5 of the second half-drum 4b and partially overlaps the opposite end of the circumferential surface 5 of the first half-drum 4a.

[0068] Advantageously, plate 22 allows the space formed between the first half-drum 4a and the second half-drum 4b to be closed at any interval between them. In fact, the width of plate 22 is greater than the predetermined maximum distance of the maximum degree of movement of the first half-drum 4a and the second half-drum 4b along the rotation axis X of drum 4 away from the end position of the stroke, so that it appears that the circumferential portion of its free end always partially overlaps one of the half-drums 4a and 4b.

[0069] Meanwhile, the plate 22 has holes 22a, the size of which can fix the fibers and allow gas to pass through (e.g., holes 5a on the circumferential surface of the drum 4), so that the effective surface of the drum 4 can be extended to collect fibers at positions spaced apart from each other in the first half-drum 4a and the second half-drum 4b, so as to properly adjust the width W of the receiving chamber or forming chamber 2, thereby properly adjusting the width of the final product unloaded from the device 20.

[0070] In an alternative embodiment (not shown) of device 20, the plate 22 described above may be replaced by a functionally equivalent device, such as a perforated ring integrally formed at one end of one of the first half-drum 4a and the second half-drum 4b and having a larger diameter than the latter. Furthermore, the perforated ring partially overlaps the opposite end of the circumferential surface 5 of the other of the first half-drum 4a and the second half-drum 4b.

[0071] Similarly, in device 20, the suction device includes suction chambers 6 disposed below the perforated circumferential surface 5 inside each drum 4, and each suction chamber includes a first half-chamber disposed inside a first half-drum 4a and a second half-chamber disposed inside a second half-drum 4b. The first and second half-chambers are movable along the axis of rotation X between a first end position and a second end position of the first half-drum 4a and the second half-drum 4b, and a belt 18 is provided that overlaps the opposite ends of the first and second half-chambers to close the space created between the first and second half-chambers at any interval between them, thereby allowing gas to be drawn in at each of the aforementioned positions.

[0072] In this embodiment, the band 18 consists of a plate fixed to the outer peripheral end of the wall 6b of the second half-chamber and partially overlapping the opposite outer peripheral end of the wall 6a of the first half-chamber. However, other functionally equivalent devices may be used.

[0073] Figures 5 and 6 illustrate the configuration of device 20, in which the first half-drum 4a and the second half-drum 4b of drum 4 are placed side-by-side, and the second vertical wall 8 is laterally placed alongside either half-drum 4a or the second half-drum 4b of drum 4 to define the minimum width W of the receiving chamber or forming chamber 2. In this configuration, the portion of the circumferential plate 22 protruding from the second half-drum 4b of each drum 4 toward the first half-drum 4a completely overlaps a portion of the circumferential surface 5 of the first half-drum 4a, and the width W of the fiber receiving chamber or collecting chamber 2 is substantially equal to the sum of the widths (or amplitudes) of the first half-drum 4a and the second half-drum 4b of each drum 4 in the direction of the rotation axis X of drum 4. In this configuration, the two suction half-chambers of the suction device 6 of each drum 4 are also placed side-by-side with each other, integral with and moving with the corresponding half-drums 4a and 4b.

[0074] Figures 7-9 illustrate the configuration of device 20, in which the first half-drum 4a and the second half-drum 4b of drum 4 are spaced apart from each other, and the second vertical wall 8 is laterally juxtaposed with either half-drum 4a or the second half-drum 4b of drum 4 to define the maximum width W of the fiber receiving chamber or forming chamber 2. In this configuration, the portion of the circumferential plate 22 protruding from the second half-drum 4b of each drum 4 toward the first half-drum 4a overlaps the minimum free end circumferential portion of the circumferential surface 5 of the first half-drum 4a to seal the space below, which is formed as the first half-drum 4a and the second half-drum 4b of drum 4 are moved apart from each other. Thus, the width W of the fiber receiving chamber or forming chamber 2 is defined, which is substantially equal to the sum of the width (or amplitude) of the first half-drum 4a and the second half-drum 4b of each drum 4 and the predetermined maximum distance between the first half-drum 4a and the second half-drum 4b in the direction of the rotation axis X of the drum. In this configuration, the two suction half-chambers of the suction device 6 of each drum 4 are also spaced apart from each other, are integral with and move together with the corresponding half-drums 4a and 4b, and overlap with the free end periphery of the wall 6a of the first half-chamber and the wall 6b of the second half-chamber to close the space created therebetween due to the mutual displacement of the first half-drum 4a and the second half-drum 4b.

[0075] Obviously, the above-described features of the device 20 also allow the width W of the receiving chamber or forming chamber 2 to be adjusted to an intermediate value between the minimum width and the maximum width by adjusting the relative position (distance) between the end of the juxtaposition of the first half-drum 4a and the second half-drum 4b and the end of the maximum separation (pitch) of the stroke of the first half-drum 4a and the second half-drum 4b.

[0076] It should be noted that plate 22 or other functionally equivalent devices can be advantageously configured to have a reduced thickness in order to reduce the height of the step caused by the presence of plate 22 on the circumferential surface 5 of drum 4 and keep the possible non-uniformity of the final product thickness within an acceptable range, or in any case, without jeopardizing the desired characteristics of the final product.

[0077] In this respect, plate 22 can be made with a relatively thin thickness, preferably between 1 mm and 5 mm, especially about 3 mm.

[0078] Furthermore, advantageously, in the region overlapping the circumferential surface of the first half-drum 4a (where the size of the hole 22a is smaller than the size of the hole 5a in half-drums 4a and 4b), the ratio between the solid and hollow portions (holes 22a) of the perforated plate 22 is greater than the ratio between the solid and hollow portions (holes 5a) of the half-drums 4a and 4b. In other words, in the region overlapping the circumferential surface of the first half-drum 4a, the plate 22 has a greater number of holes 22a than the lower holes 5a present in the half-drum 4a.

[0079] Advantageously, since the solid portion of the overlapping plate 22 may overlap the hole 5a below the drum 4, this minimizes the loss of effective surface area on the drum 4 for gas suction during operation of the device 20, especially in the case of wear or when the rotational movements of these drums 4 are not perfectly synchronized.

[0080] Figures 10-12 illustrate an apparatus according to another embodiment of the present invention, generally indicated by reference numeral 30.

[0081] Structurally and / or functionally similar to the reference above Figure 4 The corresponding elements of the device 20 described in Figure 9 and the elements of the device 30 that are the same as the latter will be given the same reference numerals and will not be described further for the sake of brevity.

[0082] The device 30 has essentially the same structural and functional features as the previously described reference device 20, but it has some particularities regarding the rotational direction of the vertical wall 7 and the second vertical wall 8, which laterally define the fiber receiving chamber and the collection chamber 2, which consist of an infinitely moving rotating pad or belt (e.g., PVC), the outward portion of which is in contact with the scraper 10.

[0083] In fact, the first vertical wall 7, extending longitudinally along the rotation axis X of the drum 4, has a rotational direction that is substantially parallel to the rotation axis X of the drum 4, i.e., along the width W of the fiber receiving chamber 2, as shown by arrow D in Figure 12. In contrast, the second vertical wall 8, extending laterally relative to the rotation axis X of the drum 4, has a vertical rotational direction (from bottom to top or vice versa), which is substantially perpendicular to the rotation axis X of the drum 4, or in other words, in the height direction of the fiber receiving chamber and the collection chamber 2, as shown by arrow C in Figure 11.

[0084] Advantageously, this design avoids potential damage to the edges of the fiber mattress 16 formed between the drums 4. Conversely, if the second vertical wall 8 is oriented in the horizontal direction (i.e., along the length of the chamber 2), movement in the same direction relative to one of the adjacent drums 4 and in the opposite direction relative to the other of the adjacent drums 4 can lead to the formation of undesirable tangled fiber clumps, which can damage the finished product.

[0085] Furthermore, the above scheme allows for reduced fiber loss in receiving chamber 2, thereby increasing subsequent output of the entire production line.

[0086] In device 30, a sealing element 31 (e.g., a PVC sheet) is further disposed between drum 4 and the second vertical wall 8 to improve the seal of the fiber receiving chamber or forming chamber 2. This sealing element can be similarly disposed in the device 20 described above.

[0087] Regarding the operation of the aforementioned devices 20 and 30, the fibers 12 impregnated with the adhesive mixture, gas, and introduced air output from the corresponding fiberizing unit 13 are introduced into the receiving chamber or forming chamber 2 and directed toward the perforated circumferential surface 5 of the drum 4, which rotates in opposite directions, as indicated by arrow B. The fibers accumulate on the circumferential surface 5 of the drum 4, forming a mattress 14 containing agglomerated fibers, while the gas, through the holes 5a of the circumferential surface 5, is appropriately drawn by the extraction device 6 (e.g., a suction device capable of generating a vacuum) to be released to the outside from the output opening 11 (arrow F). In fact, it should be noted that the size of the holes 5a of the circumferential surface 5 is reduced sufficiently to allow gas to pass through but not fibers.

[0088] Therefore, the mattress 14, carried by the rotational motion of the drum 4, is conveyed to the lower space between the drums 4, where the mattress is unloaded and collected on the conveyor belt 16 for delivery to the next processing station, storage, or other purpose.

[0089] In view of the foregoing, the device according to the present invention achieves the predetermined objective and obtains significant advantages over known devices.

[0090] In fact, because of the use of a movable drum consisting of two half-drums sliding along the axis of rotation of the drum (instead of a fixed drum as in the prior art) and because of the overlapping belt between the half-drums, the device according to the invention allows for the efficient adjustment of the width of the receiving chamber or forming chamber of fibers from the fiberizing machine as needed, and correspondingly, the width of the products unloaded from the device can be adjusted within a wide range according to the most diverse production requirements. This can be achieved in a simple manner by appropriately adjusting the relative positions (distances) between the half-drums that make up the drum and arranging them laterally juxtaposed to the drum, with the vertical walls of the chute extending longitudinally in the transverse direction relative to the axis of rotation of the drum.

[0091] Furthermore, due to the aforementioned features, the device according to the invention no longer requires a lower component for sealing the receiving chamber, and therefore it does not form clumps of impregnated fibers in the fiber receiving or collecting chamber as occurs in known devices, which could jeopardize the quality of the final product.

[0092] Furthermore, the device according to the invention advantageously allows the vertical wall to be lowered in a position laterally juxtaposed with the drum to laterally close a considerable portion of the circumferential surface of the perforations located above the lower space (existing between the drums for unloading the mattress) during drum rotation, thereby improving the production process.

[0093] Finally, it should be noted that the creation of a movable drum and overlapping plate that slides telescopably along the drum's axis of rotation does not involve a significant increase in the structural, functional, and / or construction properties of the equipment.

[0094] Those skilled in the art will be permitted to make various modifications and substitutions to the device according to the invention, but all of these fall within the scope of protection of the appended claims.

Claims

1. An apparatus (20) for continuously producing a mattress (14) comprising agglomerated mineral fibers, comprising: Mineral fibre receiving or forming chamber (2); cumulative conveyor (3) arranged below said receiving or forming chamber (2) and comprising adjacent drums (4) provided with perforated or air-permeable circumferential surfaces (5) for receiving and accumulating fibres between said drums (4) to form a mattress (14) containing mineral fibres; suction means (6) in fluid communication with said perforated or air-permeable circumferential surfaces (5) of said drums and with the lower space between said drums (4) for unloading the mattress (14) containing mineral fibres formed between said drums (4), said plant (20) being characterized in that said drums (4) each comprise a first half-drum (4a) and a second half-drum (4b) telescopically connected to each other and movable along an axis of rotation (X) between a first end-of-travel position, in which said first half-drum (4a) and said second half-drum (4b) are juxtaposed or in contact with each other, and a second end-of-travel position, in which said first half-drum (4a) and said second half-drum (4b) are spaced apart from each other by a predetermined maximum distance along the axis of rotation (X) of said drums (4), and in that an air-permeable or perforated annular band is provided which overlaps at least one of said first half-drum (4a) and said second half-drum (4b) at opposite ends of said first half-drum (4a) and said second half-drum (4b).

2. The apparatus (20) of claim 1, wherein, said fibre receiving or forming chamber (2) comprises first vertical walls (7) extending longitudinally along the axis of rotation (X) of said drums (4) and each ending below in such a way as to be tangent to the air-permeable or perforated circumferential surfaces (5) of said first half-drum (4a) and said second half-drum (4b); and second vertical walls (8) extending transversely with respect to the axis of rotation (X) of said drums (4) and each ending below in such a way as to be transversely juxtaposed to said first half-drum (4a) or said second half-drum (4b).

3. The apparatus (20) of claim 2, wherein, said first vertical walls (7) and said second vertical walls (8) of said receiving or forming chamber (2) have the same height.

4. The apparatus (20) of claim 2, wherein, said second vertical walls (8) are movable away from or towards each other between said first vertical walls (7) along the axis of rotation (X) of said drums (4) to adjust the width (W) of said receiving or forming chamber (2) by an amount equal to the sum of the width of the circumferential surfaces (5) of said drums (4) and the distance determined by the mutual positioning of said first half-drum (4a) and said second half-drum (4b) along said axis of rotation (X).

5. The apparatus (20) of claim 3, wherein, said second vertical walls (8) are movable away from or towards each other between said first vertical walls (7) along the axis of rotation (X) of said drums (4) to adjust the width (W) of said receiving or forming chamber (2) by an amount equal to the sum of the width of the circumferential surfaces (5) of said drums (4) and the distance determined by the mutual positioning of said first half-drum (4a) and said second half-drum (4b) along said axis of rotation (X).

6. The apparatus (20) of claim 1, wherein, The thickness of the breathable or perforated annular strip is between 1 mm and 5 mm.

7. The apparatus (20) of claim 1, wherein, The thickness of the breathable or perforated annular strip is 3 mm.

8. The apparatus (20) according to any one of claims 2 to 7, wherein, The annular band is perforated, wherein in the overlapping region of at least one of the first half-drum (4a) and the second half-drum (4b), the ratio between the solid and hollow portions of the annular band is greater than the ratio between the solid and hollow portions of the first half-drum (4a) and the second half-drum (4b), and the size of the hole in the annular band is smaller than the size of the hole in the first half-drum (4a) and the second half-drum (4b).

9. The apparatus (20) according to any one of claims 2 to 5, wherein, The rotation direction of the first vertical wall (7) is substantially parallel to the rotation axis (X) of the drum (4) and / or along the width (W) direction of the fiber receiving chamber or forming chamber (2), and wherein the second vertical wall (8) has a vertical rotation direction substantially perpendicular to the rotation axis of the drum (4) and / or along the height direction of the fiber receiving chamber or forming chamber (2).

10. The apparatus (20) according to any one of claims 2 to 7, wherein, The breathable or perforated annular band consists of a circumferentially extending breathable or perforated plate that is fixed to the end of the circumferential surface (5) of one of the first half-drum (4a) and the second half-drum (4b) and partially overlaps to the opposite end of the circumferential surface (5) of the other of the first half-drum (4a) and the second half-drum (4b).

11. The apparatus (20) according to any one of claims 2 to 7, wherein, The breathable or perforated annular band consists of a breathable or perforated ring integrally formed at one end of one of the first half-drum (4a) and the second half-drum (4b) and having a larger diameter than the latter, the breathable ring further partially overlapping the opposite end of the circumferential surface (5) of the other of the first half-drum (4a) and the second half-drum (4b).

12. The apparatus (20) according to any one of claims 2 to 7, wherein, The suction device (6) includes suction chambers disposed inside each drum (4) below its ventilated or perforated circumferential surface (5), each suction chamber including a first half-chamber disposed inside a first half-drum (4a) and a second half-chamber disposed inside a second half-drum (4b), the first half-chamber and the second half-chamber being movable along a rotation axis (X) between a first stroke end position and a second stroke end position of the first half-drum (4a) and the second half-drum (4b), and providing a belt (18) that overlaps with at least one of the first half-chamber and the second half-chamber at opposite ends of the half-chambers.

13. The apparatus (20) according to any one of the preceding claims 2 to 7, wherein, The first half-drum (4a) and the second half-drum (4b) are telescopically movable by means of a corresponding bracket (21) connected to the first half-drum (4a) or the second half-drum (4b) and can move back and forth in the direction of the rotation axis (X) of the drum (4).

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