A method and apparatus for producing a rock wool roll felt

Abstract

This invention discloses a method for producing rock wool rolls. After the rock wool fibers are collected into a layer by a collecting belt, a pendulum swings in a direction perpendicular to the conveying direction of the pressure roller spreading conveyor belt, folding the fibers laterally on the conveyor belt. The fibers are then pressed by a pressure roller along the conveying direction of the spreading conveyor belt. This invention also discloses a rock wool roll production device, including a pendulum for folding the fibers and a conveyor belt in front of the pendulum, as well as a pressure roller and a spreading conveyor belt in front of the pressure roller. The swing direction of the pendulum and the conveyor belt in front of the pendulum are perpendicular to the spreading conveyor belt in front of the pressure roller. The pendulum is arranged such that its swing and folding direction is perpendicular to the conveying direction of the spreading conveyor belt, causing the rock wool layer to be folded laterally in a zigzag pattern on the spreading conveyor belt before entering the pressure roller. The rock wool rolls produced by the method and equipment of this invention have uniform thickness, good fracture resistance, and high tensile strength.

Description

Technical Field

[0001] This invention relates to a rock wool roll production technology, specifically a rock wool roll production method and equipment. Background Technology

[0002] Rock wool, due to its excellent high-temperature resistance and low thermal conductivity, is widely used as an inorganic fireproof and thermal insulation material for the insulation of equipment, pipelines, and buildings, as well as as a sound-absorbing and noise-reducing material. Rock wool rolls are easy to install and are commonly used products for thermal insulation, heat insulation, and sound absorption and noise reduction.

[0003] The production process of rock wool rolls uses natural rocks such as basalt and dolomite as the main raw materials. The production equipment and processes are as follows: Figure 1 As shown, the magma is melted using a cupola or electric arc furnace 1. The molten magma flows out of the furnace outlet and is centrifuged at high speed by a centrifuge 2 into fibers. At the same time, a small amount of adhesive is sprayed in using a glue spraying device 3, and then collected by a collection belt 4 to form a cotton layer. The cotton layer 10 is as follows: Figure 2 As shown, the cotton is folded into multiple layers by swinging back and forth along the conveying direction of the cotton-laying conveyor belt 61 of the pressure roller 6, and then rolled and densified into felt by the pressure roller 6. After drying in the curing oven 7 and curing with the adhesive, it is cut into rectangular blocks with neat edges by the cutting machine. It is then rolled up manually or mechanically to form rock wool roll felt products of the required specifications, density and use.

[0004] However, the inventors discovered that existing rock wool roll production equipment produces rock wool rolls with uneven thickness, making the rolls more prone to breakage. This unevenness and fiber breakage also reduce the tensile strength of the rolled products. To solve this problem, they attempted to adjust the raw material ratio and melting temperature to improve the toughness and strength of the rock wool fibers, as well as adjust the binder ratio and dosage to help adjust the toughness and strength of the rock wool rolls. However, after repeated attempts, they failed to achieve the desired results. Summary of the Invention

[0005] To address the issues of uneven thickness, brittle rock wool fibers, and low tensile strength during the production of rock wool rolls, the applicant improved the production methods and equipment for rock wool rolls, effectively resolving these problems.

[0006] The challenge of this invention lies in the fact that the inherent connection between accidental production process factors and the occurrence of rock wool fiber breakage and low felt strength is not an easily observable, explicit influencing factor. The unclear cause hinders targeted and effective process adjustments and the development of specialized equipment. Based on accidental discoveries and in-depth analysis, with a clearer and more advanced understanding, this invention overcomes the traditional mindset of simply increasing rock wool fiber strength, thus forming the solution to the problem.

[0007] The technical solution of the present invention is: a method for producing rock wool rolls, characterized in that after the rock wool fibers are collected into a cotton layer by a collecting belt, a pendulum swings in a direction that is horizontal and perpendicular to the conveying direction of the cotton spreading conveyor belt with pressure rollers, and the cotton is folded and spread laterally on the running cotton spreading conveyor belt, and then crushed by pressure rollers in the conveying direction of the cotton spreading conveyor belt.

[0008] To achieve the above-mentioned rock wool roll production method, the present invention also provides a rock wool roll production equipment, including a pendulum for folding and laying cotton and a conveyor belt in front of the pendulum, as well as a pressure roller and a cotton laying conveyor belt in front of the pressure roller. The equipment is characterized in that: the conveyor belt in front of the pendulum is arranged perpendicularly to the cotton laying conveyor belt in front of the pressure roller, and the pendulum is arranged such that its swinging and folding direction is perpendicular to the conveying direction of the cotton laying conveyor belt, so that the rock wool layer is folded laterally on the cotton laying conveyor belt in a zigzag pattern before entering the pressure roller.

[0009] To achieve a perpendicular arrangement between the conveyor belt before the pendulum and the cotton-laying conveyor belt before the pressure roller, one embodiment involves arranging the magma outflow direction and the direction of the trapping belt of the cupola or electric arc furnace perpendicular to the direction of the cotton-laying conveyor belt. This method, due to the "L"-shaped layout of the entire production line, occupies a large area and is difficult to use for retrofitting existing straight-line production lines. It is more suitable for building new rock wool roll production equipment or retrofitting production lines with large sites.

[0010] Therefore, one embodiment for modifying an existing rock wool roll production line with a straight "I" layout is as follows: a vertical turning conveyor is installed between the collecting belt and the conveyor belt in front of the pendulum to fold the rock wool layer downward at a 45° angle and vertically turn it to convey it onto the conveyor belt in front of the pendulum.

[0011] Because the rock wool layer is laid out in continuous sheet form like a quilt on the cotton-laying conveyor belt, it cannot be vertically transported directly using two vertically aligned conveyor belts as it would with discontinuous materials or non-sheet materials without a fixed direction. Therefore, a vertical steering conveyor device is a special device that this invention needs to develop. The vertical steering conveyor device of this invention adopts the following technical solution: multiple rollers arranged horizontally on the frame, from longest to shortest, with one end suspended. The line connecting the suspended ends of the rollers forms a 45° angle with the length direction of the rollers. Conveying wheels are installed on the rollers, forming an isosceles right-angled triangular wheel-type conveying surface on the upper surface of the conveying wheels. A drive device is also installed on the frame to drive all rollers and conveying wheels to rotate in the same direction. A first transverse conveyor belt is set below the rollers, parallel to the wheel-type conveying surface and with the conveying direction consistent with the axial direction of the rollers. A conveyor belt in front of the pendulum is set below the first transverse conveyor belt to receive and reverse the rock wool layer conveyed by the first transverse conveyor belt to the pendulum located at the middle position above the cotton-laying conveyor belt.

[0012] Furthermore, the conveyor wheels on adjacent rollers are staggered, resulting in smaller gaps between rollers and between conveyor wheels, forming a densely packed conveying surface on the surface of the conveyor wheels, ensuring smooth transmission.

[0013] Furthermore, since the conveying roller shaft is cantilevered and unsupported, the conveying wheel is made of lightweight materials such as aluminum wheel, nylon wheel, and engineering plastic wheel to reduce its own weight and improve the service life of the cantilever roller shaft and its bearing seat. The surface of the conveying wheel is provided with grooves or protrusions to increase the friction with the rock wool layer and prevent slippage during conveying.

[0014] The roller is mounted on the frame via a bearing housing, and the drive device is a motor that drives the roller to rotate via a sprocket and chain transmission assembly.

[0015] Furthermore, since the overall height increases after the addition of the vertical turning conveyor, an inclined height-adjustable conveyor belt is also added between the vertical turning conveyor and the collection belt.

[0016] Further reports also include curing ovens, shearing machines, and laminating machines.

[0017] In summary, the present invention has the following beneficial technical effects:

[0018] 1. Improved the crack resistance of rock wool fibers during the production process of rock wool rolls, resulting in better uniformity of roll thickness, improved overall strength of the rolls, and significantly increased yield.

[0019] 2. Through the development of a dedicated vertical steering conveyor, without requiring changes to the production line layout...

[0020] In this case, the original linear production line can be modified. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of existing rock wool roll production equipment.

[0022] Figure 2 for Figure 1 A top view of the pendulum folding cotton on the cotton-spreading conveyor belt with pressure rollers.

[0023] Figure 3 This is a schematic diagram of the pendulum folding conveyor device on the cotton-spreading conveyor belt of the present invention.

[0024] Figure 4 for Figure 3 Top view.

[0025] Figure 5 This is a schematic diagram showing the force exerted on the rock wool layer after it has been folded and laid out, when it is compressed by a pressure roller.

[0026] Figure 6This is a schematic diagram showing the displacement of rock wool fibers under the tension of a pressure roller in the rock wool roll production equipment of the present invention.

[0027] Figure 7 This is a schematic diagram of the rock wool roll production equipment according to Embodiment 2 of the present invention.

[0028] Figure 8 This is a schematic diagram of the rock wool roll production equipment according to Embodiment 3 of the present invention.

[0029] Figure 9 This is a top view of the vertical steering conveyor used in Example 3.

[0030] Figure 10 for Figure 9 The S-direction view.

[0031] Figure 11 For rock wool layer in Figure 9 The diagram shows a vertical turning conveyor that flips downwards along a 45° inclined plane.

[0032] In the diagram: 1. Electric arc furnace, 2. Centrifuge, 3. Glue spraying equipment, 4. Collecting belt, 5. Pendulum, 6. Pressure roller, 7. Curing oven, 8. Shearing machine, 9. Vertical steering conveyor, 10. Rock wool layer, 11. Rock wool fiber, 12. Height-adjustable conveyor belt, 61. Wool-laying conveyor belt, 91. Frame, 92. Motor, 93. Gear and chain drive assembly, 94. Bearing seat, 95. Roller, 96. Conveyor wheel, 97. First transverse conveyor belt, 98. Conveyor belt in front of the pendulum. Detailed Implementation

[0033] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments to help understand the content of the present invention.

[0034] Example 1: Rock wool roll production method

[0035] A method for producing rock wool rolls, such as Figure 3 and Figure 4 As shown, the invention lies in the fact that the magma melted by the cupola furnace or electric arc furnace is spun into rock wool fibers by a centrifuge and settled onto the collection belt. After being collected by the collection belt and laid into a rock wool layer 10, and sprayed with adhesive, the pendulum 5 swings back and forth along the horizontal direction b of the cotton spreading conveyor belt 61 with the pressure roller 6, and folds the cotton horizontally back and forth on the running cotton spreading conveyor belt 61. Then, the pressure roller 6 is used to crush it into a felt along the conveyor belt direction. After curing, shearing, covering with plastic film and winding, it becomes a rock wool roll felt product.

[0036] During production and experimental research, the applicant accidentally discovered that changing the folding direction of the rock wool layer 10 during laying improved the thickness uniformity, fracture performance, and tensile strength of the finished rock wool roll. Through in-depth research and analysis, the inventor recognized that rock wool, being an inorganic fiber composed of oxides such as silicon, aluminum, iron, and magnesium, has low tensile strength and toughness, and the fibers are prone to breakage. This is mainly due to limitations in traditional rock wool roll production processes. The laying direction of the centrifugally formed rock wool fibers on the collecting belt is roughly consistent with the conveying direction of the collecting belt (most fiber length directions form a small angle with the conveying direction). After being folded and laid by the pendulum along the laying conveyor belt 61, the direction of the rock wool fibers is also roughly consistent with the conveying direction of the laying conveyor belt 61. The rotating and pressing direction of the pressure roller 6 is also consistent with the conveying direction. Figure 5 As shown, when the pressure roller 6 rotates and compacts, it generates not only a pressure P perpendicular to the rock wool layer 10 (this pressure P increases as it approaches the minimum gap between the pressure rollers), but also a frictional force F on the fibers along the circular pressing surface of the pressure roller. When the fiber folding direction is basically consistent with the direction of the tension F, because a relatively large proportion of the fiber length direction is consistent with the direction of the tension, the distance this tension acts is the displacement of the arc-shaped surface of the pressure roller. This displacement is greater than the linear displacement of the conveyor belt, causing the fibers to be stretched. When the fiber length direction is consistent with the rotation direction of the pressure roller or only at a small angle, the fiber does not have enough displacement to resist the tension F. The tension F causes the fiber to generate large internal stress, leading to the breakage of some fibers. Figure 4 The diagram shows that the folding and laying direction of the rock wool fibers on the conveyor belt has been changed, which not only improves the uniformity of the laying thickness, but also changes the fiber length direction on the laying conveyor belt 61, such as... Figure 6 The fiber length and bending direction shown have a large angle of inclination with the direction of the tensile force F, most of which are obtuse angles and the bending points are approximately flat. The tensile force F generated by the rotation of the pressure roller causes the rock wool fiber 11 to... Figure 6 As shown, the bending angle and position change along the folding position S. This change in bending angle and position causes the tension F generated by the pressure roller 6 to only cause the rock wool fiber to undergo macroscopic deformation from curved to straight and the bending point S to shift. As a result, the tensile stress on the fiber is small and will not generate sufficient internal stress to cause the single fiber to break. Therefore, the breaking performance and tensile strength of the rock wool roll are also improved.

[0037] Example 2: Vertical Layout Rock Wool Roll Production Equipment

[0038] like Figure 7As shown, the rock wool roll production equipment in this embodiment includes a cupola or electric arc furnace 1 to melt the rock used as raw material, a centrifuge to centrifuge the molten magma at high speed into fibers, which fall onto a collection belt 4 to be collected into a rock wool layer 10, a spraying device 3 on the collection belt for spraying adhesive onto the rock wool layer 10, a pendulum 5, a pressure roller 6, a curing oven 7, a shearing machine 8, a coating device, and a winding device. Figure 1 The difference is that the magma outflow direction of the cupola furnace or electric arc furnace 1, the conveying direction of the trapping belt 4, and the swing direction of the pendulum 5 are all set perpendicular to the cotton spreading conveyor belt 61 in front of the pressure roller. This allows the rock wool layer 10 to swing back and forth laterally on the cotton spreading conveyor belt 61 in a direction that is horizontal and perpendicular to the conveying direction, folding and spreading the cotton. After the rock wool layer 10 is folded laterally on the cotton spreading conveyor belt 61 and laid in a "zigzag" shape, it enters the pressure roller 6 and is then rolled into felt along the conveying direction of the conveyor belt. This improves the fracture resistance and tensile strength of the rock wool felt, improves the uniformity of the thickness, and increases the yield of the felt.

[0039] Example 3: Linear Layout Rock Wool Roll Production Equipment

[0040] like Figure 8 As shown, the rock wool roll production equipment in this embodiment also includes a cupola or electric arc furnace 1, a centrifuge, a glue spraying device 3, a collecting belt 4, a pendulum 5, a pressure roller 6, a curing oven 7, a shearing machine 8, a laminating machine for covering the sheared block rock wool felt with a plastic film, and a machine for manually or by using a winding machine to roll the rock wool felt into rolls. Unlike Example 2, most of the equipment in this embodiment still adopts the traditional "I"-shaped layout of rock wool roll production equipment. A vertical turning conveyor 9 is set between the collection belt 4 and the conveyor belt in front of the pendulum 5 to fold the rock wool layer downward at a 45° angle and vertically turn it to the conveyor belt in front of the pendulum. The swing direction of the pendulum 5 is horizontal and perpendicular to the conveying direction of the cotton spreading conveyor belt 61, so as to realize the lateral swing and folding of cotton spreading on the running cotton spreading conveyor belt 61. The key to this method is the addition of the vertical turning conveyor 9 between the collection belt 4 and the pendulum 5, so that after the continuously spread sheet-like rock wool layer is folded downward along the 45° inclined side, the conveying direction changes from longitudinal to lateral. After being folded downward again, it enters the horizontally arranged pendulum, realizing the lateral swing and folding of cotton spreading along the cotton spreading conveyor belt 61.

[0041] The structure of the vertical steering conveyor 9 is as follows: Figure 9 and Figure 10As shown, multiple rollers 95, arranged from longest to shortest with one end suspended, are horizontally mounted on the frame 91 via bearing seats 94. The line connecting the suspended ends of the rollers 95 (virtual connection) forms a 45° angle with the length direction of the rollers. Conveyor wheels 96 are mounted on the rollers 95, and the number of conveyor wheels 96 on each roller 95 is unequal. The upper surface of the conveyor wheels 96 forms an approximately isosceles right-angled triangle wheel-type conveying surface. A motor 92 is also mounted on the frame as a drive device. Through a gear and chain transmission assembly 93 consisting of gears and chains on the rollers and the motor output shaft, all rollers 95 and conveyor wheels 96 are driven to rotate in the same direction and at the same angular velocity. A first transverse conveyor belt 97 is provided below the roller shaft, parallel to the wheel conveyor surface and with the conveying direction consistent with the axial direction of the roller shaft 96; the conveyor belt 98 in front of the pendulum is provided below the first transverse conveyor belt 97 to receive the rock wool layer conveyed by the first transverse conveyor belt 97 and to convey the rock wool layer in the opposite direction to the pendulum 5, so that the pendulum 5 can swing back and forth laterally relative to the conveying direction of the cotton spreading conveyor belt to fold and spread the cotton. (See also...) Figure 11 As shown, rock wool layer 10 enters along the Y direction. Figure 9 The hypotenuse L of the isosceles right-angled triangular wheel conveyor surface of the vertical steering conveyor, i.e., the cantilever end of the roller shaft, bends and hangs down along the hypotenuse L under the action of gravity, falling onto the first transverse conveyor belt 97. While being conveyed along the X direction by the first transverse conveyor belt 97, it is bent and flipped along the hypotenuse L of the vertical steering conveyor and then conveyed transversely along the X direction. Upon reaching the right edge of the first transverse conveyor belt 97, it flips downward and falls onto the conveyor belt 98 in front of the pendulum below. After completing the flipping up and down again, it is conveyed towards the feed port of the pendulum, held by the two conveyor belts of the pendulum, and swings back and forth transversely along the cotton spreading conveyor belt 61, realizing transverse folding into a "Z" shape cotton spreading on the conveyor belt 61.

[0042] like Figure 9 As shown, the conveyor wheels 96 on adjacent rollers 95 are arranged in a staggered manner, so that the edges of the conveyor wheels 96 are close to the adjacent rollers 95. This results in smaller gaps between the rollers and the conveyor wheels, and the surfaces of the conveyor wheels 96 form a densely packed conveying surface, which ensures smooth transmission and reduces the gap between the rock wool fibers entering the conveyor wheels and rollers.

[0043] Since the roller 95 is cantilevered, the conveying wheel is made of lightweight materials such as aluminum, nylon, or engineering plastics to reduce weight and improve the life of the roller and the mounting bearing seat. The surface of the conveying wheel can be provided with grooves or protrusions to increase friction with the rock wool, prevent or reduce slippage, and improve conveying capacity.

[0044] For the modification of the original production line, since the overall height has increased after the addition of the vertical steering conveyor above the pendulum, an inclined height-adjustable conveyor belt 12 has also been added between the vertical steering rollers.

[0045] The above description is merely a preferred embodiment of the present invention. Any simple equivalent changes and modifications made in accordance with the scope and description of this patent application shall fall within the scope of this patent.

Claims

1. A rock wool roll felt production equipment, comprising a pendulum for pleating and spreading the felt and a conveyor belt in front of the pendulum, as well as a pressure roller and a felt spreading conveyor belt in front of the pressure roller, characterized in that: The swing direction of the pendulum and the conveyor belt in front of the pendulum are perpendicular to the cotton-laying conveyor belt in front of the pressure roller, so that the rock wool layer is laid in a zigzag pattern on the cotton-laying conveyor belt before being crushed by the pressure roller; it also includes a cupola furnace or electric arc furnace and a collection belt. Between the collection belt and the conveyor belt in front of the pendulum, a vertical turning conveyor device is set to fold the rock wool layer downward at a 45° angle and vertically turn it to be conveyed onto the conveyor belt in front of the pendulum. The cupola furnace, collection belt and cotton-laying conveyor belt are arranged in a straight line to form a linear layout rock wool roll production equipment; the vertical turning conveyor device has multiple horizontally arranged conveyors from long to short lengths on the frame. The machine consists of short, suspended rollers, with the line connecting the suspended ends of the rollers forming a 45° angle with the length of the rollers. Conveyor wheels are mounted on the rollers, and the conveyor wheels on adjacent rollers are staggered, forming an isosceles right-angled triangular wheel-type conveying surface on the upper surface of the conveyor wheels. A drive unit is also installed on the frame to drive all rollers and conveyor wheels to rotate in the same direction. A first transverse conveyor belt is set below the rollers, parallel to the wheel-type conveying surface and with the conveying direction consistent with the axial direction of the rollers. A conveyor belt in front of the pendulum is set below the first transverse conveyor belt to receive and reverse the rock wool layer conveyed by the first transverse conveyor belt to the pendulum located at the middle position above the cotton-laying conveyor belt.

2. The rock wool roll production equipment as described in claim 1, characterized in that: The conveyor wheel is made of aluminum, nylon, or engineering plastic, and its surface is provided with grooves or protrusions.

3. The rock wool roll production equipment as described in claim 1, characterized in that: The roller is mounted on the frame via a bearing housing, and the drive device is a motor that drives the roller to rotate via a sprocket and chain transmission assembly.

4. The rock wool roll production equipment as described in claim 1, characterized in that: An inclined height-adjustable conveyor belt is also added between the vertical steering conveyor and the collection belt.

5. The rock wool roll production equipment as described in claim 1, characterized in that: It also includes curing ovens, shearing machines, and laminating machines.

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