Mineral Wool Fiberizing with Vertical Blowing to Reduce Shot
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Solution Overview
Problem
Existing mineral wool manufacturing processes, particularly those using spinner discs, suffer from a significant amount of non-fiberized material (shot) that weakens product quality and increases weight, despite various separation methods.
Innovation Solution
The use of multiple fiberizing devices arranged around a vertical axis with vertical blowing medium and a common collection device, along with conveying devices, to form and collect fibres efficiently, reducing shot formation and enhancing production output and product homogeneity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If spinner discs are used for fiberizing, then production output can be maintained, but a significant amount of non-fiberized material (shot) is created that weakens product quality and increases weight
Solution Approach 1:
The invention divides the fiberizing process into multiple separate fiberizing devices (at least two) instead of using a single spinner disc system. Each fiberizing device processes material independently, allowing for better control and reduced shot formation while maintaining overall production output. The segmented approach enables each device to operate optimally without the complications of large-scale spinner disc operations.
Solution Approach 2:
The invention inverts the traditional horizontal fiberizing approach by using vertical fiberizing devices with vertical blowing medium flow. This fundamental reversal of the fiberizing orientation changes the dynamics of material processing, reducing shot formation while maintaining productivity. The vertical configuration allows gravity and blowing medium to work together more effectively in controlling fiber formation.
2Manufacturing precision
If multiple fiberizing devices are used to reduce shot, then product quality improves, but device complexity increases
Solution Approach 1:
The invention combines multiple fiberizing devices into a single integrated manufacturing system that feeds into a common collection device. While multiple fiberizing devices are used to reduce shot, they are merged into a unified system through shared collection and processing infrastructure. This merging approach maintains product quality benefits while reducing the overall complexity that would result from completely separate systems.
Solution Approach 2:
The collection device serves multiple functions: it collects fibers from multiple different fiberizing devices, consolidates the fiber streams, and prepares the combined material for subsequent processing. This multi-functional design reduces the need for separate collection systems for each fiberizing device, thereby reducing overall system complexity while maintaining the quality benefits of multiple fiberizing units.
3Manufacturing precision
If vertical blowing medium is used with fiberizing plates, then shot formation is reduced and fiber quality improves, but the system becomes more complex compared to traditional spinner discs
Solution Approach 1:
The invention uses a vertical blowing medium (typically air) to facilitate fiber formation and control shot. The pneumatic flow is directed vertically through and around the fiberizing plates, creating a controlled environment that promotes proper fiber formation. This pneumatic approach replaces or supplements mechanical spinner disc operations, improving fiber quality while the blowing medium system integrates with existing plant infrastructure.
Solution Approach 2:
The invention transitions from horizontal fiberizing (spinner discs rotating in horizontal planes) to vertical fiberizing (plates rotating around vertical axes with vertical blowing medium flow). This dimensional change fundamentally alters the fiber formation dynamics, allowing gravity and vertical air flow to work together to reduce shot formation. The vertical configuration adds a new dimension to the fiberizing process that improves quality without requiring proportionally greater system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach achieves a high-grade, homogeneous mineral wool product with a fiber content exceeding 90% and improved tensile strength, while increasing production capacity to match or exceed spinner disc systems.
Implementation Method 1
at least one fiberizing plate having a vertical peripheral edge, into which are formed a plurality of holes through which the molten material is led by centrifugal force to form fibres
Implementation Method 2
the flow causing the fibres to turn downwards and, at the same time, to thin
Data Source
AI summary
An apparatus for and a method of manufacturing mineral wool are disclosed, wherein multiple fiberizing devices form discrete groups of mineral wool fibers that are separately conveyed to a common collection device. When the groups of mineral wool fibers are conveyed through separate channels, the channels can differ by shape and/or size, as well as location relative to the collection device.