US 10,889,026 B2
Molding apparatus and process
Gert R. Mueller, New Albany, OH (US); Robert W. Zembrodt, Indianapolis, IN (US); Charles Fitch Appley, Cumberland, IN (US); Walter A. Johnson, Columbus, IN (US); and Steven Lee Collings, Greenfield, IN (US)
Assigned to Knauf Insulation, Inc., Shelbyville, IN (US)
Filed by KNAUF INSULATION, INC., Shelbyville, IN (US)
Filed on Dec. 13, 2017, as Appl. No. 15/841,187.
Application 15/841,187 is a continuation of application No. 14/394,665, abandoned, previously published as PCT/US2013/037129, filed on Apr. 18, 2013.
Claims priority of provisional application 61/779,713, filed on Mar. 13, 2013.
Claims priority of provisional application 61/625,888, filed on Apr. 18, 2012.
Prior Publication US 2018/0104860 A1, Apr. 19, 2018
Int. Cl. B29C 33/04 (2006.01); B29C 35/04 (2006.01); B29L 7/00 (2006.01); B29K 105/06 (2006.01); B29L 9/00 (2006.01); B28B 1/52 (2006.01); B29K 105/24 (2006.01)
CPC B29C 33/046 (2013.01) [B29C 35/04 (2013.01); B29C 35/045 (2013.01); B28B 1/52 (2013.01); B29C 33/048 (2013.01); B29C 35/049 (2013.01); B29K 2105/06 (2013.01); B29K 2105/246 (2013.01); B29K 2995/0002 (2013.01); B29K 2995/0015 (2013.01); B29L 2007/00 (2013.01); B29L 2007/002 (2013.01); B29L 2009/00 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A method of making a molded mineral wool insulation product using a molding process comprising:
inserting an uncured blank in a mold cavity formed in a mold system, the uncured blank including mineral wool fiber and uncured binder,
transferring heat from a first and/or second mold unit of the mold system to a cool pressurized gas to establish a hot pressurized gas therefrom, the first and second mold unit defining the mold cavity, the first and/or second mold unit being heated with hot oil, electrical resistance, heated platens, or any combination thereof, and the first and/or second mold unit being formed to include a passageway in fluid connection with a source of the cool pressurized gas and to include an array of holes formed in the first and/or second mold unit that are arranged to open into the passageway to cause the hot pressurized gas to be communicated from the passageway into the mold cavity, said heat transfer performed by causing the cool pressurized gas to flow through the passageway so that heat is transferred from the heated first and/or second mold unit to the cool pressurized gas so as to cause the hot pressurized gas to be established therefrom prior to the hot pressurized gas entering the mold cavity,
wherein the cool pressurized gas is compressed air;
injecting the hot pressurized gas into the mold cavity; and
transferring heat by convection from the hot pressurized gas to the uncured blank while transferring heat by conduction from the first and/or second mold unit to the uncured blank to cause the uncured binder to cure and establish a cured product therefrom.