Patent Application
20230330689
This application claims the benefit of priority of European Patent Application No. 22305531.0, filed Apr. 13, 2022, which is hereby incorporated by reference in its entirety.
The present disclosure relates generally to loose fill insulation installation systems, for example, suitable for installing loose fill insulation to an installation site. The present disclosure relates more particularly to a loose fill insulation hose operable to convey loose fill insulation from an insulation blowing machine.
Loose fill insulation is packaged in bags in which the material becomes compacted prior to storage and shipment. When removed from the bags, the insulation separates into clumps. In order to effectively install the insulation material, it is initially conditioned to increase its volume and to reduce its density. Traditionally, pneumatic devices are used to both install the insulation and perform the conditioning. The conditioning process breaks up clumps and alters the arrangement of the fibers so as to “open up' the insulation, conditioning the fiber to a more flake-like form. The conditioned insulation is then applied pneumatically to an area by blowing it through a hose connected to the pneumatic device. The insulation may be moistened and/or treated in the pneumatic device before installation.
While existing systems for installing loose fill insulation are effective, the present inventors have identified certain aspects of these systems that can be improved.
In one aspect, the present disclosure provides a loose fill insulation hose comprising a plurality of tubular sections coupled together so as to form a conduit configured to convey loose fill insulation along a path from a blowing machine to an installation site, the tubular sections comprising:
In another aspect, the disclosure provides a system for delivering loose fill insulation, the system comprising:
In another aspect, the disclosure provides a method for delivering loose fill insulation to an installation site using the system of the disclosure, the method comprising:
In another aspect, the disclosure provides a connection module for a loose fill insulation hose, the connection module comprising:
Additional aspects of the disclosure will be evident from the disclosure herein.
The accompanying drawings are included to provide a further understanding of the methods and devices of the disclosure, and are incorporated in and constitute a part of this specification. The drawings are not necessarily to scale, and sizes of various elements may be distorted for clarity. The drawings illustrate one or more embodiment(s) of the disclosure, and together with the description serve to explain the principles and operation of the disclosure.
The present inventors have acknowledged that the internal geometries of loose fill insulation hoses can help open the loose fill insulation during installation, and improve the installation performance. Moreover, the inventors have identified that the internal geometry within one or more connectors attached to hose sections can provide such improved performance.
Accordingly, one aspect of the disclosure is a loose fill insulation hose that includes a plurality of tubular sections coupled together to form a conduit configured to convey loose fill insulation along a path from a blowing machine to an installation site. The tubular sections include a first hose section, a first connector section and a second connector section. The first hose section extends from a proximal end to a distal end and includes a flexible body that surrounds the path for the insulation. The flexible body of the first hose section forms an opening with a first cross-sectional area. The first and second connector sections are both coupled to the first hose section so as to form the continuous path for conveying insulation. The first connector section includes a first tubular body with a first interior surface that surrounds the path. The first interior surface of the first tubular body includes a major surface portion and a plurality of projections that extend inward from the major surface portion. The second connector section includes a second tubular body including a second interior surface that surrounds the path. The second interior surface includes a constricted opening with a second cross-sectional area that is no more than 50% of the first cross-sectional area.
Such a loose fill insulation hose is schematically shown in
Loose fill insulation hose 120 also includes several connection modules, such as connection module 160 between first hose section 130 and second hose section 140, and connection module 180 between second hose section 140 and third hose section 150.
In the embodiment of loose fill insulation hose 120, as shown in
In embodiments of the loose fill insulation hose, the connection modules include various sections. As explained in further detail below, at least one of the connection modules includes a section with projections, and at least one of the connection modules includes a constricted opening. In some embodiments, the loose fill insulation hose has a connection module that includes both of these types of connector sections. In other embodiments, the loose fill insulation hose includes a first connection module with a section that includes projections and a second connection module with a section that includes a constricted opening. Further, in some embodiments, the loose fill insulation hose includes a connection module that has both of these sections and a connection module that has only one of these sections. Further still, in some embodiments, the loose fill insulation hose includes other types of connector sections, such as simple tubular sections.
First connector section 164 includes a tubular body 165 with an interior surface 166 that surrounds the path 163 for the conveyed loose fill insulation. Interior surface 166 has a major surface portion 167 that defines the outer portion of the conduit through tubular body 165. A plurality of projections 168, 169 extend radially inward from major surface portion 167 into the path 163. The projections 168, 169 are configured to open the loose fill insulation as it travels through connection module 160. As air flowing through the hose carries the loose fill insulation through connection module 160, fibers or particles of the loose fill insulation may catch on the projections 168, 169 and be pulled open or apart.
Second connector section 174 includes a second tubular body 175 with a second interior surface 176 that surrounds the path 163. The second interior surface 176 includes a constricted opening 177 with cross-sectional area that is substantially less than the cross-sectional area of the first hose section 130. For example, as shown in
In certain embodiments of the loose fill insulation hose as otherwise described herein, the opening formed by the tubular body of the first hose section is circular and has a first diameter, the constricted opening of the interior surface of the second connector section is circular and has a second diameter, and the second diameter is no more than 70% of the first diameter, e.g., no more than 65% of the first diameter, e.g., no more than 62% of the first diameter, e.g., no more than 50% of the first diameter, e.g. no more than 40% of the first diameter. For example, in the embodiment shown in
In other embodiments, the constricted opening is not circular. For example, in some embodiments, the constricted opening is formed by a slot. In other embodiments, the constricted opening is the result of various projections around the circumference of the tubular body, such that the constricted opening has the shape of a gear or star. Other shapes are also possible. The area of the constricted opening, as described herein, is determined at a particular location along the length of the connector section and based on the cross-section of the opening at that location.
In certain embodiments of the loose fill insulation hose as otherwise described herein, the plurality of projections of the first connector section includes a series of annular projections along a length of the first connector section. For example, each of the projections 168, 169 of first connection section 164 of connection module 160 is formed as an annular ring that encircles path 163 and extends radially inward from interior surface 166 around the circumference of tubular body 175. The projections 168, 169 are spaced at regular intervals along the length of first connector section 164. In other embodiments, the spacing along the length of the first connector section is irregular. Further, in some embodiments, the projections are not annular and have other shapes and forms. For example, the projections may be formed as spikes, as explained in more detail below. Further the projections may have various different shapes, such as square, triangular, round, or other shapes, including randomly configured shapes.
In certain embodiments of the loose fill insulation hose as otherwise described herein, the series of annular projections includes smaller projections that extend into the path by a first radial depth and larger projections that extend into the path by a second radial depth that is greater than the first radial depth. For example, connection module 160 includes a group of larger projections 169 that extend into path 163 by about 25% of the diameter of major surface portion 167, and a group of smaller projections 168 that extend radially inward about half the distance of larger projections 169. The use of both larger and smaller projections may help increase turbulence of the air flowing through connection module 160, which can assist in conditioning loose fill insulation travelling through the hose.
In certain embodiments of the loose fill insulation hose as otherwise described herein, the smaller projections and larger projections alternate along the length of the first connector section. For example, the smaller projections 168 of first connector section 164 of connection module 160 are interspersed between the larger projections 169. This repeated change in diameter may also increase turbulence within connection module 160. In other embodiments, the smaller and larger projections are arranged in a different pattern. For example, in some embodiments, the first connector section includes a greater number of smaller projections upstream and greater number of larger projections downstream. On the other hand, in other embodiments the first connector section includes a greater number of smaller projections downstream.
In certain embodiments of the loose fill insulation hose as otherwise described herein, at least some of the annular projections are tapered so as to have a reduced thickness at a radially inner edge. For example, in some embodiments, the upstream surface of the projections has a conical shape such that the projection narrows toward the center of the connection module. For example, each of the projections 168, 169 of tapered annular projections include a conical upstream surface as demonstrated by surface 171 in
In certain embodiments of the loose fill insulation hose as otherwise described herein, each of the larger projections has the same geometry. Likewise, in some embodiments each of the smaller projections has the same geometry. For example, in first connector section 164, each of the larger projections 169 have the same geometry and each of the smaller projections 168 also have the same geometry. In other embodiments, the projections have different shapes and sizes. For example, in some embodiments, the first connector section includes smaller projections with a range of radial depths that vary but are all below a threshold depth, and larger projections with a range of radial depths that are all above the threshold depth. Such projections may have similar shapes or different shapes.
In certain embodiments of the loose fill insulation hose as otherwise described herein, the constricted opening of the second connector section is formed by a circumferential projection that extends inward into the path and has the same geometry as the larger projections of the first connector section. For example, in connection module 160, constricted opening 177 of second connector section 174 is formed by a circumferential projection 179 that has the same geometry as each of the larger projections 169 of first connector section 164.
In other embodiments, the constricted opening of the second connector section has a different geometry from any of the projections of the first connector section. Such an embodiment is shown in
Connection module 260 also includes a second connector section 274 including a tubular body 270 with an interior surface 276 that narrows to a constricted opening 277. The constricted opening 277 has a reduced diameter 278 compared to the diameter of the first hose section 230 and second hose sections 230.
In certain embodiments of the loose fill insulation hose as otherwise described herein, the first connector section and the second connector section are part of the same connection module. For example, as shown in
Likewise, as shown in
In some embodiments, the second connector section is downstream of the first connector section. For example, in connection module 160, second connector section 174 including constricted opening 177 is downstream of first connector section 164. Likewise, in connection module 260, second connector section 274 is downstream of first connector section 264. In other embodiments, the second connector section is upstream of the first connector section. For example, in some embodiments, the connection module includes a connector section with a plurality of projections downstream of a connector section with a constricted opening.
While the first and second connector sections may be provided in the same connection module, as in connection module 160 and connection module 260, in other embodiments, the first connector section and second connector sections are provided in separate connection modules. A portion of such a loose fill insulation hose is shown in
Connection module 370 includes a second connector section 374. Second connector section 374 includes a tubular body 375 that surrounds a path 373 extending through connection module 370. Tubular body 375 has an interior surface 376 that narrows to a constricted opening 377. The constricted opening 377 has a reduced diameter 378 compared to the diameter of the first hose section 330.
In some embodiments, the second connection module is downstream of the first connection module. For example, in loose fill insulation hose 320, second connection module 370 including second connector section 374 with constricted open 377 is downstream of first connection module 360 with first connector section 364. In other embodiments, the second connection module is upstream of the first connection module.
The first and second connectors sections of the loose fill insulation hose may be positioned in connection modules at various locations along the loose fill insulation hose. For example, in loose fill insulation hose 120, as shown in
In certain embodiments of the loose fill insulation hose as otherwise described herein, the loose fill insulation hose further comprises a proximal connection module including a first side configured to attach to an outlet of a loose fill insulation blowing machine and a second side attached to the proximal end of the first hose section. For example, loose fill insulation hose 120, shown in
Alternatively, in other embodiments, the loose fill insulation hose includes a proximal connection module and a coupler configured to attach to an outlet of the loose fill insulation blowing machine. In such an embodiment, a first side of the proximal connection module is attached to the coupler and a second side of the proximal connection module is attached to the proximal end of a hose section. In some embodiments, the coupler is used to enable the connection between the loose fill insulation hose and the outlet of the blowing machine. For example, in some embodiments, the coupler has two female couplings to receive male couplings on the blowing machine outlet and proximal connection module. In other embodiments, the coupler has two male couplings. In still yet other embodiments the coupler may contain one male and one female coupling on opposite ends. Further, in some embodiments, the coupling changes the diameter of the opening so that a hose and blowing machine outlet of different diameters can be connected.
In other embodiments the loose fill insulation hose does not include a proximal connection module. For example, in some embodiments, one of the hose sections is either directly attached to the blowing machine outlet or is attached to the blowing machine outlet using a coupler.
In certain embodiments of the loose fill insulation hose as otherwise described herein, the first hose section and the second hose section are part of a group of hose sections that are connected in series, and the loose fill insulation hose further comprises a distal connection module attached at a distal end of the hose. For example, loose fill insulation hose 120 shown in
In some embodiments, the loose fill connection hose may include an outlet nozzle attached to the distal connection module. Still, in other embodiments, the loose fill insulation module may exclude a distal connection module. For example, in some embodiments, an outlet nozzle is connected directly to a hose section. Further, in other embodiments, the end of the hose is formed by a hose section, and neither a connection module nor an outlet nozzle is included at the end.
In certain embodiments of the loose fill insulation hose as otherwise described herein, the projections of the first connector section vary in size. For example, in some embodiments, the projections extend to varying depths from the outer surface portion. Likewise, in some embodiments, the projections vary in size along the length of the respective connection module. Further, in some embodiments, the projections vary in all dimension, while in other embodiments, the projections have some consistent dimensions and some varying dimensions.
The projections may have various different shapes. For example, in some embodiments, the projections have triangular, trapezoidal or square shapes. Further, in some embodiments, the projections have conical or cylindrical shapes. Further, the projections may have other shapes. It should be understood that the shapes described herein refer to a characteristic of the projection from one or more perspective.
In certain embodiments of the loose fill insulation hose as otherwise described herein, each of the projections of the first connector section forms a spike that extends into the path. For example, the projections 268 of connection module 260 are formed as spikes that extend from the major surface portion 267 into the path 263. In other embodiments, the projections may have other forms. For example, in some embodiments, the projections have ring shapes as in connection module 160, shown in
In certain embodiments of the loose fill insulation hose as otherwise described herein, the annular projections are perpendicular to the length of the connection module. For example, each of the projections 168, 169 of connection module 160 is aligned around an axis of the connection module 160 so that the annular projections are perpendicular to the length of connector section 164. In other embodiments, the annular projections are tilted with respect to the length of the connection module. For example, connection module 460, shown in
In certain embodiments of the loose fill insulation hose as otherwise described herein, the first tubular body of the first hose section includes projections that extend inward into the path. Such hose configurations are described, for example, in U.S. Pat. No. 7,284,573, which is hereby incorporated by reference herein in its entirety. In some embodiments, the first tubular body of the first hose section extend into the path by a first radial depth and at least some of the projections of the first connector section extend into the path by a second radial depth that is at least 3 times larger than the first radial, e.g., at least 5 times larger.
In certain embodiments of the loose fill insulation hose as otherwise described herein, the diameter of the interior surface of the first connection module is at least 1.5 inches, e.g., at least 2 inches, e.g., at least 2.5 inches. In some embodiments, the diameter of the interior surface of the first connection module is no more than 8 inches, e.g., no more than 6 inches, e.g., no more than 4 inches. For example, in some embodiments, the diameter of the interior surface of the first connection module is in a range from 1.5 inches to 8 inches, e.g., from 2 inches to 6 inches; or from 1.5 inches to 4 inches, e.g., from 2.5 inches to 3.5 inches. Further, in some embodiments each of the connection modules has the same inner diameter. In other embodiments, some of the connection modules have different inner diameters.
In certain embodiments of the loose fill insulation hose as otherwise described herein, the first side of the first connection module is a male fitting that is inserted into the distal end of the first hose section, and the second side of the first connection module is a male fitting that is inserted into the proximal end of the second hose section. For example, as shown in
In certain embodiments of the loose fill insulation hose as otherwise described herein, the first hose section is corrugated. For example, first hose section 130 of loose fill insulation hose 120, as shown in
In certain embodiments of the loose fill insulation hose as otherwise described herein, the first hose section has a length of at least 10 feet, e.g., at least 15 feet, e.g., at least 20 feet. In some embodiments, the first hose section has a length of no more than 100 feet, e.g., no more than 80 feet, e.g., no more than 60 feet, e.g., about 50 feet. For example, in some embodiments, the first hose section has a length in a range from 10 feet to 100 feet, e.g., from 12 feet to 80 feet, e.g., from 15 feet to 60 feet, e.g., from 20 feet to 50 feet. In some embodiments each of the hose sections has the same length. In other embodiments the hose sections of the loose fill insulation hose have different lengths.
In certain embodiments of the loose fill insulation hose as otherwise described herein, an inner diameter of the first hose section is at least 1.5 inches, e.g., at least 2 inches, e.g., at least 2.5 inches. In certain embodiments of the loose fill insulation hose as otherwise described herein, an inner diameter of the first hose section is no more than 8 inches, e.g., no more than 6 inches, e.g., no more than 4 inches. For example, in some embodiments, the inner diameter of the first hose section is in a range from 1.5 inches to 8 inches, e.g. from 2 inches to 6 inches, e.g., from 2.5 inches to 4 inches. Further, in some embodiments each of the hose sections has the same inner diameter. In other embodiments, some of the hose sections have different inner diameters.
In another aspect, the disclosure provides a system for delivering loose fill insulation that includes a loose fill insulation blowing machine and the loose fill insulation hose of the disclosure. The blowing machine includes a hopper configured to receive loose fill insulation, an outlet, and a blower operable to expel loose fill insulation through the outlet. The loose fill insulation hose is attached to the outlet of the loose fill insulation blowing machine.
Such a system is schematically shown in
In certain embodiments of the system of the disclosure, the hopper includes a shredder box configured to break apart the loose fill insulation. For example, hopper 104 includes a shredder box 110 including a plurality of shredding members that rotate through the packed insulation to break the insulation apart and “open” the insulation.
In certain embodiments of the system of the disclosure, the loose fill insulation blowing machine includes an air lock configured to transfer the loose fill insulation to the outlet. For example, the insulation in system 100 moves from the shredder box 110 through a stator bar 112 that includes tines for further opening the insulation and into an air lock 114. As shown in
In another aspect, the disclosure provides a method of delivering loose fill insulation to an installation site using the system of the disclosure. The method includes expelling loose fill insulation from a blowing machine into the loose fill insulation hose. The loose fill insulation is conveyed through the loose fill insulation hose to the installation site.
Such a method is depicted in
In certain embodiments of the method as otherwise described herein, the method further includes opening the loose fill insulation that is passing through the first connection module using projections extending inward into the path between the first hose section and the second hose section. For example, as the loose fill insulation in system 100 passes through first connection module 160, the projections 168 interact with the insulation and further open the insulation, as explained in more detail above.
In certain embodiments of the method as otherwise described herein, the loose fill insulation includes a fibrous material. For example, in some embodiments, the loose fill insulation is a fiberglass insulation, a cellulose insulation, a stonewool insulation, a plastic fiber insulation, a natural wool insulation, a natural cotton insulation, or another insulation including fibers. In other embodiments, the loose fill insulation includes small insulating components, such as a foam bead insulation or a plastic particle insulation.
As stated above, the first connector section including projections and the second connector section including a constricted opening may be located at various positions along the length of the loose fill insulation hose. The position of the connector sections may impact the performance of insulation that is installed using the loose fill insulation hose. For example,
As shown, compared to the hoses with only standard connection modules, the hoses with the enhanced connection modules yield increased R value and substantially increased coverage. Consistent with the description above, “section 1” is the hose section positioned toward the distal end of the hose and “section 3” is the hose section positioned near the blowing machine. For example, each of the hoses including at least one of the enhanced connection module yields an increase in average R value of at least 2%. Likewise, each of the hoses including at least one enhanced connection module yields an increase in coverage of at least 20%.
The data in
It will be apparent to those skilled in the art that various modifications and variations can be made to the processes and devices described here without departing from the scope of the disclosure. Thus, it is intended that the present disclosure cover such modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
Embodiment 1. A loose fill insulation hose comprising a plurality of tubular sections coupled together so as to form a conduit configured to convey loose fill insulation along a path from a blowing machine to an installation site, the tubular sections comprising:
Embodiment 2. The loose fill insulation hose according to embodiment 1, wherein the opening formed by the tubular body of the first hose section is circular and has a first diameter, wherein the constricted opening of the interior surface of the second connector section is circular and has a second diameter, and wherein the second diameter is no more than 70% of the first diameter, e.g., no more than 65% of the first diameter, e.g., no more than 62% of the first diameter, e.g., no more than 50% of the first diameter.
Embodiment 3. The loose fill insulation hose according to embodiment 1 or embodiment 2, wherein the first connector section is part of a first connection module.
Embodiment 4. The loose fill insulation hose according to embodiment 3, wherein the first connection module is attached to the proximal end of the first hose section.
Embodiment 5. The loose fill insulation hose according to embodiment 3, wherein the first connection module is attached to the distal end of the first hose section.
Embodiment 6. The loose fill insulation hose according to embodiment 5, wherein the first connection module is disposed at a distal end of the hose.
Embodiment 7. The loose fill insulation hose according to any of embodiments 3 to 6, wherein the second connector section is part of the first connection module.
Embodiment 8. The loose fill insulation hose according to embodiment 7, wherein the second connector section is downstream of the first connector section.
Embodiment 9. The loose fill insulation hose according to embodiment 1 to 6, wherein the second connector section is part of a second connection module.
Embodiment 10. The loose fill insulation hose according to embodiment 9, wherein the second connection module is downstream of the first connection module.
Embodiment 11. The loose fill insulation hose according to embodiment 10, wherein the second connection module is attached to the distal end of the first hose section.
Embodiment 12. The loose fill insulation hose according to any of embodiments 1 to 10, wherein the first hose section is one of a group of hose sections that are connected in series using a group of connection modules.
Embodiment 13. The loose fill insulation hose according to any of embodiments 1 to 12, wherein the constricted opening of the second connector section is formed by a circumferential projection that extends inward into the path.
Embodiment 14. The loose fill insulation hose according to any of embodiments 1 to 13, wherein the plurality of projections of the first connector section includes a series of annular projections along a length of the first connector section.
Embodiment 15. The loose fill insulation hose according to embodiment 14, wherein the series of annular projections includes smaller projections that extend into the path by a first radial depth and larger projections that extend into the path by a second radial depth that is greater than the first radial depth.
Embodiment 16. The loose fill insulation hose according to embodiment 15, wherein the smaller projections and larger projections alternate along the length of the first connector section.
Embodiment 17. The loose fill insulation hose according to any of embodiments 14 to 16, wherein at least some of the annular projections are tapered so as to have a reduced thickness at a radially inner edge.
Embodiment 18. The loose fill insulation hose according to embodiment 17, wherein the tapered annular projections include a conical upstream surface.
Embodiment 19. The loose fill insulation hose according to any of embodiments 15 to 19, wherein each of the larger projections has the same geometry.
Embodiment 20. The loose fill insulation hose according to embodiment 19, wherein each of the smaller projections has the same geometry.
Embodiment 21. The loose fill insulation hose according to any of embodiments 1 to 20, wherein the first tubular body of the first hose section includes projections that extend inward into the path.
Embodiment 22. The loose fill insulation hose according to embodiment 21, wherein the projections of the first tubular body of the first hose section extend into the path by a first radial depth and at least some of the projections of the first connector section extend into the path by a second radial depth that is at least 3 times larger than the first radial, e.g., at least 5 times larger.
Embodiment 23. A system for delivering loose fill insulation, the system comprising:
Embodiment 24. A method of delivering loose fill insulation to an installation site using the system according to embodiment 23, the method comprising:
Embodiment 25. A method of delivering loose fill insulation to an installation site using the system according to embodiment 23, the method comprising:
Embodiment 26. A method of delivering loose fill insulation to an installation site using the system according to embodiment 23, the method comprising:
Embodiment 27. A connection module for a loose fill insulation hose, the connection module comprising:
Embodiment 28. The connection module according to embodiment 27, wherein the smaller projections and larger projections alternate along the length of the first connector section.
Embodiment 29. The connection module according to embodiment 27 or embodiment 28, wherein each of the smaller projections extends into the path by the same radial depth.
Embodiment 30. The connection module according to any of embodiments 27 to 29, wherein each of the larger projections extends into the path by the same radial depth.
Embodiment 31. The connection module according to any of embodiments 27 to 30, wherein at least some of the annular projections are tapered so as to have a reduced thickness at a radially inner edge.
Embodiment 32. The connection module according to embodiment 31, wherein the tapered annular projections include a conical upstream surface.
| Number | Date | Country | Kind |
|---|---|---|---|
| 22305531.0 | Apr 2022 | EP | regional |
