Patent Application
20080121836
(1) Field of the Invention
The present invention relates generally to loose-fill insulation, and more specifically to a pourable loose-fill insulation configured to installed by pouring the insulation into the area to be insulated without blowing.
(2) Description of the Prior Art
Loose-fill insulation is typically compressed or compacted to facilitate shipping or to reduce the cost of shipping. Compressing insulation, however, generally has a negative effect on the fiber matrix of the insulation component. For example, compression may negatively affect the degree to which air flow is eliminated, or may negatively affect the fiber structure surrounding air pockets.
In loose-fill cellulosic insulation, for example, the applicants have observed that compressing the insulation for packaging can have negative effects on the insulation. For example, if traditional loose-fill cellulose insulation is compressed to about 8 pounds per cubic foot (pcf) it forms a large solid block that must be separated by a machine separator/blower to perform properly or achieve the desired R value. Examples of such machines are the MultiMatic and VoluMatic available from Unisul of Winter Haven, Fla.; the Arkfeld 118 available from Arkfeld Manufacturing, Inc. of Norfolk, Nebr.; and the USGF Monarch 1000 available from U.S. GreenFiber, LLC, of Charlotte, N.C.
The use of such machines is not always desirable. For example, the use of such machines adds additional cost to the loose-fill insulation process. Additionally, because loose-fill insulation is commonly installed in small or hard to reach areas, it may be difficult to get separator-blowers to the areas where they are needed.
The present invention provides a pourable insulation to address these, and additional, problems.
(3) Definitions
As used herein the term pourable means the ability of an insulation component to flow from its container in a substantially continuous component stream.
The term manual shaking means imparting motion to a container by hand. For example, grasping either or both ends of a bag with either or both hands and imparting any of an up-and-down motion, a side-to-side motion, a back-and-forth motion, etc., or any combination therein is considered manual shaking. Manual shaking may also be achieved with any device designed to mimic the manual shaking described above.
The term pre-classified means previously separating component particles based on the desired particle sizes.
The term R-value is a measure of thermal resistance. R-values can be calculated from thermal conductivity, k and the thickness of the material, d: R=d/k.
The term cellulosic means containing cellulose or a derivative of cellulose.
The term hammer mill means any of the variety of commercially available hammer mills or hammer mill shredders or bliss mill type shredders, or a shredder that utilizes rotating hammers to repeatedly strike the insulation particles until they are reduced in size and capable of passing through a screen.
The present invention is directed to a loose-fill insulation that can be installed simply by pouring the insulation. One embodiment of the present invention includes an insulation system for installing pourable insulation. In this embodiment, the system includes a pre-classified insulation component and a package containing the insulation component. The insulation component contained in this package has a packaged insulation density about equal to the density of the insulation after it has been installed.
Another embodiment of the invention includes a pourable insulation system comprising a pre-classified insulation component, and an adjustable compression package configured to hold the insulation component at a first compressed density and to allow the insulation component to reach, within the package, a second density that is lower than the first density.
Another embodiment of the invention includes a method of making a pre-classified pourable insulation component. The method includes shredding a cellulosic material in a pre-shredder, passing the shredded material through a screen having a diameter between about 1 inch and 4 inches; and shredding the cellulosic material in a second shredder, e.g., a bliss mill or hammer mill. By using this method, the insulation component can go from a density between about 6 pcf and 10 pcf to a density of between about 2 pcf and 5 pcf simply by manual shaking.
Another embodiment of the method of making the present invention includes shredding a cellulosic material in a pre-shredder; injecting about 1 wt. % to about 3 wt. % water into the cellulosic material; passing the shredded material through a screen having a diameter between about 1 and 4 inch opening; adding a fire retardant; shredding the cellulosic material in a second shredder; and packaging the cellulosic material. In this embodiment, the package is preferably an adjustable package that is compressed for shipping.
The present invention also includes a method of installing a pourable insulation. The method includes obtaining an adjustable package of insulation, the insulation having a first density within the package. After the package is obtained, it is shook until the insulation has a second density. Following shaking, the insulation is poured from the package, for example, into or onto the area to be insulated.
These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.
In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “left,” “right,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms.
Referring now to the drawings in general and
As mentioned component 12 is pre-classified. Pre-classification is achieved by passing the insulation component through a screen of the desired size. Preferably, the screen opening size is between about ½ inch and 4 inches. More preferably, the screen opening size is about 3 inches.
Component 12 may have any number of structures or be in any number of shapes, e.g., fibrous material, granular material, pellet material, agglomerated material, aggregated material, or any mixture thereof. Preferably, however, component 12 is a fibrous material. Somewhat similarly, component 12 may be either inorganic or organic, or a mixture of both inorganic and organic. Inorganic components may include fiberglass, rock wool, pearlite, mineral wool, or asbestos, or any mixtures thereof. Preferably, the component is organic, or carbon based, and is cellulosic. Most preferably, the cellulosic material is shredded paper fiber, e.g., shredded newspaper. By way of example, the cellulosic material may be made by the methods described below. In addition, in many embodiments, it may be preferably to include a fire retardant, for example, added at between about 7 wt. % and 15 wt. %. Preferably the fire retardant is boric acid added at about 13 wt. %.
In many embodiments, the system may also include an expansion ratio modifying agent (ERMA). The ERMA may be a variety of synthetic or natural fibers, such as polypropylene, polyethylene, nylon, polyester, polyester terephthalate, cotton, hemp, glass, mineral wool, or any mixtures thereof. Preferably, the ERMA is added at greater than about 1 wt. %, but others may prefer to add the ERMA at between about 5 wt. % and 10 wt. %.
Additionally, the system may further include between about ½ wt. % and 3 wt. % hydrocarbon, e.g. oil or mineral oil, mixed with the insulation component.
As shown, the package 14 is a pre-formed bag, but others may desire other containers for this embodiment, such as, for example, a box. The “box” embodiment would be similar to a cereal box in which the product often settles during shipping. However, the box would be sized to the proper volume for the poured density and the proper weight of product would be packaged in the box. Thus, the actual application would be substantially the same as for the pre-formed bag embodiment.
In operation, a person desiring to insulate portions of their home could simply buy a system according to the present invention and pour the insulation component directly from the container onto the area to be insulated.
In another embodiment, the adjustable compression package 24 is configured to hold the insulation component at the first, pre-compression density and the package shape is changed for shipping, but the overall volume and the insulation component density remains substantially unchanged after compression.
Preferably, adjustable package 24 is an air-permeable compression package including a plurality of holes 26 defined by the package. The package has a first compressed volume and a second larger volume. For example, before any insulation is installed into the package, the package may be considered to be at its second larger volume. After filling with insulation component 22 and compression, package 24 may be considered to be at its first compressed volume. The first compressed volume of the package is maintained substantially by the adhesion of the compressed insulation component. By manually shaking the bag, the insulation component is brought to a second density that is lower than the first density, and the bag is brought to its second larger volume.
The adjustable package of the present invention may also include a substantially air-impermeable sealed package having a first sealed volume and a second unsealed volume. The package may be, for example, a bag with an opening at one end, which is sealed after filling and compression. In this embodiment, the first sealed volume may be the smaller volume, and may be created by vacuum or by compression. The first sealed volume may be maintained by vacuum or by the adhesion of the insulation component.
In either of the above compression packages, or in similar packages, the first insulation density may be between about 6 pcf and 10 pcf and the second density is between about 2 pcf and 5 pcf. More preferably, the first insulation density is between about 6 pcf and 8 pcf and the second density is between about 3 pcf and 4 pcf. Even more preferably, the first insulation density is about 6 pcf and the second density is about 4 pcf. Additionally, the ratio of the first insulation density to the second insulation density is between about 1½ and 10 to 1, and is, more preferably, between about 1½ and 5 to 1.
Some may also prefer to include a coloring agent (CA) in the various embodiments of the insulation component. In the preferred embodiment, the CA is organic. The organic CA may be selected from the group consisting of: pigments, dyes, tints, or materials that contain a coloring agent, or materials that have color that is present for another use and not to impart color to the original material or the insulation system, and mixtures thereof. The materials may be natural or synthetic.
Block 32 represents classifying the component. Preferably, the component is classified through a screen having openings between about 1 and 4 inches in height, width, or diameter. Preferably, the openings are about 3 inches. Others may classify in other ways to achieve similar results.
Block 34 represents hydrating the insulation component. Preferably, the insulation component is hydrated by injecting about ½ wt. % to about 3 wt. % water into the cellulosic material, but others may prefer to hydrate in other amounts, by other methods, or by using other hydrants.
Block 36 represents a chemical addition, which is preferably the addition of a fire retardant. Applicants prefer to use boric acid as the fire retardant, yet others may prefer other fire retardants, which are also within the scope of the present invention.
Block 40 represents shredding the cellulosic material in a second shredder. The secondary shredder is preferably a hammer mill shredder. Preferably, the screen of the hammer mill shredder has an opening size ranging from about ½ inch to about 2 inches. Even more preferably, the screen of the hammer mill has an opening size ranging from about ¾ inch to about 1 inch.
Block 42 represents adding oil. The method of claim 45, wherein the oil is mineral oil added in between about ½ wt. % and 3 wt. %.
Block 44 represents packaging the cellulosic material or adding it to a container. Those of skill in the art will recognize that a variety of containers may be used. For example, some may prefer to use a rigid to semi-rigid cardboard box. Applicants prefer to use an adjustable package, e.g., an air-permeable compression package or substantially air-impermeable sealed package. For example, an air-permeable compression package may include a plurality of holes defined by the package, and have a first compressed volume and a second larger volume. Somewhat similarly, a substantially air-impermeable sealed package may have a first sealed volume and a second unsealed volume.
Additionally, some may prefer, either prior to packaging or as part of the packaging process, to blow the cellulosic material shred by the second shredder, e.g., by using an Unisul VoluMatic III blowing machine.
Block 46 represents compressing an adjustable package. Compression is preferably achieved using a conventional hydraulic ram or by manually hand stuffing. Following compression, it may be necessary to seal the package.
The result is an insulation component that, through manual shaking, can go from a density between about 6 pcf and 10 pcf to a density of between about 2 pcf and 5 pcf.
Block 52 represents shaking the package until the insulation has a second density, which is preferably between about 2 pcf and 5 pcf, and is more preferably, about 4 pcf. Preferably, the shaking is manual shaking performed for at least about 5 seconds. Even more preferably, the manual shaking is performed for in between about 15 seconds and 20 seconds. Some may, however, prefer to shake for more or less time, which is also within the scope of the present invention.
For some embodiments, e.g., the air-permeable compression package, the package needs no substantial alteration prior to shaking. Shaking allows air to enter the package through various holes in the package and brings the insulation component to its second density. Some compression packages, however, require alteration prior to shaking. For example, for substantially air-impermeable sealed packages, the sealed package needs to be unsealed to allow the insulation to reach its second density. The sealed package may be unsealed by creating holes in the package, or the package may have a variety of perforations that can be punched to unseal.
Block 54 represents pouring the insulation from the package. Preferably, the insulation is allowed to fall from a distance greater that about 6 inches. Applicants have found that pouring from at least this distance allows the insulation to obtain a higher R value. In contrast to the mechanically blown traditional loose-fill insulation, the pouring of the present invention is substantially gravity driven.
Some may further wish to optimize the installation of the poured insulation for various applications, e.g., thermal non-conduction, acoustic non-conduction, or electric non-conduction. In such situations, it may be necessary to measure and adjust the depth of the insulation once it has been poured.
Block 56 represents measuring the depth of the poured material. Measuring can be achieved by using a ruler to measure the height of the poured insulation.
Block 58 represents adjusting the depth to a depth optimized for specific applications. Adjusting can be achieved by removing, moving, or pouring additional insulation to reach the desired height.
The following experiments demonstrate the efficacy and utility of the method of manufacturing and the method of installing pourable insulation according the present invention.
The Applicants attempted to manufacture a pourable cellulosic insulation using the procedure shown in
The Applicants then attempted to manufacture a pourable cellulosic insulation using the procedure shown in
The Applicants found that the material manufactured using the procedure shown in
Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein, and every number between the end points. For example, a stated range of “1to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, e.g. 1 to 6.1, and ending with a maximum value of 10 or less, e.g., 5.5 to 10, as well as all ranges beginning and ending within the end points, e.g. 2 to 9, 3 to 8, 3 to 9, 4 to 7, and finally to each number 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10 contained within the range. Additionally, any reference referred to as being “incorporated herein” is to be understood as being incorporated in its entirety. It is further noted that, as used in this specification, the singular forms “a,” “an,” and “the” include plural referents unless expressly and unequivocally limited to one referent.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. For instance, the insulation may include a fire retardant component. Further, the insulation may contain pesticides, such as herbicides, fungicides, rodenticides, insecticides and other pest preventing agents. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.
