U.S. patent application number 11/021426 was filed with the patent office on 2005-05-26 for surfactant modified oils for dust control of loose-fill insulation.
This patent application is currently assigned to CertainTeed Corporation. Invention is credited to Calero, Claire, Gallagher, Kevin J., Lacaute, Daniel, Wagner, Christophe J..
Application Number | 20050112287 11/021426 |
Document ID | / |
Family ID | 29268862 |
Filed Date | 2005-05-26 |
United States Patent
Application |
20050112287 |
Kind Code |
A1 |
Gallagher, Kevin J. ; et
al. |
May 26, 2005 |
Surfactant modified oils for dust control of loose-fill
insulation
Abstract
The present invention serves to substantially improve the dust
capture property of dedusting oils, by modifying these oils with
nonionic and/or cationic surfactants. The application of surfactant
modified oils reduces dust that is generated when loose-fill
insulation is installed.
Inventors: |
Gallagher, Kevin J.;
(Plymouth Meeting, PA) ; Wagner, Christophe J.;
(Athens, GA) ; Calero, Claire; (Erquery, FR)
; Lacaute, Daniel; (Orry La Ville, FR) |
Correspondence
Address: |
DUANE MORRIS, LLP
IP DEPARTMENT
ONE LIBERTY PLACE
PHILADELPHIA
PA
19103-7396
US
|
Assignee: |
CertainTeed Corporation
|
Family ID: |
29268862 |
Appl. No.: |
11/021426 |
Filed: |
December 22, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11021426 |
Dec 22, 2004 |
|
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10136008 |
May 1, 2002 |
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Current U.S.
Class: |
427/421.1 |
Current CPC
Class: |
B01F 17/0042 20130101;
B01F 17/0021 20130101; B01F 17/0085 20130101 |
Class at
Publication: |
427/421.1 |
International
Class: |
B05D 001/02 |
Claims
1. A method of controlling dust formation in loose-fill insulation,
comprising: applying to said loose-fill insulation dedusting oil
modified with an additive consisting essentially of a surfactant of
an amount to control dust formation while the loose-fill insulation
is in a fiberized state adapted for pneumatic installation.
2. The method as recited in claim 1, wherein said combination is
applied to said loose-fill insulation in an amount of from about
0.5-2.5% by weight.
3. The method as recited in claim 1, wherein said surfactant is
nonionic.
4. The method as recited in claim 1, wherein said surfactant is
cationic.
5. The method as recited in claim 1, wherein said insulation is
installed pneumatically.
6. The method as recited in claim 3, wherein said surfactant is
glycerol monooleate.
7. The method is recited in claim 1, wherein said combination is
applied to said loose-fill insulation in an amount of about 2% by
weight.
8. The method as recited in claim 3 wherein said nonionic
surfactant is a monoester of an unsaturated or saturated acid.
9. The method as recited in claim 8 wherein said unsaturated acid
is linoleic or linolenic acid.
10. The method as recited in claim 8 wherein said saturated acid is
a C12 to C18 lauric, myristic, palmitic to stearic acid.
11. The method as recited in claim 3 wherein said nonionic
surfactant is a diester or triester of an unsaturated or saturated
acid.
12. A method of controlling dust formation in loose-fill
insulation, comprising: applying to said loose-fill insulation
dedusting oil modified with an additive consisting essentially of a
nonionic surfactant of an amount to control dust formation while
the loose-fill insulation is in a fiberized state adapted for
pneumatic installation.
13. The method as recited in claim 12, wherein said insulation is
installed pneumatically.
14. The method as recited in claim 13, wherein said combination is
applied to said loose-fill insulation in an amount of from about
1.5-2.5% by weight.
15. The method as recited in claim 13, wherein said nonionic
surfactant is glycerol monooleate.
16. The method as recited in claim 12 wherein said nonionic
surfactant is a monoester of an unsaturated or saturated acid.
17. The method as recited in claim 13 wherein said unsaturated acid
is linoleic or linolenic acid.
18. The method as recited in claim 13 wherein said saturated acid
is a C12 to C18 lauric, myristic, palmitic to stearic acid.
19. The method as recited in claim 12 wherein said nonionic
surfactant is a diester or triester of an unsaturated or saturated
acid.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a continuation of U.S.
application Ser. No. 10/136,008, filed on May 1, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to methods for improving the
dust capture properties of dedusting oils, which properties are
useful in the manufacture and installation of loose-fill
insulation.
BACKGROUND OF THE INVENTION
[0003] Over the past 40 years, many homeowners have begun to
install extra insulation in their attics or crawlspaces in an
effort to save money on heating bills. Typically, new construction
is thoroughly insulated in accordance with applicable building
codes and industry standards. A common form of insulation used by
consumers and insulation contractors has been fiberglass insulation
batts and blankets. However, insulation batts are relatively
expensive and may require some cutting and shaping during
installation.
[0004] More recently, the use of glass fiber blowing wool or
loose-fill insulation has increased in popularity. Loose-fill,
fiberglass insulation exists in many forms. Bonded and non-bonded
loose-fill fiberglass are commonly used terms to describe
loose-fill insulation products. Bonded loose-fill insulation is
derived from blanket or batt insulation which has been made with a
thermoset binder. It is produced by either pulverizing or cutting
the blanket or batt insulation, compressing the resulting product
and packaging it into bags. Non-bonded, loose-fill insulation
comprises smaller nodules of traditional, straight, short fibers
which are treated with a dedusting oil, compressed, and packaged
into bags. Both bonded and non-bonded loose fill insulations can be
installed in attics and sidewalls using a pneumatic blowing
machine.
[0005] Loose-fill insulation is popular with insulation contractors
because it can be easily and quickly applied in both new
construction as well as in existing structures. Further, loose-fill
insulation is a relatively low cost material. However, fiberglass
loose-fill insulation is typically applied by contractors rather
than homeowners because of the special blowing equipment needed.
Such insulation is typically packaged in large bags weighing e.g.,
25-35 lbs.
[0006] Cellulose loose-fill insulation is another type of
insulation commonly used by consumers, which is formed from
shredded, recycled newspapers. Cellulose insulation is desirable
for installation by consumers as it is available in smaller
packages and is less expensive than most other forms of loose-fill
insulation. However, such insulation is dusty, dirty and difficult
to blow properly, and also requires special blowing equipment to
install.
[0007] When loose-fill insulations are pneumatically applied, they
can be the source of dust and irritation for the installer. While
dedusting oils are typically applied at the time of manufacture to
control this dust, and the installers are advised to wear a dust
mask and protective gear to reduce their exposure to dust, the
effectiveness of these oils could be improved, especially when the
oils are applied at low application rates (e.g., less than about 2%
by weight).
SUMMARY OF THE INVENTION
[0008] The purpose of the present invention is to substantially
improve the dust capture properties of dedusting oils by modifying
these oils with nonionic and/or cationic surfactants. These
surfactants may be added individually, or in combination to the
dedusting oils. The application of surfactant modified oils reduces
the airborne dust that is generated when loose-fill insulation is
installed pneumatically.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0009] The present invention serves to substantially improve the
dust capture property of dedusting oils, by modifying these oils
with effective amounts of nonionic or cationic surfactants. In
testing of the present invention, oils which were modified with
various surfactants were applied through an oil application system
onto non-bonded, loose-fill insulation, at a preferred amount of
approximately 2% by weight using either air atomized or hydraulic
pressure nozzles. One such oil is commercially available as
Telura.TM. 720E from Exxon Mobil Corporation. The non-bonded,
loose-fill material was packaged and tested for its dust generation
characteristics. When compared to a control material made with an
unmodified paraffin oil with a viscosity of 100 SUS, the
non-bonded, loose-fill product made with the surfactant modified
oil exhibited substantially lower dust levels. Furthermore, by the
method of the present invention, the surfactant modified oils
reduce dust levels of insulation that are produced over a range of
fiberizing conditions.
[0010] Note that the treatment of the present invention should be
applied to loose-fill insulation at a temperature at or above about
80.degree. F., preferably from about 80-110.degree. F.
[0011] The following testing demonstrates that the use of
surfactant modified oils significantly reduced the airborne dust
levels of a sample of thermal insulation product, as compared to
similar insulations made with conventional dedusting oils. Dust
levels were measured using the methodology as disclosed in U.S.
Pat. Nos. 6,005,662 and 6,122,054, herein incorporated by
reference. Two distinct fiberizing conditions were tested. One
condition had a fiber fineness index of 2.9 and the other had a
fineness index of 2.65 when measured by ASTM D1488-97 standard test
method for micronaire reading of cotton fibers. In general, finer
fibers tend to produce more dust.
[0012] Table 1 shows the % increase in dust reduction when
loose-fill insulation made with the experimental oils was compared
to loose fill insulation using the standard dedusting oil, Prorex
100 made by Exxon Mobil.
1TABLE 1 % Dust Reduction Measured versus Standard Dust Control Oil
(Control) % Oil Fiber Applied to % Increase in Treatment Fineness
Loose Fill Dust Reduction Standard Dust Control Oil.sup.1 2.90 2.00
Control Surfactant Modified Oil- 2.90 1.90 28% Telura 720E.sup.2
Standard Dust Control Oil.sup.1 2.65 1.87 Control Surfactant
Modified Oil- 2.65 1.87 53% Telura 720E.sup.2 Surfactant Modified
Oil- 2.65 1.80 46% Telura 720E.sup.3 Standard Oil Modified with a
2.65 1.97 25% Cationic Surfactant.sup.4 .sup.1Prorex .TM. 100
Process oil from Exxon Mobil .sup.2Telura .TM. 702E oil modified
with glycerol monooleate at 2% by weight .sup.3Telura .TM. 702E oil
modified with glycerol monooleate at 1% by weight .sup.4Prorex .TM.
100 Process Oil modified with an oil containing a quaternary
ammonium compound
[0013] As noted above, in a preferred embodiment of the present
invention, the surfactant 10 modified oil tested was a standard
dust control oil, modified to include 2% by weight of glycerol
monooleate, a nonionic surfactant. Percents by weight of surfactant
may range from about 0.5-10%. It is anticipated that alternative
nonionic surfactants would also be effective, e.g., mono-, di-, and
tri-fatty acid esters of glycerol and modified esters of this type,
so long as effective amounts of such surfactants were applied.
[0014] In a preferred embodiment of the present invention, the
nonionic surfactant is a monoester of an unsaturated or saturated
acid. The unsaturated acid may be e.g., linoleic or linolenic acid.
The saturated acid may be e.g., a C12 to C18 lauric, myristic,
palmitic or stearic acid. In a further preferred embodiment, the
nonionic surfactant is a diester or triester of an unsaturated or
saturated acid.
[0015] As it relates to the loose-fill insulation, it is preferred
that the modified oil be applied to the loose-fill insulation at
from about 0.5-2.5% by weight, with an amount of about 2.0% by
weight particularly preferred.
[0016] While this invention has been described with respect to
particular embodiments thereof, it is apparent that numerous other
forms and modifications of this invention will be obvious to those
skilled in the art. The appended claims and this invention
generally should be construed to cover all such obvious forms and
modifications which are within the true spirit and scope of the
present invention.
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