U.S. patent application number 11/743050 was filed with the patent office on 2007-08-30 for fiber insulation blanket and method of manufacture.
This patent application is currently assigned to Earl Stuart Douglass. Invention is credited to Earl Stuart Douglass, Thomas Clifford Shutt.
Application Number | 20070202771 11/743050 |
Document ID | / |
Family ID | 38444604 |
Filed Date | 2007-08-30 |
United States Patent
Application |
20070202771 |
Kind Code |
A1 |
Douglass; Earl Stuart ; et
al. |
August 30, 2007 |
FIBER INSULATION BLANKET AND METHOD OF MANUFACTURE
Abstract
A fiber blanket formed with a blend of constituent fibers is
disclosed. In one disclosed embodiment, a cellulose fiber blanket
is formed having a blend of cellulose fibers comprising
approximately 85-90% by weight cellulose, resilient fibers
comprising approximately 10% by weight, and the balance being
adhesive plastic fibers. The fibers are then formed into a blanket
having an R-value at least 4.0 per inch.
Inventors: |
Douglass; Earl Stuart;
(Auburn, CA) ; Shutt; Thomas Clifford; (Denver,
CO) |
Correspondence
Address: |
GROSS & ASSOCIATES
1415 L STREET SUITE 1000
SACRAMETO
CA
95814
US
|
Assignee: |
Douglass; Earl Stuart
|
Family ID: |
38444604 |
Appl. No.: |
11/743050 |
Filed: |
May 1, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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PCT/US05/39605 |
Nov 2, 2005 |
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11743050 |
May 1, 2007 |
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Current U.S.
Class: |
442/416 ;
442/117; 442/136; 442/140; 442/152; 442/164; 442/172; 442/415 |
Current CPC
Class: |
Y10T 442/2926 20150401;
Y10T 442/2762 20150401; Y10T 442/698 20150401; Y10T 442/2664
20150401; Y10T 442/2475 20150401; Y10T 442/2631 20150401; Y10T
442/697 20150401; D04H 1/541 20130101; E04B 1/7662 20130101; D04H
1/04 20130101; D04H 1/732 20130101; Y10T 442/2861 20150401; D04H
1/435 20130101 |
Class at
Publication: |
442/416 ;
442/117; 442/136; 442/140; 442/152; 442/164; 442/172; 442/415 |
International
Class: |
D04H 13/00 20060101
D04H013/00; D04H 1/00 20060101 D04H001/00; D04H 3/00 20060101
D04H003/00; D04H 5/00 20060101 D04H005/00 |
Claims
1. A fiber blanket formed with a blend of constituent fibers
comprising: cellulose fibers comprising approximately 85-90% by
weight cellulose; resilient fibers comprising approximately 10% by
weight; adhesive plastic fibers; and said constituent fibers being
formed into a blanket having an R-value of at least 4.0 per
inch.
2. The blanket of claim 1, wherein said blend of constituent fibers
comprises a blend by weight of 85% cellulose, 10% resilient fiber
and 5% adhesive fiber.
3. The blanket of claim 1, wherein said blend of constituent fibers
comprise a blend of 89% cellulose fiber, 9% resilient fiber, and 2%
adhesive fiber.
4. The blanket of claim 3, wherein the density of said blanket may
be varied from 0.8-1.5 pounds per cubic foot.
5. The blanket of claim 1, wherein said cellulose fibers are
treated (are treated) to provide fire retardant properties.
6. The blanket of claim 5, wherein said properties are provided
using a liquid additive.
7. The blanket of claim 6, wherein said liquid additive include a
liquid borate.
8. The blanket of claim 1, wherein said cellulose fibers are
treated to provide mold resistance properties.
9. The blanket of claim 8, wherein said properties are provided
using a liquid additive.
10. The blanket of claim 9, wherein said liquid additive include a
liquid borate.
11. The blanket of claim 1, wherein said adhesive fibers contain a
material permitting heating by induction.
12. The blanket of claim 11, wherein said material comprises
carbon.
13. The blanket of claim 1, wherein said adhesive fibers contain an
additive permitting dielectric heating.
14. The blanket of claim 13, wherein said additive comprises a
compound of the alkyl aryl sulfonate group.
15. The blanket of claim 13, wherein said additive comprises a
compound of the alkyl aryl polyester alcohol group.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation application of PCT
Application PCT/US2005/039605 with an International filing date of
Nov. 02, 2005, which claims the benefit of U.S. Provisional
Application Ser. 60/517530, filed on Nov. 04, 2003, and which are
both incorporated, in their entirety, herein by reference.
BACKGROUND
[0002] 1. Field of the Disclosure
[0003] This disclosure relates generally to the composition and
manufacture of paper fiber insulation products.
[0004] 2. The Prior Art
Background
[0005] Currently, the bulk of thermal insulation material is made
from glass wool and is sold in the form of a blanket. The shape and
size of such blankets allows for convenient shipping and
installation. An alternative to glass wool is cellulose
insulation.
[0006] The industry standard R-value allows for the comparing of a
material's thermal insulating capability. The higher the R-value
number, the greater is the material's ability to insulate.
[0007] The insulating capability of a given blanket is largely
determined by the density of the constituent fibers of the blanket.
Hence, the higher the density the lower the R-value. The hollow
nature of cellulose fiber provides a potential for a higher R-value
than glass wool.
[0008] Recently adopted building codes throughout the US have set a
minimum of R-15 insulation within a 2.times.4 residential wall.
This translates to a minimum R-value of 4.1 per inch and
effectively prohibits the use of prior art cellulose insulation
products in the cities and counties where this code has been
adopted.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0009] FIG. 1 is a conceptual diagram of a process for forming a
fiber insulation blanket in accordance with the teachings of this
disclosure.
DETAILED DESCRIPTION
[0010] Persons of ordinary skill in the art will realize that the
following description is illustrative only and not in any way
limiting. Other modifications and improvements will readily suggest
themselves to such skilled persons having the benefit of this
disclosure. In the following description, like reference numerals
refer to like elements throughout.
[0011] FIG. 1 is a conceptual diagram of a system 100 for forming a
cellulose fiber insulation blanket. The process begins with the
dosing and mixing of the constituent fibers, contained in towers
105, 110, and 115 of an air-lay machine, being transferred to a
forming head 120 for shaping.
[0012] As will be described more fully below, in a preferred
embodiment, fiber insulation blankets of the present disclosure
comprise a preferably homogenous composition of cellulose fibers,
resilient fibers, and adhesive fibers, and it is desired that the
mixture resulting from the forming head process be as thoroughly
mixed as possible.
[0013] The blended fibers 121 are then deposited onto the surface
of a wire, typically a slotted conveyor belt, thereby forming a
fiber blanket 125. The blanket 125 is then transported to a thermal
forming station 130.
[0014] Heated air is then drawn through the blend to soften and
melt the adhesive plastic fibers, thereby adhering the constituent
fibers into a matrix. Cool air is then drawn through the matrix
solidifying the melted fibers and forming a continuous, coherent
blanket 135. Preferably, a forming head in conjunction with a
thermal bonding oven is suitable for this type of non-woven
process.
[0015] The blanket 135 may then be formed into batts 140 of a
desired size as required.
[0016] Finding an optimal balance between resilience and adhesion
is critical so as to provide a product with good fiber compression
recovery, low density and high R-value. For example, the finished
product must return as closely as possible to its original
thickness and shape after it has been compressed for packaging in
order to maintain the stated R-value. Compression recovery has a
strong effect on the cost of shipping and is therefore a critical
element in the commercial viability of such products.
[0017] To achieve these goals, in one disclosed aspect, a fiber
blanket is formed by using 85-90% by weight cellulose fibers with
the resilient and adhesive plastic fibers comprising the balance.
In a further disclosed embodiment, a blend by weight of 75%
cellulose, 20% resilient fiber and 5% adhesive fiber is used. In a
further disclosed embodiment, a blend by weight of 85% cellulose,
10% resilient fiber and 5% adhesive fiber is used. In yet a further
disclosed embodiment, a blend by weight of about 89% cellulose, 9%
resilient fibers and 2% adhesive fibers will produce the same
physical properties at lower cost. These blends preferably yield a
blanket whose density can be varied from 0.8-1.5 pounds per cubic
foot with an R-value ranging from 3.8-4.2, and preferably at least
4.0.
[0018] More details of exemplary constituent fibers suitable for
use in this disclosure will now be disclosed.
[0019] Referring first to the cellulose constituent, in one
preferred embodiment a cellulose fiber which complies with ASTM
standard C739-91 is utilized. Such a loose-fill insulation fiber
may be obtained from Cottonwood Manufacturing, Inc., the assignee
of the present disclosure.
[0020] Additionally, the cellulose fibers may be treated to provide
fire retardant or mold resistance properties. For example, the
cellulose fibers may be impregnated with a liquid chemical formula
as disclosed in U.S. Pat. Nos. 5,534,301 and 6,025,027 to Shutt,
also assigned to the assignee of the disclosure and each
incorporated by reference as though fully set forth herein, to
provide fire and mold protection. Liquid additives have a superior
dispersion rate because solids in solution are readily absorbed by
the cellulous fibers and quickly diffuse throughout the hollow core
and mass of each fiber. Subsequent drying of the cellulose fibers
leaves a homogenous precipitation of the impregnates as opposed to
conventional powder systems, which exhibit weak adhesion to the
surfaces of cellulose fibers. Consequently, the weight of such
liquid chemical impregnates contributes up to two-thirds less
weight to the fibers, as compared with powder alternatives. This
reduction in weight contributes to the lower density of the final
product.
[0021] Preferred treatments include liquid borates. In one
embodiment, liquid borates are applied directly to the fibers
during mixing. In a further preferred embodiment, liquid borates
are employed which are converted to boric acid inside the cellulose
fibers through the use of acid such as sulfuric acid. Additional
treatments may also include dyes and perfumes, for example, for
improved user acceptance of the product.
[0022] Referring now to the resilient plastic constituent fiber, a
polyester staple may be employed. Preferably, the resilient plastic
fibers are of hollow polyester having a denier of 15 and a length
of not less than 32 millimeters. Fibers suitable for use in this
disclosure preferably have a melting point of approximately
219.degree. C., a denier of approximately 6-15, and a length of
approximately 25-51 millimeters. Such fibers may include, KoSa.RTM.
types 209 or 210 or equivalents.
[0023] The resilient fibers may be crimped for increased
resilience, and hollow for increased denier sizing so as to exhibit
increased springiness and resiliency enabling the blankets of this
disclosure to be compressed so as to assume less bulk for shipping
at lower cost, while subsequently resuming substantially all of its
bulk thereafter in use for improved thermal insulation
properties.
[0024] Referring now to the adhesive constituent fiber, in a
preferred embodiment, adhesive plastic fiber is utilized that
comprises a polyester core and an activated co-polyethylene sheath.
The sheath preferably has a melting point of no more than
128.degree. C., and a denier of not more than 3 to promote as
complete dispersal and homogenization of the fibers as possible.
Additionally, the adhesive plastic fibers have a length of not more
than 8 millimeters, and preferably a length of not more than 6
millimeters to promote optimal bonding with the other constituent
fibers. Suitable adhesive fibers include KoSa.RTM. types 254 or 255
Celbond.RTM. Bicomponent Fiber or equivalents.
[0025] As was described above, the adhesive fibers typically are
heated to adhere and form a blanket. In an alternative embodiment,
the adhesive fibers may be treated with material that would allow
the use of Radio Frequency (RF) heating. In such an embodiment, the
blanket may the be formed using RF energy rather than prior art gas
ovens. Such an RF process is far more efficient that traditional
heating methods.
[0026] It is contemplated that the adhesive fibers may be produced
containing materials such as carbon thereby permitting heating by
induction. It is also contemplated that additives such as compounds
of the alkyl aryl sulfonate and alkyl aryl polyester alcohol groups
could be applied to the fiber surfaces to render them susceptible
to dielectric heating. It is contemplated that when using a RF
reactive material, the co-polyethylene sheath may be unnecessary,
resulting in a lower cost adhesive materials.
[0027] Examples of non-woven formulas and compositions will now be
disclosed.
[0028] In a first exemplary composition, a blend of 85% cellulose
fiber, 10% resilient fiber, and 5% adhesive fiber was used.
[0029] In a second exemplary composition, a blend of 89% cellulose
fiber, 9% resilient fiber, and 2% adhesive fiber.
[0030] In both examples, the resilient fiber comprised the KoSa
Type 210, and the adhesive fiber comprised the KoSa Type 255, as
disclosed above.
[0031] The materials were processed with an opening and dosing
station, an air-laid forming head and a thermal bonding oven
supplied by Bettarini & Serafini srl of Prato, Italy. The
R-value testing performed per ASTM C-518, and Compression Recovery
testing performed per ASTM C-167.
[0032] The results are presented in Table 1: TABLE-US-00001 Loft
Density Compression Recovery R-value/in. Sample #1 16 kg/m3 75% 85%
4.0 90 mm (1 lb/cu ft Sample #2 15 kg/m3 80% 97% 4.1 90 mm (0.81
lb/cu ft)
[0033] While embodiments and applications of this disclosure have
been shown and described, it would be apparent to those skilled in
the art that many more modifications and improvements than
mentioned above are possible without departing from the inventive
concepts herein. The disclosure, therefore, is not to be restricted
except in the spirit of the appended claims.
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