U.S. patent application number 11/471254 was filed with the patent office on 2008-01-03 for coated fibrous nodules and insulation product.
Invention is credited to Ralph Michael Fay, Thomas John Fellinger, John Brooks Smith.
Application Number | 20080003431 11/471254 |
Document ID | / |
Family ID | 38877020 |
Filed Date | 2008-01-03 |
United States Patent
Application |
20080003431 |
Kind Code |
A1 |
Fellinger; Thomas John ; et
al. |
January 3, 2008 |
Coated fibrous nodules and insulation product
Abstract
Coated fibrous nodules suitable for forming an insulation
product are provided, comprising fibrous nodules formed from
inorganic fibers, wherein a majority of the fibrous nodules has a
maximum dimension of about one-half inch, and wherein the fibrous
nodules are coated with a solution comprising water and a water
soluble binder. Also provided is an insulation product formed from
the coated fibrous nodules.
Inventors: |
Fellinger; Thomas John;
(Littleton, CO) ; Fay; Ralph Michael; (Lakewood,
CO) ; Smith; John Brooks; (Centennial, CO) |
Correspondence
Address: |
JOHNS MANVILLE
10100 WEST UTE AVENUE
LITTLETON
CO
80127
US
|
Family ID: |
38877020 |
Appl. No.: |
11/471254 |
Filed: |
June 20, 2006 |
Current U.S.
Class: |
428/375 |
Current CPC
Class: |
E04B 1/7604 20130101;
Y10T 428/2933 20150115 |
Class at
Publication: |
428/375 |
International
Class: |
D02G 3/00 20060101
D02G003/00 |
Claims
1. Coated fibrous nodules suitable for forming an insulation
product, comprising fibrous nodules formed from inorganic fibers,
wherein a majority of the fibrous nodules has a maximum dimension
of about one-half inch, and wherein the fibrous nodules are coated
with a solution comprising water and a water soluble binder.
2. The coated fibrous nodules of claim 1, wherein the inorganic
fibers comprise glass fibers.
3. The coated fibrous nodules of claim 1, wherein at least about 70
percent of the coated nodules have a maximum dimension of one-half
inch.
4. The coated fibrous nodules of claim 3, wherein at least about 80
percent of the coated nodules have a maximum dimension of one-half
inch.
5. The coated fibrous nodules of claim 4, wherein at least about 90
percent of the coated nodules have a maximum dimension of one-half
inch.
6. The coated fibrous nodules of claim 1, wherein the water soluble
binder comprises a partially hydrolyzed polyester oligomer.
7. The coated fibrous nodules of claim 1, wherein the binder is
present in the coated nodules in an amount of less than about 6 wt.
percent, on a dry solids basis.
8. The coated fibrous nodules of claim 1, wherein the inorganic
fibers have an average fiber diameter of 3 microns or less.
9. The coated fibrous nodules of claim 1, wherein the nodules
comprise glass fibers bonded together with a cured resin at one or
more of the locations where two or more of the fibers cross one
another.
10. An insulation product formed from the coated fibrous nodules of
claim 1.
11. The insulation product of claim 10, wherein the inorganic
fibers comprise glass fibers.
12. The insulation product of claim 10, wherein at least about 70
percent of the coated nodules have a maximum dimension of one-half
inch.
13. The insulation product of claim 12, wherein at least about 80
percent of the coated nodules have a maximum dimension of one-half
inch.
14. The insulation product of claim 13, wherein at least about 90
percent of the coated nodules have a maximum dimension of one-half
inch.
15. The insulation product of claim 10, wherein the water soluble
binder comprises a partially hydrolyzed polyester oligomer.
16. The insulation product of claim 10, wherein the binder is
present in the insulation product in an amount of less than about 6
wt. percent, on a dry solids basis.
17. The insulation product of claim 10, wherein the inorganic
fibers have an average fiber diameter of 3 microns or less.
18. The insulation product of claim 10, wherein when the insulation
product is formed in a standard wall cavity, the just-installed
moisture content of the insulation product is less than about 1.5
pounds.
19. The insulation product of claim 10, wherein each coated fibrous
nodule is in contact with another coated fibrous nodule to form the
insulation product.
20. The insulation product of claim 10, wherein the insulation
product has an R value from about 12 to about 16 after drying.
21. The insulation product of claim 10, wherein the insulation
product has a density of about 3 PCF or less after drying.
22. The insulation product of claim 10, wherein the insulation
product is formed on a surface of a wall, floor or ceiling
cavity.
23. The insulation product of claim 22, wherein the wall, floor or
ceiling cavity is an open cavity.
24. The insulation product of claim 10, wherein the nodules
comprise glass fibers bonded together with a cured resin at one or
more of the locations where two or more of the fibers cross one
another.
25. The coated fibrous nodules of claim 1, further comprising an
additive effective for increasing thermal insulation.
26. The coated fibrous nodules of claim 25, wherein the additive
effective for increasing thermal insulation comprises an infrared
radiation blocking agent.
27. The coated fibrous nodules of claim 26, wherein the infrared
radiation blocking agent comprises B.sub.2O.sub.3.
28. The insulation product of claim 10, further comprising an
additive effective for increasing thermal insulation.
29. The insulation product of claim 28, wherein the additive
effective for increasing thermal insulation comprises an infrared
radiation blocking agent.
30. The insulation product of claim 29, wherein the infrared
radiation blocking agent comprises B.sub.2O.sub.3.
31. The coated fibrous nodules of claim 1, further comprising a
fire retardant.
32. The insulation product of claim 10, further comprising a fire
retardant.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is the national stage filing under 35
U.S.C. 371 of International Application No. PCT/US2004/043317,
filed Dec. 22, 2004, which in turn claims the benefit of priority
of U.S. Provisional Application No. 60/532,743, filed Dec. 23,
2003, U.S. Provisional Application No. 60/532,880, filed Dec. 23,
2003, U.S. Provisional Application No. 60/532,881, filed Dec. 23,
2003, and U.S. Provisional Application No. 60/532,882, filed Dec.
23, 2003, the entire contents of which are incorporated by
reference herein.
BACKGROUND
[0002] Loose-fill fibrous insulation can be pumped or blown into an
attic, wall or wall cavity of a building such as a residential
home. Various materials can be added to the fibrous insulation to
reduce settling and static discharge, as well as to reduce the
amount of dust formed during installation. Conventional systems for
forming an insulation product from a loose-fill fibrous insulation,
and/or the use of a liquid binder dispersion or water to activate a
powered adhesive, are discussed in U.S. Pat. Nos. 4,710,480,
4,804,695, 5,641,368 and 5,952,418.
[0003] Conventional systems for forming an insulation product from
loose-fill insulation typically present various disadvantages. For
example, conventional systems often suffer from partial or complete
blockage of an adhesive nozzle and/or a blowing hose through which
the loose-fill insulation is blown. In addition, conventional
systems typically employ a relatively high moisture content such as
50% of the dry weight of the preinstalled insulation, to enable
proper adhesion between the insulation and the substrate. Such
relatively high moisture content can cause mold-related problems
such as mold growth on a paper facing of a wallboard. In addition,
drying the installed insulation product having a relatively high
moisture content can take a relatively long period of time such as
two or more days. Such a prolonged drying period can slow down the
installation process and contribute to the overall inefficiency
thereof.
[0004] Conventional systems which use sprayed cellulose loose-fill
insulation typically employ a high moisture content to ensure
adhesion of the insulation in a cavity. For example, cellulose
insulation typically contains water in an amount of 30% to 50% by
weight of the insulation. This amount of moisture corresponds to
about 2 to 3 pounds of water in the installed insulation per
standard eight foot high wall cavity, i.e., a cavity defined by a
construction of 8 foot high, nominal 2 by 4 inch framing members
(actual 1.5 inch by 3.5 inch) on 16 inch centers. The term "on
centers" refers to the distance between the centers of the framing
members. This amount of moisture can cause the installation to have
a drying time of 2 to 3 days or longer in a dry climatic region
such as Denver, Colo. That is, a wallboard typically should be
installed after 2 to 3 days or longer to reduce the potential for
mold growth. In more humid regions such as Florida, the drying time
is typically considerably longer. Longer drying times are typically
employed when the insulation is installed in a deeper cavity
structure.
[0005] A dry powdered adhesive can be added to a cellulose
insulation material prior to the addition of water to reduce the
amount of water used to enable the cellulose to adhere to a wall
cavity, as disclosed in U.S. Pat. No. 4,773,960. However, the
moisture content of the insulation soon after installation
typically remains relatively high, for example, as much as 15%
water or more.
[0006] Furthermore, cellulose insulation typically has a relatively
high moisture storage capacity, which can extend the drying period
of the cellulose insulation. ASTM C739 which sets forth the
specification for a cellulose loose-fill insulation material,
allows a moisture sorption rate as high as 15%. ASTM C764 which
sets forth the specification for an inorganic fiber loose-fill
material, allows for a moisture sorption rate of only up to 5%.
[0007] In addition, it can be difficult to form an insulation
product having an acceptable R-value from a loose-fill cellulose
material due to the inherent density and thermal characteristics of
the cellulose material.
[0008] In conventional systems which employ an insulation material
having a preinstalled moisture content less than that used in
cellulose insulation, the insulation typically does not
sufficiently adhere to particular conventional linings of wall
cavities causing collapse and lower productivity.
[0009] Other systems for installing loose-fill insulation into
vertical wall cavities employ a retaining means such as netting or
cardboard baffles to retain the loose-fill insulation during
blowing. Installing the restraining means typically requires
additional labor, for example, as much as an extra day of labor,
and can substantially add to the cost of installing the
insulation.
SUMMARY OF INVENTION
[0010] According to one aspect, coated fibrous nodules suitable for
forming an insulation product are provided, comprising fibrous
nodules formed from inorganic fibers, wherein a majority of the
fibrous nodules has a maximum dimension of about one-half inch, and
wherein the fibrous nodules are coated with a solution comprising
water and a water soluble binder.
DETAILED DESCRIPTION
[0011] A nodular insulation product can be formed by propelling
fibrous nodules coated with a binder solution at a substrate on
which the insulation is to be formed. The coated nodules can adhere
to the surface(s) of the substrate and to other nodules to form the
installed insulation product. The nodular fibrous insulation can be
effective for providing thermal and/or acoustical insulation, and
can be formed to comply with various existing and newly proposed
building code requirements.
[0012] In an exemplary embodiment, the use of the fibrous nodules
can enable the just-installed insulation to resist slumping and/or
collapse. This in turn can lead to the formation of an insulation
product having improved structural strength after the insulation is
sufficiently dried. As used herein, the term "just-installed"
refers to a time period within one hour of installation of the
insulation product. For example, the insulation material can
typically become sufficiently dry within one hour, more preferably
within one-half hour, to enable determination of properties of a
sample of the insulation product. For example, in one embodiment,
the insulation can have a moisture content of about 5% to 20% after
one-half hour. This period of time can depend on, for example,
temperature, humidity, the permeability of surrounding materials,
the amount of water initially present, and/or the airflow around
the insulation. While it can sometimes take as long as one-half
hour for the insulation material to be sufficiently dry for
measurement, in some cases it can take a relatively short period of
time such as 10 minutes.
[0013] The use of the fibrous nodules can result in an insulation
product having good thermal insulation performance, good airflow
resistance, a relatively low density, a relatively low moisture
weight to facilitate drying, and/or a relatively fast installation
time. For example, the resulting nodular fibrous insulation can
have a low moisture sorption potential that is sufficient to
decrease drying time and mold growth. The nodular fibrous
insulation can also have relatively high thermal insulation
performance at a relatively low density to enable a variety of
R-values (thermal resistance values) in standard wall cavity
depths.
[0014] The substrate at which the fibrous nodules can be propelled
can include any material on which an insulation product is capable
of being formed. For example, the substrate can include at least
one surface and preferably a plurality of surfaces, at
predetermined angular orientations. In an exemplary embodiment, the
substrate can include at least one surface of a wall, floor or
ceiling cavity in a residential or commercial building. In a
preferred embodiment, the substrate can include a surface of a wall
cavity at least defined by two framing members (such as beams,
studs, etc.) and a rear backing surface. The framing members can be
formed from any suitable material including, for example, wood
and/or metal such as steel. The rear backing surface can be formed
from any suitable material such as, for example, oriented strand
board. The framing members can have any suitable dimensions, for
example, nominal 2 by 4 inches or nominal 2 by 6 inches, and can be
about 8 feet long or longer. The spacing interval between the
framing members can be about 16 inches on center or wider,
preferably about 16 or about 24 inches on center. In an exemplary
embodiment, the substrate can include a standard wall cavity. As
used herein, the term "standard wall cavity" refers to a cavity
formed by standard 2 by 4 inch studs, 8 feet high and 16 inches on
center.
[0015] The nodular fibrous insulation can be formed at least from
fibrous nodules bound together with a binder. The fibrous nodules
can have any shape such as a generally random shape, and can be
generally spherical in shape having one or more radii. The fibrous
nodules can be relatively small in size, and preferably the nodules
can be smaller in size than relatively large-sized clumps of
insulation material used in conventional systems. As a result of
using relatively small-sized nodules, the nodules can be greater in
number than the relatively large-sized clumps used in conventional
systems. For example, the maximum dimension of the fibrous nodules
can be about three-quarters (3/4) inch, preferably about one-half
(1/2) inch, more preferably about one-quarter (1/4) inch. As used
herein, the term "maximum dimension" of a nodule refers to the
longest of the width, length, thickness or diameter of such
nodule.
[0016] The size of the nodules can depend on, for example, the
thermal insulation performance desired, the desired R-value and
density of the installed insulation, the size and shape of the
volume to be insulated, and/or the relevant building code
requirements. In an exemplary embodiment, the maximum dimension of
a majority of the nodules, preferably at least about 70%, more
preferably at least about 80%, and most preferably at least about
90%, can be about one-half inch. In a preferred embodiment, the
maximum dimension of a majority of the nodules, preferably at least
about 70%, more preferably at least about 80%, and most preferably
at least about 90%, can be about one-quarter inch.
[0017] The nodular fibrous insulation can also contain, in addition
to the fibrous nodules, particles that are larger than such fibrous
nodules, hereinafter referred to as "clumps". Preferably, the
nodular fibrous insulation is substantially free of such clumps or
has only a small amount of clumps. For example, such clumps can
adversely affect the properties of the insulation by reducing
thermal performance, producing voids in the insulation, detracting
from the appearance of the insulation by making the surface thereof
less uniform, and/or by being pulled out more easily during
scrubbing of the insulation. Thus, in an exemplary embodiment, the
insulation can be formed in a manner which results in the reduction
or substantial removal of clumps therefrom.
[0018] The dimensions of the nodules can be measured by any
suitable technique such as, for example, using a plurality of
stacked screen sieves containing various screen mesh sizes to
segregate the nodules; spreading out a sampling of the nodules on a
horizontal flat surface and physically measuring each nodule within
the sample with a tape measure; using various air flow resistance
methods to correlate nodule size with air flow resistance readings;
and/or using sonic energy measurements through samples to correlate
sound energy with nodule size.
[0019] Conventional, relatively large-sized clumps typically do not
provide the desired uniformity and aesthetically pleasing surface
appearance to meet inspection standards and/or regulations, and to
ensure consistent thermal performance. In addition, use of such
clumps can lead to a relatively high occurrence of nozzle plugging,
and can also hinder adequate wetting with a binder solution.
[0020] While not wishing to be bound by any particular theory, it
is believed that the relatively small size of the fibrous nodules
can provide various advantages in comparison with conventional,
larger-sized clumps. For example, the fibrous nodules can increase
adhesion between the installed insulation and various substrates
such as wall cavity surfaces. Use of the fibrous nodules can also
improve adhesion between the nodules themselves.
[0021] Use of the fibrous nodules can, for example, reduce or
prevent the occurrence of clogging of a nozzle and/or hose through
which the nodules are blown during application of the insulation.
By reducing or avoiding such clogging, the amount of cleanup
necessary can be reduced and/or the rate of application of the
insulation can be increased. For example, the flow rate of the dry
nodules ejected from a blowing machine can be from about 10 to
about 50 lbs/min, more preferably about 20 to about 30 lbs/min. The
amount of time it takes to fill a cavity with the insulation
product can depend on at least the volume of the cavity. For
example, the amount of time it takes to fill a standard wall cavity
can be from about 5 to about 30 seconds, for example as long as
about 20 to about 30 seconds, or as short as about 5 to about 15
seconds. As used herein, the term "standard wall cavity" refers to
a cavity formed by standard 2 by 4 inch framing members, 8 feet
high and 16 inches on center. The relatively small size of the
nodules can improve wetting thereof by the binder solution. The
insulation formed from the nodules can have good thermal and
acoustical performance and an aesthetically pleasing surface
appearance. The use of the nodules can also improve the consistency
of the R-value of the insulation.
[0022] In an exemplary embodiment, the insulation formed from the
fibrous nodules can have a reduced amount of gaps, voids and/or
bridges formed from the nodules, as a result of the use of the
relatively smaller sized nodules. Reducing the amount of gaps,
voids and/or bridges present in the installed product can minimize
heat transfer by convection. Use of the nodules can also result in
increased uniformity in filling the framing faces of a cavity.
[0023] For example, the relatively small-sized nodules can enable
filling around obstructions in building cavities such as electrical
boxes, wiring and plumbing, thereby providing a substantially
uniform and substantially void-free fill. In addition, the
relatively small-sized nodules can allow the installer to maintain
substantial surface flatness and uniformity in the insulation
product after excess material is removed from the cavity framing
faces. In addition, the fibrous nodules can form a more
structurally uniform insulation product, for example, a
substantially structurally uniform product.
[0024] Use of relatively small-sized and lightweight fibrous
nodules can enable the insulation to have a relatively low density
while still maintaining an acceptable thermal resistivity or
R-value. As used herein, the term "R-value" refers to the thermal
resistivity multiplied by the installed thickness of the
insulation. For example, the insulation can have a thermal
resistivity of from about 3.4 to about 4.0 hour-ft.sup.2-.degree.
F./(Btu-inch) over an installed density of about 0.8 to 1.0
lbs/ft.sup.3 (PCF). This corresponds to an R-value of from about 12
to about 14 hour-ft.sup.2-.degree. F./Btu in a nominal 2 by 4 inch
cavity (3.5 inch actual cavity depth). Alternatively, the
insulation can have a thermal resistivity of from about 4.0 to 4.6
hour-ft.sup.2-.degree. F./(Btu-inch) over an installed density of
about 1.5 to 1.8 lbs/ft.sup.3. This corresponds to an R-value of
from about 14 to about 16 hour-ft.sup.2-.degree. F./Btu in a
nominal 2 by 4 inch cavity (3.5 inch actual cavity depth).
Maintaining a relatively low density can enable the insulation to
be cost-competitive with low cost cellulose material and other
similar materials. The low density of the installation can also
facilitate reduction of drying time.
[0025] The fibrous nodules can contain additives such as, for
example, an anti-static agent, a de-dusting oil, a hydrophobic
agent such as a silicone, a biocide, a fungicide and/or a fire
retardant. In conventional systems, the use of a hydrophobic agent
such as silicone has been found to necessitate the use of an
additional amount of adhesive. The use of the fibrous nodules as
described herein can enable a hydrophobic agent to be used, for
example, without necessitating the use of an excessive amount of
adhesive. The fungicide can include, for example, benzimidazole
2-(4-thiazolyl), available under the trade name Irgaguard F3000
from Ciba Specialty Chemicals, Inc., located in Tarrytown, N.Y.
[0026] The fibrous nodules can include inorganic fibers formed from
a material that is effective to provide, for example, thermal
and/or acoustical insulation. For example, the inorganic fibers can
be formed from glass fibers, slag wool, mineral wool, rock wool,
ceramic fibers, carbon fibers, composite fibers and mixtures
thereof. Preferably, the inorganic fibers can have a relatively
small diameter, and more preferably can at least be formed from
glass fibers having a relatively small diameter.
[0027] Inorganic fibers having a relatively small diameter can
provide an improved degree of infrared radiation absorption and
scattering capability because the inorganic fibers can have a
higher surface area per mass ratio in comparison with fibrous
materials formed from larger fibers. In addition, inorganic fibers
having a relatively small diameter can be effective to create small
pockets of still air which can be effective to reduce solid
material conduction through the fibers.
[0028] The inorganic fibers can have any dimensions suitable for
providing thermal and/or acoustical insulation. For example, the
inorganic fibers can have an average diameter of about 3 microns or
less, preferably about 2.5 microns or less, more preferably about 2
microns or less, more preferably about 1.5 microns or less, and
most preferably about 1 micron or less. In an exemplary embodiment,
the inorganic fibers can have relatively low moisture absorption
and adsorption potential, for example, preferably less than about
5% moisture gain by weight. Such low moisture sorption potential
can enable faster drying and can limit moisture storage capacity
which can in turn reduce mold growth.
[0029] The inorganic fibers can include additives to improve
thermal insulation performance. Some studies have shown that if
convection is minimized, infrared radiation can account for about
30 to 40% of the heat flow through a fibrous insulation product. In
an exemplary embodiment, the inorganic fibers can include an
infrared radiation blocking agent of a reflecting, scattering
and/or absorbing type. In an exemplary embodiment, the infrared
radiation blocking agent can include B.sub.2O.sub.3, for example,
in an amount of at least about 8%.
[0030] Such additive(s) for improving thermal insulation
performance can be added to the insulation in any suitable manner
including, for example, including the additive(s) in the glass
chemistry, applying the additive(s) to the inorganic fibers as a
coating such as a surface coating, mixing the additive(s) with the
inorganic fibers, and/or introducing the additive(s) to the binder
solution.
[0031] The fibrous nodules can be formed by processing a fibrous
source material containing the inorganic fibers. In an exemplary
embodiment, the fibrous source material can be provided in the form
of a substance or a plurality of particles which is/are relatively
large in size, and such substance or particles can be reduced in
size to form the fibrous nodules.
[0032] For example, the fibrous source material can be provided in
any form suitable for being reduced to relatively small sized
nodules. The fibrous source material can include, for example, a
fibrous blanket such as a fiberglass blanket in which the glass
fibers are bonded together with a cured resin, a blanket of virgin
fiberglass or combinations thereof. Additionally or alternatively,
the fibrous source material can include virgin blowing wool which
is substantially free of a binder. The fibrous source material can
contain at least one additive such as, for example, an infrared
blocking agent, an anti-static agent, a silicone, a lubricating
oil, an anti-fungal agent, a biocide, a de-dusting agent such as a
hydrocarbon, a pigment or colorant and/or filler particles. Prior
to applying a binder solution to the fibrous nodules, the nodules
can have an organic content of from about 0.1 to about 10 wt.
percent, for example, from about 2.0 to about 10 wt. percent, as
measured by the loss on ignition test set forth in ASTM C764.
[0033] The fibrous nodules can be formed using any suitable process
and equipment. In an exemplary embodiment, a system for forming the
nodules can include an apparatus for reducing the size of a fibrous
source material to form the nodules, and an exit screen having a
plurality of openings of a pre-selected size which is effective to
substantially control the size of the nodules exiting from the
system.
[0034] For example, a hammer mill can be used which can tear and
shear fibrous particles or a fibrous sheet, and can roll such
particles into generally irregular spherical or rounded nodules.
The hammer mill can keep most particles in the mill until they
reach a pre-selected size. An additive can be added to the material
during processing in the hammer mill such as, for example, an
infrared barrier agent, an anti-static agent, an anti-fungal agent,
a biocide, a de-dusting agent, a pigment and/or colorant.
Alternatively, a slicer-dicer apparatus can be used which can cut
or shear a sheet of fiberglass insulation into smaller particles,
for example, into cube-like particles.
[0035] The size of the plurality of openings of the exit screen can
be pre-selected to yield a desired nodule size. The size of the
plurality of openings can depend on, for example, the type of
fibrous source material that is used, and the manner in which the
nodules are processed. In an exemplary embodiment, for fiberglass
material, the plurality of openings can be substantially
square-shaped and range in size from about 1 to about 3 inches to
produce particles that range in size from about 1/8 inch to about
3/4 inch. In a preferred embodiment, an exit screen can be used
which includes a pattern of 2 inch by 2 inch substantially square
openings or 2 inch diameter substantially circular openings. Such
an exit screen can produce, for example, particles containing
nodules having a maximum dimension of 1/4 inch.
[0036] A binder solution can be applied to the nodules which can
enable the nodules to adhere to a substrate at which the nodules
are propelled. The binder solution can also enable the nodules to
adhere together to form an insulation product on and/or above the
substrate. The binder solution can include, for example, a
water-soluble binder and water. The binder solution can be provided
as a premixed solution, or the binder solution can be produced by
adding water and a binder material to a tank and optionally
stirring the resulting mixture. The binder material can be provided
in the form of a concentrated solution or a powder. In the case a
powdered binder material is used, the mixture can be stirred for a
longer period of time to ensure proper mixture of the materials.
The mixture can optionally be heated to at least room
temperature.
[0037] The binder used to form the binder solution can include any
material that enables the nodules to substantially adhere to the
substrate surface and to other nodules, and can include, for
example, resin solids. Preferably, the binder can provide
sufficient adhesion to reduce or prevent settling, collapsing or
slumping of the installed insulation. The binder can include a
liquid-soluble binder, preferably a water-soluble binder. For
example, the binder can include a water-soluble polymer, resin or
oligomer, such as a water-soluble partially hydrolyzed polyester
oligomer, polyvinyl acetate, polyvinyl pyrilidone, polyvinyl
alcohol or mixtures thereof. In an exemplary embodiment, the binder
can include a partially hydrolyzed polyester oligomer such as
S-14063 and/or SA-3915 available from Sovereign Specialty Chemicals
located in Greenville, S.C. The S-14063 resin contains 23% to 36%
solids, and can be mixed with water, for example, at a water to
binder ratio of about 0.5:1 to about 2:1, preferably about 1:1. The
SA-3915 adhesive contains 10% to 15% solids and can be used without
further addition of water.
[0038] The binder solution can optionally include at least one
additive such as, for example, an anti-freezing agent, a viscosity
modifying agent, a biocide, a pigment.
[0039] The binder can be present in the binder solution in an
amount that enables the nodules to substantially adhere to the
substrate surface and to other nodules. Preferably, the binder can
be present in an amount which provides sufficient adhesion to
reduce or prevent settling, collapsing or slumping of the installed
insulation. For example, the binder can be present in an amount
from about 10% to about 50%, preferably from about 10% to about
20%, based on the volume of the binder solution.
[0040] After installation and drying of the insulation, the binder
can be present in the dried insulation product in an amount of less
than about 6 wt. percent, preferably from about 2 wt. percent to
about 6 wt. percent, more preferably from about 2 wt. percent to
about 4 wt. percent, most preferably about 3 wt. percent, on an
oven dry basis, for example, of an installed product having an
installed density ranging from about 0.8 to about 1.0 PCF. As used
herein, the terms "oven dry basis" and "oven dry" refer to the
material in question being measured while being substantially free
of moisture. In addition, as used herein, the terms "ambient dry
basis" and "ambient dry" refer to the material in question being
measured after equilibriating to ambient conditions, in which case
the material can contain an amount of moisture.
[0041] The nodules can be contacted with the binder solution to
produce coated nodules. The term "coated nodules" encompasses
nodules which are partially or substantially entirely coated with
the binder solution. The binder solution can be present at an outer
region of the coated nodules, for example, at the surface of the
coated nodules. The nodules can be contacted with the binder
solution while the nodules are being propelled. For example, the
nodules can be contacted with the binder solution while the nodules
are ejected from a nozzle or at a time thereafter but prior to the
nodules contacting the substrate.
[0042] The coated nodules can be used to form an insulation product
in a wall cavity. To ensure complete filling of the cavity, the
coated nodules can be applied in an amount such that the insulation
overflows from the cavity. For example, the installed insulation
can extend past the face of the frame which defines the cavity.
Thereafter, excess insulation material can be removed, rolled
and/or compressed, for example, to substantially level the
insulation with the face of the frame defining the wall cavity.
Leveling the insulation can enable a wall board or other facing
board to be installed substantially flush with the face of the
frame. In an exemplary embodiment, excess insulation can be removed
without rolling or compressing the insulation.
[0043] The insulation formed from the nodules and binder solution
can be installed using any system suitable for applying a fibrous
insulation onto a substrate. For example, the insulation can be
applied using a commercially available blowing system such as a
system specifically designed for cellulose blowing.
[0044] In an exemplary embodiment, the nodules can be provided to a
hopper of a blowing machine. The blowing machine can mix the
nodules with air and eject such mixture as a rapidly moving air
suspension from an outlet. A hose can be connected to the outlet
and convey the nodules to the substrate on which the insulation is
to be formed. Any suitable hose can be used, for example, a hose as
long as 300 feet having a diameter from about 2.5 inches to about 4
inches.
[0045] The hose can have a nozzle attached to an end thereof
through which the nodules are ejected. A handle can be provided to
assist an operator to hold and aim the nozzle during application of
the nodules. The nozzle can have at least one jet spray tip for
contacting the binder solution with the nodules near the exit end
of the nozzle, preferably at or past the exit end. In an exemplary
embodiment, two or three jet spray tips can be used opposite each
other across a moving stream of suspended nodules. For example, an
exemplary jet spray tip which can be used is available under the
trade name Unijet (25 degree or 65 degree spray), available from
Spraying Systems Co. located in Wheaton, Ill. Other exemplary
nozzles which can be used are described in, for example, U.S. Pat.
Nos. 5,641,368 and 5,921,055. A pump such as an adjustable rate
pump can be connected to a tank containing the binder solution to
provide the binder solution at a pre-selected flow rate and
pressure to the jet spray tips of the nozzle through one or more
flexible hoses. The flow rate and pressure of the binder solution
is preferably pre-selected to enable adequate coating of the
nodules with the binder solution.
[0046] An excessive amount of insulation material can be formed on
the substrate, and such excessive insulation can be removed using
any suitable means. For example, an amount of insulation material
can be removed to substantially align the insulation product with
the framing members that define the cavity in which the insulation
product is formed. The use of the relatively smaller sized nodules
can enable removal of excessive material while maintaining a
substantially smooth, even surface of the insulation product.
[0047] For example, a powered scrubber including a rotating
brush-like device can be used to reduce or remove the excess
insulation. The powered scrubber can span two adjacent wall studs.
Water or other liquid is preferably not used with the powered
scrubber. In conventional insulation systems, the rotating action
of the powered scrubber can lead to damage of the insulation such
as the tearing of large chunks of the insulation from the cavity.
The use of the powered scrubber with the insulation formed by the
present methods can reduce or avoid the occurrence of the tearing
of large chunks of the insulation from the cavity. This can be a
result of, for example, a higher degree of tackiness between the
nodules, the smaller size of the nodules, and/or the reduction of
voids in the insulation product.
[0048] The just-installed insulation product can have a relatively
low moisture content, which can in turn contribute to reducing
drying time and/or minimizing the potential for mold growth. For
example, the coated nodules can have a moisture content of less
than about 25 wt. percent, preferably less than about 20 wt.
percent, more preferably less than about 15 wt. percent, more
preferably less than about 10 wt. percent, based on the dry weight
of the nodules. For example, the water present in the
just-installed insulation can be from about 10 wt. percent to about
30 wt. percent, preferably from about 10 wt. percent to about 20
wt. percent, based on the dry weight of the nodules.
[0049] The moisture content in the just-installed insulation
product can be less than about 2.0 lbs of water per standard wall
cavity. For example, the moisture content can be less than about
0.75 lbs, more preferably less than about 0.50 lbs, and most
preferably less than about 0.25 lbs of water in a standard wall
cavity, for example, for an installed insulation product having an
R-value of 13 and an oven dry density from about 0.8 to about 1.0
PCF. Alternatively, the moisture content can be less than about 2.0
lbs, more preferably less than about 1.5 lbs, and most preferably
less than about 0.50 lbs of water in a standard wall cavity, for
example, for an installed insulation product having an R-value of
15 and an oven dry density from about 1.5 to about 1.8 PCF.
[0050] While not wishing to be bound by any particular theory,
Applicants believe that the weight of water in a standard wall
cavity or other unit volume can be an accurate indicator of the
amount of time needed to sufficiently dry the insulation. For
example, the amount of water in a standard wall cavity or other
unit volume may be a more accurate indication of drying time than,
for example, the moisture content percentage in the insulation,
since drying time is typically dependent on the total amount of
water present. In this regard, the moisture content percentage is
with respect to the weight of the material itself, and does not
necessarily indicate the total amount of water present.
[0051] The resultant coated nodules of inorganic fiber insulation
can contain binder solids in an amount of less than about 6 wt.
percent, preferably less than about 4 wt. percent, and more
preferably less than about 3 wt. percent, based on the dry weight
of the nodules, for installed densities ranging from about 0.8 to
about 1.0 PCF.
[0052] The insulation product can have a density preferably of
about 3 PCF or less, more preferably about 2 PCF or less and most
preferably about 1 PCF or less. The density can depend to some
extent on the R-value desired. The R-value of the insulation
product can be, for example, from about 12 to about 16. For
example, in a standard wall cavity, the dried installed insulation
product can have a density from about 0.8 to about 1 PCF and an
R-value of about 13, or a density from about 1.5 to about 1.8 PCF
and an R-value of about 15. The relatively low density and low
moisture content of the insulation product can result in reducing
the cost and improving drying time in comparison with conventional
systems.
[0053] In an exemplary embodiment, the distance the nodules are
propelled can be selected to achieve a predetermined density of the
nodular insulation material. For example, the nozzle can be held at
a particular distance from the substrate in order to achieve a
predetermined density of the nodular insulation material.
EXAMPLES
Example 1
[0054] Nodules formed from glass fibers were provided which were
mostly roughly spherical in shape and had an average diameter or
length of about 1/4 inch. A majority of the nodules had a maximum
dimension of 1/2 inch or less. The glass fibers had an average
diameter of 2.0 microns and contained B.sub.2O.sub.3 in an amount
of 8.7 wt. %. The glass fibers had on their surface a silicone
agent in an amount of 0.05 wt. % and a de-dusting oil in an amount
of 0.06 wt. %, based on the weight of the glass fibers.
[0055] A blowing machine available from Unisul under the trade name
Volumatic.RTM. III, was used to blow the nodules at a wall cavity.
The blowing machine was equipped with 150 feet of 4-inch diameter
hose and provided a nodule mass flow rate of approximately 18
lbs/min. The blowing machine was operated with the transmission in
third gear with 100% of the available blower air delivered to the
rotary airlock assembly and with the slide gate (feed gate) set at
12 inches. The blower and secondary gearbox speeds (rpm settings)
on the blowing machine were set to the manufacturer's recommended
settings of 1425 rpm and 1050 rpm, respectively.
[0056] The nodules flowed through the blowing hose and out from a
nozzle. A spray assembly was used to apply a binder solution to the
nodules as they exited the hose. The spray assembly included a 4
inch diameter tube connected to a binder solution source. A pump
available from Spray Tech, model 0295003, was used to generate flow
of the binder solution. The nozzle was surrounded by an annular
manifold containing two spray tips available from Spray System Co.
model TPU-65-015. The spray tips were screwed into threaded ports
located 180 degrees apart on the manifold. The ports were set at a
30 degree angle to the centerline of the direction of the nodule
flow. The arrangement of the spray tips enabled the binder solution
to be contacted with the nodules without substantially disrupting
the flow of the nodules.
[0057] The binder solution was formed from a 1:1 volumetric mixture
of water and an acrylic resin solution available from Sovereign
Chemical under the trade name S-14063. The flow rate of the binder
solution was 0.5 gallons/minute.
[0058] The insulation was applied to a wall cavity by pointing the
nozzle from the bottom to the top of the cavity, and with a side to
side motion. In this example, the nozzle was held approximately 6
feet away from the open cavity faces during the installation
process. The coated nodules formed a substantially consistent fill
in the cavity with about a 2 to 3 inch thickness of excess material
extending beyond the face of the wooden beams.
[0059] Shortly after installation, excess insulation material was
removed with the use of a commercial rotary wall scrubber available
from Krendl Machine Co., located in Delphos, Ohio, under Model No.
349B. The removed excess material was vacuumed using a 50 foot
length of 4 inch diameter hose connected to a centrifugal vacuum
fan available from Wm. W. Meyer & Sons, Inc., under the trade
name Versa-Vac (11).
[0060] Four wall cavities of varying sizes were insulated,
hereinafter referred to as Samples 1 to 4, respectively. Sample 1
was defined by 8 foot high vertical, 2 by 4 inch wooden beams
spaced on a 16 inch center. Sample 2 was defined by 8 foot high
vertical, 2 by 4 inch wooden beams spaced on a 24 inch center.
Sample 3 was defined by 8 foot high vertical, 2 by 6 inch wooden
beams spaced on a 16 inch center. Sample 4 was defined by 8 foot
high vertical, 2 by 6 inch wooden beams spaced on a 24 inch center.
Standard SPF wood framing was used to form the side and top walls
of each cavity, and oriented strand board (OSB) sheathing was used
as the back wall of each cavity. The results are shown in the
following Table 1.
[0061] In the Examples, the ratio of the binder solution to dry
nodules represents the ratio of the flow rate of the binder
solution to the flow rate of the dry nodules, by weight. The
just-installed moisture content was measured using a load cell
connected to a chain hoist. A large oven was used to dry the
samples after the initial weights were taken. The moisture content
of the just-installed insulation was measured on an oven dry mass
basis.
TABLE-US-00001 TABLE 1 Installation Using a Nozzle Positioned Six
Feet from the Cavity Sample 4 Sample 1 Sample 2 Sample 3 (2 by 6
in, (2 by 4 in, (2 by 4 in, (2 by 6 in, 24 16 in OC) 24 in OC) 16
in OC) in OC) Ratio of Binder Solution 0.24 0.26 0.24 0.26 0.24
0.26 0.24 0.26 to Dry Nodules Just-installed Moisture, 20 30 20 30
20 30 20 30 wt. % Just-installed Amount of 0.5 0.7 0.8 1.1 0.8 1.2
1.2 1.8 Water per Cavity, lbs/cavity Installation Time, 10 15 15 24
sec/cavity Dry Insulation Density, 0.8 0.9 0.8 0.9 0.8 0.9 0.8 0.9
PCF R-value 13 13 20 20
[0062] In Example 1, loss-on-ignition (LOI) testing indicated that
approximately 2 to 3% adhesive solids existed in the installed
material. In each of Samples 1 to 4, the installed material
remained in the cavity and did not undergo settling.
Example 2
[0063] Insulation was formed in the same manner as described in
Example 1, except that the nozzle was positioned two feet from the
cavity instead of six feet from the cavity during application of
the coated nodules to the cavity. The results are set forth in the
following Table 2.
TABLE-US-00002 TABLE 2 Installation Using a Nozzle Position Two
Feet from the Cavity Sample 8 Sample 5 Sample 6 Sample 7 (2 by 6
in, (2 by 4 in, (2 by 4 in, (2 by 6 in, 24 16 in OC) 24 in OC) 16
in OC) in OC) Ratio of Binder Solution 0.24 0.26 0.24 0.26 0.24
0.26 0.24 0.26 to Dry Nodules Just-Installed Moisture, 20 30 20 30
20 30 20 30 wt. % Just-installed Amount of 1.0 1.5 1.5 2.3 1.5 2.3
2.4 3.6 Water per Cavity, lbs/cavity Installation Time, 21 32 33 51
sec/cavity Dry Insulation Density, 1.7 1.8 1.7. 1.8 1.7 1.8 1.7 1.8
PCF R-value 15 15 23 23
[0064] In comparing the results shown in Tables 1 and 2, applying
the coated nodules with a 6-foot distance between the nozzle and
the cavity resulted in an insulation density of from 0.8 to 0.9
PCF, whereas applying the coated nodules with a 2-foot distance
between the nozzle and the cavity resulted in an insulation density
of from 1.7 to 1.8 PCF. Additional tests were conducted (not shown
in Table 2) in the same manner as described in Example 1, except
that the coated nodules were applied with a 4-foot distance between
the nozzle and the cavity. The density of the insulation formed
from such additional tests was from 1.3 to 1.5 PCF. The above
experimental results show that the density of the installed
insulation can be controlled by varying the distance between the
nozzle and the substrate on which the insulation is formed.
Example 3
[0065] Insulation was formed in the same manner as described in
Example 1, except that the slide gate on the blowing machine was
set to 7 inches, i.e., about 40% open. At such setting, the mass
flow rate of the dry nodules was about 10 lbs/min instead of the 18
lbs/min flow rate employed in Example 1. The results of such tests
are set forth in the following Table 3.
TABLE-US-00003 TABLE 3 Installation Using a Reduced Nodule Flow
Rate Sample 9 Sample 10 Sample 11 Sample 12 (2 by 4 in, 16 (2 by 4
in, 24 (2 by 6 in, (2 by 6 in, 24 in OC) in OC) 16 in OC) in OC)
Ratio of Binder Solution to 0.43 0.53 0.43 0.53 0.43 0.53 0.43 0.53
Dry Nodules Just-Installed Moisture, 45 45 45 45 wt. %
Just-installed Amount of 1.2 1.9 1.9 3 Water per Cavity, lbs/cavity
Installation Time, 15 20 20 29 sec/cavity Dry Insulation Density,
0.8 0.9 0.8 0.9 0.8 0.9 0.8 0.9 PCF R-value 13 13 20 20
[0066] As can be seen from Table 3, due to the reduced flow rate of
the dry nodules, the ratio of the binder solution to the dry
nodules was higher in comparison with the ratios obtained in
Example 1. In addition, the just-installed product had an
additional amount of moisture and as a result, an additional amount
of time was required to install the insulation in each cavity. The
above results show that the use of a reduced flow rate of dry
nodules can result in an increase in installation cost due to an
increased amount of binder solution usage and an increase in
installation time.
Example 4
[0067] Insulation was formed in the same manner as discussed above
in Example 1, except that instead of a 1:1 volumetric mixture of
water and the S-14063 adhesive, a water to adhesive ratio of 2:1
was used to form the binder solution. The results of such tests are
set forth in the following Table 4.
TABLE-US-00004 TABLE 4 Installation Using a Diluted Binder Solution
Sample 16 Sample 13 Sample 14 Sample 15 (2 by 6 in, (2 by 4 in, (2
by 4 in, (2 by 6 in, 24 16 in OC) 24 in OC) 16 in OC) in OC) Ratio
of Binder Solution 0.23 0.25 0.23 0.25 0.23 0.25 0.23 0.25 to Dry
Nodules Just-installed Moisture, 23 23 23 23 wt. % Just-installed
Amount of 0.6 0.9 0.9 1.4 Water per Cavity, lbs/cavity Installation
Time, 10 15 15 24 sec/cavity Dry Insulation Density, 0.8 0.9 0.8
0.9 0.8 0.9 0.8 0.9 PCF R-value 13 13 20 20
[0068] In this example, the ratio of water to binder solids was
increased, but no significant difference in drying time resulted.
The reduction in the amount of adhesive led to a reduction in cost
in comparison with Example 1. Using less adhesive may result in
less adhesion between the nodules and the cavity.
Example 5
[0069] Insulation was formed in the same manner as described in
Example 1, except that the slide gate on the blowing machine was
opened to 15 inches (86% open), and as a result the mass flow rate
of dry nodules was increased to 22 lbs/min. In addition, the flow
rate of the binder solution was increased from 0.5 gallons/minute
to 0.7 gallons/minute. The results are shown in the following Table
5.
TABLE-US-00005 TABLE 5 Installation Using an Increased Dry Nodule
Flow Rate and Increased Binder Solution Flow Rate Sample 20 Sample
17 Sample 18 Sample 19 (2 by 6 in, (2 by 4 in, (2 by 4 in, (2 by 6
in, 24 16 in OC) 24 in OC) 16 in OC) in OC) Ratio of Binder
Solution 0.27 0.30 0.27 0.30 0.27 0.30 0.27 0.30 to Dry Nodules
Just-installed Moisture, 25 25 25 25 wt. % Just-installed Amount of
0.7 1.1 1.1 1.7 Water per Cavity, lbs/cavity Installation Time, 9
14 14 22 sec/cavity Dry Insulation Density, 0.8 0.9 0.8 0.9 0.8 0.9
0.8 0.9 PCF R-value 13 13 20 20
[0070] In this Example, the installation time was improved in
comparison with the samples set forth in Example 1.
[0071] Several examples and ranges of parameters of preferred
embodiments of the present invention have been described above, but
it will be apparent to those of ordinary skill in the insulation
field that many other embodiments by manipulation of the parameters
can be employed. For example, although only a few different resin
binders are specifically disclosed, there are many soluble binders
that can function in the above disclosed invention to produce the
useful result of having sufficient tack value. While most of the
above discussion involves using the present invention in generally
vertical wall cavities, this insulation product can be used to
insulate attics or any other suitable area.
* * * * *