U.S. patent application number 12/002649 was filed with the patent office on 2008-07-03 for blended insulation blanket.
Invention is credited to Jacob T. Chacko, Jeffrey A. Tilton.
Application Number | 20080160857 12/002649 |
Document ID | / |
Family ID | 39584664 |
Filed Date | 2008-07-03 |
United States Patent
Application |
20080160857 |
Kind Code |
A1 |
Chacko; Jacob T. ; et
al. |
July 3, 2008 |
Blended insulation blanket
Abstract
An insulation blanket includes a blend of a first component and
a second component. The first component is a first fiber material
selected from a group consisting of glass fibers, mineral fibers,
basalt fibers, natural fibers and mixtures thereof. The second
component is made of a second material selected from a group
consisting of thermoplastic copolymer bi-component fibers,
monofilament fibers, a thermal setting resin and mixtures
thereof.
Inventors: |
Chacko; Jacob T.;
(Pickerington, OH) ; Tilton; Jeffrey A.;
(Shelbyville, KY) |
Correspondence
Address: |
OWENS CORNING
2790 COLUMBUS ROAD
GRANVILLE
OH
43023
US
|
Family ID: |
39584664 |
Appl. No.: |
12/002649 |
Filed: |
December 18, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60877481 |
Dec 27, 2006 |
|
|
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Current U.S.
Class: |
442/342 |
Current CPC
Class: |
B29C 65/72 20130101;
D04H 1/54 20130101; D04H 1/46 20130101; A47L 15/4209 20161101; A47L
15/4246 20130101; F16L 59/026 20130101; Y10T 442/616 20150401 |
Class at
Publication: |
442/342 |
International
Class: |
D04H 1/46 20060101
D04H001/46 |
Claims
1. An insulation blanket, comprising: a blend of a first component
and a second component; said first component being a first fiber
material selected from a group consisting of glass fibers, mineral
fibers, basalt fibers, natural fibers and mixtures thereof having
an average fiber diameter of between about 2 to about 20 microns;
said second component being a second material selected from a group
consisting of (a) thermoplastic copolymer bi-component fibers
composed of polyester, polyolefin, nylon, rayon and mixtures
thereof, (b) monofilament fibers composed of polyester, polyolefin
and nylon wherein said fibers under (a) and (b) have an average
fiber diameter of between about 10 to about 30 microns, (c) a
thermosetting resin composed of polyvinyl acetate resin, acrylic
resin, phenolic resin and mixtures thereof and (d) mixtures of (a),
(b) and (c); and wherein said blend includes between about 5 to
about 95 weight percent of said first component and between about 5
and about 95 weight percent of said second component.
2. The blanket of claim 1, wherein said first fiber material has an
average fiber length of between about 6.35 to about 304.8 mm and
said second component has an average fiber length of between about
12.7 to about 152.4 mm.
3. The blanket of claim 1, wherein said first component and said
second component are heat bonded together with a first polymer of
said thermoplastic copolymer bi-component fibers being melted and a
second polymer of said thermoplastic copolymer bi-component fiber
maintaining fiber integrity.
4. The blanket of claim 1, wherein said first component and said
second component are mechanically bonded by needling.
5. The blanket of claim 1, wherein said glass fibers are selected
from a group consisting of textile fibers including wet use chopped
strand and dry use chopped strand, rotary fibers, flame attenuated
fibers, bi-component glass fibers and mixtures thereof.
6. The blanket of claim 5, wherein said fibers are straight or
crimped in shape.
7. The blanket of claim 1, wherein said thermoplastic copolymer
bi-component fibers are selected from a group consisting of
core-sheath configuration, side-side configuration and mixtures
thereof.
8. The blanket of claim 1, wherein said fibers of said second
component are selected from a group consisting of amorphous,
crystalline and mixtures thereof.
9. The blanket of claim 1, wherein said blanket has a density of
between about 0.4 and about 10.0 lbs/ft.sup.3.
10. The blanket of claim 1, first fiber material includes a first
group of fibers having an average fiber length of between about
6.35 and about 50.0 mm and an average fiber diameter of between
about 2.0 and about 5.0 microns and a second group of fibers having
an average fiber length of between about 25.4 and about 304.8 mm
and an average fiber diameter of between about 6.0 and about 20.0
microns.
11. The blanket of claim 10, wherein said blend includes between
about 5 and about 70 weight percent of said first group of fibers
and between about 5 and about 70 weight percent of said second
group of fibers.
12. The blanket of claim 10, wherein said blend includes between
about 20 and about 60 weight percent of said first group of fibers
and between about 20 and about 60 weight percent of said second
group of fibers.
13. The blanket of claim 1, wherein said blend includes between
about 30 to about 70 weight percent of said first component and
between about 30 to about 70 weight percent of said second
component.
14. An electric appliance, comprising: a housing; and an insulation
blanket carried on at least a portion of said housing, said
insulation blanket including a blend of a first component and a
second component; said first component being a first fiber material
selected from a group consisting of glass fibers, mineral fibers,
basalt fibers, natural fibers and mixtures thereof having an
average fiber diameter of between about 2 to about 20 microns and
an average fiber length of between about 6.35 to about 304.8 mm;
said second component being a second material selected from a group
consisting of (a) thermoplastic copolymer bi-component fibers
composed of polyester, polyolefin, nylon, rayon and mixtures
thereof, (b) monofilament fibers composed of polyester, polyolefin
and nylon wherein said fibers under (a) and (b) have an average
fiber diameter of between about 10 to about 30 microns and an
average fiber length of between about 12.7 to about 76.2 mm, (c) a
thermosetting resin composed of polyvinyl acetate resin, acrylic
resin, phenolic resin and mixtures thereof and (d) mixtures of (a),
(b) and (c); and wherein said blend includes between about 5 to
about 95 weight percent of said first component and between about 5
and about 95 weight percent of said second component.
15. A dishwasher, comprising: a housing; a cleaning element; and an
insulation blanket carried on at least a portion of said housing,
said insulation blanket including a blend of a first component and
a second component; said first component being a first fiber
material selected from a group consisting of glass fibers, mineral
fibers, basalt fibers, natural fibers and mixtures thereof having
an average fiber diameter of between about 2 to about 20 microns
and an average fiber length of between about 6.35 to about 304.8
mm; said second component being a second material selected from a
group consisting of (a) thermoplastic copolymer bi-component fibers
composed of polyester, polyolefin, nylon, rayon and mixtures
thereof, (b) monofilament fibers composed of polyester, polyolefin
and nylon wherein said fibers under (a) and (b) have an average
fiber diameter of between about 10 to about 30 microns and an
average fiber length of between about 12.7 to about 76.2 mm, (c) a
thermosetting resin composed of polyvinyl acetate resin, acrylic
resin, phenolic resin and mixtures thereof and (d) mixtures of (a),
(b) and (c); and wherein said blend includes between about 5 to
about 95 weight percent of said first component and between about 5
and about 95 weight percent of said second component.
16. A method of insulating an electric appliance, comprising:
providing an insulation blanket for said electric appliance wherein
said insulation blanket includes a blend of a first component and a
second component; said first component being a first fiber material
selected from a group consisting of glass fibers, mineral fibers,
basalt fibers, natural fibers and mixtures thereof having an
average fiber diameter of between about 2 to about 20 microns and
an average fiber length of between about 6.35 to about 304.8 mm;
said second component being a second material selected from a group
consisting of (a) thermoplastic copolymer bi-component fibers
composed of polyester, polyolefin, nylon, rayon and mixtures
thereof, (b) monofilament fibers composed of polyester, polyolefin
and nylon wherein said fibers under (a) and (b) have an average
fiber diameter of between about 10 to about 30 microns and an
average fiber length of between about 12.7 to about 76.2 mm, (c) a
thermosetting resin composed of polyvinylate of (a), (b), and (c);
resin and mixtures thereof and (d) mixtures of (a), (b) and (c);
and wherein said blend includes between about 5 to about 95 weight
percent of said first component and between about 5 and 95 weight
percent of said second component.
Description
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION
[0001] The present invention relates generally to the insulation
field and, more particularly, to insulation blankets made from a
loose filled blend of materials.
BACKGROUND OF THE INVENTION
[0002] Non-woven fibrous insulation blankets made from a mixture of
reinforcing fibers and a binder such as binding fibers or powder or
liquid resins have long been known in the art. Examples of such
blankets are disclosed in, for example, U.S. Pat. Nos. 4,946,738,
4,889,764, 4,888,235 and 4,751,134 all to Chenoweth et al,
4,418,031 to Doerer et al, 5,983,586 to Berden, II et al. and
6,669,265 to Tilton et al. The use of glass fiber with average
diameters of less than 5 microns in such blankets in order to
provide desired thermal conductivity properties has been recognized
in the prior art as exemplified by U.S. Pat. Nos. 4,759,785 to
Barthe et al. and 5,674,307 to Huey et al.
[0003] The present invention relates to blended blankets that are
both inexpensive to produce and provide still further enhanced and
desirable properties over those available from blankets found in
the prior art.
SUMMARY OF THE INVENTION
[0004] In accordance with the purposes of the present invention as
described herein, an improved non-woven insulation blanket is
provided. The insulation blanket comprises a blend of a first
component and a second component. The first component is a first
fiber material selected from a group consisting of glass fibers,
mineral fibers, basalt fibers, natural fibers and mixtures thereof
having an average fiber diameter of between about 2 to about 20
microns. The second component is made from a second material
selected from a group consisting of (a) thermoplastic copolymer
bi-component fibers composed of polyester, polyolefin, nylon, rayon
and mixtures thereof, (b) monofilament fibers composed of
polyester, polyolefin and nylon wherein those fibers under (a) and
(b) have an average fiber diameter of between about 10 to about 30
microns, (c) a thermal setting resin composed of polyvinyl acetate
resin, acrylic resin, phenolic resin and mixtures thereof and (d)
mixtures of (a), (b) and (c). Further, the blend includes between
about 5 to about 95 weight percent of the first component and
between about 5 to about 95 weight percent of the second component.
More typically, the blend includes between about 30 to about 70
weight percent of the first component and between about 30 to about
70 weight percent of the second component. The fibers of the first
component may have an average length of between about 6.35 to about
304.8 mm while fibers of the second component may have an average
length of between about 12.7 to about 152.4 mm.
[0005] In one possible embodiment the first component and the
second component that are blended in the insulation blanket are
heat bonded together with a first polymer of the thermoplastic
copolymer bi-component fibers being melted and a second polymer of
the thermoplastic copolymer bi-component fiber maintaining fiber
integrity. In yet another embodiment, the first and second
components are mechanically bonded by needling.
[0006] More specifically describing the invention, the glass fibers
utilized for the first component may be selected from a group
consisting of textiles fibers including wet use chopped strand and
dry use chopped strand, rotary fibers, flame attenuated fibers,
bi-component glass fibers and mixtures thereof. The fibers may be
straight or crimped in shape.
[0007] Still further, the thermoplastic copolymer bi-component
fibers may be selected from a group consisting of core-sheath
configuration, side-side configuration and mixtures thereof. The
materials used for the second component fibers may be amorphous,
crystalline or mixtures thereof. Typically, the insulation blanket
of the present invention has a density of between about 0.4 and
about 10.0 lbs/ft.sup.3.
[0008] In yet another possible embodiment of the present invention,
the first fiber material includes a first group of fibers having an
average fiber length of between about 6.35 and about 50.0 mm and an
average fiber diameter of between about 2.0 and about 5.0 microns
and a second group of fibers having an average fiber length of
between about 25.4 and about 304.8 mm and an average fiber diameter
of between about 6.0 and about 20.0 microns. Typically, the blend
includes between about 5 and about 70 weight percent of the first
group of fibers and between 5 and about 70 weight percent of the
second group of fibers. More typically, the blend includes between
about 20 and about 60 weight percent of the first group of fibers
and between about 20 and about 60 weight percent of the second
group of fibers.
[0009] In accordance with yet another aspect of the present
invention an electric appliance is provided comprising a housing, a
heating element and an insulation blanket of the type described
above carried on at least a portion of the housing.
[0010] In accordance with yet another aspect of the present
invention a dishwasher is provided comprising a housing and an
insulation blanket of the type described above carried on at least
a portion of the housing.
[0011] In accordance with still another aspect of the present
invention a method is provided for insulating an electric
appliance. The method comprises providing an insulation blanket of
the type described above.
[0012] In the following description there is shown and described
preferred embodiments of the invention, simply by way of
illustration of several of the modes best suited to carry out the
invention. As it will be realized, the invention is capable of
other different embodiments and its several details are capable of
modification in various, obvious aspects all without departing from
the invention. Accordingly, the drawings and descriptions will be
regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWING
[0013] The accompanying drawing incorporated in and forming a part
of the specification, illustrates several aspects of the present
invention and together with the description serves to explain
certain principles of the invention. In the drawing:
[0014] FIG. 1 is a partially schematical, perspective view of a
dishwasher equipped with an insulation blanket of the present
invention.
[0015] Reference will now be made in detail to the present
preferred embodiments of the invention, examples of which are
illustrated in the accompanying drawing.
DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS OF THE INVENTION
[0016] An insulation blanket 10 is illustrated in FIG. 1. The
insulation blanket 10 comprises a blend of a first component and a
second component. The first component is a first fiber material
selected from a group consisting of glass fibers, mineral fibers,
basalt fibers, natural fibers and mixtures thereof having an
average fiber diameter of between about 2 and about 20 microns.
Natural fibers useful in the present invention include hemp, kenaf,
jutte, cotton and the like. Glass fibers useful in the present
invention include textile glass fibers including wet use chopped
strand, dry use chopped strand, E-glass, rotary glass fibers, flame
attenuated glass fiber and bi-component glass fibers such as sold
under the Miraflex trademark by Owens-Corning Fiberglas Technology,
Inc. of Summitt, Ill. Continuous glass fibers may be used and are
typically chopped to a length of between about 12.7 and 152.4 mm.
Rotary and flame attenuated glass fibers may be any length but are
generally 25.4 to 304.8 mm in length and could be pre-chopped to a
length of 6.35 to about 76.2 mm.
[0017] The fibers may be straight or irregular shaped such as
crimped. Where glass fibers are used, they are typically of the
loose fill, wet use chopped strand or textile variety although
other forms could be used. The glass fibers may be E-glass or
another type as desired. The fibers may be treated with known
lubricants and/or known anti-stat agents to aid in handling.
Lubricants useful in the present invention include but are not
limited to silicones, silanes and mineral oil. Anti-stats useful in
the present invention include but are not limited to various
quaternary ammonium compounds.
[0018] The second component of the insulation blanket may be made
from a second material selected from a group consisting of (a)
thermoplastic copolymer bi-component fibers composed of polyester,
polyolefin, nylon, rayon and mixtures thereof, (b) monofilament
fibers composed of polyester, polyolefin and nylon wherein said
fibers under (a) and (b) have a diameter of between about 10 to
about 30 microns, (c) a thermosetting resin composed of polyvinyl
acetate resin, acrylic resin, phenolic resin and mixtures thereof
and (d) mixtures of (a), (b) and (c). While the fibers in (a) and
(b) may be substantially any length, they are generally between
about 12.7 to about 152.4 mm for best results. Substantially any
configuration of bi-component fibers may be used including but not
limited to core-sheath configuration, side-side configuration and
mixtures thereof. Further, the fibers used for the second component
may be amorphous or crystalline in nature or mixtures thereof.
[0019] The insulation blanket 10 is a blend of between about 5 to
about 95 weight percent of the first component and between about 5
to about 95 weight percent of the second component. More typically,
the blanket 10 is a blend of between about 30 to about 70 weight
percent of the first component and between about 30 to about 70
weight percent of the second component. In one possible embodiment
the first component and second component of the blanket are heat
bonded together. Typically, where the second component includes
fibers such as thermoplastic copolymer bi-component fibers, those
fibers are not melted out during the heat bonding process. Thus,
for example, heat bonding may take place by melting the first
polymer of the bi-component fibers with the lower melting point
while not melting and maintaining the fiber integrity of the second
polymer of the bi-component fiber having the higher melting point.
Alternatively, the first component and second component of the
blanket may be mechanically bonded together by needling. In yet
another alternative both a heat bonding process and a needling
process may be used to bind the components together and provide a
blanket with a desired density. Typically the blanket 10 has a
density of between about 0.4 and about 10.0 lbs/ft.sup.3.
[0020] In still another embodiment, the first fiber material used
in the blanket 10 includes a first group of fibers having an
average fiber length of between about 6.35 and about 50.0 mm and an
average fiber diameter of between about 2.0 and about 5.0 microns
and a second group of fibers having an average fiber length of
between about 25.4 and about 304.8 mm and an average fiber diameter
of between about 6.0 and about 20.0 microns. Where two groups of
fibers are utilized for the first fiber material, the insulation
blanket 10 includes between about 5 and about 70 weight percent of
the first group of fibers and between about 5 and about 70 weight
percent of the second group of fibers. More typically, the
insulation blanket includes between about 20 and about 60 weight
percent of the first group of fibers and between about 20 and about
60 weight percent of the second group of fibers. The amount of each
group of fibers included in the blanket may be varied to tune the
thermal insulative, acoustic and structural properties to meet the
needs of any particular application.
[0021] By using lower fiber diameter loose filled glass fibers in
the blanket 10 of the present invention it is possible to improve
thermal and acoustical performance and, simultaneously,
advantageously provide an UL 94 V-O fire rating. The glass fibers
can be produced in line to help lower the cost of manufacture of
the blanket 10. Further, the blending of the glass fibers with
polymer fibers improves the "feel" of the blanket 10 compared to a
100% glass fiber blanket making it more acceptable to handle by
assembly workers and installers. For certain applications the
blending of the glass fibers and polymer fibers of the first and
second components may be completed by needling instead of heat
bonding. This can lower the cost of the blanket 10. Further, the
use of the polymer fibers allows the subsequent molding of the
blanket to a desired shape without adding additional binder
materials when desired. In addition, a blanket 10 including rotary
glass fibers of fine diameter for enhanced thermal properties and
longer glass fibers for structural properties bond together by
needling allows efficient, in-line production of a lower cost, high
temperature insulation product.
[0022] If desired, the blanket 10 may be subjected to a surface
treatment of a type as described in U.S. Pat. No. 6,669,265 to
Tilton et al or U.S. Pat. No. 7,128,561 to Rockwell et al. Such a
treatment serves to densify the surface, locking in the fibers.
Thus, the surface is smoother and more resistant to fraying, making
the blanket 10 easier to handle during installation.
[0023] It should be appreciated that the insulation blanket 10 is
particularly useful in insulating various components including but
not limited to electric and kitchen appliances such as dishwashers,
clothes washers, clothes dryers, water heaters, coffee makers,
toasters, vacuum cleaners and the like. As illustrated in FIG. 1
the insulation blanket 10 may be wrapped around the housing 32 of a
dishwasher 30 adapted for mounting in space S under a counter C. As
illustrated the dishwasher 30 includes a housing 32 including both
a washing chamber 34 and a door 36 for gaining access to the
washing chamber. A washing nozzle or cleaning element 38 in the
washing chamber 34 directs a fluid stream against dishes held in
the washing chamber. A circulation pump 40 circulates that fluid
under pressure through the washing nozzle 38.
[0024] Reference is now made to Table 1 in order to illustrate the
enhanced acoustical insulating properties of the blanket 10 of the
present invention compared to a typical cotton shoddy and a typical
100% polyester insulator of the prior art.
TABLE-US-00001 Absorption Coefficient 3/4'' 3.2 lb/cu.ft. 3/4'' 3.2
lb/cu.ft. 3/4'' 3.2 lb/cu.ft. frequency Typical Typical Polyester
Glass-PET Blend (Hz) Cotton Shoddy Fiber Product (per this
invention) 100 0.01 0.00 0.00 125 0.02 0.00 0.01 160 0.03 0.00 0.01
200 0.04 0.01 0.03 250 0.04 0.02 0.05 315 0.06 0.04 0.08 400 0.09
0.07 0.14 500 0.12 0.09 0.19 630 0.16 0.15 0.28 800 0.21 0.23 0.40
1000 0.27 0.33 0.52 1250 0.36 0.44 0.64 1600 0.48 0.56 0.76 2000
0.57 0.68 0.84 2500 0.70 0.78 0.90 3150 0.83 0.87 0.93 4000 0.93
0.93 0.95 5000 0.98 0.95 0.95 6300 0.98 0.92 0.95
[0025] The table lists the absorption coefficients for the various
frequencies listed. Frequency is given in Hertz (Hz) and the
absorption coefficients represent how effective the materials are
at absorbing sound for the given frequencies. The absorption
coefficient values range from 0 (no sound absorption) to 1.0 where
100% of the sound is absorbed. In reality it is not possible for a
material to have an absorption coefficient value greater than 1.0
although sound measurements can sometimes register values greater
than 1.0 due to material edge effects.
[0026] As should be appreciated, the blanket 10 of the present
invention provides superior acoustic performance to the prior art
cotton shoddy and 100% polyester fiber products of identical
densities and thicknesses at all frequencies from 250 Hz to 4,000
Hz. The most significant improvement is provided in the important
range from between 800 to 1600 Hz. This is the range of the human
voice and highest sensitivity of human hearing.
[0027] The foregoing description of preferred embodiments of the
invention has been presented for purposes of illustration and
description. It is not intended to be exhaustive or to limit the
invention to the precise form disclosed. Obvious modifications or
variations are possible in light of the above teachings. The
embodiments were chosen and described to provide the best
illustration of the principles of the invention and its practical
application to thereby enable one or ordinary skill in the art to
utilize the invention in various embodiments and with various
modifications as is suited a particular use contemplated. All such
modifications and variations are within the scope of the invention
as determined by the appended claims when interpreted in accordance
with the breadth to which they are fairly, legally and equitably
entitled.
* * * * *