US20070202771A1 - Fiber insulation blanket and method of manufacture - Google Patents
Fiber insulation blanket and method of manufacture Download PDFInfo
- Publication number
- US20070202771A1 US20070202771A1 US11/743,050 US74305007A US2007202771A1 US 20070202771 A1 US20070202771 A1 US 20070202771A1 US 74305007 A US74305007 A US 74305007A US 2007202771 A1 US2007202771 A1 US 2007202771A1
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- blanket
- fibers
- fiber
- cellulose
- adhesive
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- 239000000835 fiber Substances 0.000 title claims abstract description 68
- 238000009413 insulation Methods 0.000 title description 10
- 238000000034 method Methods 0.000 title description 7
- 238000004519 manufacturing process Methods 0.000 title description 3
- 239000000853 adhesive Substances 0.000 claims abstract description 23
- 230000001070 adhesive effect Effects 0.000 claims abstract description 23
- 239000000203 mixture Substances 0.000 claims abstract description 20
- 229920003043 Cellulose fiber Polymers 0.000 claims abstract description 18
- 239000000470 constituent Substances 0.000 claims abstract description 13
- 229920002678 cellulose Polymers 0.000 claims abstract description 9
- 239000001913 cellulose Substances 0.000 claims abstract description 9
- 239000004033 plastic Substances 0.000 claims abstract description 8
- 229920003023 plastic Polymers 0.000 claims abstract description 8
- 239000007788 liquid Substances 0.000 claims description 12
- 239000000654 additive Substances 0.000 claims description 9
- 239000000463 material Substances 0.000 claims description 9
- 238000010438 heat treatment Methods 0.000 claims description 6
- 229920000728 polyester Polymers 0.000 claims description 5
- 150000001875 compounds Chemical class 0.000 claims description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 2
- 125000003158 alcohol group Chemical group 0.000 claims description 2
- 125000002877 alkyl aryl group Chemical group 0.000 claims description 2
- 150000008055 alkyl aryl sulfonates Chemical group 0.000 claims description 2
- 229910052799 carbon Inorganic materials 0.000 claims description 2
- 239000003063 flame retardant Substances 0.000 claims description 2
- 230000006698 induction Effects 0.000 claims description 2
- 230000000996 additive effect Effects 0.000 claims 7
- BTBUEUYNUDRHOZ-UHFFFAOYSA-N Borate Chemical compound [O-]B([O-])[O-] BTBUEUYNUDRHOZ-UHFFFAOYSA-N 0.000 claims 2
- 239000000047 product Substances 0.000 description 6
- 230000008569 process Effects 0.000 description 5
- 230000006835 compression Effects 0.000 description 4
- 238000007906 compression Methods 0.000 description 4
- 238000011084 recovery Methods 0.000 description 4
- 150000001642 boronic acid derivatives Chemical class 0.000 description 3
- 239000011491 glass wool Substances 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
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- 238000002156 mixing Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
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- 238000011282 treatment Methods 0.000 description 2
- 244000204900 Talipariti tiliaceum Species 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 1
- 239000004327 boric acid Substances 0.000 description 1
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- 239000000975 dye Substances 0.000 description 1
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- 239000012467 final product Substances 0.000 description 1
- 238000000265 homogenisation Methods 0.000 description 1
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- 239000012774 insulation material Substances 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
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Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/7654—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings
- E04B1/7658—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres
- E04B1/7662—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings comprising fiber insulation, e.g. as panels or loose filled fibres comprising fiber blankets or batts
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/04—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4326—Condensation or reaction polymers
- D04H1/435—Polyesters
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
- D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2475—Coating or impregnation is electrical insulation-providing, -improving, or -increasing, or conductivity-reducing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2631—Coating or impregnation provides heat or fire protection
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2631—Coating or impregnation provides heat or fire protection
- Y10T442/2664—Boron containing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2762—Coated or impregnated natural fiber fabric [e.g., cotton, wool, silk, linen, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2861—Coated or impregnated synthetic organic fiber fabric
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2926—Coated or impregnated inorganic fiber fabric
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/697—Containing at least two chemically different strand or fiber materials
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/697—Containing at least two chemically different strand or fiber materials
- Y10T442/698—Containing polymeric and natural strand or fiber materials
Definitions
- This disclosure relates generally to the composition and manufacture of paper fiber insulation products.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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 .
- 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 .
- a forming head in conjunction with a thermal bonding oven is suitable for this type of non-woven process.
- the blanket 135 may then be formed into batts 140 of a desired size as required.
- a fiber blanket is formed by using 85-90% by weight cellulose fibers with the resilient and adhesive plastic fibers comprising the balance.
- a blend by weight of 75% cellulose, 20% resilient fiber and 5% adhesive fiber is used.
- a blend by weight of 85% cellulose, 10% resilient fiber and 5% adhesive fiber is used.
- a blend by weight of about 89% cellulose, 9% resilient fibers and 2% adhesive fibers will produce the same physical properties at lower cost.
- 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.
- the cellulose fibers may be treated to provide fire retardant or mold resistance properties.
- 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.
- 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° C., a denier of approximately 6-15, and a length of approximately 25-51 millimeters.
- Such fibers may include, KoSa® types 209 or 210 or equivalents.
- 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.
- adhesive plastic fiber that comprises a polyester core and an activated co-polyethylene sheath.
- the sheath preferably has a melting point of no more than 128° C., and a denier of not more than 3 to promote as complete dispersal and homogenization of the fibers as possible.
- 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® types 254 or 255 Celbond® Bicomponent Fiber or equivalents.
- the adhesive fibers typically are heated to adhere and form a blanket.
- the adhesive fibers may be treated with material that would allow the use of Radio Frequency (RF) heating.
- 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.
- 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.
- a blend of 85% cellulose fiber, 10% resilient fiber, and 5% adhesive fiber was used.
- a blend of 89% cellulose fiber, 9% resilient fiber, and 2% adhesive fiber In a second exemplary composition, a blend of 89% cellulose fiber, 9% resilient fiber, and 2% adhesive fiber.
- the resilient fiber comprised the KoSa Type 210
- the adhesive fiber comprised the KoSa Type 255, as disclosed above.
- 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.
Abstract
Description
- 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.
- 1. Field of the Disclosure
- This disclosure relates generally to the composition and manufacture of paper fiber insulation products.
- 2. The Prior Art
- Background
- 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.
- 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.
- 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.
- Recently adopted building codes throughout the US have set a minimum of R-15 insulation within a 2×4 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.
- FIG. 1 is a conceptual diagram of a process for forming a fiber insulation blanket in accordance with the teachings of this disclosure.
- 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.
- 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 intowers head 120 for shaping. - 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.
- The blended
fibers 121 are then deposited onto the surface of a wire, typically a slotted conveyor belt, thereby forming afiber blanket 125. Theblanket 125 is then transported to a thermal formingstation 130. - 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. - The
blanket 135 may then be formed intobatts 140 of a desired size as required. - 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.
- 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.
- More details of exemplary constituent fibers suitable for use in this disclosure will now be disclosed.
- 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.
- 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.
- 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.
- 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° C., a denier of approximately 6-15, and a length of approximately 25-51 millimeters. Such fibers may include, KoSa® types 209 or 210 or equivalents.
- 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.
- 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° 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® types 254 or 255 Celbond® Bicomponent Fiber or equivalents.
- 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.
- 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.
- Examples of non-woven formulas and compositions will now be disclosed.
- In a first exemplary composition, a blend of 85% cellulose fiber, 10% resilient fiber, and 5% adhesive fiber was used.
- In a second exemplary composition, a blend of 89% cellulose fiber, 9% resilient fiber, and 2% adhesive fiber.
- In both examples, the resilient fiber comprised the KoSa Type 210, and the adhesive fiber comprised the KoSa Type 255, as disclosed above.
- 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.
- The results are presented in Table 1:
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) - 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.
Claims (15)
Priority Applications (1)
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US11/743,050 US20070202771A1 (en) | 2005-11-02 | 2007-05-01 | Fiber insulation blanket and method of manufacture |
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PCT/US2005/039605 WO2006052581A2 (en) | 2004-11-03 | 2005-11-02 | Fiber insulation blanket and method of manufacture |
US11/743,050 US20070202771A1 (en) | 2005-11-02 | 2007-05-01 | Fiber insulation blanket and method of manufacture |
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PCT/US2005/039605 Continuation WO2006052581A2 (en) | 2004-11-03 | 2005-11-02 | Fiber insulation blanket and method of manufacture |
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US11/743,050 Abandoned US20070202771A1 (en) | 2005-11-02 | 2007-05-01 | Fiber insulation blanket and method of manufacture |
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Cited By (5)
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US20090163102A1 (en) * | 2006-10-04 | 2009-06-25 | Sellars Absorbent Materials, Inc. | Non-woven webs and methods of manufacturing the same |
US8388807B2 (en) | 2011-02-08 | 2013-03-05 | International Paper Company | Partially fire resistant insulation material comprising unrefined virgin pulp fibers and wood ash fire retardant component |
US8663427B2 (en) | 2011-04-07 | 2014-03-04 | International Paper Company | Addition of endothermic fire retardants to provide near neutral pH pulp fiber webs |
US8685206B2 (en) | 2010-08-03 | 2014-04-01 | International Paper Company | Fire retardant treated fluff pulp web and process for making same |
US8973762B2 (en) | 2006-10-04 | 2015-03-10 | Sellars Absorbent Materials, Inc. | Industrial absorbents and methods of manufacturing the same |
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