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Coated fibrous nodules and insulation product

a technology of applied in the field of coated fibrous nodules and insulation products, can solve the problems of slowing down the installation process, affecting the installation process,

Inactive Publication Date: 2008-01-03
JOHNS MANVILLE CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

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.
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.
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.
However, the moisture content of the insulation soon after installation typically remains relatively high, for example, as much as 15% water or more.
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.
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.
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.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

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 ¼ inch. A majority of the nodules had a maximum dimension of ½ inch or less. The glass fibers had an average diameter of 2.0 microns and contained B2O3 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® 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 ...

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 2Installation Using a Nozzle Position Two Feet from the CavitySample 8Sample 5Sample 6Sample 7(2 by 6 in,(2 by 4 in,(2 by 4 in,(2 by 6 in,2416 in OC)24 in OC)16 in OC)in OC)Ratio of Binder Solution0.24–0.260.24–0.260.24–0.260.24–0.26to Dry NodulesJust-Installed Moisture,20–3020–3020–3020–30wt. %Just-installed Amount of1.0–1.51.5–2.31.5–2.32.4–3.6Water per Cavity,lbs / cavityInstallation Time,21323351sec / cavityDry Insulation Density,1.7–1.81.7.–1.81.7–1.81.7–1.8PCFR-value15152323

[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 nod...

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 3Installation Using a Reduced Nodule Flow RateSample 9Sample 10Sample 11Sample 12(2 by 4 in, 16(2 by 4 in, 24(2 by 6 in,(2 by 6 in, 24in OC)in OC)16 in OC)in OC)Ratio of Binder Solution to0.43–0.530.43–0.530.43–0.530.43–0.53Dry NodulesJust-Installed Moisture,45454545wt. %Just-installed Amount of1.21.91.93Water per Cavity,lbs / cavityInstallation Time,15202029sec / cavityDry Insulation Density,0.8–0.90.8–0.90.8–0.90.8–0.9PCFR-value13132020

[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 ...

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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.

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...

Claims

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Application Information

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IPC IPC(8): D02G3/00
CPCY10T428/2933E04B1/7604
Inventor FELLINGER, THOMAS JOHNFAY, RALPH MICHAELSMITH, JOHN BROOKS
Owner JOHNS MANVILLE CORP
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