EP1812639A2 - Fiber insulation blanket and method of manufacture - Google Patents
Fiber insulation blanket and method of manufactureInfo
- Publication number
- EP1812639A2 EP1812639A2 EP05825665A EP05825665A EP1812639A2 EP 1812639 A2 EP1812639 A2 EP 1812639A2 EP 05825665 A EP05825665 A EP 05825665A EP 05825665 A EP05825665 A EP 05825665A EP 1812639 A2 EP1812639 A2 EP 1812639A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- blanket
- fibers
- fiber
- cellulose
- adhesive
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 239000000835 fiber Substances 0.000 title claims abstract description 69
- 238000009413 insulation Methods 0.000 title description 11
- 238000000034 method Methods 0.000 title description 8
- 238000004519 manufacturing process Methods 0.000 title description 4
- 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
- 150000001642 boronic acid derivatives Chemical class 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 239000011491 glass wool Substances 0.000 description 3
- 238000011084 recovery Methods 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
- 238000010586 diagram Methods 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 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
- 239000000126 substance Substances 0.000 description 2
- 238000011282 treatment Methods 0.000 description 2
- 244000204900 Talipariti tiliaceum Species 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 230000008901 benefit Effects 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
- 230000001427 coherent effect Effects 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000000975 dye Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 238000000265 homogenisation Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 239000002304 perfume Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- -1 polyethylene Polymers 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 230000035899 viability Effects 0.000 description 1
Classifications
-
- 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
-
- 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
- D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/60—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
-
- 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
-
- 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
- E04B2001/7687—Crumble resistant fibrous blankets or panels using adhesives or meltable fibres
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.
- Figure 1 is a conceptual diagram of a process for forming a fiber insulation blanket in accordance with the teachings of this disclosure.
- Figure 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 homogeneous 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.
- 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.
- 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. Patents 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.
- liquid borates are applied directly to the fibers during mixing.
- 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.
- 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 0 C, a denier of approximately 6-15, and a length of approximately 25-51 millimeters.
- Such fibers may include KoS a® 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 0 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.
- RF Radio Frequency
- the blanket may then be formed using RF energy rather than prior art gas ovens. Such an RF process is far more efficient than 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 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.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Physics & Mathematics (AREA)
- Architecture (AREA)
- Acoustics & Sound (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Laminated Bodies (AREA)
Abstract
A fiber blanket formed with a blend of constituent fibers is disclosed. In one disclosed embodiment, a cellulose fiber blanket (125) is formed having a blend of cellulose fibers (105) comprising approximately 85-90% by weight cellulose, resilient fibers (110) comprising approximately 10% by weight, and the balance being adhesive plastic fibers (115). The fibers are then formed into a blanket (135) having an R-value at least 4.0 per inch.
Description
This application is submitted in the name of inventors Earl Stuart Douglass and Thomas Clifford Shutt.
SPECIFICATION
FIBER INSULATION BLANKET AND METHOD OF MANUFACTURE
RELATED APPLICATIONS
This application claims the priority date established by U.S. Patent Application serial no. 10/981,383, filed on November 3, 2004.
BACKGROUND
Field of the Disclosure
This disclosure relates generally to the composition and manufacture of paper fiber insulation products.
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 2x4 residential wall. This translates to a minimum R-value of 4.1 per inch and effectively prohibits the use of prior ait cellulose insulation products in the cities and counties where this code has been adopted.
BRIEF DESCRIPTION OF THE DRAWING FIGURES Figure 1 is a conceptual diagram of a process for forming a fiber insulation blanket in accordance with the teachings of this disclosure.
DETAILED DESCRIPTION
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.
Figure 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.
As will be described more fully below, in a preferred embodiment, fiber insulation blankets of the present disclosure comprise a preferably homogeneous 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. 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 into batts 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. Patents 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 2190C, a denier of approximately 6-15, and a length of approximately 25-51 millimeters. Such fibers may include KoS a® 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 1280C, 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 then be formed using RF energy rather than prior art gas ovens. Such an RF process is far more efficient than 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 :
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
1. A fiber blanket formed with a blend of constituent fibers comprising: cellulose fibers comprising approximately 85-90% by weight cellulose; resilient fibers comprising approximately 10% by weight; adhesive plastic fibers; and said constituent fibers being formed into a blanket having an R-value of at least 4.0 per inch.
2. The blanket of claim 1 , wherein said blend of constituent fibers comprises a blend by weight of 85% cellulose, 10% resilient fiber and 5% adhesive fiber.
3. The blanket of claim 1 , wherein said blend of constituent fibers comprise a blend of 89% cellulose fiber, 9% resilient fiber, and 2% adhesive fiber.
4. The blanket of claim 3, wherein the density of said blanket may be varied from 0.8 - 1.5 pounds per cubic foot.
5. The blanket of claim 1, wherein said cellulose fibers are treated (are treated) to provide fire retardant properties.
6. The blanket of claim 5, wherein said properties are provided using a liquid additive.
7. The blanket of claim 6, wherein said liquid additive include a liquid borate.
8. The blanket of claim 1, wherein said cellulose fibers are treated to provide mold resistance properties.
9. The blanket of claim 8, wherein said properties are provided using a liquid additive.
10. The blanket of claim 9, wherein said liquid additive include a liquid borate.
11. The blanket of claim 1, wherein said adhesive fibers contain a material permitting heating by induction.
12. The blanket of claim 11 , wherein said material comprises carbon.
13. The blanket of claim 1, wherein said adhesive fibers contain an additive permitting dielectric heating.
14. The blanket of claim 13, wherein said additive comprises a compound of the alkyl aryl sulfonate group.
15. The blanket of claim 13, wherein said additive comprises a compound of the alkyl aryl polyester alcohol group.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US98138304A | 2004-11-03 | 2004-11-03 | |
| PCT/US2005/039605 WO2006052581A2 (en) | 2004-11-03 | 2005-11-02 | Fiber insulation blanket and method of manufacture |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| EP1812639A2 true EP1812639A2 (en) | 2007-08-01 |
| EP1812639A4 EP1812639A4 (en) | 2010-05-05 |
Family
ID=36336983
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP05825665A Withdrawn EP1812639A4 (en) | 2004-11-03 | 2005-11-02 | Fiber insulation blanket and method of manufacture |
Country Status (2)
| Country | Link |
|---|---|
| EP (1) | EP1812639A4 (en) |
| WO (1) | WO2006052581A2 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109778427B (en) * | 2019-01-28 | 2022-01-28 | 上海佳声毡业有限责任公司 | Production method of low-odor non-woven material for automobile |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4442095A (en) * | 1982-12-27 | 1984-04-10 | Merck & Co., Inc. | N-[(5-Halo-2,6-(substituted)pyrazinyl)methylene]amine antimicrobial compounds, compositions and use |
| PL181720B1 (en) * | 1994-12-21 | 2001-09-28 | Cabot Corp | Composite material, method of producing the composite material and method of producing heat insulation, sound insulation and/or adsorption material for gases, vapors and liquids PL PL PL PL PL PL |
| US5491186A (en) * | 1995-01-18 | 1996-02-13 | Kean; James H. | Bonded insulating batt |
| US5534301A (en) * | 1995-05-10 | 1996-07-09 | Echochem International, Inc. | Method for producing cellulose insulation materials using liquid fire retardant compositions |
| US6867154B1 (en) * | 1998-04-20 | 2005-03-15 | Southern Mills, Inc. | Patterned, flame resistant fabrics and method for making same |
| US6025027A (en) * | 1999-04-26 | 2000-02-15 | Mountain Develpoment | Method for producing cellulose insulation materials using liquid borate fire retardant compositions |
| JP3656732B2 (en) * | 2000-04-21 | 2005-06-08 | 日産自動車株式会社 | Energy conversion fiber and sound absorbing material |
-
2005
- 2005-11-02 WO PCT/US2005/039605 patent/WO2006052581A2/en not_active Ceased
- 2005-11-02 EP EP05825665A patent/EP1812639A4/en not_active Withdrawn
Non-Patent Citations (2)
| Title |
|---|
| No further relevant documents disclosed * |
| See also references of WO2006052581A2 * |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2006052581A3 (en) | 2006-11-23 |
| EP1812639A4 (en) | 2010-05-05 |
| WO2006052581A2 (en) | 2006-05-18 |
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