CA2481288A1 - Apparatus for installation of loose fill insulation and applicator assembly - Google Patents
Apparatus for installation of loose fill insulation and applicator assembly Download PDFInfo
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- CA2481288A1 CA2481288A1 CA002481288A CA2481288A CA2481288A1 CA 2481288 A1 CA2481288 A1 CA 2481288A1 CA 002481288 A CA002481288 A CA 002481288A CA 2481288 A CA2481288 A CA 2481288A CA 2481288 A1 CA2481288 A1 CA 2481288A1
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- discrete elements
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- 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A30/00—Adapting or protecting infrastructure or their operation
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- 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B30/00—Energy efficient heating, ventilation or air conditioning [HVAC]
- Y02B30/90—Passive houses; Double facade technology
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Abstract
An apparatus for installation of a material having discrete elements. The apparatus includes a supply of material having discrete elements and an applicator assembly for activating a substantially water-free adhesive far providing structure to the material having discrete elements during installation. In the preferred embodiment, the applicator assembly includes a material nozzle having an inlet for receiving the material and an outlet for discharging a material stream to a surface; and an adhesive applicator adjacent to the material nozzle for activating a substantially water-gee adhesive to provide structure to the material having discrete elements during installation. Also, in the preferred embodiment, the adhesive applicator includes at least one impinging nozzle and at least one tacking nozzle. The apparatus may further include a transporter system downstream of the supply of material having discrete elements for delivery of the material to the applicator assembly.
Description
APPARATUS FOR INSTALLATION OF LOOSE FILL
INSULATION AND APPLICATOR ASSEMBLY
Background of the Inyention S
This application is related to Canadian Patent File number 2,453,798 fled December 19, 2003, pending.
(1) Field of the invention The present invention relates generally to an apparatus for the installation of insulation and, more particularly, to an applicator assembly for an apparatus for the installation of insulation.
INSULATION AND APPLICATOR ASSEMBLY
Background of the Inyention S
This application is related to Canadian Patent File number 2,453,798 fled December 19, 2003, pending.
(1) Field of the invention The present invention relates generally to an apparatus for the installation of insulation and, more particularly, to an applicator assembly for an apparatus for the installation of insulation.
(2) Description of the Prior Art Z 5 Insulation is used in residential and commercial dwellings both to conserve energy and to reduce noise. The two most Gammon types of insulation are blown and batt. Blown insulation may be made from several lightweight natural or man-made materials. Batt insulation is most commonly made from fiberglass. Blown loose fill insulation is most often used for attic floors since the insulation is less expensive and more quickly installed with lower labor costs and still allows access to wiring, etc.
Fiberglass batting is still preferred for non-horizontal and floor insulation since the batting holds the fiberglass in place. The fiberglass batting is applied in the cavity formed by vertical wall studs, an outer wall, a bottom sill and a top plate.
Once the batt is fixed in position, a vapor barrier may be mounted over the insulated wall. Dry wall or other inner wall material is then mounted to the studs to complete the inner wall.
While loose fill insulation is more difficult to install in a non-horizontal wall, it may still be blown or sprayed within the stud cavity. Typically, the blown insulation is an aggregate of insulation particles mixed with dry adhesive, which is activated by a s~4zi.ao~
l water spray. However, since the insulation is loose and ilowable, it is necessary to retain the insulation in position prior to inserting the insulation in the wall cavity and/or prior to installation of the supporting skeletal wall.
One method was to utilize a perforated screen that was attached along the lower portion of the wall and moved upward as each section was completed. The perforated screen allowed the air being used to blow the insulation in place to escape but retained the loose fill insulation in place to allow the insulation to fall up behind the screen, dry and the water-based adhesive to set. This method has a number of drawbacks.
First, it takes more time to put up the screening and more skilled labor than stapling up a batt of fiberglass. Also, there may be a substantial time delay in waiting for each section of insulation to dry and set before being able to move the screen to install the next section.
Another method was to utilize a plastic membrane to blow the loose insulation behind the membrane in the wall cavity. The insulation would then be tapped and packed in an effort to prevent future settling. Once the insulation was installed, the shield I S membrane was removed and dry wall or other wall materials could be applied to form the inner wall. This method had disadvantages, as well, because it required additional time delays and manpower to maintain the shield plate in position during installation of the insulation. .
Still another method utilizes a netting material affixed to the wall studs to form an inner wall during the installation of the insulation. The netting is attached from floor to ceiling and forms a retaining barrier for the loose insulation to be blown in behind the netting. A hole was cut into the netting in order to receive the nozzle for delivery of insulation. Like the screen system, the netting permitted the air displaced by the positioned insulation to escape during the installation process. This method still has several disadvantages. For example, like the screen and membrane systems, the time involved with installing the retaining net is labor intensive and may not be easily done by just one person working alone. Also, once blown, density discrepancies throughout the blown matrix are set, resulting in inconsistent thermal and acoustic properties.
s~aai.ao~
As can be appreciated, blowing Loose insulation material mixed with water and adhesive tends to be very messy and labor intensive in terms of cleanup. For example, the blow in methods very often cause insulation material to stick to the outer surface of the wall studs causing additional labor time to clean the stud face, in addition to requiring a separate supply of water on the job site for the application process. It has also been difficult to apply the material to a substrate with a suitable amount of adhesion to the substrate, and at the same time, a suitable amount of infra-material bond strength. Such adhesion is necessary to prevent inconsistent R values for the installation of the wall because of increased installed density of the insulation.
Thus, there remains a need for a new and improved apparatus for installation of a material having discrete elements, such as blown cellulosic or fiberglass insulation, which does not require netting to hold the material in place during installation while, at the same time, includes a substantially water-free adhesive for providing structure to the material during installation.
Summary of the Invention The present invention is directed to an apparatus f~r installation of a material having discrete elements. The apparatus includes a supply of material having discrete elements and an applicator assembly for activating a substantially water-free adhesive for providing structure to the material having discrete elements during installation. In the preferred embodiment, the applicator assembly includes a material nozzle having an inlet for receiving the material and an outlet for discharging a material stream to a surface; and an adhesive applicator adjacent to the material nozzle for activating a substantially water-free adhesive to provide structure to the material having discrete elements during installation. Also, in the preferred embodiment, the adhesive applicator includes at least one impinging nozzle and at least one tacking nozzle. The apparatus may further include a transporter system downstream of the supply of material having discrete elements for delivery of the material to the applicator assembly.
57421.doc The material nozzle has a substantially oval cross-section and feeds material between the other nozzles, which mix adhesive into the material stream and provide additional adhesive to tack the material to a surface. The preferred angle of the impinging nozzle is between about 0 degrees and +90 degrees with respect to the material stream. More preferably, the angle is between about +10~ degrees and 40 degrees with about +20 degrees being most preferred. Also, in the preferred embodiment, the applicator includes at least two impinging nozzles.
The angle of the tacking nozzle is preferably betyc~een about -90 degrees and +90 degrees with respect to the material stream. More preferably, the angle is between about -15 and +1 S degrees with about +1 S degrees being most preferred.
The apparatus may further include a supply of adhesive material. The supply adhesive material includes a hot melt adhesive and a heater assembly. The hot melt adhesive is preferably a thermoplastic adhesive. Also, the heater assembly may further include a temperature control device.
In the preferred embodiment, the transporter system includes a conduit with an inlet and outlet; and an air supply to move the material having discrete elements through the conduit. The transporter system may further include a debailer for debailing bundles of the material having discrete elements.
The supply of material having discrete elements preferably includes at least one selected from the group consisting of fibrous material, granular material, pellet materials agglomerated material, and/or aggregated material. In one embodiment, the supply of material having discrete elements is inorganic. The inorganic material may include at least one selected from the group consisting of fiberglass, rock wool, pearlite, mineral wool, and asbestos. In another embodiment, the supply ofmaterial having discrete elements is organic. The organic material may be a natural material and, preferably, the natural material is cellulosic. Also, in the preferred embodiment, the supply of material having discrete elements is a non-conductive material. Specifically, the supply of non-57421.doc conductive material may be a thermally non-conductive material, an acoustically non-conductive material and/or an electrically non-conductive material.
Accordingly, one aspect of the present invention is to provide an apparatus for installation of a material having discrete elements, the apparatus including:
a supply of material having discrete elements; and an applicator assembly for activating a substantially water-free adhesive for providing structure to the material having discrete elements during installation wherein the applicator includes at least one impinging fluid nozzle converging with the material stream.
Another aspect of the present invention is to provide an applicator assembly for a device for installation of a supply of material having discrete elements, the apparatus including: a material nozzle having an inlet for receiving the material and an outlet for discharging a material stream to a surface; and an adhesive applicator adjacent to the material nozzle for activating a substantially water-free adhesive to provide structure to the material having discrete elements during installation, the adhesive applicator including: (i) at least one impinging nozzle, and (ii) at least one tacking nozzle.
Still another aspect of the present invention is to provide an apparatus for installation of a material having discrete elements, the apparatus including:
a supply of material having discrete elements; an applicator assembly for activating a substantially water-free adhesive for providing structure to the material having discrete elements during installation wherein the applicator assembly includes: a material nozzle having an inlet for receiving the material and an outlet for discharging a material stream to a surface; and an adhesive applicator adjacent to the material nozzle for activating a substantially water-free adhesive to provide structure to the material having discrete elements during installation, the adhesive applicator including: (i) at least one impinging nozzle, and (ii) at least one tacking nozzle; and a transporter system downstream of the supply of material having discrete elements for delivery of the material to the applicator assembly.
s~aat.aoo These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.
S Brief Description of the Drawin .mss Figure 1 is a schematic diagram illustrating an apparatus for installation of a material having discrete elements, such as loose fill insulation, constructed according to the present invention;
Figure 2 is a perspective view of an operator using the apparatus to install loose fill insulation into an open wall cavity;
Figure 3 is an enlarged side view of the adhesive applicator of Figure 2;
Figure 4 is a top view of the adhesive applicator of Figures 2 and 3;
Figure 5 is an enlarged front view of the material nozzle and adhesive applicator;
Figure 6 is a schematic diagram of an adhesive nozzle such as the impinging I S nozzles and tacking nozzles showing the adhesive and airflow through the nozzle;
Figure ? is a graph depicting the Weight Percent of Material Adhered as a function of the Number of the Impinging Nozzle Angle;
Figure 8 is a graph depicting the Infra-material Bond Strength versus the Impinging Nozzle Angle; and Figure 9 is a graph depicting the Optimum Angle of the Impinging Nozzles Combined with the Effect of the Tackifying Nozzles.
Descriation of the Preferred Embodiments In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as "forward;" "rearward,'" "left," "right,"
°'upwardly,"
"downwardly," and the like are words of convenience and are pat to be construed as 57421.doc limiting terms. A positive flow angle is considered to be towards the direction of the axis of material flow and a negative angle is away from the direction of material flow.
Referring now to the drawings in general and Figure 1 in particular, it will be understood that the illustrations are for the purpose of describing an embodiment of the invention and are not intended to limit the invention thereto. As best seen in Figure 1, an apparatus for installation of insulation material, generally designated 10, is shown constructed according to the present invention. The insulation apparatus 10 includes a supply of insulation material having discrete elements 12, an applicator assembly 14, and a transporter system 16. Figure 1 also shows a supply of thermoplastic hot melt adhesive material 130 and a heater assembly 160 for heating the supply of adhesive material 130.
A temperature control device 140 may be connected to the heater assembly 160 and the applicator assembly 100 to control the temperature of the adhesive during application. A
device far containing the supply of adhesive and transporting adhesive to the applicator assembly 14 is available from Sure Tack Systems, Crist Co., Inc., 201 F Bell Place, 1 S Woodstock, GA 30188-1672.
The supply of insulation material having discrete elements 12 may include at least one selected from the group consisting of fibrous material, granular material, pellet material, agglomerated material, and/or aggregated material. The supply may be any combination of fibrous material, granular material, pellet material,, agglomerated material and/or. aggregated material. The insulation material 12 may be inorganic, including natural inorganic and synthetic inorganic materials. For example, the inorganic insulation material may be at least one selected from the group consisting of fiberglass, rock wool, pearlite, mineral wool, and asbestos. The supply of material may include organic materials, including natural organic and. synthetic organic materials.
The supply of material may include cellulose, polystyrene or polyurethane. The supply of insulation material also may be an organic insulation material such as a natural cellulosic material.
The material may include any combination of organic, inorganic, synthetic, oar natural materials.
s~4ai.ao~
Fiberglass batting is still preferred for non-horizontal and floor insulation since the batting holds the fiberglass in place. The fiberglass batting is applied in the cavity formed by vertical wall studs, an outer wall, a bottom sill and a top plate.
Once the batt is fixed in position, a vapor barrier may be mounted over the insulated wall. Dry wall or other inner wall material is then mounted to the studs to complete the inner wall.
While loose fill insulation is more difficult to install in a non-horizontal wall, it may still be blown or sprayed within the stud cavity. Typically, the blown insulation is an aggregate of insulation particles mixed with dry adhesive, which is activated by a s~4zi.ao~
l water spray. However, since the insulation is loose and ilowable, it is necessary to retain the insulation in position prior to inserting the insulation in the wall cavity and/or prior to installation of the supporting skeletal wall.
One method was to utilize a perforated screen that was attached along the lower portion of the wall and moved upward as each section was completed. The perforated screen allowed the air being used to blow the insulation in place to escape but retained the loose fill insulation in place to allow the insulation to fall up behind the screen, dry and the water-based adhesive to set. This method has a number of drawbacks.
First, it takes more time to put up the screening and more skilled labor than stapling up a batt of fiberglass. Also, there may be a substantial time delay in waiting for each section of insulation to dry and set before being able to move the screen to install the next section.
Another method was to utilize a plastic membrane to blow the loose insulation behind the membrane in the wall cavity. The insulation would then be tapped and packed in an effort to prevent future settling. Once the insulation was installed, the shield I S membrane was removed and dry wall or other wall materials could be applied to form the inner wall. This method had disadvantages, as well, because it required additional time delays and manpower to maintain the shield plate in position during installation of the insulation. .
Still another method utilizes a netting material affixed to the wall studs to form an inner wall during the installation of the insulation. The netting is attached from floor to ceiling and forms a retaining barrier for the loose insulation to be blown in behind the netting. A hole was cut into the netting in order to receive the nozzle for delivery of insulation. Like the screen system, the netting permitted the air displaced by the positioned insulation to escape during the installation process. This method still has several disadvantages. For example, like the screen and membrane systems, the time involved with installing the retaining net is labor intensive and may not be easily done by just one person working alone. Also, once blown, density discrepancies throughout the blown matrix are set, resulting in inconsistent thermal and acoustic properties.
s~aai.ao~
As can be appreciated, blowing Loose insulation material mixed with water and adhesive tends to be very messy and labor intensive in terms of cleanup. For example, the blow in methods very often cause insulation material to stick to the outer surface of the wall studs causing additional labor time to clean the stud face, in addition to requiring a separate supply of water on the job site for the application process. It has also been difficult to apply the material to a substrate with a suitable amount of adhesion to the substrate, and at the same time, a suitable amount of infra-material bond strength. Such adhesion is necessary to prevent inconsistent R values for the installation of the wall because of increased installed density of the insulation.
Thus, there remains a need for a new and improved apparatus for installation of a material having discrete elements, such as blown cellulosic or fiberglass insulation, which does not require netting to hold the material in place during installation while, at the same time, includes a substantially water-free adhesive for providing structure to the material during installation.
Summary of the Invention The present invention is directed to an apparatus f~r installation of a material having discrete elements. The apparatus includes a supply of material having discrete elements and an applicator assembly for activating a substantially water-free adhesive for providing structure to the material having discrete elements during installation. In the preferred embodiment, the applicator assembly includes a material nozzle having an inlet for receiving the material and an outlet for discharging a material stream to a surface; and an adhesive applicator adjacent to the material nozzle for activating a substantially water-free adhesive to provide structure to the material having discrete elements during installation. Also, in the preferred embodiment, the adhesive applicator includes at least one impinging nozzle and at least one tacking nozzle. The apparatus may further include a transporter system downstream of the supply of material having discrete elements for delivery of the material to the applicator assembly.
57421.doc The material nozzle has a substantially oval cross-section and feeds material between the other nozzles, which mix adhesive into the material stream and provide additional adhesive to tack the material to a surface. The preferred angle of the impinging nozzle is between about 0 degrees and +90 degrees with respect to the material stream. More preferably, the angle is between about +10~ degrees and 40 degrees with about +20 degrees being most preferred. Also, in the preferred embodiment, the applicator includes at least two impinging nozzles.
The angle of the tacking nozzle is preferably betyc~een about -90 degrees and +90 degrees with respect to the material stream. More preferably, the angle is between about -15 and +1 S degrees with about +1 S degrees being most preferred.
The apparatus may further include a supply of adhesive material. The supply adhesive material includes a hot melt adhesive and a heater assembly. The hot melt adhesive is preferably a thermoplastic adhesive. Also, the heater assembly may further include a temperature control device.
In the preferred embodiment, the transporter system includes a conduit with an inlet and outlet; and an air supply to move the material having discrete elements through the conduit. The transporter system may further include a debailer for debailing bundles of the material having discrete elements.
The supply of material having discrete elements preferably includes at least one selected from the group consisting of fibrous material, granular material, pellet materials agglomerated material, and/or aggregated material. In one embodiment, the supply of material having discrete elements is inorganic. The inorganic material may include at least one selected from the group consisting of fiberglass, rock wool, pearlite, mineral wool, and asbestos. In another embodiment, the supply ofmaterial having discrete elements is organic. The organic material may be a natural material and, preferably, the natural material is cellulosic. Also, in the preferred embodiment, the supply of material having discrete elements is a non-conductive material. Specifically, the supply of non-57421.doc conductive material may be a thermally non-conductive material, an acoustically non-conductive material and/or an electrically non-conductive material.
Accordingly, one aspect of the present invention is to provide an apparatus for installation of a material having discrete elements, the apparatus including:
a supply of material having discrete elements; and an applicator assembly for activating a substantially water-free adhesive for providing structure to the material having discrete elements during installation wherein the applicator includes at least one impinging fluid nozzle converging with the material stream.
Another aspect of the present invention is to provide an applicator assembly for a device for installation of a supply of material having discrete elements, the apparatus including: a material nozzle having an inlet for receiving the material and an outlet for discharging a material stream to a surface; and an adhesive applicator adjacent to the material nozzle for activating a substantially water-free adhesive to provide structure to the material having discrete elements during installation, the adhesive applicator including: (i) at least one impinging nozzle, and (ii) at least one tacking nozzle.
Still another aspect of the present invention is to provide an apparatus for installation of a material having discrete elements, the apparatus including:
a supply of material having discrete elements; an applicator assembly for activating a substantially water-free adhesive for providing structure to the material having discrete elements during installation wherein the applicator assembly includes: a material nozzle having an inlet for receiving the material and an outlet for discharging a material stream to a surface; and an adhesive applicator adjacent to the material nozzle for activating a substantially water-free adhesive to provide structure to the material having discrete elements during installation, the adhesive applicator including: (i) at least one impinging nozzle, and (ii) at least one tacking nozzle; and a transporter system downstream of the supply of material having discrete elements for delivery of the material to the applicator assembly.
s~aat.aoo These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.
S Brief Description of the Drawin .mss Figure 1 is a schematic diagram illustrating an apparatus for installation of a material having discrete elements, such as loose fill insulation, constructed according to the present invention;
Figure 2 is a perspective view of an operator using the apparatus to install loose fill insulation into an open wall cavity;
Figure 3 is an enlarged side view of the adhesive applicator of Figure 2;
Figure 4 is a top view of the adhesive applicator of Figures 2 and 3;
Figure 5 is an enlarged front view of the material nozzle and adhesive applicator;
Figure 6 is a schematic diagram of an adhesive nozzle such as the impinging I S nozzles and tacking nozzles showing the adhesive and airflow through the nozzle;
Figure ? is a graph depicting the Weight Percent of Material Adhered as a function of the Number of the Impinging Nozzle Angle;
Figure 8 is a graph depicting the Infra-material Bond Strength versus the Impinging Nozzle Angle; and Figure 9 is a graph depicting the Optimum Angle of the Impinging Nozzles Combined with the Effect of the Tackifying Nozzles.
Descriation of the Preferred Embodiments In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as "forward;" "rearward,'" "left," "right,"
°'upwardly,"
"downwardly," and the like are words of convenience and are pat to be construed as 57421.doc limiting terms. A positive flow angle is considered to be towards the direction of the axis of material flow and a negative angle is away from the direction of material flow.
Referring now to the drawings in general and Figure 1 in particular, it will be understood that the illustrations are for the purpose of describing an embodiment of the invention and are not intended to limit the invention thereto. As best seen in Figure 1, an apparatus for installation of insulation material, generally designated 10, is shown constructed according to the present invention. The insulation apparatus 10 includes a supply of insulation material having discrete elements 12, an applicator assembly 14, and a transporter system 16. Figure 1 also shows a supply of thermoplastic hot melt adhesive material 130 and a heater assembly 160 for heating the supply of adhesive material 130.
A temperature control device 140 may be connected to the heater assembly 160 and the applicator assembly 100 to control the temperature of the adhesive during application. A
device far containing the supply of adhesive and transporting adhesive to the applicator assembly 14 is available from Sure Tack Systems, Crist Co., Inc., 201 F Bell Place, 1 S Woodstock, GA 30188-1672.
The supply of insulation material having discrete elements 12 may include at least one selected from the group consisting of fibrous material, granular material, pellet material, agglomerated material, and/or aggregated material. The supply may be any combination of fibrous material, granular material, pellet material,, agglomerated material and/or. aggregated material. The insulation material 12 may be inorganic, including natural inorganic and synthetic inorganic materials. For example, the inorganic insulation material may be at least one selected from the group consisting of fiberglass, rock wool, pearlite, mineral wool, and asbestos. The supply of material may include organic materials, including natural organic and. synthetic organic materials.
The supply of material may include cellulose, polystyrene or polyurethane. The supply of insulation material also may be an organic insulation material such as a natural cellulosic material.
The material may include any combination of organic, inorganic, synthetic, oar natural materials.
s~4ai.ao~
In one embodiment, the supply of insulation material 12 is a non-conductive insulation material. The non-conductive insulation material may be one or more of thermally non-conductive materials, acoustically non-conductive materials and electrically non-conductive materials. Also, in one embodiment, the supply of material having discrete elements is an absorptive material. Specifically the supply of absorptive material may be thermally absorptive, acoustically absorptive, electrically absorptive, and/or moisture absorptive. Combinations of various conductive, non-conductive, and absorptive properties are possible that maximize the desired performance of the installed material having discrete elements.
Referring to Figure 1, the transporter system 16 is shown. In the embodiment shown, the transporter system 16 includes a conduit 20 with an inlet and outlet, an air supply 26, and a debailer 30, The transporter system 16 transports the supply of insulation material 12 to the applicator assembly 14 to start the application process to the walls or ceilings requiring insulatian. The bags of insulation material 12 are opened by the debailer 30 and the air supply 26 provides an air stream to blow the insulation material 12 downstream in the conduit 20 to the applicator assembly 100.
The transporter system 16 may also be manually operated since an individual operator may open the bags of insulation material 12 by hand and manually place them within the applicator assembly 14 for application to the desired walls or ceilings.
Figure 2 is a perspective view of an operator using an apparatus for installation of a material having discrete elements, such as loose fill insulation, to install loose fill insulation into an open wall cavity. The operator is holding an applicator assembly 100, which includes a material nozzle 110 having an inlet 112 for receiving the material and an outlet 114 for applying said material to a surface; and an adhesive applicator 120 adjacent to the material nozzle 110 for applying a substantially water-free adhesive to provide structure to the material having discrete elements during installation.
Figure 3 is an enlarged side view of the adhesive applicator 120 surrounding the material nozzle outlet 114 showing two impinging nozzles 122, and a tacking nozzle 124 s~4zi.a~
Referring to Figure 1, the transporter system 16 is shown. In the embodiment shown, the transporter system 16 includes a conduit 20 with an inlet and outlet, an air supply 26, and a debailer 30, The transporter system 16 transports the supply of insulation material 12 to the applicator assembly 14 to start the application process to the walls or ceilings requiring insulatian. The bags of insulation material 12 are opened by the debailer 30 and the air supply 26 provides an air stream to blow the insulation material 12 downstream in the conduit 20 to the applicator assembly 100.
The transporter system 16 may also be manually operated since an individual operator may open the bags of insulation material 12 by hand and manually place them within the applicator assembly 14 for application to the desired walls or ceilings.
Figure 2 is a perspective view of an operator using an apparatus for installation of a material having discrete elements, such as loose fill insulation, to install loose fill insulation into an open wall cavity. The operator is holding an applicator assembly 100, which includes a material nozzle 110 having an inlet 112 for receiving the material and an outlet 114 for applying said material to a surface; and an adhesive applicator 120 adjacent to the material nozzle 110 for applying a substantially water-free adhesive to provide structure to the material having discrete elements during installation.
Figure 3 is an enlarged side view of the adhesive applicator 120 surrounding the material nozzle outlet 114 showing two impinging nozzles 122, and a tacking nozzle 124 s~4zi.a~
above the material nozzle outlet 114. The tacking nozzle 124 and impinging nozzles 122 are angled inward with respect to the flow of a material stream from the material nozzle outlet 114. Design and creation of nozzles to perform both impinging and tacking functions at the same time is possible.
Figure 4 is an enlarged top view of the adhesive applicator 120 showing a heater assembly 160 including a temperature control device 140, The temperature control device 140 may include a sensor electrically connected to the adhesive applicator 120 for controlling the temperature of the adhesive. The spray head assembly can be valued or unvalued with control toggles on the head. In one embodiment, the apparatus is valued at the head. The more preferred is valued for both the air and the adhesive at the head. In another embodiment the apparatus has controls for all materials and functions at the head.
Figure 5 is an enlarged front view of the material nozzle and adhesive applicator showing the substantially oval cross-section of the material nozzle 110 and the adhesive applicator 120 including two impinging nozzles 122. Different shapes of material nozzles can impact flow patterns, mixing efficiencies, material directions, and other product performances. The embodiment of the material nozzle shown includes a substantially oval cross-section, but other cross-sections of a circular, rectangular, triangular, or other regular or irregular geometric shapes, can be used to modify and enhance various properties of the apparatus. The angle of the impinging nozzles 122 is between about 0 degrees and +90 degrees witl' respect to 'the material stream.
Preferably, the angle is between about +10 degrees and +40 degrees with respect to the material stream. In the preferred embodiment of the invention, the angle is about +20 degrees with respect to the material stream.
Figure S also shows above the material nozzle 110 a tacking nozzle 124. The angle of the tacking nozzle 124 is between about -90 degrees and +90 degrees with respect to the material stream. Preferably, the angle is between about -15 and +15 degrees with +15 degrees meaning the tacking nozzle is angled inward toward the material stream +15 degrees. In the preferred embodiment of the invention, the angle of 57421.doc the tacking nozzle is about +i 0 degrees. Nozzles suitable for use as both impinging and tacking nozzles are available from Sure Tack Systems, Crist Co., Inc., 201 F
Bell Place, Woodstock, GA 30188-1672.
Figure 6 is a schematic diagram of an adhesive nozzle such as the impinging nozzles and tacking nozzles showing the adhesive and airflow through the nozzle. The nozzles receive pressurized air from an airline and adhesive from an adhesive line, both in communication with the nozzle. The adhesive stream i 80 flows through the interior of the nozzle while the pressurized air stream 190 flows outside and surrounding the adhesive stream 180.
Figure 7 is a graph depicting the Weight of Material Adhered as a function of the Impinging Nozzle Angle. The lines 1 through 5 represent the weight of material adhered using with 1 to 5 impinging nozzles, respectively. The weight of material adhered to the wall increases as the number of nozzles increases. It can also be seen that there is an optimum angle of glue application, around the preferred angel of +20 degrees to the flow of the material stream. It will be apparent to those skilled in the art that there are several interrelated variably such as increasing weight of the spray apparatus with increasing nozzle number that will have to be considered to reach the best overall performance.
Figure 8 is a graph depicting the Intra-Material Bond Strengthwersus the Impinging Nozzle Angle. The lines 1 through 5 represent the increase in infra-material bond strength as the number of impinging nozzles increases, with 5 representing 5 impinging nozzles. The desirability of increasing infra-material bond strength must be balanced with increasing glue weight and cost, and increasing apparatus weight and complexity. As the nozzle angle increases from 4 to +90 degrees, the nozzles point more into the material flow and the substantially water free adhesive is entirely entrained into the material matrix, with none of the substantially water free adhesive free for external binding to the wall. It will be apparent to those skilled in the art that different nozzle types and other variations can affect the relation of the variables in positive or negative fashion.
57421.doc Figure 9 is a depiction of the optimum angles of the impinging nozzles combined with the effect of the tackifying nozzles. On the left vertical axis, the Weight Percent of Material Adhered is shown, and the right vertical axis shows the Infra-Material Bond Strength. The horizontal axis shows the Impinging Nozzle Angle as in Figures 7 and 8.
Line A depicts the weight of material adhered using 3 nozzles as in Figure 7, and Line B
depicts the infra-material bond strength using 3 nozzles as in Figure 8. Line C depicts the effect of the use of a single tackifying nozzle in combination with two impinging nozzles.
There is a significant increase in the material adhered to the wall with the use of the combination nozzle setup as compared to the setup with three impinging nozzles only. It will be seen to those skilled in the art that some increase in intxa-material bond strength occurs by the addition of-the tackifying nozzle, but this makes up for the loss of one impinging nozzle. Thus Line D, which depicts the infra-material bond strength with the use of two impinging nozzles and one tackifying nozzle does not change significantly from the infra-material bond strength using three impinging nozzles.
Variations in air 1 S flow, air temperature, and material flow can all impact the results shown in Figures 7-9.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. By way of example, an anti-drool device can be used with the adhesive nozzles of the applicator to prevent adhesive from dripping out of the nozzles between installations of insulation. Also, the applicator assembly may be made from various materials and fitted with ergonomic handles, control switches, and the like. Similarly, the apparatus may be used with an insulating heat shield to protect an operator. All such modifications,and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.
57421.doc
Figure 4 is an enlarged top view of the adhesive applicator 120 showing a heater assembly 160 including a temperature control device 140, The temperature control device 140 may include a sensor electrically connected to the adhesive applicator 120 for controlling the temperature of the adhesive. The spray head assembly can be valued or unvalued with control toggles on the head. In one embodiment, the apparatus is valued at the head. The more preferred is valued for both the air and the adhesive at the head. In another embodiment the apparatus has controls for all materials and functions at the head.
Figure 5 is an enlarged front view of the material nozzle and adhesive applicator showing the substantially oval cross-section of the material nozzle 110 and the adhesive applicator 120 including two impinging nozzles 122. Different shapes of material nozzles can impact flow patterns, mixing efficiencies, material directions, and other product performances. The embodiment of the material nozzle shown includes a substantially oval cross-section, but other cross-sections of a circular, rectangular, triangular, or other regular or irregular geometric shapes, can be used to modify and enhance various properties of the apparatus. The angle of the impinging nozzles 122 is between about 0 degrees and +90 degrees witl' respect to 'the material stream.
Preferably, the angle is between about +10 degrees and +40 degrees with respect to the material stream. In the preferred embodiment of the invention, the angle is about +20 degrees with respect to the material stream.
Figure S also shows above the material nozzle 110 a tacking nozzle 124. The angle of the tacking nozzle 124 is between about -90 degrees and +90 degrees with respect to the material stream. Preferably, the angle is between about -15 and +15 degrees with +15 degrees meaning the tacking nozzle is angled inward toward the material stream +15 degrees. In the preferred embodiment of the invention, the angle of 57421.doc the tacking nozzle is about +i 0 degrees. Nozzles suitable for use as both impinging and tacking nozzles are available from Sure Tack Systems, Crist Co., Inc., 201 F
Bell Place, Woodstock, GA 30188-1672.
Figure 6 is a schematic diagram of an adhesive nozzle such as the impinging nozzles and tacking nozzles showing the adhesive and airflow through the nozzle. The nozzles receive pressurized air from an airline and adhesive from an adhesive line, both in communication with the nozzle. The adhesive stream i 80 flows through the interior of the nozzle while the pressurized air stream 190 flows outside and surrounding the adhesive stream 180.
Figure 7 is a graph depicting the Weight of Material Adhered as a function of the Impinging Nozzle Angle. The lines 1 through 5 represent the weight of material adhered using with 1 to 5 impinging nozzles, respectively. The weight of material adhered to the wall increases as the number of nozzles increases. It can also be seen that there is an optimum angle of glue application, around the preferred angel of +20 degrees to the flow of the material stream. It will be apparent to those skilled in the art that there are several interrelated variably such as increasing weight of the spray apparatus with increasing nozzle number that will have to be considered to reach the best overall performance.
Figure 8 is a graph depicting the Intra-Material Bond Strengthwersus the Impinging Nozzle Angle. The lines 1 through 5 represent the increase in infra-material bond strength as the number of impinging nozzles increases, with 5 representing 5 impinging nozzles. The desirability of increasing infra-material bond strength must be balanced with increasing glue weight and cost, and increasing apparatus weight and complexity. As the nozzle angle increases from 4 to +90 degrees, the nozzles point more into the material flow and the substantially water free adhesive is entirely entrained into the material matrix, with none of the substantially water free adhesive free for external binding to the wall. It will be apparent to those skilled in the art that different nozzle types and other variations can affect the relation of the variables in positive or negative fashion.
57421.doc Figure 9 is a depiction of the optimum angles of the impinging nozzles combined with the effect of the tackifying nozzles. On the left vertical axis, the Weight Percent of Material Adhered is shown, and the right vertical axis shows the Infra-Material Bond Strength. The horizontal axis shows the Impinging Nozzle Angle as in Figures 7 and 8.
Line A depicts the weight of material adhered using 3 nozzles as in Figure 7, and Line B
depicts the infra-material bond strength using 3 nozzles as in Figure 8. Line C depicts the effect of the use of a single tackifying nozzle in combination with two impinging nozzles.
There is a significant increase in the material adhered to the wall with the use of the combination nozzle setup as compared to the setup with three impinging nozzles only. It will be seen to those skilled in the art that some increase in intxa-material bond strength occurs by the addition of-the tackifying nozzle, but this makes up for the loss of one impinging nozzle. Thus Line D, which depicts the infra-material bond strength with the use of two impinging nozzles and one tackifying nozzle does not change significantly from the infra-material bond strength using three impinging nozzles.
Variations in air 1 S flow, air temperature, and material flow can all impact the results shown in Figures 7-9.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. By way of example, an anti-drool device can be used with the adhesive nozzles of the applicator to prevent adhesive from dripping out of the nozzles between installations of insulation. Also, the applicator assembly may be made from various materials and fitted with ergonomic handles, control switches, and the like. Similarly, the apparatus may be used with an insulating heat shield to protect an operator. All such modifications,and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.
57421.doc
Claims (52)
1. An apparatus for installation of a material having discrete elements, said apparatus comprising:
(a) a supply of material having discrete elements; and (b) an applicator assembly for activating a substantially water-free adhesive for providing structure to said material having discrete elements during installation wherein said applicator includes at least one impinging fluid nozzle converging with said material stream.
(a) a supply of material having discrete elements; and (b) an applicator assembly for activating a substantially water-free adhesive for providing structure to said material having discrete elements during installation wherein said applicator includes at least one impinging fluid nozzle converging with said material stream.
2. The apparatus according to Claim 1, further including a transporter system downstream of said supply of material having discrete elements for delivery of said material to said applicator assembly.
3. The apparatus according to Claim 2, wherein, said transporter system includes a conduit with an inlet and outlet; and an air supply to move said material having discrete elements through said conduit.
4. The apparatus according to Claim 3, wherein said transporter system further includes a debailer for debailing bundles of said material having discrete elements.
5. The apparatus according to Claim 1, wherein said supply of material having discrete elements includes at least one selected from the group consisting of fibrous material, granular material, pellet material, agglomerated material, and aggregated material.
6. The apparatus according to Claim 5, wherein the supply of material having discrete elements is inorganic.
7. The apparatus according to Claim 6, wherein said inorganic material includes at least one selected from the group consisting of fiberglass, rock wool, pearlite, mineral wool, and asbestos.
8. The apparatus according to Claim 5, wherein said supply of material having discrete elements is organic.
9. The apparatus according to Claim 8, wherein said organic material is a natural material.
10. The apparatus according to Claim 9, wherein said natural material is cellulosic.
11. The apparatus according to Claim 1, wherein said supply of material having discrete elements is a non-conductive material.
12. The apparatus according to Claim 11, wherein said supply of non-conductive material is a thermally non-conductive material.
13. The apparatus according to Claim 11, wherein said supply of non-conductive material is an acoustically non-conductive material.
14. The apparatus according to Claim 11, wherein said supply of non-conductive material is an electrically non-conductive material.
15. An applicator assembly for a device for installation of a supply of material having discrete elements, said apparatus comprising:
(a) a material nozzle having an inlet for receiving said material and an outlet for discharging a material stream to a surface; and (b) an adhesive applicator adjacent to said material nozzle for activating a substantially water-free adhesive to provide structure to said material having discrete elements during installation, said adhesive applicator including: (i) at least one impinging nozzle, and (ii) at least one tacking nozzle.
(a) a material nozzle having an inlet for receiving said material and an outlet for discharging a material stream to a surface; and (b) an adhesive applicator adjacent to said material nozzle for activating a substantially water-free adhesive to provide structure to said material having discrete elements during installation, said adhesive applicator including: (i) at least one impinging nozzle, and (ii) at least one tacking nozzle.
16. The apparatus according to Claim 15, wherein said material nozzle has a substantially oval cross-section.
17. The apparatus according to Claim 15, wherein the angle of said impinging nozzle is between about 0 degrees and +90 degrees with respect to said material stream.
18. The apparatus according to Claim 17, wherein said angle is between about +10 degrees and +40 degrees.
19. The apparatus according to Claim 18, wherein said angle is preferably about +20 degrees.
20. The apparatus according to Claim 15, wherein said applicator includes at least two impinging nozzles.
21. The apparatus according to Claim 15, wherein the angle of said tacking nozzle is between about -90 degrees and +90 degrees with respect to said material stream.
22. The apparatus according to Claim 21, wherein said angle is between about -15 and +15 degrees.
23. The apparatus according to Claim 22, wherein said angle is preferably about +15 degrees.
24. The apparatus according to Claim 15, further including a supply of adhesive material.
25. The apparatus according to Claim 24, wherein said supply of adhesive material includes a hot melt adhesive and a heater assembly.
26. The apparatus according to Claim 25, wherein said hot melt adhesive is a thermoplastic adhesive.
27. The apparatus according to Claim 25, wherein said heater assembly further includes a temperature control device.
28. An apparatus for installation of a material having discrete elements, said apparatus comprising:
(a) a supply of material having discrete elements;
(b) an applicator assembly for activating a substantially water-free adhesive for providing structure to said material having discrete elements during installation wherein said applicator assembly includes: a material nozzle having an inlet for receiving said material and an outlet for discharging a material stream to a surface; and an adhesive applicator adjacent to said material nozzle for activating a substantially water-free adhesive to provide structure to said material having discrete elements during installation, said adhesive applicator including: (i) at least one impinging nozzle, and (ii) at least one tacking nozzle; and (c) a transporter system downstream of said supply of material having discrete elements for delivery of said material to said applicator assembly.
(a) a supply of material having discrete elements;
(b) an applicator assembly for activating a substantially water-free adhesive for providing structure to said material having discrete elements during installation wherein said applicator assembly includes: a material nozzle having an inlet for receiving said material and an outlet for discharging a material stream to a surface; and an adhesive applicator adjacent to said material nozzle for activating a substantially water-free adhesive to provide structure to said material having discrete elements during installation, said adhesive applicator including: (i) at least one impinging nozzle, and (ii) at least one tacking nozzle; and (c) a transporter system downstream of said supply of material having discrete elements for delivery of said material to said applicator assembly.
29. The apparatus according to Claim 28, wherein, said transporter system includes a conduit with an inlet and outlet; and an air supply to move said material having discrete elements through said conduit.
30. The apparatus according to Claim 29, wherein said transporter system further includes a debailer for detailing bundles of said material having discrete elements.
31. The apparatus according to Claim 28, wherein said supply of material having discrete elements includes at least one selected from the group consisting of fibrous material, granular material, pellet material, agglomerated material and aggregated material.
32. The apparatus according to Claim 31, wherein the supply of material having discrete elements is inorganic.
33. The apparatus according to Claim 32, wherein said inorganic material includes at least one selected from the group consisting of fiberglass, rock wool, pearlite, mineral wool, and asbestos.
34. The apparatus according to Claim 32, wherein said supply of material having discrete elements is organic.
35. The apparatus according to Claim 34, wherein said organic material is a natural material.
36. The apparatus according to Claim 35, wherein said natural material is cellulosic.
37. The apparatus according to Claim 28, wherein said supply of material having discrete elements is a non-conductive material.
38. The apparatus according to Claim 37, wherein said supply of non-conductive material is a thermally non-conductive material.
39. The apparatus according to Claim 37, wherein said supply of non-conductive material is an acoustically non-conductive material.
40. The apparatus according to Claim 37, wherein said supply of non-conductive material is an electrically non-conductive material.
41. The apparatus according to Claim 28, wherein said material nozzle has a substantially oval cross-section.
42. The apparatus according to Claim 28, wherein the angle of said impinging nozzle is between about 0 degrees and +90 degrees with respect to said material stream.
43. The apparatus according to Claim 42, wherein said angle is between about +10 degrees and +40 degrees.
44. The apparatus according to Claim 43, wherein said angle is preferably about +20 degrees.
45. The apparatus according to Claim 28, wherein said applicator includes at least two impinging nozzles.
46. The apparatus according to Claim 28, wherein the angle of said tacking nozzle is between about -90 degrees and +90 degrees with respect to said material stream.
47. The apparatus according to Claim 46, wherein said angle is between about -15 and +15 degrees.
48. The apparatus according to Claim 47, wherein said angle is preferably about +15 degrees.
49. The apparatus according to Claim 28, further including a supply of adhesive material.
50. The apparatus according to Claim 49, wherein said supply of adhesive material includes a hot melt adhesive and a heater assembly.
51. The apparatus according to Claim 50, wherein said hot melt adhesive is a thermoplastic adhesive.
52. The apparatus according to Claim 50, wherein said heater assembly further includes a temperature control device.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US70035603A | 2003-11-03 | 2003-11-03 | |
| US10/700,356 | 2003-11-03 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2481288A1 true CA2481288A1 (en) | 2005-05-03 |
Family
ID=34573299
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002481288A Abandoned CA2481288A1 (en) | 2003-11-03 | 2004-09-14 | Apparatus for installation of loose fill insulation and applicator assembly |
Country Status (2)
| Country | Link |
|---|---|
| CA (1) | CA2481288A1 (en) |
| MX (1) | MXPA04008396A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107882304A (en) * | 2017-10-31 | 2018-04-06 | 陈飞华 | A kind of Mortar spraying machine for preventing mortar solidification and temperature control |
-
2004
- 2004-08-30 MX MXPA04008396A patent/MXPA04008396A/en not_active Application Discontinuation
- 2004-09-14 CA CA002481288A patent/CA2481288A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107882304A (en) * | 2017-10-31 | 2018-04-06 | 陈飞华 | A kind of Mortar spraying machine for preventing mortar solidification and temperature control |
Also Published As
| Publication number | Publication date |
|---|---|
| MXPA04008396A (en) | 2005-05-09 |
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