WO2005021884A1 - Insulating material - Google Patents
Insulating material Download PDFInfo
- Publication number
- WO2005021884A1 WO2005021884A1 PCT/AU2004/001109 AU2004001109W WO2005021884A1 WO 2005021884 A1 WO2005021884 A1 WO 2005021884A1 AU 2004001109 W AU2004001109 W AU 2004001109W WO 2005021884 A1 WO2005021884 A1 WO 2005021884A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fibres
- web
- insulating material
- spring
- bonding
- Prior art date
Links
- 239000011810 insulating material Substances 0.000 title claims abstract description 67
- 229920003043 Cellulose fiber Polymers 0.000 claims abstract description 25
- 239000002657 fibrous material Substances 0.000 claims abstract description 19
- 238000004519 manufacturing process Methods 0.000 claims abstract description 6
- 239000000463 material Substances 0.000 claims description 46
- 238000000034 method Methods 0.000 claims description 27
- 239000000835 fiber Substances 0.000 claims description 24
- 239000000155 melt Substances 0.000 claims description 21
- 238000010030 laminating Methods 0.000 claims description 13
- 238000010438 heat treatment Methods 0.000 claims description 11
- 229920002678 cellulose Polymers 0.000 claims description 10
- 239000001913 cellulose Substances 0.000 claims description 10
- 239000003063 flame retardant Substances 0.000 claims description 10
- 238000002156 mixing Methods 0.000 claims description 5
- 239000010893 paper waste Substances 0.000 claims description 5
- 229910021538 borax Inorganic materials 0.000 claims description 3
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 claims description 3
- 239000004327 boric acid Substances 0.000 claims description 3
- 239000004328 sodium tetraborate Substances 0.000 claims description 3
- 235000010339 sodium tetraborate Nutrition 0.000 claims description 3
- 238000001816 cooling Methods 0.000 claims description 2
- 239000004033 plastic Substances 0.000 claims description 2
- 229920003023 plastic Polymers 0.000 claims description 2
- 239000000123 paper Substances 0.000 description 9
- 238000009413 insulation Methods 0.000 description 8
- 238000005520 cutting process Methods 0.000 description 5
- 238000012856 packing Methods 0.000 description 5
- 229920001169 thermoplastic Polymers 0.000 description 4
- 239000004416 thermosoftening plastic Substances 0.000 description 4
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 239000011152 fibreglass Substances 0.000 description 3
- 239000011888 foil Substances 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- 229920000742 Cotton Polymers 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000005030 aluminium foil Substances 0.000 description 2
- 238000009960 carding Methods 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 239000011111 cardboard Substances 0.000 description 1
- 230000001427 coherent effect Effects 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000003621 hammer milling Methods 0.000 description 1
- 239000000383 hazardous chemical Substances 0.000 description 1
- 231100000206 health hazard Toxicity 0.000 description 1
- 230000007794 irritation Effects 0.000 description 1
- 239000002648 laminated material Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 230000036961 partial effect Effects 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- -1 polyethylene Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 230000000979 retarding effect Effects 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
- 229920001059 synthetic polymer Polymers 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 239000010784 textile waste Substances 0.000 description 1
- 230000036967 uncompetitive effect Effects 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/425—Cellulose series
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4326—Condensation or reaction polymers
- D04H1/435—Polyesters
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4391—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres
- D04H1/43918—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres nonlinear fibres, e.g. crimped or coiled 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
- D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/50—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by treatment to produce shrinking, swelling, crimping or curling of 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
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/542—Adhesive 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
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/542—Adhesive fibres
- D04H1/55—Polyesters
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
-
- 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
- D04H13/00—Other non-woven fabrics
-
- 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
- E04B1/88—Insulating elements for both heat and sound
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0276—Polyester fibres
- B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/06—Vegetal fibres
- B32B2262/062—Cellulose fibres, e.g. cotton
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/10—Properties of the layers or laminate having particular acoustical properties
- B32B2307/102—Insulating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/304—Insulating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
- B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
-
- 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
- E04B2001/7683—Fibrous blankets or panels characterised by the orientation of the fibres
Definitions
- This invention relates to insulating material. More particularly, the invention relates to insulating material which can be used as thermal or acoustic insulation.
- Paper or bonded cellulose is a logical alternative because it is relatively inexpensive and can be made into insulating material which has high thermal and acoustic resistance.
- the thermal resistance is a function of the density and the thickness of the product.
- the thickness of the product is normally referred to as "height" or "loft” of the product because it is formed as a horizontal layer where the height or loft of the product constitutes the thickness of the insulating material. Relatively low densities can be achieved when the height, loft or thickness of the product is small.
- An object of the present invention is to provide insulating material which includes cellulose fibres which are stable and are of relatively low density so that thermal and acoustic resistance properties are maintained.
- a method of making insulating material including the steps of: (i) forming a web of fibrous material including cellulose fibres and spring fibres; (ii) forming the web so that it is corrugated, lapped or wave shaped; and (iii) treating the web so that it remains corrugated, or lapped or wave shaped.
- the spring fibres constitute approximately 10% to 25% by weight of the web.
- the step of treating the web so that it remains corrugated includes the step of bonding adjacent corrugated or lapped or wave shaped parts of the web together.
- the bonding is effected by adding bonding material to the web and heating the web to a temperature which exceeds the melt point of the bonding material so that said adjacent corrugated or lapped or wave shaped parts of the web are bonded together.
- the density of the web is in the range 10kg/m 3 to 50kg/m 3 and preferably less than 20kg/m .
- the density of the insulating material is in the range 10kg/m 3 to 50kg/m 3 and preferably less than 20kg/m 3 .
- the web has a thickness in the range from 1mm to 70mm and more preferably in the range 20mm to 70mm.
- the invention also provides apparatus for making insulating material, the apparatus including means for forming a web of fibrous material including cellulose fibres and spring fibres, forming means for forming the web so that it is corrugated or lapped or wave shaped, and treating means for treating the web so that it remains corrugated or lapped or wave shaped.
- the invention also provides insulating material including a web of fibrous material which includes cellulose fibres and spring fibres, the web being treated so that it is bonded into a corrugated or lapped or wave shaped configuration.
- the insulating material can be in the form of a batt, roll or blanket.
- the shape of the corrugations can be adjusted so as to vary the effective thickness of the batt, roll or blanket.
- the thickness of the batt, roll or blanket determines its thermal and/or acoustic resistance.
- the batt, roll or blanket can be appropriately sized so that it can be fitted in various cavities normally found in buildings including wall cavities, and spaces between floor joists, between rafters or ceiling joists.
- the corrugating lapping or wave shaping of the web is applicable to fibrous material which does not necessarily include cellulose fibres. Accordingly, a further object of the invention is to provide a novel method of making insulating material from webs which include cotton, fibreglass and/or polyester.
- FIG. 1 is a fragmentary view of insulating material made in accordance with the invention
- Figure 2 is a schematic drawing showing apparatus suitable for making the insulating material of the invention
- Figure 3 is a more detailed schematic view of part of the apparatus of Figure 2
- Figure 4A diagrammatically shows a web laminated on both sides prior to folding
- Figure 4B is a diagrammatic cross-section through a laminated product
- Figure 4C is an enlarged view of a laminated product
- Figure 5 A is an enlarged view of another form of laminated product
- Figure 5B is an enlarged fragmentary view of the modified product
- Figure 6A is a schematic view of another form of laminated product
- Figure 6B is an enlarged fragmentary view of another form of laminated product
- Figure 7A is a schematic drawing of another form of laminated product
- Figure 6B is an enlarged fragmentary view of another form of laminated product
- Figure 7A is a schematic drawing of another form of laminated product
- the insulating material 2 can be used for thermal and/or acoustic insulation.
- the insulating material 2 is first formed as a web 4 of insulating material which is then corrugated or lapped or formed into a wave shape as shown.
- the corrugated or lapped or wave shaped web is then treated so that it maintains its shape so that the height H thereof determines the thickness of the insulating material 2.
- the insulating material 2 can be cut into batts, or into blankets or formed into rolls.
- the web 4 includes bonding material in the form of thermoplastic bonding fibres and spring fibres as described in more detail below.
- the thermoplastic bonding fibres are heated above their melt point so as to form the web 4 and maintain its integrity as a web.
- the web 4 is then corrugated or lapped or formed into a wave shape and is again heated above the melt point of the bonding material so that bonded regions 6 are formed between adjacent convolutions 8, as shown in Figure 1.
- Figure 2 schematically illustrates the preferred apparatus 10 for forming the insulating material 2.
- the apparatus includes a cellulose preparation stage 12, fibre mixing stage 14, web forming stage 16, corrugating stage 18 and cutting and packing stage 20.
- the cellulose preparation stage 12 includes a hopper 22 which receives waste material which includes or consists of cellulose fibres. Typically the waste material would include waste paper or cardboard material. It is preferred that newspaper stock and/or used telephone directories are used as the source of the cellulose fibres.
- the fibres pass to a shredder 24 which tears or cuts the paper into relatively small pieces. This is typically done using spinning knives or blades.
- the pieces of paper then pass to a hammermill 26.
- the piece of paper can be transported by means of a stream of air.
- the hammermill 26 reduces the pieces of paper to fibre and hammermilling or fibreizing takes place until the cellulose fibres are small enough to pass through a screen 28 of a predetermined hole size.
- the hole size of the screen 28 is in the range from 2mm to 15mm for producing fibre having a relatively high R value, the R value being a measure of the thermal resistance.
- the hole size for the screen 28 would depend on the type of hammermill and fan used for conveying the fibres. In a prototype apparatus a Williams serial number 12686 hammermill is used with a 150HP motor and in this case the preferred hole size for the screen is 8mm. A high proportion of individual fibres compared to the number of flakes of paper usually yields a higher R value. Depending on the type of paper, there is a point where if the holes in the screen 28 are too small, they tend to break the fibres down too much resulting in a web which does not have sufficient loft or height.
- the screening could be done within the hammermill 26.
- the cellulose preparation stage includes a hopper 27 for adding fire retardant 29 to the fibres emerging from the screen 28.
- the fire retardant is borax or boric acid and is added so that it constitutes about 7% to 17% by weight of the insulating material 2.
- the fibre mixing stage 14 is for the purpose of adding to the fibreized cellulose material from the screen 28, bonding fibres 31 and spring fibres 36.
- the fibre mixing stage 14 includes a bonding fibre hopper 30 which receives bonding fibre 31.
- the bonding fibres 31 are thermoplastic fibres having a length in the range from 2mm to 25mm and a thickness in the range 3 to 28 denier.
- the fibres are thermoplastic and have a melt point at about 110°C.
- the preferred material for the bonding fibre is a mix of PE/PET fibres.
- the melt point of the bonding fibres 31 is less than the combustion point of the fibreized paper and less than the melting point of the spring fibres, as discussed below.
- the fibres 31 pass from the hopper 30 to a carding or fibre opening unit 32 so as to separate the fibres and avoid balling of the fibres.
- the fibre mixing stage also includes a spring fibre hopper 34 into which spring fibres 36 are introduced.
- the spring fibres 36 are preferably synthetic fibres having a length in the range from 12mm to 100mm and a diameter from 15 to 150 decitex.
- the fibres also have a melt point which is above the melt point of the bonding fibres.
- the melt point of the spring fibres is greater than 150°C.
- the preferred material for the spring fibres is PET.
- the spring fibres 36 can be of the type which is used in upholstering furniture or in the manufacture of pillows and are sometimes referred to as pillow fibres. Recycled spring fibres are often made from textile waste such as that produced as offcuts in the manufacture of sporting footwear or pet bottles, the material usually being melted down and re-extruded as spring fibre. The fibres are crimped so as to give them bulk and inherent resilience.
- the spring fibres 36 from the hopper 34 pass to a carding or fibre opening unit 38 to again ensure that the fibres are as separate or open as possible and that balling thereof is avoided.
- the bonding fibres 31 and spring fibres 36 pass to a dosing control unit 40 which controls the rate at which these fibres are introduced into a fibre mixer 42 which also receives cellulose fibres from the screen 28.
- the dosing control unit 40 controls the rate of addition of the bonding fibres 31 and spring fibres 36 relative to the rate of the cellulose fibres added to the fibre mixer 42.
- the dosing control unit 40 can be used to adjust the relative ratios of the weights of materials added to the fibre mixer 42 and hence of the mixed fibre which forms the web 4. Table 1 below sets out the various weight percentages of the components.
- the web forming stage 16 includes a web forming apparatus 44 which forms the mixed fibrous material from the fibre mixer 42 into a generally uniform layer of a predetermined height on a conveyer belt (not shown).
- the web forming apparatus 44 may be of known type such as a chute, air-lay, vacuum belt, or combination of these known types of equipment.
- the web forming apparatus 44 could be of the type disclosed in International Publication WO 99/36622. Apparatus of this type forms a generally uniform layer of mixed fibrous materials moving on a conveyer belt.
- the web forming stage 16 also includes a bonding oven which includes convection or radiant heaters for heating the fibrous material conveyed therethrough.
- the bonding oven 46 is arranged to heat the fibrous material to a temperature which is above the melt point of the bonding fibre 31 but below the melt point of the spring fibre 36. Accordingly, the bonding oven 46 heats the materials to a temperature greater than 110°C and less than 180°C and preferably 145°C. This heating causes the bonding fibres 31 to reach their melt point in which they adhere to one another as well as to the cellulose and spring fibres. The material so heated is then conveyed to a cooler 48 which reduces the temperature to below the melt point of the bonding fibre. The formed web 4 therefore emerges on the conveyer from the cooler 48. The bond fibres thus hold the web into a structurally coherent web of fibrous material.
- the spring fibres will be randomly oriented and bonded to the cell fibres and to each other.
- the spring fibres add resilience to the web 4 and ensure that the loft in the web is maintained.
- the web 4 then passes to the corrugating stage 18.
- the stage 18 includes a forming stage 50 which causes the web 4 to be corrugated, lapped or wave shaped.
- the forming stage 50 can be implemented in a number of different ways.
- Figure 3 diagrammatically illustrates one way in which the forming stage is implemented. In this diagram the forming stage includes nip rollers 52 which partly compress in order to enable the web to be pulled through the apparatus.
- the nip rollers 52 compress the web 4 by an amount in the range from 5 to 50% so as to consolidate the web somewhat but without destroying the inherent loft which is maintained by virtue of the spring fibres 36.
- the layer 4 may be about 4mm in thickness at this stage and the rollers 52 compress the web 4 to about half its thickness. The thickness will, however, increase somewhat after leaving the rollers by virtue of the resilience provided by the spring fibres 36.
- the web thickness is of the order of say 50% of its thickness prior to passing through the nip rollers 52.
- the web 4 is then fed to shaping rollers 54 which are opposed to one another so as to define a wave shaped travel path for the web 4, as shown.
- the rollers 54 are preferably driven so that they assist in feeding the web therethrough. Also the spacing of the rollers in the upstream/downstream direction can be adjusted as well as the relative spacing in the transverse direction can be adjusted so as to produce the required wave shape.
- the rollers 54 drive the wave shaped web 4 into a compression zone defined by upper and lower variable speed conveyors 56 and 58 so as to define the adjacent convolutions 8.
- the conveyors 56 and 58 are surrounded by an oven 60 which serves as a bonding oven to remelt the bonding fibres so as to form the bonded region 6, as shown in Figure 1, between adjacent convolutions 8 in the insulating material 2.
- the temperature in the oven 60 heats the material to a temperature between 110°C and 180°C and preferably 145°C.
- the material so bonded is then conveyed to a cooling zone 62 which cools the material 2 below the melt point of the bonding fibre, i.e. below 110°C, so that the bonded regions 6 serve to maintain the web in its corrugated shape, as shown in Figure 1.
- the insulating material 2 then passes to a cutting and packing stage 20 which includes a cutting station 64 for cutting the material 2 into its desired width and length.
- the material then passes to a packing stage 66 for compressing the material into a form suitable for storage and packaging. Normally the material would be compressed in a longitudinal direction and placed in a plastic bag (not shown) for packing.
- compression in a direction in the height or thickness direction of the insulating material 2 is undesirable because it could prevent the product from resiliently returning to its position having the predetermined height H. Compression is thus preferred in a direction normal to the planes of the convolutions 8.
- the insulating material 2 has an R factor of 1 at a height H of 30-40mm when the density is approximately 15 to 20kg/m .
- most ceiling batts are regulated at between R2.5 and R3.5 (referring to Australian R values).
- Batts or webs of insulating material of the invention may be laminated prior to the packing stage 66 with a variety of laminates including foil if it were to be used for roof insulation where the foil would provide a reflective insulative surface that would primarily protect the insulation from moisture.
- Figure 4A shows the web 4 laminated with upper and lower sheets 70 and 72 of laminating material such as a synthetic polymer film. The laminating material could be heat seamed at its edges in order to form a sealed envelope. The sheets 70 and 72 of laminating material are applied prior to passing to the corrugating/folding lapping stage 18. This has the result that the laminating material extends between the adjacent convolutions.
- the upper and lower laminating layer 70 and 72 could be in the form of an open weave scrim which generally serve to maintain the structural integrity of the web 4 and prevent fibres or particles of fibres falling away from the material.
- the open weave of the scrim enables the bonding fibres to hold the corrugations together because the melted bonding fibres will adhere to one another through the scrim.
- the layers may be in the form of plastic sheet metal such as polyethylene or the like and, after corrugation, the oven 60 causes partial melting of the layers 70 and 72 so that they adhere to each other and maintain the corrugated, folded or lapped shape, as shown in Figure 4B.
- Figures 4B and 4C show in more detail the modified laminated material 76.
- FIGS 5A and 5B show side views of a modified insulating product 80.
- a laminating sheet 82 is applied to the material 2 after corrugating and, before or after it has left the cutting station 64.
- the laminating sheet 82 may comprise a sheet of reflective aluminium foil which is bonded to the upper layer of corrugations, as shown.
- the laminating layer 82 may comprise a coated metallic coil.
- Figures 6A and 6B show side views of a further laminated product 86 which is generally the same as the product 80 except that it includes a lower laminating sheet 88 which may again be in the form of an aluminium foil or coated foil bonded to the lower side of the material.
- Figures 7A and 7B show side views of a still further modified laminated product
- the product 90 is similar to the product 80 except that it has a scrim 92 bonded to the lower side of the corrugated or folded material, as shown.
- the scrim 92 helps to maintain the structural integrity of the insulating material.
- the laminating sheet 82 may be omitted and the scrim 92 bonded to the upper and lower sides of the insulating material.
- the scrim may be wrapped around and bonded to a body of the insulating material in order to maintain the shape thereof as an insulating batt.
- the scrim has a very open mesh and may be made from PET or cotton or the like.
- the length and width of the batt of material 2 can be selected to be suitable for ceiling/wall construction in each market. Roof insulation is usually produced in blanket forms and on rolls, the length and width of which is a function of roof design.
- the fire retardant 29 is added in powder or liquid form to the cellulose fibre. It is possible, however, that the fire retardant may be separately applied in liquid form to one or more of the cellulose fibres, spring fibres and/or bonding fibres. Alternatively, the fire retardant material can be added, say in liquid form, prior to the web forming stage 44.
- the insulating material of the invention can also be recycled because of the relatively high content of cellulose fibres, thus making it very environmentally friendly because it is initially made from recycled paper and then can be recycled again after its useful life.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Physics & Mathematics (AREA)
- Architecture (AREA)
- Structural Engineering (AREA)
- Acoustics & Sound (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Laminated Bodies (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2003904630A AU2003904630A0 (en) | 2003-08-27 | Insulating Material | |
AU2003904630 | 2003-08-27 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2005021884A1 true WO2005021884A1 (en) | 2005-03-10 |
Family
ID=34230046
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/AU2004/001109 WO2005021884A1 (en) | 2003-08-27 | 2004-08-19 | Insulating material |
Country Status (1)
Country | Link |
---|---|
WO (1) | WO2005021884A1 (en) |
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2418643A (en) * | 2003-10-22 | 2006-04-05 | Auto Insulations Ltd | Composite sheet insulation |
EP1736584A2 (en) * | 2005-06-22 | 2006-12-27 | Saertex France | Method of making an insulation material from waste fibres and insulating material obtained thereby |
WO2010100422A1 (en) * | 2009-03-04 | 2010-09-10 | Yorkshire Building Services (Whitwell) Limited | Thermal insulation batt |
ITMI20090366A1 (en) * | 2009-03-11 | 2010-09-12 | Warmor Roofing Srl | METHOD FOR THE REALIZATION OF A PANEL, IN PARTICULAR FOR THERMO-ACOUSTIC INSULATION, A PANEL MADE WITH SUCH A METHOD AND PLANT FOR THE CONSTRUCTION OF SUCH PANEL |
WO2012138308A1 (en) * | 2011-04-05 | 2012-10-11 | Mek Insaat Sanayi Ve Ticaret Anonim Sirketi | A cellulose -based insulation and/or filling material in elastic structure and method with regard to the manufacturing of this material |
WO2014123945A3 (en) * | 2013-02-11 | 2014-10-23 | Federal-Mogul Powertrain, Inc. | Enhanced, lightweight acoustic scrim absorber |
WO2015050702A1 (en) * | 2013-10-04 | 2015-04-09 | Dreamwell, Ltd. | Fire resistant panel and methods of fire blocking an article |
US11207863B2 (en) | 2018-12-12 | 2021-12-28 | Owens Corning Intellectual Capital, Llc | Acoustic insulator |
US11666199B2 (en) | 2018-12-12 | 2023-06-06 | Owens Corning Intellectual Capital, Llc | Appliance with cellulose-based insulator |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2079422A (en) * | 1980-06-30 | 1982-01-20 | Johns Manville | Thermal insulation by multi layer fibrous block |
WO1998028233A1 (en) * | 1996-12-23 | 1998-07-02 | Rockwool International A/S | A method of producing a mineral fiber web, a plant for producing a mineral fiber web, and a mineral fiber-insulating plate |
EP0582286B1 (en) * | 1992-08-04 | 1998-10-14 | Minnesota Mining And Manufacturing Company | Corrugated non-woven webs of polymeric microfiber |
US20030059581A1 (en) * | 2001-09-26 | 2003-03-27 | Whalen Timothy S. | Flexible radiative heat shield with corrugated substrate |
-
2004
- 2004-08-19 WO PCT/AU2004/001109 patent/WO2005021884A1/en active Application Filing
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2079422A (en) * | 1980-06-30 | 1982-01-20 | Johns Manville | Thermal insulation by multi layer fibrous block |
EP0582286B1 (en) * | 1992-08-04 | 1998-10-14 | Minnesota Mining And Manufacturing Company | Corrugated non-woven webs of polymeric microfiber |
WO1998028233A1 (en) * | 1996-12-23 | 1998-07-02 | Rockwool International A/S | A method of producing a mineral fiber web, a plant for producing a mineral fiber web, and a mineral fiber-insulating plate |
US20030059581A1 (en) * | 2001-09-26 | 2003-03-27 | Whalen Timothy S. | Flexible radiative heat shield with corrugated substrate |
Cited By (16)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2418643A (en) * | 2003-10-22 | 2006-04-05 | Auto Insulations Ltd | Composite sheet insulation |
GB2418643B (en) * | 2003-10-22 | 2006-09-06 | Auto Insulations Ltd | Composite insulation |
EP1736584A2 (en) * | 2005-06-22 | 2006-12-27 | Saertex France | Method of making an insulation material from waste fibres and insulating material obtained thereby |
FR2887562A1 (en) * | 2005-06-22 | 2006-12-29 | Saertex France Soc Par Actions | PROCESS FOR PRODUCING AN INSULATING MATERIAL FROM VIRGIN AND / OR WASTE FIBERS, INSULATING MATERIAL OBTAINED |
EP1736584A3 (en) * | 2005-06-22 | 2007-11-21 | Saertex France | Method of making an insulation material from waste fibres and insulating material obtained thereby |
WO2010100422A1 (en) * | 2009-03-04 | 2010-09-10 | Yorkshire Building Services (Whitwell) Limited | Thermal insulation batt |
ITMI20090366A1 (en) * | 2009-03-11 | 2010-09-12 | Warmor Roofing Srl | METHOD FOR THE REALIZATION OF A PANEL, IN PARTICULAR FOR THERMO-ACOUSTIC INSULATION, A PANEL MADE WITH SUCH A METHOD AND PLANT FOR THE CONSTRUCTION OF SUCH PANEL |
WO2012138308A1 (en) * | 2011-04-05 | 2012-10-11 | Mek Insaat Sanayi Ve Ticaret Anonim Sirketi | A cellulose -based insulation and/or filling material in elastic structure and method with regard to the manufacturing of this material |
WO2014123945A3 (en) * | 2013-02-11 | 2014-10-23 | Federal-Mogul Powertrain, Inc. | Enhanced, lightweight acoustic scrim absorber |
US9027706B2 (en) | 2013-02-11 | 2015-05-12 | Federal-Mogul Powertrain, Inc. | Enhanced, lightweight acoustic scrim barrier |
CN105122349A (en) * | 2013-02-11 | 2015-12-02 | 费德罗-莫格尔动力系公司 | Enhanced, lightweight acoustic scrim absorber |
JP2016513278A (en) * | 2013-02-11 | 2016-05-12 | フェデラル−モーグル パワートレイン インコーポレイテッドFederal−Mogul Powertrain, Inc. | Improved lightweight scrim sound absorber |
RU2661477C2 (en) * | 2013-02-11 | 2018-07-16 | Федерал-Могал Пауэртрейн, Инк. | Acoustic absorbent and method for manufacture thereof |
WO2015050702A1 (en) * | 2013-10-04 | 2015-04-09 | Dreamwell, Ltd. | Fire resistant panel and methods of fire blocking an article |
US11207863B2 (en) | 2018-12-12 | 2021-12-28 | Owens Corning Intellectual Capital, Llc | Acoustic insulator |
US11666199B2 (en) | 2018-12-12 | 2023-06-06 | Owens Corning Intellectual Capital, Llc | Appliance with cellulose-based insulator |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US11827439B2 (en) | Repulpable container insulation products and methods of making and using same | |
CA2190957C (en) | Polyester insulation | |
US8118177B2 (en) | Non-woven webs and methods of manufacturing the same | |
US8795470B2 (en) | System and method for producing bonded fiber/cellulose products | |
US20050170734A1 (en) | Insulation containing a mixed layer of textile fibers and of natural fibers and process for producing the same | |
CN106661785B (en) | Short fiber nonwoven molded article | |
JPH089200B2 (en) | Fiber-reinforced plastic sheet and manufacturing method thereof | |
JP2020193710A (en) | Method of forming web from fibrous material | |
US20040126580A1 (en) | Feather-based padding product, preparation method and installation for implementing said method | |
EP3067455B1 (en) | Use of polyactid acid powders in the manufacturing of beverage filter fibers | |
JPH0798387B2 (en) | Method and apparatus for making pressboard from paper coated with thermoplastic material | |
WO2005021884A1 (en) | Insulating material | |
JP2002105824A (en) | Layered fiber board, method of producing the same and device for making the same | |
EA000493B1 (en) | Process and apparatus for the production of a mineral fiberboard | |
AU2008209312B2 (en) | Method and apparatus for manufacturing a product of integrated cellulose and fibrous materials | |
EP0678137B1 (en) | A method of producing a mineral fiber-insulating web and a plant for producing a mineral fiber web | |
JPH091513A (en) | Manufacture of waste paper board | |
EP0522308A1 (en) | Method for making insulation | |
WO2001023655A1 (en) | Making a fibrous insulation product using a multicomponent polymer binder fiber | |
JP4980629B2 (en) | Insulating mat made of inorganic fiber and manufacturing method thereof | |
US20060169397A1 (en) | Insulation containing a layer of textile, rotary and/or flame attenuated fibers, and process for producing the same | |
WO2010100422A1 (en) | Thermal insulation batt | |
CN117626529A (en) | Method for producing sound-proof sheet, and sound-proof sheet | |
JP3150564B2 (en) | Method for producing multi-layer felt with different densities for each layer | |
CA3240384A1 (en) | Cellulose precursor material and apparatus and method for field conversion of the precursor into cellulose insulation |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AK | Designated states |
Kind code of ref document: A1 Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BW BY BZ CA CH CN CO CR CU CZ DE DK DM DZ EC EE EG ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NA NI NO NZ OM PG PH PL PT RO RU SC SD SE SG SK SL SY TJ TM TN TR TT TZ UA UG US UZ VC VN YU ZA ZM ZW |
|
AL | Designated countries for regional patents |
Kind code of ref document: A1 Designated state(s): BW GH GM KE LS MW MZ NA SD SL SZ TZ UG ZM ZW AM AZ BY KG KZ MD RU TJ TM AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IT LU MC NL PL PT RO SE SI SK TR BF BJ CF CG CI CM GA GN GQ GW ML MR NE SN TD TG |
|
121 | Ep: the epo has been informed by wipo that ep was designated in this application | ||
122 | Ep: pct application non-entry in european phase |