Note: Descriptions are shown in the official language in which they were submitted.
CA 02244031 1998-07-27
METHOD OF INSTALLING INSULATION
WITH DRY ADHBSIVE AND/OR COLOR DYE, AND REDUCED
AMOUNT OF ANTI-STATIC MATERIAL AND/OR COLOR DYE
This invention relates to a loose-fill fiberglass/dry
adhesive mixture and a method of applying same with a
reduced amount of anti-static material. More particularly,
this invention relates to a loose-fill/redispersible powder
adhesive mixture and a method of applying same together with
a liquid (e.g. water) for activating the adhesive in order
to create a uniform insulating product. In certain
embodiments, a powder form unactivated color dye may be
provided in the mixture, with the dye being activated by the
liquid upon installation.
CA 02244031 1998-07-27
BAÇKGROUND OF THE INVENTION
Fiberglass batt installation typically requires the
time consuming cu.tting up or shaping of batts when the need
arises to fill abnormally shaped open cavities between
studs, or insulate around electric boxes, wires, and the
like. Furthermore,.structures insulated with batts often
suffer from less than desirable thermal and sound insulation
due to the void areas sometimes found around the edges of
the batts adjacent studs or other supporting structure.
In recent years, a number of loose-fill insulation
systems have been developed in an attempt to overcome these
disadvantages inherent in residential fiberglass batt usage.
CA 02244031 1998-07-27
In order to get low density loose-fill fiberglass insulation
into enclosed verlically extending residential wall (stud
bounded) cavities in a practical manner and at a
commercially acceptable cost, it has heretofore been known
to resort to the BIBS (Blown-In-BlanketTM) system disclosed,
for example, in U.S. Patent Nos. 4,712,347 and 5,287,674 to
Sperber. Many residential contractors and the like
currently use BIBS instead of fiberglass batts for the
purpose of improving insulative qualities (both thermal and
sound) and application efficiency.
In accordance with BIBS, a supporting structure such as
flexible netting (e.g. nylon) or the like is affixed across
a plurality of wall studs in order to enclose vertically
extending wall stud defined cavities. Thereafter, hole(s)
are formed in the netting and a blowing hose is inserted
into the hole(s) for the purpose of filling the enclosed
wall cavities with blown loose-fill siliconized fiberglass
insulation. An exemplary insulation which may be used in
conjunction with BIBS is InsulSafe IIITM available from
CertainTeed Corp., Valley Forge, Pennsylvania. This loose-
CA 02244031 1998-07-27
fill fiberglass is said to be able to achieve an R-15 at a
density of 2.5 lbs./ft3 when 3.5 inches thick.
In commercial BIBS applications, the loose-fill
siliconized fiberglass may be ~lown using a commercially
available ArkSeal machine which coats the loose-fill with a
liquid adhesive as the insulation is blown behind the
netting or other (e.g. rigid) retaining structure. One of
the instant invent:ors has heard through the grapevine that
this has also been used in attic applications.
Unfortunately, the use of this liquid adhesive results in a
number of problems, including: (i) the liquid adhesive often
gums up the adhes:ive jet and/or hose thereby causing
application and clean-up inefficiencies and hardships; (ii)
storage and transport of the liquid adhesive to job sites
are burdensome, costly, and render the liquid adhesive
susceptible to freezing - the adhesive may he damaged if
frozen; (iii) user clean-up of the liquid adhesive equipment
(i.e. hose, pump, nozzle, and environment) is time-consuming
and cuts into potential production time; (iv) getting the
proper adhesive/fiberglass mixture or ratio in the field
(i.e. on site) is not as easy as it would seem - users are
CA 02244031 1998-07-27
forced to manudlly mix the adhesive on site prior to use,
this often leadincl to an improper ~too much or too little)
LOI (indicative of adhesive quantity) in the final blown
insulation product which in turn creates a non-uniform
application; and i-inally (v) users at the job site often may
not make use of the required adheslve and simply spray water
with the fiberglass in an attempt to save both time and
money - this lead:ing to a potentially inferior insulation
product prone to settling after installation is complete.
Still further, sorne users may simply blow loose-fill,
without water, into attics.
U.S. Patent No~. 4,710,309 and 4,804,695 also disclose
insulation blowing systems where the loose-fill is coated
with a liquid adhesive prior to application and during the
blowing process. Again, such systems suffer from the
problems listed above which are inherent with the use of
liquid adhesive.
It will be apparent from the above that there exists a
need in the art for eliminating the need for the use of
liquid adhesive.
CA 02244031 1998-07-27
As will be appreciated, insulation products are
properly divided into two distinct categories: organic vs.
inorganic. Fiberglass, an inorganic insu~Lation product, has
long been the insulation of choice among architects,
builders, and contractors because it is non-moisture-
absorbing, fire retardant, and provides consistently uniform
R-values. In recent years, however, cellulose, an organic
insulation product, has come into favor with many builders,
particularly because of its cost and its use of natural
products such as newspaper, cardboard, etc. (i.e.
recyclability). IJnfortunately, cellulose and its organic
nature are genera:lly viewed by many as undesirable in BIBS
and other spray/b:Low applications for the following reasons:
(i) its organic nature renders it attractive to mold,
mildew, fungus, rodents, vermin, etc.; (ii) cellulose is
penetrated by moisture (moisture does not simply coat the
product as with f:iberglass) rendering it susceptible to rot,
decay, and requir:ing undesirably long cure times when
exposed to liquid spray additives (especially in humid
environments)i (iii) cellulose often settles to a greater
degree in cavitie, than, for example, fiberglass, thereby
CA 02244031 1998-07-27
decreasing R-values within a filled cavity as time passes;
(iv) cellulose is less aesthetically appealing to many users
than fiberglass; and (v) cellulose is non-fire-resistant
because of its organic nature and therefore requires an
added chemical load for flame retardance purposes - this, of
course, increasing cost and sometimes creating an unfriendly
odor.
For example, U.S. Patent No. 4,773,960 discloses a
cellulose loose-fill insulation system (see also Suncoast~s
S.A.B.~ System). Dry organic adhesive and cellulose-based
insulation are sprayed or blown together with water which
activates the adhesive during blowing. As set forth in the
'960 patent, "insulation of the cellulose fiber type can be
pre-treated with an adhesive which, when moistened, becomes
activated and improves the setting properties of the
insulation." Unfortunately, such cellulose pre-treated
products are organic in nature and suffer from the inherent
problems outlined above. Furthermore, the dry adhesive used
to "pre-treat" the cellulose in the '960 patent as well as
other cellulose systems is starch-based (i.e. organic). An
actual adhesive clisclosed in the '960 patent is wheat starch
CA 02244031 1998-07-27
(organic). Again, the organic nature of such pre-treating
agents renders them susceptible to mold, mildew, fungus,
rodents, vermin, etc., especially when in storage along with
the cellulose prior to use.
It is also to be pointed out that many prior art
fiberglass and cellulose products have high LOI values which
leads to increased cost of product. It would satisfy a need
in the art if a fiberglass system/product with a low LOI
could be provided so as to improve yields while still
resulting in uniform applications.
It will be apparent to those of skill in the art that a
need exists in the art for a mixture including an inorganic
insulation (e.g. fiberglass) and a dry inorganic adhesive
for use in fiberglass spray systems which avoids the
problems inherent in the pre-treated organic cellulose
products discussed above thereby resulting in uniform and
efficient product applications.
It will also be apparent to those of skill in the art
that a need exists in the art for a dry mixture including
inorganic insulation (e.g. fiberglass or plastic fiber) and
CA 02244031 1998-07-27
a dry adheslve wh:ich can be blown into atlic areas easier
and cheaper than :in the past.
There also exists a need in the art for a method and
corresponding insulation mixture, having a dry-adhesive
mixed therein wherein the dry-adhesive has improved
retention characteristics within the mixture. There also
exists a need in the art for a product and method for
determining whether operators have properly installed the
insulation product (e.g. did they actually use the water or
adhesive-activating liquid during installation?).
The term "LOI" (loss-on-ignition) as used herein is
defined by ASTM C764-91, incorporated herein by reference.
LOI refers to the known method for measuring the binder
content of loose-fill mineral fiber insulation.
S ~ MARY OF THE INrVENTION
Generally speaking, this invention fulfills the above-
described needs in the art by providing a dry loose-fill
fiberglass insulation mixture adapted to be blown together
with an activating liquid into a cavity, the mixture
comprising:
CA 02244031 1998-07-27
loose-fill fiberglass;
a dry powder adhesive mixed with the :loose-fill
fiberglass so that when the mixture is coated with the
liquid and blown into a cavity, the adhesive is activated;
and
wherein the insulation mixture of fiberglass and dry
powder adhesive is substantially free of anti-static
material (defined as less than about 0.05% by weight of the
mixture).
According to certain preferred embodiments of this
invention, the dry adhesive includes vinyl ester of versatic
acid terpolymer in the form of a redispersible powder (RP).
Other redispersible powders may be used instead, or in
addition.
In certain embodiments, the RP is based on copolymers
of vinyl acetate and a type of ethylene.
This invention further fulfills the above-described
needs in the art by providing a system for blowing a
fiberglass/dry adhesive mixture into a cavity for purpo~es
of insulation, the system comprising:
CA 02244031 1998-07-27
a blower for blowing a dry mi~ture of loose-fill
flberglass and inorganic powder adhesive;
a pump for pumping an activating liquid so that the
blown dry fiberglass/adhesive mixture substantially free of
anti-static material is coated with the liquid, the liquid
activating the inorganic adhesive; and
means for blowing the coated mixture of loose-fill
fiberglass and activated adhesive into a cavity so as to
insulate the cavity.
According to certain preferred embodiments of this
invention, the mean6 for blowing results in the installed
mixture in the cavity having a density of less than or equal
to about 2.5 lb.\ft3 and an R-value of at least about 3.15
per inch thickness.
This invention still further fulfills the above-
described needs in the art by providing a method of spraying
or blowing loose-fill fiberglass insulation into a cavity,
the method comprising the steps of:
providing loose-fill fiberglass;
CA 02244031 1998-07-27
mixing the loose-fill fiberglass together with a dry
inorganic adhesive powder to make up a loose-fill mixture
substantially free of anti-static materiaL;
applying a liquid to the loose-fill mixture in order to
activate the adhec;ive; and
spraying or blowing the loose-fill mixture with
activated adhesive into the cavity so as to insulate the
cavity.
This invention further fulfills the above-described
needs in the art by providing a method of insulating an
attic by spraying or blowing loose-fill fiberglass
insulation into an attic area to be insulated, the method
comprising the steps of:
providing an attic area to be insulated;
providing loose-fill fiberglass;
mixing the loose-fill fiberglass together with a dry
polymeric based redispersible powder adhesive in order to
make up a loose-fill insulation mixture substantially free
of anti-static material, the mixture being from about 0.25
to 5.0% (preferably from about 0.75 to 2.5%) by weight
redispersible powder; and
13
CA 02244031 1998-07-27
spraying or blowing the loose--fill insulation mixture
together with an adhesive activating liquid into the attic
area to be insulated so that the loose-fill mixture is
retained in the attic area in order to insulate same with
fiberglass insulation, the resulting mixture in the attic
having an applied LOI percentage no greater than about 3.0%,
a density of less than about l.S lbs./ft3, and an R-value of
at least about 2.7 per inch thickness of insulation.
In certain at.tic embodiments, the redispersible powder
that is mixed with the loose-fill ~iberglass is based on
copolymers of vinyl acetate and ethylene, and includes a
protective colloicl.
In certain embodiments, the loose-fill fiberglass may
be blown together with the RP and a dry water-activatable
color dye so that the dye is activated upon installation
when hit with the RP activating liquia (e.g. water) thereby
being an indicator that the insulation was installed with
the liquid. The dye becomes much more colorful and viewable
to the naked eye when activated.
14
CA 02244031 1998-07-27
This invelltion will now be described with respect to
certain embodirnents thereof, accompanied by certain
illustrations wherein:
IN THE DRAWINGS
Figure 1 is a perspective view of a user
blowing/spraying a loose-fill fiberglass/dry adhesive
mixture coated wit:h an activating liquid such as water into
a vertically extending open wall cavity according to an
embodiment of this invention.
Figure 2 is a perspective view of a user
blowing/spraying a loose-fill fiberglass/dry adhesive
mixture coated with activating liquid into a vertically
extending cavity closed with a supporting structure
according to another embodiment of this invention.
Figure 3 is a perspective view of another embodiment of
this invention wherein a user is blowing/spraying a loose-
fill fiberglass/d:ry adhesive mixture coated with an
activating liquid, such as water, into an area (e.g. attic
area) to be insulated.
CA 02244031 1998-07-27
Figure 4 is an exploded perspective view of a nozzle
which may be used in certain embodiments of this invention.
DETAILED DESCRIPTION OF
CERTA]:N EMBODIME~TS OF THIS INVENTION
Referring now more particularly to the accompanying
drawings in which like reference numerals indicate like
parts throughout the several views.
In accordance with this invention, a loose-fill mixture
of (i) fiberglass and (ii) an inorganic dry adhesive in the
0 form of a redispersible po~,Jder (RP), i5 blown or sprayed
together with an activating liquid (e.g. water) into a
cavity (open or closed) to be insulated. According to
alternative embodiments, the loose-fill mixture is
blown/sprayed into attic areas, such as onto floors or
slanted (inclined) surfaces, to be insulated.
It has been found that, surprisingly, by reducing the
amount of anti-static or anti-stat material in the dry
mixture of RP and fiberglass, the RP is more uniformly
distributed throughout the mixture and clings better to the
glass fibers, presumably due to the increase in static
16
CA 02244031 1998-07-27
electricity. In certain embodiments, the dry mixture will
therefore include less than 0.10% by weight of anti-static
material, and most preferably is substantially free of anti-
static material. Exemplary anti-static materials known in
the trade include CS-II quaternary ammonium salts from
Sunshine Chemical Specialtie6, Inc.
The liquid applied to the mixture during
blowing/spraying activates the dry adhesive (and optionally
the color dye discu$sed below) so that when the insulating
mixture reaches the cavity it is retained, or sticks,
therein as will be described below. In such a manner, it is
ensured that the E)roper adhesive amount is present in the
product. Thus, the user needs only to add an activating
liquid such as wat:er to the mixture at the job site in order
to achieve a premium residential insulation product which
yields high R-values and cost-effective densities together
with uniform and consistent applications. Additionally,
productivity is increased due to the elimination of the need
for mixing and clean-up.
Firstly, a d:ry mixture of loose-fill fiberglass and dry
adhesive in the form of a redispersible powder (RP) is
CA 02244031 1998-07-27
provided. An exemplary white loose-fill fiberglass which
may be used is Perfect Fit~, commercially available from
Guardian Fiberglass, Albion, Michigan. Perfect FitTM has a
standard cube size and is coated with silicone (or other
water-resistant hydrophobic agent) as known in the trade.
The dry latex adhesive which is mixed with the loose-
fill fiberglass may be, according to certain embodiments, a
vinyl ester copolymer based resin. Such a dry adhesive is
available from Air Products, Lehigh Valley, Pennsylvania, as
AIRFLEX~ RP-238. In a typical formulation, RP-238 is a
redispersible powder which shows excellent adhesion, water
resistance, and workability. Its solid content is 99+1%,
and it utilizes a protective colloid of polyvinyl alcohol.
Other redispersible powders having similar properties may
also be used.
Other inorganic redispersible powders (RPs) from Air
Products which may be utilized in any and all embodiments
herein include (a) Airflex~ RP-140 which is a vinyl
acetate/ethylene copolymer resin type RP with a polyvinyl
alcohol (PA) protective colloid [99+1~ solids content] [RP-
140 has a white powder appearance, includes an anti-blocking
1~,
CA 02244031 1998-07-27
agent content of 10+2~, has a glass transition temperature
of 2~C/36~F, and is semi-transparent, tough-elastic]; (b)
Airflex~ RP-224 that is a vinyl acetate-ethylene (VAE)
copolymer resin type RP having a particle size of max 5%
over 60 mesh, and a polyvinyl alcohol protective colloid
[typical propert:ies of dispersion made from this RP include
about a 1-5 microns predominant particle size, a glass
transition tempe:rature of +16~ C., and a minimum film-
forming temperature of +4~]; (c) Airflex~ RP-225 that has a
vinyl acetate-ethylene (VAE) copolymer resin type and a PA
colloid; (d) Air~lex~ RP-226 that has a VAE copolymer resin
type and PA protective colloid; (e) Airflex~ RP-230 that has
a VAE copolymer resin ty~pe and PA protective colloid; (f)
Airflex~ RP-244 [VAE copolymer and PA protective colloid];
(g) Airflex~ RP-245 [VAE copolymer resin and PA protective
colloid]; (h) Airflex~ RP-2010 [VAE copolymer resin type and
PA protective co]loid]; (i) Airflex~ RP-2020 [VAE copolymer
resin type, PA colloid, max 5% particle size over 60 mesh
particle size]i l:j) Airbond0 SP-102 [acrylic copolymer resin
type, glass transition temperature of 5~C/41~F, white powder
appearance, and protective colloid]; and (k) Airbond~ SP 490
19
CA 02244031 1998-07-27
RP that has a vinyl ester copolymer resin type, PA colloid,
and min. film forming temperature of 0~C. These Airflex~
and Airbond~ RPs are available from Air Products.
The non-activated dry adhesive powder (e.g. RP-238) is
mixed with the loose-fill fiberglass, preferably at the
manufacturing plant, so that the resulting mixture is from
about 0.1 to 2.0% by weight dry adhesive, the remaining
weight being substantially represented by the fiberglass
(and possibly de-dusting and/or small amounts of anti-static
agents). As discussed above, it has been found that the
lesser the amount of anti-static material in the mixture,
the better the RP sticks to the glass or plastic fibers and
the more uniformly it is distributed. According to certain
preferred embodiments, the dry mixture is from about 0.50 to
0.75% by weight RP adhesive. Thus, the mixture is from
about 98 to 99.9'~, preferably from about 99.0 to 99.50% by
weight loose-fil:L fiberglass. As will be discussed below,
in attic embodiments the RP% may be from about 0.75-2.5% by
weight of the mixture.
The fiberglass loose-fill/dry adhesive mixture may be
sprayed or blown into both enclosed and open cavities
CA 02244031 1998-07-27
according to different embodiments of this invention
following activat:ion of the adhesive. Figure 1 is a
perspective view of the mixture being wetted with an
activating liquid (e.g. water) and thereafter blown into a
vertically extending open cavity, while Figure 2 is a
perspective view of the mixture being wetted and thereafter
blown into an enclosed cavity (e.g. in accordance with
systems where a rigid structure encloses the cavity so as to
retain the insulation therein).
As shown in Figure 1, user 3 is provided with dry
mixture blow hose 11 and activating liquid supply hose 13.
At nozzle area l'i, the loose-fill/dry adhesive mixture blown
from hose 11 is coated or wetted with the activating liquid
(e.g. water) from hose 13 and thereafter sprayed/blown into
open cavity 5. Alternatively, hoses ll and 13 may be
combined at an earlier stage so that user 3 is provided with
only one hose nozzle to grip. In either case, the dry
adhesive in the mixture supplied through hose 11 is
activated when wetted with the liquid fro~ hose 13. After
activation of the adhesive, the wet mixture is blown into
CA 02244031 1998-07-27
the cavity. The nozzle is held from about 18" - 24" from
the cavity to be insulated in certain embodiments.
As shown in Figure 1, the sprayed insulation mixture
with activated adhesive adheres to or sticks to wall 32
which may be made of plywood, Celotex~, or any other known
residential exterior insulating sheeting. No netting or
other supporting structure is needed to retain the sprayed
on mixture in open cavity 5 as shown in Figure 1.
Each cavity i9 bounded on either side by vertical studs
17 and on the top and bottom by horizontal studs 19. These
studs may be, for example, 2" x 4" as known in the trade.
Open cavities 9 and 10 in Figure 1 have been filled with the
spray-on insulation while open cavities 21 have not (open
cavity 5 is in the process of being filled).
Dry loose-fill blower 23 is attached to hose 11 and may
be, for example, a commercially available pneumatic blower
which works in conjunction with liquid pump 25 capable of
about two gallons per minute at 200 psi (although about 100
psi, for example, may be used during application of the
product). Blower 23 functions to blow the loose-fill
inorganic mixture th:rough hose 11 to nozzle area 15 where
CA 02244031 1998-07-27
the adhesive is activated by the liquid from hose 13. The
liquid is pumped through hose 13 by way of pump 25 as
discussed above. The liquid from hose 13 coats the
fiberglass and activates the adhesive, and also acts to
retain the dampened mixture in cavity 5 during spraying,
while the activated adhesive functions to hold the fiber in
cavity 5 after curing and provides desirable integrity. The
cure time of the mixture in the cavity will be from about 12
- 36 hours depending upon the ambient temperature, typically
about 24 hours or less.
Blow hose 11 and liquid hose 13 may be from about 50 to
150 ft. long. According to preferred embodiments, the hoses
are about 150 ft. long, and hose 11 has a 3 inch diameter.
Liquid hose 13 may be, for example, a one-quarter inch
diameter high pressure hose as will be appreciated by those
of skill in the art.
With respect to the hose tips adjacent nozzle area 15,
the spray head is defined by a circular metal chamber (not
shown) having a one-quarter inch supply line with a control
valve and quick connect coupling fitted over a machined
nozzle inserted into the discharge end of hose ll ln order
23
CA 02244031 1998-07-27
to apply the actlvating liquid (e.g. water) from hose 13 to
the dry mixture as it exits the discharge end of hose 11 at
the spray head. Spray jets, not shown, (e.g. H1/8 W 1501 or
H1/8 W2501 commercially available from Spraying Systems,
S Wheaton, Illinois) are threaded into the face of the spray
head in order to atomize and direct the liquid fro~ the
discharge end of hose 13 onto the dry mixture before
application.
When a 3" Krendl nozzle is used at area 15 at the end
of the fiber and liquid hose proximate the area to be
insulated, it should be held at about a 10~ downward angle
for application with the flat side up (i.e. valve on
bottom), so the jets are positioned on a compound angle
(both inward and upward), whereby proper fiber coating with
water when spraying into a wall cavity area or attic area is
achieved as is a slight pre-coating of the sheathing in the
rear of the cavity area or surface of the attic area.
It has been found by the instant inventors that during
spray-on applications into vertically extending open
cavities as shown in Figure 1, the fiberglass mixture
adheres better within the cavity when the fiberglass is
24
CA 02244031 1998-07-27
substantially free of silicone (or other similar hydrophobic
agent). Thus, in certain embodiments, substantially non-
siliconized loose-fill fiberglass is mixed with the dry RP
adhesive in spray-on applications as shown in Figure 1.
See Tables I - IV below for pump set-up and
corresponding typical required times in seconds for spraying
particular open stud vertical cavities at the listed
densities.
PUMP - TABLE I
Approximate length of time (seconds) to spray a residential
~x 4~' (inches) open 4tud cavity 16" on-center by 8~ high at
a 2.0 lb. per cubic foot density, at the listed pump
settings.
Seconds 25 30 35 40
PSI (dry) 125 110 100 95
PSI (wet) 110 100 90 90
CA 02244031 1998-07-27
T~sLE II
Approximate length of time (seconds) to spray a residential
2nx 6" open stud cavity 16" on-center by 8' high at a 2.0
lb. per cubic foot density, at the listed pump settings
(PSI).
Seconds 40 50 55 60
PSI (dry) 125 110 100 95
PSI (wet) 110 100 go go
T~BLE III
Approximate length of time (seconds) to spray a 2"x 4'~
residential open stud cavity 16" on-center by 8' high at a
2.5 lb. per cubic foot density, at the listed pump settings
(PSI).
Seconds 32 38 44 50
PSI (dry) 125 110 100 95
PSI (wet) 110 100 go go
TABLE IV
Approximate lengt:h of time (seconds) to spray a 2~x 6~
residential open stud cavity 16" on-center by 8~ high at a
2.5 lb. per cubic foot density, at the listed pump settings
(PSI).
Seconds 50 63 69 75
PSI (dry) 125 110 100 95
PSI (wet) 110 100 90 90
CA 02244031 1998-07-27
Referrlng to Charts I - IV above, the "dry" PSI pump
setting is for when substantially all virgin fiberglass/Rp
mixture is beiny used at the start-up of a job, while the
"wet" setting is for when recycled wet fiber/RP mixture is
at least partially being also blown either exclusively or
along with virgin dry mixture.
Thus, the water spray pressure (PSI)
is reduced once recycled fiber is being incorporated back
into the mix at the mixture hopper/blower.
Due to the ~ethods and processes described herein, the
average filling time for a 2~x 4" open cavity at 16~ on-
center, 8' high is about 30 - 35 seconds, and is about 50 -
55 seconds for the same style 2"x 6" cavity, both at a fiber
density of about 2.0 lb./ft3. Meanwhile, 38 - 44 seconds is
the average time for filling a 2"x 4'~ cavity at 16" on-
center, 8' high, and likewise 63 - 69 seconds for the same
style 2" x 6" cavity, each at a 2.5 lb./ft3 fiber density,
given the water pump settings set forth above in the Tables.
27
CA 02244031 1998-07-27
In spring/blowing the loose-fill
fiberglass/redis~persible powder mixture (with activated
adhesive) into the open cavity to fill it (or into an attic
area to be insulated), the user should attempt to maintain
the same nozzle angle with respect to the wall at all times.
Once the open cavity is filled to about 10" from the top of
a cavity, the user should quickly step in close (with the
end of nozzle about 12" - 15" from the cavity) and fill the
very top of the open cavity and move downward until reaching
the previously f:illed area so as to fill the entire cavity.
In this small upper section, the side to side filling rhythm
should be about twice the rate of the same rhythm or
technique used in the bottom section of the cavity.
This unique fiberglass/redispersible powder mixture,
when activated with an activating liquid, sprays well
against most types of sheathing, including plywood, particle
board, foam board, and various other sheathing products used
in the industry including those with foil laminants.
After the open cavity is finished being filled with the
insulating mixture, the user may use an electric scrubber to
shave off excess fiber. In doing so, the user should start
28
, ~ ,", ... ..
CA 02244031 1998-07-27
about 12" from the top of the cavity and proceed downward.
Thereafter, the user may re~erse the scrubber direction so
that the roller is rotating upward instead of downward. The
remainder of the overspray may then be shaved off by
starting at the bottom and moving upward until the open face
of the cavity has been completely cleaned. This technique
helps reduce the possibility of fiber sagging at the tops of
the cavities. After scrubbing drywall or wallboard is
affixed to the studs so as to close the insulated cavity
after curing of the insulation,
Figure 2 illustrates perspectively an insulation
application system and cross-sectionally a vertically
extending enclosed cavity 31. Cavity 31 is bounded by studs
laterally and by retaining rigid structure 33 and exterior
sheeting 35 on the remaining sides. Blower 23 and liquid
pump 25 as well as the hoses in the Figure 2 embodiment are
as in the Figure 1 embodiment. Additionally, loose-fill
material source 37 (e.g. hopper) is shown in Figure 2 as
being in communication with blower 23 via chute 39.
A significant difference between the Figure 1 and
~igure 2 embodiments is that in Figure 1, open cavities are
29
CA 02244031 1998-07-27
being insulated while in Figure 2 enclosed cavities are
being insulated. As shown in Figure 2, a plurality of holes
or apertures 41 are defined in rigid structure or wall 33
thereby allowing the nozzle area of hoses 11 and 13 to be
inserted into cavity 31. In such a manner, the dampened
insulation with activated adhesive is blown directly into
the cavity with structure 33 functioning to hold the
insulation in place until the adhesive cures.
It has been found by the instant inventors that
conventional siliconized (other hydrophobic agents may also
be used) loose-fill mixed with the dry adhesive
redispersible powder functions well in closed cavity
applications as shown in Figure 2 and in attic applications.
It has been found by the instant inventors that the use
of the dry fiberglass/redispersible powder adhesive mixture
in both open cavity (Figure 1) and closed cavity
applications (Figure 2) results in more uniform and
consistent applications, as well as increased productivity
potential relative to the prior art fiber~lass systems
discussed above.
CA 0224403l l998-07-27
Exemplary e~uipment for installing the loose-
fill/redispersib:1e powder adhesive mixtures according to all
embodiments of this invention presented herein are as
follows: (i) Blowing machines: Ark-Seal Big Blower (1800
RPM with 90% bleed off and 3~ gates recommended), Capitol
Equipment Model Nos. 65 and 200 (2400 RPM, 1/3 open gate, and
closed bleed-off), William W. Meyer and Sons 800, 1000, 1100
Series 4L Blower, and 3001 Series [3rd gear, 25% open air
valve, 2" open s].ide gate, and 1550 RPM], Krendl Machine Co.
Model Nos. 1000 and 2000 (slide gate - 7, and air 3~), and
Unisul Corp. Vol-U-Matic and Multi-Matic machines
(transmission - ~nd gear, 1000 RPM, 10~ gate and 100% bleed-
off where appropriate); (ii) Water Pumps: Dynesco Model
MP20 from Krendl or Unisul; (iii) Nozzle: 3 inch nozzle
from Krendl Machine Co., Inc.; (iv) Collection Device for
recycling system: Collector Box from Guardian Fiberglass,
Inc., Albion, MI; (v) Wall Scrubbers; Krendl Model # 349-B,
or Spray Insulation Components Model No. SC 1016, 1024; (vi)
Hoses: 3 inch fiber discharge hose or 3~ inch fiber
discharge hose with final fifty feet reduced to 3 inch via
reducer; (vii) Nozzle Jets: Krendl ~ QJJ Body and QW-SS-
31
. ~ . . . .. _ .
CA 02244031 1998-07-27
2501 tip, or Spraying Systems 1~ inch QJJ Body and Q W-SS-
2501 tip; (viii) Fittings: Parker Hannifin B20-5B (female
with hose-barb end) and H2C (male with 1~ inch threaded end);
and (ix) water supply tank: #T125L from Wylie Mfg. Co.
Regarding the equ:ipment set forth herein, Ark-Seal is
located in Denver, Colorado; Krendl in Delphos, Ohio; Parker
Hannifin in Wickl:iffe, Ohio; Spraying Systems in Wheaton,
Illinois; Unisul :in Winter Haven, Florida; Wylie Mfg. in
Petersburg, Texasi and Meyer in Skokie, Illinois.
This invention will now be described with respect to
certain examples as follows.
EXA~PLES 1-4
The dry fiberglass/powder mixtures according to
Examples 1-4 are set forth below in Chart 1, each element
being represented by its percentage in weight relative to
the overall mixture. For these Examples, the dry
redispersible powc~er used was RP-238 while the loose~fill
fiberglass was conventional white loose-fill coated with
silicone available from Guardian Fiberglass, Albion,
Michigan. The de--dusting oil and anti-static agent in the
mixtures were ~otll conventional.
32
CA 0224403l l998-07-27
CHART 1
Dry Mixture ~6 Fiberglass % De-dusting % RP-238 dry
Example No. by weight oil and anti- adhesive by
static agent weight
1 99.15% 0.20% 0.65%
2 99.10% 0.20~ 0.70~
3 99.05% 0.20% 0.75%
4 98.6% 0.20% 1.2
EXAMPLES 5-7
While Examples 1-4 set forth above in Chart 1 represent
the make-up of four different dry mixtures, Examples 5-7
describe the spray-on application of a dry mixture made up
of 0. 20% de-dusting/anti-static, 1.10% RP-238 dry adhesive,
and- 98.7% by weight white loose-fill fiberglass (with no
hydrophobic agent). The insulation products of Examples 5-7
were applied as shown in Figure 1. Commercially available
neumatic blowi:ng machine 23 was used to apply the dry
mixture including the adhesive, blower 23 being initially
set to run at about 1950 - 1980 RPM. Pump 25 and hose 13
were used to supply water to nozzle area 15 so that the dry
mixture exiting hose 11 was coated with water (in order to
activate the a~hesive) before spraying into cavity 5. Four
33
CA 02244031 1998-07-27
jets (H1/8VV1501 at 100 PSI) were used at nozzle area 15
adjusted to the twelve o'clock and six o'clock positions as
known in the trade with a flat spray projectory being set in
the horizontal position of each jet. Stainless steel tipped
jets are preferable over brass ones.
User 3 stood on the ground approximately five to six
feet from wall structure 7. Rear wall 32 was made of
plywood. The user turned on blower 23 and then immediately
turned on the flow valve for water hose 13. The loose-fill
fiberglass/dry adhesive mixture discharged from the nozzle
end of hose 11 was coated with water from hose 13 in order
to activate the adhesive and thereafter sprayed or blown
into cavity 5 where it was retained as shown in Figure 1.
User 3 manipulated the spray nozzle in a side to side or
back and forth manner building shelf upon shelf 16 of
insulation starting at the bottom of cavity S near the lower
horizontal stud 19 and proceeded upward as the cavity was
filled. All studs were 2" x 4" and made of wood. Cavity 5
was filled to an insulation thickness of about 1" beyond (or
exterior) the most outward protrusion of vertical studs 17
34
CA 02244031 1998-07-27
(i.e. the insulation was applied to a thickness of about 4.5
to 5.0 inches originally).
Immediately after spraying the dampened mixture into
cavity 5, the installed fiberglass product was compression
rolled using a non-stick roller (not shown) so as to pack
the insulation within the cavity to a thickness of about 3.5
inches substantially flush with the exterior faces of studs
17. After rolling, if and when gaps or voids in the
insulation finally became observed or evident, residual or
overspray fiberglass which had fallen to the floor was
placed and packed in the cavity to fill such voids.
Alternatively, an electric wall scrubber may be used to
shave off excess insulation from the cavities after blowing.
The front faces of studs 17 and l9 were then cleaned so
that wallboard could be applied in order to close cavity 5.
The user then allowed the installed fiberglass to cure (i.e.
dry). Curing at this 3.5 inch thickness took about twenty-
four hours after which the applied LOI data was taken.
The procedures and steps set forth above were carried
out numerous times (the temperature was ambient atmosphere)
CA 02244031 1998-07-27
resulting in the three Examples set forth in Chart 2 below
for Examples 5--7.
CHART 2
Example No. Density R-Value at Applied LOI
(lb.\ft3~ 3.5"
thickness
2.5 13.4 1.38~
6 2.27 11.9 1.36%
7 2.00 13.0 1.36%
The density data in pounds per cubic foot (lb.\ft3)
taken and set forth in Chart 2 illustrates that the density
of the installed and cured insulation product was less than
or equal to about 2.5 lb.\ft3, more preferably less than or
equal to about 2.0 lb.\ft3 according to certain embodiments
of this invention, while the R-value was greater than about
11, more preferably greater than about 12, and most
preferably greater than about 13 given an insulation
thickness of about 3.5 inches. This translates into R-
values of at least about 3.15 per inch thickness, 3.43 per
inch thickness, and 3.71 per inch thickness respectively.
3 t~
.. ,. ._ .. , ._ ... .
CA 02244031 1998-07-27
With respect to the applied LOI data set forth in Chart
2, this is indicative of the binder content of the final
product resulting from the RP-238 dry adhesive powder as
activated by the water. In other words, the applied LOI
shown in Chart 2 is not an indication of the de-dusting oil
and anti-static agent contents. The applied LOI percent is
generally less than about 2.0% according to certain
embodiments of this invention, and more preferably less than
about 1.50% and most preferably less than about 1.38%. This
LOI data is applicable to any and all embodiments set forth
herein, including attic applications and open cavity
applications.
It has been found surprisingly that reducing the amount
of anti-static material results in better adhesive
distribution and adherance, and a better final product.
Chart 3 below :illustrates theoretical examples of dry
fiberglass/RP rnixtures (with reduced amounts of anti-stat)
which may be b:Lown into attics or open vertical wall
cavities in al:l embodiments of this invention.
CA 02244031 1998-07-27
CHART 3
Dry Mixture % Fiber- % RP Dry ~ Anti- % De-
Example No. glass by Adhesive Static dusting
Weight by Weight Material Oil
by Weight
8 99.0% 0.90% 0~ 0.10%
9 99.1~ 0.80% 0~ 0.10%
98.8% 0.95%0.10% 0.15%
11 99.25% 0.50~0.05~ 0.20%
12 99.40% 0.50% 0% 0.10
13 97.5% 2.35% 0% 0.15%
14 98.0% 1.75% 0% 0.25
98.6~ 1.25% 0% 0.15
16 98.5% 1.35% 0% 0.15
Surprisingly, the instant inventors have found that
reducing the amount of anti-static material (e.g. quaternary
ammonium salts available from Sunshine Chemical Specialties,
Inc., Pennsauken, New Jersey) [trade name of CS-II] improves
the adhesion between the fibers and redispersible powder
within the insulation mixture. For example, in Chart 3 set
forth above, dry mixture example nos. 8, 9, and 12-16 are
completely free of anti-static rnaterial, while dry mixture
example no. 11 is substantially free of anti-static material
38
.. _ . . . . ........ . .. .... , .. , ., .. ~ ... .. . . .
CA 02244031 1998-07-27
(i.e. less than about 0.05~ by weight anti-static material),
and dry mixture example no. 10 has only 0.10% by weight
anti-static material in the mixture. By providing the
mixture with less than or equal to about 0.10% by weight
anti-static material (e.g. quaternary ammonium salt, or any
other conventional anti-static material) the adhesion
between the RP and glass fibers has surprisingly been found
to be improved, with the result being the RP being more
evenly and uniformly distributed throughout the mixture
thereby resulting in more uniform applications and improved
final products.
Another problem believed to exist by the instant
~ inventive entity, is potential scenarios where insulation
contractors apply the insulation mixture into attics, wall
cavities, or the like without using the adhesive activating
liquid (e.g. water) in order to save time and/or money.
This is undesirable. Accordingly, a unique system (for use
with all embodirnents herein~ to be described below has been
developed in order to combat this potential problem and to
allow a manufacturer to, upon examination of a final
product, determine whether or no~ the contractor who
39
CA 02244031 1998-07-27
installed the insulation followed specified procedures (i.e.
whether the contractor used the activating liquid). To
begin with, the initial insulation mixture, as set forth
above in Chart 3, includes from about 97.4% to 99.40% by
weight loose-fill fiberglass, from about 0.25% to 2.5% by
weight redispersible powder adhesive, fro~ about 0% to 0.10%
anti-static material, and finally from about 0.01% to 0.15%
by weight dry powder color dye in an unactivated particulate
powder form. This mixture preferably includes from about
0.02% to 0.10% by weight of the dye, and most preferably
approximately from about 0.02~ to 0.05% by weight of the
unactivated color dye. Exemplary dyes which may be used
include Croceine Scarlet M00, available from Chromatech,
Inc., Plymouth, Michigan, and/or Tricosol Blue No. 17732,
available from Tricon Colors, Inc., Elmwood Park, New
Jersey. It is important to note that the dye(s~ is/are
provided in the insulation mixture in a unactivated dry form
in an amount such that the fibers themselves are not colored
substantially prior to activation upon installation into an
attic or wall cavity. Due to these water or liquid
activated dyes, enough color is provided when the insulatioI-
_......
CA 02244031 1998-07-27
mixture is installed along with the adhesive and dye
activating liquid (e.g. water) as discussed above, so that
the dye in particulate form is activated (i.e. becomes
colored) when hit with the activating liquid upon
installation so that the final installed insulation product
is provided with colored specs or portions of activated dye
which indicate that the insulation was installed along with
the adhesive activating liquid (e.g. water).
When the loo~e-fill mixture is made, the dye and RP may
be mixed together to form a dry-mix, with this dry-mix then
being mixed in with the loose-fill fiberglass or plastic
fibers in order to form the mixture. Green, blue, and/or
red dye(s) may be used in certain embodiments.
Figure 3 is a perspective view of another embodiment of
this invention wherein the loose-fill fiberglass and
redispersible powder (RP) adhesive mixture coated with an
activating liquid, such as water, is blown into or onto an
attic area 51 to be insulated. Siliconized or non-
siliconized fiberglass may be used in attic applications.
The area 51 to be insulated includes supporting structure 53
which may be substantially horizontal or inclined according
41
CA 02244031 1998-07-27
to different embodiments of this invention. On top of
surface 53, the insulation mixture 55 is blown or sprayed.
The loose-fill fiberglass, as discussed above, is dry mixed
with any of the above-discussed redispersible powders and is
thereafter added to blower 23 and blown through hose 11 so
that the dry mixture is coated at the nozzle area with the
activating liquid ~e.g. water) which is pumped through hose
13 at from about 50 - 60 psi. Thus, the redispersible
powder (RP) adhesive is activated by the water at the nozzle
and is blown toward attic area 51 to be insulated in an
activated state. The nozzle may be located at the end of
both hoses as shown in figure 1, or alternatively remote
from the area to be insulated as shown in Figure 3 in dotted
lines.
The use of the polymeric based redispersible powder
(~P) adhesive in the insulation mixture 55 provides an
improvement over the prior art in that the adhesive is quick
setting and the insulation is sub~ect to less movement or
shifting in the horizontal or sloping attic area, or the
like. This effect of the redispersible powder emulsion is
42
CA 02244031 1998-07-27
especially useful on inclined attic surfaces and in the open
wall cavities discussed above.
The dry mixture in attic applications may sometimes be
different than in open wall cavity applications, in that for
attics the mixtu:re is from about 0.75 to 2.5~ RP by weight,
preferably from about 1.5 to 2.25%. RP-238 and RP-140 are
preferable as RPs.
Redispersible powders (RP) are known to be spray-dried
liquid latex, wherein a liquid emulsion is converted at high
temperatures into a free-flowing powder that, when mixed
with water or the like, produces a stable latex with
properties comparable to those of the original liquid.
Redispersible powders are typically utilized with cement-
aggregate materials. Airflex~ redispersible powders, based
on copolymers of vinyl acetate and ethylene, are preferably
used according to certain embodiments of this invention as
listed above, these powders being characterized by
copolymerization of ethylene with vinyl acetate. Polyvinyl
alcohol, also an efficient binder, is the protective colloid
which imparts redispersibility to the powders. This
description of redispersible powders is, of course, known
43
CA 02244031 1998-07-27
and applies to all embodiments herein. The instant
inventors have unco~ered the surprising fact that
redispersible powder, when mixed with fiberglass or other
fiber insulation, results in improved results relating to
spraying/blowing same and the finished product. Melt-blown
plastic fiber insulation (e.g. polyethylene) may also be
used in conjunction with these RPs in place of the glass
fibers in all embodiments herein.
Still referring to Figure 3, the activated loose-fill
mixture is blown into attic area 51 to be insulated with the
result being an attic R-value of insulation 55 of from about
R-l9 up to about R-45, a cured insulation 55 thickness of
from about 5 to 25 inches, and a cured insulation 55 density
of from about 0.25 lbs./ft3 up to about 1.5 lbs./ft3, and
preferably the density being from about 0.75 lbs./ft3 to
1.25 lbs./ft3. In certain attic embodiments, the R-value
will be at least about 2.7 per inch thickness of insulation,
preferably greater than about 3.0 per inch thickness, and
most preferably at least about 3.15 per inch thickness.
In attic applications, the wet mixture as blown/sprayed
from the and of hose 11 or nozzle is from about 15% to 30
44
CA 02244031 1998-07-27
by weight water and the remainder the fiberglass/RP mixture.
Optionally, a liquid adhesive may be used in attic
applications instead of RP, as discussed in 08/572,626.
Figure 4 is an exploded perspective view illustrating a
nozzle asse~bly 100 that may be used in conjunction with any
of the spraying embodiments herein for the purpose of
spraying the activated fiber/RP mixture toward the area to
be insulated. As illustrated, nozzle assembly 100 in Figure
4 includes line 101 for conveying the activating liquid from
its reservoir toward the nozzle, T-member 102 for allowing
one portion 106 the activating liquid (e.g. water) to
continue flowing clirectly toward nozzle 103 and another
portion 104 to veer off into tube or conduit 105. Thus, the
first portion 106 of activating liquid from T-member 102
flows into nozzle inlet 107 while the second portion 104 of
activating liquid from the T-member flows through conduit
105 and into another nozzle inlet 109. The
fiberglass/redispersible powder dry mixture is blown toward
nozzle 103 through tube 11. Thus, when the fiber/RP dry
mixture enters nozzle 103, it is hit on opposite sides by
the activating liquid from inlets 107 and 109 thereby
CA 02244031 1998-07-27
thoroughly activating the RP within the mixture.
Thereafter, the mixture with the activated adhesive is blown
through outlet 111 of nozzle 103 and toward either an open
wall cavity area to be insulated or toward an attic area to
be insulated.
In certain embodiments (attic and open wall cavity),
the nozzle 103 in Figure 4 (or any other nozzle 15 herein)
may be located at :Location 90 adjacent the blower 23 (i.e.
remote from the area or cavity to be insulated) so that the
water hose inputs the water into hose 11 back near the
blower and/or truck instead of in the attic or home being
insulated, so as to allow the adhesive and fiber to
thoroughly mix in an activated state as it travels through
hose 11 toward the cavity or attic to be insulated. An
exemplary water hose 91 is shown in dotted lines in Figure 4
for such an embodiment.
It should be noted that according to certain attic
embodiments, the fiberglass/RP mixture is from about 0.75 to
2.5% by weight dispersible powder, from about 97.4 to 99.25%
by weight loose-fill fiberglass, and the remainder being
made up of small amounts of de--dusting oil as set forth in
46
CA 02244031 1998-07-27
Chart 1 and optionally a small amount of silicone as is
known in the art. The preferred LOI% of the cured
insulation would be from about 0.75% to 2.5~ in attic
applications (and usually no greater than about 3.0%, and
most preferably no greater than about 2.0~ LOI).
Once given the above disclosure, many other features,
modifications, and improvements will become apparent to the
skilled artisan. Such other features, modifications, and
improvements are therefore considered to be a part of this
invention, the scope of which is to be determined by the
following claims.
~ . .....
