Note: Descriptions are shown in the official language in which they were submitted.
CA 02629123 2008-04-15
FOLDING BLADE FOR INSULATION BAGGER
TECHNICAL FIELD
[0001] This invention relates generally to machines for packaging fibrous
batts
of thermal insulation, and more particularly to the folding of a length of a
fibrous
insulation batt.
BACKGROUND OF THE INVENTION
[0002] Fibrous insulation is typically manufactured in common lengths and
widths, called insulation batts, to accommodate typical building frame
structure
dimensions. Fibrous insulation batts are commonly made of mineral fibers, such
as glass fibers, and usually have a density within a range of from about 0.2
to
about 1.0 pounds per cubic foot (3.2 to 16 kg/m3). Typical batt sizes are
about 16
or 24 inches (40.6 cm or 61 cm) wide by about 8 to 10 feet (2.44 m) long. The
batts can be packaged in various ways including staggering and rolling the
batts
along their length to form a roll containing about 10 batts.
[0003] Alternatively, in order to reduce storage and transportation costs, it
is
common practice to package insulation batts by folding the insulation batts
approximately in half lengthwise. The folded batts are compressed and then
provided with a covering, for example, a bag, which maintains the batts in
their
compressed state. When the bag is subsequently removed at the point of
utilization of the batts, the batts expand to their normal size.
[0004] Particular apparatus for folding and packaging insulation batts are
sized
for batts having a maximum length of 100 inches and a maximum folded length of
50 inches. It would be advantageous if the apparatus could fold and package
insulation batts longer than 100 inches.
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SUMMARY OF THE INVENTION
[0005] The above objects as well as other objects not specifically enumerated
are achieved by an apparatus for folding and packaging fibrous insulation
batts.
The apparatus comprises an unfolded batt conveyor assembly configured to move
fibrous insulation batts in a machine path. The apparatus also includes a
folding
section. The folding section includes a folding blade and an actuator. The
actuator is configured to move the folding blade along a blade path that
intersects
the machine path. The folding blade has a leading surface configured to
contact
and fold the fibrous insulation batts around the folding blade. The leading
surface
has a width and a length. The width of the leading surface is at least about
five
inches. The width of the leading surface is sufficient to provide a c-shaped
fold in
the fibrous insulation batt. The c-shaped fold has an internal c-shaped fold
width
approximately equal to the width of the leading surface. A gripper assembly is
configured to receive and move the folded fibrous insulation batts along the
blade
path that intersects the machine path. The gripper assembly is further
configured
to cooperate with a folded batt delivery assembly to move the folded
insulation
batts in the machine path. A packaging section is configured to receive and
package the folded fibrous insulation batts.
[0006] According to this invention, there is also provided an apparatus for
folding and packaging fibrous insulation batts. The apparatus comprises an
unfolded batt conveyor assembly configured to move fibrous insulation batts in
a
machine path. The apparatus further includes a folding section. The folding
section includes a folding blade and an actuator. The actuator is configured
to
move the folding blade along a blade path that intersects the machine path.
The
folding blade has a leading surface configured to contact and fold the fibrous
insulation batts around the folding blade. The leading surface of the folding
blade
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has a width and a length. The ratio of the width of the leading surface of the
folding blade to the thickness of the batt is in a range from about 0.25 to
about 2Ø
A gripper assembly is configured to receive and move the folded fibrous
insulation
batts along the blade path that intersects the machine path. The gripper
assembly
is further configured to cooperate with a folded batt delivery assembly to
move the
folded insulation batts in the machine path. A packaging section configured to
receive and package the folded fibrous insulation batts.
[0007] According to this invention, there is also provided an apparatus for
folding and packaging fibrous insulation batts. The apparatus comprises an
unfolded conveyor assembly configured to move fibrous insulation batts in a
machine path. The apparatus further includes a folding section. The folding
section includes a folding blade and an actuator. The actuator is configured
to
move the folding blade along a blade path that intersects the machine path.
The
folding blade has a leading surface configured to contact and fold the fibrous
insulation batts around the folding blade. The folded fibrous insulation batt
has a
c-shaped fold section. The c-shaped fold section has an internal c-shaped fold
width and an external c-shaped fold width. A gripper assembly is configured to
receive and move the folded fibrous insulation batts in the machine path. The
gripper assembly is further configured to cooperate with a folded batt
delivery
assembly to move the folded insulation batts in the machine path. A packaging
section is configured to receive and package the folded fibrous insulation
batts.
The ratio of the external c-shaped fold width to the internal c-shaped fold
width is
in a range from about 1.0 to about 7Ø
[0008] Various objects and advantages of this invention will become apparent
to those skilled in the art from the following detailed description of the
invention,
when read in light of the accompanying drawings.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Figure 1 is a side view in elevation, of an apparatus for folding and
packaging fibrous insulation batts.
[0010] Figure 2 is a side view in elevation, of a folding section of the
apparatus
of Figure 1.
[0011] Figure 3 is a perspective view of a folding blade of the apparatus of
Figure 1.
[0012] Figure 4 is a side view in elevation, of the fibrous insulation batt
folding
around the folding blade of Figure 3.
[0013] Figure 5 is a side view in elevation, of a folded fibrous insulation
batt
according to prior art.
[0014] Figure 6 is a side view in elevation, of a fibrous insulation batt with
a c-
shaped fold.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The description and drawings disclose an apparatus and method for
folding and packaging fibrous insulation batts. Referring now to the drawings,
there is shown in Fig. 1 an apparatus 10 for folding and packaging a fibrous
insulation batt.
[0016] The term fibrous insulation batt, as used herein, is intended to
include
fibrous insulation products manufactured in common lengths and widths. The
batt
can be made of glass fibers or of fibers of other mineral materials, such as
rock,
slag and basalt.
[0017] As shown in Figs. 1 and 2, an unfolded batt conveyor assembly 12
receives unfolded fibrous insulation batts 14 from a batt forming machine (not
shown). The unfolded batts 14 have a thickness t]. The thickness tl generally
corresponds to the insulative value of the unfolded batt 14. In one embodiment
as
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an example, an unfolded batt 14 having an R13 insulative value generally has a
thickness tl of approximately 3.5 inches (8.9 cm). Similarly in another
embodiment, an unfolded batt having an R 19 insulative value generally has a
thickness tl in a range from about 6 inches (15.2 cm) to about 8.5 inches
(21.6
cm). Alternatively, the unfolded batts 14 can have a thickness tl that is more
than
about 8.5 inches (21.6 cm) or less than about 3.5 inches (15.2 cm).
[0018] The unfolded batts 14 are moved in a machine path dl by the unfolded
batt conveyor assembly 12. The unfolded batt conveyor assembly 12 moves the
unfolded batts 14 at a speed from about 100 feetlminute to about 300
feet/minute.
However, other speeds can be used.
[0019] In one embodiment as further shown in Figs. 1 and 2, a compression
conveyor assembly 18 is disposed parallel to and above the unfolded batt
conveyor
assembly 12. In this embodiment, as the unfolded batts 14 are moved by the
unfolded batt conveyor assembly 12, the unfolded batts 14 are temporarily
compressed by the compression conveyor assembly 18. Compression of the
unfolded batts 14 substantially softens the insulation material of the
unfolded batts
14 and substantially removes the tendency of the later folded batts to unfold.
While the compression conveyor assembly 18 shown in Figs. 1 and 2 includes an
endless belt 20 rotating around compression rolls 22, it is to be understood
that
any type of compression device can be used. Alternatively, softening of some
types of fibrous insulation materials, such as those with low density or those
with
small thicknesses, is not necessary.
[0020] As further shown in Figs. 1 and 2, the unfolded batts 14 exit the
compression conveyor assembly 18 and continue to move in the machine path dl.
The unfolded batt conveyer assembly 12 moves the unfolded batts 14 into the
folding section 24. As best shown in Fig. 2, the folding section 24 includes a
folding blade 26 supported by a framework 28. In this embodiment, the
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framework 28 includes both substantially vertical and horizontal members, 30
and
32 respectively. The purpose of the substantially vertical member 30 is to
support
the horizontal member 32. The horizontal member 32 is configured to support
the
folding blade 26 as the folding blade 26 reciprocally moves along a blade path
p1
that intersects the machine path dl. While the framework 28 shown in Fig. 2
includes both substantially vertical and horizontal members, 30 and 32, it is
to be
understood that the framework 28 can any structure sufficient to support the
folding blade 26 as the folding blade 26 reciprocally moves along a blade path
p1.
As shown in Figs. 1 and 2, the framework 28 is positioned above the unfolded
batt
conveyor assembly 12. In another embodiment, the framework 28 can be
positioned in another location, such as for example below the unfolded batt
conveyor assembly 12, sufficient to support the folding blade 26.
[0021] As best shown in Fig. 2, the blade path pl intersects with the machine
path dl. The intersection of the blade path p1 and the machine path dl forms
an
angle a. In the embodiment shown in Fig. 2, the angle a is in a range from
about
45 to about 70 . In another embodiment, the angle a can be larger than about
70
or smaller than about 45 .
[0022] As further shown in Fig. 2, an actuator 34 moves the folding blade 26
along the blade path p1 to intersect the machine path dl. In this embodiment,
the
actuator 34 is a pneumatic system. Alternatively, the actuator 34 can be any
means of moving the folding blade 26 along blade path p1, including such means
as an induction coil system, or a hydraulic system.
[0023] Referring again to Fig. 2, the actuator 34 is controlled by a
controller
(not shown) and a sensor 36. The sensor 36 is positioned to sense the movement
of the unfolded batt 14 across a gap 38. The gap 38 is a space formed between
the
unfolded batt conveyor assembly 12 and a folded batt delivery assembly 40. In
operation, as the unfolded batt 14 moves in the machine path dl, the sensor 36
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senses the unfolded batt 14 moving across the gap 38. The sensor 36 is
connected
to the controller, which is configured to control the actuator 34 in response
to a
signal from the sensor 36. In order to prevent overloading of the folding and
packaging apparatus 10, or to prevent an excessive number of unfolded batts 14
from entering the folding section 24, the controller can be configured to slow
down, stop or reverse the unfolded batt conveyor assembly 12 if the sensed
loading of the folding section 24 is too great.
[0024] The sensor 36 can be any mechanism, such as a photo sensor, capable of
detecting the presence of an oncoming unfolded batt 14. While the sensor 36
shown in Fig. 2 is positioned underneath the folding blade 26, it is to be
understood that the sensor 36 can be positioned in any location sufficient to
sense
the presence of an oncoming unfolded batt 14.
[0025] As best shown in Figs. 2, 3 and 4, the folding blade 26 has a leading
surface 42. The leading surface 42 is configured to contact the unfolded batt
14 as
the folding blade 26 moves along blade path p1. As the folding blade 26
continues
to move along blade path p1, the folding blade 26 is configured to fold the
unfolded batt 14 around the folding blade 26 to form a folded batt 44. Further
movement of the folding blade 26 along blade path p 1 pushes the folded batt
44
into the folded batt delivery assembly 40.
[0026] As best shown in Fig. 3, the folding blade 26 is a solid member.
Alternatively, the folding blade 26 can be a frame, a mesh framework or any
other
device suitable to contact the unfolded batt 14 and fold the unfolded batt 14
around the folding blade 26.
[0027] In the embodiment shown in Fig. 3, the folding blade 26 is made of an
ultra high molecular weight polymer material to substantially minimize the
weight
of the moving folding blade 26. Alternatively, the folding blade 26 can be
made
of any material, such as wood or metal, sufficient to contact the unfolded
batt 14
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and fold the unfolded batt 14 around the folding blade 26. Advantageously, the
folding blade 26 has a smooth surface to discourage build-up of glass fibers.
Any
surface can be used, however.
[0028] As further shown in Fig. 3, the leading surface 42 has a substantially
rectangular cross-sectional shape. Alternatively, the leading surface 42 can
have
any other cross-sectional shape, such as for example a substantially oval
cross-
sectional shape, sufficient to contact the unfolded batt 14 and fold the
unfolded
batt 14 around the folding blade 26.
[0029] In one embodiment as best shown in Fig. 3, the leading surface 42 is
substantially flat. Alternatively, the leading surface 42 can be raised (not
shown)
or have raised portions (not shown), sufficient to contact the unfolded batt
14 and
fold the unfolded batt 14 around the folding blade 26.
[0030] Referring again to Fig. 3, the leading surface 42 has a width w and a
length 1. The length 1 of the leading surface 42 generally corresponds to
typical
batt sizes, such as for example, about 16 or 24 inches (40.6 cm or 61 cm).
Alternatively, the length l of the leading surface 42 can be other sizes. The
width
w of the leading surface is sized to provide a c-shaped fold section 46 as
best
shown in Figs. 4 and 6. The c-shaped fold section 46 will be discussed in more
detail below.
[0031] Referring again to Fig. 1, the folded batts 44 are gripped by the
folded
batt delivery assembly 40 and exit the folding section 24. The folded batt
delivery
assembly 40 is configured to grip the folded batts 44 and move the folded
batts 44
toward a stacking framework 47. In this embodiment, the folded batt delivery
assembly 40 includes a gripper assembly 48 and a folded batt delivery assembly
50. In this embodiment, the gripper assembly 48 and the folded batt delivery
assembly 50 are endless belt convey systems. Alternatively, the gripper
assembly
48 and the folded batt delivery assembly 50 can be any structure, assembly or
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mechanism sufficient to grip the folded batts 44 and move the folded batts 44
toward a stacking framework 47. In operation, as the folding blade 26 moves
along blade path p1 and folds the unfolded batts 14 to form the folded batts
44, the
folded batts 44 are pushed along blade path p1 by further movement of the
folding
blade 26. As best shown in Fig. 2, the folded batts 44 are gripped between the
gripper assembly 48 and the unfolded batt conveyor assembly 12. The gripper
assembly 48 and unfolded batt conveyor assembly 12 move the folded batts 44 in
a manner such that the folded batts 44 are subsequently gripped by the gripper
assembly 48 and the folded batt delivery assembly 50.
[0032] The gripper assembly 48 and the folded batt delivery assembly 50 move
the folded batts 44 downstream toward the stacking framework 47. The stacking
framework 47 is configured to stack a desired quantity of folded batts 44 and
deliver the stacked folded batts to a packaging apparatus 54, which can be any
apparatus suitable for packaging the folded batts 44. In the embodiment shown
in
Fig. 1, the packaging apparatus 54 includes a compression chamber 56. The
compression chamber 56 is configured to compress a quantity of stacked batts
prior to packaging. The packaging apparatus 54 further includes a bagging
apparatus 58 and a ram apparatus 60. The ram apparatus 60 is configured to
urge
the compressed stacked batts into the bagging apparatus 58. The bagging
apparatus 58 is configured to cover the compressed stacked batts with a
protective
cover. While the embodiment shown in Fig. 1 includes a stacking framework 47
and a packaging apparatus 54, it is to be understood that any structure,
assembly or
mechanism suitable to stack, compress, and package the folded batts 44 can be
used.
[0033] As previously discussed, the folding blade 26 moves along blade path
p1 thereby forming the unfolded batts 14 into folded batts 44. The folding
blade
26 includes a leading surface 42. The width w of the leading surface is sized
to
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provide a c-shaped fold section 46 as best shown in Figs. 4 and 6. The c-
shaped
fold section 46 provides batts produced by recent machines with a significant
advantage over batts folded by typical prior art folding machines. One example
of
a prior art folding machine is a folding machine of the type disclosed in U.S.
Patent No. 4,805,374 to Yawberg, which is hereby incorporated by reference, in
its entirety. In the Yawberg folding machine, a plate member is moved to fold
insulation batts substantially in half. The plate member typically has a width
of
approximately 1/2inch (1.3 cm), thereby resulting in a sharp fold section 62
as
shown in Fig. 5. The Yawberg machine provided for unfolded batts having a
maximum length of 100 inches (254 cm) and a maximum folded length of 50
inches (127 cm).
[0034] In contrast, the use of the c-shaped fold section 46 in the current
invention allows unfolded batts 14 having a length in excess of about 100
inches
(254 cm), such as for example about 105 inches (266.7 cm), to be folded
substantially in half and the resulting folded batt 44 can maintain a maximum
folded length of about 50 inches (127 cm). Maintaining the maximum folded
length of about 50 inches (127 cm) allows the use of current stacking and
packaging apparatus.
[0035] In the current embodiment as best shown in Fig. 6, the c-shaped fold
section 46 has opposing sides, 49a and 49b, and end 49c. The opposing sides,
49a
and 49b, and end 49c define a hollow space 51 within the folded insulation
batt
44. In this embodiment, the hollow space 51 is a substantially round space. In
another embodiment, the hollow space 51 can have any other shape. The hollow
space 51 has an internal c-shaped fold widthfl, which is defined as the
maximum
distance, within the hollow space 51, between the opposing sides 49a and 49b.
The c-shaped fold section 46 also has an external c-shaped fold width f2. The
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external c-shaped fold width f2 is defined as the maximum distance between the
outer surfaces of the opposing sides, 49a and 49b.
[0036] As further shown in Fig. 6, the end 49c has a surface 49d within the
hollow space 51. The shape of the surface 49d is substantially formed by the
leading edge 42 of the folding blade 26. In this embodiment, the surface 49d
is
substantially flat with curved ends. Alternatively, the surface 49d can have
another shape corresponding to a folding blade 26 having leading edge 42 of
another shape.
[0037] As further shown in Fig. 6, the folded batt 44 has an overall lengthfl.
The overall lengthfl of the folded batt 44 can be controlled by varying the
internal
widthfl of the c-shaped fold section 46. In one embodiment, the internal c-
shaped
fold width f] is approximately the same dimension as the width w of the
leading
surface 42 of the folding blade 26. In this embodiment as an example, the
internal
c-shaped fold width fl is approximately five inches (12.7 cm), the width w of
the
leading surface 46 is also about five inches (12.7 cm), and the overall
lengthfl of
the folded batt 44 is about 50 inches (127 cm). The resulting maximum length
of
the unfolded batt 14 is therefore about 105 inches (266 cm). In a similar
manner
in another embodiment, the width w of the leading surface 42 can be larger,
thereby producing a larger internal c-shaped fold width fl. The larger
internal c-
shaped fold width fl allows for a longer unfolded batt (i.e. longer than he
conventional 100 inch batt) to be folded substantially in half while still
maintaining the maximum folded length of about 50 inches (127 cm).
[0038] Referring again to Fig. 4, the width w of the leading surface 42 of the
folding blade 26 can be similar to the thickness tl of the unfolded batt 14.
In one
embodiment as an example, the width w of the leading surface 42 is
approximately
five inches (12.7 cm) and the thickness tl of the fibrous insulation is about
3.5
inches (8.9 cm). In this embodiment, the ratio of the width w of the leading
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surface 42 of the folding blade 26 to the thickness tl is approximately 1.43
inches.
Alternatively, the width w of the leading surface 42 can be about five inches
(12.7
cm) and the thickness tl can be approximately six inches (15.2 cm) resulting
in a
ratio of 0.83. In another embodiment, the width w of the leading surface 42
can be
about five inches (12.7 cm) and the thickness tl can be approximately eight
and
one-half inches (21.6 cm) resulting in a ratio of 0.58. In yet another
embodiment,
the ratio of the width w of the leading surface 42 of the folding blade 26 to
the
thickness tl can be in a range from about 0.25 to about 2.0 inches.
[0039] As best shown in Fig. 6, the external c-shaped fold width fZ of the
folded batt 44 can correspond to the internal c-shaped fold width fl of the
folded
batt 44. In one embodiment as an example, an unfolded batt 14 having a
thickness
tl of about 3.5 inches (8.9 cm) and an internal c-shaped fold widthfl of
approximately five inches (12.7 cm) has an external c-shaped fold width f2 of
approximately twelve inches (30.4 cm). In this embodiment, a ratio of the
external
c-shaped fold width, f2 to the internal c-shaped fold widthfl is about 2.4.
Alternatively, an unfolded batt 14 having a thickness tl of about six inches
(15.2
cm) and an internal c-shaped fold widthfl of approximately five inches (12.7
cm)
has an external c-shaped fold width f2 of approximately seventeen inches (43.1
cm). In this embodiment, a ratio of the external c-shaped fold width f2 to the
internal c-shaped fold width fl is about 3.4 inches. In another embodiment, an
unfolded batt 14 having a thickness tl of about eight and one/half inches
(21.6 cm)
and an internal c-shaped fold widthfl of approximately five inches (12.7 cm)
has
an external c-shaped fold width fl of approximately twenty-two inches (55.9
cm).
In this embodiment, a ratio of the external c-shaped fold width f2 to the
internal c-
shaped fold width fl is about 4.4. In yet another embodiment, the ratio of the
external c-shaped fold width f2 to the internal c-shaped fold width fl can be
in a
range from about 1.0 to about 7Ø
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[0040] The principle and mode of operation of this invention have been
described in its preferred embodiments. However, it should be noted that this
invention may be practiced otherwise than as specifically illustrated and
described
without departing from its scope.
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