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  Fiber insulation blanket and method of manufactureUSPTO Application #: 20070202771Title: Fiber insulation blanket and method of manufacture Abstract: A fiber blanket formed with a blend of constituent fibers is disclosed. In one disclosed embodiment, a cellulose fiber blanket is formed having a blend of cellulose fibers comprising approximately 85-90% by weight cellulose, resilient fibers comprising approximately 10% by weight, and the balance being adhesive plastic fibers. The fibers are then formed into a blanket having an R-value at least 4.0 per inch. (end of abstract) Agent: Gross & Associates - Sacrameto, CA, US Inventors: Earl Stuart Douglass, Thomas Clifford Shutt USPTO Applicaton #: 20070202771 - Class: 442416000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Nonwoven Fabric (i.e., Nonwoven Strand Or Fiber Material), Containing At Least Two Chemically Different Strand Or Fiber Materials, Containing Polymeric And Natural Strand Or Fiber Materials The Patent Description & Claims data below is from USPTO Patent Application 20070202771. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS REFERENCE TO RELATED APPLICATION [0001] This application is a continuation application of PCT Application PCT/US2005/039605 with an International filing date of Nov. 02, 2005, which claims the benefit of U.S. Provisional Application Ser. 60/517530, filed on Nov. 04, 2003, and which are both incorporated, in their entirety, herein by reference. BACKGROUND [0002] 1. Field of the Disclosure [0003] This disclosure relates generally to the composition and manufacture of paper fiber insulation products. [0004] 2. The Prior Art Background [0005] Currently, the bulk of thermal insulation material is made from glass wool and is sold in the form of a blanket. The shape and size of such blankets allows for convenient shipping and installation. An alternative to glass wool is cellulose insulation. [0006] The industry standard R-value allows for the comparing of a material's thermal insulating capability. The higher the R-value number, the greater is the material's ability to insulate. [0007] The insulating capability of a given blanket is largely determined by the density of the constituent fibers of the blanket. Hence, the higher the density the lower the R-value. The hollow nature of cellulose fiber provides a potential for a higher R-value than glass wool. [0008] Recently adopted building codes throughout the US have set a minimum of R-15 insulation within a 2.times.4 residential wall. This translates to a minimum R-value of 4.1 per inch and effectively prohibits the use of prior art cellulose insulation products in the cities and counties where this code has been adopted. BRIEF DESCRIPTION OF THE DRAWING FIGURES [0009] FIG. 1 is a conceptual diagram of a process for forming a fiber insulation blanket in accordance with the teachings of this disclosure. DETAILED DESCRIPTION [0010] Persons of ordinary skill in the art will realize that the following description is illustrative only and not in any way limiting. Other modifications and improvements will readily suggest themselves to such skilled persons having the benefit of this disclosure. In the following description, like reference numerals refer to like elements throughout. [0011] FIG. 1 is a conceptual diagram of a system 100 for forming a cellulose fiber insulation blanket. The process begins with the dosing and mixing of the constituent fibers, contained in towers 105, 110, and 115 of an air-lay machine, being transferred to a forming head 120 for shaping. [0012] As will be described more fully below, in a preferred embodiment, fiber insulation blankets of the present disclosure comprise a preferably homogenous composition of cellulose fibers, resilient fibers, and adhesive fibers, and it is desired that the mixture resulting from the forming head process be as thoroughly mixed as possible. [0013] The blended fibers 121 are then deposited onto the surface of a wire, typically a slotted conveyor belt, thereby forming a fiber blanket 125. The blanket 125 is then transported to a thermal forming station 130. [0014] Heated air is then drawn through the blend to soften and melt the adhesive plastic fibers, thereby adhering the constituent fibers into a matrix. Cool air is then drawn through the matrix solidifying the melted fibers and forming a continuous, coherent blanket 135. Preferably, a forming head in conjunction with a thermal bonding oven is suitable for this type of non-woven process. [0015] The blanket 135 may then be formed into batts 140 of a desired size as required. [0016] Finding an optimal balance between resilience and adhesion is critical so as to provide a product with good fiber compression recovery, low density and high R-value. For example, the finished product must return as closely as possible to its original thickness and shape after it has been compressed for packaging in order to maintain the stated R-value. Compression recovery has a strong effect on the cost of shipping and is therefore a critical element in the commercial viability of such products. [0017] To achieve these goals, in one disclosed aspect, a fiber blanket is formed by using 85-90% by weight cellulose fibers with the resilient and adhesive plastic fibers comprising the balance. In a further disclosed embodiment, a blend by weight of 75% cellulose, 20% resilient fiber and 5% adhesive fiber is used. In a further disclosed embodiment, a blend by weight of 85% cellulose, 10% resilient fiber and 5% adhesive fiber is used. In yet a further disclosed embodiment, a blend by weight of about 89% cellulose, 9% resilient fibers and 2% adhesive fibers will produce the same physical properties at lower cost. These blends preferably yield a blanket whose density can be varied from 0.8-1.5 pounds per cubic foot with an R-value ranging from 3.8-4.2, and preferably at least 4.0. [0018] More details of exemplary constituent fibers suitable for use in this disclosure will now be disclosed. [0019] Referring first to the cellulose constituent, in one preferred embodiment a cellulose fiber which complies with ASTM standard C739-91 is utilized. Such a loose-fill insulation fiber may be obtained from Cottonwood Manufacturing, Inc., the assignee of the present disclosure. Continue reading... Full patent description for Fiber insulation blanket and method of manufacture Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Fiber insulation blanket and method of manufacture patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. Start now! - Receive info on patent apps like Fiber insulation blanket and method of manufacture or other areas of interest. ### Previous Patent Application: Production method and filter comprising non woven fabric and/or filtering injector structures or sheets which are obtained using said method and which are intended for the filtration and which are intended for the filtration and elimination of legionella Next Patent Application: Absorbent article comprising a primary aqueous-liquid-absorbing agent Industry Class: Fabric (woven, knitted, or nonwoven textile or cloth, etc.) ### FreshPatents.com Support Thank you for viewing the Fiber insulation blanket and method of manufacture patent info. 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