Water spray applied loose-fill insulation

Patent metadata

Field	Value
Publication number	US-11369980-B2
Application number	US-202117158199-A
Country	US
Kind code	B2
Filing date	Jan 26, 2021
Priority date	Apr 8, 2014
Publication date	Jun 28, 2022
Grant date	Jun 28, 2022

Abstract

According to an embodiment, a method of applying loose-fill insulation within a cavity is provided. The method includes blowing loose-fill insulation particles into a cavity of a structure to install the loose-fill insulation within the cavity and thereby insulate the structure. The method also includes applying water (e.g., water mist) to the loose-fill insulation particles so that a moisture content of the installed loose-fill insulation is between about 2% and 20%. The water aids in retaining the loose-fill insulation particles within the cavity without requiring the use of an enclosure member that encloses the cavity and the loose-fill insulation is substantially free of a water soluble adhesive material that adheres the loose-fill insulation particles together within the cavity.

First claim

What is claimed is:

1. A method of applying loose-fill insulation within a cavity comprising:
breaking compressed loose-fill insulation material into a plurality of loose-fill insulation nodules, wherein a nodule size of each the plurality of loose-fill insulation nodules is between about 0.125 inches and 0.5 inches;
blowing the loose-fill insulation nodules to deliver the loose-fill insulation nodules into a cavity of a structure; and
applying a water mist to the loose-fill insulation nodules as the insulation nodules are blown into the cavity to form installed loose-fill insulation having a moisture content of between about 2% and 20%, wherein the installed loose-fill insulation is free of an aqueous or powdered adhesive material that adheres the loose-fill insulation nodules together within the cavity such that the installed loose-fill insulation is free of an adhesive material.

2. The method of applying loose-fill insulation within a cavity of claim 1 , wherein:
the loose-fill insulation material comprise fibers having diameters of between about 0.5 μm and 5.0 μm.

3. The method of applying loose-fill insulation within a cavity of claim 1 , wherein:
the water mist comprises one or more additives.

4. The method of applying loose-fill insulation within a cavity of claim 3 , wherein:
the one or more additives comprise one or more of an antifreeze agent, a mold-resistant agent, an anti-corrosion agent, a dye, and a wettability agent.

5. The method of applying loose-fill insulation within a cavity of claim 4 , wherein:
the wettability agent comprises a silicone material.

6. The method of applying loose-fill insulation within a cavity of claim 1 , further comprising:
removing excess insulation from an area beyond the cavity using a rotary scrubbing device.

7. The method of applying loose-fill insulation within a cavity of claim 1 , wherein:
applying the water mist comprises simultaneously spraying the water mist onto opposite sides of the loose-fill insulation nodules using at least two spray tips that are positioned on opposing sides of a water mist applicator device.

8. A method of applying loose-fill insulation within a cavity comprising:
breaking compressed loose-fill insulation material into a plurality of loose-fill insulation nodules;
blowing the loose-fill insulation nodules into a cavity of a structure; and
applying a water mist to the loose-fill insulation nodules as the insulation nodules are blown into the cavity to form installed loose-fill insulation having a moisture content of between about 2% and 20%, wherein the installed loose-fill insulation is free of an aqueous or powdered adhesive material that adheres the loose-fill insulation nodules together within the cavity such that the installed loose-fill insulation is free of an adhesive material.

9. The method of applying loose-fill insulation within a cavity of claim 8 , wherein:
the loose-fill insulation material comprise one or more of slag wool, mineral wool, rock wool, ceramic fiber, carbon fiber, composite fibers, and glass fibers.

10. The method of applying loose-fill insulation within a cavity of claim 8 , wherein:
breaking the compressed loose-fill insulation material comprises shredding the compressed loose-fill insulation material to form the plurality of loose-fill insulation nodules using a shredder of a loose-fill insulation application device.

11. The method of applying loose-fill insulation within a cavity of claim 8 , wherein:
the water mist is applied at a pressure of between about 300 lbs per square inch and 1500 lbs per square inch.

12. The method of applying loose-fill insulation within a cavity of claim 8 , wherein:
the water mist is applied at a flow rate of between 0.5 lbs/min and 4.0 lbs/min.

13. The method of applying loose-fill insulation within a cavity of claim 8 , wherein:
the water mist aids in retaining the loose-fill insulation nodules within the cavity without requiring the use of an enclosure member that encloses the cavity.

14. The method of applying loose-fill insulation within a cavity of claim 8 , wherein:
the water mist is applied using one or more jet spray tips.

15. A method of applying loose-fill insulation within a cavity comprising:
distributing loose-fill insulation nodules into a cavity of a structure; and
applying a water mist to the loose-fill insulation nodules as the insulation nodules are blown into the cavity to form installed loose-fill insulation having a moisture content of between about 2% and 20%, wherein the installed loose-fill insulation is free of an aqueous or powdered adhesive material that adheres the loose-fill insulation nodules together within the cavity such that the installed loose-fill insulation is free of an adhesive material.

16. The method of applying loose-fill insulation within a cavity of claim 15 , wherein:
the installed loose-fill insulation is applied at a density of between 1.10 pcf and 2.0 pcf when wet.

17. The method of applying loose-fill insulation within a cavity of claim 15 , wherein:
the installed loose-fill insulation has a density of between 1.00 pcf and 1.8 pcf when dry.

18. The method of applying loose-fill insulation within a cavity of claim 15 , wherein:
the loose-fill insulation nodules are distributed into the cavity using an insulation blowing machine.

19. The method of applying loose-fill insulation within a cavity of claim 18 , wherein:
the insulation blowing machine comprises a blowing component that delivers the loose-fill insulation nodules to the cavity via a hose.

20. The method of applying loose-fill insulation within a cavity of claim 19 , wherein:
the blowing component suspends the loose-fill insulation nodules in air and blow the suspended loose-fill insulation nodules through the hose and out a nozzle.

Assignees

• Johns Manville

Inventors

• Zhang Mingfu
• Fellinger Thomas John
• Near Daniel Elden

Classifications

• E04F21/085 Primary

  for filling building cavity walls with insulating materials · CPC title

• B05B7/149

  with separate inlets for a particulate material and a liquid to be sprayed · CPC title

• B05B7/00 Primary

  Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas (B05B3/00, B05B5/00 {, B05B11/06} take precedence) · CPC title