Bulk-fill insulation hose connection module with rough interior surface, bulk-fill insulation hose, and bulk-fill insulation installation system - Patents.com

Abstract

The present disclosure relates generally to a bulk insulation installation system. More specifically, the present disclosure relates to a connection module for a bulk insulation hose. The connection module includes a tubular body extending along an axis and having an exterior and an interior surrounding a path for transporting the bulk insulation. The connection module also includes a plurality of roughened structures bonded to the interior of the tubular body to form a roughened inner surface of the connection module. Each of the roughened structures includes at least one protrusion extending transversely to the axis of the tubular body. The roughened structures form more than 400 protrusions extending into the path of the bulk insulation.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of priority from European Patent Application No. 22306974.1, filed December 21, 2022, which is incorporated herein by reference in its entirety.

[0002] The present disclosure relates generally to a bulk insulation installation system suitable for installing bulk insulation at an installation site, for example. The present disclosure relates more particularly to a connector for a bulk insulation hose operable to transport bulk insulation from an insulation blower machine. [Background technology]

[0003] Bulk insulation is packaged in bags, in which the material is compressed prior to storage and transportation. Upon removal from the bag, the insulation separates into clumps. To effectively install the insulation, the insulation is first conditioned to increase its volume and decrease its density. Traditionally, pneumatic devices are used to both install and condition the insulation. The conditioning process breaks down clumps, changes fiber alignment, and conditions the fibers to a more flaky form, "opening" the insulation. The conditioned insulation is then pneumatically applied to the area by blowing through a hose connected to the pneumatic device. The insulation may be humidified and / or treated within the pneumatic device prior to installation.

[0004] While existing systems for installing loose-fill insulation are effective, the present inventors have identified certain aspects of these systems that can be improved. Summary of the Invention

[0005] In one aspect, the present disclosure provides a connection module for a loose-fill insulation hose, the connection module comprising: a tubular body extending along an axis, the tubular body including an exterior and an interior surrounding a passage for conveying loose-fill insulation; The connection module includes a plurality of roughened structures bonded to the inside of the tubular body to form a roughened inner surface, each of the roughened structures including at least one protrusion extending transversely to the axis of the tubular body, the roughened structures forming more than 400 protrusions extending into the path of the loose-fill insulation.

[0006] In another aspect, the present disclosure provides a connection module for a loose-fill insulation hose, the connection module comprising: a tubular body extending along an axis, the tubular body including an exterior and an interior surrounding a passage for conveying loose-fill insulation; a plurality of roughened structures bonded to the inside of the tubular body to form a roughened inner surface of the connection module, each of the roughened structures including at least one protrusion extending transversely to the axis of the tubular body, the roughened structures forming more than 800 protrusions extending into the path of the loose-fill insulation, the protrusions ... 2 a plurality of roughened structures having a density of at least one protrusion per protrusion.

[0007] In another aspect, the present disclosure provides a bulk insulation hose comprising a plurality of tubular sections joined together to form a conduit configured to transport bulk insulation along a path from a blower machine to an installation site, the tubular sections comprising: a first hose portion extending from a proximal end to a distal end, the first hose portion including a flexible body surrounding the passageway; a first connection module according to the present disclosure coupled to the first hose section.

[0008] In another aspect, the present disclosure provides a system for delivering loose-fill insulation, the system comprising: A bulk insulation blower, comprising: a hopper configured to receive the bulk insulation material; The exit and a blower operable to discharge the bulk insulation material through an outlet; and a bulk insulation hose as described herein attached to the outlet of the bulk insulation blower machine.

[0009] In another aspect, the present disclosure provides a method for delivering loose-fill insulation to an installation site using a system of the present disclosure, the method comprising: Discharging bulk insulation from a blower into a bulk insulation hose; and conveying the bulk insulation material through a bulk insulation material hose to an installation site.

[0010] In another aspect, the present disclosure provides a method for delivering loose-fill insulation to an installation site using a system of the present disclosure, the method comprising: Discharging bulk insulation from a blower into a bulk insulation hose; conveying the bulk insulation material through a bulk insulation material hose to an installation site; the delivered loose-fill insulation has a reduced density of at least 5%, e.g., at least 8%, e.g., at least 10%, compared to an unmodified system using the same blower and operating parameters with an unmodified hose; The unmodified hose includes the same hose portion as the loose-fill insulation hose, and the hose portion is coupled to a connection module having a smooth inner surface of constant diameter and the same inner diameter as the major surface portion of the first inner surface of the first connection portion.

[0011] Further aspects of the present disclosure will become apparent from the disclosure herein. [Brief explanation of the drawings]

[0012] The accompanying drawings are included to provide a further understanding of the methods and devices of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings are not necessarily to scale, and sizes of various elements may be distorted for clarity. The drawings illustrate one or more embodiments of the present disclosure and, together with the description, serve to explain the principles and operation of the present disclosure.

[0013] [Figure 1] 1 is a schematic side view of a loose-fill insulation system according to one embodiment of the present disclosure. FIG. [Figure 2] FIG. 2 is a schematic front view of the loose-fill insulation system of FIG. 1. [Figure 3] FIG. 2 is a schematic cross-sectional side view of a portion of the system of FIG. 1. [Figure 4] 4 is a schematic perspective cross-sectional end view of a connection module shown in the section of loose-fill insulation hose in FIG. 3. FIG. [Figure 5] 5 is a schematic perspective view of a portion of the connection module of FIG. 4. [Figure 6] 5 is a schematic cross-sectional end view of a portion of the connection module of FIG. 4. [Figure 7] FIG. 10 is a schematic cross-sectional end view of a portion of a connection module according to another embodiment of the present disclosure. [Figure 8] 10 is a graph showing the density of insulation delivered using connection modules with various numbers of lobes. DETAILED DESCRIPTION OF THE INVENTION

[0014] The inventors have recognized that the internal geometry of a loose-fill insulation hose can aid in opening the loose-fill insulation during installation and improve installation performance. Further, the inventors have identified that an internal geometry within one or more connectors attached to a hose segment can provide such improved performance.

[0015]

[0006] Accordingly, one aspect of the present disclosure provides a connection module for a bulk insulation hose. The connection module includes a tubular body extending along an axis and having an exterior and an interior surrounding a path for transporting bulk insulation. The connection module also includes a plurality of roughened structures bonded to the interior of the tubular body to form a roughened inner surface of the connection module. Each of the roughened structures includes at least one protrusion extending transversely to the axis of the tubular body. The roughened structures form more than 400 protrusions that extend into the path of the bulk insulation within the tubular body of the connection module.

[0016] 1A and 1B show a bulk fill insulation system 100 that includes such a connection module 160. As described in more detail below, the bulk fill insulation system 100 includes a blower machine 102 and a bulk fill insulation hose 120 connected to the blower machine 102. The connection module 160 is contained within the bulk fill insulation hose 120.

[0017] The connection module includes a tubular body extending along an axis and having an exterior and an interior surrounding a path for transporting bulk insulation. The connection module also includes a plurality of roughened structures bonded to the interior of the tubular body to form a roughened inner surface of the connection module. Each of the roughened structures includes at least one protrusion extending transversely to the axis of the tubular body. As used herein, the term "protrusion" refers to a structure extending at least 1 mm into the flow path from the support surface transversely to the axis of the tubular body. In some embodiments, the roughened structure includes a single protrusion, and the tubular body forms the support surface. In other embodiments, the roughened structure includes a support body forming the support surface, and the roughened structure includes one or more protrusions extending from the support body. The roughened structure forms more than 400 protrusions extending into the path of the bulk insulation.

[0018] Such a connection module is shown in Figures 3-6. Figure 3 shows the section of the loose-fill insulation hose 120 of Figures 1 and 2 including a connection module 160 positioned between the first hose section 130 and the second hose section 140. As shown in Figure 3, the connection module 160 has a straight tubular configuration and extends from a first end 161 to a second end 162 along an axis 164. The first end 161 of the connection module 160 is coupled to the first hose section 130, and the second end 162 is coupled to the second hose section 140. The connection module 160 includes a tubular body 165 aligned with the axis 164 and including a circumferential outer side 166 and a circumferential inner side 167, which is represented by a dashed line in the cross-sectional view shown in Figure 4.

[0019] The connection module 160 also includes a plurality of roughened structures coupled to the interior 167 of the tubular body 165, as described further below. The roughened structures form a roughened inner surface 169 of the connection module 160 that surrounds a path 168 for conveyed bulk insulation traveling through the bulk insulation hose 120. Each of the roughened structures includes at least one protrusion 172 that extends transversely to the axis 164 of the tubular body 165 and into the path 168 for the conveyed bulk insulation.

[0020] FIG. 5 shows a perspective view of a portion of the connection module 160, illustrating a roughened inner surface 169 formed by a roughened structure formed around the inner circumference of the connection module 160. FIG. 6 shows a detailed view of a portion of a cross section of the connection module 160. As shown, the tubular body 165 has an outer side 166 that extends around the circumference of the connection module 160 and an inner side 167 that faces the path along which the bulk insulation will be transported. A plurality of roughened structures 170 extend radially inward from the inner side 167 of the tubular body 165. Additionally, each of the roughened structures 170 forms at least one protrusion 172 adapted to help condition the bulk insulation. Specifically, the protrusion 172 of the roughened structure 170 is configured to open the bulk insulation as it travels through the connection module 160. As air flowing through the hose carries the bulk insulation through the connection module 160, fibers or particles of the bulk insulation can get caught on the protruding roughened structure 170, specifically the protrusions 172, and be pulled open or apart.

[0021] In accordance with the present disclosure, the connection module 160 includes a relatively large number of roughened structures such that the roughened inner surface 169 has a high density of protrusions per surface area of ​​the interior 167 of the tubular body 165. By way of example, in some embodiments, the roughened structures may be sized to have a surface area of ​​approximately 1 / cm 2 At least one protrusion per cm 2 At least two protrusions per cm 2 The roughened structure provides a protrusion density of at least three protrusions per connection module. As a result of the high density of protrusions, the connection can include a significantly greater number of protrusions than those provided by other loose-fill insulation connection modules. For example, in some embodiments, the roughened structure forms more than 800 protrusions (e.g., more than 1200, or more than 2000, or more than 5000 protrusions) extending into the path of loose-fill insulation across the interior surface of the connection module.

[0022] In some embodiments, the roughened structure, when connected, forms more than 2500 protrusions per linear meter of the inner surface of the connection module, for example, at least 5000 protrusions per linear meter, or at least 7500 protrusions per linear meter, or at least 10000 protrusions per linear meter, or at least 20000 protrusions per linear meter.

[0023] The inventors have discovered that the use of a roughened structure that forms multiple protrusions on the inner surface of a connection module can lead to highly efficient conditioning of the bulk insulation conveyed through a hose that includes the connection module. Specifically, a connection module that includes such a roughened structure can produce installed bulk insulation with a low density comparable to that produced using a hose with a highly constricted opening. In comparison, avoiding the use of a constricted opening can reduce sound during installation and make it easier to control the flow of the insulation during installation.

[0024] The roughened structure can be disposed on the inside of the tubular body in many ways. For example, in various embodiments described elsewhere herein, the roughened structure is disposed on the inside of the tubular body in a regular pattern, e.g., in rows and / or columns, or some other repeating pattern. In other embodiments, the roughened structure is disposed on the inside of the tubular body in an irregular pattern, e.g., a random pattern.

[0025] In various embodiments of the connection module, the tubular body is formed from a first material and the roughened structure is formed from a second material. For example, in some embodiments, the tubular body is formed from a plastic material such as PVC or ABS, and the roughened structure is formed from a second material such as rock, ceramic, glass, or metal. Similarly, in some embodiments, the roughened structure is formed from a reinforced polymer material. Such a design using different materials for the tubular body and the roughened structure can reduce manufacturing costs because roughened structures with complex shapes can be added to the interior surface of the connection module without having to manufacture the tubular body to include multiple roughened structures. On the other hand, in some embodiments, the roughened structure can be integrally formed with the tubular body. For example, in some embodiments, the roughened structure is provided on the tubular body by additive manufacturing, such as 3D printing. In other embodiments, the tubular shape is first generated, and the roughened structure is machined into the interior by removing some material from the tubular shape. In yet other embodiments, the tubular shape may be constructed in one or more sections or slices when viewed from the end, each section may be cast with a roughened internal surface structure, and multiple sections may then be assembled to complete the fully enclosed tubular body.

[0026] The term "tubular" as used herein with respect to a tubular body encompasses traditional round hoses and pipes, but can also be used for other enclosed passages for materials, including shapes with a flat side or a series of flat sides, and refers to shapes such as triangular, square, rectangular, pentagonal, hexagonal, octagonal, and other diverse sides. In addition, tubes can be circular, oval, elliptical, or include multiple curvatures. Tubes can also have a combination of flat and curved surfaces.

[0027] In various embodiments of the connection module, the roughened structure is formed from a plurality of particles of the second material. For example, in some embodiments, the roughened structure is formed from individual grains of mineral particles, such as cullet, rock, garnet, aluminum oxide, sand, or other abrasive particles. In some embodiments, the particles are secured to the tubular body with an adhesive, such as a layer of epoxy in which the particles are embedded. In other embodiments, the particles are embedded directly in the tubular body or are mechanically bonded to the tubular body as described further below. Furthermore, in some embodiments, the particles are attached to a carrier that is secured to the tubular body. For example, in some embodiments, the particles are secured to a flexible sheet, such as fabric or paper, that acts as a carrier, and the flexible sheet is attached to the inside of the tubular body. The particles can be arranged in a random pattern, for example, on the inner surface of the tubular body.

[0028] In various embodiments of the connection module, the particles have a rough surface. For example, in some embodiments, the particles may include a surface formed by a limited number of facets to provide sharp edges or points thereon. Such edges and points may be effective in trapping and opening fibers of the loose-fill insulation. In some embodiments, the outer surface of the particles may be at least subangular. For example, in some embodiments, the particles have an average circularity index of 0.35 or less. The term circularity index, as used herein, refers to the circularity index described in Waddell, H., "Volume, Shape, and Roundness of Rock Particles," Journal of Geology 40:443-51 (1932) and Waddell, H., "Sphericity and Roundness of Rock Particles," Journal of Geology 41:310-331 (1933), each of which is incorporated herein by reference in its entirety. The circularity index can be measured using the estimates set forth in Krumbein, W.C., "Measurement and Geological Significance of Shape and Roundness of Sedimentary Particles," Journal of Sedimentary Petrology 11:64-72 (1941), which is incorporated herein by reference in its entirety. Particles with a circularity index less than 0.35 have a greater concentration of sharp points and edges to capture loose-fill insulation fibers.

[0029] In various embodiments of the connection module, each roughened structure extends radially inward from the inside of the tubular body to a single tip that forms a respective protrusion. For example, in some embodiments, the roughened structure forms a protrusion both longitudinally and circumferentially of the connection module. Such protrusions are distinct from ridges that extend around a portion of the circumference of the connection module or along a portion of the length of the connection module.

[0030] In various embodiments of the connection module, the shapes of the roughened structures vary. For example, in embodiments in which the roughened structures are made from particles of bulk material, such as cullet or rock, the roughened structures may have random or varied shapes resulting from crushing or grinding the base material. The different shapes of the roughened structures may help trap the fibers of the bulk insulation as it is transported through the connection module. In other embodiments, the roughened structures have the same shape. For example, in some embodiments, each of the roughened structures is a manufactured part, and all of the roughened structures are the same. Of course, in some embodiments, the roughened structures may be made from manufactured parts having different shapes.

[0031] In various embodiments of the connection module, the spacing between the protrusions of adjacent roughened structures varies across the interior surface. For example, in some embodiments, the roughened structures are imprecisely scattered across the interior surface of the connection module. For example, if the roughened structures are particles attached to epoxy, the roughened structures may be deposited en masse onto the epoxy such that the distance between the protrusions is randomized within a range based on the size of the particles.

[0032] In various embodiments of the connection module, the height of the protrusions of the roughened structure is within a range of 1% to 5% of the inner diameter of the connection module. As described herein, the height of each protrusion refers to the difference between the distance between the protrusion and the central axis of the connection module and the distance between the outermost point of the inner surface and the central axis. Furthermore, the inner diameter of the connection module can be calculated as twice the distance between the outermost point of the inner surface and the central axis.

[0033] In various embodiments of the connection module, the roughened structure includes a shaft extending inward from the tubular body. Such an embodiment is illustrated in FIG. 7, which shows a portion of a cross section of a connection module 760. The connection module 760 includes a tubular body 765 having an exterior side 766 and an interior side 767. A plurality of roughened structures 770 provide the connection module 760 with a roughened inner surface 769. Each of the roughened structures 770 includes a shaft 774 and a plurality of protrusions 772 that extend transversely to the axis of the connection module 760 and into the path along which the bulk insulation is transported.

[0034] In various embodiments of the connection module, the ends of the shafts form at least some of the protrusions. For example, each of the tips 776 at the end of each shaft 774 in the connection module 760 forms a separate protrusion.

[0035] Additionally, in various embodiments of the connection module, the roughened structure includes protrusions extending laterally outward from the shaft, the protrusions forming at least some of the protrusions. For example, as shown in FIG. 7 , each of the roughened structures 770 includes a plurality of protrusions 772 extending laterally outward from a respective shaft 774. While the shafts 774 extend radially about the connection module 760, the protrusions 772 extend substantially circumferentially about the connection module 760 and transversely to the axis of the connection module 760. Thus, each of the protrusions 772 extends into the path of the bulk insulation and provides a surface for the bulk insulation to hook onto.

[0036] In various embodiments of the connection module, the protrusions are formed by threads surrounding the shaft. For example, the roughened structure 770 of the connection module 760 is formed by a screw extending through the tubular body 765. The protrusions 772 that form many of the protrusions on the roughened inner surface 769 are formed by the threads of the screw. Although the threads extend continuously around the shaft of the roughened structure 770 in a helical path, each thread forms several protrusions because the threads extend laterally from the shaft and into the flow path of the loose-fill insulation every half-way around the shaft.

[0037] In various embodiments of the connectivity modules described elsewhere herein, the diameter of the inner surface of the connectivity module is at least 40 mm, e.g., at least 50 mm, e.g., at least 60 mm. In some embodiments, the diameter of the inner surface of the first connectivity module is 200 mm or less, e.g., 150 mm or less, e.g., 100 mm or less. For example, in some embodiments, the diameter of the inner surface of the first connectivity module is in the range of 40 mm to 200 mm, e.g., 50 mm to 150 mm, e.g., 60 mm to 100 mm.

[0038] In various embodiments of the connection module described elsewhere herein, the length of the connection module is at least 15 cm, e.g., at least 20 cm, e.g., at least 25 cm, at least 30 cm, e.g., at least 35 cm, e.g., at least 40 cm. In some embodiments, the length of the connection module is 100 cm or less, e.g., 80 cm or less, e.g., 60 cm or less. For example, in some embodiments, the length of the connection module is in the range of 30 cm to 100 cm, e.g., 35 cm to 80 cm, e.g., 40 cm to 60 cm.

[0039] In various embodiments of the connection module described elsewhere herein, the roughened structure of the connection module varies in size. For example, in some embodiments, the roughened structure extends from the inside of the tubular body into the flow channel to various depths. Similarly, in some embodiments, the roughened structure varies in all dimensions, while in other embodiments, the roughened structure has some consistent dimensions and some varying dimensions.

[0040] In another aspect, the present disclosure provides a bulk insulation hose including a plurality of tubular sections coupled together to form a conduit configured to transport bulk insulation along a path from a blower machine to an installation site. The tubular sections include a first hose section extending from a proximal end to a distal end. The first hose section includes a flexible body surrounding the path. The bulk insulation hose also includes a first connection module according to the present disclosure coupled to the first hose section.

[0041] Such a bulk insulation hose is shown schematically in FIGS. 1 and 2 as part of a bulk insulation system 100. The bulk insulation hose 120 includes several tubular sections joined together to form a conduit for transporting bulk insulation along a path from the blower machine to the installation site. As used herein, the term joined is not limited to a direct connection between elements. Rather, two tubular sections may be indirectly joined to one another by other sections such that both tubular sections form part of the same path for the bulk insulation. As shown in FIGS. 1 and 2, the bulk insulation hose 120 includes a first hose section 130, a second hose section 140, and a third hose section 150, arranged in sequence from the distal end of the bulk insulation hose 120 to the proximal end attached to the blower machine 102. The first hose section 130 includes a flexible body 133 extending from a proximal end 131 to a distal end 132. Similarly, the second hose portion 140 includes a flexible body 143 extending from a proximal end 141 to a distal end 142 , and the third hose portion 150 includes a flexible body 153 extending from a proximal end 151 to a distal end 152 .

[0042] The loose-fill insulation hose 120 also includes several connection modules, such as a connection module 160 between the first hose portion 130 and the second hose portion 140, and a connection module 180 between the second hose portion 140 and the third hose portion 150.

[0043] In embodiments of the loose-fill insulation hose 120, the hose segments are attached to the connection module using clamps, as shown in FIG. 1 . For example, the first hose segment 130 is coupled to the connection module 160 using a clamp 134 that surrounds the first hose segment 130 and secures the first hose segment 130 to the connection module 160. Similarly, the second hose segment 140 is coupled to the opposite side of the connection module 160 using another clamp 144. Meanwhile, in some embodiments, the hose segments include end fittings configured to attach to the connection module. Other methods of securing the hose segments to the connection module are possible.

[0044] The connection modules of the present disclosure can be positioned at various locations along a bulk insulation hose. For example, in the bulk insulation hose 120, as shown in FIGS. 1 and 2, the connection module 160 is located between the first hose section 130 and the second hose section 140 near the distal end of the hose 120. In other embodiments, the connection module of the present disclosure can be positioned between other pairs of hose sections along the length of the hose. Furthermore, in some embodiments, several connection modules of a bulk insulation hose can be configured in accordance with the connection modules of the present disclosure. In some embodiments, the connection module can be at the proximal or distal end of the hose assembly 120, and in conjunction with its positioning between one or more hose sections. A "connection module" as described herein is configured to connect to a bulk insulation hose. In some embodiments, the connection module may, but need not, connect the bulk insulation hose to another component, such as another bulk insulation hose. For example, as described below with respect to distal connection module 190 in FIG. 1, the connection module of the present disclosure can be connected to the end of a bulk insulation hose without connecting anything to the bulk insulation hose.

[0045] In various embodiments of the bulk insulation hose described elsewhere herein, the bulk insulation hose further comprises a proximal connection module including a first side configured to attach to an outlet of a bulk insulation blower machine and a second side attached to the proximal end of the first hose section. For example, the bulk insulation hose 120 shown in FIGS. 1 and 2 includes a proximal connection module 185 having a first side 186 and a second side 187. The second side 187 of the proximal connection module 185 is attached to the proximal end 151 of the third hose section 150, and the first side 186 of the proximal connection module 185 is attached to the outlet 106 of the bulk insulation blower machine 102. Thus, the proximal connection module 185 is at the proximal end of the bulk insulation hose 120 and receives the bulk insulation as it leaves the blower machine 102. In some embodiments, the proximal connector module may include a roughened structure, as described above, so that the loose-fill insulation passing through the proximal connector module can be tailored toward the beginning of the hose.

[0046] Alternatively, in other embodiments, the bulk insulation hose includes a proximal connection module and a coupler configured to attach to the outlet of a bulk insulation blower machine. In such embodiments, a first side of the proximal connection module is attached to the coupler, and a second side of the proximal connection module is attached to the proximal end of the hose section. In some embodiments, the coupler is used to enable connection between the bulk insulation hose and the blower machine outlet. For example, in some embodiments, the coupler has two female couplings for receiving male couplings on the blower machine outlet and the proximal connection module. In other embodiments, the coupler has two male couplings. In still other embodiments, the coupler can include one male coupling and one female coupling on opposite ends. Furthermore, in some embodiments, the coupling varies the diameter of the opening so that hoses and blower machine outlets of different diameters can be connected.

[0047] In other embodiments, the loose-fill insulation hose does not include a proximal connection module. For example, in some embodiments, one of the hose sections is either attached directly to the blower machine outlet or is attached to the blower machine outlet using a coupler.

[0048] In various embodiments of the bulk insulation hose described elsewhere herein, the first hose section is one of a group of hose sections connected in series, and the bulk insulation hose further includes a distal connection module attached to the distal end of the hose. For example, the bulk insulation hose 120 shown in FIG. 1 includes a group of hose sections including a first hose section 130, a second hose section 140, and a third hose section 150 connected in series. In other embodiments, the hose can include more than three hose sections, such as four, five, or more hose sections connected in series. The distal end of the bulk insulation hose 120 includes a distal connection module 190. In some embodiments, the distal connection module can include a roughened structure, as described above. Thus, the bulk insulation passing through the distal connection module can be tailored toward the end of the hose.

[0049] In some embodiments, the loose-filled connection hose can include an outlet nozzle attached to the distal connection module. In yet other embodiments, the loose-filled insulation module can exclude the distal connection module. For example, in some embodiments, the outlet nozzle is connected directly to the hose section. Furthermore, in other embodiments, the end of the hose is formed by the hose section, and neither the connection module nor the outlet nozzle is included in the end.

[0050] In various embodiments of the loose-fill insulation hose described elsewhere herein, the first hose section includes protrusions extending inwardly into the channel. Such hose configurations are described, for example, in U.S. Patent No. 7,284,573, which is incorporated herein by reference in its entirety. In some embodiments, the protrusions of the first hose section extend into the channel a first radial depth, and at least some of the roughened structures of the first connection module extend into the channel a second radial depth that is at least three times greater, e.g., at least five times greater, than the first radial depth.

[0051] In various embodiments of the loose-fill insulation hose described elsewhere herein, a first side of the first connection module is a male fitting inserted into the distal end of the first hose section, and a second side of the first connection module is a male fitting inserted into the proximal end of the second hose section. For example, as shown in FIG. 1 , first side 161 and second side 162 of first connection module 160 are each formed as a male fitting inserted into first hose section 130 and second hose section 140, respectively. In other embodiments, the first connection module includes a female fitting, and the hose sections include male fittings inserted into the connection module. Furthermore, in some embodiments, the first connection module includes a male fitting on one side and a female fitting on the other side. Such a configuration allows for a connection between two adjacent connection modules without an intervening hose section or coupler.

[0052] In various embodiments of the loose-fill insulation hose described elsewhere herein, the first hose section is corrugated. For example, the first hose section 130 of the loose-fill insulation hose 120 has a corrugated tubular body 133, as shown in Figures 1-3. A corrugated hose can have increased flexibility and strength compared to a similar hose having a smooth outer surface. The other hose sections of the loose-fill insulation hose 120 are similarly corrugated, as shown in Figures 1 and 2. In other embodiments, the hose sections can have different outer shapes, such as smooth.

[0053] In various embodiments of the loose-fill insulation hose described elsewhere herein, the first hose section has a length of at least 10 feet, e.g., at least 15 feet, e.g., at least 20 feet. In some embodiments, the first hose section has a length of 100 feet or less, e.g., 80 feet or less, e.g., 60 feet or less, e.g., about 50 feet. For example, in some embodiments, the first hose section has a length ranging from 10 feet to 100 feet, e.g., from 12 feet to 80 feet, e.g., from 15 feet to 60 feet, e.g., from 20 feet to 50 feet. In some embodiments, each of the hose sections has the same length. In other embodiments, the hose sections of the loose-fill insulation hose have different lengths.

[0054] In various embodiments of the loose-fill insulation hose described elsewhere herein, the inner diameter of the first hose section is at least 1.5 inches, e.g., at least 2 inches, e.g., at least 2.5 inches. In various embodiments of the loose-fill insulation hose described elsewhere herein, the inner diameter of the first hose section is 8 inches or less, e.g., 6 inches or less, e.g., 4 inches or less. For example, in some embodiments, the inner diameter of the first hose section is in the range of 1.5 inches to 8 inches, e.g., 2 inches to 6 inches, e.g., 2.5 inches to 4 inches. Further, in some embodiments, each of the hose sections has the same inner diameter. In other embodiments, some of the hose sections have different inner diameters.

[0055] In another aspect, the present disclosure provides a system for delivering bulk insulation including a bulk insulation blower and a bulk insulation hose of the present disclosure. The blower includes a hopper configured to receive the bulk insulation, an outlet, and a blower operable to discharge the bulk insulation through the outlet. The bulk insulation hose is attached to the outlet of the bulk insulation blower.

[0056] Such a system is shown schematically in Figures 1 and 2. The bulk insulation system 100 includes a blower coupled to a bulk insulation hose 120, as described in detail above. The bulk insulation blower 102 includes a hopper 104 configured to receive the insulation material. The blower 102 conditions the insulation material, which is then delivered to the hose 120 through an outlet 106 using a blower 108. The blower 108 circulates air through the blower 102 to carry the bulk insulation material through the hose 120 to an installation location at the distal end of the hose.

[0057] In various embodiments of the disclosed system, the hopper includes a shredder box configured to break down the bulk insulation. For example, the hopper 104 includes a shredder box 110 that includes a plurality of shredder members that rotate through the baled insulation to break it apart and "open" the insulation.

[0058] In various embodiments of the disclosed system, the bulk insulation blower includes an airlock configured to transport the bulk insulation to an outlet. For example, the insulation in the system 100 travels from the shredder box 110 through a stator bar 112, which includes teeth to further open the insulation, and into an airlock 114. As shown in FIG. 2 , the airlock 114 includes a plurality of sealed vanes 116 that rotate around a drum and transport the insulation to a region where airflow from the blower 108 carries the insulation through the outlet 106. The airlock 114 directs the airflow out through the outlet 106 rather than back into the shredder box 110.

[0059] In another aspect, the present disclosure provides a method of delivering bulk insulation to an installation site using the system of the present disclosure, the method including discharging bulk insulation from a blower into a bulk insulation hose, and transporting the bulk insulation through the bulk insulation hose to the installation site.

[0060] Such a method is shown in Figure 1. Baled insulation 101 is first introduced into a blower machine 102 via a hopper 104. The baled insulation 101 is broken open by a shredder box 110 and a stator bar 112 as it moves into an airlock 114. The airlock 114 then moves the insulation to a position where air from a blower 108 can carry the insulation through a hose 120 to the installation site at the distal end of the hose 120, where loose-fill insulation 118 is delivered to the installation site.

[0061] In various embodiments of the methods described elsewhere herein, the methods further include opening the bulk insulation passing through the first connection module using a roughened structure extending inwardly in a path between the first and second hose sections. For example, as the bulk insulation in system 100 passes through first connection module 160, roughened structure 168 interacts with the insulation to further open it, as described in more detail above.

[0062] In various embodiments of the methods described elsewhere herein, the delivered bulk insulation has a reduced density of at least 5%, e.g., at least 8%, e.g., at least 10%, compared to an unmodified system using the same blower machine and operating parameters with an unmodified hose. The unmodified hose includes the same hose section as the bulk insulation hose and is coupled to a connection module having a smooth inner surface of constant diameter and an inner diameter the same as the inside of the tubular body of the connection module.

[0063] In various embodiments of the methods described elsewhere herein, the bulk-fill insulation comprises a fibrous material. For example, in some embodiments, the bulk-fill insulation comprises fiberglass fibers, cellulose fibers, stone wool fibers, plastic fibers, natural wool fibers, natural cotton fibers, or another type of fiber. In other embodiments, the bulk-fill insulation comprises small insulating components, such as foam bead insulation or plastic particle insulation. [Example]

[0064] Figure 8 shows the density of the blown insulation in various tests using connection modules with different numbers of lobes. In each test, the insulation was blown through a 450 m 3 The insulation was blown through two sections of smooth hose ("Couronne tuyau semi rigide φ80") manufactured by Isol International (Conflans-Sainte-Honorine, France), each 20 m long and 80 mm in diameter. The hose sections were connected by a 20 cm long section of PVC pipe with a diameter of 76 mm. For each test, an 18 kg bag of Isolene+ manufactured by Saint-Gobain Isover, France (Courbevoie, France) was blown into an open box with an area of ​​2 m x 1 meter. The various test connection modules were included at the end of the hose. The connection modules were 3D printed from PLA and had an inner diameter of 76 mm and an outer diameter of 80 mm.

[0065] Variations in the number of protrusions on the connection module were achieved by varying the overall length of the connection module while maintaining the same density of protrusions per internal surface area. Each protrusion was formed as a single point, similar to a nail, and had an average length into the channel of 6.6 mm. The protrusions were arranged in equally spaced rows every 10 mm along the length of the connection module. Each row contained 28 protrusions, evenly spaced around the circumference of the connection module. The position of every other row of protrusions was slightly rotated around the circumference of the connection module so that the protrusions in one row were positioned midway between two protrusions in an adjacent row relative to the circumference of the connection module. Tests using connection modules with a greater number of protrusions included additional rows and corresponding increases in length, but were otherwise identical.

[0066] After the entire insulation bag was blown into the containment area, the density of the blown insulation was determined by measuring the height of the blown insulation and measuring the mass. As can be seen, as the number of lobes in the connection module increased, the density of the delivered insulation decreased. Furthermore, when the connection module contained at least 400 lobes, the density decreased by at least 10 percent.

[0067] It will be apparent to those skilled in the art that various modifications and variations can be made in the processes and devices described herein without departing from the scope of the disclosure. Thus, the present disclosure is intended to cover all such modifications and variations of the present invention provided they come within the scope of the appended claims and their equivalents.

[0068] Additional aspects of the present disclosure are provided by the following non-limiting numbered embodiments, which may be combined in any number and in any manner not logically or technically consistent. Embodiment 1. A connection module for a loose-fill insulation hose, comprising: a tubular body extending along an axis, the tubular body including an exterior and an interior surrounding a passage for conveying loose-fill insulation; A connection module comprising: a plurality of roughened structures bonded to the inside of a tubular body to form a roughened inner surface of the connection module, each of the roughened structures including at least one protrusion extending transversely to the axis of the tubular body, the roughened structures forming more than 400 protrusions extending into the path of the loose-fill insulation. Embodiment 2. A connection module for a loose-fill insulation hose, comprising: a tubular body extending along an axis, the tubular body including an exterior and an interior surrounding a passage for conveying loose-fill insulation; a plurality of roughened structures bonded to the inside of the tubular body to form a roughened inner surface of the connection module, each of the roughened structures including at least one protrusion extending transversely to the axis of the tubular body, the roughened structures forming more than 800 protrusions extending into the path of the loose-fill insulation, the protrusions ... 2 a plurality of roughened structures having a density of at least one protrusion per roughened structure; Embodiment 3. A connection module according to embodiment 1 or 2, wherein the roughened structure forms more than 2000 protrusions, for example more than 5000 protrusions. Embodiment 4. The protrusion is cm 2 At least two protrusions per cm 2 4. A connection module according to any one of embodiments 1 to 3, having a density of at least three protrusions per module. Embodiment 5. A connection module described in any one of embodiments 1 to 4, wherein the roughened structure, when connected, forms more than 2500 protrusions per linear meter of the inner surface of the connection module, for example at least 5000 protrusions per linear meter, or at least 7500 protrusions per linear meter, or at least 10000 protrusions per linear meter, or at least 20000 protrusions per linear meter. Embodiment 6. A connection module according to any one of embodiments 1 to 5, wherein the tubular body is formed from a first material and the roughened structure is formed from a second material. Embodiment 7. A connection module according to embodiment 6, wherein the roughened structure is formed from a plurality of particles of a second material. Embodiment 8. A connection module according to embodiment 7, wherein the particles are randomly distributed inside the tubular module. Embodiment 9. A connection module according to embodiment 7, wherein the particles have a rough surface. Embodiment 10. A connection module according to any one of embodiments 7 to 9, wherein the second material comprises cullet. Embodiment 11. A connection module according to any one of embodiments 7 to 10, wherein the particles are attached to a carrier that is fixed to the tubular body. Embodiment 12. A connection module described in any one of embodiments 1 to 11, wherein each roughened structure extends radially inward from the inside of the tubular body to a single tip forming a respective protrusion. Embodiment 13. The connection module according to any one of embodiments 1 to 12, wherein the shapes of the roughened structures are different. Embodiment 14. A connection module according to any one of embodiments 1 to 13, wherein the spacing between the protrusions of adjacent roughened structures varies across the inner surface. Embodiment 15. The connection module according to any one of embodiments 1 to 14, wherein the height of the protrusions of the roughened structure is within the range of 1% to 5% of the inner diameter of the connection module. Embodiment 16. A connection module according to any one of embodiments 1 to 15, wherein the roughened structure comprises a shaft extending inward from the tubular body. Embodiment 17. A connection module according to embodiment 16, wherein the end of the shaft forms at least some of the protrusions. Embodiment 18. A connection module as described in embodiment 16 or 17, wherein the roughened structure includes protrusions extending laterally outward from the shaft, the protrusions forming at least some of the protrusions. Embodiment 19. A connection module as described in embodiment 18, wherein the protrusion is formed by a thread surrounding the shaft. Embodiment 20. A connection module described in any one of embodiments 1 to 19, wherein the roughened structure is arranged in a regular pattern on the inside of the tubular body, for example in rows and / or columns, or in some other repeating pattern. Embodiment 21. A connection module according to any one of embodiments 1 to 19, wherein the roughened structure is arranged in a regular pattern, for example, a random pattern, on the inside of the tubular body. Embodiment 22. A bulk insulation hose comprising a plurality of tubular sections joined together to form a conduit configured to transport bulk insulation along a path from a blower machine to an installation location, the tubular sections comprising: a first hose portion extending from a proximal end to a distal end, the first hose portion including a flexible body surrounding the passageway; A loose-fill insulation hose comprising: a first connection module according to any one of embodiments 1 to 21 coupled to a first hose section. Embodiment 23. A loose-fill insulation hose according to embodiment 22, wherein the first connection module is attached to the proximal end of the first hose section. Embodiment 24. A loose-fill insulation hose according to embodiment 22, wherein the first connection module is attached to the distal end of the first hose section. Embodiment 25. A loose-fill insulation hose according to embodiment 24, wherein the first connection module is attached between the first hose section and the second hose section. Embodiment 26. A loose-fill insulation hose according to embodiment 24, wherein the first connection module is disposed at the distal end of the hose. Embodiment 27. A loose-fill insulation hose according to any one of embodiments 22 to 26, wherein the first hose section is one of a group of hose sections connected in series using a group of connection modules. Embodiment 28. A system for delivering loose-fill insulation, the system comprising: A bulk insulation blower, comprising: a hopper configured to receive the bulk insulation material; The exit and a blower operable to discharge the bulk insulation material through an outlet; A system comprising: a bulk insulation hose according to any one of embodiments 22 to 27 attached to an outlet of a bulk insulation blower. Embodiment 29. A method of delivering loose-fill insulation to an installation site using the system of embodiment 27, the method comprising: Discharging bulk insulation from a blower into a bulk insulation hose; conveying the bulk insulation material to an installation site through a bulk insulation material hose. Embodiment 30. A method of delivering loose-fill insulation to an installation site using the system of embodiment 28, the method comprising: Discharging bulk insulation from a blower into a bulk insulation hose; conveying the bulk insulation material through a bulk insulation material hose to an installation site; the delivered loose-fill insulation has a reduced density of at least 5%, e.g., at least 8%, e.g., at least 10%, compared to an unmodified system using the same blower and operating parameters with an unmodified hose; The method, wherein the unmodified hose includes the same hose portion as the loose-fill insulation hose, and the hose portion is coupled to a connection module having a smooth inner surface of constant diameter and an inner diameter the same as the major surface portion of the first inner surface of the first connection portion.

Claims

1. 1. A connection module for a loose-fill insulation hose, said connection module comprising: a tubular body extending along an axis, the tubular body including an exterior and an interior surrounding a passage for conveying loose-fill insulation; a plurality of roughened structures bonded to the inside of the tubular body to form a roughened inner surface of the connection module, each of the roughened structures including at least one protrusion extending transversely to the axis of the tubular body, the roughened structures forming more than 400 protrusions extending into the path of the loose-fill insulation.

2. 2. The connection module of claim 1, wherein the roughened structure forms more than 800 protrusions, such as more than 1200 protrusions, such as more than 2000 protrusions, such as more than 5000 protrusions.

3. The protrusion is ２ At least one protrusion per cm, e.g. ２ 3. A connection module according to claim 1 or 2, having a density of at least two protrusions per protrusion.

4. A connection module according to any one of claims 1 to 3, wherein the tubular body is made from a first material and the roughened structure is made from a second material.

5. The connection module of claim 4 , wherein the roughened structure is formed from a plurality of particles of the second material.

6. 6. The connection module of claim 5, wherein the particles are randomly distributed inside the tubular module.

7. The connection module of claim 6 , wherein the particles have a rough surface.

8. A connection module according to any one of claims 5 to 7, wherein the second material comprises mineral particles.

9. A connection module according to any one of claims 5 to 8, wherein the particles are attached to a carrier fixed to the tubular body.

10. The connection module of any one of claims 1 to 4, wherein the roughened structure comprises a shaft extending inwardly from the tubular body.

11. The connection module of claim 10 , wherein the roughened structure includes a protrusion extending laterally outward from the shaft, the protrusion forming at least some of the protrusions.

12. 12. The connection module of claim 11, wherein the protrusion is formed by a thread surrounding the shaft.

13. 1. A bulk insulation hose comprising a plurality of tubular sections joined together to form a conduit configured to transport bulk insulation along a path from a blower machine to an installation site, the tubular sections comprising: a first hose portion extending from a proximal end to a distal end, the first hose portion including a flexible body surrounding the passage; A loose-fill insulation hose comprising: a first connection module according to any one of claims 1 to 12 coupled to the first hose section.

14. 1. A system for delivering loose-fill insulation, said system comprising: A bulk insulation blower, comprising: a hopper configured to receive the bulk insulation material; The exit and a blower operable to discharge the bulk insulation material through the outlet; and a bulk insulation hose according to claim 13 attached to the outlet of the bulk insulation blower.

15. 15. A method of delivering loose-fill insulation to an installation site using the system of claim 14, said method comprising: Discharging bulk insulation from a blower into the bulk insulation hose; conveying the bulk insulation through the bulk insulation hose to the installation site.

16. 15. A method of delivering loose-fill insulation to an installation site using the system of claim 14, said method comprising: Discharging bulk insulation from a blower into the bulk insulation hose; and conveying the bulk insulation material through the bulk insulation material hose to the installation site; the delivered loose-fill insulation has a reduced density of at least 5%, e.g., at least 8%, e.g., at least 10%, compared to an unmodified system using the same blower and operating parameters with an unmodified hose; The method, wherein the unmodified hose includes the same hose portion as the loose-fill insulation hose, and the hose portion is coupled to a connection module having a smooth inner surface of a constant diameter and an inner diameter the same as a major surface portion of the first inner surface of the first connection portion.

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