Insulation wrapping material and apparatus and method for insulation wrapping, transportation, and preparation for installation

Abstract

A composition of matter for wrapping cellulose insulation that is formed to become part of the insulation when the two are aerated. The invention also includes a wrapped cellulose insulation that includes a compressed cellulose insulation and a wrapper wherein the compressed cellulose insulation and the wrapper together form an insulation product without disposing of the wrapper. The invention also includes a method for transporting and preparing the wrapped cellulose insulation product for installation that involves wrapping a bale of the cellulose insulation in the wrapper, inserting the wrapped bale of insulation into a container, removing the wrapped bale of insulation at a location of interest, and aerating the wrapped bale of insulation for further processing.

Description

Atty Docket No. CF-014PCTINSULATION WRAPPING MATERIAL AND APPARATUS AND METHOD EOR INSULATION WRAPPING, TRANSPORTATION, AND PREPARATION FOR INSTALLATIONBACKGROUND OF THE INVENTION1. Field of the Invention.

[0001] The present invention relates to efficient insulation wrapping for transport and offloading of the wrapped insulation. More particularly, the present invention relates to the preparation of cost effective cellulose insulation wrapping, transportation, and preparation for installation. The invention includes an insulation wrapping material and method that minimize waste, maximize insulation transportability, and preparation for installation onsite.2. Description of the Prior Art.

[0002] Existing cellulose insulation is shredded, treated, fiberized, and packaged in a central plant. Bags containing the processed and packaged cellulose insulation are then distributed to users who open the bag, add the contents to an installation machine, such as a blower arranged to re-aerate cellulose fibers that may have been compressed in the packaging process, and blowing them into their installed positions. The existing processes for packaging, transporting, and preparing the cellulose insulation can be costly. More generally, existing packaging materials for cellulose and non-cellulose insulation transported to an installation site are relatively costly and produce considerable waste that must be disposed of.

[0003] What is needed is a cost-effective wrapping material and apparatus and method for wrapping insulation for transportation and installation preparation. The wrapping material should be configured to enable effective insulation wrapping, transport, and installation with minimal wrapper material waste. The apparatus should include equipment for preparing wrapped bales of insulation for efficient transportation and with an eye on subsequent processing of the wrapped bales at the installation site. The apparatus should further include equipment to move wrapped insulation into and / or out of a transportation container with minimal manual labor required. Moreover, the apparatus should include equipment for insulation installation onsite. The installation site may be, but is not limited to, a commercial building, a residential building, or a building manufacturing facility.Atty Docket No. CF-014PCTSUMMARY OF THE INVENTION

[0004] The present invention is a composition of matter, an apparatus, and a method for cost-effective insulation transport and preparation for installation. While this disclosure of the invention is primarily about cellulose insulation, it is not limited to cellulose insulation.

[0005] The invention includes a wrapper that is the composition of matter made of a material suitable for inclusion with the insulation when that insulation is installed, such as by blowing it in place. In an embodiment of the invention, the wrapper material is formed of a cellulose material used to wrap a cellulose insulation. The wrapper material may optionally be treated with a fire retardant substance to meet smolder and flame specifications and / or one or more other additives. The wrapper may be wetted to facilitate either or both of the insulation wrapping process, insulation packing for transport, and insulation preparation for installation. The wrapper includes a mechanism for maintaining its form as an enclosure for insulation insertion therein. That mechanism may be preapplied with moisture or heat-activated glue but not limited thereto.

[0006] The invention also includes an apparatus for wrapping the insulation with the wrapping material, moving the wrapped insulation into a transport container, moving the wrapped insulation out of the transport container, and preparing the wrapped insulation for installation. The apparatus may optionally include one or more container configurations.

[0007] In an embodiment of the invention, the wrapping component of the apparatus is or includes one or more pieces of equipment as a compaction machine modified to releasably retain the wrapper thereto. The compaction machine may use directional compaction to reduce pillowing of the insulation while being compacted and to control the direction of expansion forces of the compacted insulation within the wrapper. Alternatively or additionally, the compaction machine may be shaped to control or offset any pillowing of the insulation within the wrapper during compaction. Vacuum may be applied to the wrapper during the compaction process to hold the wrapper in place during compaction.

[0008] The wrapper material is formed as an enclosure with an open end into which insulation material is inserted. The wrapper may be prefolded and scored for easy insertion into the compaction machine. The wrapper may optionally have at least one side secured to the compaction machine, or at least backed up by the compaction machine to limit tearing or bursting of the wrapper while the insulation material is compacted into the wrapper. TheAtty Docket No. CF-014PCTwrapper may include one or more reinforcing cross ties or other form maintaining mechanism to prevent or reduce pillowing of the insulation material within that may otherwise occur during compaction. The wrapper may further be configured to include features to limit to local areas any tearing of the material during compaction and / or shipping.

[0009] In another embodiment, the wrapping component of the apparatus is or includes equipment that wraps with the consumable wrapper material prefabricated bales or pallets of insulation that has previously been compacted. This embodiment of the wrapper component is configured to enclose the bale of insulation or compacted insulation on a pallet to secure the bale or palleted insulation for transport. The wrapper is consumed with fiberizing of the bale or palleted insulation at the delivery location. The insulation may be compressed into the wrapper at a fixed location using a ram or other compressing equipment known to those of skill in the art. Alternatively, the insulation is compressed separate from the wrapper into a form of interest, such as a bale. The compressing equipment may then be used to push the compressed insulation into the wrapper of prepared fixed dimensions. Alternatively, the wrapper may be laid out, such as on a floor, and the bale of insulation placed on it. The wrapper is then secured about the bale, which can be done manually.

[0010] In an embodiment of the invention, the wrapped insulation insertion component of the apparatus is or includes equipment arranged to pack wrapped bales and / or pallets into the trailer of a transporter. That equipment moves the wrapped insulation into the trailer automatically so that physical labor is not required to move the insulation. The equipment includes either or both a roller bed and a walking floor. Optionally, a cable or webbing may be used to drag one or more pallets toward the aerator. The bales or pallets are optionally sized and shaped so that two or more sets of bales / pallets fit within the trailer in parallel to one another. The bales / pallets may be forklifted into the trailer or otherwise be caused to move into the trailer. A gantry crane may also be used to cause movement of the wrapped insulation into the container.

[0011] In an embodiment of the invention, the wrapped insulation removal component and the wrapped insulation preparation component may be configured as one piece of equipment or two pieces of equipment integrated together. The roller bed or walking floor may be used to extract the wrapped insulation from the transport container. An automated device moves the roller bed or walking floor to cause bales / pallets to move out from within the trailer. The preparation component is either positioned adjacent to the exit port of the trailer to receive the wrapped balesAtty Docket No. CF-014PCTor insulation on a pallet or it is affixed to the trailer and moved into position at the installation location. A gantry crane may be used to move the wrapped bale from the container to the preparation component. The wrapped insulation may be removed from the front or rear of the container. The wrapped bales / pallets may be inserted and removed at one end of the container. Alternatively, the wrapped insulation may be inserted at one end of the container and removed from the container at the opposing end.

[0012] The wrapped insulation preparation component is configured to aerate the wrapped insulation and the wrapper itself so that the insulation and wrapper become together blown-in insulation. The wrapper may be size-reduced separately from size reduction of the bale of insulation contained in the wrapper. Alternatively, both may be size-reduced together. The preparation component may be a mill such as a flail mill. It may alternatively or in addition be a bale eater or a shredder. The preparation component is configured to adequately size reduce the wrapper such that it forms or is incorporated into the insulation stream uniformly and without clogging. That may be achieved by conventional bale break methods wherein the aerated insulation / wrapper drop into an airlock and subsequently blown to the end use. Alternatively, a traditional vacuum to cyclone to blower approach may be used such that the bale breaking zone is under vacuum.

[0013] An automatically opening and closing door akin to a garage door may be incorporated between the storage of wrapped bales and the size reduction of the bales. This can function to separate dust generated in the shredding / milling process from the rest of bales container. It can also serve a safety function of assuring that nothing other than a bale enters the shredding / milling section to prevent operator injury. Optionally, one or more safety devices or systems may be added to the preparation component with automated door to make sure that the equipment does not operate if anything other than a bale is in the shredding / milling area. Example safety devices include, but are not limited to, optical, capacitive, inductive, moisture sensing, and / or torque sensing devices may be employed.

[0014] In an embodiment of the invention, a robotic device may be deployed to carry out the size-reducing activity wherein the robotic device includes a size reducer mechanism that can be driven in a selectable pattern about the bale. This embodiment enables more specific insulation / wrapper sizing. It also permits the user to carry out the size reduction in a closedAtty Docket No. CF-014PCTenvironment that allows for air sealing of the room and isolation of operators from direct contact with flying particulates such as dust.

[0015] The preparation component optionally includes one or more sensors to sense characteristics of interest such as moisture existence and / or material characteristics that would adversely impact the processing of the insulation / wrapper, with a feedback controller to stop or divert the preparation activity. The sensors may be capacitive but not limited thereto. The preparation component may be coupled to a vacuum to feed the size-reduced material to the blowing system used to deliver the insulation to its final location.

[0016] The present invention is a cost-effective apparatus and method using a unique insulation wrapper material composition to transport insulation and prepare that insulation for installation by blowing it into place.BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a perspective view of the insulation wrapper of the present invention affixed to a portion of an insulation compaction machine of the apparatus of the present invention.

[0018] FIG. 2 is a top plan view of the insulation wrapper of FIG. 1.

[0019] FIG. 3 is a side view of the insulation wrapper of FIG. 1.

[0020] FIG. 4 is a simplified perspective view of a configuration for bale placement within a trailer.

[0021] FIG. 5 is a partial top perspective view of an end of the insulation preparation component of the invention joined to an open end of the trailer.

[0022] FIG. 6 is a partial side view of the preparation component joined to the trailer end and showing wrapped insulation bales on a roller bed or walking floor.

[0023] FIG. 7 is a side view of the end of the trailer with the wrapped insulation on pallets and showing optional means to store the pallets.DETAILED DESCRIPTION OF THE INVENTION

[0024] The present invention includes an insulation wrapper 10 represented in FIGS. 1-3. The wrapper 10 is used to wrap compressed insulation 12, which may be cellulose insulation but not limited thereto. The wrapper 10 is made of a material suitable to function as an insulation material. That is, rather than use some type of plastic material to secure compressed insulationAtty Docket No. CF-014PCTfor transportation and then discard it when it is opened, the wrapper 10 is a composition corresponding to the compressed insulation 12. For example, if the compressed insulation 12 is made partially or completely of cellulose material, the wrapper 10 is made of the same or a similar material. The wrapper 10 may be made as a unitary sheet of material or a plurality of sheets joined together with sufficient strength to secure the compressed insulation 12 in a compressed state during transportation. The wrapper 10 is a consumable as much as the compacted insulation 12 is a consumable so that the wrapper 10 and its contents are completely consumed.

[0025] The invention is also an apparatus for wrapping the insulation 12 in the wrapper 10 and for transferring the wrapped insulation into a container, such as a trailer, boxcar, or other means for holding and moving large volumes of materials. The apparatus includes a wrapping component 14 that is in the form of a modified compaction machine 14. The compaction machine 14 includes a wrapper holding frame 16 that releasably holds the wrapper 12 uniformly in place as a compacting plate 18 compacts the insulation 12 in the wrapper 10. The compaction machine 14 may use directional compaction to reduce pillowing of the insulation 12 once released from the modified compaction machine 14 and during transport. It may also be useful in controlling the direction of expansion forces of the compacted insulation within the wrapper 10. Alternatively or additionally, the compaction machine 14 may be shaped to control or offset any pillowing of the insulation 12 within the wrapper 10 during compaction or after being released from compaction. Vacuum may be applied to the wrapper 10 and / or insulation 12 during the compaction process to hold the wrapper 10 in place during compaction.

[0026] The wrapper 10 is retained to the compaction machine 14 in any shape desired, including in a shape that maximizes the packing of a plurality of bales of wrapped insulation for transport, such as in a rectangular shape, for example. As shown in FIGS. 1-3, the wrapper 10 is formed into a rectangular shape with opening 20 at a top thereof for receiving the insulation 12. The wrapper 10 optionally includes one or more shape retaining frames 22 that keep the wrapper 10 open in the desired shape until compaction is complete. The retaining frames 22 may be made of a material similar to that of the wrapper 10 and thereby form part of the insulation in subsequent processing.

[0027] Once the insulation 12 has been compacted in the wrapper 10, bales of insulation 24 so formed are transferred into a transport container 26 for movement to a location of interest. TheAtty Docket No. CF-014PCTcontainer 26 may be a trailer coupled to a tractor, a boxcar of a train, or other container type. As shown in FIG. 4, the bales of insulation 24 may be positioned in the container 26 as two rows in parallel. Other configurations are possible. The container 26 may be modified to include a walking beam or rolling floor 28 that facilities movement of the bales 24 into and out of the container 26. Bales 24 of each of the two rows may be moved independently in and out of the container 26. For example, an entire first row may be moved before moving the entire second row, the bales 26 of the rows may be moved alternatively or in any other order of interest.

[0028] With reference to FIGS. 5 and 6, the invention further includes a compacted insulation processor 30. The processor 30 may be connected to the container 26 or a separate apparatus moved to open end 32 of the container 26 and temporarily connected thereto. The processor 30 is arranged to size-reduce the compacted insulation 12 in preparation for movement to a location of interest with reduced density to function as insulation.

[0029] The processor 30 is effectively a fiber aeration machine 30 arranged to convert the compacted insulation 12 into a composition of fibers that has a lower bulk density than that of the compacted insulation 12. The fiber aeration machine 30 includes a fiber separator 32 in the form of a shredder, an impeller (such as is used in blowers and fans), a chopper or intensifier (such as a rapidly rotating blade) or a fiberizer (such as a dry milling process) to aerate the compacted insulation 12. The fiber aeration machine 30 may include an aerator or other type of fiber aeration mechanism. Multiple stages of aeration and possible separation may be used. The fiber aeration machine 30 shown represents one or more components that may be used to aerate the compacted insulation 12 to separate fibers prior to installation, reducing the bulk density of the compacted insulation 12 to produce a blown-in-place insulation product. One or more additives may be applied to one or more of the compacted insulation 12, the wrapper 10, and the insulation product. Such additives include, but are not limited to, a fire retardant material, and may be applied upon entering or exiting the fiber aeration machine 30. Output 34 of the fiber aeration machine 30 is coupled to an insulation material delivery component, which may be a tube coupled to a fan, blower, or vacuum.

[0030] The fiber aeration machine 30 further optionally includes one or more monitors positioned to monitor the condition of any one or more of the compacted insulation 12, the fiber separator 32, the finished insulation, and / or other components of the machine 30. The fiber aeration machine 30 also optionally includes one or more controllers arranged to enableAtty Docket No. CF-014PCTregulation of the components of the machine 30. The controllers may include a remote controller, a controller coupled to the machine 30, and a controller managed by an operator, such as a person moving the end insulation product into the installation location. The fiber aeration machine 30 optionally includes airlock 38 configured to facilitate conveyance of the insulation 12 to its end use location.

[0031] FIG. 7 represents an alternative arrangement for moving the bales 24 into and out of the container 26. Specifically, each of the bales 24 is removably retained on a pallet 40. The pallet 40 is rolled into and out of the container 26 on the rolling floor 28. In this embodiment, when the bales 24 are to be moved to the aeration machine 30, the invention includes a pallet processor 42. The pallet processor 42 includes a pallet elevator 44 and an empty pallet conveyor 46. After bale removed, pallet 40 is lowered by pallet processor 42 and pallet elevator 44 to align with and then be moved to empty pallet conveyor 46. The empty pallet conveyor 46 moves the empty pallets away from the pallet elevator 44 for reinsertion into the container 26 or other options.

[0032] An advantage of the unique wrapper 10 and processing apparatus of the present invention is the transport efficiency and labor reduction resulting from the use thereof. The components of the invention are sized and configured sufficiently to enable their operation in the field, although they may also be used for insulation production and transport to a remote location using an alternative delivery mechanism. While the present invention has been described with respect to specific embodiments, it is not intended to those expressly described embodiment. Instead, the invention is described in the appended claims as well as all reasonable equivalents.

Claims

Atty Docket No. CF-014PCTWhat Is Claimed Is:

1. A wrapper material composition for wrapping cellulose-based insulation wherein the wrapper material composition is usable as an insulation when aerated.

2. The wrapper material of Claim 1, wherein the wrapper material composition is substantially the same as a composition of the cellulose-based insulation.

3. The wrapper material of Claim 1, wherein the wrapper material composition is an outer layer of the cellulose-based insulation.

4. The wrapper material composition of Claim 1, wherein the wrapper material composition is treated with a fire retardant.

5. The wrapper material composition of Claim 1, wherein the wrapper material composition is shredded.

6. The wrapper material composition of Claim 5, wherein the wrapper material composition is shredded with shredding of the cellulose-based insulation.

7. A wrapped cellulose insulation comprising:compressed cellulose insulation; anda wrapper for wrapping the compressed cellulose insulation therein, wherein the compressed cellulose insulation and the wrapper together form an insulation product without disposing of the wrapper.

8. The wrapped cellulose insulation of Claim 7, wherein the compressed cellulose insulation is treated with a fire retardant.

9. The wrapped cellulose insulation of Claim 8, wherein the wrapper is treated with a fire retardant.Atty Docket No. CF-014PCT10. The wrapped cellulose insulation of Claim 9, wherein the fire retardant of the compressed cellulose insulation and the fire retardant of the wrapper are the same.

11. The wrapped cellulose insulation of Claim 7, wherein the compressed cellulose insulation and the wrapper are formed of substantially the same material.

12. A method for transporting and preparing a cellulose insulation product for installation, the method comprising the steps of:wrapping a bale of cellulose insulation in a wrapper, wherein the wrapper is formed of a material suitable for use as an insulator;inserting the wrapped bale of insulation into a container;transporting the wrapped bale of insulation to a location of interest; removing the wrapped bale of insulation from the container; andaerating the wrapped bale of insulation for further processing.

13. The method of Claim 12, further comprising the step of compressing the bale of insulation into the wrapper.

14. The method of Claim 12, wherein the step of aerating includes the step of shredding the wrapper and the bale of insulation together.

15. The method of Claim 12, further comprising the step of treating the wrapper with a fire retardant.

16. The method of Claim 12, wherein the steps of inserting and removing the wrapped bale of insulation include using a roller bed or walking floor in the container to enable movement of the wrapped bale of insulation.

17. The method of Claim 12, further comprising blowing the aerated wrapped bale of insulation to a location of interest.Atty Docket No. CF-014PCT18. The method of Claim 17, wherein the steps of aerating and blowing the wrapped bale of insulation occur in the same equipment.

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