Insulation De-aggregation Rotor Configuration for Uniform Fiber Separation

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Solution Overview

Problem

Existing machines for de-aggregating bales of loose fill insulation often fail to fully de-aggregate the insulation, leading to clumps that can clog the system and result in suboptimal thermal insulation properties due to incomplete separation of fibers.

Innovation Solution

The design incorporates a rotor configuration within the de-aggregation chamber, utilizing upper and lower de-aggregation members with paddles that maintain the bale in a horizontal position, ensuring even engagement and preventing compaction, along with features like interleaved paddles and a rotary valve to enhance de-aggregation and recirculation, ensuring uniform density and thermal conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the bale is introduced at an angle as in conventional designs, then the upper rotor can engage the bale, but only an edge of the lower surface is exposed to the rotor resulting in uneven de-aggregation

Engineering Contradiction:

Improvede-aggregation uniformityVSAvoidbale positioning

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

Instead of introducing the bale at an angle as in conventional designs, the patent inverts the approach by maintaining the bale in a generally horizontal position during de-aggregation. This allows the entire lower surface of the bale to be exposed to the rotor, ensuring uniform engagement and even de-aggregation of insulation throughout the bale.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the dimensional orientation of bale engagement from angular/introduced at tilt to horizontal/maintained level. By using guide members to maintain the bale in a generally horizontal position, the entire lower surface area becomes accessible to the rotor blades, transforming the engagement from edge-only to surface-wide contact.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If the insulation is not fully de-aggregated, then the process is faster, but clumps of compressed insulation remain that can clog the machine and reduce thermal insulation properties

Engineering Contradiction:

Improvede-aggregation speedVSAvoidclog prevention

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent employs multiple rotors with blades that continuously and repeatedly engage the insulation bale from different positions. The first rotor engages the lower surface, and the second rotor engages the upper surface, creating continuous de-aggregation action throughout the bale rather than single-pass processing, ensuring complete fiber separation without clumps.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The de-aggregation process is segmented into multiple stages with different rotors handling different portions of the bale. The first rotor processes the lower surface while the second rotor processes the upper surface, dividing the complex de-aggregation task into manageable segments that collectively achieve complete fiber separation.

Inventive Principle:

Principle #1Segmentation

3Device complexity

If the insulation fibers are not sufficiently separated, then the machine operates simpler, but the desired density and thermal insulation properties cannot be achieved

Engineering Contradiction:

Improvede-aggregation mechanismVSAvoidfiber separation uniformity

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent applies different rotor configurations to different locations on the bale. The first rotor with its blades is positioned to engage the lower surface, while the second rotor engages the upper surface. Each rotor is specifically designed for its location, creating locally optimized de-aggregation that collectively achieves uniform fiber separation throughout the entire bale.

Inventive Principle:

Principle #3Local quality

4Device complexity

If the bale is not maintained in horizontal position, then the machine structure is simpler, but unequal sections of the bale are removed resulting in uneven load on rotors and inconsistent insulation quality

Engineering Contradiction:

Improvebale positioning mechanismVSAvoidde-aggregation consistency

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent introduces guide members as intermediary elements between the bale and the rotors. These guide members maintain the bale in a generally horizontal position during processing, acting as mediators that ensure consistent orientation without requiring complex positioning mechanisms. The guide members translate the bale's weight and processing forces into maintained horizontal alignment.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS9457355B2Apparatus for converting bales of insulation to loose fill

Publication Date: 2016.10.04 OMACHRON INTELLECTUAL PROPERTY INC

AI summary

A machine for de-aggregating a bale of insulation and blowing de-aggregated insulation, has a single upper de-aggregation member and a single lower de-aggregation member, each de-aggregation member having a rotary mounted shaft having a length and a plurality of paddles angularly staggered around the shaft and extending along the length of the shaft, the paddles of the upper de-aggregation member have first and second paddles having differing lengths and both the first and second paddles are interleaved with the paddles of the lower de-aggregation member.