Insulation Nozzle Expansion Section Velocity Control
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Solution Overview
Problem
Conventional methods for blowing fibrous insulation into cavities face challenges such as insulation build-up on supporting members, material wastage, user error, and difficulty in controlling insulation density, leading to overfilling and increased costs due to excess material usage.
Innovation Solution
A nozzle assembly with an expansion section that reduces particle velocity and a binder outlet to form an insulation product with controlled density and thermal resistivity, minimizing excess material usage while maintaining desired thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional blowing methods direct insulation flow back and forth perpendicular to supporting members, then the cavity can be filled with insulation material, but insulation build-up occurs on supporting members and material fly-off increases
Solution Approach 1:
The patent changes the flow direction parameter from perpendicular-to-parallel orientation and modifies the velocity distribution through a specific nozzle profile. This transforms the harmful perpendicular impacting flow into a beneficial parallel flowing flow that reduces build-up and fly-off while maintaining effective cavity filling.
2Quantity of substance
If conventional systems require frequent nozzle position adjustments for parallel and perpendicular directional control, then the insulation flow can be directed to fill the cavity, but user error and fatigue increase
Solution Approach 1:
The nozzle assembly performs self-adjustment of flow direction through its specialized internal geometry. The flow direction automatically aligns parallel to the supporting members without requiring user intervention for directional control, eliminating the need for frequent manual adjustments and reducing operator fatigue.
3Productivity
If conventional techniques blow insulation at high velocity, then the insulation can be delivered to the cavity, but the density becomes difficult to control and overfilling occurs
Solution Approach 1:
The nozzle assembly transforms the velocity parameter through its expansion section, converting high-velocity incoming flow into a controlled parallel flow with optimized velocity distribution. This maintains productive delivery speed while achieving precise density control and eliminating overfilling.
4Reliability
If conventional systems use excess insulation and binder material to ensure adequate coverage, then the cavity can be fully insulated, but installation costs increase
Solution Approach 1:
By changing the flow characteristics from perpendicular impacting flow to parallel flowing flow, the system achieves more uniform and efficient material distribution. This reduces the total quantity of insulation and binder material needed while maintaining adequate and reliable coverage throughout the cavity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The nozzle assembly effectively reduces insulation density and thermal resistivity, minimizing material waste and installation costs while ensuring adequate thermal insulation, with a thermal resistivity of R-3.3 to R-4.0 per inch.
Implementation Method 1
at least one expansion section in which the cross-sectional area of the nozzle body expands in the direction of flow, the at least one expansion section being effective to reduce the velocity of the particles flowing therethrough
Data Source
AI summary
A nozzle assembly for conveying a flow of particles of insulation material suspended in air to a substrate to form an insulation product on the substrate is provided, including: a nozzle body defining a flow path for accommodating the flow of particles of insulation material suspended in air, wherein the nozzle body comprises an inlet for receiving the flow of particles of insulation material suspended in air; an outlet for propelling the flow from the nozzle assembly; and at least one expansion section in which the cross-sectional area of the nozzle body expands in the direction of flow, the at least one expansion section being effective to reduce the velocity of the particles flowing therethrough; and at least one binder outlet for providing a binder to the flow of particles of insulation material propelled from the outlet.