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AU676553B2 - Method and apparatus for producing insulation materials - Google Patents
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AU676553B2 - Method and apparatus for producing insulation materials - Google Patents

Method and apparatus for producing insulation materials Download PDF

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Publication number
AU676553B2
AU676553B2 AU64732/94A AU6473294A AU676553B2 AU 676553 B2 AU676553 B2 AU 676553B2 AU 64732/94 A AU64732/94 A AU 64732/94A AU 6473294 A AU6473294 A AU 6473294A AU 676553 B2 AU676553 B2 AU 676553B2
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AU
Australia
Prior art keywords
cellulosic
shredded
transporting
curing
resilient
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Ceased
Application number
AU64732/94A
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AU6473294A (en
Inventor
Aaltje Elisabeth Maude
Derek Worthington Maude
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Individual
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Priority to AU64732/94A priority Critical patent/AU676553B2/en
Publication of AU6473294A publication Critical patent/AU6473294A/en
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Publication of AU676553B2 publication Critical patent/AU676553B2/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Description

1IIU1 1 2IWWI 11ogulallon 3,2(2)
AUSTRALIA
Patents Act 1990
ORIGINAL
COMPLETE SPECIFICATION STANDARD PATENT o Application Number: Lodged: Invention Title: METHOD AND APPARATUS FOR PRODUCING INSULATION
MATERIALS
r o The following statement is a full description of this invention, including the best method of performing it known to us ILL y METHOD AND APPARATUS FOR PRODUCING INSULATION MATERIALS FIELD OF THE INVENTION This invention relates to a method and apparatus for the manufacture of insulation materials and to an insulation material made by the process and relates particularly but not exclusively to insulation materials and methods and apparatus for their manufacture manufactured from a combination of shredded and defibrillated fibrous cellulosic materials preferably in the form of an open, lightweight batt, blanket or strip.
BACKGROUND OF THE INVENTION The thermal insulation and sound attenuation properties of cellulosic materials are well known and it is known that such materials may be used in insulation materials. Advantages of using such materials in insulation materials are that waste materials such as, newspaper, can be removed from the waste stream and recycled to form a useful product. Disadvantages of using cellulosic materials on insulation materials are that the materials must be treated to make them fire retardant and preferably insect, vermin and decay resistant. It is known to treat cellulosic materials such as wastepaper with fire retardant compounds such as, borax. Such compounds are hygroscopic and cellulosic materials treated with such compounds are non-resilient and subject to degradation.
A need exists for the effective utilization of waste materials. Paper waste and other fibrous cellulosic materials have been recognised as potential resource materials for various products including insulation materials due to ••oo their inherent insulating properties. Until now there has been a lack of economical methods to convert such waste to acceptable and viable materials 25 which are environmentally friendly, low in production energy consumption and S resistant to hazards or degradation which would reduce their life expectancy and, therefore, their usefulness.
Cellulosic fibres from paper waste or other cellulosic materials have been used previously as insulation but in a very limited way. Production has been restricted to loose fill products requiring special application methods and devices. Such material is highly vulnerable to moisture in its untreated state and could be subjected to long term degradation problems.
LI I I -~e Mineral fibre insulation materials are brittle by nature and tend to degrade and break down if subjected to mechanical stresses releasing fine mineral particles into the environment which pose an unknown health risk. There is therefore a need to replace mineral fibre insulation materials with insulation materials which are less likely to be hazardous to health.
Various proposals have been put forward to utilize waste cellulosic materials to produce insulating materials. British patent 1359996 discloses an insulation material comprising a sandwich of shredded paper between two outer facing sheets of paper suitably treated with fire retardant materials such as ammonium dihydrogen phosphate and ammonium sulphate. At least one of the facing sheets is perforated. The outer facing sheets may be bonded to the shredded paper by spraying the shredded paper with a suitable bonding agent or adhesive prior to covering with the facing sheets. Pressure may be applied to the sandwich configuration to assist with the bonding of the shredded paper to 15 the outer facing sheets. The material is specifically identified as an insulation material primarily designed as an acoustic insulation material with some thermal insulation properties. The product may be stored in rolls or cut into insulation batts of convenient size.
Australian patent Nos. 527843 and 540132 disclose a method of forming 20 a batt of bonded synthetic or wool fibres in which the mixture of fibres is ragged, teased or otherwise doffered to form a sliver of randomly dispersed fibres. The sliver is then passed through a lapping machine to form a mat of desired thickness. The mat is then sprayed with a mixture of fireproofing resins, smoke retardants and pesticides cured and if desired cut into batts of appropriate S25 configuration.
.ooooi S"PCT application No. PCT/AU91/00515 (the contents of which are incorporated herein by reference and referred to as "our earlier application") discloses a method of manufacturing a flexible, resilient, open fibrous cellulosic insulating material which comprises providing a shredded fibrous cellulosic material, coating said shredded material with a rigid or non-rigid binder to form a coated shredded material, introducing a defibrillated cellulosic material on and into said coated shredded material to provide a filled shredded material and I L ILI L h I-I forming and curing said filled shredded maierial to cause said binder to bind the material to provide said flexible, resilient, open fibrous cellulosic insulating material. Our earlier application also discloses apparatus for manufacturing an insulation material as above which comprises apparatus for the manufacture of sandwich cellulosic insulation material which includes means to form a mat of evenly distributed shredded cellulosic material, means to introduce defibrillated cellulosic material into the shredded cellulosic material, means to provide a cover sheet of cellulosic material to each face of the mat, means to introduce a bonding material to the shredded cellulosic material and to the cover sheets to permit the shredded cellulosic materials and the cover sheets to be bonded together to form a bonded insulation material.
The present invention seeks to overcome problems of prior art methods and apparatus for the manufacture of batts or insulation materials and to provide a safe and effective insulation material or to provide alternative methods and 15 apparatus for the manufacture of such batts or insulation materials.
DESCRIPTION OF THE INVENTION The present invention, therefore, provides in one form a method of manufacturing a flexible, resilient, open fibrous cellulosic insulating material which comprises providing a shredded fibrous cellulosic material, treating said shredded material with a fire retardant material, introducing a defibrillated cellulosic material onto said treated shredded material to form a filled shredded material, concurrently or separately treating the filled shredded material with a rigid or non-rigid binder and forming and curing said filled shredded material as may be required, to cause said binder to bind the material to form said flexible, S25 resilient, open fibrous cellulosic insulating material.
.oooe: The present invention also provides apparatus for manufacturing a flexible, resilient, open fibrous cellulosic insulation material which includes means to transport evenly distributed shredded cellulosic material to a first treatment station, means for treating the material with a fire retardant, means for transporting the treated material to a second treatment station, means to introduce defibrillated ceilulosic material onto the shredded cellulosic material to form a filled shredded material, concurrently or separately providing means to I rr introduce a rigid or non-rigid binder onto the material, means to transport the material to curing means, as may be required, to cure the material to form said flexible, resilient, open fibrous cellulosic insulating material.
The present invention also provides a method of manufacturing a flexible, resilient, open fibrou, cellulosic insulating material which comprises providing a shredded fibrous cellulosic material to a first treatment station, spraying said shredded material as it falls under gravity with a solution of a fire retardant material, transporting the material so produced to a second treatment station, introducing a defibrillated cellulosic material onto and into or within said treated shredded material as it falls under gravity, to provide a filled shredded material, concurrently or separately spraying the filled shredded material with a rigid or non-rigid binder and forming and curing said filled shredded material as may be required to cause said binder to bind the material to form said flexible, resilient, open fibrous cellulosic insulating material.
15 The invention also provides apparatus for manufacturing a flexible, resilient, open fibrous cellulosic insulation material which includes means to transport evenly distributed shredded cellulosic material to a first treatment station, means for spraying the material as it falls under gravity, with a solution of a fire retardant material, means for transporting the treated material to a second 20 treatment station, means to introduce defibrillated cellulosic material onto and into or within the shredded cellulosic material, concurrently or separately providing means to introduce a rigid or non-rigid binder to the material, means to 2 transport the material to curing means, as may be required, to cure the material to form said flexible, resilient, open fibrous cellulosic insulating material.
Preferably the means for transporting the material to either the first or S second treatment station is a pneumatic transporting means. Preferably the means for transporting the defibrillated material to the second treatment station is also a pneumatic transporting means. Preferably the material, prior to curing, is delivered onto a sheet of cellulosic material to provide a cover on at least the under face of the material. A screed means may also be included prior to the curing means to fc'rr material into a substantially even layer.
a Lh Other preferred features of the invention will be apparent from the following description.
DETAILED DESCRIPTION OF THE INVENTION Preferred forms of apparatus and method in accordance with the invention will now be described with reference to the accompanying drawings, in which: The Figure represents a schematic elevational view of apparatus according to the invention; Referring to the Figure there is shown apparatus 10 including hopper 11, first duct 12, first treatment station 13, conveyor 14, second duct 15, second treatment station 16, and second conveyor 17. Shredded paper from, for example telephone directories, is fed into hopper 11 and drawn into first duct 12 through access 18 in duct 12 due to the venturi effect created by fan 19 connected to duct 12 which forces air into the duct. The material is blown along the duct 12, by the air from fan 19 to treatment station 13 in the form of a L Dpper.
Due to the large increase in the cross section at the end 20 of duct 12 the material loses velocity and drops gently to the base of the hopper 13. As the material falls in the hopper it is sprayed with fire retardant comlposition via jets or nozzles 21 from a supply of fire retardant material (not shown) via conduits or pipes 22. The material is thus dampened with the fire retardant composition and falls to the base of the hopper 13 where it passes to conveyor 14. Conveyor 14 feeds the material to feed hopper 23 and thence into second duct 15. The S* material as with duct 12, is drawn into the duct 15 due to the venturi effect created by fan 24 connected to duct 15. The material is blown along duct 15 by S25 the air from fan 24 to the second treatment station or hopper 16. The material OlOO° may, if necessary, be dried by heating the air from fan 24. Again, as above, the material then passes into the hopper 16 where again it suffers a large loss of velocity due to the large volume expansion, into the hopper 16 and falls gently towards the bottom of the hopper. As the material falls, bonding composition is sprayed onto the material in the hopper through jets or nozzles 28 supplied by conduits or pipes 29 from storage tank (not shown). Defibrillated cellulosic material from feed hopper 25 is blown into the hopper 16 through duct 26 by way I Ir of fan 27. The defibrillated cellulosic material is introduced into the duct 26 in similar manner to that previously described in relation to ducts 12 and 15. The treated material then passes out the base of the hopper 16 onto the conveyor 17.
If necessary the material may be screeded by bar 30 to achieve a layer of material of substantially uniform height and passed, if necessary to a curing station if the nature of the bonding composition is such that curing is required.
Due to the increase in the cross section and thus the volume of the duct 12, just prior to access 18, a reduction of pressure in the duct results, which assists in drawing the material in hopper 11 into the duct 12. Similar increases in the cross sections of the ducts 15 and 26 assist in drawing the material from hoppers 13 and 25 respectively into the ducts 15 and 26. The provision of a gap of about 0.5 to 1.0 cm. between the bottom of the hoppers 11, 13 and 25 and the ducts 12, 15 and 26 also assist in allowing free flow of material from the hoppers into the respective ducts. The air flow provided by fans 19, 24 and 27 15 may be provided from a single fan source by providing appropriate interconnecting ducting. The rates of delivery of the various materials to the various hoppers or the rate of production and thickness or density of the final material may be controlled by controlling the air flow in the ducts, by control of the rate of addition of shredded material to the hopper 11 and by control of the speed of the various conveyors 14 and 17.
Bottom sheet 31 from reel 32 is sprayed on the upper side thereof with the same bonding composition if it is desired to include face sheets covering the basic flexible, resilient, open fibrous cellulosic insulating material formed.
Preferably there is at least a bottom cover sheet provided. Similarly top sheet 33 25 may be sprayed on it's underside with the same bonding material. The top and S bottom sheets may thus be brought into contact with the shredded material and pressed to maintain the desired thickness of material, between hot plates (not shown) and cured as may be necessary. The resultant "sandwich" flexible, resilient, open fibrous cellulosic insulating material may then be cut into batts, blankets or strip materials.
The shredded material is preferably shredded newspaper, telephone directories, shredded stationary or computer paper but may be any suitable cellulosic material. The defibrillated material is preferably cardboard or other waste cellulosic material which has been ground or milled to form a finely divided defibrillated fluffy material. The defibrillated material may be made from waste cellulosic materials such as, bagasse, straw, rice hulls, peanut shells, coconut husks and the like. It is necessary as indicated in our earlier application, that a dry fire retardant is incorporated during the manufacture of the defibrillated cellulosic material. The dry fire retardant is necessary because in the grinding or milling paper or other cellulosjk material the resulting dust can create an explosive mixture with air therefore it is a safety requirement to incorporate a fire retardant during the manufacture of the defibrillated cellulosic material. The binding composition used is as disclosed in our earlier application.
The apparatus of the invention thus produces in it's most preferred form and configuration, a "sandwich" of shredded filled cellulosic material between 15 two sheet materials bonded by a suitable bonding material which is flexible, resilient and able to be cut into insulation batts of appropriate size or into strips of flexible insulation material for lagging pipes, ducts and the like. The sheet materials may be any suitable sheet material such as paper, plastics film, aluminium film or the like. It is possible to omit the upper sheet material provided 20 that the upper surface of the shredded filled cellulosic material treated with binder is dried sufficiently prior to the compression of the batt to the desired thickness before the binder sets.
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Claims (15)

1. A method of manufacturing a flexible, resilient, open fibro:.s cellulosic insulating material which comprises providing a shredded fibrous cellulosic material to a first treatment station, treating said shredded material with a fire retardant material, transporting the material so produced to a second treatment station, introducing a defibrillated cellulosic material onto said treated shredded material to form a filled shredded material, concurrently or separately treating the filled shredded material with a rigid or non-rigid binder and forming and curing said filled shredded material as may be required, to cause said binder to bind the material to form said flexible, resilient, open fibrous cellulosic insulating material, in which the means for transporting the material to either or both of the first or second treatment stations is by a pneumatic transporting means. o•
2. A method as claimed in claim 1 in which the defibrillated material is transported to the second treatment station by a pneumatic transporting means.
3. A method as claimed in claims 1 or 2 in which the material, prior to curing, is delivered onto a sheet of cellulosic material to provide a cover on at least the under face of the material. o o
4. A method as claimed in any one of claims 1 to 3 in which a screed means S•is provided prior to the curing means to form the material into a substantially even layer. 0* 0 Apparatus for manufacturing a flexible, resilient, open fibrous cellulosic insulation material which includes means to transport evenly distributed shredded cellulosic material to a first treatment station, means for treatinC the material with a fire retardant, means for transporting the treated material to a second treatment station, means to introduce defibrillated cellulosic material onto the shredded cellulosic material to form a filled shredded material, concurrently or separately providing means to introduce a rigid or non-rigid r binder onto the material, means to transport the material to curing means, as may be required, to cure the material to form said flexible, resilient, open fibrous cellulosic insulating material, in which the means for transporting the material to either or both of the first or second treatment stations is a pneumatic transporting means.
6. An apparatus as claimed in claim 5 in which the means for transporting the defibrillated material to the second treatment station is a pneumatic transporting means.
7. An apparatus as claimed in claims 5 or 6 in which the material, prior to curing, is delivered onto a sheet of cellulosic material to provide a cover on at least the under face of the material. eo o o
8. An apparatus as claimed in any one of claims 5 to 7 in which a screed means is provided prior to the curing means to form the material into a substantially even layer.
9. A method of manufacturing a flexible, resilient, open fibrous cellulosic insulating material which comprises providing a shredded fibrous cellulosic S. •material to a first treatment station, spraying said shredded material as it falls under gravity with a solution of a fire retardant material, transporting the material so produced to a second treatment station, introducing a defibrillated cellulosic material onto and into or within said treated shredded material as it falls under gravity, to provide a filled shredded material, concurrently or separately spraying the filled shredded material with a rigid or non-rigid binder and forming and curing said filled shredded material as may be required to cause said binder to bind the material to form said flexible, resilient, open fibrous cellulosic insulating material, in which the means for transporting the material to either or both of the first or second treatment stations is a pneumatic transporting means. IIISa C I I A method as claimed in claim 9 in which the means for transporting the defibrillated material to the second treatment station is a pneumatic transporting means.
11. A method as claimed in claims 9 or 10 in which the material, prior to curing, is delivered onto a sheet of cellulosic material to provide a cover on at least the under face of the material.
12. A method as claimed in any one of claims 9 to 11 in which a screed means is provided prior to the curing means to form the material into a substantially even layer.
13. Apparatus for manufacturing a flexible, resilient, open fibrous cellulosic insulation material which includes means to transport evenly distributed shredded cellulosic material to a first treatment station, means for spraying the material as it falls under gravity, with a solution of a fire retardant material, means for transporting the treated material to a second treatment station, means to introduce defibrillated cellulosic material onto and into or within the shredded cellulosic material, concurrently or separately providing means to introduce a ,i".rigid or non-rigid binder to the material, means to transport the material to curing means, as may be required, to cure the material to form said flexible, resilient, open fibrous cellulosic insulating material, in which the means for transporting the material to either or both of the first or second treatment stations is a pneumatic transporting means.
14. An apparatus as claimed in claim 13 in which the means for transporting the defibrillatcd material to the second treatment station is a pneumatic transporting means. An apparatus as claimed in claims 13 or 14 in which the material, prior to curing, is delivered onto a sheet of cellulosic material to provide a cover on at least the under face of the material. A:" //Y IIIP CI IB
16. An apparatus as claimed in any one of claims 13 to 15 in which a screed means is provided prior to the curing means to form the material into a substantially even layer.
17. A method of manufacturing a flexible, resilient, open fibrous cellulosic insulating material substantially as hereinbefore described with or without reference to the accompanying drawings.
18. Apparatus for manufacturing a flexible, resilient, open fibrous cellulosic insulation material substantially as hereinbefore described with or without reference to the accompanying drawings. DATED this 2nd day of January, 1997 oo I" AALTJE ELIZABETH MAUDE and DEREK WORTHINGTON MAUIDE *i WATERMARK PATENT TRADEMARK ATTORNEYS THE ATRIUM 290 BURWOOD ROAD HAWTHORN VICTORIA 3122 AUSTRALIA AU6473294WPC[DOC. 36]IAS:JC:SH[EK] 0 ,9 ABSTRACT A method and apparatus for the manufacture of insulation materials and an insulation material made by the process is disclosed. The insulation materials are manufactured from a combination of shredded and defibrillated fibrous cellulosic materials preferably in the form of an open, lightweight batt, blanket or strip. e a.. 9
AU64732/94A 1993-06-16 1994-06-15 Method and apparatus for producing insulation materials Ceased AU676553B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU64732/94A AU676553B2 (en) 1993-06-16 1994-06-15 Method and apparatus for producing insulation materials

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
AUPL9391 1993-06-16
AUPL939193 1993-06-16
AU64732/94A AU676553B2 (en) 1993-06-16 1994-06-15 Method and apparatus for producing insulation materials

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AU6473294A AU6473294A (en) 1994-12-22
AU676553B2 true AU676553B2 (en) 1997-03-13

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT201700029362A1 (en) * 2017-03-16 2018-09-16 Enerpaper S R L PROCEDURE FOR REALIZING A THERMAL AND / OR ACOUSTIC INSULATING MATERIAL IN FLAKES

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AUPN200895A0 (en) * 1995-03-28 1995-04-27 Griffiths, Alan Lyle Insulation, and method and machine for forming same

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB561489A (en) * 1942-11-03 1944-05-22 Henry Peter Bayon Improvements relating to the production of sheets, panels and the like from waste wood products
DE3641464A1 (en) * 1986-12-04 1988-06-16 Uwe Welteke HEAT-INSULATING PANEL CONTAINING NATURAL FIBERS AND METHOD AND DEVICE FOR THEIR PRODUCTION
WO1992008588A1 (en) * 1990-11-12 1992-05-29 Derek Worthington Maude Method and apparatus for producing insulation materials

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB561489A (en) * 1942-11-03 1944-05-22 Henry Peter Bayon Improvements relating to the production of sheets, panels and the like from waste wood products
DE3641464A1 (en) * 1986-12-04 1988-06-16 Uwe Welteke HEAT-INSULATING PANEL CONTAINING NATURAL FIBERS AND METHOD AND DEVICE FOR THEIR PRODUCTION
WO1992008588A1 (en) * 1990-11-12 1992-05-29 Derek Worthington Maude Method and apparatus for producing insulation materials

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT201700029362A1 (en) * 2017-03-16 2018-09-16 Enerpaper S R L PROCEDURE FOR REALIZING A THERMAL AND / OR ACOUSTIC INSULATING MATERIAL IN FLAKES
EP3375934A1 (en) * 2017-03-16 2018-09-19 Enerpaper S.r.l. Process of making a flocks-based thermal and/or acoustic insulating material

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Publication number Publication date
AU6473294A (en) 1994-12-22

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