Europaisch.

es Patentamt
European Patent Office

Publication number:

EUROPEAN

1 46

A2

Office europeen des brevets

PATENT

APPLICATION

Int. CI.4: E 04

@ Application number: 84114765.5

B 1/76

Date of filing: 04.12.84

Applicant: MANVILLE SERVICE CORPORATION

Ken-Caryl Ranch
Denver Colorado 80217IUS)

Priority: 05.12.83 US 558690

Date of publication of application:
03.07.85 Bulletin 85/27

@ Inventor: Kielmeyer, William Henry

3374 West Chenango Avenue
Englewood Colorado 8011 0{US)

Designated Contracting States:

AT BE CH DE FR GB LI LU NL SE

@ Representative: Grattinger, Gunter

Wittelsbacher Strasse 5 Postfach 16 49
D-8130 Starnberg(DE)

(m) Hybrid blowing insulation.

( A hybrid fiber glass cellulosic blowing insulation. Fiber
glass nodules are blended with cellulosic fibers which have
been treated with a flame retardant in proportions ranging
from 30 to 70% fiber glass and from 70 to 30% treated
cellulosic fibers. Some examples of the hybrid insulation are
more effective at insulating and, hence, less costly per
square foot to install, than either of their component parts.
Further, the insulation of the present invention will not
smoulder when exposed to a temperature exceeding 500F
(260C) for a period of six (6) or more hours.

Croydon Printing Company Ltd

840

and Summary of the

Background

attics

which

is

by pneumatic

means)

have

owners

its

comparative

treated

cellulosic
There

available

this

in

also

can

treated

wire

or

electrical

wood members
processed

in

used

the

thickness,

is

nodulated

unattractive

difficulties.

have

by chemical

of .the
and

density

breeding

ground

Nonetheless,
a hot

to

exposed

to. i g n i t e

can,

in

untreated

In

building.

to.

reduced

smouldering

sufficient

tendency

This

fiber

However.

significantly

when

attic.

or

currently

cellulesic

treatment.

smoulder

can

these

as a

wood p u l p ) .

flamability.

cellulose

which are

fiber
to

addition,

settle,

decreasing

its

adversely

affecting

its

batts

cannot

compete

cost

alone.

The

equipment,

fiber

glass

blanket
this

cf

into

it

cellulosic
with

does
do

time

smouldering
run

into

have

not

fibers.

fibers

and

handling

rather

than

enough

even

involved

in
it

making

fiber

basis

of

turning

further

batts,

insulation,

blowing

economic

the

on

problem

high

Generally,

cellulosic

nodules,

particular

no such

nodules

glass

with

compels

has

glass
pests,

glass

adds
even

to

less

competitive.
The

hybrid

overcomes

the

cellulosic

fibers

of

of

construction

Typically,

to

R-per-inch

cost

retardants

is

characteristics.

While

cost

its

its

increasing

insulating

the

because

a wall

has

newspaper

of

Originally,

fibers

temperatures

each

of

blowing

Another

or f i b e r i z e d

with

of

of

glass.

insulation.

allure

in

box

fiber

with

because

form

One

walls

as

popular

application

newspaper

problems

be reduced

cellulosic

produce

of

flame
the

Further,

even

and

blowing

developments

vermin

turn,

of

difficulties

hazard.

for

(shredded

a number

are

forms

experienced
racent

fiber

certain

for

such

increasingly

a nodulated

is

used

frequently

cavities

installation.

of

ease

become

insulation

"blowing"

or
into

blown

alike

and c o n t r a c t o r s

home

insulation

fill"

"loose

insulation

(particulate
and

of

kinds

Various

Invention

from

30%
which

between

treated
is

insulation

blowing

of

disadvantages
while
30

to

cellulosic

drawing
70% by
fiber

smoulder-resistant

on

the

both

nodulated

the

advantages

weight
produces
and

of

has

fiber
a
an

glass
hybrid

invention

present
fiber
of

each.

nodules
blowing

R-per-inch

glass

and

A blend
and

70 t o

insulation

which

exceeds

2.3.

The

insulation

hybrid

settle

as badly

effect,

extend

cellulosic

as

fiber

fibers,

cost

actually
insulation

is

with

cellulosic

fibers

neighborhood

of 3 . 0 .
will

The

hybrid

The

characteristics

and

hybrid
and

value

may

blowing

advantages

after

apparent

more

cases,

nodules

glass

R-per-inch

of the

60-40%
in

the

of

the

of

the

reading

The

fiber

process.

For

example,

the

disclosed

process

3,584,796.

An advantage

and

products

board

alternative

is

of

Because

claimed

this

process

to

produce
in

U.

characteristics

thermal

in

by

is

flame

any

known
Patent
batt

nodules.

An

Patent

the

the

scrap

slicad

S.

this

S.

that

the

and

using

U.

is

of

conductivity),

with

produced

blanket

glass

claimed

and

superior

reduced

density,

fiber

produced

and

used

be

can

described

the

using

in which

method,

nodules,

of

be

be

nodules

glass

treated

may

invention

present

been

can

nodules

the

70% f i b e r

has

nodules

glass

Embodiments
of

30 to

which

fiber

retardant.

hammermilling

between

from

cellulosic

30%

Preferred

insulation

blowing

of

a blend

comprises

into

fiber

some

combined

become

Description

to

value.

of

propagation

moderately

in

and

40-60%

only

the

open

description.

following

70

is

in

fibers,

hold

nodules

preventing

alone

same

features,

invention

present

the

preferably

more

Other

fibers

for

less

and

and does not

pests

cellulosic

glass

insulation

hybrid

to

The

the

compaction

cellulose

than

expensive

fiber.

while

glass

reducing

This

smouldering.

unattractive

cellulosic

pure

the

is

and d i c e d
4,366,927.

nodules

latter

(lower
is

method

preferred.
The
shredded

or

newspaper

cellulosic

fiber

number

commercially

fire

of

must

retardant

should

cellulose

fiber

retardant

exceeds

example
acid

of

in a

may be

fiber

cellulosic

applied

be

treated

available

fire

of
as

at

least

a liquid

the

form

wood

pulp.

with

less

no

More

the

retardant
2 to

will
than

1,

solution

do.
16%

Any of

However,
of

the

the

amount

the

treated
of

flame

fiber.

An

of

borax

and b o r i c

This

fire

retardant

a mixture
the

treated,
case,

cellulosic

by w e i g h t .
and

either

the

treated

is

either

retardant.

preferably,

of

of

In

fire

materials

comprise

24% by weight

a suitable
ratio

fiberized

weight.

by

take

may

excess

moisture

removed

by drying
the

of

form

and

powder

retardants

fire

alternative

may be

mixture

the

or

into

employing

various

sulfates,

phosphates,

available,

any one of which would

Ft.

Industries,
This

processed

installed
this

marketed

3% boric

and

Premium

by

This

"R-Fact."
installed

with

vertically

moving

where

and

disc

flash

they

pair

to

create

fibers.

These

belt

grinding
of

are acted

teeth

fibers

into

an

method

of

which

fibers

have

been

and

then

against

a
and

separated
into

fall

and

patent

mill

partially
disc

at

Canadian
pulp

is

tradename

The

pulp,

which

a feed

a rotating

further

act

disc,

to

comb

collection

intermingled

loosely

27% by

source

the

an
of

analysis

horizontally

a fixed

on by

intermeshed

having
the

separate

fed

at

R-per-inch

the

at

are

dried,

under

in

wood

retardants

An

foot.

described

compacted

fire

collections

intermingled

of

R-per-inch

3.57

cubic

per
is

product
bales

has

pulp

pounds

chemical

wet
and

said

2.0

Briefly,

compressed

hopper

of
this

of

1,126,466.

wood

K-2

"Supertherm."

cellulosic

Canada

in

Ltd.,

are

by

approximately

An a l t e r n a t e

Industries

marketed

a 3.6

be

of

application.

foot.

to

Many

salts

tradename

cubic
it

shows

is

have

to

per

acid.

processed

density

manufacture

pounds

fiber

the

under

purported

2.67

cellulosic

borax

treated

of

density

treated

weight

is

newspaper

in t h i s

fiber

in

combinations

inorganic

be s u i t a b l e

Colorado

Collins,

fibers

fibers.

the

soluble

cellulosic

treated

suitable

cellulosic

"pounded"
other

and

the

to

applied

of

fibers.
As
with

treated
flameless
to

insure

hybrid

exothermic
that

blowing

test

each

box

made

flame

this

blended
of

beams

Midway

between

are
the
077

positioned

positioned

within

the

second

insulation

oxidation
undesirable

board
on

16"

2 by 4's

in

placed

P-Chromalox
the

box,

positioned

two

to

measure

heat

smouldering,
In

and

apparatus

fixture

into

which

of

2" x

4"

above

propagation

Two

contact
the
(i.e.,

ceiling

center

ring

the
to

developed
x 2'

ring.
in

to

a 2'

simulate

of

order

comprised

approximate

first

were

a pair
to

centers

transmitted

not

was

test

inches

to

fibers

self-perpetuating.

property

the

cellulosic

all,

subject

is

that

heater

the

not

are

a method
The

sample.

refractory

wooden

retardant,

insulation,

if

most

noted,

previously

x 1'
x 24"

joists.

the

box

is

thermocouples

are

with

ring

and

in

the

the

embedded

smouldering)

within

the

to

sample

tested

be

heat

the

thermocouples
hours
for

the
8

hour

determined

to

be

thermocouple

carbonization

or

inch from the

temperature

heater

each

Criteria
in

(charring)

the

put

the

at

two
The

than

more
625F

for

4500F

exceeding

(i.e.,

hour.

for

exceeded

the

volts

120
half

(260C)

usually

time.

of

at

temperatures

once

500F

and

period

The

with

techniques

current

least

exceeded

period

of

amps

at

filled

then

installation

hours.

eight

plate

shorter

some

for

monitored

were

the

of

40

is

cavity

normal

then,

ring

of

temperature

ceiling

using

and,

means)

pneumatic
through

simulated

The

sample.

(330C)

failure

(240C)
sample

were
the

at

2"

than

more

one

ring.
Example I

fiber

Scrap
having

glass
in

sizes

approximate

cubes.

This

hammermilled

1.1

with

an

pcf

with

the

The

cellulose.
of

period

two

Insulation

Blower

Mechanical,

rather

intimate
speed

(R) values

and

The
assume
fiber

into

blown

samples

shown

increased

then

was

in

smoulder

results

TABLE

costs
glass.

are p r e s e n t e d

the

I.

of

$.08

Actual
for

glass

a Vanco

idle

engine

is

fibrous
rpm,

above

frames

to

Model
at

determine

and

to

blended

100%.

for

UW2590-16
=1800

rpm.
insure

to

preferred

valve

blended

were

materials.

the

of

density

nodules

speed

blending

2200

to

test

of

hopper

diverse

two

nodules

inch

1/2

a blown

mechanically

were

the

to

"Supertherm" described

pneumatic,

the

has

nodules

produce

inch

1/4

from 100% f i b e r

the

than

to

These

density.

fiber

in

of

typically

components
with

of

mixing

range

ranging

minutes

five

the

that

at

formulations

hammermilled

product

cellulose

treated

in

tested

R-19

was

idle

The

opened

the

and

thermal

coverage,

resistance.

of

these

tests

for

the

various

Also

shown

are

comparative

per

pound

for

cellulose

component

comparison

costs

only.

will

and

vary

compositions

costs.
$.30
and

These
per

these

a
costs

pound
cost

for
data

failed
and

the

hot

60% to
have

an i n s t a l l e d

than

cellulose.
this

blend

not

only

passed

of

only

three

cost

additional

The
of

from

blends

The

test.

plate

blowing

insulation

100%

40% to

cellulose

60% f i b e r

glass

the

hot

plate

test,

but

cents

per

square

foot

more

of

advantage

and

70%

60%,

containing

40% c e l l u l o s e

they
makes

blends

three

The

smoulder-resistant

being

cost

with

competitive

pure

cellulose.
EXAMPLE I I
Virgin
of

density
6% or
Patent
3/4

0.5

less,

square

1/2"

thick.

0.49

lbs/ft3.

fibers

was

used

procedures.

glass

0.6

to

4,366,927

inch

Fiber

pounds

sliced
to
with

in

in

the

per

cubic

and d i c e d u s i n g
nodules

produce

in

a delaminated)
these

By t h e m s e l v e s ,
These

wool,

nodules

Example

The r e s u l t s

form

foot

of

and

a binder

the

method

the

size

with

were

then

using

the

same

blending

and c o m p a r a t i v e

costs

appear

-5-

of
S.

1/4

inch

to

from

1/16

tc

density

of

installed

blended

content

in U.

of

varying

have

having

described

range

thickness

nodules

blanket

the

cellulosic
and

blowing

in TABLE I I .

formulations

All
and

30%

cellulose

formulations
1/2

cent

these

square

per

have

blends
of

problems

In

can be seen

that

alone.

fibers

glass

nature's

best

pockets.

The

fiber

the

cost

low cost

less
the

insulation
The

insulation
fiber

possibly,

due

cellulose

fibers

to

fact

the

insulator

(an

increase

(i.e.,

the

that

the

air

and
air

the
able

R-per-inch

a larger

nodules

is

nodules

to

is
of

the

than

pure

a lower
separate

amount of e n t r a p p e d

how

one

of
air

finer

the

and

the

produce

of
tiny

pockets

lower

than

with

basis

myriads

isolated

it

unexpected.

Isolated

(i.e.,

invention

present

R-per-inch

on the

fiberglass

of

number

capability

with

glass

the

the

associated

of TABLES I and I I ,

isolates

glass

two

Hence,

without

ordinarily

offered

70%

within

come

alone.

a higher

work.

to
of

density
the

be

can

addition,

blends

is wholly

result

Fiber

more

has

actually

In

cellulose

results

the

believed

the

of

and

glass

cellulose

breeding

synergistic

are

of

advantages
pest

or

insulators.

conductivity).
adding

of

explanation

alone

the

blowing

foot

This

diameter,

better

70% c e l l u l o s e

70% blend

A possible

test.

plate

and

by comparing

the

70% f i b e r

60%

the

fact,

hot

and

the

smouldering

therewith.
cellulose

the

passed

namely,

30%

between

the

thermal
a hybrid

cellulose

by

R-per-inch),
and

open

the

air).

EXAMPLE I I I
Armed
found,
original
The

with

even

lower

density

of

an

blanket

was

the

density
from

sliced

of

success
0.4
and

Example

II,

Applicant

sought,

and

fiber
to
diced

The b l a n k e t used had an

glass.
1
b
/
f
t
3
0.5
and 5% b i n d e r c o n t e n t .
using

the

method

of

the

previous

into

example
thick.

The

1b/ft3.

which

nodules
diced

This

the

wool

blended

was

utilized

in

blending

and blowing

techniques.

and cost

comparisons

appear

The

80%

per

alone.
hand,
is
and

uncertain;
cost

compaction

All

four

R-19

which

noted,

testing.
could

square

foot.

the

material

during

density

with

the

cellulosic

identical
of

hot

the

inch
0 .
fiber
and

equipment
hot

tested

test

plate

below

were

The

components

the

increase
Because

will

most

will

packaging

of

of

cellulose

blend

thickness

aeration

be

fluffed

significantly

other

therefore,

installed
the

not

was

the

on

packaging,

probably

not

installed

were,

density,

cne

hsd

that

hybrid

of

The impact

the

was

blends

that

two

test

plate

however,

blending.

packaging

per

installation,

the

be

before

packaged

of

blown

results

failing
for

to

prior

packaged

1/2"

in TABLE I I I .

foot

should

The

to

using

examples

cellulose.

square

It

two

blend

only

containing
costs

previous

1/16"

by

square

had

nodules

forced

thusly

1/2"

were

during
such

that
these

impact

estimates.
EXAMPLE IV
The
blended

with

treated

wood

is

viewed

another
In

pulp.

original

the

present

Example

of

some

is

as

glass

cellulosic
of

areas
in

due,

introduction

fiber

diced

form

unfavorably

its

tradename

low d e n s i t y ,

part,

world,

the

an u n t r e a t e d
described

that

in

this

processed

problems

was

then

case,

associated

marketed

newspaper
with

The wood pulp

product.
supra,

III

Example

fibers,

the
to

of

under

of
the

"R-Fact."
The

glass

nodules

and

cellulosic

fibers

were

blended

in

amounts

blends

These

$.15

cost

presumes
for

presented

tested

for

and

from

30

smoulder

for

above.

The

information

is

presented

$.30

of
the

comparison

wood

treated
only

of

facts

these

Table

IV.

The

diced

fiber

glass

and

These
will

costs

the

using

in

pulp,

actual

as

results

for

pound

per

70% c e l l u l o s e .

to

resistance

described

a cost

pound

per

30% glass

to

then

were

comparitive

costing

70

and p r o c e d u r e

apparatus
and

from

ranging

costs

are

from

vary

those

presumed.

All
blend

passed

samples

with

the

plate, smoulder-resistance testing.

hot

the

case

with

Examples

and I I I ,

cost

for

the

that

for

these

two compounds,

The

present

II

40/60

blend

effect

from

30% t r e a t e d

70

to

blended,
than

produce

either

believed

be

to

increased

of

the

a result

of

the

improve

enhance

discovered

an

70% f i b e r

to

fibers.
less

These
costly

materials
fiber
in

the

effective.
unexpected

glass

two

insulation

nodules

when

material
This

is

maintaining

an

by

individual

properties

nodules

fibers,

cellulose

These

insulation

indicating

individually.

glass

fibers.
the

cellulose,

has
30

the

IV show a l o w e r

Example

cost

air

trapped

cellulosic
or

the

As was

may be most

effective,
of

glass/cellulose

ratio
from

fibrous

30/70

and

glass

cellulosic

two

of

this

the
of

blends

fiber

of

combining

a more

amount

settling
pockets

of

the

invention

synergistic

of

exception

preventing
trapped

of

air

the

blended

will

become

materials.
Various
apparent

changes,

following

modifications
reading

of

the

and

alterations
foregoing

specification.

Accordingly,

it

alterations

as

considered

a part

is

intended

that

within

the

come
of

the

present

all

such

scope

of

invention.

changes,
the

modifications

and

clsims,

be

appended

1.

fiber

by weight
cellulosic
flame

500F

(260C)

for

cellulosic
to make

cellulosic

flame
The

glass

is

The

6.
fiber

glass

in the

The

insulation
(240C)

wood p u l p .

temperatures

blowing
and

smolder

being

which

temperature
and

hours

Claim

1
of

having

an

wherein

said

and

boric

borax

of

Claim

wherein

said

of

Claim

wherein

said

Claim

fiber

are

1 wherein

the

preferably

in

blend
the

of

range

respectively.

insulation

of

cellulosic

fibers

1 wherein

Claim

have

an

the

blended
value

R-per-inch

of 3 . 0 .
insulation

blowing

inches

greater

no
above

exceeding

8.

of

and 60-40% by w e i g h t

exhibits

two

insulation

and c e l l u l o s i c

neighborhood
The

with

newspaper.

treated

nodules

7.

of

insulation
insulation

blowing

of 40-60% by weight

six

a combination

blowing

nodules

70%

retardant.

processed

The

5.

with

blowing
is

fiber

of

insulation

treated

having

period

blowing

it

4.

treated

insulation

plate

2.3.

is

fiber

hot

to

30% by w e i g h t

70 to
been

having

blowing

at l e a s t

fiber
3.

cellulosic

of

The

2.

fiber

to

value

R-per-inch

hybrid

exposed

when

exceeds

acid

said

fiber

from

30

from

comprising

with

blended

cellulosic

said

retardant,

resistant

nodules

glass

fiber,

insulation

blowing

A hybrid

a heat

of

Claim

3 wherein

than

temperature

625F

(320C).

of

producing

A method

said

when

source

hybrid

said

hybrid

of

450F

heat

source

has

insulation

blowing

comprising
a)
board

blanket,

or
b)

mixture

such

from

70

insulation
signs

of

to

30%
with

cellulosic

treating

of borax

in
by
an

smoldering

glass

weight

and b o r i c

acid,

cellulose

R-per-inch
when

with

from

of

amounts

fibers

fiber

said

blending

fibers

fiber

from

preformed

flame

retardant

like,

as a mixture
c)

cellulosic

the

of

nodules

forming

of

exposed

at
to

nodules

glass
30

to

to

a wire

said

70% by weight

produce

least

and

2.3

a
and

having

hybrid
which

treated

glass

and

blowing
shows

no

a temperature

in

of 500F

excess

The

9.
formed

or

the

The

by

slicing

method
and

of

Claim

of

at

six

least
said

3 wherein

hours.
glass

nodules

are

glass

nodules

are

process.
of

then

The method

made by s h r e d d i n g
12.

Claim
dicing

8 wherein
the

said

preformed

fiber

glass

blanket

13.

The

cellulosic

of

Claim

8 wherein

the

cellulosic

fibers

are

Claim

8 wherein

the

cellulosic

fibers

are

newspaper.

The method

made by t r e a t i n g

between

method

a period

like.
11.

and

for

by a h a m m e r m i l l i n g
10.

formed

(260C)

of

wood p u l p .
method
fibers

40-60%. by weight

of
are

Claim

8 wherein

preferably

the

blended

and 60-40% by w e i g h t ,

fiber
in

glass

nodules

amounts

ranging

respectively.