Loosefill insulation blowing machine with a full height bale guide

A machine for distributing blowing insulation material from a package of compressed loosefill insulation material is provided. The machine includes a chute. The chute has an inlet portion, an outlet portion, a bale guide and a cutting mechanism. The inlet portion is configured to receive the package with the package having a substantially vertical orientation. The inlet portion has a vertical height. The bale guide has a length and is configured to urge the package against the cutting mechanism. The cutting mechanism is configured to open the package. A lower unit is configured to receive the material exiting the outlet portion of the chute. The lower unit includes a plurality of shredders and a discharge mechanism. The discharge mechanism is configured to discharge conditioned loosefill insulation material into an airstream. The length of the bale guide extends substantially across the height of the inlet portion of the chute.

BACKGROUND

When insulating buildings and installations, a frequently used insulation product is loosefill insulation material. In contrast to the unitary or monolithic structure of insulation materials formed as batts or blankets, loosefill insulation material is a multiplicity of discrete, individual tufts, cubes, flakes or nodules. Loosefill insulation material is usually applied within buildings and installations by blowing the loosefill insulation material into an insulation cavity, such as a wall cavity or an attic of a building. Typically loosefill insulation material is made of glass fibers although other mineral fibers, organic fibers, and cellulose fibers can be used.

Loosefill insulation material, also referred to as blowing wool, is typically compressed in packages for transport from an insulation manufacturing site to a building that is to be insulated. Typically the packages include compressed loosefill insulation material encapsulated in a bag. The bags can be made of polypropylene or other suitable material. During the packaging of the loosefill insulation material, it is placed under compression for storage and transportation efficiencies. Typically, the loosefill insulation material is packaged with a compression ratio of at least about 10:1.

The distribution of loosefill insulation material into an insulation cavity typically uses an insulation blowing machine that can condition the loosefill insulation material to a desired density and feed the conditioned loosefill insulation material pneumatically through a distribution hose. Blowing insulation machines typically have a funnel-shaped chute or hopper for containing and feeding the blowing insulation material after the package is opened and the blowing insulation material is allowed to expand.

It would be advantageous if insulation blowing machines could be improved to make them easier to use.

SUMMARY

The above objects as well as other objects not specifically enumerated are achieved by a machine for distributing blowing insulation material from a package of compressed loosefill insulation material. The machine includes a chute configured to receive the package of compressed loosefill insulation material. The chute has an inlet portion, an outlet portion, a bale guide and a cutting mechanism. The inlet portion is configured to receive the package of compressed loosefill insulation material with the package having a substantially vertical orientation. The inlet portion of the chute has a vertical height. The bale guide has a length and is configured to urge the package against the cutting mechanism as the package slides within the chute. The cutting mechanism is configured to open the bag of insulation. A lower unit is configured to receive the compressed loosefill insulation material exiting the outlet portion of the chute. The lower unit includes a plurality of shredders and a discharge mechanism. The discharge mechanism is configured to discharge conditioned loosefill insulation material into an airstream. The length of the bale guide extends substantially across the height of the inlet portion of the chute.

There is also provided a machine for distributing blowing loosefill insulation material from a package of compressed loosefill insulation material. The machine includes a chute configured to receive the package of compressed loosefill insulation material. The chute has an inlet portion, an outlet portion, a bale guide and a cutting mechanism. The inlet portion is configured to receive the package of compressed loosefill insulation material with the package having a substantially vertical orientation. The bale guide has a length, a vertical orientation and is configured to urge the package against the cutting mechanism as the package slides within the chute. The cutting mechanism is configured to open the bag of insulation. A lower unit is configured to receive the compressed loosefill insulation material exiting the outlet portion of the chute. The lower unit includes a plurality of shredders and a discharge mechanism. The discharge mechanism is configured to discharge conditioned loosefill insulation material into an airstream. The length of the bale guide is configured to retain the vertical orientation of the package as the package slides within the chute and engages the cutting mechanism.

There is also provided a machine for distributing blowing loosefill insulation material from a package of compressed loosefill insulation material. The machine includes a chute configured to receive the package of compressed loosefill insulation material. The chute has a depth, an inlet portion, an outlet portion, a bale guide and a cutting mechanism. The inlet portion is configured to receive the package of compressed loosefill insulation material with the package having a substantially vertical orientation. The bale guide has a depth, a vertical orientation and is configured to urge the package against the cutting mechanism as the package slides within the chute. The cutting mechanism is configured to open the bag of insulation. A lower unit is configured to receive the compressed loosefill insulation material exiting the outlet portion of the chute. The lower unit includes a plurality of shredders and a discharge mechanism. The discharge mechanism is configured to discharge conditioned loosefill insulation material into an airstream. The depth of the bale guide forms a retention structure configured to retain within the chute loosefill insulation material exiting the package and expanding toward the inlet portion of the chute.

There is also provided a machine for distributing blowing loosefill insulation material from a package of compressed loosefill insulation material. The machine includes a chute configured to receive the package of compressed loosefill insulation material. The chute has a width, an inlet portion, an outlet portion, a bale guide and a cutting mechanism. The inlet portion is configured to receive the package of compressed loosefill insulation material with the package having a substantially vertical orientation. The bale guide extends from the inlet portion of the chute, has a width and is configured to urge the package against the cutting mechanism as the package slides within the chute. The cutting mechanism is configured to open the bag of insulation. A lower unit is configured to receive the compressed loosefill insulation material exiting the outlet portion of the chute. The lower unit includes a plurality of shredders and a discharge mechanism. The discharge mechanism is configured to discharge conditioned loosefill insulation material into an airstream. The width of the bale guide is less than 20.0% of the width of the chute.

Various objects and advantages of the loosefill insulation blowing machine with a full height bale guide will become apparent to those skilled in the art from the following detailed description, when read in light of the accompanying drawings.

DETAILED DESCRIPTION OF THE INVENTION

The loosefill insulation blowing machine with a full height bale guide will now be described with occasional reference to specific embodiments. The loosefill insulation blowing machine with a full height bale guide may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the loosefill insulation blowing machine with a full height bale guide to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the loosefill insulation blowing machine with a full height bale guide belongs. The terminology used in the description of the loosefill insulation blowing machine with a full height bale guide herein is for describing particular embodiments only and is not intended to be limiting of the loosefill insulation blowing machine with a full height bale guide. As used in the description of the loosefill insulation blowing machine with a full height bale guide and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities of dimensions such as length, width, height, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the loosefill insulation blowing machine with a full height bale guide. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the loosefill insulation blowing machine with a full height bale guide are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements.

The description and figures disclose a loosefill insulation blowing machine with a full height bale guide. The bale guide is positioned within an inlet portion of a chute. The chute configured to receive a package of compressed loosefill insulation material. The bale guide is configured for several functions. First, the bale guide is configured to urge the package of compressed loosefill insulation material against a cutting mechanism as the package is slid into the chute. Next, the bale guide is configured to retain expanding loosefill insulation material within the interior of the chute as the package is cut by the cutting mechanism. Finally, the bale guide is configured to retain the package in an upright orientation as the package engages the cutting mechanism, thereby substantially preventing sagging of the package as the moves past the cutting mechanism.

The term “loosefill insulation material”, as used herein, is defined to mean any insulating material configured for distribution in an airstream. The term “finely conditioned”, as used herein, is defined to mean the shredding, picking apart and conditioning of loosefill insulation material to a desired density prior to distribution into an airstream.

Referring now toFIGS. 1-3, a loosefill insulation blowing machine (hereafter “blowing machine”) is shown generally at10. The blowing machine10is configured for conditioning compressed loosefill insulation material and further configured for distributing the conditioned loosefill insulation material to desired locations, such as for example, insulation cavities. The blowing machine10includes a lower unit12and a chute14. The lower unit12is connected to the chute14by one or more fastening mechanisms15, configured to readily assemble and disassemble the chute14to the lower unit12. The chute14has an inlet portion16and an outlet portion18.

Referring again toFIGS. 1-3, the inlet portion16of the chute14is configured to receive compressed loosefill insulation material typically contained within a package (not shown). As the package of compressed loosefill insulation material is guided into an interior of the chute14, the cross-sectional shape and size of the chute14relative to the cross-sectional shape and size of the package of compressed loosefill insulation material directs an expansion of the compressed loosefill insulation material to a direction toward the outlet portion18, wherein the loosefill insulation material is introduced to a shredding chamber23positioned in the lower unit12.

Referring again toFIGS. 1-3, optionally the chute14can include one or more handle segments17, configured to facilitate ready movement of the blowing machine10from one location to another. The handle segment17can have any desired structure and configuration. However, it should be understood that the one or more handle segments17are not necessary to the operation of the blowing machine10.

Referring again toFIGS. 1-3, the chute14includes a bail guide19, mounted at the inlet portion16of the chute14. The bail guide19is configured to urge a package of compressed loosefill insulation material against a cutting mechanism20as the package of compressed loosefill insulation material moves further into the interior of the chute14. The bail guide19will be discussed in more detail below.

Referring again toFIGS. 1-3, the chute14includes a distribution hose storage structure80. The distribution hose storage structure80is configured to store a distribution hose38within the chute14in the event the blowing machine10is not in use. The distribution hose storage structure80includes a hose hub82attached to flanges84a,84b, with each of the flanges84a,84bbeing mounted in opposing sides of the chute14.

Referring now toFIG. 2, the shredding chamber23is mounted in the lower unit12, downstream from the outlet portion18of the chute14. The shredding chamber23can include a plurality of low speed shredders24a,24band one or more agitators26. The low speed shredders24a,24bare configured to shred, pick apart and condition the loosefill insulation material as the loosefill insulation material is discharged into the shredding chamber23from the outlet portion18of the chute14. The one or more agitators26are configured to finely condition the loosefill insulation material to a desired density as the loosefill insulation material exits the low speed shredders24a,24b. It should be appreciated that any quantity of low speed shredders and agitators can be used. Further, although the blowing machine10is described with low speed shredders and agitators, any type or combination of separators, such as clump breakers, beater bars or any other mechanisms, devices or structures that shred, pick apart, condition and/or finely condition the loosefill insulation material can be used.

Referring again to the embodiment shown inFIG. 2, the agitator26is positioned vertically below the low speed shredders24a,24b. Alternatively, the agitator26can be positioned in any location relative to the low speed shredders24a,24b, such as horizontally adjacent to the low speed shredders24a,24b, sufficient to finely condition the loosefill insulation material to a desired density as the loosefill insulation material exits the low speed shredders24a,24b.

In the embodiment illustrated inFIG. 2, the low speed shredders24a,24brotate in a counter-clockwise direction, as shown by direction arrows D1a, D1band the one or more agitators26also rotate in a counter-clockwise direction, as shown by direction arrow D2. Rotating the low speed shredders24a,24band the agitator26in the same counter-clockwise directions, D1a, D1band D2, allows the low speed shredders24a,24band the agitator26to shred and pick apart the loosefill insulation material while substantially preventing an accumulation of unshredded or partially shredded loosefill insulation material in the shredding chamber23. However, in other embodiments, the low speed shredders24a,24band the agitator26could rotate in a clock-wise direction or the low speed shredders24a,24band the agitator26could rotate in different directions provided an accumulation of unshredded or partially shredded loosefill insulation material does not occur in the shredding chamber23.

Referring again to the embodiment shown inFIG. 2, the low speed shredders24a,24brotate at a lower rotational speed than the agitator26. The low speed shredders24a,24brotate at a speed of about 40-80 revolutions per minute (rpm) and the agitator26rotates at a speed of about 300-500 rpm. In another embodiment, the low speed shredders24a,24bcan rotate at a speed less than about 40-80 rpm, provided the speed is sufficient to shred and pick apart the loosefill insulation material. In still other embodiments, the agitator26can rotate at a speed less than or more than 300-500 rpm provided the speed is sufficient to finely shred the loosefill insulation material and prepare the loosefill insulation material for distribution into an airstream.

Referring again toFIG. 2, the shredding chamber23includes a first guide shell120positioned partially around the low speed shredder24a. The first guide shell120extends to form an arc of approximately 90°. The first guide shell120has an inner surface121. The first guide shell120is configured to allow the low speed shredder24ato seal against the inner surface121and thereby direct the loosefill insulation material in a downstream direction as the low speed shredder24arotates.

Referring again toFIG. 2, the shredding chamber23includes a second guide shell122positioned partially around the low speed shredder24b. The second guide shell122extends to form an arc of approximately 90°. The second guide shell122has an inner surface123. The second guide shell122is configured to allow the low speed shredder24bto seal against the inner surface123and thereby direct the loosefill insulation material in a downstream direction as the low speed shredder24brotates.

Referring again toFIG. 2, the shredding chamber23includes a third guide shell124positioned partially around the agitator26. The third guide shell124extends to form an approximate semi-circle. The third guide shell124has an inner surface125. The third guide shell124is configured to allow the agitator26to seal against the inner surface125and thereby direct the finely conditioned loosefill insulation material in a downstream direction as the agitator26rotates.

In the embodiment shown inFIG. 2, the inner surfaces121,123and125, are formed from a high density polyethylene material (hdpe) configured to provide a lightweight, low friction sealing surface and guide for the loosefill insulation material. Alternatively, the inner surfaces121,123and125can be formed from other materials, such as aluminum, sufficient to provide a lightweight, low friction sealing surface and guide that allows the low speed shredders24a,24band the agitator26to direct the loosefill insulation material downstream.

Referring again toFIG. 2, a discharge mechanism, shown schematically at28, is positioned downstream from the one or more agitators26and is configured to distribute the finely conditioned loosefill insulation material exiting the agitator26into an airstream, shown schematically by arrow33inFIG. 3. In the illustrated embodiment, the discharge mechanism28is a rotary valve. In other embodiments, the discharge mechanism28can be other structures, mechanisms and devices, such as for example staging hoppers, metering devices or rotary feeders, sufficient to distribute the finely conditioned loosefill insulation material into the airstream33.

Referring again toFIG. 2, the finely conditioned loosefill insulation material is driven through the discharge mechanism28and through a machine outlet32by the airstream33. The airstream33is provided by a blower34and associated ductwork, shown in phantom at35. In alternate embodiments, the airstream33can be provided by other structures and manners, such as by a vacuum, sufficient to provide the airstream33through the discharge mechanism28.

Referring again toFIG. 2, the low speed shredders24a,24b, agitator26and discharge mechanism28are mounted for rotation. In the illustrated embodiment, they are driven by an electric motor36and associated drive means (not shown). However, in other embodiments, the low speed shredders24a,24b, agitator26and discharge mechanism28can be driven by any suitable means. In still other embodiments, each of the low speed shredders24a,24b, agitator26and discharge mechanism28can be provided with its own source of rotation. In the illustrated embodiment, the electric motor36driving the low speed shredders24a,24b, agitator26and discharge mechanism28is configured to operate on a single 15 ampere, 110 volt a.c. electrical power supply. In other embodiments, other suitable power supplies can be used.

Referring again toFIG. 2, the discharge mechanism28is configured with a side inlet92. The side inlet92is configured to receive the finely conditioned loosefill insulation material as it is fed in a substantially horizontal direction from the agitator26. In this embodiment, the side inlet92of the discharge mechanism28is positioned to be horizontally adjacent to the agitator26. In another embodiment, a low speed shredder24aor24b, or a plurality of low speed shredders24a,24bor agitators26, or other shredding mechanisms can be horizontally adjacent to the side inlet92of the discharge mechanism28or in other suitable positions.

Referring again toFIG. 2, a choke110is positioned between the agitator26and the discharge mechanism28. In this position, the choke110is configured to allow finely conditioned loosefill insulation material to enter the side inlet92of the discharge mechanism28and redirect heavier clumps of conditioned loosefill insulation material past the side inlet92of the discharge mechanism28and back to the low speed shredders,24aand24b, for further conditioning. In the illustrated embodiment, the choke110has a substantially triangular cross-sectional shape. However, the choke110can have other cross-sectional shapes sufficient to allow finely conditioned loosefill insulation material to enter the side inlet92of the discharge mechanism28and redirect heavier clumps of conditioned loosefill insulation material past the side inlet92of the discharge mechanism28and back to the low speed shredders,24aand24b, for further conditioning.

Referring again toFIG. 2, in operation, the inlet portion16of the chute14receives a package of compressed loosefill insulation material. As the package of compressed loosefill insulation material moves into the chute14, the bale guide19urges the package against the cutting mechanism20thereby cutting an outer protective covering and allowing the compressed loosefill insulation within the package to expand. As the compressed loosefill insulation material expands within the chute14, the chute14directs the expanding loosefill insulation material past the outlet portion18of the chute14and into the shredding chamber23. The low speed shredders24a,24breceive the loosefill insulation material and shred, pick apart and condition the loosefill insulation material. The loosefill insulation material is directed by the low speed shredders24a,24bto the agitator26. The agitator26is configured to finely condition the loosefill insulation material and prepare the loosefill insulation material for distribution into the airstream33by further shredding and conditioning the loosefill insulation material. The finely conditioned loosefill insulation material exits the agitator26and enters the discharge mechanism28for distribution into the airstream33provided by the blower34. The airstream33, entrained with the finely conditioned loosefill insulation material, exits the insulation blowing machine10at the machine outlet32and flows through the distribution hose38toward an insulation cavity (not shown).

Referring now toFIG. 4, the inlet portion16of the chute14includes longitudinal sides64a,64band lateral sides66a,66b. The longitudinal sides64a,64bof the inlet portion16of the chute14, are configured to be substantially vertical and centered about major longitudinal axis A-A. The lateral sides66a,66bare configured to be substantially horizontal and centered about major lateral axis B-B. In operation, a package of compressed loosefill insulation material50is fed into the inlet portion16of the chute14in a manner such that the package50has a substantially vertical orientation. The term “vertical orientation”, as used herein, is defined to a mean major face52aof the package50extends along the longitudinal side64a, opposing major face52bextends along the substantially vertically-oriented bale guide19, and opposing minor faces54a,54bof the package50are extend along the lateral sides66a,66b. Alternatively, the chute14can be configured such that the package50has a substantially horizontal orientation when fed into the inlet end16of the chute14.

Referring now toFIGS. 6aand 6b, the bale guide19is illustrated. The bale guide19is formed from one or more sheet materials having a thickness T. In the illustrated embodiment, the thickness T is approximately 0.125 inches. However, in other embodiments, the thickness T can be more or less than approximately 0.125 inches. The sheet material forming the bale guide19is configured to be flexible, thereby allowing the bale guide19to flex as the package50contacts the bale guide19. In turn, the resilient nature of the bale guide19produces a force that urges the package50into contact with the cutting mechanism20as the package50progresses into the inlet end16of the chute14. In the illustrated embodiment, the bale guide19is formed from a polymeric material having a low coefficient of friction that allows the package50to easily slide against the bale guide19, such as for example, high density polyethylene (hdpe). However, in other embodiments, the bale guide19can be formed from other materials suitable to flexibly urge the package50into sliding contact with the cutting mechanism20.

Referring again toFIGS. 6aand 6b, the bale guide19has a first flat portion70, a curved portion72extending from the first flat portion70and a second flat portion74extending from the curved portion72. The first and second flat portions70,74are oriented in a stacked arrangement, thereby forming the curved portion72. A plurality of apertures76(a single aperture is shown for purposes of clarity) extend through the first and second stacked flat portions70,74.

Referring now toFIGS. 4 and 5, a plurality of fasteners76is used to attached the bale guide19to the longitudinal side64bof the inlet portion16of the chute14such that the curved portion72of the bale guide19is positioned downstream from the stacked first and second flat portions70,72. In the illustrated embodiment, the fasteners76are rivets. However, in other embodiments, the fasteners76can have other forms sufficient to attach the bale guide19to the longitudinal side64bof the inlet portion16of the chute14, including the non-limiting example of threaded fasteners.

Referring again toFIGS. 5 and 6b, the curved portion72of the bale guide19has a diameter DCP. The diameter DCP of the curved portion72is configured such that the curved portion72of the bale guide19extends across a depth DC of the inlet portion16of the chute14a distance sufficient to ensure engagement of the package50with the cutting mechanism20. In the illustrated embodiment, the curved portion72has a diameter DCP in a range of from about 2.0 inches to about 3.0 inches and the depth DC of the inlet portion16is in a range of from about 8.0 inches to about 10.0 inches. Accordingly, the curved portion72of the bale guide19extends across approximately 20.0% to about 37.5% of the depth DC of the inlet portion16of the chute14. Without being held to the theory, it is believed that a curved portion72having a larger diameter would hinder entry of the package50into the inlet portion16of the chute14and a curved portion72having a smaller diameter would provide insufficient engagement of the package50with the cutting mechanism20.

Referring again toFIG. 5, as discussed above the curved portion72of the bale guide19extends across approximately 20.0% to about 37.5% of the depth DC of the inlet portion16of the chute14. Advantageously, the extension of the bale guide19across the inlet portion16provides a retention structure (e.g. dam). The retention structure is useful to retain loosefill insulation material exiting the package50and expanding in a direction, as shown by direction arrows D3, toward the inlet portion16of the chute14. The loosefill insulation material expanding in the direction D3toward the inlet portion16of the chute14will be substantially retained within the chute14by the bale guide19.

While the bale guide19is shown inFIGS. 6aand 6bas having a substantially circular cross-sectional shape, the bale guide19can have other cross-sectional shapes, such as for example a triangular cross-sectional shape. A triangularly-shaped bale guide could be oriented with the narrow portion of the triangle positioned near the inlet portion16of the chute14and a larger portion of the triangle arranged in a downstream direction.

Referring again toFIGS. 5 and 6b, the bale guide19is positioned at the inlet portion16of the chute and has a width WBG. The width WBG of the bale guide19is configured such that the bale guide19extends from the inlet portion16of the chute14into the chute14only a small distance compared to an overall chute width WC. In the illustrated embodiment, the width WBG of the bale guide19is in a range of from about 4.0 inches to about 6.0 inches and the width WC of the chute14is in a range of from about 32.0 inches to about 36.0 inches. Accordingly, the bale guide19extends into the chute14approximately 11.1% to about 18.8% of the width WC of the chute14. Advantageously, positioning the bale guide19at the inlet portion16of the chute14and limiting the distance the bale guide19extends into the chute14provides more space within the interior of the chute14for the distribution hose38to be wound around the hub82with the machine10in a storage mode.

Referring again toFIGS. 4 and 6a, the bale guide19has a length LBG. The length LBG of the bale guide19is configured such that the bale guide19extends substantially across a height HIP of the inlet portion16of the chute14. The term “substantially across”, as used herein, is defined to mean the length LBG of the bale guide19is in a range of from about 70.0% of the height HIP of the inlet portion16of the chute14to about 100.0% of the height HIP of the inlet portion16of the chute14. Without being held to the theory, it is believed the length LBG of the bale guide19of at least 70.0% of the height HIP of the inlet portion16of the chute14advantageously retains the package50in an upright orientation as the package50is slid into the inlet portion16of the chute14and subsequently engages the cutting mechanism20. An upright orientation of the package50substantially prevents sagging of the package50as the package50moves past the cutting mechanism20. It has been found that maintaining an upright orientation of the package50leads to more efficient expansion of the compressed loosefill insulation material as the compressed loosefill insulation material exits the package in a direction toward the shredding chamber23. In the illustrated embodiment, the length LBG of the bale guide is about 15.0 inches and the height HIP of the inlet portion16of the chute14is about 21.0 inches. Accordingly, the length LBG the bale guide19is approximately 71.0% of the height HIP of the inlet portion16of the chute14. However, in other embodiments, the length LBG of the bale guide19can be more than 71.0% of the height HIP of the inlet portion16of the chute14.

The principle and mode of operation of the loosefill insulation blowing machine with a full height bale guide have been described in certain embodiments. However, it should be noted that the loosefill insulation blowing machine with a full height bale guide may be practiced otherwise than as specifically illustrated and described without departing from its scope.