Abstract:
A combination including unbonded loosefill insulation material compressed in a package and a blowing insulation machine is provided. The unbonded loosefill insulation material has insulative characteristics. The blowing insulation machine is configured to receive the compressed unbonded loosefill insulation material from the package. The blowing insulation machine has a plurality of shredders configured to condition unbonded loosefill insulation material to a desired density. The blowing insulation machine is further configured to distribute the conditioned unbonded loosefill insulation material into an airstream. The blowing insulation machine has pre-set, fixed operating parameters tuned to the unbonded loosefill insulation material. The blowing insulation machine, having the tuned pre-set, fixed operating parameters, combines with the insulative characteristics of the unbonded loosefill insulation materials to provide blown loosefill insulation material having the insulation manufacturer&#39;s prescribed insulative values at specific layer thicknesses.

Description:
RELATED APPLICATIONS 
       [0001]    This is a continuation application which claims the benefit of U.S. Provisional Patent Application No. 61/250,244, filed Oct. 9, 2009, U.S. Pat. No. 7,980,498, issued Jul. 19, 2011, and pending U.S. Continuation-In-Part patent application Ser. No. 12/924,939, filed Oct. 8, 2010, the disclosures of which are incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    A frequently used insulation product is unbonded loosefill insulation. In contrast to the unitary or monolithic structure of insulation batts or blankets, unbonded loosefill insulation is a multiplicity of discrete, individual tufts, cubes, flakes or nodules. Unbonded loosefill insulation is usually applied to buildings by blowing the unbonded loosefill insulation into an insulation cavity, such as a wall cavity or an attic of a building. Typically unbonded loosefill insulation is made of glass fibers although other mineral fibers, organic fibers, and cellulose fibers can be used. 
         [0003]    Unbonded loosefill insulation, also referred to as blowing wool, is typically compressed and encapsulated in a bag. The compressed unbonded loosefill insulation and the bag form a package. Packages of compressed unbonded loosefill insulation are used for transport from an insulation manufacturing site to a building that is to be insulated. The bags can be made of polypropylene or other suitable materials. During the packaging of the unbonded loosefill insulation, it is placed under compression for storage and transportation efficiencies. The compressed unbonded loosefill insulation can be packaged with a compression ratio of at least about 10:1. The distribution of unbonded loosefill insulation into an insulation cavity typically uses a loosefill blowing machine that feeds the unbonded loosefill insulation pneumatically through a distribution hose. Loosefill blowing machines can have a chute or hopper for containing and feeding the compressed unbonded loosefill insulation after the package is opened and the compressed unbonded loosefill insulation is allowed to expand. 
         [0004]    It would be advantageous if the loosefill blowing machines could be easier to use. 
       SUMMARY 
       [0005]    The above objects as well as other objects not specifically enumerated are achieved by a combination including unbonded loosefill insulation material compressed in a package, the unbonded loosefill insulation material having insulative characteristics and a blowing insulation machine configured to receive the compressed unbonded loosefill insulation material from the package. The blowing insulation machine has a plurality of shredders configured to condition unbonded loosefill insulation material to a desired density. The blowing insulation machine is further configured to distribute the conditioned unbonded loosefill insulation material into an airstream. The blowing insulation machine has pre-set, fixed operating parameters tuned to the unbonded loosefill insulation material. The blowing insulation machine, having the tuned pre-set, fixed operating parameters, combines with the insulative characteristics of the unbonded loosefill insulation materials to provide blown loosefill insulation material having the insulation manufacturer&#39;s prescribed insulative values at specific layer thicknesses. 
         [0006]    According to this invention there is also provided a combination including unbonded loosefill insulation material compressed in a package, the unbonded loosefill insulation material having insulative characteristics and a blowing insulation machine configured to receive the compressed unbonded loosefill insulation material from the package. The blowing insulation machine has a plurality of shredders configured to condition unbonded loosefill insulation material to a desired density. The blowing insulation machine is further configured to distribute the conditioned unbonded loosefill insulation material into an airstream. The blowing insulation machine has non-adjustable operating parameters tuned to the unbonded loosefill insulation material. The blowing insulation machine, having the tuned non-adjustable operating parameters, combines with the insulative characteristics of the unbonded loosefill insulation materials to provide blown loosefill insulation material having the insulation manufacturer&#39;s prescribed insulative values at specific layer thicknesses. 
         [0007]    Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a front view in elevation of a loosefill blowing machine. 
           [0009]      FIG. 2  is a front view in elevation, partially in cross-section, of the loosefill blowing machine of  FIG. 1 . 
           [0010]      FIG. 3  is a side view in elevation of the loosefill blowing machine of  FIG. 1 . 
           [0011]      FIG. 4  is a perspective view of a building having an attic with insulation cavities. 
           [0012]      FIG. 5  is an enlarged color photograph illustrating one embodiment of an unbonded loosefill insulation material. 
           [0013]      FIG. 6  is an enlarged color photograph illustrating an individual tuft of the unbonded loosefill insulation material of  FIG. 5 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0014]    The present invention will now be described with occasional reference to the specific embodiments of the invention. This invention 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 invention to those skilled in the art. 
         [0015]    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 this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention 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. 
         [0016]    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 present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention 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. 
         [0017]    In accordance with embodiments of the present invention, the description and figures disclose unbonded loosefill insulation systems. The unbonded loosefill insulation systems include a loosefill blowing machine and an associated unbonded loosefill insulation material. Generally, the operating parameters of the loosefill blowing machine are tuned to the insulative characteristics of the associated unbonded loosefill insulation material such that the resulting blown unbonded loosefill insulation material provides improved insulative values. The term “loosefill blowing machine”, as used herein, is defined to mean any structure, device or mechanism configured to condition and deliver insulation material into an airstream. The term “loosefill insulation material”, as used herein, is defined to any conditioned insulation materials configured for distribution in an airstream. The term “unbonded”, as used herein, is defined to mean the absence of a binder. The term “finely conditioned”, as used herein, is defined to mean the shredding of unbonded loosefill insulation material to a desired density prior to distribution into an airstream. 
         [0018]    One example of a loosefill blowing machine, configured for distributing compressed unbonded loosefill insulation material (hereafter “loosefill material”), is shown at  10  in  FIGS. 1-3 . The loosefill blowing machine  10  includes a lower unit  12  and a chute  14 . The lower unit  12  can be connected to the chute  14  by a plurality of fastening mechanisms  15  configured to readily assemble and disassemble the chute  14  to the lower unit  12 . As further shown in  FIGS. 1-3 , the chute  14  has an inlet end  16  and an outlet end  18 . 
         [0019]    The chute  14  is configured to receive loosefill material and introduce the loosefill material to a shredding chamber  23  as shown in  FIG. 2 . Optionally, the chute  14  can include a handle segment  21 , as shown in  FIG. 3 , to facilitate easy movement of the blowing insulation machine  10  from one location to another. However, the handle segment  21  is not necessary to the operation of the loosefill blowing machine  10 . 
         [0020]    As further shown in  FIGS. 1-3 , the chute  14  can include an optional guide assembly  19  mounted at the inlet end  16  of the chute  14 . The guide assembly  19  is configured to urge a package of loosefill material against an optional cutting mechanism  20 , as shown in  FIGS. 1 and 3 , as the package moves into the chute  14 . 
         [0021]    As shown in  FIG. 2 , the shredding chamber  23  is mounted at the outlet end  18  of the chute  14 . In the illustrated embodiment, the shredding chamber  23  includes a plurality of low speed shredders  24   a  and  24   b  and an agitator  26 . The low speed shredders,  24   a  and  24   b,  are configured to shred and pick apart the loosefill material as the loosefill material is discharged from the outlet end  18  of the chute  14  into the lower unit  12 . Although the loosefill blowing machine  10  is shown with a plurality of low speed shredders,  24   a  and  24   b,  any type of separator, such as a clump breaker, beater bar or any other mechanism that shreds and picks apart the loosefill material can be used. 
         [0022]    Referring again to  FIG. 2 , the agitator  26  is configured to finely condition the loosefill material for distribution into an airstream. In the illustrated embodiment, the agitator  26  is positioned beneath the low speed shredders  24   a  and  24   b.  In other embodiments, the agitator  26  can be positioned in any desired location relative to the low speed shredders,  24   a  and  24   b,  sufficient to receive the loosefill material from the low speed shredders,  24   a  and  24   b,  including the non-limiting example of horizontally adjacent to the shredders,  24   a  and  24   b.  In the illustrated embodiment, the agitator  26  is a high speed shredder. Alternatively, any type of shredder can be used, such as a low speed shredder, clump breaker, beater bar or any other mechanism configured to finely condition the loosefill material and prepare the loosefill material for distribution into an airstream. 
         [0023]    In the embodiment illustrated in  FIG. 2 , the low speed shredders,  24   a  and  24   b,  rotate at a lower speed than the agitator  26 . The low speed shredders,  24   a  and  24   b,  rotate at a speed of about 40-80 rpm and the agitator  26  rotates at a speed of about 300-500 rpm. In other embodiments, the low speed shredders,  24   a  and  24   b,  can rotate at a speed less than or more than 40-80 rpm, provided the speed is sufficient to shred and pick apart the loosefill material. The agitator  26  can rotate at a speed less than or more than 300-500 rpm provided the speed is sufficient to finely condition the loosefill material and prepare the loosefill material for distribution into an airstream. 
         [0024]    Referring again to  FIG. 2 , a discharge mechanism  28  is positioned adjacent to the agitator  26  and is configured to distribute the finely conditioned loosefill material in an airstream. In this embodiment, the finely conditioned loosefill material is driven through the discharge mechanism  28  and through a machine outlet  32  by an airstream provided by a blower  36  mounted in the lower unit  12 . The airstream is indicated by an arrow  33  as shown in  FIG. 3 . In other embodiments, the airstream  33  can be provided by other methods, such as by a vacuum, sufficient to provide an airstream  33  driven through the discharge mechanism  28 . In the illustrated embodiment, the blower  36  provides the airstream  33  to the discharge mechanism  28  through a duct  38 , shown in phantom in  FIG. 2  from the blower  36  to the discharge mechanism  28 . Alternatively, the airstream  33  can be provided to the discharge mechanism  28  by other structures, devices or mechanisms, including the non-limiting examples of a hose or pipe, sufficient to provide the discharge mechanism  28  with the airstream  33 . 
         [0025]    The shredders,  24   a  and  24   b,  agitator  26 , discharge mechanism  28  and the blower  36  are mounted for rotation and driven by a motor  34 . The mechanisms and systems for driving the shredders,  24   a  and  24   b,  agitator  26 , discharge mechanism  28  and the blower  36  will discussed in more detail below. 
         [0026]    In operation, the chute  14  guides the loosefill material to the shredding chamber  23 . The shredding chamber  23  includes the low speed shredders,  24   a  and  24   b,  configured to shred and pick apart the loosefill material. The shredded loosefill material drops from the low speed shredders,  24   a  and  24   b,  into the agitator  26 . The agitator  26  finely conditions the loosefill material for distribution into the airstream  33  by further shredding the loosefill material. The finely conditioned loosefill material exits the agitator  26  and enters the discharge mechanism  28  for distribution into the airstream  33  caused by the blower  36 . The airstream  33 , with the finely conditioned loosefill material, exits the machine  10  at a machine outlet  32  and flows through a distribution hose  46 , as shown in  FIG. 3 , toward the insulation cavity, not shown. 
         [0027]    Referring again to  FIG. 2 , the discharge mechanism  28  is configured to distribute the finely conditioned loosefill material into the airstream  33 . In the illustrated embodiment, the discharge mechanism  28  is a rotary valve. Alternatively, the discharge mechanism  28  can be other mechanisms including staging hoppers, metering devices, or rotary feeders, sufficient to distribute the finely conditioned loosefill material into the airstream  33 . 
         [0028]    Referring again to  FIG. 2 , the low speed shredders,  24   a  and  24   b,  rotate in a counter-clockwise direction r 1  (as shown in  FIG. 2 ) and the agitator  26  rotates in a counter-clockwise direction r 2  (also shown in  FIG. 2 ). Rotating the low speed shredders,  24   a  and  24   b,  and the agitator  26  in the same counter-clockwise direction allows the low speed shredders,  24   a  and  24   b,  and the agitator  26  to shred and pick apart the loosefill material while substantially preventing an accumulation of unshredded or partially shredded loosefill material in the shredding chamber  23 . In other embodiments, the low speed shredders,  24   a  and  24   b,  and the agitator  26  each could rotate in a clock-wise direction or the low speed shredders,  24   a  and  24   b,  and the agitator  26  could rotate in different directions provided the relative rotational directions allow finely conditioned loosefill material to be fed into the discharge mechanism  28  while preventing a substantial accumulation of unshredded or partially shredded loosefill material in the shredding chamber  23 . 
         [0029]    Referring again to  FIG. 2 , the discharge mechanism  28  has a side inlet  47 . The side inlet  47  is configured to receive the finely conditioned loosefill material as it is fed from the agitator  26 . In the illustrated embodiment, the agitator  26  is positioned to be adjacent to the side inlet  47  of the discharge mechanism  28 . In other embodiments, a low speed shredder  24 , or a plurality of shredders  24  or agitators  26 , or other shredding mechanisms can be adjacent to the side inlet  47  of the discharge mechanism or in other suitable positions. 
         [0030]    As shown in  FIG. 2 , an optional choke  48  can be positioned between the agitator  26  and the discharge mechanism  28 . The choke  48  is configured to redirect heavier clumps of loosefill material past the side inlet  47  of the discharge mechanism  28  and back to the low speed shredders,  24   a  and  24   b,  for further conditioning. The cross-sectional shape and height of the choke  47  can be configured to control the conditioning properties of the loosefill material entering the side inlet  47  of the discharge mechanism  28 . While the illustrated embodiment of the choke  48  is shown as having a triangular cross-sectional shape, it should be appreciated that the choke  48  can have any cross-sectional shape and height sufficient to achieve the desired conditioning properties of the loosefill material entering the side inlet  47  of the discharge mechanism  28 . 
         [0031]    Referring again to  FIG. 2 , the lower unit  12  includes the blower  36 , the duct  38  extending from the blower  36  to the discharge mechanism  28 , the motor  34 , the low speed shredders,  24   a  and  24   b  and the agitator  26 . The lower unit  12  also includes a first drive system (not shown) and a second drive system (not shown). Generally, the first drive system is configured to drive the agitator  26  and also configured to drive the second drive system. The second drive system is configured to drive the low speed shredders,  24   a  and  24   b,  and the discharge mechanism  28 . 
         [0032]    The first drive system includes a plurality of drive sprockets, idler sprockets, tension mechanisms and a drive chain (for purposes of clarity none of these components are shown). The first drive system components are rotated by the motor  34 , which, in turn causes rotation of the agitator. 
         [0033]    Referring again to  FIG. 2 , the second drive system includes a plurality of drive sprockets, idler sprockets, tension mechanisms and a drive chain (also for purposes of clarity none of these components are shown). The second drive system components are rotated by the first drive system, which, in turn causes rotation of the first low speed shredder  24   a,  the second low speed shredder  24   b  and rotation of the discharge mechanism  28 . 
         [0034]    In the embodiment illustrated in  FIG. 2 , the first and second drive systems are configured such that the motor  34  drives each of the shredders,  24   a  and  24   b,  the agitator  26  and the discharge mechanism  28 . In other embodiments, each of the shredders,  24   a  and  24   b,  the agitator  26  and the discharge mechanism  28  can be provided with its own motor. 
         [0035]    In the illustrated embodiment, the motor  34  driving the first and second drive systems is configured to operate on a single 15 ampere, 110 volt a.c. power supply. In other embodiments, other power supplies can be used. 
         [0036]    Referring again to  FIG. 2  and as discussed above, the blower  36  provides the airstream to the discharge mechanism  28  through the duct  38  connecting the blower  36  to the discharge mechanism  28 . In the illustrated embodiment, the blower  36  is a commercially available component, such as the non-limiting example of model 119419-00 manufactured by Ametek, Inc., headquartered in Paoli, Pa., although other blowers can be used. 
         [0037]    Referring again to  FIG. 2 , the motor  34 , configured to drive the first and second drive systems is controlled by a first controller (not shown). The first controller is configured to control the rotational speed of the motor  34  at a fixed rotational speed such that the resulting rotational speed of the low speed shredders,  24   a  and  24   b,  the agitator  26  and the discharge mechanism  28  are also fixed. The first controller can be any structure, device or mechanism sufficient to control the rotational speed of the motor  34  at a fixed rotational speed. As a result of the fixed rotational speed of the low speed shredders,  24   a  and  24   b,  the agitator  26  and the discharge mechanism  28 , the flow rate of the finely conditioned loosefill material through the loosefill blowing machine  10  is also at a fixed level. 
         [0038]    Referring again to  FIG. 2 , the blower  36 , configured to provide the airstream  33  to the discharge mechanism  28  through a duct  38 , is controlled by a second controller (not shown). The second controller is configured to control the operation of the blower  36  such that the resulting flow rate of the airstream from the blower  36  to the discharge mechanism  28  is fixed at a desired flow rate level. The second controller can be any structure, device or mechanism sufficient to control the rotational speed of the blower  36  at a fixed rotational speed. As a result of the fixed rotational speed of the blower  36 , the flow rate of the airstream  33  through the loosefill blowing machine  10  is also at a fixed level. 
         [0039]    While the embodiment of the loosefill blowing machine  10  has been described above as having various components operating at certain fixed rotational speeds, it should be appreciated that in other embodiments, the fixed rotational speeds can be at other rotational levels. 
         [0040]    Referring now to  FIG. 4 , one example of a building having insulation cavities is illustrated at  50 . The building  50  includes a roof deck  52 , exterior walls  53  and an internal ceiling  54 . An attic space  55  is formed internal to the building  50  by the roof deck  52 , exterior walls  53  and the internal ceiling  54 . A plurality of structural members  57  positioned in the attic space  5  and above the internal ceiling  54  defines a plurality of insulation cavities  56 . The insulation cavities  56  can be filled with finely conditioned loosefill material distributed by the loosefill blowing machine  10  through the distribution hose  46 . 
         [0041]    Referring now to  FIG. 5 , a sample of finely conditioned loosefill material is illustrated generally at  60 . The sample of finely conditioned loosefill material  60  has been conditioned by the loosefill blowing machine  10  and distributed into the airstream  33 . For purposes of clarity, the sample of the loosefill material  60  has been magnified by an approximate factor of 2×. The loosefill material  60  has been conditioned by the blowing wool machine  10  illustrated in  FIGS. 1-3  and discussed above. The loosefill material  60  includes a multiplicity of individual “tufts”  62 . The term “tuft”, as used herein, is defined to mean any cluster of insulative fibers. 
         [0042]    Referring again to  FIG. 5 , a first physical characteristic of the sample of loosefill material  60  is “voids”. The term “void” as used herein, is defined to mean a space between adjoining tufts  62 . The voids can be complete voids  64 , meaning the absence of any loosefill material fibers in the space between the adjacent tufts,  62 , or partial voids  66 , meaning a minimal amount of loosefill material fibers in the space between the adjacent tufts  62 . Complete voids  64  and partial voids  66  are illustrated in  FIG. 5 . The voids,  64  and  66 , have a void size, a void frequency of occurrence and a void distribution. The term “void size”, as used herein, is defined to mean the average length of the space between adjoining tufts  62 . The term “void frequency of occurrence”, as used herein, is defined to mean the number of void occurrences per volumetric measure. The term “void distribution”, as used herein, is defined to mean the grouping or degree of concentration of the voids per volumetric measure. The void size, void frequency of occurrence and void distribution of the voids,  64  and  66 , are some of the factors that determine the insulative value (“R value”) of the finely conditioned loosefill material  60 . The term “R value”, as used herein, is defined to mean a measure of thermal resistance and is usually expressed as ft 2 ·° F.·h/Btu. 
         [0043]    As shown in  FIG. 5 , the void size of the loosefill material  60  is in a range of from about 2.5 mm to about 7.6 mm. The void frequency of occurrence of the loosefill material  60  is in a range of from about 1.0 per cubic centimeter to about 2.0 per cubic centimeter. The void distribution within the loosefill material  60  is in a range of from about 1.0 per cubic centimeter to about 2.0 per cubic centimeter. It is believed that the loosefill material  60  has relatively smaller, less frequent and more evenly distributed voids than the voids of conventional unbonded loosefill insulation (not shown) by an amount within a range of from about 10% to about 30%. Without being bound by the theory, it is believed that the relatively smaller, less frequent and more evenly distributed voids of the loosefill material  60  contribute to an improved insulative value. 
         [0044]    The void size, void frequency of occurrence and void distribution of the voids,  64  and  66 , can be measured by various image analysis techniques. The term “image analysis”, as used herein, is defined to mean the extraction of meaningful information from images, including digital images. In some instances, the image analysis techniques can include x-ray computed tomography, optical microscopy and magnetic resonance imaging. In other instance, higher resolution imaging can be employed with electron microscopy. 
         [0045]    As further shown in  FIG. 5 , another physical characteristic of the tufts  62  is an average “major tuft dimension” MTD. The term “major tuft dimension”, as used herein, is defined to mean the average length of a tuft  62  along its longest segment. The major tuft dimension MTD can be another determinative factor of the insulative value of the loosefill material  60 . In the illustrated embodiment, the tufts  62  have a “major tuft dimension” MTD in a range of from about 2.5 mm to about 7.6 mm. It is believed that the major tuft dimension MID of the loosefill material  60  is relatively shorter than the major tuft dimension of conventional unbonded loosefill insulation (not shown) by an amount within a range of from about 10% to about 30%. Without being bound by the theory, it is believed that the shorter major tuft dimension MTD of the loosefill material  60  contributes to an improved insulative value. The major tuft dimension MTD can be measured using the various image analysis techniques discussed above. 
         [0046]    Referring again to  FIG. 5 , another physical characteristic of the tufts  62  is a “tuft density”. The term “tuft density”, as used herein, is defined to mean the weight of the loosefill material  60  per volumetric measure of tuft  62 . As shown in  FIG. 5 , the tuft density of the tufts  62  can be relatively dense as visually observed from the apparent compaction of the loosefill material  60  within the tufts  62 . The tuft density can be another determinative factor of the insulative value of the loosefill insulation  60 . In the illustrated embodiment, the tuft density of the tufts  62  is in a range of from about 4.0 kilograms per cubic meter to about 11.2 kilograms per cubic meter. It is believed that the tuft density of the loosefill material  60  is relatively less than the tuft density of conventional unbonded loosefill insulation (not shown) by an amount within a range of from about 10% to about 30%. Without being bound by the theory, it is believed that the lesser tuft density of the loosefill material  60  contributes to an improved insulative value. The tuft density can be measured using the various image analysis techniques discussed above. 
         [0047]    Referring now to  FIG. 6 , an individual tuft  62  of the loosefill material  60  is illustrated. For purposes of clarity, the individual tuft  62  has been magnified by an approximate factor of 8×. Another physical characteristic of the tuft  62  is a plurality of irregularly-shaped projections  70  extending from an outer surface  71  of the tuft  62 . The term “projection”, as used herein, is defined to mean any bump, protrusion or extension of the outer surface  71  of the tuft  62 . The percentage of the outer surface  71  of the tuft  62  having irregularly-shaped projections  70  can be another determinative factor of the insulative value of the loosefill material  60 . As shown in  FIG. 6 , the outer surface  71  of the tuft  62  has irregularly-shaped projections  70  in an amount in the range of from about 50% to 80%. It is believed that the percentage of irregularly-shaped projections  70  extending from the outer surface  71  of the tuft  62  of the loosefill material  60  is relatively greater than the percentage of irregularly-shaped projections extending from the outer surface of a tuft of conventional unbonded loosefill insulation (not shown) by an amount within a range of from about 10% to about 30%. Without being bound by the theory, it is believed that the higher percentage of irregularly-shaped projections  70  extending from the surface  71  of the tuft  62  of the loosefill material  60  contributes to an improved insulative value. The percentage of irregularly-shaped projections  70  extending from the surface  71  of the tuft  62  can be measured using the various image analysis techniques discussed above. 
         [0048]    Referring again to  FIG. 6 , another physical characteristic of the tuft  62  is a plurality of “hairs”  72  extending from the irregularly-shaped projections  70  of the tuft  62 . The term “hairs”, as used herein, is defined to mean any portion of the insulation fibers extending from the irregularly-shaped projections  70 . While the hairs  72  are shown in  FIG. 6  as extending from the irregularly-shaped projections  70  and into space, it should be appreciated that the hairs  72  can also extend from the irregularly-shaped projections  70  into the body of the tuft  62 . The quantity of irregularly-shaped projections  70  having hairs extending therefrom can be another determinative factor of the insulative value of the loosefill material  60 . In the embodiment shown in  FIG. 6 , the quantity of irregularly-shaped projections  70  having extending hairs  72  is in a range of from about 60% to about 80%. It is believed that the tufts  62  of the loosefill material  60  have relatively more hairs  72  extending from irregularly-shaped projections  70  than conventional unbonded loosefill insulation by an amount in a range of from about 10% to about 30%. Without being bound by the theories, it is believed that the increased quantity of the hairs  72  of the tuft  62  contribute to an improved insulative value (R) for several reasons. First, it is believed that the hairs  72  extend into the voids,  64  and  66  as shown in  FIG. 5 , thereby partially filling the voids, which contributes to the ability of the loosefill material  60  to reduce radiation heat transfer between the tufts  62 . Second, it is believed that the extended hairs  72  contribute in maintaining a separation between the tufts  62 , which can substantially prevent an increased density of the loosefill material  60 . The percentage of the irregularly-shaped projections  70  having extending hairs  72  can be measured using the various image analysis techniques discussed above. 
         [0049]    Referring again to  FIG. 6 , the tuft  62  includes a multiplicity of fibers  74  arranged in a random orientation. The term “fibers”, as used herein, is defined to mean any portion of the loosefill material  60 . A sixth physical characteristic of the tufts  62  is “gaps”  76 . The term “gaps” as used herein, is defined to mean a portion of the tuft  62  having a lighter density than other portions of the tuft  62 . The gaps  76  have a gap size, a gap frequency of occurrence and a gap distribution. The gap size, gap frequency of occurrence and gap distribution are additional factors that can determine the insulative value (“R value”) of the loosefill material  60 . 
         [0050]    The term “gap size”, as used herein, is defined to mean the average length of the portion of the tuft  62  having a lighter density. The term “gap frequency of occurrence”, as used herein, is defined to mean the number of gap  76  occurrences per volumetric measure. The term “gap distribution”, as used herein, is defined to mean the grouping or concentration of the gaps  76  per volumetric measure. As shown in  FIG. 6 , the gap size of the loosefill material  60  is in a range of from about 1.2 mm to about 2.5 mm The gap frequency of occurrence of the loosefill material  60  is in a range of from about 3.0 to about 5.0 per cubic centimeter. The gap distribution within the loosefill material  60  is in a range of from about 3.0 to about 5.0 per cubic centimeter. It is believed that the loosefill material  60  has relatively larger, more frequent and more evenly distributed gaps than the gaps of conventional unbonded loosefill insulation (not shown) by an amount within a range of from about 10% to about 30%. Without being bound by the theory, it is believed that the relatively larger, more frequent and more evenly distributed gaps of the loosefill material  60  contribute to an improved insulative value (R). The gap size, gap frequency of occurrence and gap distribution of the tufts  62  can be measured using the various image analysis techniques discussed above. 
         [0051]    Referring again to  FIG. 6 , another physical characteristic of the tuft  62  is a generally cubic shape. The term “cubic”, as used herein, is defined to mean having a shape more in the form of a cube. The generally cubic shape of the tuft  62  results in more cubic consistency. The term “cubic consistency”, as used herein, is defined to mean the percentage of an object that fills a cubically-shaped volume. As shown in  FIG. 6 , the tufts  62  fill a cubically-shaped volume in a range of from about 40% to about 80%. It is believed that the tuft  62  of the unbonded loosefill insulation  60  has relatively more cubic consistency than conventional loosefill insulation by an amount in a range of from about 10% to about 30%. Without being bound by the theory, it is believed that the increased cubic consistency of the tuft  62  contributes to an improved insulative value of the loosefill material  60 . It is believed that the cubic consistency of the tufts  62  allows the tufts  62  to “nest” at an optimum level. The term “nest”, as used herein, is defined to mean the close fitting together of a plurality of tufts  62 . It is believed that an optimum level of nesting by the tufts  62  provides an optimum insulative value of the loosefill material  60 . In contrast, tufts  62  that nest too much, too close together, result in an unacceptably high density level of the improved loosefill insulation  60 . Tufts  62  that nest too little result in an unacceptably poor insulative value. Accordingly, the increased cubic consistency of the tufts  62  provides a balance between the density of the loosefill material  60  and the insulative value of the loosefill material  60 . The cubically-shaped volume of the tufts  62  can be measured using the various image analysis techniques discussed above. 
         [0052]    The physical characteristics discussed above for the finely conditioned loosefill material  60  and the tufts  62  contribute to an “open structure”. That is, the voids,  44  and  46 , major tuft dimension MTD, tuft density, irregularly-shaped projections  70 , extended hairs  72  and gaps  76  cooperate to form an “open structure” for the loosefill material  60 . The term “open structure”, as used herein, is defined to mean a relatively porous structure incorporating relatively numerous and large gaps or voids. Conversely, the physical characteristics discussed above for the conventional loosefill insulation typically combine to form a relatively “closed structure”. The term “closed structure”, as used herein, is defined to mean a more definitively defined boundary enclosing densely oriented fibers forming relatively few and small voids and gaps. It is believed the open structure of the loosefill material  60  provides an improved insulative value. 
         [0053]    While the sample loosefill material illustrated in  FIGS. 5-6  are believed to be representative of the loosefill material  60 , it is to be understood that variations among samples may occur. 
         [0054]    As discussed above, the operating parameters of the loosefill blowing machine  10  are tuned to the insulative characteristics of the associated unbonded loosefill insulation material such that the resulting blown loosefill insulation material provides improved insulative values. The operating parameters of the loosefill blowing machine can include the flow rate of the finely conditioned loosefill material  60  through the loosefill blowing machine  10  and the flow rate of the airstream  33  through the loosefill blowing machine  10 . As further discussed above, the flow rate of the finely conditioned loosefill material  60  through the loosefill blowing machine  10  is fixed by the fixed rotational speed of the low speed shredders,  24   a  and  24   b,  the agitator  26  and the discharge mechanism  28 . The flow rate of the airstream  33  through the loosefill blowing machine  10  is fixed by the fixed rotational speed of the blower  36 . By fixing the operating parameters of the loosefill blowing machine  10 , the loosefill blowing machine  10  advantageously provides no operating parameter adjustments to the machine user. Accordingly, the operating parameters of the loosefill blowing machine  10  are pre-set for the machine user. The pre-set and fixed operating parameters of the loosefill blowing machine  10 , coupled with the insulative characteristics of the associated unbonded loosefill insulation material  60 , result in an integrated system configured to provide blown loosefill material having desired and improved insulative values. 
         [0055]    In one embodiment, the results of the pre-set and fixed operating parameters of the loosefill blowing machine  10 , coupled with the loosefill material  60  described above, provide the improved insulative characteristics of the resulting blown insulation material as shown in Table 1. 
         [0000]    
       
         
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                 (R) 
                   
                   
                   
                   
                   
                 (k) 
               
               
                 Thermal 
                   
                   
                   
                   
                   
                 Thermal 
               
               
                 Resistance 
                   
                   
                   
                   
                   
                 Conductivity 
               
               
                 (ft 2  · ° F. · h/ 
                 Thickness 
                 Weight 
                 Number 
                 Coverage 
                 Density 
                 (Btu-in/ 
               
               
                 Btu) 
                 (inches) 
                 (lbs/sf) 
                 of Bags 
                 (sqft/bag) 
                 (lbs/ft 3 ) 
                 (hr · ft 2  · ° F.)) 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 60 
                 19.25 
                 0.882 
                 30.9 
                 32.3 
                 0.550 
                 0.321 
               
               
                 49 
                 16.00 
                 0.697 
                 24.5 
                 40.9 
                 0.523 
                 0.327 
               
               
                 44 
                 14.50 
                 0.617 
                 21.6 
                 46.2 
                 0.510 
                 0.330 
               
               
                 38 
                 12.75 
                 0.527 
                 18.5 
                 54.1 
                 0.496 
                 0.336 
               
               
                 30 
                 10.25 
                 0.406 
                 14.2 
                 70.2 
                 0.475 
                 0.342 
               
               
                 26 
                 9.00 
                 0.349 
                 12.2 
                 81.8 
                 0.465 
                 0.346 
               
               
                 22 
                 7.75 
                 0.293 
                 10.3 
                 97.1 
                 0.454 
                 0.352 
               
               
                 19 
                 6.75 
                 0.251 
                 8.8 
                 113.6 
                 0.446 
                 0.355 
               
               
                 13 
                 4.75 
                 0.170 
                 6.0 
                 167.7 
                 0.429 
                 0.365 
               
               
                 11 
                 4.00 
                 0.141 
                 4.9 
                 202.0 
                 0.423 
                 0.364 
               
               
                   
               
             
          
         
       
     
         [0056]    As shown in Table 1, the thermal resistance (R) of the resulting blown insulation material  60  can be varied by varying the Thickness. As one specific example of the improved insulative characteristic, a thermal resistance (R) of 30 having a thickness of 10.25 inches can be achieved with as few as 14.2 bags of compressed insulation material. The resulting Density of the resulting blown insulation material  60  advantageously is reduced to 0.475 and the thermal conductivity is also advantageously reduced to 0.342. 
         [0057]    While the specific example discussed above is based on a thermal resistance (R) value of 30, it should be noted that Table 1 advantageously includes similar improvements for other values of thermal resistance (R). 
         [0058]    While the discussion above has been focused on pre-setting and fixing the operating characteristics of the loosefill blowing machine  10  by fixing the flow rate of the finely conditioned loosefill material  60  through the loosefill blowing machine  10  and the flow rate of the airstream  33  through the loosefill blowing machine  10 , it should be appreciated that in other embodiments, other operating parameters of the loosefill blowing machine  10  can be coupled with the insulative characteristics of the associated unbonded loosefill insulation material to provide improved insulative characteristics of the resulting blown insulation material. As one example, the quantity of shredders,  24   a  or  24   b,  or agitators  26  can be increased. As another example, the shredding characteristics of the shredders,  24   a  or  24   b,  or the conditioning characteristics of the agitator  26  can be changed. In still other embodiments, the flow of the loosefill material  60  through the loosefill blowing machine  10  can be altered such that the loosefill material  60  is subjected to additional conditioning. 
         [0059]    Summarizing, an unbonded loosefill insulation system is formed by the coupling of a loosefill blowing machine, having fixed operating parameters, and an associated unbonded loosefill insulation material. The fixed operating parameters of the loosefill blowing machine are tuned to the insulative characteristics of the associated unbonded loosefill insulation material such that the resulting blown unbonded loosefill insulation material provides improved insulative values. 
         [0060]    The principle and methods of assembly of the insulation blowing system have been described in its preferred embodiments. However, it should be noted that the insulation blowing system may be practiced otherwise than as specifically illustrated and described without departing from its scope.