Abstract:
An improved apparatus for applying loose fill insulation generally includes an insulation feed portion and an insulation gun. The insulation feed portion is driven by a motor which is controlled by a clutch and a clutch control circuit. An insulation gun is mounted to a hose which communicates with the insulation feed portion. A switch mounted on the gun opens and closes the clutch control circuit. When the switch is closed, the clutch is engaged and air blown insulation is supplied to the gun. When the switch is open, the clutch is disengaged and air blown insulation is not supplied to the gun.

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
   This application claims the benefit of U.S. Provisional Patent Application No. 60/676,663 filed Apr. 29, 2005. 

   FIELD OF THE INVENTION 
   This invention relates to an apparatus for delivering and distributing loose fill insulation into an insulation space. 
   BACKGROUND OF THE INVENTION 
   Systems for applying loose fill insulation have typically included an insulation hopper and insulation feed device for feeding loose fill insulation material to an air box, a blower for forcing pressurized air into the air box and an insulation hose for conveying an air stream containing loose fill insulation material to an insulation space. A significant shortcoming of present loose fill insulation systems is that they lack an ergonomically adapted means for aiming and controlling the flow of insulation. Moreover, present systems lack a means for shutting off the system when insulation is not required by an operator who is applying the insulation. Accordingly, a need exists for an air blown insulation system including a means for aiming the flow of insulation and for providing a high degree of control over the system for an operator who is applying insulation at an insulation space. 
   BRIEF DESCRIPTION OF THE INVENTION 
   In a first embodiment of the present invention the aforementioned needs are addressed by an improved system for the pneumatic delivery of insulation. The first embodiment of the improved system generally includes an insulation feed portion and an insulation gun. The insulation feed portion generally includes a motor, a blower, an air box, an insulation hopper and an insulation feed device. The motor drives the blower through a blower clutch which may be engaged or disengaged by opening or closing a clutch control circuit. The blower is connected to the air box via an air duct. The insulation feed device feeds loose fill insulation into the air box. The insulation feed device is preferably arranged in the system such that it operates when the blower is running. An insulation hose is attached to the air box to carry a stream of air and insulation from the air box to an insulation space. In the improved system, an insulation gun is mounted to the distal end of the insulation hose. The insulation gun includes a hollow barrel portion and a handle portion. The hollow barrel portion connects with the distal end of the insulation hose. The handle portion further includes a switch connected in the clutch control circuit. The switch is preferably biased in an open position which causes the blower clutch to be disengaged. When the switch is in the closed position, the clutch control circuit is closed and the clutch is engaged which activates the blower. The switch is preferably located on the handle portion such that when an operator is not holding the handle portion, the switch is open and the clutch is disengaged. 
   A second embodiment of the present invention also includes a motorized blower, an insulation hopper, a insulation feed device and an air box. The second embodiment system is similar to the first embodiment system with the exceptions that a second clutch is interposed between the motor and the insulation feed device and a second control circuit is added to control the second clutch. Accordingly, in the second embodiment system, the blower control clutch is referred to as the first clutch and the circuit that controls the first clutch is referred to as the first control circuit. When the second control circuit is closed, the second clutch is engaged and the insulation feed device is activated. When the second control circuit is open, the insulation feed clutch is disengaged and the insulation feed device is inactive. The insulation gun of the second embodiment also includes a hollow barrel portion and a handle portion. The handle portion further includes a first switch which is biased in the open position such that when the handle portion is not held by an operator the first switch is open. The first switch of the gun of the second embodiment is connected in both the first control circuit and the second control circuit. Accordingly, when the first switch is open, both the first and second control circuits are open which causes the first clutch associated with the blower and the second clutch associated with the insulation feed device to be disengaged rendering both the blower and the insulation feed device inactive. The insulation gun of the second embodiment also includes a second switch which is connected in the second control circuit which controls the second clutch associated with the insulation feed device. The second switch has a first closed position in which the second control circuit is closed thus causing the insulation feed device to operate and a second open position in which the second control circuit is open thus causing the insulation feed system to not operate. Accordingly, in this arrangement, the first control circuit controlling the blower includes the first switch and the second switch in series while the second control circuit includes just the second switch. Thus, the second switch may be opened to shut down the insulation feed device while the first switch is closed to activate the blower. This will result in the gun receiving a flow of air without insulation or will cause the air box, hose and gun to be substantially cleared of remaining insulation. When both switches are closed, both the insulation feed device and the blower are activated so that air blown insulation is delivered to the gun. When the first switch is open, neither the insulation feed device or the blower operate. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1A  is a schematic showing a first embodiment of the system for applying insulation. 
       FIG. 1B  is a schematic showing a second embodiment of the system for applying insulation. 
       FIG. 2A  is a perspective view of an insulation gun for use in the first embodiment system of the present invention. 
       FIG. 2B  is a perspective view of an insulation gun for use in the second embodiment system of the present invention. 
       FIG. 3A  is a side view of an insulation gun for use in the first embodiment system of the present invention. 
       FIG. 3B  is a side view of an insulation gun for use in the second embodiment system of the present invention. 
       FIG. 4A  is an end view of an insulation gun for use in the first embodiment system of the present invention. 
       FIG. 4B  is an end view of an insulation gun for use in the second embodiment system of the present invention. 
       FIG. 5A  is an exploded perspective view of an insulation gun for use in the first embodiment system of the present invention. 
       FIG. 5B  is an exploded perspective view of an insulation gun for use in the second embodiment system of the present invention. 
       FIG. 6  is a perspective view of a barrel attachment fitting for an insulation. 
   

   DETAILED DESCRIPTION 
   Referring to the drawings,  FIG. 1A  schematically illustrates a first embodiment of an improved insulation delivery system  10  for applying loose fill insulation. System  10  generally includes an insulation feed portion  11  and an insulation gun  60 . An insulation gun  60  is used to direct loose fill insulation into an insulation space  5 . Insulation space  5  may generally include a space above a horizontal surface such as may be found in an attic, or, as shown in  FIG. 1A , space  5  may consist of a vertical space disposed between wall frame studs which is enclosed with retaining mesh for retaining loose fill insulation as is well known by those skilled in the art. As will be described in greater detail below, the distal end of insulation gun is preferably pointed for penetrating retaining mesh prior to injecting loose fill insulation. 
   As shown in  FIG. 1A , insulation feed portion  11  includes a blower  12 , a motor  16 , a blower clutch  14 , an insulation hopper  30 , an insulation feed device  32 , an air box  20  and an insulation hose  50 . Blower  12  is connected to a motor  16  through blower clutch  14  which engages or disengages blower  12  with motor  16 . An air duct  22  connects blower  12  with an air box  20 . Insulation hopper  30  holds dry, loose fill insulation  31 . Insulation feed device  32  which is also powered by motor  16  feeds loose fill insulation from hopper  30  through port  34  into air box  20 . Insulation hose  50  has a proximate end  52  which is connected to air box  20 . When feed device  32  and blower  12  are operating, loose fill insulation  31  and air mix within air box  20  and escape together as a stream of air and insulation through insulation hose  50 . 
   Insulation delivery system  10  further includes an insulation gun  60 . Insulation gun  60  is a hand held unit for controlling and directing the application of insulation. Insulation gun  60  includes a handle portion  62  and a barrel portion  72 . Barrel portion  72  further comprises a proximate portion  74  which attaches directly to handle portion  62  and a distal portion  76  which connects with proximate portion  74 . Handle portion  62  includes a switch  64  which is connected with a blower control circuit  15 . Blower control circuit  15  is associated with blower clutch  14  such that blower clutch  14  is engaged when blower control circuit  15  is closed and such that blower clutch  14  is disengaged when blower control circuit  15  circuit is open. Switch  64  is preferably positioned on handle portion  62  such that handle portion  62  must be grasped by an operator in order to close switch  64 . Switch  64  is connected within blower control circuit  15  such that when switch  64  is open blower control circuit  15  is open and blower clutch  14  is disengaged and such that when switch  64  is closed, blower control circuit  15  is closed and blower clutch  14  is engaged. Accordingly when an operator grasps handle portion  62 , blower clutch  14  is engaged and blower  12  and insulation feed device  32  operate to supply a stream of air and insulation to insulation gun  60 . Conversely, when an operator releases handle portion  62 , blower clutch  14  is disengaged and blower  12  and insulation feed device  32  cease operation such that no air and insulation are supplied to gun  60 . 
     FIGS. 2A ,  3 A,  4 A,  5 A and  6  provide detailed views of insulation gun  60 . Insulation gun  60  is adapted for use in the first embodiment of the insulation system  10  diagrammed in  FIG. 1A . As can be seen in  FIG. 2A , insulation gun  60  includes a barrel portion  72  and a handle portion  62 . Barrel portion  72  further includes a proximate portion  74  and a distal portion  76 . Proximate portion  74  is mounted to handle portion  62  by a barrel fitting  68  which is shown in greater detail in  FIG. 6 . The forward end of distal portion  76  is tapered at a sharp angle for penetrating insulation retaining fabric which encloses spaces between wall studs. Distal portion  76  has a coupling portion  76 A for engaging the forward end of proximate portion  74 . Coupling portion includes a slot  76 B for receiving a retaining pin  74 B fixed to the forward end of distal portion  74 . This arrangement allows for the substitution of various distal portions having varying lengths and shapes. For example, a much longer distal portion may be used to inject insulation at an elevated injection point for a ten or twelve foot wall. A shorter distal portion may be appropriate for work in narrow or confined spaces. The rear end of proximate portion  74  has a coupling portion  74 B for coupling with the forward end of insulation hose  50  shown in  FIG. 1A . 
   As noted above, the forward end of distal portion  76  is tapered at a sharp angle for penetrating insulation retaining fabric. Insulation retaining fabric generally comprises a loosely woven fibers which can be easily penetrated as the forward end of distal portion  76  passes into the space. Thus the forward end of distal portion  76  acts as a means for injecting loose fill insulation into a space enclosed by insulation retaining fabric. 
   Handle portion  62  includes a stock portion  62 A and a grip portion  62 B. Stock portion  62 A is adapted to receive barrel fitting  68 . Stock portion  62 A includes control circuit coupling  66  for making a connection with blower control circuit  15  shown in  FIG. 1A . Grip portion  62 B includes a switch  64  which is preferably spring biased in an open position. When grip portion  62 B is grasped by an operator, switch  64  is closed thus causing blower control circuit  15  to be closed. Thus, switch  64  functions as a “dead man” switch so that blower control circuit  15  is opened when an operator lets go of grip portion  62 B. Yet an operator holding insulation gun  60  may selectively release pressure from switch  64  to stop operation of blower  12 . 
   An operator using insulation delivery system  10  would perform the following steps: 1. Fill insulation hopper  30  with loose fill insulation  31 . 2. Activate motor  16 . 3. Position insulation gun  60  to penetrate or locate within an insulation space  5 . 4. Close switch  64  and open switch  64  as needed to control the flow of loose fill insulation into insulation space  5 . 
   Referring to the drawings,  FIG. 1B  schematically illustrates a second embodiment of an improved insulation delivery system  100  for applying insulation. System  100  generally includes an insulation feed portion  111  and an insulation gun  160 . As with insulation delivery system  10 , insulation gun  160  is used to control the flow and application of loose fill application. 
   Improved insulation delivery system  100  is shown schematically in  FIG. 1B . Insulation delivery system  100  is similar to insulation system  10  with the exception of a second clutch  214  for controlling insulation feed device  132  is interposed between a motor  116  (and a blower  112 ) and insulation feed device  132  and a second control circuit  214 A is added for controlling insulation feed clutch  214 . Thus, the clutch controlling blower  112 , in the second system should be referred to as a first clutch  114  and the circuit controlling first clutch  114  is now referred to as first control circuit  114 A. Insulation delivery system  100  further includes an insulation gun  160  which differs in some respects from insulation gun  60  of delivery system  10 . Insulation gun  160  includes a modified handle portion  162 . Handle portion  162  includes a first switch  164  which is connected with both the blower control circuit  114 A and insulation feed control circuit  214 A such that first switch  164  must be closed in order for either of insulation feed device  132  or blower  112  to operate. A second switch  180  is located on a stock portion  162 A of handle portion  162 . Second switch  180  is connected to second control circuit  214 A such that when second switch  180  is closed, second clutch  214  controlling insulation feed device  132  is engaged thus activating insulation feed device  132  if first switch  164  is also closed and such that when second switch  180  is open, second clutch  214  is disengaged thus deactivating insulation feed device  132 . When second switch  180  is open, an operator can close first switch  164  to activate blower  112  without activating insulation feed device  132 . This will cause most of any remaining insulation in air box  152  to clear out and then, after air box  152  is generally cleared of insulation, air will flow to flow to gun  160 . 
   An operator using insulation delivery system  100  would perform the following steps: 1. Fill insulation hopper  130  with loose fill insulation  31 . 2. Activate motor  116 . 3. Position insulation gun  160  to penetrate or locate within an insulation space  5 . 4. To provide a flow of insulation and air to insulation gun  160 , close second switch  180  and close first switch  164 . 5. To provide a flow of air without insulation to insulation gun  160 , open second switch  180  and close first switch  164 . 5. To stop the flow of both insulation and air to insulation gun  160 , open first switch  164 . 
     FIGS. 2B ,  3 B,  4 B,  5 B and  6  provide detailed views of insulation gun  160 . Insulation gun  160  is adapted for use in the second embodiment of the insulation system  100  diagrammed in  FIG. 1B . Insulation gun  160  is generally similar to insulation gun  60  except that handle portion  62  is replaced by a handle portion  162  adapted for use with blower control circuit  114 A and insulation feed control circuit  214 A. Accordingly handle portion  162  includes a stock portion  162 A and a handle portion  162 B. Stock portion  162 A is adapted to receive barrel fitting  68  for mounting barrel portion  72 . Stock portion  162 A includes control circuit coupling  166  for making a connection with blower control circuit  114 A and insulation feed control circuit  214 A shown in  FIG. 1B . Handle portion  162 B includes a first switch  164  which is preferably spring biased in an open position. When handle portion  162 B is grasped by an operator, first switch  164  is closed thus causing first circuit  114 A controlling first clutch  114  and second circuit  214 A controlling second clutch  214  to be closed. Thus, switch  164  functions as a “dead man” switch so that first circuit  114 A and second circuit  214 A are opened, thus deactivating blower  112  and insulation feed device  132  when an operator lets go of handle portion  162 B. A second switch  180  is integrated in stock portion  162 A for opening and closing second circuit  214 A controlling second clutch  214 . Accordingly, first switch  164  and second switch  180  are in series in second circuit  214 A. This creates a second condition needed for closing second circuit  214 A, namely the closing of second switch  180 . Accordingly, second circuit  214 A is closed and insulation feed device  132  operates when both first switch  164  and second switch  180  are closed. When second switch  180  is open, first circuit  114 A can be closed by first switch  164  to exclusively operate blower  112  and clear air box a 53  of most remaining insulation and then to supply mostly air without insulation to insulation gun  160 . 
   It is to be understood that while certain forms of this invention have been illustrated and described, it is not limited thereto, except in so far as such limitations are included in the following claims and allowable equivalents thereof.