Patent Publication Number: US-6336474-B1

Title: To hose used to install loose fill insulation

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is related to, and claims priority of, co-pending U.S. application Ser. No. 09/817,429 filed Mar. 26, 2001, entitled IMPROVEMENT TO HOSE USED TO INSTALL LOOSE FILL INSULATION. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to hoses, and in particular, a hose for installing loose fill insulation. 
     DESCRIPTION OF THE RELATED ART 
     Loose fill insulation is packaged in bags in which the material becomes compacted during storage and shipment. When removed from the bags, the insulation separates into clumps. In order to effectively install the insulation material, it must first be “fluffed up” or conditioned to reduce its density. Traditionally, pneumatic devices are used to both install the insulation and perform the conditioning. The conditioning process breaks up the clumps and then “fluffs” or “opens up” the insulation. The conditioned insulation is then applied pneumatically to an area by blowing it through a hose connected to the pneumatic device. The insulation may be moistened and/or treated with an adhesive in the pneumatic device before installation. 
     FIGS.  5 ( a ) and  5 ( b ) show an example of a prior art pneumatic apparatus  10  for dispensing loose fill insulation. FIG.  5 ( a ) is an isometric view of the apparatus  10 , showing a hopper  16  for storing loose fill insulation, blower  22 , and a hose  26  for dispensing the insulation. FIG.  5 ( b ) is a side view of the apparatus  10  showing the inner workings in detail. The apparatus includes shafts  52 ,  60  with spikes  54 ,  62  extending therefrom for conditioning the insulation, which is placed in the hopper  16 . 
     The spikes  54 ,  62  break apart the clumps of insulation and prepare it to be dispensed. 
     The conditioned insulation passes from the hopper  16  through the spikes  54 ,  62  to dispensing assembly  20 , where it is blown through hose  26  by blower  22 . In operation, the user simply points the hose  26  where he desires the insulation, and it is dispensed. 
     Often, the conditioning which occurs within the insulation dispensing apparatus is not enough to fully “open up” the insulation. If the insulation is not sufficiently conditioned when it leaves the dispensing apparatus it may be applied unevenly (i.e. in clumps), and it may not have the manufacturer&#39;s specified density for the installed thermal resistance desired. Conversely, insulation which is well conditioned allows adhesive and moisture to penetrate the insulation fibers, and applies to surfaces more evenly. Thus, there is currently a need for an improved device for increasing the conditioning of loose fill insulation. 
     SUMMARY OF THE INVENTION 
     The present invention is a tube for enhancing the conditioning of loose fill insulation. The tube preferably comprises a hose for dispensing loose fill insulation in an insulation dispensing apparatus. The tube includes projections formed around its inner periphery which serve to condition the insulation as it passes from one end of the tube to the other. 
     The above and other advantages and features of the present invention are better understood from the following detailed description of the preferred embodiments of the invention which is provided in connection with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG.  1 ( a ) is a front elevation view of the tube of the present invention. 
     FIG. 1 ( b ) is a top plan view of the tube of FIG.  1 ( a ). 
     FIG.  2 ( a ) is a cross-sectional view of the tube of the present invention with a projection according to a first exemplary embodiment. 
     FIG.  2 ( b ) is a cross-sectional view of the tube of the present invention with a projection according to a second exemplary embodiment. 
     FIG.  2 ( c ) is a cross-sectional view of the tube of the present invention with a projection according to a third exemplary embodiment. 
     FIG.  2 ( d ) is a cross-sectional view of the tube of the present invention with a projection according to a fourth exemplary embodiment. 
     FIG. 3 is the a cross sectional view of the tube showing how the webs are attached to one another. 
     FIG. 4 is an exemplary method of forming the hose of the present invention. 
     FIG.  5 ( a ) is an isometric view of a conventional apparatus for dispensing loose fill insulation. 
     FIG.  5 ( b ) is a cutaway side elevation view of the apparatus for dispensing loose fill insulation shown in FIG.  5 ( a ). 
     FIG. 6 is a cross-sectional view of the tube of the present invention with a projection according to a fifth exemplary embodiment. 
    
    
     DETAILED DESCRIPTION 
     In a conventional insulation dispensing apparatus, such as the one described above and shown in FIGS.  5 ( a ) and  5 ( b ), loose fill insulation is placed into a hopper or housing of the apparatus where it is conditioned. The apparatus typically includes a mechanism for conditioning the insulation, as well as means for dispensing the insulation, such as a hose or other similar means. Sometimes, however, the conditioning mechanism within the dispensing apparatus does not provide sufficient conditioning. The present invention comprises an improved hose or tube  100 , for attachment to an insulation dispensing apparatus. The hose or tube  100  includes a projection  140  along its inner surface  150  which serves to condition loose fill insulation as it passes through the tube. 
     The present invention comprises a tube  100  for dispensing loose fill insulation. The tube  100  preferably comprises a flexible hose coupled to an insulation dispensing apparatus. In FIGS.  1 ( a ) and  1 ( b ), the tube  100  is formed as a cylindrical hose having an approximately circular cross-section. However, the tube  100  may have a cross-section of a variety of shapes (e.g. oval, rectangular, polygonal) without departing from the scope of the invention. Further, although it is preferred that the tube  100  be used as a flexible external hose for an insulation dispensing apparatus, the tube  100  may be formed as an internal component in an insulation dispensing apparatus which is either rigid or flexible. Alternately, the tube  100  may comprise the inner liner of a hose. 
     The tube  100  comprises an inner web  130  surrounded by an outer cap  120 . In the exemplary embodiment shown in FIGS.  1 ( a ) and ( b ), the inner web  130  is formed in a cylindrical shape, and the outer cap  120  is formed as a helical member extending around the outer periphery of the inner web  120 . The inner web  130  includes a first helical projection  131  which extends around its entire outer periphery. The inner web  130  also includes a second helical projection  140  which extends around its inner periphery which is shown specifically in FIGS.  2 ( a )- 2 ( d ). The first helical projection  131  extends away from a longitudinal axis A of the inner web  130 , and the second helical projection  140  extends towards the longitudinal axis A of the inner web  130 . The outer cap  120  comprises a helical member  121  which is wound around the outer periphery of the inner web  130  and which is disposed at a position substantially aligned with helical projection  140 , and in between portions of the helical projection  131 . 
     FIG.  2 ( a ) shows a cross-sectional view of the tube  100  of the present invention taken along section line  2 ( a )— 2 ( a ) in FIG.  1 ( a ). FIG.  2 ( a ) shows a first exemplary embodiment of the helical projection  140  of the present invention. Reference numeral  150  indicates the inner portion of the tube  100  generally, and reference numeral  160  indicates an outer portion. Insulation (indicated by the arrow) passes along inner portion  150  as it is dispensed through the tube  100 . The helical projection  140  of inner web  130  extends into the inner portion  150  of the tube  100  by a specific length, typically {fraction (1/1000)} of an inch (0.025 millimeters) to ¼ of an inch (6.35 millimeters), depending on the length of the insulation fiber and the diameter of the tube  100 . Thus, the helical projection  140  provides a small partial obstruction in the path of insulation traveling through the tube  100 . 
     In operation, as insulation is blown through the tube  100  by an insulation dispensing apparatus, the insulation collides with the different portions of helical projection  140 , and is further “opened up” or conditioned. The individual fibers of the insulation are essentially ‘grabbed’ by the projection  140  as they pass through the tube  100 . As a portion of the fiber is attached to the projection  140 , the flow of air through the tube  100  causes the fiber to become stretched. This stretching action causes the insulation which exits the tube  100  to be better conditioned (i.e. less dense) than the insulation which enters the tube. In particular, the present invention lowers the density of the insulation fibers by approximately 10-20%. Accordingly, insulation installed using the tube  100  of the present invention is less clumpy and adheres better to the surface to which it is applied than insulation installed by conventional hoses. 
     Although FIG.  2 ( a ) shows the helical projection  140  as being substantially perpendicular to the axis A of the tube  100  (shown in FIG.  1 ( a )), other exemplary embodiments of the present invention are also contemplated by the inventor. 
     FIG.  2 ( b ) shows a second exemplary embodiment of the present invention where the helical projection, now labeled  140 ′, is angled with respect to the axis A of the tube  100  by an angle less then ninety (90) degrees. The exemplary projection  140 ′ is angled so that it points towards the direction from which insulation flows through the tube in FIG.  2 ( b ), however, the projection can alternately be angled in the opposite direction. The angling of the projection  140 ′ can be accomplished in one of two ways. The projection  140 ′ can be angled by extruding the inner web  130  with an angled projection. Alternately, the projection can be formed by extruding the inner web  130  as it is shown in FIG.  2 ( a ), and angling the projection during manufacture by controlling the forward thrust of a rotating mandrel  200  (shown in FIG. 4) as the tube  100  is fabricated. The process for extruding the inner web  130 , as well as the fabrication process for the tube  100 , is explained in detail below with respect to FIGS. 3 and 4. 
     FIG.  2 ( c ) shows a third exemplary embodiment of the present invention where the helical projection, now labeled  140 ″, is formed to have a serrated edge  141 . This serrated edge  141  can be formed by extruding the inner web  130  with a serrated edge as explained below. 
     FIG.  2 ( d ) shows a fourth exemplary embodiment of the present invention where a modified outer cap  120 ′ forms the helical projection, now labeled  142 . Again, by changing the profile of the die used to manufacture the outer cap, the structure of the fourth exemplary embodiment can be accomplished as explained below. 
     FIG. 6 shows a fifth exemplary embodiment of the present invention where a first portion  241  of a helical projection  240  includes a projection  245  extending perpendicularly therefrom. A second portion  242  of the helical projection  240  does not include such a perpendicular projection in the exemplary embodiment, but may alternatively include such a perpendicular projection. In the fifth exemplary embodiment, the projection  245  performs a stabilizing function during manufacture of the tube  100 . In particular, when an outer cap tape  170  is wrapped around an inner web tape  160 , the projection  245  maintains the first and second portions  241 ,  242  of the helical projection  240  in a parallel relationship with respect to each other, and in a orthogonal relationship with respect to the primary axis of the insulation hose. Without this stabilizer projection  245 , the first and second portions  241 ,  242  of the helical projection  240  have a tendency to collapse against each other during manufacture (an undesirable result). The stabilizer projection  245  prevents this condition by providing an impediment to the collapse. 
     In the fifth exemplary embodiment, reference numeral  250  indicates an inner portion of the tube  100  generally, and reference numeral  260  indicates an outer portion. Insulation (indicated by the arrow) passes along inner portion  250  as it is dispensed through the tube  100 . The helical projection  240  of inner web  230  extends into the inner portion  250  of the tube  100  by a specific length, typically {fraction (1/1000)} of an inch (0.025 millimeters) to ¼ of an inch (6.35 millimeters), depending on the length of the insulation fiber and the diameter of the tube  100 . Thus, the helical projection  240  provides a small partial obstruction in the path of insulation traveling through the tube  100 . 
     FIGS. 3 is a cross sectional view of the tube  100  showing how the inner web  130  (with helical projection  140 ) and outer cap  120  are formed. FIG. 3 shows an inner web  130  having a helical projection  140  as shown in FIG.  2 ( a ), but the foregoing explanation applies equally as well to exemplary embodiments shown in FIGS.  2 ( b )- 2 ( d ). The materials for both the inner web  130  and outer cap  120  are preferably formed by extrusion of plastic through a die. The plastic may comprise any well known plastic in the art, for example, polypropalenes, urethanes, and polyvinyl chlorides may be used. However, these components need not be formed of strictly plastic, and may be formed of any suitable materials, including metals (e.g. aluminum), by any suitable process known to those skilled in the art. The inner web  130  is not formed as a cylindrical member as it is shown in FIGS.  1 ( a ) and  1 ( b ). The web  130  is actually formed as a tape extrusion  160  with a W-shaped cross section as shown in FIG.  3 . The tape  160  is wrapped around a cylindrical rotating mandrel  200  (shown in FIG. 4) to form the cylindrical inner web  130  shown in FIGS.  1 ( a ) and  1 ( b ). The mandrel  200  rotates in either the clockwise or counter-clockwise (as shown in FIG. 4) direction to roll the tape  160  onto its outer surface. FIG. 3 shows a cross section of two segments of the tape  160 . Each segment of the tape  160  has a W-shaped cross section with a inverted V-shaped central portion  161 , and two L-shaped outer portions  162 . The central portion  161  of the W-shape, when wound around the mandrel  200 , creates the first helical projection  131  of the tube  100 , and outer portions  162  create the second helical projection  140 . The outer portions  162  are preferably formed so that lower portions  163  thereof extend below the central portion  161  by a distance D approximately {fraction (1/1000)} of an inch (0.025 millimeters) to ¼ of an inch (6.35 millimeters), depending on the length of the insulation fiber and the diameter of the tube  100 . The projections  163  of the inner web tape  160  create the helical projection  140  when tape  160  is wound around the cylindrical mandrel  200 . 
     The outer cap  120  is also formed from a tape-like extrusion  170 . The outer cap tape  170 , however, is formed to have an inverted U-shape. The outer cap tape  170  is formed to fit over at least two outer portions  162  of the inner web tape  160  as shown in FIG.  3 . The central open portion of the U-shape is approximately the same width and length as the combined width and length of the two adjacent outer portions  162 . A small gap  180  exists between the adjacent outer portions  162  of the segments of tape  160 . The outer cap tape  170  covers the two adjacent outer portions  162  and gap  180 , and thus holds the different segments of the inner web tape  160  together to form tube  100 . 
     As stated above, the inner web  130  and outer cap  120  can be manufactured to have different configurations than the one shown in FIG.  3 . The exemplary embodiment of FIG.  2 ( b ) can be fabricated by extruding an inner web where the outer portions  162  of the inner web tape  160  are angled by an angle less than ninety (90) degrees with respect to the central portion  161 . This involves merely changing the die used to extrude the inner web tape  160 . The exemplary embodiment shown in FIG.  2 ( c ) can be formed in a similar manner by changing the shape of the die used to extrude the inner web tape  160  to have a serrated edge. The exemplary embodiment of FIG.  2 ( d ) can be formed by changing the shape of the die used to extrude the outer cap tape  170 . 
     FIG. 4 shows an exemplary method of forming the tube  100  of the present invention from the inner web tape  160  and outer cap tape  170 . The inner web tape  160  is wound around the cylindrical rotating mandrel  200  to form the cylindrical shape of tube  100  shown in FIG. 1 ( a ). As the tape  160  is wound around the mandrel  200 , the outer cap tape  170  is melted onto the web  130 . As stated above with reference to FIG.  2 ( b ), the forward thrust of the mandrel can be controlled so as to create a helical projection  140  which is angled by an angle of less than ninety (90) degrees with respect to the axis A of the tube  100 . This is accomplished by forcing the mandrel  200  forward (in the direction shown by arrow) while it is rotating. This forward thrust pulls the projections  163  of the web tape  160  in the direction of the force, and thus creates a tube  100  as is shown in FIG.  2 ( b ). 
     The outer cap tape  170  is secured to the inner web tape  160  by injecting molten plastic into the area around the cap as it is wound around the mandrel  200 . The cap  120  is melted onto the web  130  at gap portions  180  formed between the segments of the tape as it is wound around the mandrel  200 . Thus, the cap  180  seals the different segments of the inner web tape  160 , and holds the tube  100  together. The shape of the tube  100  may be altered by simply changing the shape of the mandrel  200 . 
     Although the above explanation describes the inner web  130  as being formed in a helical shape, it may be formed in other ways without departing from the scope of the invention. Instead of being formed as a continuous helical member, the inner web  130  may be formed by a series of non-continuous rings. The non-continuous rings may be formed by manufacturing the tube  100  as described above, and thereafter cutting the helical member  140 , using for example a rotating knife die, at different portions so that a plurality of non-continuous rings are formed. The cross section of a tube  100  manufactured in such a manner would appear the same as the cross sections shown in FIGS.  2 ( a )- 2 ( d ) and  3 , the only difference being that the projection  140  would comprise a plurality of cylindrical projections rather than one continuous projection. 
     Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.