Compositions – Chemically interactive reactants – Organic reactant admixed with inorganic reactant
Reexamination Certificate
2000-04-25
2003-05-13
Anthony, Joseph D. (Department: 1714)
Compositions
Chemically interactive reactants
Organic reactant admixed with inorganic reactant
C252S183110, C428S378000, C428S392000, C427S213000, C427S387000, C427S389800
Reexamination Certificate
active
06562257
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to a pourable or blowable loose-fill insulation for sidewall and attic installation, and in particular to a loose-fill insulation comprising glass fibers which are compressed and packaged in relatively small containers for easier installation by consumers.
In recent years, many homeowners have begun to install extra insulation in their attics or crawlspaces in an effort to save money on heating and cooling bills. A common form of insulation used by consumers has been fiberglass insulation batts. However, insulation batts are relatively expensive and may require some cutting and shaping during installation.
More recently, the use of glass fiber blowing wool or loose-fill insulation has increased in popularity. Loose-fill insulation is not formed into a blanket or batt, but rather comprises smaller nodules of straight, short fibers which are packaged into large bags usually weighing about 35 lbs. (16 kg). The insulation is installed by adding the loose-fill to the hopper of a pneumatic blower which blows the loose fill insulation into the desired area. Loose-fill insulation is popular because it can be easily and quickly applied in both new as well as in existing structures. Moreover, loose-fill insulation is a relatively low cost material.
An optimal loose-fill product would comprise a mass of glass fibers compacted into a container for shipping in such a manner so that when the container is opened, the compacted glass fibers are capable of expanding as closely as possible to their original volume before compaction. The ability of a mass of compacted glass fibers to expand towards its original volume is referred to as “recoverability.” An increase in recoverability is desirable in order to increase insulative and handling properties. When there is very little recovery, the compacted fibers expand very little and have properties similar to brick. This situation is referred to as “bricking” and is undesirable because it leads to poor insulative and handling properties. Installation of loose-fill insulation generally involves feeding bags containing compressed glass fibers into a hopper where the bags are opened and the contents deposited on to a conveyor which transports the glass fibers to a blower. When bricking occurs the bags become very difficult to open in the hopper and even when the bags are opened the conveyor is often damaged. Causes of bricking are: 1) mechanical interactions such as the rubbing of glass fibers against on another leading to glass fiber fracture and clumping, and 2) chemical interactions of glass fiber towards one another and the environment. Chemical interaction is defined herein as: 1) bonding resulting from an attracting force, such as hydrogen bonding or Van der Waals bonding or 2) chemical bonding, which is typically covalent bonding.
A common solution to promote recoverability and prevent bricking is the addition of sizing compositions containing lubricants to the glass fibers before they are compacted into a container for shipment as loose-fill insulation. Lubricants help minimize the interaction of glass fibers with one another thereby increasing recoverability. However, lubricants primarily function to reduce the mechanical interactions of glass fibers and do very little to reduce the chemical interactions of glass fibers towards one another and/or to the environment. It would therefore be desirable to discover agents which effectively reduce the chemical interactions of glass fibers and thereby increase recoverability. Furthermore, low recoverability is encountered when shipments of compacted glass fibers are stored in hot and humid conditions. Lubricants do little to prevent the chemical interactions of water with compacted glass fibers under hot and humid conditions. It would therefore be desirable to discover agents which effectively reduce the chemical interactions of glass fibers with water under hot and humid conditions in order to increase recoverability and to reduce bricking. A solution contemplated by this invention is the application of a sizing composition comprising agents capable of chemically interacting with the surface of compacted glass fibers.
Agents, commonly referred to as “coupling agents,” are known to chemically interact with glass fibers. An example of the use of coupling agents is found in U.S. Pat. No. 5,972,503. These coupling agents are used to chemically couple glass fibers with a binder or polymer matrix in order to make fiberglass insulation batts or composite materials. Coupling agents have a functional group which chemically interacts with the glass fiber surface and another functional group which chemically interacts with a binder or polymer matrix. Unlike coupling agents, the agents used in this invention are intended to increase the recoverability of compacted glass fibers by chemically interacting with the surface of glass fibers in the absence of any binder or any polymer matrix.
SUMMARY OF THE INVENTION
The present invention solves the problem of low recoverability and prevents bricking of compacted glass fibers by adding a sizing composition comprising locking agents which are capable of chemically interacting with the glass fiber surface thereby reducing the chemical interactions of the glass fibers to one another and to the environment. The blocking agents of the present invention include any agents which chemically interact with the glass fiber surface by: 1) bonding resulting from an attracting force, such as hydrogen bonding or Van der Waals bonding or 2) chemical bonding, which is typically covalent bonding. The blocking agents are preferably applied to glass fibers before they are compacted for shipping.
Suitable blocking agents for the present invention comprise a functionalized organic substrate (i.e., at least one organic functional group bonded to an organic substrate). Exemplary types of functionalized organic substrates include alcohols, amines, esters, reactive siloxanes, silazanes, silanes, lactams, lactones, anhydrides, carbenes, nitrenes, orthoesters, imides, enamines, imines, amides, and imides.
DETAILED DESCRIPTION OF THE INVENTION
Application of Blocking Agents of Glass Fibers
The sizing composition of the present composition which comprises blocking agents and optional lubricants is preferably deposited on the surfaces of fibers as they exit and cascade downwardly from a bushing or spinner during their manufacture. Glass fibers are typically manufactured by supplying molten glass to a fiber forming device such as a bushing or a spinner. Fibers of glass are attenuated from the device and are blown generally downwardly within a forming chamber and are deposited onto a forming conveyor. The glass fibers may then be chopped to a suitable size. Preferably the sizing composition is applied to the glass fibers as they are being formed by means of suitable spray applicators so as to result in a distribution of the sizing composition throughout a glass fiber mass. The sizing composition may be applied to the fibers as a solution or dispersion in an organic or aqueous medium. Preferably the sizing composition is applied to the fibers as an aqueous solution. Evaporation of the liquid medium occurs before the fibers have been collected.
The glass fiber may be further processed by air blowing to a packaging machine were they are compacted into a container, preferably a plastic bag, for shipment as a loose-fill insulation product. Additional additives, such as antistatic agent, mineral oil for dust reduction, and colorant, may be sprayed along the air blowing path.
Lubricants
In addition to blocking agents, the sizing composition of the present invention preferably comprises a lubricant. Preferably the lubricant is present in the sizing composition in the range of from 0.01%-2.5 wt. % based on the total weight of the glass fibers, preferably from 0.05-0.50 wt. %, and more preferably from 0.10-0.25 wt. Any suitable lubricant may be used in the sizing composition. Examples of lubricants include ethyleneglycol, ethyleneglycol stearates, ethy
Chen Liang
Downey William E.
Anthony Joseph D.
Barns Stephen W.
Eckert Inger H.
Gasaway Maria C.
Owens Corning Fiberglas Technology Inc.
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