Repulpable container insulation products and methods of making and using same
Container insulation including a batt comprised of large paper particles, at least 90% of which by weight are greater than 10 mm in diameter. Less than 5% by weight binder fibers are used, which have a length of at least 20 mm. Most preferably, no binder fibers are used. Where the batts are faced with paper, the paper is coated with a biodegradable coating. The resulting product is repulpable and recyclable in accordance with Fiber Box Association (FBA) testing protocols.
1. An insulation batt comprised essentially of large paper particles, less than 5% by weight of said paper particles having a diameter of 10 mm or less, at least 90% of which are greater than 10 mm in diameter, and at least 55% by weight have a particle size of greater than 20 mm in diameter; and 5% or less binder fibers, which have a length of at least 20 mm.
2. The insulation batt of claim 1 in which said batt is faced with paper.
3. The insulation batt of claim 2 in which said batt is free of binder fibers.
4. The insulation batt of claim 3 which is shaped to be fitted to the interior of a cardboard box shipping container.
5. The insulation batt of claim 4 which is re-pulpable and recyclable.
6. The insulation batt of claim of claim 5 in which the particle size distribution for said paper particles includes:
50-60% by weight of said particles having size of 10-20 mm, 20-30% by weight of said particles having a size of 20-30 mm, 10-20% by weight of said particles having a size of 30-40 mm, and up to 5% by weight of said particles having a size of 40 mm or greater.
7. The insulation batt of claim 6 , in which said batt is about ¼ to about 3 inches thick and has a density from about one to about seven pounds per cubic foot.
8. The insulation batt of claim 7 in which prior to compression into said batt, said paper particles have a moisture content of between 14-16%.
9. The insulation batt of claim 8 in which prior to compression into said batt, said paper particles have a density of 4-5 grams per 8 volume ounces (0.017-0.021 g/cc.).
10. The insulation batt of claim 9 in which said batt has exposed edges which are not wrapped with said facing paper.
11. The insulation batt of claim 1 which is re-pulpable and recyclable.
12. The insulation batt of claim 11 in which the particle size distribution for said paper particles includes:
50-60% by weight of said particles having size of 10-20 mm, 20-30% by weight of said particles having a size of 20-30 mm, 10-20% by weight of said particles having a size of 30-40 mm, and up to 5% by weight of said particles having a size of 40 mm or greater.
13. The insulation batt of claim 12 , in which said batt is about ¼ to about 3 inches thick and has a density of from about one to about seven pounds per cubic foot.
14. The insulation batt of claim 1 in which the particle size distribution for said paper particles includes:
50-60% by weight of said particles having size of 10-20 mm, 20-30% by weight of said particles having a size of 20-30 mm, 10-20% by weight of said particles having a size of 30-40 mm, and up to 5% by weight of said particles having a size of 40 mm or greater.
15. The insulation batt of claim 14 , in which said batt is about ¼ to about 3 inches thick and has a density of from about one to about seven pounds per cubic foot.
16. The insulation batt of claim 1 in which prior to compression into said batt, said paper particles have a moisture content of between 10 and 20%.
17. The insulation batt of claim 16 in which prior to compression into said batt, said paper particles have a density of 4-5 grams per 8 volume ounces (0.017-0.021 g/cc.).