Granted Patent B2

US 12,565,371 · App. 18/612,835 · Granted Mar 3, 2026

Inventors: Alan B. Collison (Pierce, NE); Reid Borgman (Norfolk, NE)

Assignee: MP Global Products, L.L.C.

B65D81/3823B29C70/08B29C70/12B29C70/508B29C70/545B32B7/14B32B27/32B32B29/005B32B29/02B32B29/08B65B11/08B65D5/0227B65D27/00B65D27/005B65D81/3858B29K2301/12B29K2311/12B29L2031/712B32B2260/028B32B2260/046B32B2398/20B65D2565/384B65D2565/385Y02W30/80Y02W90/10

Abstract

Claims (26)

1 . An insulation material comprising:

a batt formed of a mixture of thermoplastic binder fibers and cellulose fibers bound together by the thermoplastic binder fibers, the thermoplastic binder fibers representing between about 0.5% and about 25% by weight of the batt, the batt having a density that is less than about 10 pound per cubic foot, the batt having a thickness that is greater than or equal to about 1/16 of an inch, wherein the insulation material is repulpable.

2 . The insulation material of claim 1 wherein the thermoplastic binder fibers represent less than or equal to 10% by weight of the batt.

3 . The insulation material of claim 1 wherein the thermoplastic binder fibers are bicomponent fibers made of at least two materials selected from a group consisting of polyvinyl alcohol, polyethylene, polyester, polypropylene, and mixtures thereof.

4 . The insulation material of claim 1 wherein the thermoplastic binder fibers have a length of less than about 24 mm.

5 . The insulation material of claim 1 wherein the thermoplastic binder fibers have a denier within a range from about 0.02 den to about 3 den.

6 . The insulation material of claim 1 wherein the cellulose fibers include at least one of paper fibers and cardboard fibers.

7 . A method for producing an insulation material, the method comprising:

mixing cellulose reinforcement fibers with thermoplastic binder fibers to form a mixture, the thermoplastic binder fibers representing between about 0.5% and about 25% by weight of the mixture;

applying heat to the mixture to melt the thermoplastic binder fibers; and

allowing the mixture to cool such that the thermoplastic binder fibers bind the cellulose reinforcement fibers together to form a batt, the batt having a density that is less than about 10 pound per cubic foot, the batt having a thickness that is greater than or equal to about 1/16 of an inch, wherein the insulation material is repulpable.

8 . The method of claim 7 wherein the thermoplastic binder fibers represent less than or equal to 10% by weight of the mixture.

9 . The method of claim 7 wherein the thermoplastic binder fibers are bicomponent fibers made of at least two materials selected from a group consisting of polyvinyl alcohol, polyethylene, polyester, polypropylene, and mixtures thereof.

10 . The method of claim 7 wherein the thermoplastic binder fibers have a length of less than about 24 mm.

11 . The method of claim 7 wherein the thermoplastic binder fibers have a denier within a range from about 0.02 den to about 3 den.

12 . The method of claim 7 wherein the cellulose reinforcement fibers include at least one of paper fibers and cardboard fibers.

13 . An insulation liner comprising:

a first paper layer; and

a cellulose fiber pad, the cellulose fiber pad including thermoplastic binder fibers and cellulose reinforcement fibers bound together by the thermoplastic binder fibers, the thermoplastic binder fibers representing between about 0.5% and about 25% by weight of the cellulose fiber pad, the cellulose fiber pad having a thickness that is greater than or equal to about 1/16 of an inch, wherein the thermoplastic binder fibers are bicomponent fibers made of at least two materials selected from a group consisting of polyvinyl alcohol, polyethylene, polyester, polypropylene, and mixtures thereof, wherein the insulation liner is repulpable.

14 . The insulation liner of claim 13 wherein the thermoplastic binder fibers represent less than or equal to 10% by weight of the cellulose fiber pad.

15 . The insulation liner of claim 13 wherein the thermoplastic binder fibers have a length of less than about 24 mm.

16 . The insulation liner of claim 13 wherein the thermoplastic binder fibers have a denier within a range from about 0.02 den to about 3 den.

17 . The insulation liner of claim 13 wherein the cellulose reinforcement fibers include at least one of paper fibers and cardboard fibers.

18 . The insulation liner of claim 13 wherein the first paper layer is coupled to the cellulose fiber pad.

19 . The insulation liner of claim 13 further comprising a second paper layer coupled to at least one of the cellulose fiber pad and the first paper layer.

20 . The insulation liner of claim 19 wherein the first paper layer is coupled to the cellulose fiber pad on a first side of the cellulose fiber pad, and the second paper layer is coupled to the cellulose fiber pad on a second side of the cellulose fiber pad that is opposite of the first side.

Assignments (2)

Continuity (8)

References Cited (400)

Cited By (3)

US 12,656,050 US 12,668,412 US 12,709,453