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. A method for forming a container insulation batt comprising: providing large paper particles, at least 90% of which are greater than 10 mm in diameter; mixing said large paper particles with 5% or less binder fibers, which have a length of at least 20 mm; compressing said large paper particles and said binder fibers into a container insulation batt.
2. The method of claim 1 in which paper coated with a biodegradable coating is applied to said batt.
3. The method of claim 1 in which: said insulation batt is an air laid batt.
4. The method of claim 3 in which said large paper particles as provided have a moisture content of between 10 and 20%.
5. The method of claim 4 in which said paper particles as provided have a density of 4-5 grams per 8 volume ounces (0.017-0.021 g/cc).
6. The method of claim 5 in which said large paper particles as provided have a particle size distribution as follows:
less than 5% by weight of said particles having size of less than 10 mm or less, 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. A method for forming a container insulation batt comprising: forming paper particles with an attrition mill with a plate spacing of about ½″; applying moisture in the form of water and steam to said paper after it is milled in said attrition mill; sizing the paper particles produced by said attrition mill such that at least 90% of the said particles to be used in a batt are greater than 10 mm in diameter; 5% or less binder fibers, which have a length of at least 20 mm; compressing said paper particles into an insulating batt.
8. The method of claim 7 in which water and steam are applied at a rate which yields paper particles having a moisture content of between 10 and 20%.
9. The method of claim 7 in which said paper particles are sized to the following particle size distribution:
less than 5% by weight of said particles having size of 10 mm or less, 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.
10. The method of claim 9 in which said paper particles are mixed with less than 5% binder fibers having a length of at least 20 mm.