Batt for use as building material

Abstract

A generally rigid batt for use as wall board, insulating paneling or acoustic paneling. The batt is formed of wood chips, recycled paper and a binder synthetic fibers, and a binder which are thoroughly mixed and evenly dispersed throughout. The wood chips, recycled paper and synthetic fibers are compressed into a batt of desired density, height and width. The shaped batt is heated causing the binder to become molten and bond the synthetic fibers, wood chips and reconstituted paper together. The shaped batt is cooled forming a generally rigid structure.

1 . A batt for use as wall board, insulation paneling and acoustical paneling wherein:
 said batt comprises wood chips, recycled paper and synthetic fibers blended to be substantially evenly distributed throughout, said blended wood chips, recycled paper and bi-component polyester fibers being configured to form said batt with a dimension of width, height and length;   said fibers being bonded with said wood chips and recycled paper, causing said batt of desired width, height and length dimension to be substantially rigid.   
   
   
       2 . The batt of  claim 1  wherein said wood chips comprise up to 60% volume of said batt. 
   
   
       3 . The batt of  claim 1  wherein said recycled paper comprises between 40% and 80% volume of said batt. 
   
   
       4 . The batt of  claim 1  wherein said synthetic fibers are bi-component polyester fibers with one of said bi-component fibers acting as a binder and bonding others of said fibers, said wood chips and said recycled paper together forming said batt. 
   
   
       5 . The batt of  claim 1  wherein said batt consists of about 50% of said wood chips, about 30% of said recycled papers and about 10% of said synthetic fibers. 
   
   
       6 . The batt of  claim 1  wherein said recycled paper at least partially comprises shredded, discarded newspapers treated with a fire retardant. 
   
   
       7 . The batt of  claim 1  wherein said batt is compressed to between 100 to 500 kg/m 3 . 
   
   
       8 . A batt for use as insulation panels, wall board panels and acoustical panels comprising:
 bi-component fibers, irregular sized wood chips and shredded reconstituted paper mixed to be evenly disbursed, said mixture being shaped to form said batt of a desired width, height and length and heated to cause a meltable component of said bi-component fibers to bond said bi-component fibers, reconstituted paper and wood chips into a substantially rigid structure.   
   
   
       9 . The batt of  claim 8  wherein at least one of end, upper, lower and side surfaces of said batt are planar. 
   
   
       10 . The batt of  claim 8  wherein at least one of upper, lower and side surfaces of said batt are irregular. 
   
   
       11 . The batt of  claim 8  wherein end surfaces of said batt are planar. 
   
   
       12 . A method of forming generally rigid batts for use as insulating wall board, insulating acoustical paneling or acoustic paneling including the steps of:
 delivering wood chips, recycled cellulose and synthetic fibers into a mixing chamber and causing said wood chips, said recycled cellulose and said synthetic fibers to be evenly inter-disbursed;   moving said combined wood chips, recycled cellulose and said synthetic fibers into a forming chamber and shaping by compression said wood chips, recycled cellulose and synthetic fibers into a batt of desired density with fixed dimensions of height and width;   combining a binder with said combined wood chips, recycled cellulose and synthetic fibers;   moving said shaped batt into a heating chamber and causing said binder to become molten and bond with said synthetic fibers, said wood chips and said recycled cellulose forming said batt into a generally rigid stable entity;   moving said batt into a cutting area and cutting said batt into dimensions of desired length forming said batt at a desired width, height and length.   
   
   
       13 . The method of  claim 12  including utilizing bi-component fibers as said synthetic fibers and causing a component of said bi-component fibers to act as said bonder. 
   
   
       14 . The method of  claim 12  including forming said batt with a top, a bottom, opposed sides, and opposed ends each having a surface of one of planar and roughened. 
   
   
       15 . The method of  claim 12  including forming said batt with roughened ends and planar sides, top and bottom. 
   
   
       16 . The method of  claim 12  including compressing said batt to between 100-500 kg/m 3 . 
   
   
       17 . The method of  claim 12  including compressing said batt to be between ⅛″ to 2″ thick.