Folding blade for insulation bagger

Abstract

An apparatus for folding and packaging fibrous insulation batts. The apparatus comprises an unfolded batt conveyor assembly configured to move fibrous insulation batts in a machine path. The apparatus also includes a folding section. The folding section includes a folding blade and an actuator. The actuator is configured to move the folding blade along a blade path that intersects the machine path. The folding blade has a leading surface configured to contact and fold the fibrous insulation batts around the folding blade. The leading surface has a width and a length. The width of the leading surface is at least five inches. The width of the leading surface is sufficient to provide a c-shaped fold in the fibrous insulation batt. The c-shaped fold has an internal c-shaped fold width approximately equal to the width of the leading surface. A gripper assembly is configured to receive and move the folded fibrous insulation batts along the blade path that intersects the machine path. The gripper assembly is further configured to cooperate with a folded batt delivery assembly to move the folded insulation batts in the machine path. A packaging section is configured to receive and package the folded fibrous insulation batts.

Description

TECHNICAL FIELD

This invention relates generally to machines for packaging fibrous batts of thermal insulation, and more particularly to the folding of a length of a fibrous insulation batt.

BACKGROUND OF THE INVENTION

Fibrous insulation is typically manufactured in common lengths and widths, called insulation batts, to accommodate typical building frame structure dimensions. Fibrous insulation batts are commonly made of mineral fibers, such as glass fibers, and usually have a density within a range of from about 0.2 to about 1.0 pounds per cubic foot (3.2 to 16 kg/m³). Typical batt sizes are about 16 or 24 inches (40.6 cm or 61 cm) wide by about 8 to 10 feet (2.44 m) long. The batts can be packaged in various ways including staggering and rolling the batts along their length to form a roll containing about 10 batts.

Alternatively, in order to reduce storage and transportation costs, it is common practice to package insulation batts by folding the insulation batts approximately in half lengthwise. The folded batts are compressed and then provided with a covering, for example, a bag, which maintains the batts in their compressed state. When the bag is subsequently removed at the point of utilization of the batts, the batts expand to their normal size.

Particular apparatus for folding and packaging insulation batts are sized for batts having a maximum length of 100 inches and a maximum folded length of 50 inches. It would be advantageous if the apparatus could fold and package insulation batts longer than 100 inches.

SUMMARY OF THE INVENTION

The above objects as well as other objects not specifically enumerated are achieved by an apparatus for folding and packaging fibrous insulation batts. The apparatus comprises an unfolded batt conveyor assembly configured to move fibrous insulation batts in a machine path. The apparatus also includes a folding section. The folding section includes a folding blade and an actuator. The actuator is configured to move the folding blade along a blade path that intersects the machine path. The folding blade has a leading surface configured to contact and fold the fibrous insulation batts around the folding blade. The leading surface has a width and a length. The width of the leading surface is at least about five inches. The width of the leading surface is sufficient to provide a c-shaped fold in the fibrous insulation batt. The c-shaped fold has an internal c-shaped fold width approximately equal to the width of the leading surface. A gripper assembly is configured to receive and move the folded fibrous insulation batts along the blade path that intersects the machine path. The gripper assembly is further configured to cooperate with a folded batt delivery assembly to move the folded insulation batts in the machine path. A packaging section is configured to receive and package the folded fibrous insulation batts.

According to this invention, there is also provided an apparatus for folding and packaging fibrous insulation batts. The apparatus comprises an unfolded batt conveyor assembly configured to move fibrous insulation batts in a machine path. The apparatus further includes a folding section. The folding section includes a folding blade and an actuator. The actuator is configured to move the folding blade along a blade path that intersects the machine path. The folding blade has a leading surface configured to contact and fold the fibrous insulation batts around the folding blade. The leading surface of the folding blade has a width and a length. The ratio of the width of the leading surface of the folding blade to the thickness of the batt is in a range from about 0.25 to about 2.0. A gripper assembly is configured to receive and move the folded fibrous insulation batts along the blade path that intersects the machine path. The gripper assembly is further configured to cooperate with a folded batt delivery assembly to move the folded insulation batts in the machine path. A packaging section configured to receive and package the folded fibrous insulation batts.

According to this invention, there is also provided an apparatus for folding and packaging fibrous insulation batts. The apparatus comprises an unfolded conveyor assembly configured to move fibrous insulation batts in a machine path. The apparatus further includes a folding section. The folding section includes a folding blade and an actuator. The actuator is configured to move the folding blade along a blade path that intersects the machine path. The folding blade has a leading surface configured to contact and fold the fibrous insulation batts around the folding blade. The folded fibrous insulation batt has a c-shaped fold section. The c-shaped fold section has an internal c-shaped fold width and an external c-shaped fold width. A gripper assembly is configured to receive and move the folded fibrous insulation batts in the machine path. The gripper assembly is further configured to cooperate with a folded batt delivery assembly to move the folded insulation batts in the machine path. A packaging section is configured to receive and package the folded fibrous insulation batts. The ratio of the external c-shaped fold width to the internal c-shaped fold width is in a range from about 1.0 to about 7.0.

Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the invention, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view in elevation, of an apparatus for folding and packaging fibrous insulation batts.

FIG. 2 is a side view in elevation, of a folding section of the apparatus of FIG. 1.

FIG. 3 is a perspective view of a folding blade of the apparatus of FIG. 1.

FIG. 4 is a side view in elevation, of the fibrous insulation batt folding around the folding blade of FIG. 3.

FIG. 5 is a side view in elevation, of a folded fibrous insulation batt according to prior art.

FIG. 6 is a side view in elevation, of a fibrous insulation batt with a c-shaped fold.

DETAILED DESCRIPTION OF THE INVENTION

The description and drawings disclose an apparatus and method for folding and packaging fibrous insulation batts. Referring now to the drawings, there is shown in FIG. 1 an apparatus 10 for folding and packaging a fibrous insulation batt.

The term fibrous insulation batt, as used herein, is intended to include fibrous insulation products manufactured in common lengths and widths. The batt can be made of glass fibers or of fibers of other mineral materials, such as rock, slag and basalt.

As shown in FIGS. 1 and 2, an unfolded batt conveyor assembly 12 receives unfolded fibrous insulation batts 14 from a batt forming machine (not shown). The unfolded batts 14 have a thickness t1. The thickness t1 generally corresponds to the insulative value of the unfolded batt 14. In one embodiment as an example, an unfolded batt 14 having an R13 insulative value generally has a thickness t1 of approximately 3.5 inches (8.9 cm). Similarly in another embodiment, an unfolded batt having an R19 insulative value generally has a thickness t1 in a range from about 6 inches (15.2 cm) to about 8.5 inches (21.6 cm). Alternatively, the unfolded batts 14 can have a thickness t1 that is more than about 8.5 inches (21.6 cm) or less than about 3.5 inches (15.2 cm).

The unfolded batts 14 are moved in a machine path d1 by the unfolded batt conveyor assembly 12. The unfolded batt conveyor assembly 12 moves the unfolded batts 14 at a speed from about 100 feet/minute to about 300 feet/minute. However, other speeds can be used.

In one embodiment as further shown in FIGS. 1 and 2, a compression conveyor assembly 18 is disposed parallel to and above the unfolded batt conveyor assembly 12. In this embodiment, as the unfolded batts 14 are moved by the unfolded batt conveyor assembly 12, the unfolded batts 14 are temporarily compressed by the compression conveyor assembly 18. Compression of the unfolded batts 14 substantially softens the insulation material of the unfolded batts 14 and substantially removes the tendency of the later folded batts to unfold. While the compression conveyor assembly 18 shown in FIGS. 1 and 2 includes an endless belt 20 rotating around compression rolls 22, it is to be understood that any type of compression device can be used. Alternatively, softening of some types of fibrous insulation materials, such as those with low density or those with small thicknesses, is not necessary.

As further shown in FIGS. 1 and 2, the unfolded batts 14 exit the compression conveyor assembly 18 and continue to move in the machine path d1. The unfolded batt conveyer assembly 12 moves the unfolded batts 14 into the folding section 24. As best shown in FIG. 2, the folding section 24 includes a folding blade 26 supported by a framework 28. In this embodiment, the framework 28 includes both substantially vertical and horizontal members, 30 and 32 respectively. The purpose of the substantially vertical member 30 is to support the horizontal member 32. The horizontal member 32 is configured to support the folding blade 26 as the folding blade 26 reciprocally moves along a blade path p1 that intersects the machine path d1. While the framework 28 shown in FIG. 2 includes both substantially vertical and horizontal members, 30 and 32, it is to be understood that the framework 28 can any structure sufficient to support the folding blade 26 as the folding blade 26 reciprocally moves along a blade path p1. As shown in FIGS. 1 and 2, the framework 28 is positioned above the unfolded batt conveyor assembly 12. In another embodiment, the framework 28 can be positioned in another location, such as for example below the unfolded batt conveyor assembly 12, sufficient to support the folding blade 26.

As best shown in FIG. 2, the blade path p1 intersects with the machine path d1. The intersection of the blade path p1 and the machine path d1 forms an angle α. In the embodiment shown in FIG. 2, the angle α is in a range from about 45° to about 70°. In another embodiment, the angle α can be larger than about 70° or smaller than about 45°.

As further shown in FIG. 2, an actuator 34 moves the folding blade 26 along the blade path p1 to intersect the machine path d1. In this embodiment, the actuator 34 is a pneumatic system. Alternatively, the actuator 34 can be any means of moving the folding blade 26 along blade path p1, including such means as an induction coil system, or a hydraulic system.

Referring again to FIG. 2, the actuator 34 is controlled by a controller (not shown) and a sensor 36. The sensor 36 is positioned to sense the movement of the unfolded batt 14 across a gap 38. The gap 38 is a space formed between the unfolded batt conveyor assembly 12 and a folded batt delivery assembly 40. In operation, as the unfolded batt 14 moves in the machine path d1, the sensor 36 senses the unfolded batt 14 moving across the gap 38. The sensor 36 is connected to the controller, which is configured to control the actuator 34 in response to a signal from the sensor 36. In order to prevent overloading of the folding and packaging apparatus 10, or to prevent an excessive number of unfolded batts 14 from entering the folding section 24, the controller can be configured to slow down, stop or reverse the unfolded batt conveyor assembly 12 if the sensed loading of the folding section 24 is too great.

The sensor 36 can be any mechanism, such as a photo sensor, capable of detecting the presence of an oncoming unfolded batt 14. While the sensor 36 shown in FIG. 2 is positioned underneath the folding blade 26, it is to be understood that the sensor 36 can be positioned in any location sufficient to sense the presence of an oncoming unfolded batt 14.

As best shown in FIGS. 2, 3 and 4, the folding blade 26 has a leading surface 42. The leading surface 42 is configured to contact the unfolded batt 14 as the folding blade 26 moves along blade path p1. As the folding blade 26 continues to move along blade path p1, the folding blade 26 is configured to fold the unfolded batt 14 around the folding blade 26 to form a folded batt 44. Further movement of the folding blade 26 along blade path p1 pushes the folded batt 44 into the folded batt delivery assembly 40.

As best shown in FIG. 3, the folding blade 26 is a solid member. Alternatively, the folding blade 26 can be a frame, a mesh framework or any other device suitable to contact the unfolded batt 14 and fold the unfolded batt 14 around the folding blade 26.

In the embodiment shown in FIG. 3, the folding blade 26 is made of an ultra high molecular weight polymer material to substantially minimize the weight of the moving folding blade 26. Alternatively, the folding blade 26 can be made of any material, such as wood or metal, sufficient to contact the unfolded batt 14 and fold the unfolded batt 14 around the folding blade 26. Advantageously, the folding blade 26 has a smooth surface to discourage build-up of glass fibers. Any surface can be used, however.

As further shown in FIG. 3, the leading surface 42 has a substantially rectangular cross-sectional shape. Alternatively, the leading surface 42 can have any other cross-sectional shape, such as for example a substantially oval cross-sectional shape, sufficient to contact the unfolded batt 14 and fold the unfolded batt 14 around the folding blade 26.

In one embodiment as best shown in FIG. 3, the leading surface 42 is substantially flat. Alternatively, the leading surface 42 can be raised (not shown) or have raised portions (not shown), sufficient to contact the unfolded batt 14 and fold the unfolded batt 14 around the folding blade 26.

Referring again to FIG. 3, the leading surface 42 has a width w and a length l. The length l of the leading surface 42 generally corresponds to typical batt sizes, such as for example, about 16 or 24 inches (40.6 cm or 61 cm). Alternatively, the length l of the leading surface 42 can be other sizes. The width w of the leading surface is sized to provide a c-shaped fold section 46 as best shown in FIGS. 4 and 6. The c-shaped fold section 46 will be discussed in more detail below.

Referring again to FIG. 1, the folded batts 44 are gripped by the folded batt delivery assembly 40 and exit the folding section 24. The folded batt delivery assembly 40 is configured to grip the folded batts 44 and move the folded batts 44 toward a stacking framework 47. In this embodiment, the folded batt delivery assembly 40 includes a gripper assembly 48 and a folded batt delivery assembly 50. In this embodiment, the gripper assembly 48 and the folded batt delivery assembly 50 are endless belt convey systems. Alternatively, the gripper assembly 48 and the folded batt delivery assembly 50 can be any structure, assembly or mechanism sufficient to grip the folded batts 44 and move the folded batts 44 toward a stacking framework 47. In operation, as the folding blade 26 moves along blade path p1 and folds the unfolded batts 14 to form the folded batts 44, the folded batts 44 are pushed along blade path p1 by further movement of the folding blade 26. As best shown in FIG. 2, the folded batts 44 are gripped between the gripper assembly 48 and the unfolded batt conveyor assembly 12. The gripper assembly 48 and unfolded batt conveyor assembly 12 move the folded batts 44 in a manner such that the folded batts 44 are subsequently gripped by the gripper assembly 48 and the folded batt delivery assembly 50.

The gripper assembly 48 and the folded batt delivery assembly 50 move the folded batts 44 downstream toward the stacking framework 47. The stacking framework 47 is configured to stack a desired quantity of folded batts 44 and deliver the stacked folded batts to a packaging apparatus 54, which can be any apparatus suitable for packaging the folded batts 44. In the embodiment shown in FIG. 1, the packaging apparatus 54 includes a compression chamber 56. The compression chamber 56 is configured to compress a quantity of stacked batts prior to packaging. The packaging apparatus 54 further includes a bagging apparatus 58 and a ram apparatus 60. The ram apparatus 60 is configured to urge the compressed stacked batts into the bagging apparatus 58. The bagging apparatus 58 is configured to cover the compressed stacked batts with a protective cover. While the embodiment shown in FIG. 1 includes a stacking framework 47 and a packaging apparatus 54, it is to be understood that any structure, assembly or mechanism suitable to stack, compress, and package the folded batts 44 can be used.

As previously discussed, the folding blade 26 moves along blade path p1 thereby forming the unfolded batts 14 into folded batts 44. The folding blade 26 includes a leading surface 42. The width w of the leading surface is sized to provide a c-shaped fold section 46 as best shown in FIGS. 4 and 6. The c-shaped fold section 46 provides batts produced by recent machines with a significant advantage over batts folded by typical prior art folding machines. One example of a prior art folding machine is a folding machine of the type disclosed in U.S. Pat. No. 4,805,374 to Yawberg, which is hereby incorporated by reference, in its entirety. In the Yawberg folding machine, a plate member is moved to fold insulation batts substantially in half. The plate member typically has a width of approximately ½ inch (1.3 cm), thereby resulting in a sharp fold section 62 as shown in FIG. 5. The Yawberg machine provided for unfolded batts having a maximum length of 100 inches (254 cm) and a maximum folded length of 50 inches (127 cm).

In contrast, the use of the c-shaped fold section 46 in the current invention allows unfolded batts 14 having a length in excess of about 100 inches (254 cm), such as for example about 105 inches (266.7 cm), to be folded substantially in half and the resulting folded batt 44 can maintain a maximum folded length of about 50 inches (127 cm). Maintaining the maximum folded length of about 50 inches (127 cm) allows the use of current stacking and packaging apparatus.

In the current embodiment as best shown in FIG. 6, the c-shaped fold section 46 has opposing sides, 49a and 49b, and end 49c. The opposing sides, 49a and 49b, and end 49c define a hollow space 51 within the folded insulation batt 44. In this embodiment, the hollow space 51 is a substantially round space. In another embodiment, the hollow space 51 can have any other shape. The hollow space 51 has an internal c-shaped fold width f1, which is defined as the maximum distance, within the hollow space 51, between the opposing sides 49a and 49b. The c-shaped fold section 46 also has an external c-shaped fold width f2. The external c-shaped fold width f2 is defined as the maximum distance between the outer surfaces of the opposing sides, 49a and 49b.

As further shown in FIG. 6, the end 49c has a surface 49d within the hollow space 51. The shape of the surface 49d is substantially formed by the leading edge 42 of the folding blade 26. In this embodiment, the surface 49d is substantially flat with curved ends. Alternatively, the surface 49d can have another shape corresponding to a folding blade 26 having leading edge 42 of another shape.

As further shown in FIG. 6, the folded batt 44 has an overall length f1. The overall length f1 of the folded batt 44 can be controlled by varying the internal width f1 of the c-shaped fold section 46. In one embodiment, the internal c-shaped fold width f1 is approximately the same dimension as the width w of the leading surface 42 of the folding blade 26. In this embodiment as an example, the internal c-shaped fold width f1 is approximately five inches (12.7 cm), the width w of the leading surface 46 is also about five inches (12.7 cm), and the overall length f1 of the folded batt 44 is about 50 inches (127 cm). The resulting maximum length of the unfolded batt 14 is therefore about 105 inches (266 cm). In a similar manner in another embodiment, the width w of the leading surface 42 can be larger, thereby producing a larger internal c-shaped fold width f1. The larger internal c-shaped fold width f1 allows for a longer unfolded batt (i.e. longer than he conventional 100 inch batt) to be folded substantially in half while still maintaining the maximum folded length of about 50 inches (127 cm).

Referring again to FIG. 4, the width w of the leading surface 42 of the folding blade 26 can be similar to the thickness t1 of the unfolded batt 14. In one embodiment as an example, the width w of the leading surface 42 is approximately five inches (12.7 cm) and the thickness t1 of the fibrous insulation is about 3.5 inches (8.9 cm). In this embodiment, the ratio of the width w of the leading surface 42 of the folding blade 26 to the thickness t1 is approximately 1.43 inches. Alternatively, the width w of the leading surface 42 can be about five inches (12.7 cm) and the thickness t1 can be approximately six inches (15.2 cm) resulting in a ratio of 0.83. In another embodiment, the width w of the leading surface 42 can be about five inches (12.7 cm) and the thickness t1 can be approximately eight and one-half inches (21.6 cm) resulting in a ratio of 0.58. In yet another embodiment, the ratio of the width w of the leading surface 42 of the folding blade 26 to the thickness t1 can be in a range from about 0.25 to about 2.0 inches.

As best shown in FIG. 6, the external c-shaped fold width f2 of the folded batt 44 can correspond to the internal c-shaped fold width f1 of the folded batt 44. In one embodiment as an example, an unfolded batt 14 having a thickness t1 of about 3.5 inches (8.9 cm) and an internal c-shaped fold width f1 of approximately five inches (12.7 cm) has an external c-shaped fold width f2 of approximately twelve inches (30.4 cm). In this embodiment, a ratio of the external c-shaped fold width f2 to the internal c-shaped fold width f1 is about 2.4. Alternatively, an unfolded batt 14 having a thickness t1 of about six inches (15.2 cm) and an internal c-shaped fold width f1 of approximately five inches (12.7 cm) has an external c-shaped fold width f2 of approximately seventeen inches (43.1 cm). In this embodiment, a ratio of the external c-shaped fold width f2 to the internal c-shaped fold width f1 is about 3.4 inches. In another embodiment, an unfolded batt 14 having a thickness t1 of about eight and one/half inches (21.6 cm) and an internal c-shaped fold width f1 of approximately five inches (12.7 cm) has an external c-shaped fold width f2 of approximately twenty-two inches (55.9 cm). In this embodiment, a ratio of the external c-shaped fold width f2 to the internal c-shaped fold width f1 is about 4.4. In yet another embodiment, the ratio of the external c-shaped fold width f2 to the internal c-shaped fold width f1 can be in a range from about 1.0 to about 7.0.

The principle and mode of operation of this invention have been described in its preferred embodiments. However, it should be noted that this invention may be practiced otherwise than as specifically illustrated and described without departing from its scope.

Claims

1. An apparatus for folding and packaging fibrous insulation batts, the apparatus comprising:

an unfolded batt conveyor assembly configured to move fibrous insulation batts in a machine path;

a folding section including a folding blade and an actuator, the actuator being configured to move the folding blade along a blade path that intersects the machine path, the folding blade having a leading surface configured to contact and fold the fibrous insulation batts around the folding blade, the leading surface having a width and a length, the width of the leading surface being at least five inches, the width of the leading surface being sufficient to provide a c-shaped fold in the fibrous insulation batt, the c-shaped fold having a having an internal c-shaped fold width approximately equal to the width of the leading surface;

a gripper assembly configured to receive and move the folded fibrous insulation batts along the blade path that intersects the machine path, the gripper assembly further configured to cooperate with a folded batt delivery assembly to move the folded insulation batts in the machine path; and

a packaging section configured to receive and package the folded fibrous insulation batts.

2. The apparatus of claim 1 in which the fibrous insulation batt has an unfolded length of at least about 105 inches, the fibrous insulation batt being folded with a c-shaped fold in a manner resulting in the fibrous insulation batt having a maximum folded length of about 50 inches.

3. The apparatus of claim 1 in which the leading surface of the folding blade has a substantially rectangular cross-sectional shape.

4. The apparatus of claim 1 in which the folding blade is made from ultra high molecular weight polymer material.

5. The apparatus of claim 1 in which the leading surface is substantially flat.

6. The apparatus of claim 1 in which the folding blade forms a substantially round hollow space within a c-shaped fold section of the folded batt.

7. An apparatus for folding and packaging fibrous insulation batts, the batt having a thickness, the apparatus comprising:

an unfolded batt conveyor assembly configured to move fibrous insulation batts in a machine path;

a folding section including a folding blade and an actuator, the actuator being configured to move the folding blade along a blade path that intersects the machine path, the folding blade having a leading surface configured to contact and fold the fibrous insulation batts around the folding blade, the leading surface of the folding blade having a width and a length, wherein the ratio of the width of the leading surface of the folding blade to the thickness of the batt is in a range from about 0.25 to about 2.0;

a gripper assembly configured to receive and move the folded fibrous insulation batts along the blade path that intersects the machine path, the gripper assembly further configured to cooperate with a folded batt delivery assembly to move the folded insulation batts in the machine path; and

a packaging section configured to receive and package the folded fibrous insulation batts.

8. The apparatus of claim 7 in which a fibrous insulation batt has an unfolded length of at least about 105 inches, the fibrous insulation batt being folded with a c-shaped fold in a manner resulting in the fibrous insulation batt having a maximum folded length of about 50 inches.

9. The apparatus of claim 7 in which the leading surface of the folding blade has a substantially rectangular cross-sectional shape.

10. The apparatus of claim 7 in which the folding blade is made from ultra high molecular weight polymer material.

11. The apparatus of claim 7 in which the leading surface is substantially flat.

12. The apparatus of claim 7 in which the folding blade forms a substantially round hollow space within a c-shaped fold section of the folded batt.

13. An apparatus for folding and packaging fibrous insulation batts, the apparatus comprising:

an unfolded conveyor assembly configured to move fibrous insulation batts in a machine path;

a folding section including a folding blade and an actuator, the actuator being configured to move the folding blade along a blade path that intersects the machine path, the folding blade having a leading surface configured to contact and fold the fibrous insulation batts around the folding blade, the folded fibrous insulation batt having a c-shaped fold section, the c-shaped fold section having an internal c-shaped fold width and an external c-shaped fold width;

a gripper assembly configured to receive and move the folded fibrous insulation batts along the blade path that intersects the machine path, the gripper assembly further configured to cooperate with a folded batt delivery assembly to move the folded insulation batts in the machine path; and

a packaging section configured to receive and package the folded fibrous insulation batts;

wherein the ratio of the external c-shaped fold width to the internal c-shaped fold width is in a range from about 1.0 to about 7.0.

14. The apparatus of claim 13 in which a fibrous insulation batt has an unfolded length of at least about 105 inches, the fibrous insulation batt being folded with a c-shaped fold in a manner resulting in the fibrous insulation batt having a maximum folded length of about 50 inches.

15. The apparatus of claim 13 in which the leading surface of the folding blade has a substantially rectangular cross-sectional shape.

16. The apparatus of claim 13 in which the folding blade is made from ultra high molecular weight polymer material.

17. The apparatus of claim 13 in which the folding blade forms a substantially round hollow space within a c-shaped fold section of the folded batt.

18. The apparatus of claim 13 in which the folding blade is a solid member.