Blow-in cellulose fiber insulation

Abstract

Recycled pulp materials are becoming scarce. Recycling of paper diapers is being encouraged. Blowing-in housing insulation using cellulose fiber is desired. [Solution] This is a residential insulation material made of recycled newspaper, waste paper, and other pulp materials, recycled cellulose fiber, boric acid, and borax-containing cellulose fiber. It is made of 50% recycled pulp material from waste paper, 30% cotton-like pulp material extracted from paper diapers, and 20% boron-based compounds. The cellulose fiber insulation material is a multifunctional cotton-like natural wood fiber insulation material made from waste paper such as newspapers, which has been treated with chemicals to add flame retardant, water repellent, and mold-resistant properties. The entanglement of natural wood fibers creates a layer of air, and each fiber also contains natural air bubbles, making it even more difficult for heat and sound to be transmitted. Furthermore, the moisture absorption and release properties unique to wood fiber maintain a moderate humidity level, resulting in a comfortable life.

Description

[Technical field]

[0001] This invention relates to a blown-in cellulose fiber insulation material, and more particularly to a blown-in cellulose fiber insulation material made from recycled paper diapers. [Background technology]

[0002] In houses in cold regions, residential insulation materials are installed in the attic, ceiling, inner surface of exterior walls, etc. For example, the insulation layer installed in the attic of a house is formed by blowing a large number of small pieces of blow-in insulation material made of crushed insulating material such as inorganic fiber mats into the attic with an air flow and accumulating it to a certain thickness.

[0003] Conventionally, blown-in insulation materials are manufactured by crushing inorganic fiber mats such as glass wool and rock wool into many small masses of cotton, and then compressed and packed in vinyl bags etc. for supply. This is described in the following Patent Document 1. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2009-228284 A DISCLOSURE OF THEINVENTION [Problem to be solved by the invention]

[0005] However, conventional blown-in insulation materials have problems in that when blown into the ceiling to form an insulation layer, they have many voids, and their density is lower than that of the inorganic fiber mat before crushing, or their density varies widely. Thermal conductivity is proportional to density. If the density is low, the thermal conductivity increases, and the insulation performance decreases. Furthermore, if the density varies widely, the thermal conductivity also varies widely, and the low-density parts become thermal defects.

[0006] Furthermore, the blown-in insulating material produced by the above method has the following problems. That is, the small cotton clumps tend to get tangled with each other and to get caught on the underside of the ceiling. Also, when the crushed small cotton clumps are compressed, packed, and supplied, they often get tangled with each other and form large clumps, so even if the insulation material to be blown in is supplied to a hopper equipped with an agitator and separated into individual small cotton clumps before being sent to a hose for air transport, it is not possible to reliably break them down into small cotton clumps, and they are sent to the transport hose in fairly large clumps, which can easily cause clogging.

[0007] On the other hand, the use of disposable diapers is increasing due to the aging of the population and the increase in the number of people requiring nursing care in recent years. As a result, the burden on local governments regarding the disposal of used disposable diapers has become a major social issue. Used paper diapers account for more than 4% of the total amount of municipal waste, and this amount is expected to increase in the future. This is because they contain a lot of moisture and the amount of heat generated during incineration is about one-third that of combustible waste, equivalent to that of food waste, making them difficult to incinerate. This will increase incineration costs and CO2 emissions. Therefore, recycling of paper diapers is desirable, but the mainstream of recycling is thermal recycling, where the diapers are processed into RPF (fuel), etc. Therefore, there is a strong demand for material recycling of used paper diapers. [Means for solving the problem]

[0008] The invention described in claim 1 is a product produced by mixing a first pulp material made from crushed waste paper with a second cotton-like pulp material extracted from paper diapers, paper napkins, and incontinence absorbent pads in a predetermined ratio, primarily crushing the mixture, adding boric acid and borax, stirring the mixture, secondary crushing the mixture, and compressing and molding the mixture. A blown-in cellulose fiber insulation material , The composition comprises 50% by weight of the first pulp material, 30% by weight of the second pulp material, and 20% by weight of the boric acid and borax. It is a blown-in cellulose fiber insulation material. For example, recycled pulp materials made from recycled newspapers, cardboard, waste paper, etc., recycled cellulose fiber (recycled pulp material) made from used paper diapers (including liquid absorbent materials such as paper napkins and incontinence pads), and blown-in cellulose fiber insulation containing appropriate amounts of boric acid and borax. Incidentally, paper diapers contain cotton-like pulp in addition to the water absorbent material (SAP), and this cotton-like pulp is used as the recycled pulp material. Cellulose fiber is generally produced by loosening and defibrating pulp (wood fiber) in water. Its thermal insulation performance is equivalent to that of residential glass wool (24k, 32k), and its thermal conductivity is around 0.038W / mk.

[0009] In this case, cellulose fiber insulation is sprayed by mixing it with adhesive and water, spraying it onto structures or walls (gaps) with a spray gun, and allowing it to dry naturally. Application is quick, there is a time required for drying, and there is a limit to how much thickness can be applied at one time. The excess can be scraped off and reused. No dust is generated. This is the so-called blowing method. There are other methods, such as using a blowing device to blow cellulose fiber insulation into the ceiling space so that it piles up, and first laying a special sheet on the roof, walls, floor, etc., to create a space to be filled, and then blowing the insulation into this closed space. The advantage of the blowing method is that the cellulose fiber insulation can be firmly filled even in small gaps. The designed insulation performance can be realized during on-site construction.

[0010] The characteristics of this cellulose fiber insulation are as follows: 1) Moisture absorption and release performance The greatest feature of cellulose fiber is the moisture absorption and release properties of wood fiber, creating a comfortable indoor environment without relying on ventilation or air conditioning. Wood fibers require a constant slight moisture level. Even when wood is completely dry, it has the ability to regulate humidity. Wood is ideal for regulating humidity in homes in Japan's uniquely hot and humid environment. 2) Condensation prevention performance If there is a small gap in the insulation material, only that part will be cooled or heated. This temperature difference with the room is the cause of condensation. Cellulose fiber can be installed without gaps, and the cellulose has moisture permeability, moisture absorption and release properties, making it an insulation material that is resistant to condensation. Cellulose fiber can be filled with cellulose without any gaps, so it performs well as an insulation material, and at the same time, it can be expected to have the effect of preventing condensation. In addition, because the construction method involves blowing in fibrous cellulose to fill the gaps, it can be installed in even the smallest of places without leaving any gaps, making it an ideal insulation material to prevent moisture, which can cause condensation and mold. 3) Anti-mold and insect-repellent properties Boric acid is added to cellulose fiber. Boric acid has low toxicity and hardly accumulates or remains in the human body. Boric acid is an excellent wood preservative. In other words, it has only a weak acute effect on mammals, is effective against lower animals and microorganisms, and is colorless and odorless. In addition, it can treat difficult-to-inject materials to the core (it diffuses through wet wood) and does not corrode metals. 4) Sound absorption and sound insulation performance Cellulose fiber contains air in each fiber, and this thick layer of air absorbs sound and makes it difficult for it to be transmitted. In addition, since it is densely packed without any gaps, the house is sealed and has high sound absorption and sound insulation properties.

[0011] 5) Thermal insulation performance Cellulose fiber is a natural wood fiber. Wood fiber contains a lot of air. It is this air that creates the insulating properties of cellulose fiber. Insulation is a building material that traps air and suppresses the transfer of heat, with a thermal conductivity of 0.06 W / (m·k) or less. By installing cellulose fiber without any gaps, it prevents solar heat from entering in the summer and prevents warm air from escaping in the winter. 6) Fire resistance performance Cellulose fiber is mainly made from newspapers, but by adding boric acid and borax, the flames do not spread in the event of a fire. Also, because it is a natural material made from wood (newspaper), it does not emit harmful gases in the event of a fire, and the insulation does not melt due to heat. 7) Energy saving and eco-friendly Cellulose fiber, a "recycled paper insulation material," requires less energy to produce than mineral fibers such as glass wool and rock wool. It is an environmentally friendly, eco-friendly insulation material. Specifically, pulp, the raw material for newspapers, is made from wood. Wood is crushed into small pieces, dissolved in water with chemicals, and the cellulose and helix are extracted to create pulp, the raw material for paper. Recycling of paper begins in water at room temperature, so it does not require much energy. In contrast, recycling of metals and plastics requires heating above the melting point of the material, which requires the input of a huge amount of energy. 8) Workability The insulation is installed without gaps to prevent heat loss. Cellulose fiber insulation can be blown into the interior wall covered with a moisture permeable sheet using a special blowing machine, leaving no gaps. Perfect insulation reduces the running costs of utility bills. Cellulose fiber is applied by blowing without using adhesives, so it can be applied densely even in small gaps.

[0012] This blown-in cellulose fiber insulation material contains boric acid, making it flame retardant (to prevent ignition during the manufacturing process). The addition of boric acid also provides an insect repellent effect. The addition of boric acid also makes it water repellent, which helps prevent excessive moisture absorption. Boric acid prevents mold growth. It also allows water vapor to pass through, so it does not cause condensation inside the wall. The cellulose fiber itself has a moisture-regulating effect (hygroscopicity). It is heavy (more than three times that of 16K glass wool) because it is installed at a high density to achieve insulating performance, and as a secondary effect, it has extremely high soundproofing effects. A wall made of two sheets of hard plasterboard and 10cm thick cellulose fiber has a soundproofing effect of -60dB. When installing insulation in walls by blowing it in, it can be installed without gaps even if there are electrical outlets or diagonal braces. Even in ceilings with pipes, wiring, downlights, etc., high airtightness and soundproofing can be achieved by installing cellulose fiber on the ceiling without any gaps. This reduces the amount of airtight tape and adhesive used. It does not irritate the skin, so there is little discomfort to the skin or mouth during installation. It does not condense, so there is no need for moisture-proof sheets or layers.

[0013] Borax, an additive in insulation materials, has a weak alkaline aqueous solution that has cleaning and disinfecting properties and acts as a preservative (anti-mold).

[0014] The first pulp material The first pulp material is recycled pulp from waste paper, and the second pulp material is cotton-like pulp recycled from paper diapers. It has been confirmed that the thermal conductivity tends to increase when the ratio of the latter is increased (for example, when the first and second pulp materials are both 40% by weight). Effect of the Invention

[0015] According to the invention described in claim 1, it is possible to apply the material at an appropriate density as a blown-in insulation material. It is also possible to promote material recycling of disposable diapers. Of course, it is possible to exhibit excellent insulation effects as a residential insulation material. Furthermore, after application, it is possible to improve the moisture-proofing and moisture-absorbing functions of the house. Therefore, it is possible to achieve prevention of condensation, mold, and pests, high soundproofing, and high waterproofing.

[0016] Further, according to the above invention, In addition to the above effects, it is possible to clear the prescribed thermal conductivity (λ = 0.035 to 0.040) that is considered suitable for thermal insulation materials. Furthermore, by compressing and packaging it during the manufacturing process of the thermal insulation material, it becomes easy to handle, such as by transporting it to the site. In addition, installation of this product can prevent condensation and mold. It increases the durability of houses and homes. It can suppress deterioration. It can prevent termites and other pests. It has high soundproofing properties, making the house quiet. It also has high fire resistance, making the house more resistant to fire. [Brief description of the drawings]

[0017] [Figure 1] FIG. 1 is a perspective photograph showing a blow-in cellulose fiber insulation material (test specimen) according to Example 1 of the present invention. [Diagram 2] FIG. 1 is a cross-sectional view showing the internal structure of a blown-in cellulose fiber insulation material (test specimen) according to Example 1 of the present invention. [Diagram 3] FIG. 1 is a schematic diagram showing the configuration of a device for measuring the thermal conductivity of a blown-in cellulose fiber insulation material (test specimen) according to Example 1 of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] BEST MODE FOR CARRYING OUT THE DISCLOSURE Hereinafter, embodiments of the blown cellulose fiber insulation material according to the present invention will be described in detail with reference to the drawings. EXAMPLES

[0019] Hereinafter, the blown cellulose fiber thermal insulation material according to the first embodiment of the present invention will be described with reference to Figs. 1 to 3. First, the blown-in cellulose fiber insulation material according to this embodiment is manufactured by the following process. That is, it is manufactured by including the steps of: step A of preparing a first pulp material (pulp recycled from waste paper); step B of preparing a second pulp material (cotton-like pulp derived from paper diapers); step C of mixing the first pulp material and the second pulp material in a predetermined ratio; step D of primarily grinding this mixture; step E of adding boric acid and borax to this ground mixture; step F of stirring the mixture after the addition; step G of secondary grinding of the stirred mixture; step H of compressing the ground material; and step I of packaging the compressed ground material.

[0020] The first pulp material in step A is mainly produced from old newspapers, cardboard, etc. The raw materials are not limited to recycled waste products, and surplus products that have not been distributed in the market can also be used. In step B, for example, the collected used paper diapers are agitated with water and a decomposing agent (the paper diapers are agitated in water to remove waste matter) to decompose them into the surface material, water-absorbing material SAP, and other components that make up the paper diapers, and the separated wastewater containing pulp is taken out. The wastewater is then separated into water and pulp using a rotary screen, and the pulp is dehydrated in a screw dehydrator to produce recycled pulp. It is also possible to use the cotton-like pulp of paper napkins in place of or in place of a part of a paper diaper. The insulation material is manufactured by cutting and mixing the mixed cellulose raw material (a mixture of pulp materials), and adding boric acid and ammonium sulfate as flame retardants to prevent the generation of frictional heat when the mixture is crushed. The manufacturing equipment used, such as a grinding machine, a mixer, a compression press, a packing machine, etc., are commercially available products. Furthermore, boric acid and borax are commercially available products.

[0021] The blown-in cellulose fiber insulation material manufactured by the above process (first material: 50% recycled waste paper pulp, second material: 30% recycled cotton-like pulp, and 20% boric acid and borax) was confirmed to have thermal conductivity that meets the prescribed standard value in the tests described below.

[0022] The test method was based on the test conducted by the General Building Research Corporation of Japan (JIS A9523:2023 "Blow-in fibrous insulation material" 6.3 thermal conductivity). The measurement method was based on JIS A 1412-2:1999 "Method of measurement of thermal resistance and thermal conductivity of thermal insulation material - Part 2: Heat flow meter method (HFM method)." An overview of the test equipment is shown in Figure 3. The test specimen is shown in FIG. 1 (a perspective view of the test specimen) and FIG. 2 (a cross-sectional view thereof). The thermal conductivity λ and thermal resistivity R of the test specimen in the device in Figure 3 are calculated using the following formula. λ=q×d / ΔT, R=ΔT / q λ: thermal conductivity, R: thermal resistance, q: heat flow density, d: thickness of test specimen, ΔT: temperature difference of test specimen (Θ1-Θ2), Θ1: surface temperature of high temperature side of test specimen, Θ2: surface temperature of low temperature side of test specimen. The equipment type is: one test piece, symmetrical configuration; type of calibration standard plate: extruded polystyrene foam; test piece position: horizontal; heat flow direction: upward.

[0023] The manufactured insulation material is delivered to the site and installed by a blowing or spraying method. For example, the insulation material is unpacked, water is added and mixed, and the insulation material is blown onto the inner wall surface of a wall, for example. As a result, the high insulation effect makes it possible to realize a house that is cool in the summer and warm in the winter. This insulation material is also an ecological resource that is kind to both the earth and people. Furthermore, after construction, the insulation material walls are able to absorb moisture and maintain a comfortable indoor temperature. In addition, installation of this product can prevent condensation and mold. It increases the durability of houses and homes. It can suppress deterioration. It can prevent termites and other pests. It has high soundproofing properties, making the house quiet. It also has high fire resistance, making the house more resistant to fire.

[0024] One characteristic of cellulose fiber insulation is that its thermal conductivity (around 0.038 W / mk) is hardly affected by the density of the material. The main raw material for cellulose fiber insulation is cotton-like pulp derived from waste paper such as newspapers and disposable diapers. It is flame retardant with the addition of an appropriate amount of boron-based compounds. Cellulose fiber insulation has many air bubbles in its fibers, and in addition, the fibers are entangled to hold a layer of air, giving it excellent sound absorption properties. It provides soundproofing effects such as soundproofing for parting walls in apartment buildings and reducing noise from outside the house. Cellulose fiber insulation has moisture absorption and release properties unique to wood fiber. Cellulose fiber insulation absorbs and releases moisture in response to changes in temperature and humidity, preventing condensation inside the walls and improving the temperature and humidity environment inside the room. Insulation materials that mainly use recycled materials consume very little energy during production. This "cellulose fiber insulation material" will definitely contribute to the realization of a low-carbon society, from production, construction, occupancy, and demolition. By preventing insulation defects through reliable construction, it can greatly contribute to reducing heating and cooling energy during occupancy and extending the life of buildings.

[0025] In particular, when this blown-in cellulose fiber insulation is installed, the following effects are prominent: (Moisture absorption and release performance) The greatest feature of cellulose fiber is the moisture absorption and release properties of wood fiber, which gives it the ability to regulate humidity. (Condensation prevention performance) Cellulose fiber can be installed without gaps, and the cellulose is moisture permeable, absorbs and releases moisture, making it an insulating material that is resistant to condensation. Because cellulose fiber can be filled without gaps, it is expected to have an insulating effect as well as a condensation-preventing effect. (Mold and insect repellent) The cellulose fiber has boric acid added, which acts as an excellent wood preservative. (Sound absorption and sound insulation performance) Cellulose fiber contains air in each fiber, and this thick layer of air absorbs sound and makes it difficult for it to be transmitted. When it is densely packed without gaps, the house becomes sealed, and it exhibits high sound absorption and sound insulation performance. (Thermal insulation performance) Cellulose fiber is a natural wood fiber that contains a lot of air. Air is the greatest insulator, and this is what gives cellulose fiber its insulating properties. (Fire resistance) By adding boric acid and borax, the flames will not spread even if the material catches fire. (Energy saving and ecology) Cellulose fiber, a "recycled paper insulation material," does not require any energy to produce. It is an environmentally friendly, eco-friendly insulation material. (Workability) Using a special machine, cellulose fiber can be blown into an area covered with a breathable sheet, leaving no gaps. [Industrial Applicability]

[0026] This invention is extremely useful as a technology for blown-in cellulose fiber insulation for use in housing and the like.

Claims

[Claim 1] A blown-in cellulose fiber insulation material is manufactured by mixing a first pulp material obtained by crushing waste paper with a second cotton-like pulp material extracted from paper diapers, paper napkins, and incontinence absorbent pads in a predetermined ratio, primarily crushing the mixture, adding boric acid and borax, stirring the mixture, secondary crushing the mixture, and compression molding the mixture, A blown cellulose fiber insulation material comprising 50% by weight of said first pulp material, 30% by weight of said second pulp material, and 20% by weight of said boric acid and borax.

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