Natural fiber-based insulation material and process of manufacture thereof

Abstract

Disclosed herein is a natural fiber-based insulation material and its process of manufacture thereof. The natural fiber-based insulation material, according to the embodiments herein, comprises hand-graded and hand-woven Magra wool rolls, offering exceptional acoustic and thermal insulation properties. These rolls are lightweight, cost-effective, non-toxic, biodegradable, breathable, energy-efficient. The material also serves as an excellent alternative to conventional thermal and acoustic insulation products manufactured from synthetic materials including glass fiber, mineral wool, and plastics.

Description

Natural fiber-based insulation material and process of manufacture thereofCROSS REFERENCE TO RELATED APPLICATION

[0001] This application is based on and derives the benefit of Indian Provisional Application 202411020746 filed on 19thMarch 2024, the contents of which are incorporated herein by reference.TECHNICAL FIELD

[0002] Embodiments disclosed herein relate to an insulation material, and more particularly to an acoustic and thermal insulation material based on natural fibers and a process of manufacturing thereof.BACKGROUND

[0003] Energy consumption in the construction sector is recognized as a major contributor to the overall energy usage in many countries. The UN Environment program has reported that buildings account for approximately 40% of energy consumption, 25% of water usage, and contribute to about 50% of total greenhouse gas emissions, globally. Building sector is also accountable for one-third of CO2 productions, the primary greenhouse gas associated with climate change.

[0004] The existing cooling, heating, and air-conditioning systems in buildings significantly contribute to energy consumption, with the concomitant consumption of fossil fuels. It is estimated that heating and air conditioning contribute to almost two thirds of building energy consumption and CO2 emissions. Consequently, the imperative to reduce energy consumption in buildings is a major concern, posing challenges to the current policies worldwide.

[0005] The environmental impact associated with buildings arises not solely from the energy consumed during their use but also from the materials employed in their construction and their impact on human health. The use of high-performance acoustic and thermal insulation materials has emerged as a pivotal strategy for conserving energy by minimizing heat losses and gains during the heating and cooling of buildings. The escalating frequency of extreme temperature fluctuations underscores the necessity for effective building insulation to maintain optimal indoor temperatures. Additionally, the transition to indoor activities in the post-COVID era highlights the importance of appropriate spatial acoustics and thermal comfort in building design and construction.

[0006] A good insulation system is estimated to save up to 65% of energy consumption in domestic buildings. This offers substantial environmental benefits by mitigating the impact of carbon footprint from material usage and disposal, irrespective of the type of materials used. An ideal insulation material should offer superior acoustic insulation, minimize heat loss, and exhibit low environmental impacts and manufacturing costs. However, many prevalent thermal and acoustic insulation materials currently available in the market lack sustainability, frequently containing carcinogens that poses risk with prolonged human exposure. Balancing effectiveness with eco-friendliness in insulation choices is pivotal to ensuring the long-term sustainability of buildings and safeguarding human well-being.

[0007] Conventional insulation materials used in buildings are manufactured from synthetic materials including glass fiber, mineral wool, and plastics. Roughly 60% of these thermal insulation materials are derived from mineral or inorganic fibrous materials such as fiber glass and stone wool. Another 30% comprises foam materials including expanded polystyrene, extruded polystyrene, and polyurethane. The remaining 10% consists of other non-traditional or composite materials like wool-wood insulations and gypsum-foam. Although these materials are widely used, their non-renewable, non-disposable, and toxic / carcinogenic nature gives rise to diverse environmental concerns. For instance, materials based on glass fiber, sourced from silica, can pose carcinogenic risks to human health. Similarly, sound insulation materials, which typically involve porous synthetic materials like rock wool, glass wool, polyurethane, or polyester, are predominantly derived from petrochemicals and can have adverse effect to both human health and environment.

[0008] The detrimental impact of synthetic thermal and acoustic insulation materials has spurred a growing demand for eco-friendly, biodegradable, sustainable and high- performance alternatives. Despite the evident environmental, economic, and social benefits of natural insulation materials, their commercial utilization in construction insulation remains limited. Some challenges contributing against the advancement of natural fibers into the field of building insulation are poor water absorbing capacity, lower mechanical properties, poor fire resistance, and low resistance to termite effects. Concerns also persist about potential toxicity that may be imposed by the use of chemicals used in their manufacturing process.

[0009] Hence, there is a need for the development of a sustainable, energy-efficient, non-toxic, biodegradable, breathable, and eco-friendly insulation material from natural fibers that possess superior acoustic and thermal insulation properties, along with a less energy intensive manufacturing process.OBJECTS

[0010] The principal object of embodiments herein is to provide a process for the manufacture of a natural fiber-based insulation material.

[0011] Another object of embodiments herein is to provide a process which is highly energy efficient and sustainable.

[0012] Another object of embodiments herein is to provide an eco-friendly method for the manufacture of natural fiber-based insulation material.

[0013] Another object of embodiments herein is to provide a process for the manufacture of a natural fiber-based insulation material with high acoustic and thermal insulation properties.

[0014] Another object of embodiments herein is to provide a natural fiber-based insulation material.

[0015] Another object of embodiments herein is to provide a natural fiber-based insulation material from sheep wool.

[0016] Another object of embodiments herein is to provide a natural fiber-based insulation material that exhibits high acoustic and thermal insulation properties.

[0017] Another object of embodiments herein is to provide a natural fiber-based insulation material which is handwoven.

[0018] Another object of embodiments herein is to provide a natural fiber-based insulation material that can reduce carbon footprints.

[0019] Another object of embodiments herein is to provide a natural fiber-based insulation material that is non-toxic and non-carcinogenic.

[0020] Another object of embodiments herein is to provide a natural fiber-based insulation material which has minimal environmental impact.

[0021] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating at least one embodiment and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.DETAILED DESCRIPTION

[0022] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0023] For the purposes of interpreting this specification, the definitions (as defined herein) will apply and whenever appropriate the terms used in singular will also include the plural and vice versa. It is to be understood that the terminology used herein is for the purposes of describing particular embodiments only and is not intended to be limiting. The terms “comprising”, “having” and “including” are to be construed as open-ended terms unless otherwise noted.

[0024] The words / phrases "exemplary", “example”, “illustration”, “in an instance”, “and the like”, “and so on”, “etc.”, “etcetera”, “e.g.,”, “i.e.,” are merely used herein to mean "serving as an example, instance, or illustration. Any embodiment or implementation of the present subject matter described herein using the words / phrases "exemplary", “example”, “illustration”, “in an instance”, “and the like”, “and so on”, “etc.”, “etcetera”, “e.g.,” , “i.e.,” is not necessarily to be construed as preferred or advantageous over other embodiments. The terms “Magra wool insulation rolls”, “wool insulation rolls” are interchangeably used herein.

[0025] Embodiments herein disclose a natural fiber-based insulation material and a process for the manufacture of the same.

[0026] The process for the manufacture of the natural fiber-based insulation material, according to the embodiments herein, includes: collecting natural fibers; sorting the fibers to obtain homogenized fibers; skirting and scouring the homogenized fibers; carding the resultant fibers to obtain carded sliver; spinning the carded sliver into yarns; and handweaving the yarns to produce rolls.

[0027] In one embodiment, the natural fiber is wool. Examples of wool include, but are not limited to, sheep wool, camel wool, llama wool, alpacas’ wool, guanacos’ wool, vicunas’ wool, yak wool, and musk oxen wool. In one embodiment, the natural fiber is sheep wool.

[0028] In one embodiment, the insulation material is composed of 80 - 100% sheep wool. In one embodiment, the insulation material is composed of 100% sheep wool.

[0029] Sheep wool possess a range of advantageous properties including, breathability, non-combustibility, hygroscopicity, hypoallergenic qualities, and ability to purify and diminish Volatile Organic Compounds (VOCs) in the air. The structure of sheep wool fibers, with millions of tiny air pockets, allows for efficient moisture absorption and release, while maintaining optimal thermal performance. Sheep wool has high water and nitrogen content, and the self-ignition temperature of sheep wool is in the range of 560° - 600°C which is twice as high as wood (270°C), rendering it an exceptional flame-retardant material. Further, sheep wool does not produce toxic gases. The wool fibers also possess the unique ability to permanently bind with VOCs, contributing to air purification. Moreover, sheep wool is a long lasting, low-cost, light weight, and sustainable material which will compost down at the end of its life, further emphasizing its environmentally friendly profile. As a raw material, wool is abundant, continuously renewable, and can be locally produced.

[0030] Non-limiting examples of sheep wool include, Magra, Chokla, Marwari, Merino, Debouillet, Tesswater, Bond, Cormo, Rambouillet, etc. In one embodiment, the natural fiber is Magra wool. Magra wool represents sheep wool sourced from Magra sheep found primarily in the Thar Desert. It inherits exceptional qualities from its unique ecosystem, including resilience to harsh climates.

[0031] The process for the manufacture of the natural fiber-based insulation material, according to the embodiments herein, involves the collection of high-quality natural fibers. In one embodiment, the process involves the collection of Magra wool fibers.

[0032] In one embodiment, the collection of high-quality natural fibers involves shearing the sheep to obtain wool fleece. In one embodiment, the sheep is cleaned by washing before shearing. Washing helps to remove contaminants including grease, dust, wax, suint, dirt, any natural impurities, or residue chemicals from the wool. In one embodiment, the sheep is washed manually. In one embodiment, the sheep is washed using a pressure washer.

[0033] Methods for shearing sheep include, but are not limited to, hand shearing using blade shears, machine shears using handpieces, cutters, or clippers, and / or automated shearing using electrical machines. In one embodiment, sheep is hand sheared to collect the wool fleece.In one embodiment, sheep is machine sheared to collect the wool fleece. In one other embodiment, the machine shearing is solar powered. Factors considered while selecting wool to ensure good quality include, but are not limited to, fiber length, fineness, color consistency, and uniformity.

[0034] In one embodiment, the process involves sorting of the fibers fleece to obtain homogenized fibers. Sorting, as used herein, refers to the grading of wool into different categories based on their length, texture, color, and quality resulting in a homogeneous fiber ready for further processing. In one embodiment, the wool fibers are sorted based on the part of the body it comes from. The best quality fibers come from sides and shoulders of the sheep and the lower quality comes from the lower legs.

[0035] In one embodiment, the process involves cleaning of the sorted fibers. Cleaning of wool can be performed by any method generally known in the art including, but not limited to, scouring, skirting, carbonizing, mechanical cleaning, enzymatic cleaning or solvent degreasing. In one embodiment, the sorted wool is cleaned by skirting. Skirting, as used herein, refers to the removal of “tags” or dense bales of wool from the legs and belly regions of the sheep.

[0036] In one embodiment, cleaning involves scouring. Raw wool in its natural state contains a high level of lanolin or wool wax secreted by the sebaceous glands. Scouring, as used herein, refers to a process for cleaning and preparing the wool before further processing using traditional techniques, such as large vats or kiers, or modem machinery such as washing machines or continuous scouring lines. The process may involve cold, warm or hot water rinse, detergent wash, and / or alkali treatment to effectively remove grease, dirt, and other contaminants.

[0037] In one embodiment, the scouring involves hot water rinse. In one embodiment, scouring includes soaking the wool in hot water at a temperature in the range of 60 - 70°C. In one embodiment, the wool is soaked overnight. In one embodiment, the pre-treated wool is subjected to mechanical action such as agitation, squeezing or tumbling to dislodge and release dirt and contaminants from fibers. In one embodiment, the scoured wool is subjected to multiple rinse cycles to remove impurities, or dirt. In one embodiment, rinsing is done using clean water. In one embodiment, the wool after scouring is dried to ensure that required moisture level is maintained. In one embodiment, the moisture level of the wool is maintained in the range of 16 to 17%.

[0038] In one embodiment, the process involves carding the wool fibers to generate a loose voluminous web or sliver of fibres that can be further processed into yarn or other textile products. Carding, as used herein, is a mechanical process that detangles, aligns, and intermixes fibers to produce a continuous web suitable for subsequent processing. During this stage, the fibers are aligned in a parallel fashion, generating a loose and voluminous web fundamental for achieving the desired structure in subsequent phases.

[0039] Carding of wool can be achieved by different methods including hand carding, drum carding and / or cottage carding. In one embodiment, the wool is fed into the carding machine where they pass through a series of rollers or drums covered with fine wire teeth or carding cloth that straighten them into slivers. The carding machine may have multiple rollers that rotate at different speeds, called carding sections, to align further and blend the fibres. In one embodiment, the wool after carding is rolled into rovings for spinning.

[0040] In one embodiment, the process involves spinning the carded sliver into yarns. Spinning is a process of twisting fibres together to create a yam. A high twist produces a smooth, strong yarn with a fine texture, more suitable for worsted processing. A lower twist produces a thicker, loftier yam with a softer feel preferred for woolen processing. Spinning can be performed using spinning wheels, drop spindles or automated spinning machines. In one embodiment, the spinning involves hand spinning using spinning wheels or drop spindles. The resulting yarn can be used for knitting, weaving, felting or other textile crafts.

[0041] In one embodiment, the process involves handweaving the yarns to produce a loose insulation roll of exceptional density and interlock by skilled artisans. Weaving is the process of interlacing warp and weft yarns in a weaving machine, or loom. In one embodiment, traditional looms are employed for handweaving. Yarns running lengthwise in the loom are the “warp,” while yams running crosswise form the fdling or “weft ”. In one embodiment, the process involves interlacing warp and weft yarns in a weaving machine or loom to produce Magra wool insulation rolls. In one embodiment, weaving involves interlacing one set of cotton yam in warp with wool sliver in weft.

[0042] Handweaving is pivotal in achieving not only optimum insulation properties but also structural robustness. The interconnected fibers obtained from hand weaving intricately trap pockets of air, effectively regulating temperature and moisture.

[0043] The Magra wool insulation rolls, according to the embodiments herein, can be made into any form depending on its intended use. In one embodiment, the wool roll is formulated the form of sheets. In one embodiment, the Magra wool insulation roll is used inthe form of baffles that can be hung from the roof to cut extra noise of the room. In one embodiment, the Magra wool insulation roll is mounted along with honey-comb structure to create thermal and acoustic tiles. In one embodiment, the Magra wool insulation roll is used in the form of batts that can be applied behind the wall or on the ceiling.

[0044] The choice of handweaving imparts a unique artisanal touch, enhancing the product's aesthetic value and mitigating carbon footprint challenge. Weavers follow a slow determined process to incorporate the wool sliver as weft between the warp yarns slowly and meticulously without compromising the texture and individuality of the yams. Adhesive bonding is not applied for making the insulation roll because it will compromise on the density of the fiber and ultimately the performance of the product. The handwoven method not only maintains the wool’s natural properties but also offers a distinct tactile experience, setting it apart from mechanized alternatives.

[0045] The insulations rolls, according to the embodiments herein, cannot be made with the technical specifications on power looms, since they are only suitable for strong fibers that can withstand the mechanical stress of rapid weaving. The weaving process for Magra wool requires a slow, deliberate approach, as each wool sliver is delicate and must be carefully introduced as the weft between the warp yarns.

[0046] In one embodiment, the insulation rolls are subjected to parasite treatment to make it resistant to moth and termites. In one embodiment, parasite treatment is performed using a solution of boric acid and borax. In one embodiment, the insulation rolls are soaked in a solution of 8 - 12% boric acid and borax for 60 - 80 minutes and air dried. In one embodiment, the insulation rolls are soaked in a solution of 10% boric acid and borax for 75 minutes. In one embodiment, the soaked insulation rolls are air dried at 35 - 45 degrees for 2 - 3 days. In one embodiment, the soaked insulation rolls are air dried at 40°C for 2 days. In one embodiment, parasite treatment is performed after handweaving.

[0047] In one embodiment, the parasite treatment is performed using permethrin. Permethrin is an insecticide and repellent, effective for protecting wool from insect pests like moths and carpet beetles. In one embodiment, permethrin at 0.1% on wool weight is applied to the insulation rolls and soaked for 40 - 60 minutes, followed by boiling at 90 - 95°C. The treated material is rinsed with water and sun dried for 2 - 3 days.

[0048] In one embodiment, the handwoven Magra wool insulation rolls are meticulously packed for distribution and installation to ensure that the rolls remain in its pristine condition until it reaches it intended destination.

[0049] The process for the manufacture of the insulation material, according to the embodiments herein, exemplifies an energy -efficient and environmentally friendly approach, relying on renewable energy sources to curtail waste production and diminish carbon footprint. Embodiments herein integrate solar power into every facet of technology and infrastructure employed for shearing, processing, and weaving of sheep wool. This holistic utilization of solar energy ensures a sustainable and energy-efficient workflow, reducing the overall energy consumption.

[0050] The natural fiber-based insulation material, according to the embodiments herein, can be made in the form of rolls, batts, sheets, linings, or panels. In one embodiment, the insulation material is in the form of rolls. Accordingly, the natural fiber-based insulation material comprises hand-graded and hand-woven Magra wool insulation rolls.

[0051] In one embodiment, the dimensions of the insulation rolls are in the range of 6' x 2' to 10' x 6' (length x width). In one embodiment, the rolls have the size of 8' x 4'. The number of threads per wool roll is in the range of 180 - 200. In one embodiment, the wool roll has 190 threads / roll (Table 1).

[0052] The natural fiber-based insulation material, according to the embodiments herein, exhibits thermal and acoustic insulation properties.

[0053] Thermal insulation, as used herein, refers to a material or a combination of materials which retard the rate of heat flow or heat transfer between solid objects, fluids, or gases by conduction, convection, and radiation by introducing a barrier between them. Thermal insulation plays a crucial role across industries, including but not limited to, construction, automotive, aerospace, agriculture, food and beverage, and energy sectors. In buildings, thermal insulation retards the heat flow into or out of a building due to its high thermal resistance and enhances energy efficiency, diminishes environmental impact, and elevates comfort.Table 1: Specifications of Magra wool insulation rolls, according to embodiments disclosed herein.

[0054] In one embodiment, the thermal insulation property of the insulation material is quantified in terms of thermal conductivity. Thermal conductivity refers to the amount of heat (in watts) transferred through one square meter of an insulating material of a given thickness with a temperature difference of one degree (kelvin or Celsius) across it. Thermal conductivity is inversely proportional to thermal insulation. The lower the thermal conductivity of the material the greater the material’s ability to resist heat transfer, and thus the higher its thermal resistance. In one embodiment, the thermal conductivity of the insulating material is 0.19 mW / cm°C at a density of 126 Kg / m3.

[0055] The insulation material, according to the embodiments herein, also exhibits acoustic insulation. Acoustic insulation, as used herein, refers to methods and materials used to reduce the noise transmission from one area to another and improve the sound quality in indoor environments. Acoustic insulation creates quieter spaces, dampens echoes and vibrations, and enhances the privacy and comfort in homes and workspaces by absorbing, reflecting or blocking sound waves. The high density, irregular shape and soft fibrous quality of sheep wool provide excellent sound proofing comparable to conventional synthetic insulation materials.

[0056] In one embodiment, the sound absorption performance of the insulation material is quantified in terms of sound transmission loss (STL). STL refers to a quantification of how much sound energy is prevented from travelling through an acoustic barrier. STL is a function of frequency, and it varies greatly with frequency for the same material. It is defined as the logarithmic ratio between the total incident power (Wi) on the structure relative to the total transmitted power (Wt).

[0057] In one embodiment, the sound absorption performance of the insulation material is quantified in terms of noise reduction coefficient (NRC). NRC refers to the average sound absorption performance of a material and ranges between 0.0 to 1.0. In one embodiment, the noise reduction coefficient of the insulation material lies in the range of 0.68 to 0.82 at sounds in the frequency range of 250 - 2000 Hz. In one embodiment, the insulation material exhibitsa noise reduction coefficient of 0.82 at a sound frequency of 2000 Hz with a sound transmission loss of 15 dB.

[0058] The insulation material, according to the embodiments herein, exhibits a moisture content in the range of 0.75 - 0.95%. In one embodiment, the moisture content is 0.84%, indicating that the material remains relatively dry. This enhances stability, minimizes the risk of microbial growth, and helps maintain the material’s insulation efficiency over time.

[0059] The insulation material, according to the embodiments herein, exhibits a moisture absorption in the range of 1.00 - 1.20%. In one embodiment, the moisture absorption is 1.10% indicating good resistance to humidity. The insulation material, according to the embodiment herein, have lesser risk of mold formation since it can absorb water in high humidity circumstances and release it in low humidity situations.

[0060] The insulation material, according to the embodiments herein, exhibits a Sulphur content of 0.18 - 0.24%. In one embodiment, the Sulphur content is 0.22%. Excess sulfur can contribute to material degradation, particularly in humid environments, by reacting with moisture to form acidic compounds. However, the low sulfur content of 0.22% minimizes this risk, ensuring greater durability. The reduced sulfur content also enhances the material’s eco-friendliness and makes it safer for use in sustainable, non-toxic insulation applications.

[0061] The insulation material, according to the embodiments herein, is heat and corrosion resistant, microbial resistant, odorless, and non-flammable. Even in events of fire, the insulation material would not release any toxic gases. In one embodiment, the insulation material exhibits a compression recovery in the range of 86 - 94% after compression loading. In one embodiment, the compression recovery is 92%.

[0062] The insulation material, according to the embodiments herein, is breathable and can naturally absorb and release moisture. While the exterior layer of wool is hydrophobic and water resistant, its cortex or inner layer is hydrophilic. The cortex can absorb water without the wool feeling damp. This helps to protect the surrounding timbers from moisture and prevent mold. The natural ability of wool to absorb moisture in humid conditions and give it off when dry, can help maintain stable temperatures within a building. In one embodiment, the insulation material is capable of absorbing micropollutants.

[0063] The insulation material, according to the embodiments herein, is safe and easy to install. Unlike many man-made insulations, Magra sheep wool insulation rolls would not cause irritation to the skin, eyes, or lungs. Whereas a face mask, goggles and gloves are requiredwhen handling glass wool or rock wool insulation, sheep wool insulation does not require any such precautions.

[0064] The insulation material, according to the embodiments herein, is easy to cut and shape for an exact fix. The insulation material also reduces carbon footprint providing an environmentally friendly alternative to traditional insulation materials. The use of natural fibers and solar-powered, hand-processed techniques minimize waste generation and reduces the overall environmental impact of the insulation production process.

[0065] The insulation material, according to the embodiments herein, is self-sustaining. Due to the inherent qualities of sheep wool, the Magra wool insulation roll requires only minimal maintenance, ensuring prolonged and enduring performance over time. The insulation material, according to the embodiments herein, is long lasting.

[0066] The natural fiber-based insulation material, disclosed herein, serves as an excellent alternative to conventional thermal and acoustic insulation products manufactured from synthetic materials including glass fiber, mineral wool, and plastics. The insulation material is suitable for providing both heat and sound insulation in diverse building components, including but not limited to attics, roofs, walls, floors, ceilings, as well as for insulating pipes, ducting, and water tanks. The insulation material, can be employed in thermal and acoustic insulation applications in various sectors, including but not limited to, sonic labs, audio studios, green architecture, construction, automotive, aerospace, agriculture, food and beverage, and energy sectors.

[0067] The insulation material, according to the embodiments herein, adds aesthetic value to buildings, in addition to their thermal and acoustic properties. In one embodiment, the insulation material is used in the form of sheets. In one embodiment, the insulation material is used in the form of baffles that can be hung from the roof. In one embodiment, the insulation material can be mounted as honey-comb structure to create thermal and acoustic tiles. In one embodiment, the insulation material is used in the form of batts that can be applied behind the wall or on the ceiling.

[0068] The insulation material, according to the embodiments herein, harnesses the indigenous, regenerative and environmentally friendly fibres, introducing a line of sustainable thermal and acoustic solutions for the construction industry. This innovative approach not only addresses the ecological concerns associated with conventional materials but also empowers local communities, promoting a holistic, localized, and environmentally sound approach to climate resilience in the built environment.

[0069] The invention is further described by reference to the following examples by way of illustration only and should not be construed to limit the scope of the embodiments disclosed herein. It will be apparent to those skilled in the art that many modifications, both to materials and methods, may be practiced without departing from the scope of the claimed embodiments.Experimental study

[0070] Experiments were conducted to characterize the Magra insulation wool for their thermal and insulation properties rolls as disclosed in various embodiments herein. Experiment 1: Determination of thermal conductivity of Magra wool insulation rolls.

[0071] The insulation rolls have been tested using Indian standard methods for determination of thermal conductivity of insulation materials viz. IS 3144: 1990, IS: 8183: 1993, and IS 3346: 1980 at temperature of 25±2°C and humidity of 65+5%. The insulation rolls have been characterized to determine their material composition, density, moisture content, moisture absorption, flammability, thermal conductivity, Sulphur content, heat resistance, corrosive nature, microbial resistance, and odor.

[0072] Table 2 lists the test parameters of the insulation rolls along with the test methods, and the standard requirements as per IS 8183 : 1993, according to embodiments disclosed herein.Table 2: Results of Indian standard tests of the insulation roll along with the test methods, and the standard requirements as per IS 8183 : 1993, according to embodiments disclosed herein.

[0073] The results indicate that the Magra wool insulation rolls satisfy the requirements as per IS 8183 : 1993.

[0074] Thermal conductivity, indicates how easily heat flows through a material, with lower values signifying better insulation. The thermal conductivity values of the Magra wool insulation rolls is 0.19 mW / cm C, indicating the excellent thermal insulation of the material.

[0075] The thermal conductivity values of commonly used natural and synthetic insulation materials are presented in Table 3.

[0076] Magra wool insulation rolls exhibit superior thermal insulation compared to all natural insulation materials. While phenol formaldehyde, polyisocyanurate, inorganic innovative aerogel and vacuum insulation panels provide slightly better thermal insulation, Magra wool insulation offers significant advantages in terms of sustainability, safety, and durability. As a natural, biodegradable, and renewable material, it has a lower environmental impact than synthetic alternatives, which release harmful VOCs during production and disposal. Unlike synthetic materials that degrade in humid conditions or emit toxic fumes, Magra wool effectively regulates moisture and retains its insulation properties over time. Additionally, it is easy to install without specialized handling, unlike fragile VIPs or rigid synthetic insulations that require precise installation. With its eco-friendliness, breathability, long-term stability, and ease of use, Magra wool presents a more practical and sustainable insulation solution.

[0077] Table 3 : Thermal conductivity values of commonly used insulation materials.Experiment 2: Evaluation of sound transmission loss (STL) and noise reduction coefficient (NRC) of Magra wool insulation rolls.

[0078] The sound transmission loss (STL) and noise reduction coefficient (NRC) of the wool insulation rolls have been estimated using standardized testing procedure viz. ASTM C423 with centre frequencies ranging from 250 Hz to 2000 Hz. Table 4 lists the sound transmission loss (STL) and noise reduction coefficient (NRC) of the insulation rolls, according to embodiments disclosed herein.

[0079] Table 4: Sound transmission loss (STL) and noise reduction coefficient s(NRC) of the Magra wool insulation rolls, according to embodiments disclosed herein.

[0080] The results indicate that Magra wool insulation rolls exhibit excellent acoustic insulation properties, particularly in the mid-to-high-frequency range (500 Hz to 2000 Hz). The material demonstrates strong sound absorption, with an increasing dB drop and noise reduction coefficient (NRC) at higher frequencies, making it highly effective for minimizing speech noise, office noise, and high-pitched sounds. Given its superior acoustic performance, Magra wool insulation is well-suited for environments requiring effective noise control, such as offices, auditoriums, homes, and recording studios.

[0081] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and / or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments and examples, those skilled in the art will recognize that the embodiments and examples disclosed herein can be practised with modification within the scope of the embodiments as described herein.

Claims

CLAIMSWe claim:

1. A process for manufacturing a natural fiber-based insulation material, the process comprising: collecting natural fibers; sorting the fibres to obtain homogenized fibers; skirting and scouring the homogenized fibers; carding the resultant fibres to obtain carded sliver; spinning the carded sliver into yarns; and handweaving the yarns into rolls, wherein the natural fiber is Magra sheep wool.

2. The process as claimed in Claim 1, wherein collecting natural fibres comprises hand shearing or machine shearing of sheep.

3. The process as claimed in Claim 2, wherein machine shearing is solar powered.

4. The process as claimed in Claims 1, wherein sorting comprises grading of the fibers based on their length, texture, color, source location, and quality.

5. The process as claimed in claim 1, wherein skirting comprises removing dense bales of wool from the legs and belly regions of the sheep.

6. The process as claimed Claim 1, wherein scouring comprises soaking the homogenized fibers in hot water at a temperature in the range of 60 - 70°C with mechanical agitation overnight, and drying at room temperature to maintain a moisture level in the range of 16 to 17%.

7. The process as claimed in Claim 1, wherein carding comprises hand carding, drum carding and / or cottage carding.

8. The process as claimed in Claim 1, wherein spinning comprises hand spinning using a spinning wheel or drop spindle.

9. The process as claimed in Claim 1, wherein handweaving comprises interlacing one set of cotton yam in warp yarn with wool sliver in weft yarn in a weaving machine or loom.

10. The process as claimed in Claim 1, further comprises parasite treatment of the insulation rolls.

11. The process as claimed in Claim 10, wherein parasite treatment comprises soaking the insulation rolls in a solution of 8 - 12% boric acid and borax for 60 - 80 minutes and air drying at 35 - 45 degrees for 2 - 3 days.

12. A natural fiber-based insulation material obtained from the process as claimed in claim 1, comprising 80 - 100% sheep wool.

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