Cellulose-Based Industrial Absorbent with Fire Retardancy
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Solution Overview
Problem
Current industrial absorbents lack improved absorbency, are costly due to petroleum-based materials, and pose fire risks, while also relying on non-renewable resources.
Innovation Solution
Development of industrial absorbents made primarily from cellulose, treated with fire retardants and processed to increase bulk-to-weight ratio, using scrap cellulose and thermally bonded with bicomponent fibers and thermoplastic scrims for enhanced absorbency and fire retardancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polypropylene is used as the primary material for industrial absorbents, then fire retardancy is improved, but cost increases and dependency on non-renewable resources increases
Solution Approach 1:
The patent uses a composite structure combining cellulose fibers (from renewable sources) with polypropylene binder fibers. This composite approach allows the absorbent to achieve fire retardancy through the polypropylene component while using cost-effective and renewable cellulose as the primary absorbent material, thereby reducing dependency on expensive non-renewable resources.
Solution Approach 2:
The patent modifies the cellulose material parameters by treating it with fire retardant chemicals and processing it to achieve specific bulk-to-weight ratios (10-30). These parameter changes enable cellulose-based absorbents to meet fire safety requirements traditionally associated with synthetic materials, while maintaining lower costs and renewable sourcing.
2Ease of manufacture
If cellulose is used as the primary material for industrial absorbents, then cost decreases and renewable resource dependency is reduced, but fire risk increases
Solution Approach 1:
The patent introduces fire retardant chemicals as intermediary substances that are applied to the cellulose fibers during processing. These intermediaries modify the fire characteristics of the cellulose, reducing its flammability while preserving the cost and renewable benefits of using cellulose as the primary material.
Solution Approach 2:
By creating a composite structure where cellulose fibers are bound together with polypropylene binder fibers, the patent achieves fire retardancy through the synthetic component while maintaining the economic and environmental advantages of using renewable cellulose as the bulk absorbent material.
3Quantity of substance
If bulk-to-weight ratio is increased to improve absorbency, then absorbency increases, but material density decreases
Solution Approach 1:
The patent deliberately changes the physical parameters of the cellulose material by controlling its bulk-to-weight ratio to fall within the range of 10-30. This parameter optimization increases the absorbency capacity (1-2.5 times its own weight) while managing the bulk density to achieve the desired balance between absorbency and compactness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The cellulose-based absorbents exhibit increased absorbency, reduced costs, and improved fire safety, utilizing recycled materials and reducing dependence on non-renewable resources, while maintaining or exceeding the performance of existing products.
Implementation Method 1
The non-woven web is then heated in an oven to cause an outer layer of the bicomponent fiber to melt. The molten material contacts other fiber and when re-hardened or cooled creates bonds between at least some of the bicomponent fiber and the cellulose.
Implementation Method 2
The heating process also causes at least a portion of the first and second scrims to bond with the non-woven web.
Implementation Method 3
the cellulose used in certain embodiments of the invention is treated with a fire retardant to ensure that the end product has a fire retardancy that is equivalent to or better than current industrial absorbents
Data Source
AI summary
An industrial absorbent and methods of manufacturing the same. In one embodiment, the industrial absorbent includes a first scrim made from at least one thermoplastic material; a second scrim made from at least one thermoplastic material; and a middle layer positioned between the first and second scrims. The middle layer includes a dry-laid web of fire-retardant treated cellulose and opened, individuated staple bicomponent fiber. At least some of the bicomponent fiber in the middle layer is thermally bonded to at least some of the cellulose in the middle layer, and the first and second scrims are thermally bonded to the middle layer.