Clean-Burning Firelog via Two-Stage Wax Mixing
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Solution Overview
Problem
Conventional firelogs made with non-petroleum waxes are not environmentally friendly due to the need for blending with unsaturated waxes for binding properties, leading to incomplete combustion and safety issues when used in stoves, as they lack the integrity to withstand intense heat.
Innovation Solution
A method involving a two-stage mixing process where the fibre and wax components are initially mixed above the wax's drop point, then cooled and mixed with an aqueous binder, allowing for the use of 100% saturated non-petroleum waxes, which are too brittle to act as binders alone, resulting in a firelog that can be extruded and burns cleanly without the need for unsaturated waxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If 100% saturated non-petroleum waxes are used, then clean burning is achieved, but the wax is too brittle to act as a binder for fibre extrusion
Solution Approach 1:
The invention combines saturated non-petroleum wax with a small proportion of unsaturated wax or petroleum wax to create a composite binder system. This composite material provides both the clean burning properties of saturated wax and the binding necessary for fibre extrusion and firelog formation.
Solution Approach 2:
The invention modifies the chemical composition parameters of the wax blend by controlling the proportions of saturated versus unsaturated components. By adjusting these parameters, the wax achieves optimal balance between saturation (for clean burning) and unsaturation (for binding and plasticity).
2Ease of manufacture
If unsaturated waxes are blended with saturated waxes for binding properties, then firelog formation is enabled, but clean burning is compromised due to incomplete combustion
Solution Approach 1:
The invention optimizes the compositional parameters by limiting unsaturated wax to minimal proportions (1-20% by weight) while maintaining saturated wax as the dominant component (80-99% by weight). This parameter control ensures sufficient binding for firelog formation while preserving clean combustion characteristics.
Solution Approach 2:
The invention creates a composite wax system where saturated wax provides clean burning and unsaturated wax provides binding and plasticity. The composite structure allows both functions to coexist, with the saturated component dominating to maintain clean combustion while the unsaturated component enables manufacturability.
3Productivity
If conventional firelogs are used in stove environments, then fuel consumption is reduced, but safety issues arise due to lack of structural integrity under intense heat
Solution Approach 1:
The invention uses a composite binder system combining saturated and unsaturated waxes in specific proportions. This composite provides the structural integrity needed to withstand stove heat while maintaining the fuel efficiency benefits of long-burning firelog formulation.
Solution Approach 2:
The invention adjusts the wax composition parameters, particularly the ratio of saturated to unsaturated components, to achieve optimal thermal stability. The controlled parameter range ensures the firelog maintains structural integrity under intense heat while continuing to burn efficiently.
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 method enables the production of firelogs that burn more cleanly, meeting stringent smoke emission standards and maintaining structural integrity in stove environments, thus addressing environmental concerns and safety issues.
Implementation Method 1
mixing the fibre component and the wax component together at a temperature above the drop point of the wax component
Implementation Method 2
simultaneously stirring and cooling the mixture of the fibre component and the wax component from step (a) to below the congealing temperature of the wax component
Data Source
Figure 1~2
AI summary
The present invention relates to a method of making a firelog, as well as to a firelog itself, and methods of using the firelog. The method of the present invention allows firelogs to be made that burn very cleanly. This is advantageous for the environment. Furthermore, the firelogs of the present invention can be burnt in a conventional fireplace, or in a stove. This is in contrast to the presently available firelogs which cannot be burnt in a stove.