Thermo-Acoustic Panels Using Tannery-Waste Collagen Xerogel
Solution Overview
Problem
Existing thermal and sound insulation materials, such as polymers, fiberglass, and mineral fibers, face issues with environmental impact, flammability, high production costs, hygroscopic properties, and poor thermal conductivity under humid conditions, while sand-based panels lack thermal insulation and are easily damaged.
Innovation Solution
A macroporous xerogel composite comprising collagen fibers from tannery waste, pelt trimming, and mineral fillers like silica sand or kaolin, which is processed to create a thermo-acoustic insulation material with low thermal conductivity and high sound absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymer materials are used for heat and sound insulation, then insulation performance is improved, but environmental harm and flammability increase
Solution Approach 1:
The invention changes the chemical composition parameters by replacing polymer materials with a composite system consisting of inorganic binder (calcium sulfate hemihydrate), collagen fibers from tannery waste, and mineral fillers. This parameter change transforms the material from organic polymer-based to inorganic composite-based, eliminating flammability and environmental persistence issues while maintaining insulation performance through optimized phase proportions and microstructure control.
Solution Approach 2:
The invention creates a composite material system combining multiple components: calcium sulfate hemihydrate binder, collagen fibers for structural framework, mineral fillers (silica sand, perlite, kaolin) for insulation, and hydrophobic additives. This composite structure integrates the advantages of each component - the binder provides fire resistance, collagen provides tensile strength and porosity, mineral fillers provide thermal insulation, and hydrophobic agents provide moisture resistance, achieving overall performance superior to single-material solutions.
2Object-affected harmful factors
If mineral fiber materials are used for insulation, then fire resistance is improved, but hygroscopic properties worsen thermal conductivity
Solution Approach 1:
The invention introduces hydrophobic additives as intermediary substances that coat the collagen fibers and mineral fillers, creating a water-repellent barrier. This intermediary layer prevents moisture from penetrating into the porous structure of the insulation material, thereby maintaining low thermal conductivity even in humid conditions while preserving the fire-resistant inorganic binder matrix.
Solution Approach 2:
The invention applies local quality modification by treating specific regions of the material (the fiber surfaces and pore walls) with hydrophobic coatings, while the bulk material maintains its porous insulating structure. This localized treatment ensures moisture resistance at critical interfaces without compromising the overall thermal insulation performance or requiring complete material densification.
3Object-affected harmful factors
If sand-based panels are used for sound insulation, then sound absorption is improved, but mechanical strength and thermal insulation worsen
Solution Approach 1:
The invention achieves multi-functionality by designing a composite material where mineral fillers (silica sand, perlite, kaolin) simultaneously provide three functions: (1) sound absorption through porous structure and material damping, (2) thermal insulation through low thermal conductivity of mineral particles and air pockets, and (3) structural skeleton formation for mechanical strength. The collagen fiber network binds these mineral particles together, creating a unified structure where all components contribute to multiple performance aspects rather than single-function specialization.
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 material provides effective thermal and sound insulation, mechanical strength, and fire safety, while being environmentally friendly and cost-effective, with a thermal conductivity of 0.034-0.045 W/mK and tensile strength of 100-500 kPa.
Implementation Method 1
a) providing a liquid dispersion comprising a collagen containing solid tannery waste, a mineral filler and a cross-linking agent
Implementation Method 2
c) molding the liquid dispersion of (a) by freezing at a temperature at or below -10 °C to provide a hydrated molded product
Implementation Method 3
d) defrosting the molded hydrated product of (c)
Implementation Method 4
e) removing the liquid from the molded hydrated product and drying to provide a thermo-acoustic insulation material
Implementation Method 5
providing a liquid dispersion comprising a collagen containing solid tannery waste, a mineral filler and a cross-linking agent
Data Source
Figure 1~2
AI summary
The present invention relates to a thermo-sound insulation material comprising a) at least 25 wt% of collagen fibers obtained from collagen containing solid tannery waste; b) at least 1wt% pelt trimming; and c) at least 30 wt% mineral filler.