Hemp Shive Composite Fleece for Thermal Insulation
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Solution Overview
Problem
Existing methods for processing hemp fibers do not effectively utilize hemp shives, leading to material losses and inefficiencies, and lack properties for energy efficiency, sound insulation, and sustainable construction applications.
Innovation Solution
A multi-stage impact digestion method separates hemp shives from fibers, mixing them with binder fibers to form a fiber flake mixture, which is then processed into a thermally bonded fleece with controlled fiber arrangement, utilizing hemp shives for improved air conditioning and insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hemp shives are separated and discarded as waste material in conventional processing, then fiber production is simplified, but material utilization efficiency deteriorates
Solution Approach 1:
The invention recovers hemp shives that were previously discarded as waste material. The shives are collected during the impact digestion process and reintegrated into the fiber production process by mixing them with hemp fibers and binder fibers to form a composite fleece, thereby converting waste into a useful material component.
Solution Approach 2:
The invention creates a composite material by combining hemp shives with hemp fibers and binder fibers. This composite approach allows the utilization of previously wasted shives while maintaining the functional properties of the original fibers, achieving both material efficiency and product performance.
2Stability of the object's composition
If hemp shives are mixed early in the processing sequence, then material homogeneity is improved, but segregation and material losses during transport and processing increase
Solution Approach 1:
The hemp shives are prepared and positioned on the fiber flake template in advance, but the actual mixing occurs only at the optimal moment during fleece formation. This preliminary positioning without premature mixing prevents segregation and material losses during transport while still achieving homogeneous distribution in the final product.
Solution Approach 2:
The mixing of hemp shives with fibers occurs continuously during the fleece formation process rather than as a separate batch operation. This continuous mixing action ensures homogeneous distribution while minimizing material handling steps that could cause segregation and loss.
3Productivity
If conventional fiber processing methods are used, then production speed is maintained, but thermal insulation and sound absorption properties deteriorate
Solution Approach 1:
The invention incorporates hemp shives into the fiber composite to enhance thermal insulation and sound absorption properties. The composite structure formed by combining different fiber types and shives provides superior insulation performance while maintaining production efficiency through integration with existing fleece formation equipment.
Solution Approach 2:
The hemp shives are distributed throughout the fleece structure to provide localized insulation properties. The varying distribution and arrangement of shives within the composite material create regions with enhanced thermal and acoustic insulation characteristics throughout the entire product.
4Device complexity
If only hemp fibers are utilized, then processing complexity is reduced, but overall material efficiency deteriorates
Solution Approach 1:
The invention makes the hemp processing system multi-functional by simultaneously producing both traditional hemp fibers and utilizing previously wasted shives. The same processing equipment and fleece formation system handle both fiber types, making the system versatile and maximizing material utilization without significantly increasing complexity.
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 achieves high material efficiency, utilizing up to 95% of the hemp plant, producing a fiber composite material with enhanced thermal insulation, sound absorption, and eco-friendly properties suitable for construction and other applications.
Implementation Method 1
a multi-stage impact digestion method
Implementation Method 2
The hemp is subsequently subjected to at least one impact digestion step, at least one opening step, and at least one mixing step
Implementation Method 3
The mixed fiber/hemp shive mixture fleece is subsequently thermally bonded in a temperature treatment unit to form a mixed fiber/hemp shive mixture fleece
Data Source
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AI summary
The present invention comprises a method for producing a textile material using hemp, wherein hemp shives are separated from hemp fibers from harvested hemp in a multi-stage impact pulping process, and a fiber composite material formed from the textile material. In a first method variant, the hemp fibers are dissolved into hemp fiber flakes; binding fibers are dissolved into binding fiber flakes; the hemp fiber flakes and the binding fiber flakes are mixed with at least one mixing device to form a fiber flake mixture; the fiber flake mixture is deposited with a feeding device as a mat-like mixed fiber flake substrate; hemp shives are embedded and/or applied to the fiber flake mixture and/or to the surface of the mixed fiber flake substrate before the mixed fiber flake substrate is fed into a random web spinning machine, forming a mixed fiber flake-hemp shive substrate.The mixed fiber flakes and hemp shives feedstock is broken up and mixed by an opening unit, thereby processing it into a mixed fiber and hemp shives mixture; this mixture is conveyed into a nonwoven formation zone of the random web forming machine and deposited there as a mixed fiber and hemp shives mixture nonwoven; and the mixed fiber and hemp shives mixture nonwoven is subsequently thermally bonded in a heat treatment unit to form a mixed fiber and hemp shives mixture nonwoven fabric. In a second process variant, a bonding fiber and hemp shives mixture nonwoven fabric is produced in a similar manner. Both the mixed fiber and hemp shives mixture nonwoven fabric and the bonding fiber and hemp shives mixture nonwoven fabric are very well suited as fiber composite materials.