Flame-Retardant Insulation Mat Forming with Microwave-Heated Paper Pulp
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Solution Overview
Problem
The existing methods for manufacturing flame-retardant heat insulating formed products, such as mats, are costly due to the requirement of sewing, melting, or adhesive-based joining processes and the use of expensive materials, which hinders economic efficiency and environmental sustainability.
Innovation Solution
A method involving the defibration of paper pulp, mixing with boric acid or boron as a flame retardant, and short fibers with a low melting point, followed by microwave heating within a forming die made of corrugated cardboard to form a mat-shaped product, simplifying the manufacturing process and reducing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods using sewing, melting, or adhesive-based joining processes are used to manufacture heat insulating formed products, then the structural integrity and durability of the product are improved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent replaces mechanical joining systems (sewing, melting, adhesive application) with a chemical bonding system where a binder uniformly coats and binds insulating particles throughout the product. This substitution eliminates complex mechanical equipment and multi-step processes while achieving reliable structural integrity through chemical adhesion.
Solution Approach 2:
The patent changes the bonding mechanism from mechanical (sewing needles, heat fusion, adhesive layers) to chemical (binder molecules forming bonds between particles). This parameter change in the bonding approach simplifies the manufacturing process by eliminating the need for specialized joining equipment and multiple operational steps.
2Manufacturing precision
If expensive materials and complex forming dies are used to manufacture heat insulating formed products, then the product quality and performance are improved, but the economic efficiency deteriorates
Solution Approach 1:
The patent employs a disposable forming die made from inexpensive materials that is used once and then discarded. This eliminates the need for expensive, durable forming dies that require maintenance and replacement. The low cost of the single-use die is offset by the elimination of complex joining operations and expensive materials, improving overall economic efficiency while maintaining product quality.
Solution Approach 2:
The forming die creates a precise copy or impression of the desired product shape in the insulating material. This copying mechanism ensures consistent product quality and dimensions without requiring expensive, precision-engineered permanent molds. The simple die structure can be easily manufactured and replaced if needed.
3Ease of operation
If traditional heat insulating materials like glass wool are used, then the material is inexpensive and has good workability, but hygiene problems and environmental issues arise due to difficulty in recycling
Solution Approach 1:
The patent creates a composite material system combining insulating particles (which can be recycled organic or inorganic materials) with a binder substance. This composite structure maintains the workability and low cost of traditional materials while enabling the use of environmentally friendly, recyclable components. The binder holds together recycled particles, preserving the material's functional properties.
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
This approach significantly lowers production costs and enhances environmental sustainability by utilizing readily available paper materials and reducing the need for expensive forming dies, while maintaining sound insulation and flame-retardant properties.
Implementation Method 1
the step of heating the flame-retardant heat insulating loose material together with the forming die with a microwave heating apparatus to form
Implementation Method 2
charging short fibers with a low melting point into the flame-retardant heat insulating defibrated cotton
Data Source
Figure 1(a)~1(h)
Figure 2~3
AI summary
To provide a method of manufacturing a flame-retardant heat insulating formed product in the shape of a mat and the like which has a sound insulation effect, is excellent in environmental characteristics and is excellent in economic efficiency with the manufacturing steps simplified, the method of manufacturing a flame-retardant heat insulating formed product includes the step of pouring water in used paper or a pulp material to defibrate and obtain defibrated cotton, the step of charging a flame retardant such as a boric acid into the defibrated cotton, and by stirring and heating, obtaining flame-retardant heat insulating defibrated cotton, the step of charging short fibers with a low melting point made of polyester or the like into the flame-retardant heat insulating defibrated cotton, and by mixing and stirring, obtaining a flame-retardant heat insulating loose material, the step of filling a forming die made of corrugated cardboard provided with a lid having air vents with the flame-retardant heat insulating loose material, the step of heating the flame-retardant heat insulating loose material together with the forming die with a microwave heating apparatus to form, and the step of removing a mat-shaped formed product from the forming die.