Repulpable Paper Fiber Insulation Batt for Recyclable Shipping Boxes

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Solution Overview

Problem

Insulated boxes are typically made of disparate materials, making recycling impossible due to the combination of materials used for insulation and the box structure.

Innovation Solution

A method of forming a shipping container by mixing paper fibers with a recycling-compatible fiber, applying heat and pressure to create a paper fiber batt, which is then trimmed and positioned within a corrugated box, achieving a repulpability of greater than 85%. This involves using a mixture of paper reinforcement fibers with meltable PE/PP bi-component thermoplastic binder fibers distributed randomly to form a batt.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional insulated boxes are made with disparate materials for insulation and box structure, then insulation performance and structural integrity are achieved, but recyclability becomes impossible

Engineering Contradiction:

Improveinsulation performanceVSAvoidrecyclability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the insulation material and box structure into a single integrated component made from repulpable paper fiber batt. This eliminates the need for separate insulation and structural materials, allowing the entire assembly to be recycled together without separation requirements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses homogeneous repulpable paper fiber material for both the insulation batt and the box structure. This homogeneity ensures that all components have the same recycling properties, enabling single-stream recycling without requiring separation of different material types.

Inventive Principle:

Principle #33Homogeneity

2Strength

If paper fiber batt is mixed with meltable PE/PP bi-component thermoplastic binder fiber, then binding strength and structural integrity are improved, but material complexity increases

Engineering Contradiction:

Improvebinding strengthVSAvoidmaterial composition

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent uses meltable PE/PP bi-component thermoplastic binder fiber that undergoes parameter changes (melting and solidifying) during the forming process. The binder fiber melts when mixed with paper fibers, binds them together, and then solidifies to provide structural integrity, achieving binding strength through controlled material state changes rather than complex formulations.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining paper reinforcement fibers with meltable PE/PP bi-component thermoplastic binder fibers. This composite approach leverages the complementary properties of each material: the structural integrity of paper fibers and the binding capability of the thermoplastic binder, achieving enhanced overall material performance.

Inventive Principle:

Principle #40Composite materials

3Manufacturing precision

If heat and pressure are applied to the fiber mixture, then the paper fiber batt forms with proper density and structure, but energy consumption increases

Engineering Contradiction:

Improvebatt densityVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent utilizes the phase transition of the meltable PE/PP bi-component thermoplastic binder fiber from solid to liquid (melting) and back to solid (solidifying) during the heating process. This phase transition enables the binder fiber to flow and bind paper fibers together at lower temperatures and pressures compared to traditional thermal pressing methods, reducing energy consumption while achieving proper batt density.

Inventive Principle:

Principle #36Phase transitions

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 resulting insulation material is repulpable, allowing for high recyclability, with a repulpability of over 85%, and can be integrated into corrugated cardboard boxes, enabling single-stream recycling without material separation.

Implementation Method 1

Heat is applied to the mixture to melt the PE/PP bi-component thermoplastic binder fiber to bind the PE/PP bi-component thermoplastic binder fiber to the paper reinforcement fibers to form a batt

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

At least one of heat and heat and pressure is applied to the layer of the mixture forming a paper fiber batt

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS12565371B2Insulation material and method of making insulation material

Publication Date: 2026.03.03 PREGIS EVERTEC LLC

AI summary

A repulpable insulation material includes a batt formed of a mixture of thermoplastic binder fibers and cellulose fibers bound together by the thermoplastic binder fibers, the thermoplastic binder fibers making up about 0.5% to 25% by weight of the batt, the repulpable insulation material having a weight within a range from 1000 GSM to 1600 GSM, wherein subjecting the repulpable insulation material to a repulpability test produces greater than 85% fiber yield.