Repulpable Paper Particle Insulation Batt
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Solution Overview
Problem
Current packaging insulation products are not repulpable, hindering the repulpability of cardboard shipping containers and creating environmental and disposal issues, as they are not recyclable according to industry standards.
Innovation Solution
The development of packaging insulation batts made from large paper particles greater than 10 mm in diameter, with less than 5% binder fibers of at least 20 mm length, and faced with biodegradable-coated paper, allowing for repulpability and recyclability as per the Fiber Box Association testing protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional insulation materials (expanded styrene, polymer bags with cotton, thermoplastic fibrous batts) are used, then thermal insulation performance is achieved, but repulpability of cardboard containers is hindered
Solution Approach 1:
The patent changes the particle size parameter of the insulation material from conventional fine particles to large particles greater than 10 mm in diameter. This parameter change enables the insulation material to be repulpable while maintaining effective thermal insulation properties, resolving the contradiction between insulation performance and repulpability.
Solution Approach 2:
The patent uses a composite structure consisting of large paper particles as the primary insulation component with minimal binder fibers (less than 5% by weight) and biodegradable-coated paper facing. This composite material approach allows the insulation to maintain structural integrity for thermal performance while enabling repulpability of the cardboard container.
2Object-generated harmful factors
If large paper particles greater than 10 mm in diameter are used, then repulpability is achieved, but insulation density and structural integrity may be compromised
Solution Approach 1:
The patent applies different qualities to different parts of the insulation batt: large paper particles (greater than 10 mm) are used in the bulk for repulpability and insulation, while minimal binder fibers (less than 5% by weight) are used locally at particle interfaces for bonding, and biodegradable-coated paper facing is applied locally on the surfaces for structural integrity and protection. This local quality differentiation resolves the contradiction between repulpability and structural integrity.
3Object-generated harmful factors
If binder fiber content is reduced to less than 5%, then repulpability is improved, but bonding strength between particles may decrease
Solution Approach 1:
The patent changes the binder fiber length parameter to at least 20 mm, which is significantly longer than conventional binder fibers. This parameter change compensates for the reduced binder content (less than 5% by weight) by providing longer bonding elements that can effectively bridge and bond the large paper particles, maintaining structural integrity while enabling repulpability.
4Strength
If conventional small cellulosic particles are used, then batt density and bonding are improved, but repulpability is lost
Solution Approach 1:
The patent inverts the conventional approach by using large paper particles (greater than 10 mm) instead of small particles for the insulation batt. This inversion of the particle size parameter enables repulpability while maintaining effective thermal insulation properties, challenging the conventional wisdom that small particles are necessary for good insulation performance.
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 solution enables the insulation and cardboard containers to be fully repulped and recycled, meeting industry standards for repulpability and recyclability, while maintaining effective thermal insulation properties.
Implementation Method 1
The particles are compressed to a density of from about 0.02 to about 0.1 grams per cubic centimeter
Implementation Method 2
The particles are heated to a temperature sufficient to melt the binder fibers
Implementation Method 3
heated to a temperature sufficient to melt the binder fibers thereby binding the binder fibers to the paper particles to form a cohesive structure
Implementation Method 4
maintaining effective thermal insulation properties
Data Source
AI summary
Container insulation including a batt comprised of large paper particles, at least 90% of which by weight are greater than 10 mm in diameter. Less than 5% by weight binder fibers are used, which have a length of at least 20 mm. Most preferably, no binder fibers are used. Where the batts are faced with paper, the paper is coated with a biodegradable coating. The resulting product is repulpable and recyclable in accordance with Fiber Box Association (FBA) testing protocols.