Wet-Process Fire-Retardant Cellulose Insulation With Low Dust
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Solution Overview
Problem
Existing methods for producing cellulose-based insulation face challenges such as high fabrication costs, limited availability of feedstock, inefficient fire-retardant chemical application, and excessive dust generation, which hinder its adoption as a viable alternative to fiberglass insulation.
Innovation Solution
A method involving the use of liquid fire-retardant chemicals combined with cellulose feedstock in a wet state, followed by disentanglement and partitioning of fibers to enhance chemical attachment and reduce dust, utilizing a system that includes pulping, partitioning, and mixing processes to create fire-retardant cellulose insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If powdered fire-retardant chemical is applied to cellulose fibers, then fire retardant coverage is achieved, but excessive dust is generated and chemical retention is poor
Solution Approach 1:
The patent changes the physical state of the fire-retardant chemical from powdered (solid) form to liquid form. This parameter change eliminates dust generation during application and improves chemical retention on cellulose fibers, directly resolving the contradiction between achieving fire retardant coverage and minimizing dust generation
Solution Approach 2:
The patent introduces an intermediary substance (liquid carrier or binder) to deliver the fire-retardant chemical to the cellulose fibers. This liquid intermediary improves chemical retention and prevents the dust generation problems associated with direct powdered chemical application
2Quantity of substance
If liquid borate is applied to dry fibers, then the amount of borate needed is reduced, but fiber embrittlement and breaking occur which increases dustiness
Solution Approach 1:
The patent inverts the conventional approach by applying liquid fire-retardant chemical to wet cellulose fibers instead of dry fibers. This reversal prevents fiber embrittlement and breaking while maintaining effective chemical retention, thereby reducing dustiness without compromising the reduction in chemical quantity needed
Solution Approach 2:
The patent applies the fire-retardant chemical to fibers while they are in a wet, more resilient state before drying. This beforehand cushioning of the fibers in a flexible state prevents embrittlement and breaking that would occur if dry fibers were treated, thus preventing dust generation
3Weight of moving object
If dry state fiber partitioning is performed, then fiber separation is achieved, but fiber fracture and excess dust formation occur
Solution Approach 1:
The patent uses hydraulic principles by performing fiber partitioning and disentanglement in a wet state with liquid present. This hydraulic environment allows fibers to be separated through fluid mechanics rather than mechanical dry handling, preventing fiber fracture and dust formation while achieving effective fiber separation
4Reliability
If conventional methods are used to adhere fire-retardant powder to fibers, then chemical application is achieved, but manufacturing cost increases and effectiveness is limited
Solution Approach 1:
The patent changes the physical state of the fire-retardant chemical from solid powder to liquid form, which fundamentally alters the application process. This parameter change eliminates the need for complex adherence mechanisms (mechanical impingement or oil-based binders), reducing manufacturing complexity and cost while improving chemical retention effectiveness
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 reduces manufacturing costs, improves fire-retardant chemical retention, minimizes dust, and ensures a sustainable supply of feedstock, resulting in a cost-effective and efficient production of cellulose insulation with enhanced fire resistance.
Implementation Method 1
combining a fire-retardant chemical in liquid form with the cellulose feedstock prior to drying of the cellulose material... allowing the fire-retardant chemical to diffuse into the exterior surface and/or core of the fibers
Implementation Method 2
allowing the fire-retardant chemical to diffuse into the exterior surface and/or core of the fibers
Implementation Method 3
disentanglement and partitioning of fibers to enhance chemical attachment and reduce dust, utilizing a system that includes pulping, partitioning, and mixing processes
Implementation Method 4
drying of the cellulose material... The fire-retardant chemical may be combined with the at least one solvent to be in liquid form before contacting the fibers
Data Source
AI summary
Methods for making fire retardant material including fire retardant cellulosic insulation are described. The methods include arrangements for partitioning fibers derived from fiber feedstocks and adding at least a portion of fibers of one or more feedstocks and a fire retardancy chemical compound to a mixer prior to fiber drying. The fibers may be disentangled and/or partitioned prior to mixing with the fire retardancy chemical compound. The fibers may be partially dewatered prior to the drying or other steps of the methods. The feedstock may include old newsprint (ONP), old corrugated containers (OCC), and/or other cellulose-based materials. The method further includes retaining the fibers feedstock and the chemical compound together for enough time to ensure adherence and impregnation of enough of the chemical to and in the fibers after the drying process. Fibers may be partitioned and disentangled prior to, during, and/or after treatment with the fire retardancy compound. The fire retardant cellulose insulation may be a standalone product or may be a component of a finished insulation end product.