System Design Review P17701 ABVI Upcycling: Cotton Insulation Lucas Jackling, Mitchell Goepel, Samantha Kon, Denning Crenshaw

Agenda Team Vision for Project Phase Thermal Insulation Acoustic Insulation Plans for next phase Questions/Concerns

Team Vision Goals of System-Level Design Phase: Research During this phase, the team planned to take the information established in the problem definition phase and explore possible solutions to the problem from a system-level perspective. Research A large portion of this phase was designated for conducting research into the cotton insulation market: benchmarking existing products, performance characteristics, testing, and feasibility. Securing Project Resources A major factor in the team’s ability to make project process was securing critical resources. The major resource which was required to create cotton insulation prototypes was a supply of shredded cotton. The ultimate system will require machine shredding of clothing garments at high volumes. The team’s goal was to contact a shredding company or companies during the system-level design phase who would be willing to work with the team and sell them material to use. Another goal was to obtain a sample piece of cotton insulation which is commercially available on the market from which the team could collect critical benchmarking data such as density, fiber composition, and response to compression (“fluffiness”)

Team Vision Outputs of System-Level Design Phase: Research Although project research is ongoing, a few research areas have been explored during this phase. Insulation Testing Standards: Research into standard testing protocols for home insulation was conducted. Publicly available information from websites such as Owens Corning and Bonded Logic revealed some common threads among the types of tests that are conducted and to what testing standards. These include: ASTM C518 for R-Value testing ASTM E84 to test surface burning characteristics NFPA 101 for determining flame spread class (A, B, or C) of insulation Department of Energy - Cotton Insulation Standards: Benchmarking other Insulation Products: Acoustimac EcoCare Bonded Logic UltraTouch Applegate Chemical Research: What chemicals are used for fireproofing and binding properties in insulation? Fire: Borates, Phosphates Binding: Polyolefin How acoustic insulation is made and what it does Bonded Logic, UltraQuiet, Applegate, Acoustimac. Baffles vs Panels Securing Project Resources During the system-level design phase, several leads were pursued to try to connect the team with a shredding resource. Eventually, the team was successful in contacting a company called Fiber Conversion in Broadalbin, NY and Millbury Recycling in Millbury, MA. Both companies process and upcycle textiles, and therefore have ample shredding capability. The team established an open relationship with both suppliers, who have agreed to send the team sample shreds of some materials for the team to analyze. These resources could potentially do much more for the team than shredding. They might also be able to provide the team with information and consulting on the “how-to’s” of making cotton insulation since the company has experience re-purposing textiles. A team member also met with a local contact who deals in cotton insulation, and obtained a sample of Bonded Logic’s thermal insulation.

Thermal Insulation Functional Decomposition Benchmarking Thermal Concept Development Thermal Pugh Chart Thermal Product Cost Analysis Thermal Insulation

Functional Decomposition

Benchmarking R-value per Inch - This is the value that represents the insulation properties of the product per every inch of thickness. STC 3.5" - Sound Transmission Class, which is an integer rating of how well an insulating material blocks airborne sound, specifically for the 3.5" thick material. Flame Spread - Is an integer rating that describes the rate at which fire spread on the material. Smoke Spread - Is an integer rating that describes the rate at which smoke is produced when the material is aflame.

Thermal Concept Development

Thermal Pugh Chart

Thermal Product Cost Analysis Average density of 1.36 lb/ft3 for R-13 thru R-30 products Home Depot price per pound of cotton: $2.53/lb Next Steps: Identify all costs to go from low-value garments to high-value insulation Make a business model/proposal

Thermal Product Testing Parameter Tested Bonded Logic “Ultratouch” Applegate “Cotton Armor” Owens Corning Fiberglass Batt R-Value ASTM C-518 Surface Burning Characteristics ASTM E-84 Fire Hazard Classification UL-723 - Moisture Resistance ASTM C-739 ASTM E-96 Corrosion, Fungi, and Bacterial Resistance Sound-Transmission ASTM E-90

Acoustic Concept Development Acoustic Pugh Chart Acoustic Insulation

What Is Acoustic Insulation Acoustic Insulation usually refers to panels or baffles that are mounted or hung There are fiberglass acoustic batts for use in internal walls however they do not provide barely any thermal insulation. The main aspects of Acoustic Panels/Baffles Reduces echoes Lowers sound within room Does not significantly change sound transfer through walls

Acoustic Concept Development

Acoustic Pugh Chart

Plans for Next Phase - Detailed Design Acquiring raw material to begin prototyping Running additional feasibility tests (product and business) Developing bill of materials Developing test plans Researching additional topics as needed

Questions/Concerns