CN113605137A

CN113605137A - Methods and systems for fiberizing nanocellulose material

Info

Publication number: CN113605137A
Application number: CN202110491294.2A
Authority: CN
Inventors: 陈大仁; 张又文
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-05-04
Filing date: 2021-05-06
Publication date: 2021-11-05
Also published as: AU2021267203A1; EP4146862A1; WO2021224778A9; KR20230047956A; TW202202694A; TWI816115B; BR112022022489A2; WO2021224778A1; JP2023525069A; CA3182366A1

Abstract

Embodiments of the present invention overcome the deficiencies of the prior art by enhancing the properties of cellulose pulp by infusing a form of cellulose. For example, these properties may include mechanical and barrier properties, i.e., tensile strength, impermeability to liquids (e.g., water, oil, sauce) and gases (e.g., oxygen or carbon dioxide) are greatly improved. Another embodiment of the present invention further provides automated apparatus and systems for forming a fiberized cellulose composite material including features that act as strength enhancing agents, oligomerizing agents, carbohydrates, plasticizers, antimicrobial agents, water repellants, and/or transparent composite materials.

Description

Methods and systems for fiberizing nanocellulose material

Technical Field

Aspects of the present invention generally relate to updating and recyclable materials. More particularly, embodiments of the present invention relate to pure cellulose materials in connection with consumer products.

Prior Art

The growing concern over the environmental crisis-pollution of plastic waste-has led to an extensive investigation of sustainable and renewable materials. In order to avoid petroleum-derived polymers, a natural biopolymer, plant-based cellulose fiber, provides a substitute for the materials research community. Cellulose fibres are of increasing interest due to their ubiquitous origin, sustainability, renewability and, more importantly, provide 100% room temperature biodegradability to the final product.

However, many existing biodegradable products based on cellulose fibers have not met with promise. For example, the cost of producing these cellulosic fiberized products is economically prohibitive for large-scale production. In addition, many cellulosic fiber products rely heavily on high proportions of synthetic chemical ingredients to achieve these properties or effects due to the need for water resistance, oil resistance, or non-tackiness. For example, many existing products require a fluorocarbon coating on the surface of the pores of a food or beverage item. In addition, some of these fluorocarbon-based chemicals, such as perfluorooctanesulfonic acid (PFOA or C8), can have long term negative health and environmental impacts.

Disclosure of Invention

Embodiments of the present invention overcome the disadvantages of the prior art by injecting cellulose fibrillation form to enhance the properties of the cellulose pulp. For example, these properties may include mechanical and barrier properties, i.e. tensile strength, impermeability to liquids (e.g. water, oil or sauce) and gases (e.g. oxygen or carbon dioxide) are greatly improved.

Another embodiment of the present invention further provides a fiberized cellulose composite material having properties including a reinforcing agent, an oligomerizing agent, a carbohydrate, a plasticizer, an antimicrobial agent, a water repellant, and/or a transparent composite material.

Drawings

Those skilled in the art will appreciate that the elements of the figures are for simplicity and clarity of illustration and that not all permutations and alternatives are shown. For example, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present disclosure. It will further be appreciated that certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. It will also be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting, unless the context requires otherwise.

Figures 1a to 1d illustrate an aqueous suspension of cellulosic fibres according to one embodiment.

Fig. 2 is a Scanning Electron Microscope (SEM) image of a material for cellulose fibers (3 wt.%), according to an embodiment.

Fig. 3a to 3d are Scanning Electron Microscope (SEM) images of semi-processed cellulose fiber fibers according to one embodiment, wherein a-B are SEM images of Y cellulose fibers and c-d B cellulose fiber fibers.

FIGS. 4a to 4d are SEM images of mechanically grounded semi-processed fibers according to an embodiment, where a-B are Y cellulose fibers and c-d represent B cellulose fibers.

Fig. 5 is an image showing containers made of cellulose L28b, L29b, L30b, and Y that can hold 10 days of oil according to one embodiment.

Fig. 6A is an image showing a food containing boiling water in a material for about 5 minutes according to one embodiment.

Fig. 6B is an image showing a food product heated with boiling water and 800 watts of microwaves for the next 2 minutes, according to one embodiment.

Fig. 7 is another SEM image of a cellulosic structural material used in a food container according to an embodiment.

FIG. 8 is a flow diagram of a method of generating a material according to one embodiment.

FIG. 9 is three images of a film according to one embodiment.

Fig. 10A-13 are diagrams of devices employed in accordance with an embodiment.

Fig. 14A-D are diagrams of final products made in accordance with embodiments of the present invention.

Description of the symbols

802 grinding tool

804 mixer

806 mixture

808 grinding material

810 former

812 dissolved matter

814 drying

816 final material

818 intermediate material

Method of implementation

Embodiments the accompanying drawings, which form a part hereof, and in which are shown by way of illustration specific exemplary embodiments that may be practiced. The drawings and exemplary embodiments are intended to provide an understanding that the present disclosure is to be considered an exemplification of the principles of one or more embodiments and is not intended to limit any embodiment illustrated. Embodiments may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the embodiments to any skilled person in the art. The following detailed description is, therefore, not to be taken in a limiting sense.

Embodiments of the present invention include a material, such as a Green Composite (GCM), that may include a fiberized cellulose, typically free of chemical additives or agents, from which plant fibers may be independently derived. In one embodiment, the chemical proliferation or formulation may be natural based. In another embodiment, the chemical additive or formulation may be manufactured by a laboratory. In some embodiments, the plant fibers may be derived from bagasse, bamboo, abaca, sago, hemp, flax, hops, jute, sisal, palm, corn, cotton, wood, or agricultural wastes thereof, and any combination thereof. In other embodiments, the plant fiber may be a pre-processed or semi-processed cellulose. In other embodiments, the plant fibers are processed through a high pressure homogenizer or a mechanical mill to obtain a green composite with fibrillated cellulose. In a further example, a composite material with fibrillated cellulose (cellulose that does not produce microorganisms) is obtained by a bacterial strain. In an alternative embodiment, the material of the fibrillated cellulose may be obtained from a marine source.

In one embodiment, the shape and size of the cellulose may depend on the source of the fibers or the combination and fabrication process of the fibers. Nonetheless, the fiberized cellulose generally has a diameter and a length, as described below. The fibrillated cellulose, in one embodiment, may have a diameter of about 11 to 5000 micrometers (nm). In another embodiment, the cellulose may have a diameter of about 5 to 150 microns or from about 100 to 1000 microns.

In further embodiments, the material may have enhanced properties, enhancing, reinforcing or improving various properties, without the need for chemical additives or agents. In another embodiment, the material has various characteristics suitable for carrying food or liquid items that are generally free of chemical fats or agents. For example, as shown in the prior art, various chemical agents or additives provide desirable tensile strength, whether dry or wet, enhanced oil resistance, gas and/or liquid impermeability during manufacture or coating in a composite material. Aspects of the present invention, rather than utilizing various chemical additives or agents added to the material, include a composite material and fiberized cellulose that is free of these additives.

For example, the length of the cellulose may be about 0.1 to 1000 microns, about 10 to 500 microns, about 1 to 25 microns, or about 0.2 to 100 microns. In some embodiments, the cellulose has different diameter celluloses, such as materials in a 1:100 weight ratio. In another embodiment, the weight ratio of cellulose is 1: 50. In further embodiments, the blended cellulosic material may have advantages of increased tensile strength, dry or wet, enhanced oil resistance, gas and/or liquid impermeability, and cost savings.

In some embodiments, a material of fiberized cellulose may have an oxygen transmission rate of about 8000 cm/cube per square foot per 24 hours or less. In another embodiment, the oxygen transmission rate is about 5000 cm/cube per square foot per 24 hours or less. In another embodiment, the oxygen transmission rate is about 1000 cm/cube per square foot per 24 hours or less.

Further, in some embodiments, the material may have a water vapor transmission rate of about 3000 grams per square foot per 24 hours or less. Further, for another embodiment, the water vapor transmission rate may be about equal to or less than 1500 grams per square foot per 24 hours.

In some embodiments, the material may have a dry tensile strength of about 30 megapascals (Mpa) or more. In another embodiment, the dry tensile strength may be about 70 megapascals. In another embodiment, the dry tensile strength may be about 100 megapascals or more. In some embodiments, the material may have a dry tensile modulus of about 4 gigapascals (Gpa) or greater. In another embodiment, a dry tensile modulus of about 6 gigapascals or more.

In some embodiments, the material may have about 45Nm g^-1Or the above dry tensile index characteristics. In another embodiment, the characteristic may be about 80Nm g^-1Or higher.

In some embodiments, the material may have a wet tensile strength of about 5MPa or greater. In another embodiment, the wet tensile strength may be about 20MPa or greater.

In some embodiments, the material may have a wet tensile modulus of about 0.4MPa or greater. In another embodiment, the wet tensile modulus may be about 1.0MPa or greater.

In some embodiments, the material may have about 5Nm g^-1Or higher wet tensile index properties. In another embodiment, the wet tensile index may be about 20Nm g^-1Or higher.

In another embodiment, the material may include a binder to enhance drying and/or wetting. In one embodiment, the adhesive may comprise a polymer. In other embodiments, the binder may include a metal salt. In another embodiment, the binder may include an oligomerizing agent. In other embodiments, the binder may include a carbohydrate acid. In other embodiments, the adhesive may include a plasticizer. In some embodiments, the weight ratio of cellulose to binder in the present invention may be in the range of about 33:1 to 1: 1.

For example, the polymer may include polyester, gelatin, polylactic acid, gibberellic acid, sodium alginate, thermoplastic starch, polyethylene, formic acid colloid, polyvinyl alcohol, or polypropylene.

In another embodiment, the binder may include a metal salt. For example, the metal salts may include potassium carbonate, potassium aluminum sulfate, calcium carbonate, and calcium phosphate. In some embodiments, the weight ratio of cellulose to binder in the present invention may be in the range of about 33:1 to 1: 1.

In another embodiment, the binder may include an oligomerizing agent. In one example, oligomers may include oligonucleotides, oligopeptides, and polyethylene glycol. In some embodiments, the weight ratio of cellulose to binder in the present invention may be in the range of about 33:1 to 1: 1.

In other embodiments, the binder may include a carbohydrate acid. For example, carbohydrate acids may include citric acid, acid acids, and glutamic acid. In some embodiments, the weight ratio of cellulose to binder in the present invention may be in the range of about 33:1 to 1: 1.

In embodiments, adhesives using plasticizers may reduce brittleness and gas permeability of the adhered composite. In some embodiments, the plasticizer may include a polyol. In one embodiment, the polyol may include glycerol. In one embodiment, the polyol may include sorbitol. In one embodiment, the polyol may comprise a pentagonal alcohol. In some embodiments, the polyol may include polyethylene glycol. In some embodiments, the weight ratio of plasticizer to composite to binder is about 5:33:1 to about 1: 1.

In another embodiment, the plasticizer may include branched polysaccharides, waxes, fatty acids, fats, and oils.

Aspects of the present invention may further include a water repellent as a chemical additive to repel gases and/or liquid water. In some embodiments, the water repellant comprises animal wax, animal oil, or animal fat. In one embodiment, the water repellent agent comprises a petroleum derived wax or a petroleum based wax. In other embodiments, the water repellant comprises a vegetable wax, vegetable oil, or vegetable fat.

In some embodiments, the animal-based water repellant may include beeswax, shellfish, and whale oil.

In some embodiments, the petroleum-based wax water insect repellent can include paraffin, and mineral oil.

In some embodiments, the vegetable water repellant may include carnauba wax, soybean oil, palm oil, carnauba wax, and coconut oil.

In some embodiments, the water repellant may include a binder such as potassium carbonate, potassium sulfate, calcium carbonate, and calcium phosphate.

In a further embodiment, the material may comprise fibrillated cellulose and, optionally, may comprise an antimicrobial agent. In some embodiments, the antimicrobial agent may comprise tea polyphenols. In some embodiments, the antimicrobial agent may include a salt of propiophenone, para-hydroxybenzoic acid, quaternary ammonium salt, acetamide, benzoic acid, sapronic acid, and potassium sorbate.

Additionally, another embodiment of the present invention may include a material having fibrillated cellulose, which may further optionally include a transparent composite to increase the transmission of light at wavelengths from about 300 microns to 800 microns. In some embodiments, the material may comprise a branched polysaccharide. In some embodiments, the weight ratio of material to transparent composite material is different, which may depend on the desired transparency, e.g., about 99:1 to about 1: 99.

In some embodiments, the branched polysaccharide may include starch, polysaccharides, and garamenan.

In some embodiments, a glucan may include shredded amantadine, larvay blue, and minium.

In certain aspects, the products provided herein are made from the materials disclosed herein and are readily formed into a specified shape, e.g., planar or volumetric. For example, a two-dimensional example may be a planar sheet, where the planar sheet may be used to decompose to form a final product. In another embodiment, the material is soluble in a liquid for ready use in forming the final product. In another embodiment, a three-dimensional embodiment (i.e., a solid) may be the final product.

In one aspect, in certain embodiments, the final product may comprise a container of edible or digestible items, as shown in fig. 5-7. For example, an end product embodying the material of this embodiment may comprise a food container or package. Food containers or packages may include airplane or airline meal containers, disposable cups, ready-to-eat food containers, capsules, ice cream boxes or containers, and chocolate containers. In some embodiments, the product may include a snack container, such as a noodles, instant soup, or the like, that may further contain a flavoring. In such a case, the food product may be placed in the container of the present invention in water or liquid at an elevated temperature (e.g., about 100 degrees celsius) for the consumer to digest or eat the consumable or digested item placed in the container of the various aspects of the present invention.

In another embodiment, for products where aircraft meal and beverage containers may be used. At present, the airplane meal container is made of various forms of plastics and has the characteristics of lightness, proper hardness, oil resistance and the like. In addition, existing plastic containers may be heated by an oven. However, heating may release carcinogens from the plastic container to the edible item. Therefore, this is to be avoided as much as possible. The examples of the present invention and the above-mentioned properties can exhibit water resistance, heat resistance, oil resistance and the like, but do not release carcinogenic substances.

In another embodiment, the capsule example may be a coffee capsule. For example, the coffee capsule may be a disposable capsule. In another example, the coffee capsule may be a disposable coffee bag or pouch. In this case, the electric coffee machine may deposit or inject hot water at high temperature or pressure into the capsule in order to start the coffee making process, and coffee may drip from the capsule or bag into the cup of the consumer. Since the capsule or bag comprises a biodegradable and sustainable material having one or more of the above-mentioned properties, the capsule or bag body is easily recycled without imposing a burden on the environment.

In one embodiment, the capsule may have a sidewall with a thickness of about 500 microns. In one embodiment, the capsule may include a top or lid having a thickness of about 500 microns. In yet another embodiment, the capsule may include a bottom thickness of about 300 microns. In yet another embodiment, the capsule may be formed in-line with a mold during formation of the mold (discussed below), and the thickness of the top, side walls and bottom have different thicknesses.

In some embodiments, the product may include a filter to separate whether permanent, semi-impermeable, or slightly impermeable to particles or molecules in the fluid. For example, the product may include a mask or a filter membrane having a solid-liquid separation, a liquid-liquid separation, or a gas-liquid separation effect, etc.

In some embodiments, the product may include a cosmetic or skin care container product, a medical product, such as a powder box, a color palette, a protective glass, or a medical grade treatment. In some embodiments, the product may include medical devices, automobiles, electronics, and a portion of a building material (as a reinforcement material).

In general, in some embodiments, a container embodying materials of the present invention may be a container, a planar sheet, a tray, a plate, a spool, a plate, or a film. In such embodiments, the width or length of the material may be between about 0.01 millimeters to 10000 millimeters or more. In one embodiment, the width or length may be between about 0.01 mm to 1000 mm. In embodiments, the film may be a thin film having a thickness of about 0.01 to 3.0 millimeters. In one embodiment, the thickness may be about 0.02 mm 0.20 mm. In other embodiments, the present disclosure may also be directed to food packaging, and the product may include a weight ratio of oil to water of about 100:1 to about 1: 100.

In another embodiment, aspects of the invention may provide a material for the manufacture, generation or fabrication of cellulose having the above-described characteristics.

Example 1

In addition to the materials described above, aspects of the invention may include a cellulose fibrillation process or method.

Referring now to fig. 8, a flow diagram may illustrate a method for creating such a material, according to one embodiment. For example, cellulose paper board (about 3.0 wt%) is torn into pieces, such as a4 size paper. The shredded pieces are thrown into a pulper (not shown in fig. 8). The pulping process may take about 20 minutes. Next, the process can begin, for example, using a mechanical grinder 802. For example, the mechanical grinder 802 may be a homogenizer. In one embodiment, the mechanical grinder 802 may include two grinding wheels facing each other. The spacing or distance between the two grinding wheels can be adjusted according to the desired end product. In another embodiment, the surface grooves or pattern may be adjusted according to the desired end product. Thus, the pulp suspension 806 is then fed to the mechanical mill, optionally about 1-10 times or so. In other cases, the pulp suspension 806 may be fed to a refiner (not shown), e.g., a colloid mill, a double disc mill, to further refine the cellulose pulp before entering the mechanical mill 802.

In one embodiment, fig. 1a to 1d show the state of fibrillated cellulose with increasing number of passes. For example, FIG. 1a may represent an aqueous suspension of cellulose fibers having 0 cycles or passages. In other words, as shown in fig. 1a, the content of the pulp suspension 806 may reach 100%. In fig. 1a, the pulp cannot be fibrillated to achieve the quality and performance of aspects of the present invention.

In one embodiment, fig. 1b may show a mill pass 808, where the pulp suspension 806 has passed through the mechanical mill 802 after 1 pass. For example, the mill run 808 may now comprise an aqueous suspension of fibrillated cellulosic fibers. In another example, fig. 1c shows an image of the mill backings 808 that have passed through the mechanical mill 802 after 2 cycles or 2 cycles have elapsed. In one example, the fibrillated cellulose fibers in the mill-back 808 are finer than the fibrillated cellulose fibers shown in fig. 1 b. Fig. 1d may show an image of the mill-back 808 after 3 cycles/pass. In such an embodiment, the mill run 808 may comprise fibrillated cellulose fibers that are finer than the fibers in fig. 1 c.

In other embodiments, fibrillated cellulose is tested and used at about 2.5 weight percent (wt.%), about 3.0 weight percent (wt.%), about 3.6 weight percent (wt.%), and about 4.0 weight percent (wt.%) at different concentrations of fibrillated cellulose fiber. For example, about 2.5 weight ratio (wt.%) of fibrillated cellulose indicates a situation where the grinding is not sufficiently abrasive, and therefore the relevant properties or characteristics are not tested. While L028, L029, and L030 in fig. 5 show that cellulose is referred to as having cellulose at about 3.0 weight ratio (wt.%), about 3.6 weight ratio (wt.%), and about 4.0 weight ratio (wt.%), respectively.

In one embodiment, various characteristics/properties of the cellulose were tested. For example, in table 1, the properties of mechanical, water vapor and gas permeability are shown.

Table 1

Fig. 2 further illustrates a Scanning Electron Microscope (SEM) image of the fiberized cellulose at a concentration of about 3 weight percent (wt.%).

Example 2

In one example, instead of being obtained at mill-tailings 808 using a direct pulp solution in example 1 above, semi-processed cellulose fibers can be obtained commercially. Thus, the semi-processed cellulose fibers (e.g., about 3 wt.%) are fed to a colloid mill and ground for about 1 minute. Alternatively, the fibrillated cellulose fibers may be further treated in a mechanical grinder 802.

FIG. 3 shows a Scanning Electron Microscope (SEM) image of a semi-finished fiber through impact milling for 1 minute in another example. For example, table 2 shows the properties of different fiberized cellulose from different sources.

TABLE 2

FIG. 3 illustrates that a-B in Table 2 are SEM images of Y cellulose fibers and c-d are SEM images of B-cellulose fibers.

In another embodiment, fig. 4 shows SEM images of semi-processed fibers 1 time after grinding with a mechanical grinder. For example, FIGS. 4a-B are for Y cellulose fibers and FIGS. 4c-d are for B cellulose fibers.

In one aspect, the mixer 804 can provide a suspension of cellulose pulp in water 806, the suspension comprising a mixture of cellulose pulp in water, wherein the weight ratio of cellulose to water is about 0.01 to 100. The ratio may be about 0.03 to 0.10. In some embodiments, the mill tailings 808 from the mechanical mill 802 may be retained if it can be reused for milling by the mechanical mill 802. For example, as described above, the post-grind 808 that passes through the grinder 802 may be 1-100 times. In another embodiment, the number of passes or cycles may be further limited to 1-10.

In another embodiment, the weight ratio of cellulose to water and/or the number of passes through the mechanical grinder 802 may be a function of the desired characteristics of the final product. For example, if the final product requires low water vapor transmission and low oxygen transmission, the initial mixture 806 may increase the weight ratio of cellulose to water or times approaching 0.1. In another embodiment, relatively low water vapor transmission and relatively low oxygen transmission may indicate a higher shelf life, while relatively high water vapor transmission and relatively high oxygen transmission may indicate a lower shelf life.

In one embodiment, the mill pass 808 may be processed by a former 810. For example, former 810 may generate intermediate material 818 having a desired material of fibrillated cellulose based on milled material 808. For example, the weight ratio of fibrillated cellulose to liquid (e.g., water) of intermediate material 818 may be between about 0.001 and 99. In another embodiment, the ratio may be about 0.001 to 0.10. In one embodiment, former 810 may comprise a mesh or web. For example, former 810 may include negative or positive pressure, or any combination thereof. In one embodiment, the former 810 may apply pressure to separate the fibrillated cellulose in the mill 808 from the liquid to form the intermediate material 818. Due to the fibrillated nature of the fibrillated cellulose fibers and the process of passing through mechanical grinder 802, fibers having different lengths may form intermediate material 818 as shown in the various SEM images of fig. 2-4 and 7.

In another embodiment, the base layer 812 may be used to form the intermediate material 818. In one embodiment, the GCM of aspects of the invention may include a fibrous pulp layer (e.g., base layer 812) and a fibrillated cellulose layer (e.g., from post-grinding 808). For example, former 810 may subject base layer 812 to a mesh or frame to form a construction for intermediate material 818. For example, the base layer 812 may be first in the form of a solution or syrup of water and pulp material. The slurry may be in a trough and the mesh may also be in a trough. Water from the tank may be removed or reduced by negative pressure, such as vacuum, to form a base layer 812 on the mesh.

Subsequently, in one embodiment, the former 810 may include a sprayer or applicator for spraying or applying the abrasive article 808 onto the base layer 812 to form the intermediate material 818. Fibers having different sizes between the base layers 812 in the mill backs 808, the post mill 808 is injected into the base layers 812. In one embodiment, mill backs 808 may be applied. Or sprayed on the surface of the intermediate material 818 with the edible piece. For example, assuming the final product is a bowl, the mill-off 808 may be applied or sprayed onto the inner surface of the final product.

In one embodiment, the intermediate material 818 may exhibit a mesh or web pattern on its outer surface, as shown at 502 or 504.

In another embodiment, the former 810 may coat the intermediate material 818 onto a flat surface, formed by a dry or natural process.

In another embodiment, a dryer 814 may be further provided to dry or dehumidify the transition materials of the dryer. In one embodiment, the dryer 814 may provide drying conditions of 30 degrees celsius to 200 degrees celsius. In another embodiment, dryer 814 may include a heated surface, such as infrared heating. In another embodiment, microwave heating or air heating may be used without departing from the spirit and scope of the embodiments. In another embodiment, dryer 814 may also be assisted by negative and/or positive pressure.

Example 3

In one example of a final product that may embody aspects of the present invention, a cellulose-based bowl was successfully produced using a combination of the materials and methods described previously. In one embodiment, the functionality of the cellulose-based food container in this example can be used to demonstrate the filling of a typical edible oil into the container, as shown in fig. 5. In this example, a food container of edible oil and cellulose may be heated in a microwave oven at 800 watts for 4 minutes, observed for 10 days, as shown in fig. 5. In such figures, the container in fig. 5 may be represented as made of cellulose L28b, L29b, L30b and Y. In one embodiment, each of the embodiments of fig. 5 may carry oil for about 10 days. In another embodiment, the final product may be heated in an oven environment to a temperature of up to 260 degrees celsius, or cooked rice may be cooked in a steamer, or the like.

In another example, another set of tests were also performed on the composite according to one example by loading the containers with the addition of the bubble noodles (after cooking with the addition of hot water). Observations were recorded the next day. An example of a cellulosic structure in a container (e.g., a food container) is shown in fig. 6A. For example, figure 6A shows an image of a series of fibrillated cellulose, leaving the bubble side itself in the container for about 5 minutes.

In another example, fig. 6B shows a series of images of cellulose loaded with boiling water and fibrils heated in an 800 watt electric microwave oven, leaving the bubble side itself in the container for about 2 minutes.

Fig. 7 is an SEM image of a food container for the cellulose of fig. 6A and 6B, according to one embodiment.

Example 4

Referring now to fig. 9a to 9c, images show the film of example 4 according to an embodiment.

In one embodiment, the composite material according to aspects of the present invention may be in a fibrillated cellulose based transparent composite film. In one example, a film may be prepared by dissolving fibrillated cellulose and amylopectin powders in water to produce solutions containing about 1 weight percent (wt.%) solute, respectively. In the dissolution of the amylopectin powder, the powder may be gradually added thereto, and the solution may be heated by a microwave oven at a power of 800W for 1 minute. In one embodiment, the process may be repeated about 4-5 times until a clear solution is formed.

In one embodiment, to produce a composite film, the ratio of fibrillated cellulose, e.g., post mill 808 to amylopectin, may be about 1:1, for example about 250g of mill-out (for example, about 1% fibrillated cellulose may be mixed with about 250g of amylopectin solution to produce a solution with about 0.5% solute. then, about 100g of the mixed solution is poured onto a hydrophobic surface, such as a silicone surface, and dried at room temperature.

In another embodiment, the ratio of fibrillated cellulose to amylopectin is from 2: 1, 250g of mill pass 808 (e.g., about 2% fibrillated cellulose) can be mixed with about 250g of amylopectin solution to produce a solution of about 1% solute. Then, about 100g of the mixed solution was poured on a hydrophobic surface such as a silicone surface, and dried at 50 ℃ for 12 hours.

As shown in the figure. Fig. 9a to 9c may show images of cellulose-based films wherein the ratio of fibrillated cellulose to amylopectin is a) 0:1, b) 1:1 and c) 2: 1.

in one embodiment, the addition of pullulan may enhance the film forming process to smooth the surface of the film, wherein the film of the film made from fibrillated cellulose (e.g., hereinafter referred to as post-grind 808) is highly wrinkled. While other films with amylopectin provide a smoother, more uniform surface. In one embodiment, the film having a composite of fibrillated cellulose and amylopectin may generally be free of uneven surfaces.

In another embodiment, the mechanical properties of the transparent composite film are shown below, where fibrillated cellulose is denoted as L41B and amylopectin is denoted as B.

Table 3 shows the properties of the fibrillated cellulose films with addition of pullulan.

Example 5

Fibrillated cellulose with water repellent

In one embodiment, aspects of the present invention may include fibrillated cellulose having water-repellent capabilities. In one example, the mixture may contain the correct proportions of cellulose and hydrophobizing agent and be stirred for 3 minutes using a mechanical stirrer. The mixture may be further diluted to 4000mL and poured onto a mold 810. In one aspect, the former 810 may apply negative and/or positive pressure to produce a wet preform with a dryness of 25-35%. The mechanical and barrier properties of the mixtures are shown in Table 4.

Table 4 illustrates the performance of fibrillated cellulose films with different water repellents.

In addition, all of the above embodiments can be made using the apparatus as shown in FIGS. 10A to 13. In the schematic diagram of fig. 10A, the 1000 element can be seen as a container, after loading the pulp, using its vacuum principle to attract the paper fibers from the water cylinder containing the pulp onto 1001. For example, 1001 includes a fiber connector or mold, e.g., a net, since the paper fibers of the vat stay in the net and the liquid passes through the net, and the vacuum principle includes first pumping and draining the water from the vat, then making the first material by closely adhering the vacuum environment on 1001 element, 1001 has a rotation function to put the mold down or on the vat into 1000 pulp vat to form the product, and then rotating 180 degrees to remove the water by the vacuum device.

In another embodiment, the device 1004 may be connected to 1002 components, and the device 1004 may be capable of moving up and down, left and right to perform its vacuum suction function, and may be configured to mount 1002 components to absorb the remaining material on 1001. As shown in fig. 10A and 10B, the 1002 and 1004 elements may be moved to a third element or water removal device. 1002 with a rotating function, the mold can be removed with water downwards or upwards. In addition, the present invention does not require a linear arrangement or alignment of the

furnishing elements

1000, 1002, 1004, 1006, and 1008. Since 1004 elements can move in multiple directions, 1000, 1006 or 1008 elements can be arranged in relative positions of circle, triangle, upper, lower, etc. Additionally, element 1004 may include a robotic arm or device to move. In another embodiment, element 1004 may be moved to 1006 or 1008 manually, mechanically or rail-assisted, etc. 1004 may transfer product in one or more groups.

A single process step: the second material is received through 1002 and 1004 and, in one embodiment, is effectively added to the first material by

elements

1002 and 1004. For example, the second material can be adhesively bonded to the first material via 1006 elements, and as in the above example, the first and second materials are intimately mixed together as a third material. In another embodiment, the third material shows that the first material and the second material are present in different layers.

A plurality of working procedures: 1001 and 1000 can receive the first material, 1001 and 1006 can receive the second material, the system can simultaneously produce two products, and then 1002 and 1004 can be used to transfer the materials to the next workstation, thereby achieving continuous production, and the production period is shortened compared with the single process of the former process.

In another embodiment, the container or station storing the second material is additionally charged with an incubation or heating source. For example, the 1002 or 1004 elements themselves, or in addition to a heat source, can function to keep the vessel warm or heated so that the second material can be brought to about 40 degrees celsius or higher during or before mixing with the first material to achieve the best and most efficient production efficiency. In another embodiment, the heat source may be heated by electric heat, steam, liquid, or the like.

In one embodiment, after mixing of the first and second materials is completed, 1002 and 1004 components are moved 1008 to a component de-watering station to perform de-watering or de-watering steps as described above. For example,

elements

1002 and 1004 move the third material from element 1006 to element 1008 after the process of mixing the first and second materials. In another embodiment, the third material is in a vacuum-sealed state during the mixing process of the third material at 1002, 1004, 1006, 1008 elements, and then has positive pressure and compression functions on 1008 elements, so that the space pressure for loading the bonding material is increased, and further the moisture in the bonding material is removed by pressing, and in addition to the original 1002 and 1004 negative pressure design, the third material is further pumped or the dryness and humidity of the bonding material are reduced. 1008 the positive pressure and compression chamber mounting surface can be turned up or down.

And finally, the combined material enters a shaping stage to be made into a final product.

In another embodiment, the second material may also be directly the main body of the third material, i.e. as represented in fig. 10B. For example, in fig. 10B the second material is not mixed with the first material after entering the second component.

The apparatus of the present invention may be an automated apparatus, as shown in fig. 11A, i.e., the first member, the second member and the third member are a set of consecutive apparatuses.

In another embodiment of the present invention, as shown in FIGS. 11B, 11C, and 11D, the third material is removably and separately provided.

In addition, while the elements 1004 are shown in FIGS. 11A-D as being moved by a track, persons skilled in the relevant art may readily use other means to move 1004 elements without departing from the principles of the invention, and the movement need not be limited to movement in one plane.

In addition, in one embodiment, the present invention also includes a software system for operating the apparatus of the present invention, including sensors disposed at

elements

1000, 1001, 1002, 1004, 1006, 1008, etc. for transmitting parameter information. The software system also includes different interfaces, whether centralized or presented over a network to the mobile device. Even though as illustrated in FIGS. 11B-11D, in various embodiments, separate components may have coherent or separate interfaces and software to communicate and operate the operation of the device. The software system also reports alert and warning functions, providing an administrator with efficient management of the manufacturing process.

The mould and the transfer mould have the overturning function: 1001 mould installation equipment possesses the rotation function, and the mould can be gone into 1000 thick liquids buckets in the shaping in-process mould surface and utilize vacuum adsorption material upwards or downwards. 1002 the transfer mould device also has the function of selecting and rotating, the mould can rotate after transferring the product, and the moisture is discharged by using a vacuum and gravity mode.

Grouting and forming: 1001 and 1002 are closed, 1000 pulp can be used for feeding materials into 1001 mold cavity through a water pump, moisture in the pulp is taken out in a vacuum mode, a first material is completed, and 1006 can be reused for pouring a second material in the same mode. 1000 and 1006 in the pouring system the vat can be mounted at any position, below or above the plant.

FIGS. 12A and B illustrate another embodiment of an apparatus, also derivative of FIGS. 10A-11D. For example, the paper molding process may include: 1. the paper board is decomposed into paper pulp by a pulping system, and other materials required by the paper pulp can be added into the paper pulp, mixed and then enter a forming system. 2. The paper pulp material is attached to the surface of the mould by using vacuum or vacuum as power, and then the redundant water is discharged by using a water discharging system on the surface of the mould, so that a thin wet blank layer is formed on the surface of the mould. 3. The surface of the formed product needs much moisture, and residual moisture in the material can be discharged by utilizing the modes of natural air drying, hot air, air pressure, mold heating for assisting hot press forming and the like.

While the above description provides several forming processes:

the pulp dragging forming method-forming method is that a vacuum cavity is made in a mould, the fibers of the paper pulp can be uniformly laminated on a forming net attached to the surface of the mould under the action of vacuum, the surface of the mould faces upwards and enters a paper pulp groove, and a large amount of water can be taken away by a vacuum suction mode. When the product reaches a certain thickness, the product mold leaves the pulp groove, and the wet blank pulp on the mold surface is dewatered.

Slip casting method-the surface of the mould is upward, a pulp groove is made around the mould, the pulp is connected to the pulp groove by means of pulp pipeline, the pulp can give the amount of pulp according to the thickness of the product, a vacuum cavity is made in the mould, the fiber of the pulp can be uniformly laminated on the forming net attached on the surface of the mould under the action of vacuum, and a large amount of water can be taken away by means of vacuum suction, so that wet blank pulp is formed on the surface of the mould and then the action of dewatering is carried out.

Suck-back molding-the mold surface is facing down into the pulp vat and a large amount of water is carried away by vacuum suction. When the product reaches a certain thickness, the product mold leaves the pulp groove, and the wet blank pulp on the mold surface is dewatered.

Because the invention effectively combines two materials, two or more layers are combined more tightly under the condition of utilizing the specific arrangement in the process through the characteristics of the fiber and the cellulose.

Thus, fig. 12A and B illustrate a transverse system, 1204, 1204 ' and 1204 "clamps, 1202, 1202 ', 1202" transfer molds, 1201, 1201 ' molds, 1200 first ply, 1206 second ply, 1208 dewatering or positive presses. The device is characterized as either a landscape system or a multi-task bit system, where 1202 or 1201 may be rotated and 1201' may also be rotated.

Or a vertical system as depicted in fig. 13. The vertical system includes a machine with 1304 clamp, 1301 mould, 1300 first layer pulp, 1306 second layer pulp, 1308 dewatering, positive pressure, hot air, compression, heating, etc. Wherein, 1301 mould can do the rotation design.

In another embodiment, the systems of fig. 12A and B and fig. 13 may be partially combined.

From the above embodiments, the present invention may include the following steps by using the forming manner of the pulp barrel 1 and the pulp barrel 2:

if two forming dies need to be matched with rotation actions to be completed simultaneously in a vertical system, the forming workstation can use the upper injection + the backward suction or the backward suction + the upper injection, and the rotation actions can be utilized: 1. the motor drives the mechanism to rotate the mold, 2, the mold moves vertically to drive the connecting rod, the rack or the mechanical structure device to rotate.

In addition, the invention can realize the processes which cannot be realized in the past by combining the following steps:

therefore, the above table illustrates that the apparatus of the present invention can have a plurality of (more than one) pulp barrels mainly in the forming stage, and can be used for manufacturing different forming processes to meet other different product requirements:

thick material finished product of more than 2mm

After the forming station is finished, the paper pulp can be connected or transferred to 1008 a dewatering process, and the equipment has positive pressure, compression and other devices for dewatering, can accelerate the forming time of paper pulp drainage, and is favorable for forming thick products.

Multilayer transfer stack molding (comprising composite material)

The joining of the first layer of material to the second layer of material may be accomplished simultaneously using a linear transfer system or a vertical rotation system. The composite material with thick and thin parts can be manufactured by stacking more than two materials or the same material by using 1002 and 1004 transfer products.

Multi-color molding

The molding of multicolor materials can be simultaneously finished by utilizing a linear transfer system or a vertical rotating system, and the plastic suction process of paper pulp with different colors on a single product is finished.

Dyeing and forming

Paper pulp dyeing is to change other colours in the forming process of paper pulp plastic uptake, and the work that is a very consuming time on the washing of pipeline, we can use the mode of many thick liquid buckets to place the paper pulp dyeing agent in independent forming bucket, and the first layer material can move to the plastic uptake dyeing agent in the second layer dyeing agent after the shaping, makes the paper pulp surface attach the colour, shifts to the stoving again and makes, and this system can shorten the time that different colour dyeing agents were changed, need not wash the slurrying system.

Optimizing additives

The time-consuming machine of the pulp additive in the pulp forming is very important, the pulp additive can be added and placed in an independent forming barrel, the pulp additive can be added at a proper time, the combining capacity of the additive and the pulp fiber is improved, the independent additive can also reduce the possibility that pulp backwater is polluted by additives of other systems, and the backwater quality is improved.

Shaping of multilayer materials

The forming process of the first layer material and the second layer material can be simultaneously completed by the aid of the method. More than two or the same materials can be stacked together to make a composite material using 1002 and 1004 transfer products.

In fig. 14A to 14D, because of the process and material toughness of the present invention, the present invention can make special design requirements from the fiber material, for example, as shown in fig. 14A, the fastening manner of the lunch box can be pressed inward from the notch of the edge of the lid, so that the fork opening of the edge of the carrier can move into the slit of the notch. Or as shown in fig. 14B, the edge of the cover leaves a slight clearance from the height of the carrier edge's fork so that the carrier edge's fork can be inserted. Or the arc design is made from the upper end of the cover body to correspond to the supporting point at the bottom of the carrier (as shown in fig. 14C), and the supporting point at the bottom of the carrier can be designed without four feet to lift the bottom for exhausting, so that the steam has a circulation space, and the strength of the carrier is kept (as shown in fig. 14D).

In general, aspects of the present invention overcome the disadvantages of prior methods in which toxic chemicals (e.g., fluoropolymers and their derivatives) were added. Aspects of the present invention also overcome the disadvantages of prior methods of using pulp as one or more base layers. It is generally understood that pulp fibers have diameters in the range of 10 to 50 micrometers (μm). While aspects of the invention are more finely dimensioned, for example in the range of 1 μm or less.

Although variable and application dependent, the following are examples of methods of using the devices disclosed herein. Those skilled in the art will recognize that these steps may be performed in any practical order to produce a material for a desired use.

The foregoing description and drawings merely explain and illustrate the invention and the invention is not limited thereto. While the specification has been described with respect to certain implementations or embodiments, numerous details are set forth for the purpose of explanation. Accordingly, the foregoing is considered as illustrative only of the principles of the invention. For example, the present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described arrangements are illustrative and not restrictive. It will be apparent to those skilled in the art that the present invention is susceptible to additional embodiments or examples and that certain of these details described herein can be varied considerably without departing from the basic principles of the invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the invention and are thus within its scope and spirit.

The above description is illustrative and not restrictive. Many variations of the embodiments may become apparent upon review of the disclosure. Accordingly, scope embodiments should be determined, not with reference to the above description, but should instead be determined with reference to the pending claims along with their full scope or equivalents.

One or more features of any embodiment may be used in combination with one or more features of any other embodiment without departing from the scope embodiments. The use of "a," "an," or "the" is intended to mean "one or more" unless specifically stated to the contrary. Recitation of "and/or" is intended to mean the most inclusive sense of the term unless specifically indicated to the contrary.

While this disclosure may be embodied in many different forms, the drawings and discussion are submitted with the understanding that the disclosure is representative of one or more principles of the invention and is not intended to limit any embodiment to the illustrated embodiments.

The present disclosure provides a solution to the long felt need described above. In particular, aspects of the present invention overcome the challenges of relying on existing practices of using chemical formulations to provide enhanced properties to cellulosic materials.

Further advantages and modifications of the above-described system and method may readily occur to those skilled in the art.

Therefore, the disclosure in its broader aspects is not limited to the specific details, representative systems and methods, and illustrative examples shown and described. Various modifications and alterations may be made to the above specification without departing from the scope or spirit of the disclosure, and it is intended that the disclosure encompass all such modifications and alterations insofar as they come within the scope of the following claims and the equivalents thereof.

Claims

1. An apparatus for forming a biodegradable carrier material, comprising:

the first element is loaded with a first material;

the first element includes a fiber splice for carrying a portion of the fibers within the first material;

the second element absorbs part of the fibers of the fiber connector;

the third element contacting the second material with a portion of the fibers, the second material further combining with the portion of the fibers to form a third material; and

a water removal device to reduce the moisture of the third material.

2. The apparatus of claim 1, further comprising a shaping device to shape the dewatered third material.

3. The apparatus of claim 1, the first material comprising pulp.

4. The apparatus of claim 1, the second material comprising a refined material.

5. The apparatus according to claim 1, the third element further comprising a container for carrying the second material.

6. The apparatus of claim 5, the third element further comprising a heating source.

7. The apparatus of claim 6, the heating source storing the second material above about 40 degrees celsius.

8. The apparatus of claim 6, the heating source causes the second material to reach above about 40 degrees celsius when contacting the first material.

9. The apparatus of claim 1, the third material being a chemical additive that does not generally increase the tensile strength, oil resistance, gas and/or liquid impermeability, tensile modulus, or tensile index of the lift material.

10. The apparatus of claim 1, the third material comprising the following properties:

about 8000 centimeters of cubic per square foot per 24 hours (cm)³ m^-224h^-1) Or less oxygen transmission;

about 3000 grams per square foot per 24 hours (g m)^-224h^-1) Or less water vapor transmission rate;

a dry tensile strength of about 30MPa or greater;

a dry tensile modulus of about 4GPa or greater; and

about 45Nm g^-1Or a higher dry tensile index.

11. The apparatus of claim 1, the third material comprising the following properties:

a wet tensile strength of about 5MPa or greater;

a wet tensile modulus of about 0.4MPa or greater; and

about 5Nm g^-1Or a higher wet tensile index.

12. The apparatus of claim 1, wherein the third material comprises cellulose of different diameters in a weight ratio of 1:100 or 1: 50.

13. The apparatus of claim 1, wherein the third material comprises cellulose fibers having a diameter of about 1 nm to about 10000 nm.

14. The apparatus of claim 1, wherein the third material comprises cellulose of about 0.1 to 1000 microns, about 10 to 500 microns, about 1 to 25 microns, or about 0.2 to 100 microns.

15. The apparatus of claim 1, wherein the third material is a planar sheet.

16. The apparatus of claim 1, wherein the third material is a carrier edible container.

17. The apparatus of claim 1, wherein the third material is a fiber blend.

18. The apparatus of claim 1, wherein the third material comprises a thin film having a thickness of about 0.01 to 3.0 millimeters (mm).

19. The apparatus of claim 1, wherein the length of the flat plate varies from 0.01 mm to 10000 mm.

20. An apparatus for forming a biodegradable carrier material, comprising:

the second element adsorbs a second material, and the second material comprises a fiber refined material;

the third element changes the second material into a third material in a vacuum state; and

a water removal device to reduce the moisture of the third material.

21. A method of forming a biodegradable carrier material comprising:

loading a first material into a mold, the mold carrying a portion of the fibers in the first material;

adsorbing the portion of the fibers;

providing a second material in contact with the portion of the fibers, the second material further blending with the portion of the fibers to form a third material; and

the moisture of the third material is reduced.

22. A method of forming a biodegradable carrier material comprising:

adsorbing a second material with a carrier, the second material comprising a fiber-refined material;

changing the second material into a third material in a vacuum state; and

the moisture of the third material is reduced.