EP4146862A1 - Procédé, appareil et système d'un matériau de nanocellulose fibrillée - Google Patents

Procédé, appareil et système d'un matériau de nanocellulose fibrillée

Info

Publication number
EP4146862A1
EP4146862A1 EP21800152.7A EP21800152A EP4146862A1 EP 4146862 A1 EP4146862 A1 EP 4146862A1 EP 21800152 A EP21800152 A EP 21800152A EP 4146862 A1 EP4146862 A1 EP 4146862A1
Authority
EP
European Patent Office
Prior art keywords
cellulose
fibrillated cellulose
unit
fibers
fibrillated
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21800152.7A
Other languages
German (de)
English (en)
Other versions
EP4146862A4 (fr
Inventor
Yiu Wen CHANG
George Dah Ren CHEN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US17/241,050 external-priority patent/US20210254285A1/en
Application filed by Individual filed Critical Individual
Publication of EP4146862A1 publication Critical patent/EP4146862A1/fr
Publication of EP4146862A4 publication Critical patent/EP4146862A4/fr
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N1/00—Pretreatment of moulding material
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21D—TREATMENT OF THE MATERIALS BEFORE PASSING TO THE PAPER-MAKING MACHINE
    • D21D1/00—Methods of beating or refining; Beaters of the Hollander type
    • D21D1/20—Methods of refining
    • D21D1/30—Disc mills
    • D21D1/303—Double disc mills
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/08—Moulding or pressing
    • B27N3/20—Moulding or pressing characterised by using platen-presses
    • B27N3/203—Moulding or pressing characterised by using platen-presses with heating or cooling means
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H11/00—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
    • D21H11/16—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only modified by a particular after-treatment
    • D21H11/18—Highly hydrated, swollen or fibrillatable fibres
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/21—Macromolecular organic compounds of natural origin; Derivatives thereof
    • D21H17/24—Polysaccharides
    • D21H17/28—Starch
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
    • D21H21/16—Sizing or water-repelling agents
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
    • D21H21/28—Colorants ; Pigments or opacifying agents
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H25/00—After-treatment of paper not provided for in groups D21H17/00 - D21H23/00
    • D21H25/04—Physical treatment, e.g. heating, irradiating
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J5/00—Manufacture of hollow articles by transferring sheets, produced from fibres suspensions or papier-mâché by suction on wire-net moulds, to couch-moulds
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W90/00—Enabling technologies or technologies with a potential or indirect contribution to greenhouse gas [GHG] emissions mitigation
    • Y02W90/10—Bio-packaging, e.g. packing containers made from renewable resources or bio-plastics

Definitions

  • aspects of the invention generally relate to renewal and recyclable material. More particularly, embodiments of the invention relate to fibrillated cellulose materials made for consumer products.
  • Embodiments of the invention overcome the shortcomings of prior technologies by infusing nanocellulose in a fibrillated form to enhance the properties of cellulose l pulp.
  • These properties may include, for example, the mechanical and barrier properties, i.e. , tensile strength, liquid, and gas impermeability such as oxygen, carbon dioxide, and oil, may be improved substantially.
  • Another embodiment of the invention further provide a fibrillated cellulose composite material that include layers or mixtures of fibrillated cellulose to create properties of being a strength-enhancing agent, an oligomer, carboxylic acid, plasticizer, an antimicrobial agent, water repellant, and/or a transparent composite.
  • the composite material further may be generally free from chemical additives to enhance the above properties.
  • the composite material may further include a base substrate such as pulp and another layer such as fibrillated cellulose.
  • FIGS. 1 A through 1 D illustrate a material of the cellulose fibers aqueous suspension according to one embodiment.
  • FIG. 2 is a scanning electron microscope (SEM) image for a material with fibrillated cellulose (3 wt. %) according to one embodiment.
  • FIG. 3Ato 3D are scanning electron microscope (SEM) images for semi- processed cellulose fibers where a-b are SEM images for Y-cellulose fibers and c-d for B- cellulose fibers according to one embodiment.
  • SEM scanning electron microscope
  • FIGS. 4A to 4D are SEM images for mechanically ground semi-processed fibers, where a-b are Y-cellulose fibers, and c-d for B-cellulose fibers according to one embodiment.
  • FIG. 5 illustrates images of containers made of fibrillated cellulose L28b, L29b, L30b, and Y were able to hold oil for 10 days according to one embodiment.
  • FIG. 6A are images showing food items with boiling water in a material for about 5 minutes according to one embodiment.
  • FIG. 6B are images showing food items with boiling water and under microwave being heated at 800 Wfor 2 minutes according to one embodiment.
  • FIG. 7 is another SEM image of a material for a structure of fibrillated cellulose used in food container according to one embodiment.
  • FIG. 8 is a flow diagram of a method for generating a material according to one embodiment.
  • FIG. 9 illustrates three images showing a film according to one embodiment.
  • FIGS. 10Ato 13 illustrate apparatuses according to one embodiment.
  • FIGS. 14Ato 14D illustrate exemplary end products produced by aspects of the embodiments.
  • Embodiments of the invention include a material, such as a Green Composite MaterialTM (GCMTM), that may comprise fibrillated cellulose as a core material without any material.
  • GCMTM Green Composite Material
  • the composite material may include pulp and fibrillated cellulose.
  • the composite material may be generally free from chemical additives or agents.
  • the composite material may be independently derived plant fibers.
  • the chemical additives or agents may be naturally based or non-toxic.
  • the chemical additives or agents may be created by laboratories.
  • these plant fibers may be derived from bagasse, bamboo, abaca, sisal, hemp, flax, hop, jute, kenaf, palm, coir, corn, cotton, wood, and any combination thereof.
  • the plant fibers may be pre- processed or semi-processed cellulose.
  • a green composite material with fibrillated cellulose may be obtained by processing plant fibers through a refining process, such as a high-pressure homogenizer or refiner.
  • a composite material with fibrillated cellulose obtained via bacterial strains (without the cellulose producing microorganism).
  • a material with fibrillated cellulose may be obtained from a marine source.
  • the shape and size of the cellulose may depend on the source of origin of the fiber or a combination of fibers and the process of making it. Nonetheless, fibrillated cellulose generally has a diameter and a length, as described below.
  • the fibrillated cellulose in one embodiment, may have a diameter of about 1-5000 nanometer (nm). In yet another embodiment, the fibrillated cellulose may have a diameter of about 5-150 nm or from about 100-1 OOOnm. In yet another embodiment, the fibrillated cellulose may have a diameter of about 5000-1 OOOOnm.
  • the material may have enhanced properties that heighten, enhance, or improve various properties without toxic chemical additives or agents.
  • the material having various properties that are suitable to carry food or liquid items that is generally free from chemical additives or agents.
  • various toxic chemical additives or agents have added to materials during manufacturing process or coated thereon that provide a desirable tensile strength, either dry or wet, enhanced oil barrier, gas and/or liquid impermeability.
  • aspects of the invention instead of with the various toxic chemical additives or agents added to the material, include a composite material with the fibrillated cellulose that is generally free from these additives or agents.
  • the fibrillated cellulose may have a length of about 0.1 - 1000 micrometers, about 10 - 500 micrometers, about 1 - 25 micrometers, or about 0.2 - 100 micrometers.
  • a material with fibrillated cellulose of different diameters such as with a weight ratio of 1 : 100.
  • the fibrillated cellulose may be with a weight ratio of 1 :50.
  • the material with mixed fibrillated cellulose may afford the advantages such as improved tensile strength, either dry or wet, enhanced oil barrier, gas and/or liquid impermeability, and cost savings.
  • a material with fibrillated cellulose may possess a property of an oxygen transmission rate of about 8000 cm 3 rrr 2 24 IT 1 or less. In another embodiment, the oxygen transmission rate of about 5000 cm 3 nr 2 24 IT 1 or less. In yet another embodiment, the oxygen transmission rate of about 1000 cm 3 rrr 2 24 IT 1 or less.
  • the material may possess a property of a water vapor transmission rate of about 3000 g rrr 2 24 IT 1 or less. Moreover, for another embodiment, the water vapor transmission rate may be about 1500 g rrr 2 24 h 1 or less.
  • a material may possess a property of a dry tensile strength of about 30 MPa or higher. In another embodiment, the dry tensile strength may be about 70 MPa. In yet another embodiment, the dry tensile strength may be about 100 MPa or higher. In some embodiments, the material may possess a property of a dry tensile modulus of about 4 GPa or higher. In another embodiment, the dry tensile modulus of about 6 GPa or higher.
  • the material may possess a property of a dry tensile index of about 45 Nm g -1 or higher. In another embodiment, the property may be about 80 Nm g -1 or higher.
  • the material may possess a property of a wet tensile strength of about 5 MPa or higher. In another embodiment, the wet tensile strength may be about 20 MPa or higher.
  • the material may possess a property of a wet tensile modulus of about 0.4 MPa or higher. In another embodiment, the wet tensile modulus may be about 1.0 MPa or higher.
  • the material may possess a property of a wet tensile index of about 5 Nm g -1 or higher. In another embodiment, the wet tensile index may be about 20 Nm g -1 or higher.
  • the material may include an adhesive agent to enhance dry and/or wet strength.
  • the adhesive agent may include polymers.
  • the adhesive agent may include metal salts.
  • the adhesive agent may include oligomers.
  • the adhesive agent may include a carboxylic acid.
  • the adhesive agent may include a plasticizer.
  • the weight ratio of fibrillated cellulose to the adhesive agent in the present invention may be about 33:1 to 1:1.
  • the polymers may include polyester, gelatin, polylactic acid, chitin, sodium alginate, thermoplastic starch, polyethylene, chitosan, chitin glucan, polyvinyl alcohol, or polypropylene.
  • the polymers may include in chemical additives that may be applied to the composite materials of aspects of the invention.
  • the chemical additives may be embedded in the material itself or may be sprayed or coated thereon.
  • the adhesive agent may include metal salts.
  • the metal salts may include potassium zirconium carbonate, potassium aluminum sulphate, calcium carbonate, and calcium phosphate.
  • the weight ratio of fibrillated cellulose to the adhesive agent in the present invention may be about 33:1 to 1:1.
  • the adhesive agent may include oligomers.
  • the oligomers may include oligonucleotide, oligopeptide, and polyethylene glycol.
  • the weight ratio of fibrillated cellulose to the adhesive agent in the present invention may be about 33: 1 to 1:1.
  • the adhesive agent may include a carboxylic acid.
  • the carboxylic acid may include citric acid, adipic acid, and glutaric acid.
  • the weight ratio of fibrillated cellulose to the adhesive agent in the present invention may be about 33:1 to 1:1.
  • the adhesive agent with the plasticizer may reduce a brittleness and gas permeability of the adhered composite.
  • the plasticizer may include polyol.
  • the polyol may comprise glycerol.
  • the polyol may comprise sorbitol.
  • the polyol may comprise pentaerythritol.
  • the polyol may comprise polyethylene glycol.
  • the weight ratio of plasticizer to the composite material to an adhesive agent is about 5: 33: 1 to about 1 : 1 : 1.
  • the plasticizer may comprise branched polysaccharide, wax, fatty acid, fat and oil.
  • aspects of the invention may further include a water repellent agent as a chemical additive to repel gas and/or liquid state water.
  • the water repellent agent comprises an animal-based wax, an animal-based oil or an animal-based fat.
  • the water repellent agent comprises a petroleum-derived wax or a petroleum-based wax.
  • the water repellent agent comprises a plant-based wax, a plant-based oil or a plant-based fat.
  • an animal-based water repellent may comprise beeswax, shellac and whale oil.
  • a petroleum-based wax water repellent may comprise paraffin wax, paraffin oil and mineral oil.
  • a plant-based water repellent may comprise carnauba wax, soy oil, palm oil, palm wax, carnauba wax and coconut oil.
  • a water repelling agent may comprise adhesive agent such as potassium zirconium carbonate, potassium aluminum sulphate, calcium carbonate and calcium phosphate.
  • the material may comprise fibrillated cellulose further optionally may include an antimicrobial agent.
  • an antimicrobial agent may comprise tea polyphenol.
  • an antimicrobial agent may comprise pyrithione salts, parabens, paraben salts, quaternary ammonium salts, imidazolium, benzoic acid sorbic acid and potassium sorbate.
  • another embodiment of the invention may include a material having fibrillated cellulose further optionally comprises a transparent composite to increase the transmission of light with wavelength from about 300 to 800nm.
  • a material may comprise branched polysaccharides.
  • the weight ratio of the material to transparent composite ranges differently, which may depend on the transparency required, e.g., about 99: 1 to about 1 :99.
  • branched polysaccharides may comprise starch, dextran, xantham gum, and galactomannan.
  • a dextran may comprise agarose, pullulan, and curdan.
  • a dextran may comprise agarose, pullulan, and curdan.
  • the two-dimensional example may be a planar sheet where the planar sheet may be used to be decomposed for forming end products.
  • the material may be in a solution that may be ready for forming end products.
  • the three-dimensional example may be end products.
  • the end product may include containers for digestible or edible items, such as those shown in FIGS. 5 to FIG. 7.
  • the end products that embody the materials as described in this application may include food containers or packages.
  • the food containers or packages may include airplane or airline meal containers, disposable cups, ready-to-eat food containers, capsules, ice cream carton or containers, and chocolate containers.
  • a product may comprise instant food containers that may further contain spices, e.g., instant cup noodles, instant soup, or the like.
  • the container may be subjected to water or liquid at high temperature, such as about 100 degrees Celsius.
  • the airplane meal containers are made of various forms of plastic for properties of lightweight, rigidity, oil resistance, etc.
  • existing plastic containers may be subjected to heating via an oven. The heating may release carcinogenic substance from the plastic container to the digestible or edible items. As such, such effects are not desirable.
  • Embodiments of the invention, along with the properties described above, may exhibit properties that are water resistant, high heat tolerance, oil resistant, etc., without releasing carcinogenic substance.
  • the capsule example may be a capsule for machines for hot beverage.
  • the capsule may be contain coffee, tea, herbs, or other drinks.
  • the capsule may be a disposable capsule.
  • the capsule may be a disposable coffee bag or pouch.
  • the electrical beverage machine may deposit or inject water at high temperature or high pressure to the capsule so that the beverage making process may start and that the coffee may drip out of the capsule or pouch to a consumer’s cup.
  • the capsule or pouch comprises the biodegradable and sustainable materials having one or more properties as described above, the capsule or pouch may be easily recycled without creating burden to the environment.
  • the capsule may have a sidewall with a thickness of about 500 micron.
  • the capsule may include a top or a lid having a thickness of about 500 micron.
  • the capsule may include a bottom thickness of about 300 micron.
  • the capsule may be formed/created in one pass from the former (to be discussed below) and that the thickness of a top, a sidewall and a bottom with different thickness.
  • a product may include a filter to separate, whether permanently, semi-impermeable, or lightly impermeable to particles or molecules in fluid.
  • the product may include a face mask or filter membrane with solid-liquid separation, liquid-liquid separation, or gas-liquid separation effects, etc.
  • a product may comprise cosmetic or skincare container products, medical products, e.g., powder case, palette, protective glass, or medical- grade disposals.
  • a product may comprise part of medical device, automobile, electronic device, and construction material (as reinforcement material).
  • containers embodying materials of the invention may be in a form of containers, planar sheets, trays, plates, reels, boards, or films.
  • a width or length of the material may range from about 0.01 mm to 10000 mm or above. In one embodiment, the width or length may range from about 0.01 mm — 1000 mm. In the embodiment where the films may be a thin layered film with a thickness of about 0.01 - 3.0 mm. In one embodiment, the thickness may be about 0.02 - 0.20 mm. In yet other embodiments, the product may comprise a food package containing oil to water weight ratio of about 100:1 to about 1:100.
  • aspects of the invention may provide a process of manufacturing, generating, or creating the material comprising fibrillated cellulose having properties of the above.
  • Example 1 In addition to the material provided above, aspects of the invention may include a cellulose fibrillation process or method.
  • a flow diagram may illustrate a method for creating such material according to one embodiment.
  • the examples shown below are generally free from toxic chemical additives to improve mechanical properties of the composite material.
  • a cellulose paper board (about 3.0 wt. %) was torn into pieces such as A4 sized paper. The shredded pieces is thrown into a pulping machine (not shown in FIG. 8). The pulping process may take about 20 minutes.
  • a refiner 802 may be used to begin the process.
  • the refiner 802 may be a homogenizer, a grinder, a chemical refinement chamber/bath, a combination of a mechanical and chemical fiber refinement device, or the like.
  • the refiner 802 may include a two grindstones facing each other. The separations or distances between the two grindstones may be adjusted as a function of the desirable end products. In another embodiment, surface grooves or patterns may be adjusted as a function of the desirable end products.
  • a pulp suspension 806 is then fed into the refiner, optionally for about 1 - 10 passes. In other instances, the pulp suspension 806 may be fed into a refiner (not shown), e.g., colloid mill, double disk grinder, to refine further the cellulose pulp before entering the refiner 802.
  • FIGS. 1a to 1d show the condition of fibrillated cellulose with increasing numbers of passes.
  • FIG. 1a may represent a cellulose fibers aqueous suspension with 0 cycle or pass.
  • FIG. 1b may illustrate a post-refinement 808 where the pulp suspension 806 has passed the refiner 802 after 1 pass.
  • the post refinement 808 may now include fibrillated cellulose fibers aqueous suspension.
  • FIG. 1c illustrates an image of a post-refinement 808 that has passed the refiner 802 after 2 passes or 2 cycles.
  • the fibrillated cellulose fibers in the post-refinement 808 is finer than that of what’s shown in FIG.
  • FIG. 1 d may illustrate an image of a post-refinement 808 after 3 cycles/passes.
  • the post-refinement 808 may include even finer fibrillated cellulose fibers than that in FIG. 1c.
  • the post-refinement 808 may include fibrillated cellulose fibers and water with concentrations of fibrillated cellulose at about 2.5 wt.% of cellulose (and 97.5% water), about 3.0 wt.% of cellulose, about 3.6 wt.% of cellulose, and about 4.0 wt.% of cellulose were tested and used.
  • fibrillated cellulose fibers concentration with about 2.5 wt.% or even regular pulp suspension solution would be insufficient for achieving properties of aspects of the invention.
  • the fibrillated cellulose with the post-refinement 808 with about 3.0 wt.%, about 3.6 wt.%, and about 4.0 wt.% are termed herein as L028, L029, and L030, respectively, in FIG. 5.
  • FIG. 2 may illustrate a SEM image of fibrillated cellulose at about 3 wt. % concentration.
  • a semi-processed cellulose fibers may be obtained from a market source.
  • the semi-processed cellulose fibers e.g., about 3 wt. % is fed into a colloid mill and grind for about 1 minute.
  • the fibrillated cellulose fibers may further be processed in the refiner 802.
  • FIG. 3 may illustrate an SEM image for semi-processed fibers after colloid milling for 1 minute.
  • Table 2 shows the properties of different fibrillated cellulose from different source.
  • FIG. 3 may illustrate where a-b are SEM images for Y-cellulose fibers in Table 2 and c-d are SEM images for B- cellulose fibers.
  • FIG. 4 shows SEM images for semi-processed fibers after mechanically ground for 1 cycle/pass.
  • FIG. 4 a-b are for Y-cellulose fibers
  • FIG. 4 c-d are for B-cellulose fibers.
  • a mixer 804 may provide a suspension of pulp 806 of cellulose pulp in water comprises a mixture of cellulose pulp in water, wherein the cellulose to water weight ratio is about 0.01 to 100. In another embodiment, the weight ratio may be about 0.03 to 0.10.
  • the post-refinement 808 from the refiner 802 may be kept in the event that it may be used to be grinded again by the refiner 802. For example, as described above, the number of passes that the post-refinement 808 goes through the refiner 802 may be from 1 - 100. In another embodiment, the number of passes or cycles may be further limited to 1 - 10.
  • a weight ratio of the fibrillated cellulose to water and/or the number of passes through the refiner 802 may be a function of the end products’ desirable properties. For example, if the end product requires a low water vapor transmission, and a low oxygen transmission, then the post-refinement 808 may be with a weiaht ratio of cellulose to water closer to about 0.03-0.043-4% fas demonstrated by L28b - L30b) and/or the number of passes may increase.
  • the relative low water vapor transmission, and relative low oxygen transmission may indicate high shelf life while the relative high water vapor transmission and relative high oxygen transmission may indicate lower shelf life.
  • the post-refinement 808 may be processed by a former 810.
  • the former 810 may generate an intermediate 818 based on the post-refinement 808 to a desirable material with the fibrillated cellulose.
  • the intermediate 818 may be at a ratio by weight of fibrillated cellulose to liquid (e.g., water) of about 0.001 to 99. In another embodiment, the ratio may be from about 0.001 to 0.10.
  • the former 810 may include a mesh or fibrous network.
  • the former 810 may include a negative pressure and/or positive pressure or any combination thereof.
  • the former 810 may apply pressure to separate the fibrillated cellulose in the post refinement 808 from liquid to form the intermediate 818. Due to the fibrillated nature of the fibrillated cellulose fibers and through the process of the refiner 802, the fibers with different lengths may form the intermediate 818, as shown by the various SEM images in FIGS. 2-4 and 7.
  • a base layer 812 may be used in conjunction with the post-refinement 808 to form the intermediate 818.
  • the GCM of aspects of the invention may include a composite material having a substrate layer of pulp (e.g., the base layer 812) and a fibrillated cellulose layer (e.g., from the post refinement 808).
  • the former 810 may subject the base layer 812 to a mesh, a mold, or a frame to form a construct for the intermediate 818.
  • the base layer 812 may first be in a form of a solution or slush of water and pulp material. The slush may be in a tank and the mesh may be in the tank as well. Through a negative pressure such as a vacuum, water from the tank may be removed or reduced so the based layer 812 is formed on the mesh.
  • the former 810 may include a sprayer or an applicator for spraying or applying the post-refinement 808 to the base layer 812 to form the intermediate 818.
  • the post-refinement 808 is infused with the base layer 812.
  • the post-refinement 808 may be applied or sprayed on a surface of the intermediate 818 that carries edible items. For example, suppose an end product is a bowl, the post-refinement 808 may be applied or sprayed onto an interior surface of the end product.
  • the intermediate 818 may exhibit patterns of the mesh or the fibrous network, as shown in 502 or 504, on an exterior surface thereof.
  • the former 810 may spread the intermediate 818 on a flat surface for drying or forming by natural process.
  • a dryer 814 may further be provided to dry or dehumidify the intermediate 818.
  • the dryer 814 may provide a drying condition of 30°Celcius to 200°Celcius.
  • the dryer 814 may include a heated surface, such as an infra-red heating.
  • microwave heating or air heating may be used without departing from the spirit and scope of the embodiments.
  • the dryer 814 may also be aided by negative pressure and/or positive pressure.
  • a cellulose based bowl is successfully produced by adopting combinations of materials and methods described previously.
  • the functionality of the cellulose based food container in this example, may be used to prove filling typical cooking oil into the container, as shown in FIG. 5.
  • the cooking oil with the cellulose-based food container may be heated by microwave at 800W for 4 minutes and observed for 10 days, which is shown in FIG. 5.
  • the container in FIG. 5 may represent ones made of fibrillated cellulose L28b, L29b, L30b, and Y.
  • each of the ones in FIG. 5 may be able to hold oil for about 10 days.
  • FIG. 6A shows an example of a fibrillated cellulose structure in a container, such as a food container.
  • FIG. 6A illustrates a series of images of a fibrillated cellulose filled with boiling water and let it stand for about 5 minutes.
  • FIG. 6B illustrates a series of images of the fibrillated cellulose filled with boiling water and microwave heated at 800 W for about 2 minutes.
  • FIG. 7 is another image showing a SEM image for a structure of fibrillated cellulose in food container in FIGS. 6Aand 6B according to one embodiment.
  • FIGS. 9a through 9c images illustrate a film according to example 4 of an embodiment.
  • a composite material according to aspects of the invention may be in a transparent composite film based on fibrillated cellulose.
  • the film may be produced by dissolving the fibrillated cellulose and pullulan powder in water to produce solutions containing about 1 wt.% of solute, separately.
  • the powder may be progressively added thereto, and the solution may be heated via microwave at power of 800W for 1 minute. In one embodiment, this process may repeat for about 4-5 times until a clear solution is formed.
  • the fibrillated cellulose such as the post-refinement 808, to pullulan may be with a ratio of about 1:1,
  • about 250 g of the post-refinement 808 e.g., the fibrillated cellulose of about 1%) may be mixed with about 250 g of pullulan solution to produce a solution with about 0.5% solute.
  • about 100 g of the mixed solution was poured onto a hydrophobic surface, e.g., silicone surface and allowed to dry at room temperature.
  • 250 g of the post-refinement (e.g., the fibrillated cellulose of about 2%) may be mixed with about 250 g of pullulan solution to produce a solution with about 1 % solute. Then, about 100 g of the mixed solution was poured onto a hydrophobic surface, e.g., silicone surface and allowed to dry at 50 °C and 12 hours.
  • a hydrophobic surface e.g., silicone surface
  • FIGS. 9a through 9c may illustrate images of cellulose based film where fibrillated cellulose to pullulan with a ratio of a.) 0:1 , b.) 1:1, and c.) 2:1.
  • the addition of pullulan may enhance the film forming process to smooth the film’s surface, where film made of fibrillated cellulose (e.g., the post-refinement 808), herein termed as L41b below, is highly wrinkled. Whereas the other films with pullulan provide smoother and even surface.
  • the film of the composite material with the fibrillated cellulose and pullulan may be generally free from uneven surface.
  • mechanical properties of transparent composite film were shown below, where fibrillated cellulose is denoted as L41b, and pullulan is represented as B.
  • aspects of the invention may include fibrillated cellulose with water repellant.
  • the mixture may include a correct ratio of cellulose and a water repellant, and blended for 3 minutes using a mechanical blender.
  • the mixture may further be diluted to 4000 ml_ and pour onto the former 810.
  • 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 mixture may be shown in Table 4. [0091 ] Table 4 illustrates properties of fibrillated cellulose films with different water repellant.
  • the 1000 component may be regarded as a container.
  • the paper fiber may be received by the 1001 from the water tank containing the pulp using its vacuum principle.
  • 1001 may include a fiber catcher.
  • the fiber joint may be a mesh, because the paper fibers of the water tank may stay in the mesh body, and the liquid will pass through the mesh.
  • the vacuum principle includes first pumping and discharging the water in the water tank, and then allowing the vacuum environment to be tightly received on the 1001 component to make a first material.
  • the component 1001 may be rotated to have the component faching upward or downward to enter into the container 1000 to form the final product.
  • the component 1001 may be roated again (e.g., 180 degrees) so that any remaining moisture or water or liquid may be extracted.
  • a component 1004 may be connected to a component 1002, and the component 1004 may move its vacuum suction function up, down, left, and right, and the component 1004 may be installed and configured with its component 1002.
  • component 1002 may be used to receive the first material on the element 1001. As shown in FIGS. 10Aand 10B, the components 1002 and 1004 may be moved to the third unit or the water removal device. Similarly, in one embodiment, the component 1002 may be roated to have the water removed.
  • the arrangement of the present invention in the components 1000, 1002, 1004, 1006, and 1008 does not require linear arrangement.
  • the component 1004 may move in multiple directions, 1000, 1006 or 1008 may be circular, triangular, above, below and other relative positions.
  • the component 1004 may include a robotic arm or device to move.
  • the component 1004 may be moved manually, and may be moved to 1006 or 1008 by mechanical, rotating disk, or with rail assistance, either manually or with motorized assistance (e.g., such as with robotic arms).
  • the component 1004 may be moved individually or collectively when multiple components 1004 may be employed.
  • the second material in a singular manufacturing process, such as one product item or a mold loading process, the second material may be received through 1002 and 1004.
  • the second material is effectively added to the first material by the components 1002 and 1004.
  • the second material may be joined to the first material through the component 1006, and as in the above example, the first and second materials are closely mixed to form a third material.
  • the third material may show that the first material and the second material exhibit different layers.
  • the components 1000 and 1001 may receive the first material.
  • the components 1001 and 1006 may receive the second material.
  • multiple station configuration may produce two different products.
  • the components 1002 and 1004 move the materials to the next station, the two different products may be produced simultaneously or substantially simultaneously.
  • the time needed for producing different products are greatly reduced and the space neeed to for the equipment may be reduced as well.
  • the container or workstation storing the second material additionally adds a source of heat or heating.
  • a source of heat or heating may be added to the container, so that the second material may be mixed with the first material or before the second material is mixed with the first material to about 40 or more degrees Celsius to obtain the best and most efficient production of the final product efficiency.
  • the heating source may be heated by means of electric heating, steam, liquid or the like.
  • the components 1002 and 1004 are moved to a component 1008 dewatering station to perform the steps of water removal or water reduction.
  • the third material may be moved from the component 1006 to the component 1008.
  • the third material is in a vacuum-sealed state during the mixing process of the components 1002, 1004, 1006, and 1008 during the mixing of the third material, and then the positive pressure function or pressurization function is used on the component 1008 to make it load the space for combining the materials.
  • the component 1008 may be rotated.
  • the second material may also directly serve as the main body of the third material, as shown in FIG. 10B.
  • the second material is not mixed with the first material.
  • the device of the present invention may be an automated device, as shown in FIG. 11 A, that is, the first unit, the second unit, and the third unit are a set of coherent devices.
  • the third material may be made detachable and separated with a combination of components.
  • FIGS. 11 A to D show that the component 1004 is moved by a track, but those skilled in the related art may easily use other methods to move the component 1004 without departing from the basic principles of the present invention, and the movement does not need to be limited to move in the same plane.
  • embodiments of the present invention also includes a software system to operate the apparatus of the present invention, including sensors at the components 1000, 1001, 1002, 1004, 1006, 1008, etc. to transmit parameter information.
  • the software system also may include different interfaces, whether it is a centralized interface or may be presented on a mobile device via the network.
  • separate components may have a continuous or separate interface and software to communicate and operate the operation of the units or components.
  • the software system also may report notifications and warning functions to provide administrators with efficient management of the production process.
  • the mold and the transfer mold have a rotational feature in some embodiments.
  • the component 1001 e.g., mold
  • the component 1002 may include the rotation function.
  • the component 1001 may be rotated after the product is transferred, and the water or moisture may be discharged by means of vacuum or gravitational force.
  • Grouting When 1001 and 1002 are mated or joined, in one example, a pouring cavity may be inside the component 1001 , and and may use a pump to feed the material in the container 1000 into the cavity of the component 1001 , and then the water therein may be drawn or taken out by vacuum or other forces. Once, the first material is completed, the second material may be completed by applying the component 1006 in the same way. In one example, in using the components 1000 and 1006, the slurry bucket (e.g., container 1000) may be installed at any position below or above the equipment.
  • FIGS. 12Aand B may now illustrate another embodiment of the device, which is also an extension of of FIGS. 10A-11D.
  • the paper forming process may include: 1. decompose the cardboard into pulp through the pulping system. The pulp may be mixed with other materials required for the pulp before entering the forming system. 2. Use vacuum or suction force as the power to attach the pulp material to the surface of the mold, and then use the drainage system on the surface of the mold to drain the excess water, so that a thin layer of wet embryo material is formed on the surface of the mold. 3. After molding, the surface of the product needs a lot of moisture. Natural air drying, hot air, air pressure, mold heating and other methods may be used to assist hot pressing to drain the remaining moisture of the material.
  • Slurry molding method-the molding method is to use the inside of the mold to make a vacuum cavity. Under the action of vacuum, the fibers of the pulp may be uniformly layered and attached to the molding net on the surface of the mold, and the mold surface faces upward into the pulp In the tank, a large amount of water will be taken away by vacuum suction. When the product reaches a certain thickness, the product mold will leave the pulp tank, and the wet embryo pulp on the surface of the mold will be dehydrated.
  • FIGS. 12Aand B illustrate a horizontal, linear or a substantially linear system where, 1204, 1204' and 1204" may be fixing units, 1202, 1202', 1202" may be transferring element, 1201 , 1201 ' are molds or mesh, and 1200 may be the first layer of a material; 1206 may be a second material; and 1208 may be a dehydration or positive press component.
  • the feature of this equipment may be a horizontal or a linear system (in terms of flow of end product), a multi-station system, or an assembly line, and 1202 or 1201 may be rotated, and 120T may also be rotated.
  • the vertical system includes 1304 as a fixing unit, 1301 as a mold, 1300 as a first material, 1306 as a second material, and 1308 for dehydration, dewatering, positive pressure, hot air, compression, heating, and other machines.
  • the 1301 mold may be designed for rotation.
  • FIGS. 12A and B and FIG. 13 may be partially combined.
  • the method of forming the container 1 of the first material and the container 2 of the second material may include one or more features:
  • the molding workstation may use the injection + suction or suction + injection.
  • the above rotation actions may be used: 1. Motor drive mechanism to rotate the mold , 2. The vertical movement of the mold drives the connecting rods, racks or mechanical structure equipment to rotate.
  • the present invention may further enable the following combinations to achieve processes that were not possible in the past:
  • the equipment of the present invention may be equipped with multiple (more than one) slurries during the molding stage, which may produce different molding processes to fulfill other different product requirements:
  • the forming station After the forming station is completed, it may be connected or transferred to the 1008 dehydration process.
  • the dehydration equipment of this equipment is equipped with positive pressure and compression devices, which may accelerate the time of pulp drainage and forming, which is beneficial for forming thick products.
  • Multilayer transfer stacking molding including composite materials
  • the use of a linear transfer system or a vertical rotation system may simultaneously complete the connection of the first layer of material and the second layer of material.
  • the 1002 and 1004 transfer products may be used to stack two or more or the same materials together to make thick and thin composite materials.
  • Timing of pulp additives in pulp molding is very important. One may add them and put them in a separate molding barrel. We may choose appropriate timing to add them to increase the ability of the additives to combine with the pulp fibers. Independent additives may also reduce The chance of pulp backwater being contaminated by additives in other systems will improve the quality of the backwater.
  • the transfer products 1002 and 1004 may be used to stack two or more or the same materials together to make a composite material.
  • FIG. 14A special features of elements of the containers may enhance this usage.
  • airplane food containers need to be light-weight, durable, and reheatable or heatable.
  • ovens or steamers on board a commercial airplane may be used to heat the meals.
  • the meal items may be with sauce, soup, or other liquids or fluids and some of these meal items are served warm or hot.
  • aspects of the invention may include a lid for the container and the lid is also made of the material illustrated in the present application.
  • the lid and the container may include a locking mechanism that enable safe transportation of the containers and the meals.
  • a tongue element in the container’s outer edge at the end of its curved end may enter an opening created by an end of the lid.
  • the end of the lid may include a tip that may bend toward the container, thus creating the opening, instead of away from the container.
  • the tip may include a sufficient length that pushes against the curved end of the container so as to allow the tongue element to engage the upper end of the opening of the lid.
  • the engagement of the tip and the curved end, as well as the tongue and the upper end of the lid is strong to keep the lid intact during transportation and heating/reheating.
  • the tongue may be inserted to a tight opening by the end of the lid so it is a friction fit between the container and the lid.
  • the outer surface of the lid and the bottom of the container may include complimentary features. For example, as shown in FIG.
  • the meal containers need to be stackable.
  • the lid may include a lowered center portion or a recess with a contoured or concaved curved edge connecting the lowered center portion and the surface of the lid.
  • the footers of the container may be positioned inside the lowered center with each of the footers (e.g., 4) to engage four corners of the lowered portion and the contoured/concaved curved edge.
  • the footers are protruding from the bottom of the container, as shown in FIG. 14D.
  • the footers are configured to create additional airflow by creating spaces between the container and the lid in a stacked position so that heat or steam may flow between the container and the lid.
  • such feature further may maintain the wet tensile strength of the container.
  • aspects of the invention overcome shortcomings of the prior approaches where there are toxic chemicals (e.g., fluoropolymers and its derivatives) are added. Aspects of the invention also overcome the shortcomings of prior approaches of using pulps as the base layer or layers. It is to be understood that pulp fibers are in the 10 to 50 micrometer (pm) range for their diameters. Whereas aspects of the invention are finer in size, such as in the range of below 1 pm.
  • toxic chemicals e.g., fluoropolymers and its derivatives
  • the present disclosure provides a solution to the long-felt need described above.
  • aspects of the invention overcome challenges of relying on existing practices of using chemical formulas to provide enhanced properties for cellulose materials.

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Wood Science & Technology (AREA)
  • Forests & Forestry (AREA)
  • Wrappers (AREA)
  • Polysaccharides And Polysaccharide Derivatives (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Paper (AREA)

Abstract

La présente invention concerne des procédés, un appareil et un système d'un matériau de nanocellulose fibrillée qui permettent de pallier les inconvénients des technologies antérieures en infusant de la nanocellulose sous une forme fibrillée pour améliorer les propriétés de la pâte cellulosique. Ces propriétés, qui peuvent comprendre, par exemple, les propriétés mécaniques et de barrière, c'est-à-dire, la résistance à la traction, l'imperméabilité aux liquides et aux gaz, tels que l'oxygène, le dioxyde de carbone, et l'huile, peuvent être considérablement améliorées. L'invention concerne également un matériau composite de cellulose fibrillée qui a les propriétés d'un agent qui améliore la résistance, d'un oligomère, d'un acide carboxylique, d'un plastifiant, d'un agent antimicrobien, d'un agent hydrofuge, et d'un composite transparent.
EP21800152.7A 2020-05-04 2021-05-04 Procédé, appareil et système d'un matériau de nanocellulose fibrillée Pending EP4146862A4 (fr)

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US202063019849P 2020-05-04 2020-05-04
US202063019852P 2020-05-04 2020-05-04
US17/241,050 US20210254285A1 (en) 2016-02-24 2021-04-26 Cellulose materials and methods of making and using the same
PCT/IB2021/053711 WO2021224778A1 (fr) 2020-05-04 2021-05-04 Procédé, appareil et système d'un matériau de nanocellulose fibrillée

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TWI827002B (zh) * 2022-04-15 2023-12-21 樂緹股份有限公司 環保食器之塑形原材備置及該食器成形工法
WO2024084378A1 (fr) * 2022-10-16 2024-04-25 Chang Yiu Wen Procédé, appareil et système avancés d'un matériau de nanocellulose fibrillée

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JPH10212690A (ja) * 1997-01-23 1998-08-11 Oji Paper Co Ltd 低密度体
CN1100181C (zh) * 1997-09-02 2003-01-29 北京市畅达贸易发展公司 纸质餐具自动化生产设备
ES2467694T3 (es) * 2010-04-27 2014-06-12 Omya Development Ag Proceso para la fabricación de materiales estructurados usando geles de celulosa nanofibrilares
WO2012071578A2 (fr) * 2010-11-24 2012-05-31 Bc Genesis Llc Dosages biologiques pharmacologiques pour recherche de médicaments, évaluation de toxicité et recherche sur le cancer in vitro à l'aide d'un échafaudage 3d de nano-cellulose et de tissus vivants
CN103966888B (zh) * 2013-02-05 2016-08-03 金东纸业（江苏）股份有限公司 复合物及其制备方法，应用其的浆料及纸张
JP6314094B2 (ja) * 2015-01-22 2018-04-18 大王製紙株式会社 複合紙の製造方法及び複合紙
CN109152394B (zh) * 2016-02-24 2023-07-14 寰科创新有限公司 纤维素材料及其制备和使用方法
EP3508637B1 (fr) * 2016-08-31 2021-07-21 Seiko Epson Corporation Dispositif de production de feuille
EP3409691B1 (fr) * 2017-05-31 2019-10-02 SAPPI Biochemtech B.V. Procédé de production d'un matériau de nanocellulose
SE542093C2 (en) * 2018-02-27 2020-02-25 Stora Enso Oyj Method for production of a paper, board or non-woven product comprising a first ply
US11479919B2 (en) * 2018-08-23 2022-10-25 Eastman Chemical Company Molded articles from a fiber slurry
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KR20230047956A (ko) 2023-04-10
JP2023525069A (ja) 2023-06-14
BR112022022489A2 (pt) 2023-01-10
TWI816115B (zh) 2023-09-21
EP4146862A4 (fr) 2024-06-05
CA3182366A1 (fr) 2021-11-11
TW202202694A (zh) 2022-01-16
AU2021267203A1 (en) 2022-12-08
WO2021224778A9 (fr) 2022-12-01
WO2021224778A1 (fr) 2021-11-11

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