EP4232632A1 - A moulding material, a method for preparing such material and a moulded product - Google Patents
A moulding material, a method for preparing such material and a moulded productInfo
- Publication number
- EP4232632A1 EP4232632A1 EP21882295.5A EP21882295A EP4232632A1 EP 4232632 A1 EP4232632 A1 EP 4232632A1 EP 21882295 A EP21882295 A EP 21882295A EP 4232632 A1 EP4232632 A1 EP 4232632A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- moulding material
- moulded product
- dry
- moulding
- cellulose
- 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
Links
- 239000000463 material Substances 0.000 title claims abstract description 129
- 238000000465 moulding Methods 0.000 title claims abstract description 60
- 238000000034 method Methods 0.000 title claims abstract description 30
- 229920002678 cellulose Polymers 0.000 claims abstract description 39
- 239000001913 cellulose Substances 0.000 claims abstract description 39
- 239000002023 wood Substances 0.000 claims abstract description 28
- 239000000654 additive Substances 0.000 claims abstract description 19
- 239000007787 solid Substances 0.000 claims abstract description 18
- 230000000996 additive effect Effects 0.000 claims abstract description 16
- 230000004888 barrier function Effects 0.000 claims description 25
- 229920002134 Carboxymethyl cellulose Polymers 0.000 claims description 16
- 239000000725 suspension Substances 0.000 claims description 16
- 238000003825 pressing Methods 0.000 claims description 12
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 12
- 239000002245 particle Substances 0.000 claims description 9
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 claims description 6
- 229920000126 latex Polymers 0.000 claims description 6
- 238000002156 mixing Methods 0.000 claims description 6
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 5
- 239000004816 latex Substances 0.000 claims description 5
- 239000001301 oxygen Substances 0.000 claims description 5
- 229910052760 oxygen Inorganic materials 0.000 claims description 5
- 239000011248 coating agent Substances 0.000 claims description 4
- 238000000576 coating method Methods 0.000 claims description 4
- 239000006185 dispersion Substances 0.000 claims description 4
- 229920000098 polyolefin Polymers 0.000 claims description 4
- 235000014113 dietary fatty acids Nutrition 0.000 claims description 3
- 239000000194 fatty acid Substances 0.000 claims description 3
- 229930195729 fatty acid Natural products 0.000 claims description 3
- 150000004665 fatty acids Chemical class 0.000 claims description 3
- 235000013312 flour Nutrition 0.000 claims description 3
- 229920005610 lignin Polymers 0.000 claims description 3
- 239000004971 Cross linker Substances 0.000 claims description 2
- 238000001465 metallisation Methods 0.000 claims description 2
- 239000000843 powder Substances 0.000 claims description 2
- 239000000047 product Substances 0.000 description 24
- 239000000835 fiber Substances 0.000 description 17
- 239000002775 capsule Substances 0.000 description 13
- 239000001768 carboxy methyl cellulose Substances 0.000 description 13
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 13
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 13
- 241000196324 Embryophyta Species 0.000 description 7
- 238000009826 distribution Methods 0.000 description 6
- 239000002028 Biomass Substances 0.000 description 5
- 238000004806 packaging method and process Methods 0.000 description 5
- 239000000126 substance Substances 0.000 description 5
- 108090000790 Enzymes Proteins 0.000 description 4
- 102000004190 Enzymes Human genes 0.000 description 4
- 238000000227 grinding Methods 0.000 description 4
- 238000000265 homogenisation Methods 0.000 description 4
- 239000004033 plastic Substances 0.000 description 4
- 229920003023 plastic Polymers 0.000 description 4
- 229910001220 stainless steel Inorganic materials 0.000 description 4
- 239000010935 stainless steel Substances 0.000 description 4
- 241000894006 Bacteria Species 0.000 description 3
- QMGYPNKICQJHLN-UHFFFAOYSA-M Carboxymethylcellulose cellulose carboxymethyl ether Chemical compound [Na+].CC([O-])=O.OCC(O)C(O)C(O)C(O)C=O QMGYPNKICQJHLN-UHFFFAOYSA-M 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 238000004898 kneading Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 239000003921 oil Substances 0.000 description 3
- 229920003043 Cellulose fiber Polymers 0.000 description 2
- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 2
- 229920002488 Hemicellulose Polymers 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 229910001882 dioxygen Inorganic materials 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 239000004519 grease Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000005022 packaging material Substances 0.000 description 2
- 108010059892 Cellulase Proteins 0.000 description 1
- 125000002353 D-glucosyl group Chemical group C1([C@H](O)[C@@H](O)[C@H](O)[C@H](O1)CO)* 0.000 description 1
- 244000166124 Eucalyptus globulus Species 0.000 description 1
- 229920001131 Pulp (paper) Polymers 0.000 description 1
- QYTDEUPAUMOIOP-UHFFFAOYSA-N TEMPO Chemical group CC1(C)CCCC(C)(C)N1[O] QYTDEUPAUMOIOP-UHFFFAOYSA-N 0.000 description 1
- 241000251555 Tunicata Species 0.000 description 1
- 239000012736 aqueous medium Substances 0.000 description 1
- 239000012620 biological material Substances 0.000 description 1
- 210000002421 cell wall Anatomy 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000000748 compression moulding Methods 0.000 description 1
- 230000001143 conditioned effect Effects 0.000 description 1
- 239000002537 cosmetic Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 239000003925 fat Substances 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 235000013305 food Nutrition 0.000 description 1
- 239000013538 functional additive Substances 0.000 description 1
- 150000004676 glycans Chemical class 0.000 description 1
- 239000011121 hardwood Substances 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- GDOPTJXRTPNYNR-UHFFFAOYSA-N methyl-cyclopentane Natural products CC1CCCC1 GDOPTJXRTPNYNR-UHFFFAOYSA-N 0.000 description 1
- 210000001724 microfibril Anatomy 0.000 description 1
- 108700005457 microfibrillar Proteins 0.000 description 1
- 239000002121 nanofiber Substances 0.000 description 1
- 229920005615 natural polymer Polymers 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920001282 polysaccharide Polymers 0.000 description 1
- 239000005017 polysaccharide Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 239000011122 softwood Substances 0.000 description 1
- 241000894007 species Species 0.000 description 1
- 238000009864 tensile test Methods 0.000 description 1
- 238000001771 vacuum deposition Methods 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
- D21J3/00—Manufacture of articles by pressing wet fibre pulp, or papier-mâché, between moulds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/003—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor characterised by the choice of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/003—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor characterised by the choice of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2001/00—Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0037—Other properties
- B29K2995/0059—Degradable
- B29K2995/006—Bio-degradable, e.g. bioabsorbable, bioresorbable or bioerodible
Definitions
- the additive may be selected from carboxymethyl cellulose (CMC), latex, citric acid, crosslinkers and combinations thereof.
- the additive is preferably added to the suspension of the fibrillated cellulose material before addition of the dry wood-based material. Adding the additive to the suspension of the fibrillated cellulose material before the addition of the dry wood-based material facilitates the formation of a homogeneous moulding material. Common papermaking additives and performance chemicals, such as antiflocculants, hydrophobation chemicals, latices, wet strength agents, and lubricants, may also be added.
- the method may further comprise transferring of the moulding material into a mould.
- the mould may have a three-dimensional shape.
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Dry Formation Of Fiberboard And The Like (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
The present invention relates to to a moulding material comprising 60-98 wt% of a dry wood-based material; 2-40 wt% of a fibrillated cellulose material; and 0-10 wt% of an additive, as calculated on the total dry solids in the moulded material. The invention also relates to a method for preparing such moulding material, as well as a moulded product prepared from said moulding material, and use of the moulding material in a moulded product.
Description
A MOULDING MATERIAL, A METHOD FOR PREPARING SUCH MATERIAL AND
A MOULDED PRODUCT
FIELD OF THE INVENTION
The present invention concerns a moulding material of biomass, a method for preparing such moulding material, as well as a moulded product prepared from said moulding material, and use of the moulding material in a moulded product.
TECHNICAL BACKGROUND
In our modern life, we depend heavily on plastics for multiple purposes, among others packaging for food or cosmetics. Those fossil-based materials are a problem for our nature and the climate.
During recent years there has been an increased awareness of the impact of packaging material on the environment and there is a demand for materials that cause less harm to the environment than petroleum-based plastics. There are ways to form packages by pressing and forming products out of fibre-based biomaterials. Plant-based materials can comprise cellulose, hemicellulose and lignin and be obtained from trees, shrubs, plants and agricultural crops. Cellulose has a special potential, as the most abundant renewable natural polymer on earth, with its crystalline structure, and the availability of methods for preparing large volumes on an industrial scale.
Moulded cellulose pulp provides for an environmentally friendly packaging material that is recyclable, compostable, and eventually biodegradable. In the literature, plastic-free composites are described that are made from pulp fibers, MFC and additives (e.g. Kojima el al., 2014; Diop et al., 2017; Pårs-Rosell, 2017). Another technique for making packaging products is pressing and stamping dry air-laid pulp, but the different shapes or products that can be produced are rather limited.
Small packaging details with three-dimensional shapes are still usually made from fossil-based plastic materials. There is a need for an economically viable process that is rapid and requires a lower energy consumption and allows for the manufacturing large volumes of small packaging details with advanced three-dimensional structures, such as screw caps.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 shows moulded products in the form of capsules of a moulding material of biomass with increasing carboxymethyl cellulose (CMC) content from left to right; and
Figure 2 shows moulded products in the form of capsules of a moulding material of biomass with increasing microfibrillated cellulose (MFC) content from left to right.
DESCRIPTION OF THE INVENTION
The objective of this disclosure is to provide a moulding material prepared from biomass and that is suitable for manufacturing large volumes of small details, a method for preparing the moulding material, as well as a moulded product prepared from said moulding material, and use of the moulding material in a moulded product. A further objective is to provide a material comprising biomass suitable for moulding and that may be pressed under high pressure and heat for formation into packaging details and other end applications.
In a first aspect the present invention relates to a moulding material comprising 60-98 wt% of a dry wood-based material; 2-40 wt% of a fibrillated cellulose material; and 0-10 wt% of an additive, as calculated on the total dry solids in the moulded material.
The wood-based material may be selected from dry particulate fibres, dry- cut cellulose, wood flour, sawdust and different combinations thereof. The fibre length distribution of the fibres can be modified, such as by grinding the fibres to reduce the size of the fibres. Preferably, the wood-based material comprises a cut, particulate or pulverized consistency, ranging in particle size dimension from 0.01 - 2mm, preferably 0.03 - 1mm, more preferably 0.05 - 0.3mm.
According to one aspect, the wood-based material range in particle size dimension from 10 - 300 μm. For instance, wood flour usually comprises an average particle diameter between 10 - 30 μm, whereas sawdust comprises an average particle diameter between 30 - 600 μm.
The moulding material may comprise 60-98 wt%, or 60-94 wt%, or 60-90 wt%, or 60-80 wt% of dry wood-based material, as calculated on the total dry solids in the moulding material.
The fibrillated cellulose is preferably microfibrillated cellulose (MFC). The source for the MFC may be various tree species, other plants, or bacteria. The fibrillated material may also be cellulose nanofibrils. The moulding material may comprise 2-40 wt%, or 5-30%, or 5-20%, or 5-15%, or 10- 20 wt% of a fibrillated cellulose material, as calculated on the total dry solids in the material. MFC will provide a barrier function against oxygen gas of the moulded end product.
The additive may be selected from carboxymethyl cellulose (CMC), latex, citric acid, crosslinkers and combinations thereof.
The total fibrous part of the moulding material may comprise at least 50 wt%, or at least 60 wt%, or at least 70 wt%, or at least 80 wt% or at least 90 wt% of fibres having a fibre length of less than 1 mm.
In a second aspect the present invention relates to a method for preparing the moulding material according to the present invention, the method
comprising providing a suspension comprising the fibrillated cellulose material, e.g. MFC; optionally adding an additive, additional water, or both; and adding the dry wood-based material to the suspension to obtain a moulding material comprising 60-98 wt% of a dry wood-based material; 2- 40 wt% of fibrillated cellulose material; and 0-10 wt% of an additive, as calculated on the total dry solids in the moulding material.
The fibrillated cellulose material may be suspended in an aqueous media, preferably the fibrillated material is suspended in water. The suspension of fibrillated cellulose material contains 2-30 wt%, or 2-25 wt%, or 2-20 wt%, or 5-15 wt% solids, as calculated on the dry solid content in the suspension.
The addition of the dry wood-based material to the suspension of fibrillated material, may be made gradually during mixing. The wood-based material added to the suspension of the fibrillated cellulose material may have a dry content of from 80 to 100 wt%, or from 90 to 100 wt%, or from 90 to 98 wt%.
Said wood-based material is provided in a particulate form with a modified fibre length distribution, obtained e.g. by grinding wood-based material to reduce the size of its fibres, in order to improve the mouldability of the moulding material.
The additive is preferably added to the suspension of the fibrillated cellulose material before addition of the dry wood-based material. Adding the additive to the suspension of the fibrillated cellulose material before the addition of the dry wood-based material facilitates the formation of a homogeneous moulding material. Common papermaking additives and performance chemicals, such as antiflocculants, hydrophobation chemicals, latices, wet strength agents, and lubricants, may also be added.
The method may further comprise transferring of the moulding material into a mould. The mould may have a three-dimensional shape. The moulding material according to the present invention has a sufficiently high moisture content to get a good mouldability, which provides for a good filling of every corner in the mould and allows for pressing of small objects with advanced three-dimensional shapes, such as screwcaps, coffee capsules, etc. The moisture content is also high enough to provide for hydrogen bonding to occur during drying, which results in a high material strength. If the dry solid content in the moulding material that is filled into the mould is too low, large amounts of water must be removed which slows down the process and may also require more energy. Thus, the dry solid content of the moulding material may be at least 40 wt%, or at least 65 wt%. The moulding material may have a dry solid content from 40 to 90 wt%, or from 65 to 80 wt%, most preferably from 65 to 75 wt%, as calculated on the total weight of the mixture. A relatively low moisture content also reduces the risk for liquid water flowing out during pressing and that functional additives escape from the material with the water.
The method may further comprise pressing the moulding material in the mould to form a moulded product. The pressing may be made at a temperature of from 120 °C to 200 °C, or from 130 °C to 180 °C, or from 140 °C to 170 °C. The pressing may be made at a pressure of from 0.5 to 600 MPa, or from 700 to 900 kPa. The pressing may be made for a time of from 10 seconds to 10 minutes, or from 15 seconds to 7 minutes, or from 30 seconds to 7 minutes, or from 1 minute to 7 minutes, or from 1 minute to 5 minutes. The pressing of the material in the mould may enhance the gas barrier properties of the moulded product such as oxygen gas barrier properties. The method may alternatively comprise injection moulding to form a moulded product. Thus, a further aspect of the present invention is a method for preparing a moulded product comprising the measures described herein.
A benefit with the moulding material and the method according to the present invention is their simplicity, such as the possibility of making a moulded product using only chemicals that are already available in the regular papermaking industry. A further advantage with the moulding material is that normally only small changes are required in the standard compression moulding equipment used for shaping the corresponding articles in fossil-based plastic material.
Thus, the present invention also encompasses a moulded product comprising the moulding material according to the present invention. A still further aspect is a moulded product obtained with the method according to the present invention. The moulded product may have a moisture content of 35 wt% or less, preferably 0-10 wt%, as calculated on the total weight of the material. The moulded product may comprise an oxygen barrier, a moisture barrier or a combination of these. Moulded products prepared from the moulding material according to the present invention may be selected from screw caps, or containers for single or multiple use, such as bottles for oils or coffee capsules.
The moulded product may be provided with barrier properties, such as an oxygen barrier, a moisture barrier, grease resistance, or water repellence properties, or a combination of these. Such barrier properties may be provided by grafting the moulded product with fatty acid chloride, such as with the chromatogeny process; metallization, such as by vacuum deposition; coating with a barrier dispersion, such as a latex, an aqueous dispersion of fine polymer particles, preferably a bio-based latex; or coating with a polyolefin, e.g. PE, PP or PET, preferably a bio-based polyolefin; or a combination thereof. The barrier may be applied on the outside, the inside, or both sides of the pressed object. The moulded product may also be provided with at least one specific barrier layer, such as a layer comprising the composite material grafted with a fatty acid chloride; coated with a barrier dispersion, or a polyolefin, e.g. PE, PP or PET; or being
metallized; or a combination thereof. Barrier properties may also be provided by blending an additive that may provide barrier properties into the moulding material, such as by adding, e.g. a hydrophobation chemical, or a latex; to the suspension of the fibrillated cellulose material;
An advantage with the moulded product according to the present invention is that it possesses a good barrier against fats, including grease and oil; as well as gases, such as air and oxygen.
The present invention also relates to the use of the moulding material according to the present invention in a screwcap, or in a container for single or multiple use, such as a bottle for oil, or a coffee capsule.
Cellulose is a polysaccharide consisting of a linear chain of β(1→ 4) linked D-glucose units and the main component in the cell walls of all plants. It can occur with different components depending on the type or part of the plant. While cellulose occurs together with lignin and hemicelluloses in wood, certain bacteria may produce a pure cellulose. Fibres of cellulose are significantly longer than wide. Cellulose fibres can have a mean width of 0.01 to 0.05 mm, while their length can vary considerably depending on the type of plant and its growing location. For example, the fibre length of softwood can be from 2.5 to 4.5 mm, while hardwood and Eucalyptus can have a fibre length from 0.7 to 1.6 mm. The aspect ratio, i.e. the ratio of the fibre length to the fibre width, can be at least 10, but also as large as 6500. The fibre length distribution can be modified, such as by grinding the cellulose fibres to reduce the size of the fibres. The cellulose constitutes the structural backbone of the material according to the present invention, and also provides some of the rigidity and strength.
Microfibrillated cellulose, MFC, is liberated from wood pulp or from other sources, for example selected from the group consisting of plants, tunicate, and bacteria, by means of mechanical disintegration, such as by
homogenization, microfluidization, grinding, or using a supermass colloider (SMC), often preceded by a chemical pretreatment, such as by oxidation with 2,2,6,6-tetramethylpiperidine-1-oxyl (TEMPO) or by carboxymethylation; or by enzyme-treatment, such as by endoglucanases. Other terms used for the microfibrillated cellulose are nanofibrillated cellulose (NFC), nanofibrillar cellulose (NFC), microfibrillar cellulose (MFC), cellulose microfibril (CMF) and cellulose nanofibre (CNF). MFC typically have a smallest dimension in the range 2-100 nm, while the length can be several micrometers, such as up to 10 μm, and therefore the aspect ratio of MFC (ratio of length to diameter) is very large.
The term "dry solid content" is used herein for the content of dry matter in a suspension as calculated on the total weight of the suspension.
EXAMPLES
Example 1
Preparation of moulding materials
Native MFC was prepared by high-pressure homogenization of enzyme treated bleached pulp. The dry solid content of the MFC was 11 wt%.
Carboxymethyl cellulose, CMC, Finnfix 5 (CPKelco) in powder form, 93 wt% dry solid content, was used as an additive.
The fibre material (i.e. the wood-based material) was a dry-cut, bleached pulp (Stora Enso, Skutskar Mill) with a particle size distribution between 40 - 300 μm. The dry solid content of the fibre material was 95 wt%.
First, the MFC was mixed together with the CMC powder with a spoon. Depending on the desired final moisture content, water was added in the required amount. The dry fibers were then mixed in gradually with a kitchen kneading machine (Kenwood) and mixed until everything was roughly
distributed. The mixture was then filled into a lab extruder with twin screws for blending the material.
The final solids content was varied according to Table 1. For the most dry samples, final mixing was performed in a kitchen blender (Kenwood).
The MFC content was around 10 wt-% based on dry weight, and the CMC content was about 2 wt-% based on dry weight.
Mechanical properties
A stainless steel mould was used to produce round, flat samples with a diameter of 80 mm and a thickness of about 1.3 mm. An amount corresponding to 6 g of dry material was used. The mould with material in was put in a heated platen press, 150 °C for 5 min at the pressure 0.5 MPa. The samples were conditioned at 23 °C, 50% RH and then cut into 15 mm wide strips, and tensile properties were measured in a Zwick Z010 material tester at 2 mm/min crosshead speed. The results are found in Table 1.
Table 1. Results from tensile testing
Example 2
Pressing of capsules - varying CMC content
A native MFC was prepared by high-pressure homogenization of enzyme treated bleached pulp. Carboxymethyl cellulose, CMC, Finnfix 5 (CPKelco) was used as an additive. The fibre material (i.e. the wood-based material) was a dry cut, bleached pulp (Stora Enso, Skutskär Mill) with a particle size distribution between 40 - 300 μm.
First, the MFC was mixed together with the CMC powder and water with a spoon. The dry fibers were then mixed in gradually with a kitchen kneading machine (Kenwood) into a "dough".
The solids content of the dough was 40 wt-%, the MFC content was 10 wt- % based on dry weight. One sample was prepared with no CMC content, and two samples with CMC content of 2 and 4 wt-% respectively, based on dry weight.
A stainless steel mould was used to produce simple capsule demonstrators. Moulding material was put in a heated platen press, 150 °C for 5 min at the pressure 0.8 MPa.
It was seen that an increased CMC content prevented the "walls" of the capsule to crumble, resulting in a higher capsule. The samples are shown in Figure 1, with increasing CMC content from left to right. The bottom of the capsule gets strong due to the high pressure acting on it, but the walls have a very high angle which do not bear load easily.
Example 3
Pressing of capsules - varying MFC content
A native MFC was prepared by high-pressure homogenization of enzyme treated bleached pulp. Carboxymethyl cellulose, CMC, Finnfix 5 (CPKelco) was used as an additive. The fibre material (i.e. the wood-based material) was a dry cut, bleached pulp (Stora Enso, Skutskar Mill) with a particle size distribution between 40 - 300 μm.
First, the MFC was mixed together with CMC powder and water. The dry fibers were then mixed in gradually with a kitchen kneading machine (Kenwood) into a "dough" corresponding to the "moulding material" according to the invention.
The solids content of the dough was 40 wt-%, and content of CMC was 4 wt% based on dry weight. With this mixture as a base, four samples were prepared with varying MFC content: 0 wt%; 10 wt%; 14 wt% and 17 wt%.
Each of the four samples were used for producing a respective capsule demonstrator, using a stainless steel mould. Said stainless steel mould comprising the moulding material was put in a heated platen press, 150 °C for 5 min at the pressure 0.8 MPa.
The resulting four capsule demonstrators are shown in Figure 2, with increasing MFC content from left to right. It can be seen that with higher MFC content, the object was more intact and had higher walls.
Claims
1. A moulding material comprising:
- 60-98 wt% of a dry wood-based material comprising a particulate consistency and ranging in particle size dimension from 0.01 - 2mm;
- 2-40 wt% of a fibrillated cellulose material; and
- 0-10 wt% of an additive, as calculated on the total dry solids in the moulding material.
2. The moulding material according to claim 1, wherein the wood-based material is selected from dry cut cellulose, wood flour, sawdust, lignin powder and different combinations thereof.
3. The moulding material according to claim 1 or 2, wherein the additive is selected from carboxymethyl cellulose (CMC), latex, citric acid, crosslinkers and combinations thereof.
4. The moulding material according to any one of claims 1-3, wherein the fibrillated material is microfibrillated cellulose (MFC).
5. The moulding material according to any one of claims 1-4, wherein the total dry content in the moulding material is at least 40 wt%, preferably at least 50 wt%, more preferably at least 65-75 wt%, as calculated on the total weight of the material.
6. The moulding material according to any one of claims 1-5, wherein the material is further provided with barrier properties.
7. A method for preparing the moulding material according to any one of claims 1-6, the method comprising providing a suspension comprising fibrillated cellulose material; optionally adding an additive, additional water, or both of these; and adding the dry wood-based material to the suspension to obtain a moulding material comprising 60-98 wt% of a dry wood-based material; 2-40 wt% of fibrillated cellulose material; and 0-10 wt% of an additive, as calculated on the total dry weight in the moulding material.
8. The method according to claim 7, wherein the suspension medium is water.
9. The method according to claim 7 or 8, wherein the suspension of microfibrillated cellulose contains 2-30 wt% dry matter.
10 The method according to any one of claims 7-9, wherein addition of the dry wood-based material is made gradually during mixing.
11 The method according to any one of claims 7-10, wherein the suspension of the fibrillated cellulose material is mixed with additives before addition of the dry wood-based material.
12. The method according to any one of claims 7-11, further comprising transferring the moulding material into a mould.
13. The method according to claim 12, further comprising pressing the moulding material comprising the microfibrillated cellulose and the dry wood-based material, to form a moulded product.
14 The method according to claim 12 or 13, further comprising providing the moulded product with an oxygen barrier, a moisture barrier or a combination of these.
15 The method according to claim 14, where the barrier is provided on at least one side of the moulded product.
16. The method according to any one of claims 14-15, wherein the barrier properties are provided by blending in an additive that may provide barrier properties into the moulding material; grafting the moulding material or the moulded product with a fatty acid chloride; metallization; coating the moulding material with a barrier dispersion; coating with a polyolefin; or a combination of these.
17. A moulded product comprising the moulding material according to claim 1.
18. A moulded product according to claim 17, wherein the water content is 10 wt% or less, as calculated on the total weight of the product.
19 The moulded product according to claim 17 or 18 further comprising an oxygen barrier, a moisture barrier or a combination of these.
20 A moulded product obtained with the method according to anyone of claims 7-16.
21. The moulded product according to claim 21, which is a screwcap or a container for single or multiple use.
22 Use of the moulding material according to any one of claims 1- 6 in a screwcap or a container for single or multiple use.
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SE2051238 | 2020-10-23 | ||
PCT/IB2021/059746 WO2022084928A1 (en) | 2020-10-23 | 2021-10-22 | A moulding material, a method for preparing such material and a moulded product |
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EP4232632A1 true EP4232632A1 (en) | 2023-08-30 |
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EP21882295.5A Pending EP4232632A1 (en) | 2020-10-23 | 2021-10-22 | A moulding material, a method for preparing such material and a moulded product |
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KR20110018447A (en) * | 2008-06-17 | 2011-02-23 | 아크조 노벨 엔.브이. | Cellulosic product |
US20100163197A1 (en) * | 2008-12-29 | 2010-07-01 | Kristina Fries Smits | Tissue With Improved Dispersibility |
FR3003581B1 (en) * | 2013-03-20 | 2015-03-20 | Ahlstroem Oy | FIBROUS MEDIUM BASED ON FIBERS AND NANOFIBRILS OF POLYSACCHARIDE |
SE538088C2 (en) * | 2013-12-10 | 2016-03-01 | Stora Enso Oyj | Method and apparatus for manufacturing a screw cap |
JP6860137B2 (en) * | 2016-07-29 | 2021-04-14 | 日本製紙株式会社 | Molding materials for manufacturing fibrous molded products and molded products using them |
SE540870C2 (en) * | 2017-04-12 | 2018-12-11 | Stora Enso Oyj | A gas barrier film comprising a mixture of microfibrillated cellulose and microfibrillated dialdehyde cellulose and a method for manufacturing the gas barrier film |
SE542217C2 (en) * | 2018-04-12 | 2020-03-17 | Stora Enso Oyj | A method for the production of a coated paper, paperboard or film and a coated paper, paperboard or film |
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