Classifications

• • 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
  • D21H15/00—Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution
  • D21H15/02—Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution characterised by configuration
• • 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
  • D21H11/14—Secondary fibres
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
  • C08L1/02—Cellulose; Modified cellulose
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2205/00—Polymer mixtures characterised by other features
  • C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
  • C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
• • 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
  • D21H11/12—Pulp from non-woody plants or crops, e.g. cotton, flax, straw, bagasse

Definitions

• the disclosure relates to cellulosic compositions that are useful as structural building components for objects including, but not limited to, buildings,
• Recycling of paper and textile materials reguires the breakdown of such materials into fibres or fibre-like material which may then be reformed into material to provide paper and paper-like products.
• a recycling process has previously been
• cellulosic based compositions derived from pulp and paper processing waste and plant fibres which have high load bearing capacities and the ability for use as structural components .
• the disclosure provides a cellulosic composition comprising fibres having a length weighted average fibre length ("LWAFL”) of 0.25 to 0.40mm.
• LWAFL length weighted average fibre length
• the disclosure also provides a cellulosic composition comprising, by weight:
• the length weighted average fibre length (“LWAFL”) provides a measure of the average length of the fibres in a sample of fibres which is weighted by the length of the individual fibres.
• the LWAFL gives emphasis to the longer fibers in the sample and imparts less emphasis to the shorter fibers and fines.
• the LWFAFL is sometimes referred to as just the weighted average fibre length or "WAFL” .
• the LWAFL can be compared to other measures of the average length of the fibres in a sample such as the arithmetic or numerical average (AFL) and the weight weighted average fiber length (WWAFL) . These averages are obtained through the following calculations: ⁇ ( * 3 ⁇ 4)
• the composition has a Water Retention Value (WRV) of 600% to 2000%, more preferably, 700% to 1300%.
• WRV Water Retention Value
• the water retention value is defined as the amount of water that participates in the swelling of the fibrous material and that which is not released under the application of a centrifugal force.
• the WRV is also highly correlated to the bonding ability of kraft fibers.
• the test to determine the WRV is carried out by placing a pad of moist fibers in a centrifuge tube that has a fritted glass filter at its base. The centrifuge is accelerated at 3000g for 15 minutes to remove water from the outside surfaces and lumens of the fiber. The remaining water is believed to be associated with submicroscopic pores within the cell wall. The centrifuged fibers are weighed, dried at 105°C, and then reweighed. The WRV can then be
• the composition comprises, by weight :
• the cellulosic composition may be in a wet or dry state .
• the cellulosic composition are dried in the form of pellets, granules or powders. In the dry state, the cellulosic composition may be conveniently stored and transported.
• the dry pellets, granules or powders may be mixed with water to form mouldable, fine pulps that may be dried to create materials for use as structural components.
• the mouldable, fine pulps may be moulded using any suitable method including, but not limited to, spray molding, injection molding, extrusion or three stage molding.
• the moulded or green articles may be subsequently dried to form a product
• composition according to the disclosure may be from 0.5 g/cm3 to 1.5 g/cm3.
• the tensile modulus of the product may be from 3500 MPa to 10800 MPa and the tensile strength may be from 27 MPa to 115 MPa.
• waterproofing, lime, fire retardants including natron silicate, glues, metal powders and graphites for
• the composition may be prepared by any one or combination of processing methods including, but not limited to, ultra friction grinding, high pressure homogenizing, cryo grinding, extrusion, steam explosion, ultra sonic treatment, enzyme-fibre separation, high consistency/medium consistency/low consistency refining, chemical treatment or Whitewater fines recovery.
• processing methods including, but not limited to, ultra friction grinding, high pressure homogenizing, cryo grinding, extrusion, steam explosion, ultra sonic treatment, enzyme-fibre separation, high consistency/medium consistency/low consistency refining, chemical treatment or Whitewater fines recovery.
• compositions of the composition may be prepared separately and mixed together.
• two or more intermediary compositions with different fibre length distributions may be prepared and mixed in the reguired proportions to form the compositions defined above.
• raw materials may be used in the preparation of the compositions as described herein, including, but not limited to, short/ultra short cellulose fibres/fines recovered from waste streams, for example, recovered paper, recovered fines in Whitewater from paper & pulp processing and recovered cotton fibers. Additional raw materials may also include any cellulosic fibers used in pulp & paper processing and various plant fibers having a high cellulosic content, for example, hemp, flax, cotton, abaca, sisal and jute.
• the disclosure also provides a product made from a composition as described herein.
• FIG. 1 is a schematic view of an apparatus for measuring the Water Retention Value (WRV) of fibre samples
• Figures 2-6 depict Norval Wilson stained microscope images of wet pulp compositions derived from wastepaper a the scales indicated;
• Figure 7 depicts Norval Wilson stained microscope images of wet pulp compositions derived from hemp
• Figures 8-13 are graphs of the fibre length
• Embodiments provide cellulosic composition made up of fibres having different specific lengths, a high degree of fibrillation and a high water retention capacity. These composition may be subsequently moulded and dried to produce finished wood-like or horn-like articles of high strength and which therefore can be used as load bearing products .
• the composition comprise fibres having a length weighted average fibre length ("LWAFL") of 0.25 to 0.40mm, preferably 0.28 to 0.38mm.
• LWAFL length weighted average fibre length
• the fibre lengths in the composition are distributed in a skewed bell curve, with the composition comprising, by weight:
• fibres of a length weighted average fibre length of 1.2 mm to 2.0 mm are less than 3% (preferably less than 1%) fibres of a length weighted average fibre length of 1.2 mm to 2.0 mm .
• composition consists of a significant amount of fines (fibre length ⁇ 0.2mm) mixed with short length fibres (fibre length of 0.2-1.2mm) .
• the composition has a high degree of fibrillation indicatd by a high Water Retention Value (WRV) of 600-2000%, preferably, 700-1300%.
• WRV Water Retention Value
• composition is prepared by any one or combination of processing methods including, but not limited to, ultra friction grinding, high pressure homogenizing, cryo grinding, extrusion, steam explosion, ultra sonic
• compositions of the composition may be prepared separately and mixed together.
• two or more intermediary compositions with different fibre length distributions are prepared and mixed in the required proportions to form the composition.
• raw materials may be used in the preparation of the composition, including, but not limited to, short/ultra short cellulose fibres/fines recovered from waste streams, for example, recovered paper, recovered fines in Whitewater from paper & pulp processing and recovered cotton fibers. Additional raw materials may also include any cellulosic fibers used in pulp & paper processing and various plant fibers having a high
• cellulosic content for example, hemp, flax, cotton, abaca, sisal and jute.
• the composition may be dried for transport and/or storage in the form of pellets, granules or powders. From these forms, the compositions may be re-wetted to form moldable, fine pulps. Alternatively, the compositions may be prepared as a pulp and used directly in a molding process. The compositions as a pulp may be moulded by any moulding operations known to persons skilled in the art, for example, spray molding, injection molding, extrusion or three stage molding. The moulded or green articles may be subsequently dried to form a product.
• the composition can be used to create a material with appropriate hardness, strength and ductility to be used as a structural material yet remains (as a wet pulp) capable of being readily handled during processing and manufacture of articles from the
• composition including very large articles. Furthermore, the composition does not require excessive energy to produce and is therefore economically viable.
• the composition when molded and dried, can be used to create structural and industrial components such as coffins, electronic housings, structural building pillars, beams, boards, sheets, veneers, boxes, chairs, cabinets, cases and other furniture, car parts and toys.
• structural and industrial components such as coffins, electronic housings, structural building pillars, beams, boards, sheets, veneers, boxes, chairs, cabinets, cases and other furniture, car parts and toys.
• composition will vary.
• density may vary from 0.5 to 1.5g/cm3
• tensile modulus may vary from
• 3500 to 10800MPa and the tensile strength may vary from 27 to 115MPa.
• Sample F 1.9kWh/kg
• the specific edge load (the amount of energy applied across one meter of refiner plate's bar edge and
• the fibres were processed until the spread of the average fibre length matched a known "bell curve". From experience and knowing the process inputs, this occurs after a certain time period of processing. However, the fibres may be sampled to confirm that they have this distribution of fibre lengths.
• Suspension properties morphological properties as well as resistance to dehydration and swelling behaviour 0.2g (dry weight) of each Sample A-F after the grinding process described above were strongly diluted by pre-suspending in water, stirring, and subseguently filling with water to 5000 ml. From this suspension, 25 ml were taken (corresponding to 1.0 mg (dry weight) fibrous material) and photographed. The photographs were subseguently analysed (double determination) using
• FibreLab 3.0 equipment to determine the fibre- morphological properties and distribution parameters for the separated and suspended fibres, including the fibre length. The results for fibre length are provided in Table 1 below. Table 1 - Fibre length
• LFAFL length weighted average fibre length
• Table 2 The results shown in Table 2 below are an evaluation of the distribution of fibre lengths within certain length ranges.
• the majority of fibres of all six Samples (A to F) after processing are 0.2-0.5mm, which is considered to be the short fibre or fibre fragment range.
• Figures 8-13 Each of these Figures (for respective samples) contains two graphs.
• the top graph in each of Figures 8-13 shows the distribution of fibres having lengths of ⁇ 0.06mm whilst the lower graph in each of these Figures shows the distribution of fibres having lengths of >0.1mm.
• Table 2 Distribution of fibre lengths (length weighted average length in length ranges) by weight%
• the fines content of the ground samples were investigated further by determining the fraction of the fines (fibres ⁇ 0.2mm) in each Sample based on the arithmetic average fibre length (AFL) .
• This fraction for each Sample is compared to the length weighted fraction of fines (as per Table 2) is shown in Table 3 below.
• Table 3 the fines content of all Samples (A to F) is very high.
• the hemp cellulose Sample F notably contained markedly more fine material than the wastepaper samples (A to E) .
• the swell tube was filled to approximately two-thirds capacity (resulting in a solids content of approximately 0.150wt%) .
• the swell tube was sealed with a plug and subjected to a centrifugal force of 3000g for 15 minutes. Six parallel determinations were performed .
• the values of the water retention capacity are extremely high and atypical particularly compared to commercially available, strongly ground celluloses.
• the higher WRC generally equates to a denser material which when moulded and dried into a final product results in a product which has a lower tear or tensile strength but a higher load bearing capacity and Young's modulus.
• a preferred range for Water Retention Capacity is generally between 700 and 1200% as above this range, the low tear strength makes it difficult to form sheets - as was found with Sample C.
• Samples A to F were ground as described above and mixed with water in a mixer to a solids concentration in the range between 0.3 and 0.4wt% (3 to 4 g/L) as per Table 8 below.
• the objective was to produce test sheets with an average grammage of m A of 80 ⁇ 2 g/m 2 , for use in subsequent strength testing according to the Rapid-Kothen method (in accordance with ISO 5269-2) . It is noted that due to the very low dehydration capability of all of the Samples, the ISO 5269-2 test specifications had to be adapted by reducing the volume of filling water in the cylinder and varying the period of drop and suction to suit the required conditions for sheet forming for each of Samples A to F.
• test sheets After producing the test sheets for each of the Samples, the test sheets were acclimatised in standard climate conditions (23C°/50% relative air humidity) .
• the grammage of the acclimatised test sheets was ten determined according to DIN EN ISO 536. The results of the grammage testing are shown in Table 9.
• test sheets were subjected to thickness and apparent sheet density testing, the results of which are shown in Table 10.
• Table 10 Sheet thickness and apparent sheet density
• the tensile strength corresponds to that of ground cellulose. Whilst the tensile strength values for the Samples differ, there is little variation in the Young's modulus of the Samples which is high. The high Young's modulus of each of the Samples is indicative that the Samples can withstand tensile loads elastically for long periods of time. Without wishing to be bound by theory, it is expected that this is due to the high amount of fibrillation of the fibres and the subseguent linkages between the fibrillated fibres.
• test sheets were cut into strips and subjected to tear resistance testing according to DIN EN 21974. The results are shown in Table 12. The resistance to tearing is not corrected according to the grammage, only according to the tear index. Table 12 - Tear Resistance

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• Organic Chemistry (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Dry Formation Of Fiberboard And The Like (AREA)
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