Methods and systems for fibrillating nanocellulose materials

Abstract

Embodiments of the present invention enhance the properties of cellulosic pulp by infusing the cellulosic form, overcoming the deficiencies of the prior art. For example, these properties can include mechanical and barrier properties, i.e., tensile strength, liquid (e.g., water, oil, sauce) and gas (e.g., oxygen or carbon dioxide) impermeability are greatly improved. Another embodiment of the present invention further provides automated equipment and systems to produce fiberized cellulosic composites, including properties as strength enhancers, oligomerization agents, carbohydrates, plasticizers, antibacterial agents, water repellents, and / or transparent composites.

Description

Technical Field

[0001] Aspects of this invention generally relate to updated and recyclable materials. More specifically, embodiments of the invention relate to pure cellulose materials and consumer products.

[0002] Prior Technology

[0003] Growing concerns about the environmental crisis—plastic waste pollution—have spurred extensive investigations into sustainable and renewable materials. To circumvent petroleum-derived polymers, a natural biopolymer, plant-based cellulose fibers, has offered an alternative for materials research. Cellulose fibers are gaining increasing attention due to their ubiquitous availability, sustainability, and renewability; more importantly, they provide 100% room-temperature biodegradability for the final product.

[0004] However, many existing biodegradable products based on cellulose fibers fail to meet expectations. For example, the cost of producing these cellulose fiber products is economically disadvantageous for large-scale production. Furthermore, many cellulose fiber products rely heavily on high proportions of synthetic chemicals to achieve properties or effects such as water resistance, oil resistance, or non-stickiness. For instance, many existing products require a fluorocarbon coating on the porous surfaces of food or beverage items. Moreover, some of these fluorocarbon-based chemicals, such as perfluorooctane sulfonate (PFOA or C8), can have long-term negative impacts on health and the environment. Summary of the Invention

[0005] Embodiments of the present invention overcome the drawbacks of the prior art by injecting cellulose fibers to improve the properties of cellulose pulp. For example, these properties may include mechanical and barrier properties, i.e., tensile strength, and impermeability to liquids (e.g., water, oil, or sauces) and gases (e.g., oxygen or carbon dioxide) are greatly improved.

[0006] Another embodiment of the present invention further provides a fibrous cellulose composite material having properties including reinforcing agents, oligomers, carbohydrates, plasticizers, antibacterial agents, waterproofing agents, and / or transparent composite materials. Attached Figure Description

[0007] The elements in the drawings are intended to be illustrative and straightforward, and therefore not all coherence and choices are represented. For example, common but well-known elements that are useful or necessary in commercially viable embodiments are typically not described in order to minimize obstruction to the various embodiments disclosed herein. It will be further understood that certain actions and / or steps may be described or illustrated in a particular order of occurrence, and those skilled in the art will understand that such specificity in sequence is not actually required. It will also be understood that the terminology and expressions used herein may be defined in relation to their respective fields of investigation and research, unless otherwise specified herein.

[0008] Figure 1 a to 1d illustrate a substance of aqueous suspension of cellulose fibers according to one embodiment.

[0009] Figure 2 This is a scanning electron microscope (SEM) image according to one embodiment, for a cellulose (3 wt.%) material.

[0010] Figure 3 a to 3d are semi-processed cellulose fiber images of scanning electron microscope (SEM) images according to one embodiment, wherein ab is a SEM image of Y cellulose fiber and cd is a B cellulose fiber.

[0011] Figure 4 a to 4d are SEM images of mechanically grounded semi-processed fibers according to one embodiment, where ab is Y cellulose fiber and cd represents B cellulose fiber.

[0012] Figure 5 The image shows, according to one embodiment, a container made of cellulose L28b, L29b, L30b, and Y. These containers are capable of preserving oil for 10 days.

[0013] Figure 6A This is an image showing food containing boiling water in a material for about 5 minutes, according to one embodiment.

[0014] Figure 6B The image shows food being heated with boiling water and an 800-watt microwave for 2 minutes, according to one embodiment.

[0015] Figure 7 This is another SEM image of a cellulose structural material used in a food container according to one embodiment.

[0016] Figure 8 This is a flowchart of a method for generating materials according to one embodiment.

[0017] Figure 9 These are three images of a membrane according to one embodiment.

[0018] Figure 10A-13 It is the device used according to the embodiment.

[0019] Figure 14A -D is the final product drawing produced according to an embodiment of the present invention.

[0020] Symbol Explanation

[0021] 802 Abrasive

[0022] 804 Mixer

[0023] 806 mixture

[0024] 808 Grinding Material

[0025] 810 Molding Machine

[0026] 812 Dissolved matter

[0027] 814 Drying

[0028] 816 Last Material

[0029] 818 Intermediate Material

[0030] Implementation Methods

[0031] The embodiments can now be described more fully by way of the accompanying drawings, which form part of this document and illustrate specific exemplary embodiments that can be practiced. These drawings and exemplary embodiments are intended to be understood as examples of one or more principles of embodiment and should not be construed as limiting any of the embodiments illustrated. Embodiments may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure can be thorough and complete and can fully convey the scope of the embodiments to any person skilled in the art. Therefore, the following detailed description is not to be limited in meaning.

[0032] Embodiments of the present invention include a material, such as a green composite material (GCM), which may include fibrous cellulose, is generally free of chemical additives or formulations, and can be independently derived from plant fibers. In one embodiment, the chemical additives or formulations may be based on natural sources. In another embodiment, the chemical additives or formulations may be laboratory-manufactured. In some embodiments, these plant fibers may be derived from bagasse, bamboo, abaca, ziza, hemp, flax, hops, jute, king oyster, palm, corn, cotton, wood, or any combination thereof of agricultural waste. In other embodiments, the plant fibers may be pre-processed or semi-processed cellulose. In other embodiments, the plant fibers are processed using a high-pressure homogenizer or mechanical mill to obtain a green composite material with fibrous cellulose. In a further embodiment, a composite material with fibrous cellulose is obtained by bacterial strains (without producing microbial cellulose). In an alternative embodiment, the fibrous cellulose material may be obtained from marine sources.

[0033] In one embodiment, the shape and size of the cellulose may depend on the source of the fibers or the combination and manufacturing process of the fibers. Nevertheless, fibrous cellulose generally has a diameter and length, as described below. In one embodiment, fibrous cellulose may have a diameter of about 11 to 5000 micrometers (nm). In another embodiment, the diameter of the cellulose may be about 5 to 150 micrometers or from about 100 to 1000 micrometers.

[0034] In further embodiments, the material may have reinforcing properties, improving, enhancing, or enhancing various properties without the need for chemical additives or agents. In another embodiment, the material, possessing various properties, is suitable for carrying food or liquid articles that are generally free of chemical fats or agents. For example, as shown in the prior art, various chemical agents or additives are used during manufacturing or coated into composite materials to provide desired tensile strength, whether dry or wet, and enhanced oil resistance, gas and / or liquid impermeability. Various aspects of the present invention do not utilize various chemical additives or agents added to the material, but rather comprise a composite material free from the use of these additives and made of fibrous cellulose.

[0035] For example, the length of cellulose may be approximately 0.1 to 1000 micrometers, approximately 10 to 500 micrometers, approximately 1 to 25 micrometers, or approximately 0.2 to 100 micrometers. In some embodiments, cellulose with different diameters is used, such as materials with a weight ratio of 1:100. In another embodiment, the weight ratio of cellulose is 1:50. In further embodiments, blended cellulose materials may have advantages such as improved tensile strength, dry or wet properties, enhanced oil resistance, gas and / or liquid impermeability, and cost savings.

[0036] In some embodiments, the cellulose-based material may have an oxygen permeability of about 8,000 cm³ / s² / 24h or less. In another embodiment, the oxygen permeability is about equal to or less than 5,000 cm³ / s² / 24h. In yet another embodiment, the oxygen permeability is about equal to or less than 1,000 cm³ / s² / 24h.

[0037] Furthermore, in some embodiments, the material may have a water vapor transmission rate of approximately equal to or less than 3000 grams per square foot per 24 hours or less. Additionally, in another embodiment, the water vapor transmission rate may be approximately equal to or less than 1500 grams per square foot per 24 hours.

[0038] In some embodiments, the material may have 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 have a dry tensile modulus of about 4 GPa or higher. In yet another embodiment, a dry tensile modulus of about 6 GPa or higher.

[0039] In some embodiments, the material may have a content of approximately 45 Nm g. -1 The dry tensile index characteristic is 80 Nm g or higher. In another embodiment, this characteristic can be about 80 Nm g. -1 Or higher.

[0040] In some embodiments, the material may have a wet tensile strength of about 5 MPa or higher. In another embodiment, the wet tensile strength may be about 20 MPa or higher.

[0041] In some embodiments, the material may have 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.

[0042] In some embodiments, the material may have a content of about 5 Nm g. -1 Or a higher wet tensile index. In another embodiment, the wet tensile index may be about 20 Nm g. -1 Or higher.

[0043] In another embodiment, the material may include an adhesive to improve drying and / or wetting strength. In one embodiment, the adhesive may include a polymer. In other embodiments, the adhesive may include a metal salt. In another embodiment, the adhesive may include an oligomer. In other embodiments, the adhesive may include a carbohydrate acid. In other embodiments, the adhesive may include a plasticizer. In some embodiments, the weight ratio of cellulose to adhesive in this invention may be approximately 33:1 to 1:1.

[0044] For example, polymers may include polyester, gelatin, polylactic acid, ethylenedin, sodium alginate, thermoplastic starch, polyethylene, formic acid, formic acid gel, polyvinyl alcohol, or polypropylene.

[0045] In another embodiment, the binder may include a metal salt. For example, the metal salt may include potassium carbonate, potassium aluminum sulfate, calcium carbonate, and calcium phosphate. In some embodiments, the weight ratio of cellulose to binder in this invention may be approximately 33:1 to 1:1.

[0046] In another embodiment, the adhesive may include an oligomer. In one example, the oligomer may include oligonucleotides, oligopeptides, and polyethylene glycol. In some embodiments, the weight ratio of cellulose to adhesive in this invention may be approximately 33:1 to 1:1.

[0047] In other embodiments, the binder may include carbohydrate acids. For example, carbohydrate acids may include citric acid, citric acid, and glutamic acid. In some embodiments, the weight ratio of cellulose to binder in this invention may be approximately 33:1 to 1:1.

[0048] In some embodiments, the use of a plasticizer in the adhesive can reduce the brittleness and gas permeability of the adhesive composite material. In some embodiments, the plasticizer may comprise a polyol. In one embodiment, the polyol may comprise glycerol. In one embodiment, the polyol may comprise sorbitol. In one embodiment, the polyol may comprise pentaglycerol. In some embodiments, the polyol may comprise polyethylene glycol. In some embodiments, the weight ratio of the plasticizer to the composite material to the adhesive is approximately 5:33:1 to approximately 1:1.

[0049] In another embodiment, the plasticizer may include branched polysaccharides, waxes, fatty acids, fats, and oils.

[0050] The invention may further include a waterproofing agent as a chemical additive to repel gases and / or liquid water. In some embodiments, the waterproofing agent includes animal waxes, animal oils, or animal fats. In one embodiment, the waterproofing agent includes petroleum-derived waxes or petroleum-based waxes. In other embodiments, the waterproofing agent includes plant-based waxes, plant oils, or plant fats.

[0051] In some implementations, animal-derived waterproofing agents may include beeswax, shellfish, and whale oil.

[0052] In some implementations, petroleum-based wax-based insect repellents may include paraffin wax, paraffin wax, and mineral oil.

[0053] In some implementations, plant-based waterproofing agents may include palm wax, soybean oil, palm oil, palm wax, palm wax, and coconut oil.

[0054] In some implementations, the waterproofing agent may include adhesives such as potassium carbonate, potassium sulfate, calcium carbonate, and calcium phosphate.

[0055] In further embodiments, the material may include fibrous cellulose, and optionally, an antibacterial agent may be included. In some embodiments, the antibacterial agent may include tea polyphenols. In some embodiments, the antibacterial agent may include phenylacetone salts, p-hydroxybenzoic acid, p-hydroxybenzoic acid, tetramethylammonium salts, acetamide, benzoic acid, and potassium sorbate.

[0056] Furthermore, another embodiment of the invention may include a material having fibrous cellulose, which may further optionally include a transparent composite material to increase the transmission of wavelength light, from about 300 micrometers to 800 micrometers. In some embodiments, the material may include branched polysaccharides. In some embodiments, the weight ratio of the material to the transparent composite material varies, which may depend on the desired transparency, for example, from about 99:1 to about 1:99.

[0057] In some implementations, the branched polysaccharide may include starch, polysaccharide, and galacmanan.

[0058] In some embodiments, a glucan may include arganase, lauran, and gentian.

[0059] In some respects, the products provided herein are manufactured from the materials disclosed herein and are readily formed into specified shapes, such as planar or three-dimensional. For example, a two-dimensional example may be a planar plate, which can be used to decompose to form the final product. In another embodiment, the material is soluble in a liquid so that it can be readily used to form the final product. In yet another embodiment, a three-dimensional embodiment (i.e., a solid) may be the final product.

[0060] In one aspect, in some embodiments, the final product may include a container for an edible or digestible article, such as Figures 5 to 7As shown. For example, end products embodying the materials described in this embodiment may include food containers or packaging. Food containers or packaging may include airplane or airline meal containers, disposable cups, ready-to-eat food containers, capsules, ice cream boxes or containers, and chocolate containers. In some embodiments, the product may include fast food containers that may further contain flavorings, such as instant noodles, instant soup, etc. In this case, when a consumer digests or consumes an edible or digestible article placed in a container of any aspect of the invention, the food may be placed in a container of water or liquid at a high temperature (e.g., about 100 degrees Celsius).

[0061] In another embodiment, this applies to products that can use in-flight meal and beverage containers. Currently, in-flight meal containers are made of various forms of plastic, possessing characteristics such as lightweight, suitable rigidity, and oil resistance. Furthermore, existing plastic containers can be heated in an oven. However, heating may release carcinogens from the plastic container into edible items. Therefore, this should be avoided as much as possible. The embodiments of the present invention, along with the aforementioned characteristics, exhibit properties such as water resistance, heat resistance, and oil resistance, but do not release carcinogens.

[0062] In another embodiment, the capsule example could be a coffee capsule. For instance, a coffee capsule might be a disposable capsule. In another example, a coffee capsule might be a disposable coffee pouch or bag. In this case, an electric coffee machine might deposit or inject hot water into the capsule under high temperature or pressure to initiate the coffee-making process, and coffee might drip from the capsule or pouch into the consumer's cup. Because the capsule or pouch comprises biodegradable and sustainable materials having one or more of the aforementioned properties, the capsule or pouch is easily recyclable without burdening the environment.

[0063] In one embodiment, the capsule may have sidewalls with a thickness of approximately 500 micrometers. In another embodiment, the capsule may include a top or cap with a thickness of approximately 500 micrometers. In yet another embodiment, the capsule may include a bottom thickness of approximately 300 micrometers. In yet another embodiment, the capsule may be formed together with a mold during the molding process (discussed below), and the top, sidewalls, and bottom may have different thicknesses.

[0064] In some embodiments, the product may include a filter for separation, whether permanent, semi-impermeable, or only slightly impermeable to particles or molecules in a fluid. For example, the product may include a mask or filter membrane that has solid-liquid separation, liquid-liquid separation, or gas-liquid separation effects.

[0065] In some embodiments, the product may include cosmetic or skincare container products, medical products such as powder boxes, palettes, protective glass, or medical-grade treatments. In some embodiments, the product may include part of medical devices, automobiles, electronic devices, and building materials (as reinforcement materials).

[0066] In general, in some embodiments, the container embodying the material of the present invention can be a container, a flat plate, a tray, a plate, a roll, a sheet, or a film. In such embodiments, the width or length of the material may be between about 0.01 mm and 10,000 mm or more. In one embodiment, the width or length may be between about 0.01 mm and 1,000 mm. In an embodiment, the film may be a thin film with a thickness of about 0.01 to 3.0 mm. In one embodiment, the thickness may be about 0.02 mm to 0.20 mm. In other embodiments, the invention may also be food packaging, and the product may include an oil-to-water weight ratio of about 100:1 to about 1:100.

[0067] In another embodiment, aspects of the invention may provide a cellulose manufacturing, production, or production material having the above-described properties.

[0068] Example 1

[0069] In addition to the materials described above, aspects of the present invention may include a cellulose fibrillation process or method.

[0070] Now refer to Figure 8 A flowchart can illustrate a method for creating such a material according to one embodiment. For example, cellulose paperboard (approximately 3.0% by weight) is torn into pieces, such as A4-sized paper. The shredded pieces are then fed into a pulper ( Figure 8 (Not shown in the image). The pulping process may take approximately 20 minutes. Next, the process can be started, for example, using a mechanical mill 802. For example, the mechanical mill 802 may be a homogenizer. In one embodiment, the mechanical mill 802 may include two grinding wheels facing each other. The spacing or distance between the two grinding wheels can be adjusted according to the desired final product. In another embodiment, the surface grooves or patterns can be adjusted according to the desired final product. Thus, the pulp suspension 806 is then fed into the mechanical mill, optionally about 1-10 times. In other cases, the pulp suspension 806 can be fed into a refining machine (not shown), for example, a colloid mill, a two-disc mill, to further refine the cellulose pulp before entering the mechanical mill 802.

[0071] In one embodiment, Figure 1 a to 1d illustrate the state of fibrillated cellulose through increasing numbers. For example, Figure 1'a' can represent an aqueous suspension of cellulose fibers with zero cycles or passes. In other words, such as... Figure 1 As shown in figure a, the content of pulp suspension 806 can reach 100%. Figure 1 In step a, the pulp cannot form fibrillation to achieve the quality and performance of the present invention in all aspects.

[0072] In one embodiment, Figure 1 b can be shown as a post-milling material 808, wherein the pulp suspension 806 has passed through the mechanical mill 802 once. For example, post-milling material 808 may now include an aqueous suspension of fibrillated cellulose fibers. In another example, Figure 1 Image c shows the finished product 808 after passing through the mechanical mill 802 for two cycles or two rounds. In one example, the fibrillated cellulose fibers in the finished product 808 are... Figure 1 The fibrillated cellulose fibers shown in b are fine. Figure 1 Image d can show an image of the polished material 808 after 3 cycles / passes. In such an embodiment, the polished material 808 may include a larger... Figure 1 c contains finer fibrillated cellulose fibers.

[0073] In other embodiments, different concentrations of fibrillated cellulose fibers, approximately 2.5 wt.%, approximately 3.0 wt.%, approximately 3.6 wt.%, and approximately 4.0 wt.%, were tested and used. For example, approximately 2.5 wt.% fibrillated cellulose indicated insufficient grinding, therefore related properties or characteristics were not tested. Figure 5 L028, L029 and L030 show that the cellulose content is approximately 3.0 wt.%, approximately 3.6 wt.%, and approximately 4.0 wt.%, respectively.

[0074] In one embodiment, various properties / characteristics of cellulose were tested. For example, mechanical, water vapor, and gas permeability properties are shown in Table 1.

[0075] Table 1

[0076]

[0077] Figure 2 Also shown are scanning electron microscope (SEM) images of fibrotic cellulose, at a concentration of approximately 3% by weight (wt.%).

[0078] Example 2

[0079] In one example, instead of using a direct pulp solution at milling post 808 in Example 1 above, semi-processed cellulose fibers can be obtained from the market. Thus, the semi-processed cellulose fibers (e.g., about 3 wt.%) are fed into a colloid mill and ground for about 1 minute. Alternatively, fibrillated cellulose fibers can be further processed in a mechanical mill 802.

[0080] Figure 3 A scanning electron microscope (SEM) image of semi-processed fibers subjected to impact grinding for 1 minute is shown in another embodiment. Table 2, for example, shows the properties of different fibrillated celluloses from different sources.

[0081] Table 2

[0082]

[0083] Figure 3 In Table 2, ab represents the SEM image of Y-cellulose fibers, and cd represents the SEM image of B-cellulose fibers.

[0084] In another embodiment, Figure 4 The image shows a SEM image of the semi-processed fibers after one pass of mechanical grinding. For example, Figure 4 ab is used for Y-cellulose fibers. Figure 4 cd is used for β-cellulose fibers.

[0085] On one hand, mixer 804 can provide a suspension of cellulose pulp 806 in water, the suspension comprising a mixture of cellulose pulp and water, wherein the weight ratio of cellulose to water is about 0.01 to 100. The ratio can be about 0.03 to 0.10. In some embodiments, the post-grind material 808 from mechanical grinder 802 can be retained if it can be reused by mechanical grinder 802 for grinding. For example, as described above, the number of times post-grind material 808 passes through grinder 802 can be 1-100. In another embodiment, the number of passes or cycles can be further limited to 1-10.

[0086] In another embodiment, the weight ratio of cellulose to water and / or the number of passes through the mechanical grinding machine 802 may be a function of the desired characteristics of the final product. For example, if the final product requires low water vapor transport and low oxygen transport, the initial mixture 806 may have a cellulose weight ratio close to 0.1 with water, or the number of passes may be increased. In another embodiment, relatively low water vapor transport and relatively low oxygen transport may indicate a longer shelf life, while relatively high water vapor transport and relatively high oxygen transport may indicate a shorter shelf life.

[0087] In one embodiment, the post-milling material 808 can be processed by a molding machine 810. For example, the molding machine 810 can generate an intermediate material 818 with fibrillated cellulose as a desired material based on the post-milling material 808. For example, the weight ratio of fibrillated cellulose to liquid (e.g., water) in the intermediate material 818 can be from about 0.001 to 99. In another embodiment, this ratio can be from about 0.001 to 0.10. In one embodiment, the molding machine 810 can include a mesh or fiber web. For example, the molding machine 810 can include negative pressure or positive pressure or any combination thereof. In one embodiment, the molding machine 810 can apply pressure to separate the fibrillated cellulose in the post-milling material 808 from the liquid to form the intermediate material 818. Due to the fibrillating nature of the fibrillated cellulose fibers and the process of the mechanical mill 802, such as Figure 2-4 As shown in the various SEM images in Figure 7, fibers of different lengths can form intermediate material 818.

[0088] In another embodiment, the base layer 812 can be used to form the intermediate material 818. In one embodiment, the GCM of an aspect of the invention may include a pulp layer (e.g., base layer 812) and a fibrillated cellulose layer (e.g., from post-milling 808). For example, a formulator 810 may subject the base layer 812 to a mesh or frame to form a structure for the intermediate material 818. For example, the base layer 812 may initially be in the form of a solution or syrup of water and pulp material. Slurry may be in a tank, and mesh may also be in a tank. By using negative pressure, such as a vacuum, water from the tank can be removed or reduced, thereby forming the base layer 812 on the mesh.

[0089] Subsequently, in one embodiment, the forming device 810 may include a sprayer or applicator for spraying or applying the post-grind material 808 onto the base layer 812 to form the intermediate material 818. The post-grind material 808 is injected into the base layer 812 with fibers of different sizes within it. In one embodiment, the post-grind material 808 may be applied or sprayed onto the surface of the intermediate material 818 containing edible articles. For example, assuming the final product is a bowl, the post-grind material 808 may be applied or sprayed onto the inner surface of the final product.

[0090] In one embodiment, the intermediate material 818 may display a mesh or fiber mesh pattern on its outer surface, as shown in 502 or 504.

[0091] In another embodiment, the forming device 810 can apply the intermediate material 818 to a flat surface and form it by drying or natural processes.

[0092] In another embodiment, a dryer 814 may be further provided to dry or dehumidify the transition material of the dryer. In one embodiment, the dryer 814 may provide drying conditions from 30 degrees Celsius to 200 degrees Celsius. In another embodiment, the dryer 814 may include a heating surface, such as infrared heating. In another embodiment, microwave heating or air heating may be used without departing from the spirit and scope of the embodiment. In another embodiment, the dryer 814 may also be assisted by negative pressure and / or positive pressure.

[0093] Example 3

[0094] In one example of a final product that may embody various aspects of the invention, a cellulose-based bowl was successfully produced using the combination of the materials and methods described above. In one embodiment, the functionality of this cellulose-based food container can be used to demonstrate the ability to fill the container with typical edible oils, such as… Figure 5 As shown. In this embodiment, the food container containing edible oil and cellulose was heated in an 800-watt microwave oven for 4 minutes and observed for 10 days, as... Figure 5 As shown in the diagram. Figure 5 The container may be made of cellulose L28b, L29b, L30b, and Y. In one embodiment, Figure 5 Each embodiment can hold the oil for approximately 10 days. In another embodiment, the final product can be heated to a maximum of 260 degrees Celsius in an oven, or cooked in a steamer, etc.

[0095] In another embodiment, another set of tests was also conducted on the composite material by adding instant noodles (and then cooking them in hot water) to a container, according to one embodiment. The observations were recorded the following day. Figure 6A Examples of cellulose structures in containers (such as food containers) are shown. For example, Figure 6A The images show a series of images of cellulose fibrils, with the instant noodles themselves remaining in the container for about 5 minutes.

[0096] In another embodiment, Figure 6B A series of images showcasing cellulose fibers being placed in boiling water and heated in an 800-watt microwave oven, allowing the instant noodles to remain in the container for approximately 2 minutes.

[0097] According to one embodiment, Figure 7 It is aimed at Figure 6A and 6B SEM image of a food container made of cellulose.

[0098] Example 4

[0099] Now for reference Figure 9 a to Figure 9c, The image shows the membrane of Example 4 according to the embodiment.

[0100] In one embodiment, the composite material according to various aspects of the present invention can be used in a transparent composite membrane based on fibrillated cellulose. In one example, the membrane can be prepared by dissolving fibrillated cellulose and amylopectin powder in water to produce solutions each containing about 1 wt.% of solute. In the dissolution of the amylopectin powder, the powder can be gradually added, and the solution can be heated for 1 minute in a microwave oven at 800W. In one embodiment, this process can be repeated about 4-5 times until a clear solution is formed.

[0101] In one embodiment, for the production of the composite membrane, the ratio of fibrillated cellulose, such as milled material 808, to amylopectin can be about 1:1, for example, about 250g of milled material (e.g., about 1% fibrillated cellulose can be mixed with about 250g of amylopectin solution to produce a solution with about 0.5% solute). Then, about 100g of the mixed solution is poured onto a hydrophobic surface, such as a silicone surface, and dried at room temperature.

[0102] In another embodiment, the ratio of fibrillated cellulose to amylopectin is 2:1. 250g of milled material 808 (e.g., about 2% fibrillated cellulose) can be mixed with about 250g of amylopectin solution to produce a solution of about 1% solute. Then, about 100g of the mixed solution is poured onto a hydrophobic surface, such as a silicone surface, and dried at 50°C for 12 hours.

[0103] As shown in the figure. Figure 9 Images a through 9c can be shown of cellulose-based membranes in which the ratio of fibrillated cellulose to amylopectin is a) 0:1, b) 1:1, and c) 2:1.

[0104] In one embodiment, the addition of amylopectin can enhance the film-forming process to produce a smoother film surface, whereas films made from fibrillated cellulose (e.g., referred to below as milled material 808) are highly wrinkled. Other films containing amylopectin offer a smoother, more uniform surface. In one embodiment, films made from composites of fibrillated cellulose and amylopectin can generally have a smooth surface.

[0105] In another embodiment, the mechanical properties of the transparent composite film are shown below, wherein fibrillated cellulose is denoted as L41b and amylopectin is denoted as B.

[0106] Table 3 shows the properties of fibrillated cellulose membranes with added amylopectin.

[0107]

[0108] Example 5

[0109] fibrillated cellulose with waterproofing agent

[0110] In one embodiment, aspects of the invention may include fibrillated cellulose with water-repellent properties. In one example, the mixture may contain the correct proportions of cellulose and a hydrophobic agent and be stirred using a mechanical mixer for 3 minutes. The mixture may be further diluted to 4000 mL and then poured onto mold 810. In one aspect, molder 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 are shown in Table 4.

[0111] Table 4 illustrates the properties of fibrillated cellulose membranes with different water-repellent agents.

[0112]

[0113]

[0114] Furthermore, all the above embodiments can be manufactured using the equipment shown in Figures 10A to 13. From the simplified diagram in Figure 10A, element 1000 can be considered a container. After the pulp is loaded, its vacuum principle is used to adsorb paper fibers from a water tank containing pulp onto element 1001. For example, 1001 includes a fiber connector or mold; for instance, the fiber connector can be a mesh, as the paper fibers in the water tank will remain on the mesh, and the liquid will pass through it. The vacuum principle involves first extracting and discharging the water from the water tank, and then allowing the vacuum environment to tightly adsorb the material onto element 1001 to form the first material. 1001 has a rotation function, allowing the mold to face downwards or upwards into the 1000 pulp tank to form the product. It is then rotated 180 degrees and the vacuum device is used to remove water.

[0115] In another embodiment, device 1004 can be connected to element 1002, and device 1004 can move its vacuum adsorption function up, down, left, and right, and its device can be equipped with element 1002 to adsorb material left on 1001. Figure 10A and 10BAs shown, elements 1002 and 1004 are movable to a third element or a dewatering device. 1002 has a rotation function, allowing the mold to be oriented downwards or upwards during dewatering. Furthermore, the arrangement of elements 1000, 1002, 1004, 1006, and 1008 in this invention does not require a linear arrangement. Since element 1004 can move in multiple directions, 1000, 1006, or 1008 can be arranged in relative positions such as circles, triangles, above, or below. Additionally, element 1004 may be moved using a robotic arm or device. In another embodiment, element 1004 can be moved manually, mechanically, or by track-assisted methods to 1006 or 1008. 1004 can be used to transfer products in one or more sets.

[0116] Single process: The second material is received via elements 1002 and 1004. In one embodiment, the second material is effectively added to the first material by elements 1002 and 1004. For example, the second material is bonded to the first material via element 1006, and as in the above example, the first and second materials are tightly mixed together to form a third material. In another embodiment, the third material shows that the first and second materials are at different levels.

[0117] Multi-stage process: 1001 and 1000 can accept the first material, and 1001 and 1006 can accept the second material. This system can produce two products at the same time. Then, 1002 and 1004 are used to transfer the materials to the next workstation together, thereby achieving continuous production. The production cycle of this method will be shorter than the previous single-stage process.

[0118] In another embodiment, the container or workstation storing the second material is further equipped with a heat source or insulation. For example, element 1002 or 1004 itself, or with an additional heat source, can provide heat or insulation to the container, allowing the second material to reach approximately 40 degrees Celsius or higher during or before mixing with the first material, thus achieving optimal and most efficient production. In another embodiment, the heat source can be electric, steam, liquid, or other heating methods.

[0119] In one embodiment, after the first and second materials are mixed, as described above, elements 1002 and 1004 are moved to element 1008 for dehydration or water reduction. For example, after mixing the first and second materials, elements 1002 and 1004 move the third material from element 1006 to element 1008. In another embodiment, during the mixing process, the third material is in a vacuum-sealed state through elements 1002, 1004, 1006, and 1008. Element 1008 then has positive pressure and compression functions, increasing the spatial pressure of the bonding material and forcing out moisture. Combined with the negative pressure design of elements 1002 and 1004, this further removes water from the third material or reduces the moisture content of the bonding material. The positive pressure and compression chamber of element 1008 can be oriented upwards or downwards and also has a flipping function.

[0120] Finally, the materials are combined to enter the shaping stage to make the final product.

[0121] In another embodiment, the second material can also be directly used as the main body of the third material, i.e., as shown below. Figure 10B What it represents. For example, Figure 10B After the second material enters the second element, it no longer mixes with the first material.

[0122] The device of this invention can be an automated device, such as... Figure 11A As shown, the first element, the second element, and the third element form a continuous set of equipment.

[0123] In another embodiment of the invention, such as Figure 11B , 11C As shown in 11D, it can be detached and separated to be made of a third material.

[0124] in addition, Figure 11A As shown in D, element 1004 is moved by a track, but those skilled in the art can easily move element 1004 in other ways without departing from the basic principles of the invention, and the movement is not limited to movement in a plane.

[0125] In another embodiment, the present invention also includes a software system for operating the device of the present invention, including sensors located at components 1000, 1001, 1002, 1004, 1006, 1008, etc., to transmit parameter information. The software system also includes different interfaces, whether a centralized interface or one that can be displayed on a mobile device via a network. Even so... Figures 11B to 11D As listed, in different embodiments, separate components may have coherent or separate interfaces and software to communicate and operate the device. The software system also provides reporting prompts and alerts, enabling administrators to efficiently manage the production process.

[0126] The mold and transfer mold have a flipping function: the 1001 mold installation equipment has a rotation function, allowing the mold surface to face upwards or downwards when entering the 1000 slurry tank to utilize vacuum adsorption of the material during the molding process. The 1002 transfer mold equipment also has a selective rotation function, allowing the mold to rotate after transferring the product, using vacuum and gravity to expel moisture.

[0127] Slurry casting: When 1001 and 1002 are closed, the mold has a casting cavity inside. The pulp from 1000 can be pumped into the cavity of mold 1001 through a water pump. Then, the water in the pulp is removed using a vacuum method to complete the first material. The second material can then be cast using 1006 in the same way. In the casting system, the slurry tanks 1000 and 1006 can be installed anywhere, either below or above the equipment.

[0128] Figure 12A The device, which is another embodiment of B, is also... Figure 10A-11D This is a derivative of [the previous sentence]. For example, the paper-plastic molding process may include: 1. Breaking down cardboard into pulp through a pulping system, adding other materials needed for pulping, mixing them, and then feeding them into the molding system. 2. Using vacuum or vacuum-driven methods, the pulp material is adhered to the mold surface, and then the excess water is drained using a drainage system on the mold surface, forming a thin layer of wet preform on the mold surface. 3. If the product surface still has a lot of moisture after molding, the remaining moisture can be removed by natural air drying, hot air, air pressure, or hot pressing assisted by mold heating.

[0129] The above description provides several molding processes:

[0130] The pulp forming method utilizes a vacuum chamber created inside a mold. Under vacuum, the pulp fibers are evenly deposited onto a forming mesh on the mold surface. The mold, with its surface facing upwards, enters the pulp tank, while a large amount of water is removed by vacuum suction. When the product reaches a certain thickness, the mold leaves the pulp tank, and the wet pulp on the mold surface undergoes dehydration.

[0131] Slurry casting method - The mold surface faces upward, and a pulp tank is made around the mold. The pulp is connected to the pulp tank through pulp pipelines. The amount of pulp is metered according to the thickness of the product. A vacuum chamber is made inside the mold. Under the action of vacuum, the pulp fibers can be evenly layered and attached to the forming mesh on the mold surface, while a large amount of water is removed by vacuum suction. This method forms a wet pulp blank on the mold surface, which is then dewatered.

[0132] In the reverse suction molding method, the mold is placed face down into the pulp tank, and a large amount of water is removed by vacuum suction. When the product reaches a certain thickness, the mold leaves the pulp tank, and the wet pulp on the mold surface undergoes dehydration.

[0133] Because this invention effectively combines two materials, through the properties of the fiber itself and cellulose, and by utilizing a specific arrangement in the process, the bond between two or more layers becomes tighter.

[0134] therefore, Figure 12A B describes a transverse system, where 1204, 1204', and 1204" are clamps, 1202, 1202', and 1202" are transfer molds, 1201 and 1201' are molds, 1200 is the first layer of slurry, 1206 is the second layer of slurry, and 1208 is a dewatering or positive pressure machine. This equipment is characterized as either a transverse system or a multi-position system, where 1202 or 1201 can rotate, and 1201' can also rotate.

[0135] Or like Figure 13 The described vertical system includes 1304 as a fixture, 1301 as a mold, 1300 as the first layer of slurry, 1306 as the second layer of slurry, and 1308 as a machine for dewatering, positive pressure, hot air, compression, heating, etc. Mold 1301 can be designed for rotation.

[0136] In another embodiment, Figure 12A With B and Figure 13 The system can be partially combined.

[0137] From the above embodiments, the forming method of the present invention utilizing the slurry tank 1 and the slurry tank 2 may include:

[0138] In a vertical system, if two molding dies need to be completed simultaneously, a rotational motion is required. In the molding workstation, top injection + back suction or back suction + top injection can be used. The above rotational motion can be achieved by: 1. A motor driving a mechanism to rotate the mold; 2. The vertical movement of the mold driving a connecting rod, rack, or mechanical structure to rotate.

[0139] In addition, the present invention enables the following combinations to achieve processes that were previously impossible:

[0140]

[0141] Therefore, the table above illustrates that the equipment of the present invention can have multiple (more than one) slurry tanks in the molding stage, enabling different molding processes and fulfilling various product requirements:

[0142] Products made of thick materials with a thickness of 2mm or more

[0143] After the forming station is completed, it can be connected to or transferred to the 1008 dewatering process. This equipment has positive pressure and compression devices for dewatering, which can accelerate the pulp drainage and forming time, which is beneficial for forming thick products.

[0144] Multilayer transfer stack molding (including composite materials)

[0145] A linear transfer system or a vertical rotation system can be used to simultaneously connect the first layer of material to the second layer. 1002 and 1004 transfer products can be used to stack two or more materials, or the same materials, together to create composite materials of varying thicknesses.

[0146] Multicolor molding

[0147] Using a linear transfer system or a vertical rotation system, multi-colored materials can be formed simultaneously, and a vacuum forming process with different colored pulps on a single product can be completed.

[0148] Dyeing and molding

[0149] In the pulp thermoforming process, changing the pulp dyeing color is a time-consuming task when cleaning the pipes. We can use a multi-pulp tank method to place the pulp dye in an independent forming tank. After the first layer of material is formed, it can be moved to the second dye layer to form the dye, so that the pulp surface is coated with color. Then it is transferred to the drying process. This system can shorten the time for changing different color dyes and eliminates the need to clean the pulping system.

[0150] Optimized additives

[0151] The timing of adding pulp additives during pulp forming is very important. We can add them in a separate forming tank and choose the appropriate time to add them to increase the ability of the additives to bind with the pulp fibers. Separate additives can also reduce the chance of pulp recycle water being contaminated by additives from other systems and improve the quality of the recycle water.

[0152] Multi-layer material molding

[0153] This allows for the simultaneous molding of the first and second layers of material. 1002 and 1004 transfer products can be used to stack two or more, or identical, materials together to create composite materials.

[0154] And from Figures 14A to 14D Because of the process and material toughness of this invention, it is possible to make special design requirements from fiber materials, for example, Figure 14A As shown, in the fastening method of the lunchbox, it can be pressed inward from the cut on the edge of the lid, allowing the fork on the edge of the food container to be inserted into the gap of the cut. Or as... Figure 14BThe image shows a small gap between the edge of the cover and the fork at the edge of the carrier, allowing the fork at the edge of the carrier to be inserted. Alternatively, the top of the cover can be designed with an arc shape to correspond to the support point at the bottom of the carrier (e.g., Figure 14C The support points at the bottom of the carrier can be designed without four legs, raising the bottom for ventilation and allowing steam to circulate while maintaining the carrier's strength (e.g., Figure 14D ).

[0155] In general, aspects of the present invention overcome the disadvantages of prior art methods, which involve the addition of toxic chemicals (e.g., fluoropolymers and their derivatives). These aspects also overcome the disadvantages of existing methods that use pulp as one or more base layers. Generally, pulp fibers are understood to have diameters in the range of 10 to 50 micrometers (μm). The aspects of the present invention, however, are finer in size, for example, in the range of less than 1 μm.

[0156] Although variable and application-dependent, the following are examples of methods using the apparatus disclosed herein. Those skilled in this art will recognize that these steps can be performed in any practical order to produce materials for the desired purpose.

[0157] The above description and figures are merely illustrative and explanatory, and the invention is not limited thereto. While the specification describes certain embodiments or examples, many details are set forth for illustrative purposes. Therefore, the foregoing is only intended to illustrate the principles of the invention. For example, the invention may have other specific forms without departing from its spirit or essential characteristics. The described arrangements are illustrative and not restrictive. For those skilled in the art, the invention allows for additional embodiments or examples, and some of the details described herein may be considerably varied without departing from the basic principles of the invention. It should be appreciated that those skilled in the art can devise various solutions that, while not explicitly described or shown herein, embody the principles of the invention and are therefore within its scope and spirit.

[0158] The foregoing description is illustrative and not restrictive. Many variations of the embodiments may become apparent during the review of the disclosure. Therefore, the scope of embodiments should not be determined by reference to the foregoing description, but rather by reference to the pending claims and their full scope or equivalents.

[0159] One or more features in any embodiment may be used in combination with one or more features in any other embodiment without departing from the scope of the embodiment. The terms “a,” “single,” or “a” are intended to mean “one or more” unless specifically stated otherwise. The use of “and / or” is intended to represent the most inclusive understanding of the term unless explicitly stated otherwise.

[0160] Although this disclosure may be embodied in many different forms, it is understood at the time of submission of the drawings and discussions that this disclosure is an embodiment of one or more inventive principles and is not intended to limit any embodiment to the illustrated embodiment.

[0161] This disclosure provides a solution to the aforementioned long-standing needs. In particular, aspects of the present invention overcome the challenges of relying on existing practices that use chemical formulations to provide reinforcing properties to cellulose materials.

[0162] Further advantages and modifications to the above systems and methods may readily occur to those skilled in the art.

[0163] Therefore, the disclosure is not limited in a broader sense to specific details, representative systems and methods, and the illustrative examples described above. Various modifications and alterations may be made to the above specifications without departing from the scope or spirit of this disclosure, which shall cover all such modifications and alterations provided that they fall within the scope of the following claims and their equivalents.

Claims

1. An apparatus for producing a biodegradable carrier material, comprising: The first element loads the first material from a container; The first element includes a fiber connector to hold a portion of the fibers within a first material, the first material including pulp; The second element adsorbs a portion of the fibers of the fiber connector; The third element brings the second material into contact with a portion of the fiber, so that the second material is effectively added to the first material. The second material is a refined fiber material, and the second material is then mixed with the portion of the fiber to become a third material. and A dehydration device is used to reduce the moisture content of the third material; The first element, the second element, and the third element form a transverse system. The first and second elements have a rotation function so that the mold can face upwards or downwards. The third element also includes a container for carrying the second material.

2. The apparatus according to claim 1 further includes a shaping device for shaping the dehydrated third material.

3. The device according to claim 1, wherein the second element is capable of multi-directional movement to stack two or more materials together.

4. The device according to claim 1, wherein the third element further comprises a heating source.

5. The device according to claim 4, wherein the heating source keeps the second material at a temperature above 40 degrees Celsius.

6. The apparatus of claim 4, wherein the heating source causes the second material to reach a temperature of 40 degrees Celsius or higher when in contact with the first material.

7. The device according to claim 1, wherein the third material does not contain chemical additives or the third material does not contain chemical additives that increase or improve the tensile strength, oil resistance, gas and / or liquid impermeability, tensile modulus, or tensile index of the material.

8. The device according to claim 1, wherein the third material comprises the following properties: 8000 cubic centimeters per square foot per 24 hours (cm) 3 m -2 24h -1 or less oxygen penetration; 3000 grams per square foot per 24 hours (gm) -2 24h -1 A water vapor transport rate of 30 MPa or less; a dry tensile strength of 30 MPa or more; 4 GPa or higher dry tensile modulus; and 45 Nmg -1 Or a higher dry tensile index.

9. The device according to claim 1, wherein the third material comprises the following properties: A wet tensile strength of 5 MPa or above; 0.4 MPa or higher wet tensile modulus; and 5Nmg -1 Or a higher wet tensile index.

10. The device of claim 1, wherein the third material comprises cellulose with a diameter of 1-10000 nanometers.

11. The apparatus of claim 1, wherein the third material comprises cellulose having a particle size of 0.1 to 1000 micrometers, 10 to 500 micrometers, 1 to 25 micrometers, or 0.2 to 100 micrometers.

12. The device according to claim 1, wherein the third material is a flat plate.

13. The apparatus of claim 1, wherein the third material is a fiber mixture.

14. An apparatus for producing a biodegradable carrier material, comprising: The second element adsorbs the second material, which includes the material after fiber refinement. The third element transforms the second material into the third material in a vacuum state; and A dehydration device is used to reduce the moisture content of the third material. The second element can rotate so that the mold can face up or down, and the second element can move in multiple directions to stack two or more materials together.

Images