Process for making a plant fiber sponge
Patent Information
- Application Number
- CN202411702425.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-26
- Publication Date
- 2026-10-23
AI Technical Summary
传统纤维海绵制作工艺中制胶反应不充分、粘度低，稳定性和均匀性差，孔洞不均匀、骨架强度低
[0017]本发明优点在于：环保可持续，采用植物纤维(木浆纤维素)为主要原料，减少了对石油化工等不可再生资源的依赖，具有环保可持续的优点。整个制作过程中使用的化学试剂相对较少，且大部分可以回收利用，降低了对环境的污染。产品性能优良，经过碱化、黄化、成化、混合和发泡成型等多道工序，使植物纤维海绵具有较高的强度、弹性和吸水性。海绵内部的孔洞均匀分布，提高了海绵的透气性和舒适性。添加增强纤维辅料，进一步增强了海绵的耐用性。生产效率高，该制作工艺采用自动化设备和流水线作业，提高了生产效率，降低了人工成本。各个工序之间通过高位差自流和机械运输等方式进行物料转移，减少了中间环节的时间浪费和物料损失。产品质量稳定，严格控制各个工序的工艺参数，如反应时间、温度、粘度等，确保了产品质量的稳定性。采用先进的检测设备和方法，对产品进行实时监测和质量控制，保证了产品符合相关标准和要求。应用范围广泛，植物纤维海绵具有良好的性能和环保特点，可广泛应用于家居、清洁、医疗、美容等领域。可以根据不同的需求进行定制化生产，满足不同客户的特殊要求。
Abstract
Description
Technical Field
[0001] This invention relates to a process for manufacturing plant fiber sponges. Background Technology
[0002] With increasing emphasis on environmental protection and sustainable development, traditional synthetic sponges, due to their non-degradability and potential environmental hazards, are gradually failing to meet the needs of modern society. Plant fiber sponges, as a new type of environmentally friendly material, have emerged to address this need.
[0003] Plant fibers are renewable and biodegradable, aligning with the current concept of green development. Among various plant fibers, wood pulp cellulose is widely available, relatively inexpensive, and boasts excellent performance. Through specific manufacturing processes, wood pulp cellulose can be transformed into sponge products with good water absorption, elasticity, and durability. Traditional sponge manufacturing processes typically rely on petrochemical raw materials, consuming large amounts of non-renewable resources and potentially releasing harmful substances during production and use. In contrast, plant fiber sponge manufacturing processes use natural wood pulp cellulose as the primary raw material, reducing negative environmental impact. Furthermore, with continuous technological advancements, the performance requirements for sponge products are increasing. This manufacturing process, through a series of steps including alkalization, xanthation, formation, mixing, and foaming, allows for precise control of the sponge's structure and properties, resulting in excellent performance in water absorption, breathability, and softness, meeting the application needs of various fields. Traditional fiber sponge manufacturing processes suffer from incomplete adhesive reactions, low viscosity, poor stability and uniformity, uneven pore size, and low skeletal strength.
[0004] In conclusion, the emergence of plant fiber sponge manufacturing technology not only meets people's demand for environmentally friendly materials, but also provides a new direction for the development of sponge products. Summary of the Invention
[0005] The purpose of this invention is to provide a process for manufacturing plant fiber sponges to solve the problems mentioned in the background art.
[0006] To solve the above-mentioned technical problems, the technical solution provided by the present invention is: a process for manufacturing plant fiber sponges, specifically including the following steps:
[0007] 1) Wood pulp alkalization process: The wood pulp cellulose is manually added to the alkalization kettle, and the sodium hydroxide solution is dripped and stirred for 50-70 minutes;
[0008] Sodium hydroxide reacts with wood pulp cellulose in an alkalization reaction, dissolving the wood pulp cellulose and eventually swelling it into fluffy, cotton-like alkalized cellulose.
[0009] 2) Cellulose xanthation process: After the alkalization process is completed, all materials are flowed into the xanthation kettle by gravity through a high-pressure difference. Carbon disulfide is added to the glue-making kettle and stirred to make the alkalized cellulose more fully dissolved in the sodium hydroxide solution to form a gel solution. The gel-making reaction occurs with the carbon disulfide to generate high-viscosity cellulose xanthate. After the xanthation reaction is completed, pure water is added to the kettle to dilute it to the required viscosity. The prepared adhesive is stored for later use.
[0010] 3) Static curing reaction: The diluted cellulose xanthate is added to the curing tank through a high-level difference, and the mixture is allowed to stand for curing while the temperature is maintained. During the curing process, the viscose undergoes hydrolysis to generate cellulose viscose.
[0011] 4) Cellulose viscose mixing operation: Put the cellulose viscose after the formation is completed into the mixing tank, add sodium sulfate crystals, pure water, dye solution and reinforcing fiber auxiliary materials, stir thoroughly for 50-70 minutes to form a uniform, high-viscosity particulate mixture, pour it into a square-shaped mold containing a low-concentration sodium sulfate solution, wait for curing, and form a sponge foam.
[0012] 5) Electric heating foaming molding operation: The hole-forming mold is transported to the heating zone. Low-voltage AC power is applied to the upper and lower electrode plates of the mold to raise its temperature and start the hole-forming process. The sodium sulfate crystal particles in the sponge foam are incorporated into the solution. At the same time, the cellulose viscose solution is regenerated into wood pulp cellulose at high temperature. The fibers are fixed and formed into a skeleton. During the process of salt crystal incorporation, pores are formed in the cellulose. The wood pulp sponge product is basically formed. The hole-forming process takes 50-70 minutes.
[0013] 6) Sponge cleaning operation: Push the mold from the hole forming line to the cleaning area for cleaning;
[0014] 7) Finished product processing and packaging operations.
[0015] As a preferred embodiment, the dye solution in step 4) is formed by mixing food-grade dye and pure water, and is first added to an intermediate tank and stirred before use.
[0016] As a preferred embodiment, the cleaning process in step 6) includes eight steps of solution washing and squeezing.
[0017] The advantages of this invention are: Environmentally friendly and sustainable. Using plant fiber (wood pulp cellulose) as the main raw material reduces reliance on non-renewable resources such as petrochemicals, thus offering environmental sustainability benefits. The entire production process uses relatively few chemical reagents, most of which are recyclable, reducing environmental pollution. Excellent product performance. Multiple processes, including alkalization, xanthation, curing, mixing, and foaming, give the plant fiber sponge high strength, elasticity, and water absorption. The uniform distribution of pores within the sponge improves breathability and comfort. The addition of reinforcing fiber auxiliaries further enhances the sponge's durability. High production efficiency. The manufacturing process utilizes automated equipment and assembly line operations, improving production efficiency and reducing labor costs. Material transfer between processes is achieved through high-level gravity flow and mechanical transport, reducing time waste and material loss in intermediate stages. Stable product quality. Strict control of process parameters at each stage, such as reaction time, temperature, and viscosity, ensures product quality stability. Advanced testing equipment and methods are used for real-time monitoring and quality control, guaranteeing that the product meets relevant standards and requirements. With a wide range of applications, plant fiber sponges possess excellent performance and environmentally friendly characteristics, making them suitable for various fields such as home furnishing, cleaning, medical, and beauty applications. Customized production is available to meet the specific requirements of different customers. Detailed Implementation
[0018] For the purposes of the detailed description below, it should be understood that the invention may take various alternative variations and sequences of steps unless expressly stated otherwise. Furthermore, except in any operational instance, or otherwise indicated, all figures representing the amounts of ingredients used, for example, in the specification and claims, should be understood to be modified in all cases by the term “about.” Therefore, unless indicated to the contrary, the numerical parameters set forth in the following specification and appended claims are approximations varying with the desired performance to be obtained according to the invention. It is not at all an attempt to limit the application of the doctrine of equivalents to the scope of the claims; each numerical parameter should be interpreted at least according to the number of significant figures reported and by applying ordinary rounding techniques.
[0019] Although the numerical ranges and parameters illustrating the broad scope of the invention are approximate, the values listed in the specific examples are reported as precisely as possible. However, any numerical value inherently contains some error that is necessarily caused by the standard deviation found in their respective test measurements.
[0020] Furthermore, it should be understood that any numerical range described herein is intended to include all subranges falling within it. For example, the range “1 to 10” is intended to include all subranges between the minimum value 1 and the maximum value 10, i.e., a minimum value equal to or greater than 1 and a maximum value equal to or less than 10.
[0021] Example
[0022] A process for manufacturing plant fiber sponges includes the following steps:
[0023] 1) Wood pulp alkalization process: The wood pulp cellulose is manually added to the alkalization kettle, and the sodium hydroxide solution is dripped and stirred for 50-70 minutes;
[0024] Sodium hydroxide reacts with wood pulp cellulose in an alkalization reaction, dissolving the wood pulp cellulose and eventually swelling it into fluffy, cotton-like alkalized cellulose.
[0025] 2) Cellulose xanthation process: After the alkalization process is completed, all materials are flowed into the xanthation kettle by gravity through a high-pressure difference. Carbon disulfide is added to the glue-making kettle and stirred to make the alkalized cellulose more fully dissolved in the sodium hydroxide solution to form a gel solution. The gel-making reaction occurs with the carbon disulfide to generate high-viscosity cellulose xanthate. After the xanthation reaction is completed, pure water is added to the kettle to dilute it to the required viscosity. The prepared adhesive is stored for later use.
[0026] 8) Static curing reaction operation: The diluted cellulose xanthate is added into the curing tank through a high-level difference, and the mixture is allowed to stand for curing while the temperature is maintained. During the curing process, the viscose undergoes hydrolysis to generate cellulose viscose.
[0027] 9) Cellulose viscose mixing operation: Put the cellulose viscose after the formation is completed into the mixing tank, add sodium sulfate crystals, pure water, dye solution, and reinforcing fiber auxiliary materials, stir thoroughly for 50-70 minutes to form a uniform, high-viscosity particulate mixture, pour it into a square-shaped mold containing a low-concentration sodium sulfate solution, wait for curing, and form a sponge foam.
[0028] 10) Electric heating foaming molding operation: The hole-forming mold is transported to the heating zone, and low-voltage AC power is applied to the upper and lower electrode plates of the mold to raise its temperature.
[0029] The process begins with heating to initiate the pore-forming process, incorporating sodium sulfate crystal particles from the sponge into the solution. Simultaneously, the cellulose viscose solution regenerates into wood pulp cellulose at high temperatures, fixing the fibers to form a skeleton. During the incorporation of salt crystals, pores are formed within the cellulose, and the wood pulp sponge product is essentially formed. The pore-forming process takes 50-70 minutes.
[0030] 11) Sponge cleaning operation: Push the mold from the hole forming line to the cleaning area for cleaning;
[0031] 12) Finished product processing and packaging operations.
[0032] As a preferred embodiment, in step 4), the dye solution is formed by mixing food-grade dye and pure water, and is first added to the intermediate tank and stirred before use.
[0033] As a preferred embodiment, the cleaning process in step 6) includes eight steps of solution washing and squeezing.
[0034] The technical problem solved by this invention is as follows:
[0035] Effective treatment of wood pulp cellulose: Through alkalization, wood pulp cellulose is dissolved and swollen into fluffy, cotton-like alkalized cellulose, solving the problem of the difficulty in directly utilizing wood pulp cellulose. The alkalization reaction between sodium hydroxide solution and wood pulp cellulose provides a foundation for subsequent xanthation and molding steps.
[0036] Achieving efficient cellulose xanthate reaction: In the cellulose xanthation process, the alkalized material flows by gravity into the xanthation kettle, where carbon disulfide is added to initiate the cellulose xanthate reaction, generating high-viscosity cellulose xanthate. This solves the problems of insufficient cellulose xanthate reaction and low viscosity in traditional processes, improving product quality and performance.
[0037] Ensuring viscose curing and molding: The static curing reaction process allows diluted cellulose xanthate to stand and cure in a curing tank, undergoing hydrolysis to generate cellulose viscose. Multiple excipients are added during the cellulose viscose mixing process to form a uniform, high-viscosity mixture containing particles, which is then introduced into a pore-forming mold and allowed to cure, thus solving the stability and uniformity issues in the sponge molding process.
[0038] Optimized foaming process: The electric heating foaming process heats the mold by passing low-voltage AC current through the upper and lower electrode plates, causing the sodium sulfate crystals in the sponge foam to dissolve into the solution. Simultaneously, the cellulose viscose solution regenerates wood pulp cellulose, forming a skeleton and creating pores within the cellulose. This solves the problems of uneven pore size and low skeleton strength in traditional foaming processes, improving the quality and performance of the sponge.
[0039] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.
Claims
1. A process for manufacturing plant fiber sponges, characterized in that, Specifically, the following steps are included: 1) Wood pulp alkalization process: The wood pulp cellulose is manually added to the alkalization kettle, and the sodium hydroxide solution is dripped and stirred for 50-70 minutes; Sodium hydroxide reacts with wood pulp cellulose in an alkalization reaction, dissolving the wood pulp cellulose and eventually swelling it into fluffy, cotton-like alkalized cellulose. 2) Cellulose xanthation process: All materials completed in the alkalization process are gravity-fed into the xanthation kettle via a high-level difference, along with carbon disulfide. Add to the glue-making kettle and stir to make the alkalized cellulose more fully dissolve in the sodium hydroxide solution to form a gel solution, and react with carbon disulfide to produce high-viscosity cellulose xanthate. After the xanthation reaction is completed, add pure water to the kettle to dilute to the required viscosity. Store the prepared adhesive for later use. 3) Static curing reaction: The diluted cellulose xanthate is added to the curing tank through a high-level difference, and the mixture is allowed to stand for curing while the temperature is maintained. During the curing process, the viscose undergoes hydrolysis to generate cellulose viscose. 4) Cellulose viscose mixing process: The cellulose viscose after processing is placed in a mixing tank, and sodium sulfate crystals, pure water, dye solution, and reinforcing fiber additives are added. The mixture is stirred thoroughly for 50-70 minutes to form a homogeneous, high-viscosity mixture containing particles. This mixture is then introduced into the mixing tank. A low-concentration sodium sulfate solution is placed in a mold with holes and left to solidify, forming a sponge-like foam. 5) Electric heating foaming molding operation: The hole-forming mold is transported to the heating zone. Low-voltage AC power is applied to the upper and lower electrode plates of the mold to raise its temperature and start the hole-forming process. The sodium sulfate crystal particles in the sponge foam are incorporated into the solution. At the same time, the cellulose viscose solution is regenerated into wood pulp cellulose at high temperature. The fibers are fixed and formed into a skeleton. During the process of salt crystal incorporation, pores are formed in the cellulose. The wood pulp sponge product is basically formed. The hole-forming process takes 50-70 minutes. 6) Sponge cleaning operation: Push the mold from the hole forming line to the cleaning area for cleaning; 7) Finished product processing and packaging operations.
2. The process for manufacturing plant fiber sponge according to claim 1, characterized in that: In step 4), the dye solution is formed by mixing food-grade dye and pure water, and is first added to the intermediate tank and stirred before use.
3. The process for manufacturing plant fiber sponge according to claim 1, characterized in that: The cleaning process in step 6) includes eight steps of solution washing and squeezing.