Bacterial Cellulose Non-Woven Production With Thermal Fermentation Control
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Solution Overview
Problem
Existing methods for producing bacterial cellulose (BC) non-woven face inefficiencies such as low yield, high pre-polymer content, and suboptimal mechanical properties, particularly low tensile strength, due to batch-wise production and inadequate temperature control during fermentation processes.
Innovation Solution
A method involving controlled temperature regulation of the gaseous atmosphere above the bacterial culture, maintaining it within 10 K of the culture medium's temperature, and continuous or semi-static production processes to enhance yield and mechanical properties of BC non-woven, minimizing pre-polymer content and ensuring homogeneous structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If static or discontinuous production processes are used, then production simplicity is maintained, but productivity and yield are limited
Solution Approach 1:
The patent implements continuous production processes where bacterial cellulose is synthesized continuously in the culture vessel rather than in batch-wise static fermentation. The culture medium flows continuously through the system, enabling uninterrupted BC synthesis and significantly increasing productivity while maintaining process simplicity through continuous operation.
2Productivity
If batch-wise production is used, then process simplicity is maintained, but production time and cost increase
Solution Approach 1:
The continuous production system eliminates batch-wise operation delays and setup times. Bacterial cellulose synthesis proceeds continuously with continuous medium flow, reducing total production time and increasing efficiency without requiring complex batch processing operations.
3Strength
If temperature control is not optimized, then process simplicity is maintained, but BC quality and mechanical properties deteriorate
Solution Approach 1:
The patent implements optimized temperature control where the gaseous atmosphere temperature is maintained within 10 K of the culture medium temperature. This parameter optimization significantly improves BC tensile strength and mechanical properties while using simple temperature regulation mechanisms without complex control systems.
4Productivity
If production time is extended to increase yield, then BC quantity increases, but pre-polymer content increases and quality decreases
Solution Approach 1:
The continuous production process with optimized temperature parameters enables high BC yield while maintaining structural homogeneity. The continuous flow system prevents pre-polymer accumulation by maintaining consistent synthesis conditions, producing homogeneous BC non-woven with high quality even at extended production times.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves increased space-time-yield and improved tensile strength, producing BC non-woven with reduced pre-polymer content and homogeneous structure, suitable for applications like wound dressings and cosmetic pads.
Implementation Method 1
at least during steps a) and d), more preferably at least during steps a), b), d) and e), more preferably during steps a) to g) the gaseous atmosphere above the bacterial culture is kept at a temperature that is at most 10 K below the highest temperature of the culture medium in the culture vessel
Implementation Method 2
a) Synthesizing BC by incubating a bacterial culture in a culture vessel, wherein the bacterial culture comprises liquid culture medium and BC-synthesizing bacteria
Data Source
AI summary
The present invention relates to a method for producing bacterially synthesized cellulose (BC) non-woven as well as to BC non-woven produced by the method and uses of such BC non-woven. The present invention also relates to an apparatus for production of the BC non-woven. Preferably, the bacterially synthesized cellulose (BC) of the present invention is biotechnologically produced nano-structured cellulose (BNC).