Finely Fibrous Cellulose Composite Sheet Production via Emulsion Mixing
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Solution Overview
Problem
Current methods for producing finely fibrous cellulose composite sheets lack industrial productivity and simplicity, as they often require impregnation steps that can lead to non-uniformity and limited reactive compound penetration, and existing techniques fail to efficiently convert finely fibrous cellulose into composite sheets while maintaining good industrial productivity.
Innovation Solution
A method involving the mixing of an emulsion of a reactive compound with an aqueous suspension of finely fibrous cellulose, followed by filtration and drying on a porous substrate to form a prepreg sheet, which eliminates the need for impregnation and porosity enhancement steps, allowing for efficient production of finely fibrous cellulose composite prepreg, composite, and laminate sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional impregnation methods are used to form composite sheets, then the composite can be formed, but the process becomes complex and productivity decreases
Solution Approach 1:
The patent combines the sheet formation process and composite formation process into a single integrated process. The reactive compound emulsion is mixed with the cellulose suspension before sheet formation, so that the polymer and fiber composite are formed simultaneously during the sheet making process, eliminating separate impregnation steps and improving both simplicity and productivity
Solution Approach 2:
The reactive compound is emulsified and mixed with the cellulose suspension in advance, before the sheet formation process. This preliminary mixing ensures that the polymer and fiber are uniformly distributed from the start, allowing the composite to form automatically during sheet making without requiring subsequent impregnation treatment
2Manufacturing precision
If impregnation steps are used to form composite sheets, then the composite can be formed, but non-uniformity occurs and reactive compound penetration is limited
Solution Approach 1:
The reactive compound emulsion is uniformly distributed throughout the cellulose suspension before sheet formation, ensuring that every local region of the developing sheet receives the polymer simultaneously. This uniform initial distribution eliminates the non-uniformity that occurs with post-formation impregnation methods
Solution Approach 2:
By merging the mixing step with the sheet formation process, the patent ensures that the reactive compound and cellulose fibers are combined uniformly throughout the entire sheet at once, rather than requiring sequential impregnation steps that create non-uniformity
3Stability of the object's composition
If finely fibrous cellulose is processed into composite sheets, then thermal dimensional stability improves, but the process becomes complex and less productive
Solution Approach 1:
The patent merges the composite formation process with the sheet formation process, so that the thermal dimensional stability benefit is achieved simultaneously with sheet production. The reactive compound emulsion is mixed with the cellulose suspension before sheet making, allowing the polymer to bind the fine fibers and provide thermal stability in a single process step rather than requiring separate impregnation and curing steps
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
This method enables the production of finely fibrous cellulose composite sheets with improved thermal dimensional stability, transparency, and productivity, reducing costs and environmental impact by eliminating unnecessary steps and solvent use, while ensuring uniform dispersion of fibers within the polymer.
Implementation Method 1
an emulsion of a reactive compound with an aqueous suspension containing a finely fibrous cellulose to prepare a mixed liquid
Implementation Method 2
dewatering this mixed liquid by filtration on a porous substrate to form a water-containing sheet
Implementation Method 3
performing heating and drying the water-containing sheet
Data Source
AI summary
The present invention relates to a method of producing a finely fibrous cellulose composite prepreg sheet, the method including a preparation step of mixing an emulsion of a reactive compound with an aqueous suspension containing a finely fibrous cellulose to prepare a mixed liquid, a papermaking step of dewatering the mixed liquid by filtration on a porous substrate to form a water-containing sheet, and a drying step of heating and drying the water-containing sheet; and a method of producing a finely fibrous cellulose composite sheet, the method including subjecting the finely fibrous cellulose composite prepreg sheet produced by the aforementioned production method to a curing treatment. The present invention is able to provide a method of producing a finely fibrous cellulose composite prepreg sheet with good efficiency, a method of producing a finely fibrous cellulose composite sheet, and a method of producing a finely fibrous cellulose composite laminate sheet.