Cellulose Nanofiber Fibrillation in Polyester Resin

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Solution Overview

Problem

Current methods for fibrillating cellulose nanofibers require water or organic solvents, leading to dehydration challenges and complex production steps, which hinder their efficient dispersion into resins and result in poor reinforcement properties.

Innovation Solution

Fibrillating cellulose directly in a polyester-based resin without using water or organic solvents, allowing for straightforward combination with other resins and eliminating the need for dehydration steps, thereby simplifying the production process and enhancing resin composition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If cellulose is fibrillated in water or organic solvent, then cellulose nanofibers can be obtained, but dehydration steps are required and production complexity increases

Engineering Contradiction:

Improvenanofiber dispersion qualityVSAvoidproduction process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention extracts and eliminates the water or organic solvent medium from the fibrillation process, performing fibrillation directly in the polyester resin itself. This removes the need for subsequent dehydration steps while maintaining nanofiber dispersion quality

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The polyester resin serves multiple functions: it acts as both the processing medium and the final resin matrix. This eliminates the need for separate solvent removal steps and directly produces the desired resin composition with dispersed nanofibers

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If cellulose nanofibers are dehydrated to remove water, then resin dispersion can be improved, but nanofibers re-flocculate and dispersion quality deteriorates

Engineering Contradiction:

Improveresin dispersion qualityVSAvoidnanofiber dispersion uniformity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention extracts the water removal step entirely by performing fibrillation directly in the polyester resin without introducing water as a medium, thus eliminating the re-flocculation problem that occurs during dehydration

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The fibrillation is performed preliminarily in the polyester resin matrix itself before any potential flocculation can occur, ensuring uniform dispersion is locked in before the nanofibers have opportunity to re-aggregate

Inventive Principle:

Principle #10Preliminary action

3Productivity

If organic solvent is used for fibrillation to avoid water, then dehydration steps are eliminated, but additional dispersion and solvent removal steps are required

Engineering Contradiction:

Improveproduction efficiencyVSAvoidproduction process steps

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The polyester resin serves as both the processing medium for fibrillation and the final resin matrix, eliminating the need for separate solvent removal steps and reducing overall process complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention merges the fibrillation process directly with the resin matrix formation, combining what would otherwise be separate steps (fibrillation in solvent followed by solvent removal and resin addition) into a single integrated process

Inventive Principle:

Principle #5Merging (Combining)

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 high-strength resin compositions with improved dispersion and mechanical properties, such as fracture toughness, by directly fibrillating cellulose in a polyester-based resin, reducing production complexity and costs.

Implementation Method 1

cellulose is fibrillated in a polyester based resin

Methodology Applied

Scientific EffectCavitation: Cavitation

Implementation Method 2

cellulose is fibrillated in a polyester based resin

Methodology Applied

Scientific EffectShear stress: Shear Stress

Data Source

PatentUS8735470B2Method for fibrillating cellulose, cellulose nanofiber, masterbatch, and resin composition

Publication Date: 2014.05.27 DIC CORP

AI summary

The present invention provides a method for manufacturing a cellulose nanofiber, characterized by comprising the step of fibrillating cellulose in a polyester based resin, preferably in a polyester based resin having an ester group concentration of 6.0 mmol/g or more and a cellulose nanofiber produced by the manufacturing method concerned. In addition, the present invention provides a masterbatch composition containing the cellulose nanofibers and the polyester based resin. Furthermore, the present invention provides a resin composition containing the masterbatch composition and a diluent resin and a processed product thereof.