Cellulose Film Formation by Sub-Zero Fiber Shearing
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Solution Overview
Problem
Existing methods for producing cellulose films require substantial chemical and energy inputs, reducing their sustainability, and there is a need for simpler, low-energy, and low-chemical-input processes.
Innovation Solution
A method involving blending and mixing fibrous materials, such as cellulose fibers, with a basic aqueous solution at sub-zero temperatures, followed by mechanical shearing and separation, to produce cellulose films with desirable properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods (TEMPO oxidation, carboxymethylation, high-pressure homogenization, microfluidization) are used to fabricate cellulose nanofibrils, then transparent cellulose films can be produced, but substantial amounts of chemicals and energy input are required, significantly reducing sustainability
Solution Approach 1:
The patent changes the temperature parameter to sub-zero conditions (below 0°C, preferably -10°C to -20°C) to enable cellulose fiber blending and film formation without requiring energy-intensive nanofibrillation processes. This temperature parameter change allows the use of conventional blending equipment instead of high-pressure homogenization or microfluidization devices, dramatically reducing energy consumption while maintaining film transparency.
Solution Approach 2:
The patent extracts and eliminates the need for complex nanofibrillation processes (TEMPO oxidation, carboxymethylation, high-pressure homogenization, microfluidization) from the cellulose film production process. By taking out these energy-intensive steps and replacing them with simple sub-zero blending, the method maintains film transparency while significantly reducing chemical and energy inputs.
2Reliability
If conventional methods (TEMPO oxidation, carboxymethylation, high-pressure homogenization, microfluidization) are used to fabricate cellulose nanofibrils, then transparent cellulose films can be produced, but substantial amounts of chemicals are required, significantly reducing sustainability
Solution Approach 1:
The patent extracts and eliminates the need for complex chemical treatment processes (TEMPO oxidation, carboxymethylation) from the cellulose film production process. By taking out these chemical-intensive steps and replacing them with simple sub-zero blending, the method maintains film transparency while significantly reducing chemical consumption.
Solution Approach 2:
The patent employs self-service by using the cellulose fibers themselves as the film-forming material without requiring external chemical modifiers or oxidants. The sub-zero temperature blending process allows the natural properties of cellulose fibers to be utilized directly, eliminating the need for substantial chemical inputs while achieving transparent film formation.
3Ease of manufacture
If conventional blending equipment is used at normal temperatures, then the process is simple, but the fiber diameter reduction is insufficient to achieve desired film properties
Solution Approach 1:
The patent changes the temperature parameter to sub-zero conditions (below 0°C, preferably -10°C to -20°C) to enhance the effectiveness of conventional blending equipment. This temperature parameter change enables significant fiber diameter reduction (at least 60% smaller than original fibers) while maintaining process simplicity, as the same blending equipment can achieve superior fiber fragmentation and film properties when operated at sub-zero temperatures.
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 results in cellulose films with high light transmittance, mechanical strength, and biodegradability, achieved through reduced fiber diameters and lengths, using less energy and chemicals.
Implementation Method 1
mixing the fibrous material in a basic aqueous solution
Implementation Method 2
cellulose fibers are mixed with a basic aqueous solution, followed by mechanical shearing
Implementation Method 3
mechanical shearing and separation, to produce cellulose films with desirable properties
Implementation Method 4
blending of the fibrous material comprises shearing the fibers along a longitudinal direction of the fibers
Data Source
AI summary
A method for producing a polymeric material is disclosed. The method combines blending of fibers and treating the fibers with a basic aqueous solution. In some embodiments, the blending of the fibers is performed at a blending speed sufficient to shear the fibers in one or both of a longitudinal direction and lateral direction of the fibers. In some embodiments, one or both of the blending and treating are performed in a sub-zero temperature, at a temperature of less than 0° C., or in a range of from about 0° C. to about −20° C. One example application of the method is in the making of a cellulose film from wood pulp.