Nano-fibrillar Cellulose Gel Production for Cost-Efficient Composites
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Solution Overview
Problem
Current composite materials are often expensive and environmentally unfriendly, with high processing costs due to the use of polymers and the need for surface treatment of fillers, necessitating a cost-efficient and environmentally friendly alternative.
Innovation Solution
The production of nano-fibrillar cellulose gels through fibrillation of cellulose fibers in the presence of fillers and/or pigments, forming a meta-stable gel network that improves runnability and reduces environmental impact, using a process that involves monitoring viscosity changes during shearing to confirm gel formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polymers are used in composite materials, then the composite structure and performance are improved, but the cost and environmental impact increase
Solution Approach 1:
The patent replaces expensive polymers with inexpensive natural fillers such as cellulose, calcium carbonate, and starch. These natural materials can be processed and degraded more easily, reducing both manufacturing costs and environmental impact while maintaining composite material functionality
Solution Approach 2:
The patent changes the material composition parameters by substituting synthetic polymers with natural fillers. This parameter change affects both cost (reduction) and environmental properties (improvement), while maintaining the structural integrity of the composite through proper filler-reinforcement design
2Strength
If fillers are added to composite materials, then the performance is improved, but the processing cost increases due to surface treatment requirements
Solution Approach 1:
The patent uses natural fillers that do not require expensive surface treatments. Materials like cellulose, calcium carbonate, and starch can be directly incorporated into the composite structure without additional processing steps, eliminating surface treatment costs while maintaining performance
Solution Approach 2:
The natural fillers inherently possess surface properties that allow direct integration with the matrix material. The fillers self-compatibilize with the surrounding material system, eliminating the need for external surface treatment processes and reducing manufacturing complexity
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 resulting composite materials are cost-efficient, environmentally friendly, and exhibit improved runnability, making them suitable for various applications, including plastics, paints, and construction materials, while replacing traditional materials like plastics and metals.
Implementation Method 1
The fibrillation is performed until the gel is formed, wherein the formation of the gel is verified by the monitoring of the viscosity in dependence of the shearing rate
Implementation Method 2
forming a meta-stable gel network that improves runnability
Implementation Method 3
The cellulose macromolecules (composed of 1-4 glycosidic linked β-D-Glucose molecules) are linked together by hydrogen bonds to form a so called primary fibril
Implementation Method 4
The fundamental design concept of composites is that the bulk phase accepts the load over a large surface area, and transfers it to the reinforcement material, which can carry a greater load
Implementation Method 5
the bulk phase accepts the load over a large surface area, and transfers it to the reinforcement material
Data Source
AI summary
A process for the production of composite materials comprising nano-fibrillar cellulose gels, by providing cellulose fibres and at least one filler and/or pigment, combining the cellulose fibres and the at least one filler and/or pigment, fibrillating the cellulose fibres in the presence of the at least one filler and/or pigment until a gel is formed, subsequently providing at least one further filler and/or pigment and combining the gel with the at least one further filler and/or pigment.