Cellulose Layer Form Pressing for Low-Energy Production
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Solution Overview
Problem
Existing processes for producing cellulose-based products are energy-intensive and complex, requiring multiple steps and high energy consumption, which hinders the production of environmentally friendly, cost-effective, and aesthetically appealing products with desired mechanical and chemical properties.
Innovation Solution
A method involving the use of at least two layers of cellulose fibers, with one or both sides pre-treated with a biodegradable adhesive coating, arranged in a superimposed relationship within a forming mold and subjected to form pressing at controlled temperatures and pressures, allowing the layers to move relative to each other until a predetermined end-pressure is reached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional drying processes are used for cellulose-based products, then the products achieve sufficient mechanical strength and stability, but the energy consumption increases significantly and production time is extended
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical state of cellulose fibers through controlled thermal treatment at elevated temperatures (100-200°C) and pressures (1-100 MPa). This transforms the cellulose structure to achieve sufficient mechanical strength without requiring traditional drying processes, thereby eliminating the energy-intensive evaporation step while maintaining product integrity
Solution Approach 2:
The patent utilizes phase transitions by subjecting cellulose fibers to controlled heating and pressurization that induces structural changes in the material. The thermal and pressure treatment causes phase transitions in the cellulose matrix, enabling the formation of a dense, strength-providing structure without water evaporation, thus avoiding the energy-consuming drying process
2Strength
If traditional multi-step production processes are used for cellulose-based products, then the products achieve desired mechanical and chemical properties, but the process complexity and production time increase
Solution Approach 1:
The patent merges multiple traditional production steps (forming, drying, and thermal treatment) into a single integrated process. By combining these operations into one step where cellulose fibers are formed and simultaneously subjected to thermal and pressure treatment, the patent reduces process complexity while achieving the desired mechanical and chemical properties of the final product
Solution Approach 2:
The patent applies preliminary action by pre-treating cellulose fibers with adhesive coatings before the main forming process. This preliminary step ensures proper layer bonding and product integrity during the subsequent single-step thermal pressurization process, eliminating the need for separate drying and bonding steps that would increase process complexity
3Stability of the object's composition
If adhesive coatings are applied to cellulose layers, then the layers bond effectively to form stable structures, but the material cost and processing complexity increase
Solution Approach 1:
The patent uses parameter changes by selecting adhesive coatings with specific glass transition temperatures that allow bonding to occur during the thermal pressurization process. The adhesive's thermal and rheological parameters are optimized to enable effective layer bonding at the processing conditions (100-200°C, 1-100 MPa), achieving stable structures without requiring excessive adhesive material or additional processing 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 results in cellulose-based products with enhanced mechanical stiffness, reduced material requirements, lower production costs, and improved aesthetic and performance properties, such as low heat or cold conductivity, compostability, recyclability, and attractive haptic, while avoiding the need for energy-intensive drying steps.
Implementation Method 1
at least one side of said first (104a) and/or said second (104b) layer is pre-treated with an adhesive coating
Implementation Method 2
form pressing said stack (104) of at least two layers including the one first (104a) and the one second (104b) layers in a forming mold (102) at a forming temperature of at least 50° C. up to a forming end-pressure of at most 1100 MPa
Implementation Method 3
heating said cellulose blank to a forming temperature of 100° C. to 200° C.
Implementation Method 4
form pressing said stack (104) of at least two layers including the one first (104a) and the one second (104b) layers in a forming mold (102) at a forming temperature of at least 50° C. up to a forming end-pressure of at most 1100 MPa, into a cellulose based product (103, 700) of a predetermined shape
Data Source
AI summary
The present invention relates to a method of producing a cellulose-based product (103,700), wherein the method comprises the steps of: (i) providing at least two layers including one first (104a) and one second (104b) layer, and wherein said first (104a) and second layer (104b) each comprise cellulose fibers, and wherein at least one side of said first (104a) and/or said second (104b) layer is pre-treated with an adhesive coating, (ii) arranging said at least two layers including the one first (104a) and the one second (104b) layers in a superimposed relationship to each other in a forming mold (102) of a form press (101), thereby generating a stack (104) of said at least two layers including the one first (104a) and the one second (104b) layers, wherein said first (104a) and second (104b) layers are oriented within the stack (104) such that said at least one pre-treated side of said respective first (104a) and/or second (104b) layer is facing towards the superimposed layer, (iii) form pressing said stack (104) of at least two layers including the one first (104a) and the one second (104b) layers in a forming mold (102) at a forming temperature of at least 50° C. up to a forming end-pressure of at most 1100 MPa, into a cellulose based product (103, 700) of a predetermined shape and a single layer configuration, wherein in said step (iii) said layers including said one first (104a) and said one second (104b) layers are moveable with respect to each other until said forming end-pressure is reached.