Dry-Formed Cellulose Moulding with Controlled Moisture Bonding
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Solution Overview
Problem
Existing cellulose product manufacturing methods, particularly those using wet-forming techniques, face challenges with high water consumption, energy demands, and limited control over mechanical properties, making them inefficient and resource-intensive.
Innovation Solution
A dry-forming method using an air-formed cellulose blank structure with a moisture content of 4-15 wt%, subjected to a forming pressure of 1-100 MPa and a temperature of 100-200°C in a single pressing operation, forming hydrogen bonds for a rigid and dimensionally stable product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wet-forming techniques are used to produce cellulose products, then the products can be formed with sustainable packaging material properties, but high water consumption and energy demand for drying occur
Solution Approach 1:
The invention extracts and removes the excessive water from the traditional wet-forming process by using air-formed cellulose blank structures with controlled low moisture content (4-15 wt%). This eliminates the need for high water consumption in the forming process while maintaining the sustainability benefits of cellulose-based packaging materials.
Solution Approach 2:
The invention changes the moisture content parameter from the traditional high water content in wet-forming (typically 70-90 wt% water in pulp suspension) to a controlled low moisture content (4-15 wt%) in air-formed blank structures. This parameter change fundamentally reduces water consumption while enabling dry-forming technology.
2Ease of manufacture
If wet-forming techniques are used to produce cellulose products, then the products can be formed with sustainable packaging material properties, but high energy demand for drying occurs
Solution Approach 1:
The invention extracts and eliminates the energy-intensive drying step by removing excessive water from the process through air-forming technology. The cellulose blank structure is formed with controlled low moisture content from the start, so no subsequent drying is needed, dramatically reducing energy consumption.
Solution Approach 2:
The invention skips the entire drying stage that is mandatory in wet-forming processes. By using air-formed blank structures with inherently low moisture content, the process rushes through directly to the forming stage without the time-consuming and energy-intensive drying step.
3Ease of manufacture
If air-formed cellulose blank structure with high humidity (up to 45 wt% water) is used in dry-forming, then the blank structure can be formed, but the forming process becomes energy demanding and time consuming due to water removal
Solution Approach 1:
The invention optimizes the moisture content parameter to a specific range (4-15 wt%) that is sufficiently low to enable efficient dry-forming without excessive energy demand for water removal, yet high enough to provide adequate flexibility and bonding capability during forming. This precise parameter control resolves the contradiction between formability and energy efficiency.
Solution Approach 2:
The invention performs preliminary action by pre-forming the cellulose blank structure with controlled low moisture content through air-forming technology before the actual product forming. This preliminary moisture control prevents the need for energy-intensive water removal during the forming process.
4Ease of manufacture
If air-formed cellulose blank structure with high humidity (up to 45 wt% water) is used in dry-forming, then the blank structure can be formed, but the forming process becomes time consuming
Solution Approach 1:
The invention changes the moisture content parameter to a low range (4-15 wt%) that enables rapid forming without excessive water removal requirements. This parameter optimization dramatically reduces forming time while maintaining product quality.
Solution Approach 2:
The invention rushes through the forming process by using pre-dried air-formed blank structures that require minimal water removal during forming. The low moisture content allows the process to skip lengthy drying phases and complete forming quickly.
5Ease of manufacture
If wet-forming techniques are used, then cellulose products can be produced, but control over mechanical properties with high precision is difficult
Solution Approach 1:
The invention changes the moisture content to a precisely controlled low range (4-15 wt%) that provides optimal bonding characteristics and mechanical properties. This precise parameter control enables high precision in controlling mechanical properties, as the low moisture content creates consistent bonding conditions during forming.
Solution Approach 2:
The invention performs preliminary action by pre-controlling the moisture content of the cellulose blank structure through air-forming technology before forming. This preliminary moisture control ensures consistent and precise mechanical properties in the final product, as the bonding conditions are predetermined and uniform.
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 reduces water and energy consumption, minimizes curing time, and achieves a rigid, dimensionally stable cellulose product with improved mechanical properties in a single pressing operation.
Implementation Method 1
forming hydrogen bonds for a rigid and dimensionally stable product
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 1e
AI summary
A method for dry-forming a cellulose product in a dry-forming mould system from an air-formed cellulose blank structure. The dry-forming mould system comprises a forming mould having a first mould part and an opposing second mould part arranged to cooperate with each other in a pressing direction upon forming of the cellulose product. The method comprises the steps: providing the air-formed cellulose blank structure and arranging the cellulose blank structure in the forming mould between the first mould part and the second mould part, wherein the cellulose blank structure has a moisture content in the range of 4-15 wt%, preferably in the range of 6-10 wt%, when arranged between the first mould part and the second mould part; forming the cellulose product by pressing and heating the cellulose blank structure when arranged between the first mould part and the second mould part in a single pressing operation, wherein in the single pressing operation the cellulose blank structure is pressed with a forming pressure in the range of 1-100 MPa, preferably in the range of 8-20 MPa, and heated to a forming temperature in the range of 100-200 °C, preferably in the range of 120-170 °C.