Cellulose Staple Fiber Formation on a Common Surface

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Solution Overview

Problem

Current methods for producing yarn and non-woven materials often rely on synthetic materials that pose environmental concerns during recyclability and disposal, or natural materials like cotton that have negative environmental effects during growth and processing.

Innovation Solution

A method and apparatus for manufacturing natural fiber-based raw wool using a cellulose suspension that is dried and cut into staple fibers, forming a fluffy, airy arrangement suitable for yarn or non-woven production, with the fibers being refined from plant-based materials and processed to create a unique, unoriented network.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If synthetic materials are used for producing yarn and non-woven materials, then productivity and ease of manufacture are improved, but environmental harm increases due to recyclability and disposal issues

Engineering Contradiction:

Improveproduction efficiencyVSAvoidenvironmental harm

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the material parameter from synthetic polymers to regenerated cellulose fibers, maintaining the production efficiency while eliminating the environmental harm associated with synthetic materials. The cellulose suspension is processed through drying and cutting to create staple fibers that can be used in conventional textile manufacturing processes.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a disposable approach with regenerated cellulose fibers that can be easily processed and discarded without environmental harm. The fibers are made from renewable plant-based materials and can be composted or biodegraded, replacing durable synthetic materials that persist in the environment.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Object-generated harmful factors

If natural materials like cotton are used, then environmental recyclability is improved, but environmental harm increases during growth and processing

Engineering Contradiction:

ImproverecyclabilityVSAvoidenvironmental impact during growth

Core Design Contradiction:

Object-generated harmful factorsVSObject-affected harmful factors

Solution Approach 1:

The patent extracts the beneficial recyclability property of natural materials while removing the harmful growth and processing impacts by using regenerated cellulose from plant-based materials. The cellulose is processed into a suspension and then regenerated into fibers, bypassing the need for agricultural cultivation and associated environmental harms.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses cellulose suspension as an intermediary form between plant-based raw materials and final fiber products. This intermediate state allows for controlled processing that eliminates the environmental harms associated with traditional cotton cultivation while maintaining the recyclability and biodegradability of natural fibers.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If cellulose suspension is dried and cut into staple fibers, then natural fiber based raw wool is formed with improved processability, but manufacturing complexity increases

Engineering Contradiction:

ImproveprocessabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-forming the cellulose into a suspension with controlled rheology before drying and cutting. The suspension is prepared with specific viscosity and fiber distribution characteristics that facilitate uniform drying and consistent staple fiber formation, simplifying the overall manufacturing process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces complex mechanical fiber processing systems with a more straightforward drying and cutting process. The cellulose suspension naturally forms a coherent structure during drying that can be easily cut into staple fibers using simple cutting mechanisms, avoiding the need for complex mechanical carding or combing processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution provides an eco-friendly, processable natural fiber-based raw wool with improved recyclability and reduced environmental impact, enabling the production of yarn and non-woven materials with enhanced filtering and insulating properties.

Implementation Method 1

The cellulose suspension is dried by removing water from the cellulose suspension

Methodology Applied

Scientific EffectDrying: Evaporation

Data Source

PatentUS11453961B2Method and apparatus for manufacturing natural fiber based staple fibers on a common surface

Publication Date: 2022.09.27 SPINNOVA OY

AI summary

The application relates to a method and apparatus for manufacturing a natural fiber based staple fibers. The application further relates to the staple fibers, staple fiber based raw wool and products comprising such. A method comprises providing a cellulose suspension (101, 310, 510) including water, refined cellulose fibrils and at least one rheology modifier, directing the cellulose suspension through a nozzle (102, 320, 520) onto a surface (300, 400, 500), drying the cellulose suspension onto the surface (103, 300, 400, 500) for forming a fiber (350, 550), and cutting the cellulose suspension on the surface for forming staple fibers (105).