Dry Cellulose Fiber Processing and Compression Molding
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Solution Overview
Problem
Current methods for processing high-strength paper products into individual fibers often result in significant damage and energy consumption, and existing cellulosic products require time-consuming drying and form strong interfiber bonds, limiting in-line manufacturing and recycling efficiency.
Innovation Solution
A method involving dry defibration of primary and secondary fibers using a micro-impact mill with controlled air flow, followed by forming nonwoven fabrics with controlled fiber distribution and bonding, and subsequent processing into molded parts and transport containers, utilizing a compression molding apparatus to minimize energy use and enhance product properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If high-strength paper products are processed into individual fibers using conventional methods, then fiberization is achieved, but significant fiber damage and high energy consumption occur
Solution Approach 1:
The patent applies parameter changes by controlling air flow velocity (≤11 m/s, preferably ≤8 m/s) in the micro-impact mill to reduce fiber damage during dry fiberization, and by adjusting forming pressure (1 MPa to 100 MPa) and temperature (100°C to 200°C) in the pressure forming device to optimize fiber bonding while maintaining fiber integrity
Solution Approach 2:
The patent replaces conventional mechanical fiberization methods with a micro-impact mill using controlled air flow for dry fiberization, and replaces traditional wet bonding with a pressure forming device that uses heat and pressure to bond fibers, eliminating the need for drying and reducing fiber damage
2Productivity
If conventional cellulosic products are formed and dried, then product formation is achieved, but time-consuming drying and strong interfiber bonds limit manufacturing efficiency
Solution Approach 1:
The patent utilizes phase transitions by applying heat and pressure in the pressure forming device to directly bond fibers in a controlled manner, eliminating the need for evaporation-based drying. The forming pressure (1 MPa to 100 MPa) and temperature (100°C to 200°C) facilitate rapid bonding without time-consuming drying steps
Solution Approach 2:
The patent applies preliminary action by pre-heating the press plates to forming temperature (100°C to 200°C) before fiber placement, and by controlling the sequence of pressure application and heating to achieve rapid bonding, thereby eliminating subsequent drying time and enabling inline production
3Ease of manufacture
If dry fiberization is used to obtain individual fibers, then fiber isolation is achieved, but fibers exhibit increased stiffness and reduced adaptability
Solution Approach 1:
The patent applies parameter changes by using controlled forming pressure (1 MPa to 100 MPa) and temperature (100°C to 200°C) in the pressure forming device to soften and bond the stiff dry fibers, enabling them to conform to the desired product shape while maintaining their isolated fiber structure
Solution Approach 2:
The patent introduces heat and pressure as intermediary factors that temporarily modify the physical state of dry fibers during forming, allowing stiff fibers to become more adaptable and conformable during the bonding process, after which they maintain their structural integrity in the final product
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 approach allows for the production of high-strength, low-damage cellulosic fibers with improved stiffness and reduced conformability, enabling efficient in-line manufacturing and recycling while maintaining the structural integrity of the final products.
Implementation Method 1
The individual fibers are introduced into a flowing transport stream and distributed as evenly as possible
Implementation Method 2
The molded part is produced by moistening the nonwoven fabric with water and then dehumidifying it under heat and/or pressure
Implementation Method 3
the cellulose preform is pressed by means of the forming mold with a forming pressure acting on the cellulose preform via the forming surface, the forming pressure being in the range of 1 MPa to 100 MPa
Data Source
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Figure 5
AI summary
Method for processing cellulose-containing single fibers (100) obtained by dry fiberization of primary and/or secondary fibers, wherein the steps are uniformly distributing the single fibers (100), avoiding agglomeration of the single fibers (100), applying the uniformly distributed single fibers (100) in a non-directional manner to a carrier (104), and mechanically bonding the single fibers (100) to form a nonwoven fabric (106), apparatus for processing cellulose-containing single fibers (100) obtained by dry fiberization of primary and/or secondary fibers, nonwoven fabric (106), transport container and molded part.