Elastane-Cellulose Fiber Regeneration via Lyocell
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Solution Overview
Problem
The recycling of cellulose from old textiles often results in fibers with short chain lengths and undesirable properties due to contamination with synthetic plastics like polyurethane, which are difficult to remove and affect the purity and quality of the cellulose.
Innovation Solution
Incorporating elastane into the cellulose fibers during the lyocell or viscose method, allowing it to be processed without separate removal, and utilizing its thermoplastic properties to enhance the extensibility, elasticity, and strength of the fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If synthetic plastics like polyurethane are removed completely from recycled cellulose, then the purity of cellulose is improved, but the manufacturing process becomes elaborate and costly
Solution Approach 1:
The patent converts the harmful effect of elastane contamination into a beneficial property by intentionally incorporating elastane into the cellulose fiber structure during regeneration. This eliminates the need for elaborate removal processes while improving fiber extensibility and elasticity. The elastane that was previously considered an impurity becomes a functional component enhancing the mechanical properties of the recycled cellulose.
2Strength
If elastane is incorporated into cellulose fibers during lyocell or viscose method, then the extensibility and elasticity of fibers are improved, but the purity of cellulose is reduced
Solution Approach 1:
The patent creates a composite material system where elastane and cellulose are combined at the fiber level during the regeneration process. This composite structure allows the elastane to enhance the mechanical properties of cellulose fibers, providing improved extensibility and elasticity. The composite approach transforms the traditional purity-vs-performance trade-off into a synergistic relationship where the combination of materials creates superior functional properties.
3Loss of substance
If recycled textiles are used as starting material, then resource efficiency is improved, but the chain length of cellulose becomes short and properties deteriorate
Solution Approach 1:
The patent changes the physical and chemical parameters of the recycling process, specifically the regeneration conditions, to preserve cellulose chain length. By optimizing the dissolution and regeneration parameters in lyocell or viscose methods, the process maintains longer cellulose chains from recycled textiles, preventing deterioration of fiber properties while achieving resource efficiency through recycling.
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 enables the production of cellulose fibers with improved mechanical properties, such as increased extensibility and elasticity, while reducing the need for elaborate plastic depletion processes, thus making the recycling process more efficient and cost-effective.
Implementation Method 1
utilizing its thermoplastic properties to enhance the extensibility, elasticity, and strength of the fibers
Data Source
AI summary
A method of manufacturing a molded body which comprises cellulose, wherein the method comprises: i) providing a starting material which comprises cellulose and elastane, in particular wherein the elastane in the starting material is present separated from the cellulose, wherein the starting material is a solid body, and ii) generating the molded body which comprises cellulose, in particular by a lyocell-method or a viscose-method, on basis of the starting material, such that the regenerated cellulosic molded body comprises at least a part of the elastane of the starting material. The part of the elastane of the starting material is incorporated in the regenerated cellulosic molded body. Furthermore, a regenerated cellulosic molded body which comprises elastane incorporated in the cellulose, and which is manufactured according to a lyocell-method or a viscose-method.