Fiber Body Forming Method Using Thermoplastic Resin
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Solution Overview
Problem
Fiber bodies bound with thermoplastic resin may curl, and those bound with β-1,3-glucan can be difficult to disentangle, presenting challenges in flexibility and recyclability.
Innovation Solution
A fiber body forming method involving defibration, web formation, application of a thermoplastic resin liquid with specific viscosity and particle size, and subsequent heating to achieve a fiber body with high storage elastic modulus, preventing curling and enabling easy disentanglement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fibers are bound together with a thermoplastic resin, then the fiber body can be formed, but the fiber body may be liable to curl in some cases
Solution Approach 1:
The patent applies parameter changes by carefully controlling the glass transition temperature (Tg) of the thermoplastic resin within a specific range (75°C to 120°C). This parameter optimization ensures that the resin provides sufficient binding strength while preventing curling of the fiber body, resolving the contradiction between binding strength and curling resistance.
2Shape
If fibers are bound together using β-1,3-glucan, then the fiber body is not likely to curl, but it may be difficult to again disentangle the fibers thus bound together
Solution Approach 1:
The patent changes the material parameter from thermosetting β-1,3-glucan to thermoplastic resin with controlled Tg (75°C to 120°C). This parameter change maintains curling resistance while enabling easy disentanglement through heating, as thermoplastic resins soften and lose binding strength above their glass transition temperature.
3Strength
If the storage elastic modulus is increased to prevent curling, then the fiber body rigidity is improved, but the flexibility at elevated temperatures may be reduced
Solution Approach 1:
The patent optimizes the glass transition temperature parameter of the thermoplastic resin to fall within 75°C to 120°C. This parameter setting ensures that the fiber body maintains high storage elastic modulus (600 MPa or more at 100°C and 400 MPa or more at 150°C) for rigidity and curling prevention, while still allowing sufficient flexibility at elevated temperatures for processing and application.
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 method ensures high rigidity at elevated temperatures, prevents curling during printing, and allows for easy recycling of fibers by using a thermoplastic resin that binds cellulose fibers effectively, enhancing the fiber body's elastic modulus and breaking strength.
Implementation Method 1
a step of applying a liquid containing a thermoplastic resin which binds the fibers to the web; and a step of heating the web to which the liquid is applied to form a fiber body
Implementation Method 2
in the step of applying a liquid, the liquid may be applied by an ink jet method
Implementation Method 3
a step of heating the web to which the liquid is applied to form a fiber body
Data Source
AI summary
A fiber body forming method includes a step of defibrating a raw material containing fibers to form a defibrated material; a step of depositing the defibrated material to form a web; a step of applying a liquid containing a thermoplastic resin which binds the fibers to the web; and a step of heating the web to which the liquid is applied to form a fiber body, and in the method described above, the fiber body has a storage elastic modulus of 600 MPa or more at 100° C. and a storage elastic modulus of 400 MPa or more at 150° C.