Fiber Composition with Deinking Waste Solids for Paper Recycling

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Solution Overview

Problem

The challenge is to effectively utilize deinking waste solids, which are typically discarded due to their small size and dark ink particles, in paper recycling, as they are not suitable for direct reuse and conventional disposal methods are costly and environmentally unsustainable.

Innovation Solution

Incorporating deinking waste solids as a filler with a binder such as polyvinyl alcohol (PVOH) or cellulose nanofibrils into fibers or films, allowing the binder to impregnate or encapsulate the filler, thereby creating a usable product that can retain the waste solids at a high rate in paper products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If deinking waste solids are directly reused in paper products, then material utilization is improved, but the small size and dark ink particles prevent suitable reuse

Engineering Contradiction:

Improvewaste solids utilizationVSAvoidfiller suitability

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

The patent encapsulates deinking waste solids particles within binder matrices to form composite fibers. The filler particles are nested inside the binder structure, creating a hierarchical composition where the binder protects and holds the filler particles, transforming unsuitable waste solids into usable fiber components.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent creates composite fibers by combining binder materials (such as cellulose or synthetic polymers) with deinking waste solids filler. This composite structure allows the waste solids to be retained and utilized within the fiber matrix, converting previously unusable material into a functional component of the final paper product.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If conventional disposal methods are used for waste solids, then handling is simplified, but cost and environmental sustainability deteriorate

Engineering Contradiction:

Improvewaste handlingVSAvoiddisposal cost and environmental impact

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent converts the harmful or useless deinking waste solids into a beneficial filler material for paper production. By treating the waste solids as a resource rather than waste, the process transforms an environmental burden into a valuable component, reducing disposal costs and improving sustainability while maintaining ease of manufacture through integrated processing.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The waste solids from the deinking process are reused within the same paper manufacturing system to produce new paper products. This self-service approach closes the material loop, where the output of one process (waste solids) becomes the input for another process (fiber production), eliminating the need for external disposal systems and reducing environmental impact.

Inventive Principle:

Principle #25Self-service

3Reliability

If binder encapsulates filler particles, then retention in water is improved, but particle integrity must be maintained

Engineering Contradiction:

Improveparticle retentionVSAvoidparticle integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The binder forms a flexible matrix or shell around the filler particles, creating a protective enclosure that maintains particle integrity while allowing the composite structure to flex and adapt. This flexible binding approach prevents particle breakdown during processing while ensuring reliable retention in the aqueous environment of paper manufacturing.

Inventive Principle:

Principle #30Flexible shells and thin films

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 retention of deinking waste solids in paper products, reducing waste and environmental impact while providing a sustainable solution for recycling, as the binder-trapped particles remain intact in water and can be bonded into paper webs, enhancing the recycling efficiency.

Implementation Method 1

the binder can impregnate with the filler, or the binder can encapsulate the filler

Methodology Applied

Scientific EffectEncapsulation:

Implementation Method 2

the binder can impregnate with the filler

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS10597501B2Fibers with filler

Publication Date: 2020.03.24 GPCP IP HOLDINGS LLC

AI summary

The present invention is directed to articles of manufacture, including fibers and films, and methods of making thereof. In accordance with the present invention, the article includes a binder impregnated with or encapsulating a filler. The binder is a polyvinyl alcohol (PVOH), cellulose nanofibrils, or a combination of the PVOH and cellulose nanofibrils. The filler is deinking waste solids comprising ash and cellulose fines.