Foam-Assisted Drying of Nano- and Microfibrillated Cellulose

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Solution Overview

Problem

Current drying methods for nano- and microfibrillated cellulose, such as freeze-drying, are costly and difficult to scale up, and existing foam technology methods do not effectively address the drying process, making them inefficient and costly for industrial applications.

Innovation Solution

A method involving mixing nano- or microfibrillated cellulose with a foaming agent, using pressurized air to create a foam, and applying it to a non-adhesive substrate for drying with infrared or air dryers, which breaks down the foam structure to produce a dry, redispersible powder with controlled particle distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If freeze-drying is used to dry nano- and microfibrillated cellulose, then the drying quality is maintained, but the production cost increases and scalability decreases

Engineering Contradiction:

Improvedrying qualityVSAvoidproduction cost and scalability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention changes the drying parameters by using infrared radiation (electromagnetic energy) instead of the conventional freeze-drying conditions, enabling direct drying of wet foam without freezing, thus reducing cost and improving scalability while maintaining drying quality

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the mechanical freeze-drying system with an infrared drying system that uses electromagnetic radiation to evaporate water from the foam, simplifying the process and enabling industrial-scale production

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If foam technology is used to form NFC foam sheets, then the production efficiency is improved, but the drying effectiveness is insufficient

Engineering Contradiction:

Improveproduction efficiencyVSAvoiddrying effectiveness

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The invention introduces infrared radiation as an intermediary energy carrier to transfer thermal energy to the foam material, enabling effective and rapid drying that complements the foam forming process

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The drying process uses periodic infrared radiation application to efficiently remove moisture from the foam structure, maintaining both production efficiency and drying effectiveness

Inventive Principle:

Principle #19Periodic action

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 method enables cost-effective and scalable drying of nano- and microfibrillated cellulose, resulting in materials with enhanced mechanical properties and low water content, facilitating easier transportation and tailored end-use applications.

Implementation Method 1

drying with infrared or air dryers

Methodology Applied

Scientific EffectInfrared radiation: Infrared Radiation

Implementation Method 2

drying with infrared or air dryers

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

nanofibrillated cellulose (NFC) foam is formed into a sheet

Methodology Applied

Scientific EffectFoam formation: Foam

Data Source

PatentUS12077650B2Foam assisted drying process of nano- and microfibrillated cellulose

Publication Date: 2024.09.03 TEKNOLOGIAN TUTKIMUSKESKUS VTT OY

AI summary

According to an example aspect of the present invention, there is provided a method for foam assisted drying of nano- and microfibrillated cellulose, which is easily up-scalable and cost-efficient.