Low-Viscosity Emulsion Foam Reducer for Wood Product Water Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Foam and entrained air reduce processing efficiency and impact product quality in industries such as food and pulp and paper, while current defoamers with high viscosity and detergents negatively affect water resistance in cellulose and wood-based products.
Innovation Solution
A defoaming agent is formulated using water-soluble fatty acids that react with ions like calcium, magnesium, and aluminum to form insoluble hydrophobic particles, eliminating the need for high viscosity and detergents, and incorporating non-polar oils to enhance effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high viscosity emulsions are used to suspend hydrophobic particles, then defoaming effectiveness is improved, but pumping difficulty increases and particle settlement occurs
Solution Approach 1:
The patent changes the viscosity parameter of the emulsion from high to low (below 200 centipoise) while maintaining defoaming effectiveness through optimized composition ratios of non-polar hydrocarbon, emulsifier, and water, eliminating pumping difficulties and particle settlement
Solution Approach 2:
The patent creates a composite emulsion system combining non-polar hydrocarbon, emulsifier, and water in specific ratios to achieve both low viscosity and effective defoaming performance, resolving the contradiction between suspension capability and fluidity
2Reliability
If detergents and wetting agents are added to defoamer formulations, then foam reduction is improved, but water resistance of wood-based products deteriorates
Solution Approach 1:
The patent extracts and eliminates detergents and wetting agents from the defoamer formulation, achieving effective foam control through a detergent-free emulsion composed of non-polar hydrocarbon, emulsifier, and water, thereby preserving the water resistance of wood-based products
Solution Approach 2:
The patent replaces persistent detergent molecules with a biodegradable emulsion system that performs defoaming function temporarily and breaks down, avoiding long-term negative effects on product water resistance
3Productivity
If conventional defoamers are used in wet process cellulose products, then foam control is improved, but water resistance specification compliance deteriorates
Solution Approach 1:
The patent employs a biodegradable emulsion formulation that performs defoaming during processing and then degrades, leaving no persistent residues that would compromise the water resistance specifications of the final cellulose or wood-based products
Solution Approach 2:
The patent modifies the chemical composition parameters of the defoamer to exclude water-soluble components that migrate into the product, creating an emulsion that maintains processing efficiency while ensuring specification compliance
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 defoaming agent effectively reduces foam without affecting water resistance, reduces emissions, and conserves resources by using less volatile hydrocarbons, achieving up to 20-35% less wax usage and improved water resistance in wood-based products.
Implementation Method 1
water soluble fatty acids soaps which react with soluble metals, anions and cations in the industrial water, to form an insoluble hydrophobic particle
Implementation Method 2
The soap in the present invention is no longer soap after reacting with process water. Thus it does not interfere with water resistance, but contributes to improved water resistance.
Implementation Method 3
The addition of non-polar oils, fats, wax, solvents and blends thereof to form emulsion improves the effectiveness of the defoamer
Implementation Method 4
Water based foam is usually destabilized by reducing the surface tension of the bubbles
Implementation Method 5
Water insoluble or hydrophobic solids which are water insoluble or hydrophobic. These small particles, when in contact with the bubble, thin the bubble at the point of contact and causes bubble to pop.
Data Source
AI summary
Methods are provided for defoaming water used in processing of various products such as cellulose or wood-based products or in food processing which is formed by reacting a fatty acid with a compound selected from the group consisting of ammonia, sodium, potassium and combinations thereof so as to form a water soluble soap, dispersing the water soluble soap in water and homogenizing the dispersed water soluble soap with hydrophobic oil or hydrocarbon oil to produce the emulsion. Methods for preparing an emulsion used in this process are also provided. The emulsion is advantageous in that it can improve water resistance and/or reduce the use of water resistant additives during processing of cellulose or wood-based products or food-grade products.