Lyocell Fiber Production Using Cellulose and Alpha-1,3-Glucan
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Solution Overview
Problem
Current methods for producing lyocell fibers, such as the amine-oxide process, result in significant raw material loss and high costs due to the need to shorten cellulose molecules, while attempts to use α(1→3)-glucan in these processes are unsatisfactory under large-scale conditions.
Innovation Solution
A method for producing lyocell fibers using a spinning solution comprising aqueous amine oxide and a mixture of cellulose and α(1→3)-glucan, where α(1→3)-glucan is prepared enzymatically and added to the cellulose solution or pulp before processing, allowing for cost-effective and efficient fiber production on existing facilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cellulose molecules are shortened to achieve desired degree of polymerization, then fiber production becomes feasible, but raw material loss increases significantly
Solution Approach 1:
The patent applies preliminary action by pre-assembling α(1→3)-glucan chains enzymatically before fiber formation. This allows the polysaccharide structure to be prepared in advance with the desired molecular weight and configuration, eliminating the need for subsequent shortening operations that cause material loss in traditional cellulose processing.
Solution Approach 2:
The patent changes the fundamental parameter of polysaccharide structure by using α(1→3)-glucan instead of traditional cellulose. This parameter change enables fiber formation without the need to shorten long polymer chains, as the enzymatically synthesized α(1→3)-glucan naturally achieves the appropriate molecular characteristics for spinning.
2Ease of manufacture
If α(1→3)-glucan is used in amine-oxide process, then production cost may be reduced, but fiber quality becomes unsatisfactory under large-scale conditions
Solution Approach 1:
The patent creates a composite material system by combining α(1→3)-glucan with amine oxide solvent. This composite approach allows the enzymatically produced polysaccharide to be processed using established large-scale spinning infrastructure, thereby maintaining fiber quality standards while potentially reducing production costs through alternative raw material pathways.
3Quantity of substance
If long cellulose chains are used from natural sources, then raw material utilization is maximized, but degree of polymerization is too high for spinning
Solution Approach 1:
The patent replaces mechanical/chemical shortening methods with enzymatic synthesis. Instead of mechanically or chemically breaking down long cellulose chains (which causes material loss), the invention uses enzymatic assembly to build α(1→3)-glucan chains to the precise molecular weight needed for spinning, thereby maximizing raw material utilization while achieving the required degree of polymerization.
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 achieves cost-effective production of lyocell fibers with improved fibrillation capability and reduced material loss, enabling the production of high-quality textiles and nonwoven products with enhanced properties like peach-skin-effect, white-abrasion resistance, and reduced pilling.
Implementation Method 1
a spinning solution comprising aqueous amine oxide and, as a fiber-forming substance, a mixture of cellulose and α(1→3)-glucan
Implementation Method 2
the precipitation of the spinning solution in the precipitation bath
Data Source
AI summary
The present invention relates to a method for the production of polysaccharide fibers which, as a fiber-forming substance, comprise a mixture of cellulose and α(1→3)-glucan, as well as to the fibers made thereof and to their use.