Microfibrillated cellulose ultrasonic re-dispension
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Solution Overview
Problem
Current methods for preparing microfibrillated cellulose and its compositions with inorganic particulate materials are energy-intensive and inefficient, particularly due to high viscosity issues, and there is a need for economical methods to achieve high loading levels in paper and coated paper products without compromising physical, mechanical, and optical properties.
Innovation Solution
Applying ultrasonic energy to dewatered, partially dried, or dried microfibrillated cellulose compositions, either alone or with inorganic particulate materials, to re-disperse and de-agglomerate them, forming a flowable slurry with enhanced tensile strength and viscosity, using a recirculation loop with sonication probes and controlled temperature and energy input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If conventional methods are used to prepare microfibrillated cellulose compositions, then the process can be performed with standard equipment, but the energy consumption is excessively high due to high viscosity issues
Solution Approach 1:
The patent applies ultrasonic energy treatment to change the physical state and reduce viscosity of microfibrillated cellulose compositions, enabling easier processing at lower energy consumption. The ultrasonic treatment modifies the rheological parameters of the slurry, making it more flowable without requiring excessive mechanical energy input.
Solution Approach 2:
The patent replaces conventional high-energy mechanical mixing and homogenization methods with ultrasonic energy treatment. This substitution uses acoustic field effects rather than mechanical shear forces to achieve de-agglomeration and viscosity reduction, significantly lowering the mechanical energy required for processing.
2Quantity of substance
If high loading levels of filler are added to paper products to replace expensive components, then cost savings increase, but the physical, mechanical and optical requirements of the final product deteriorate
Solution Approach 1:
The ultrasonic treatment modifies the surface properties and dispersion characteristics of microfibrillated cellulose, enabling high filler loading levels while maintaining good interfacial adhesion and network formation in the paper matrix. This parameter change allows achieving both high concentration and maintained performance.
Solution Approach 2:
The patent creates a composite system where ultrasonic-treated microfibrillated cellulose acts as an effective filler that can be combined with paper fibers at high loading levels. The treatment enhances the composite nature of the material, allowing it to maintain structural integrity and performance properties even at high concentrations.
3Duration of action of stationary object
If dewatered or dried microfibrillated cellulose compositions are stored for later use, then storage stability improves, but re-dispersion becomes difficult and energy-intensive
Solution Approach 1:
The patent uses ultrasonic energy treatment to replace conventional high-energy mechanical mixing methods for re-dispersion of stored compositions. The ultrasonic cavitation and acoustic radiation pressure effects efficiently break down aggregates and restore flowability with much lower overall energy input compared to traditional high-shear mixing.
Solution Approach 2:
The ultrasonic treatment changes the physical state and aggregation morphology of the dried or dewatered composition, converting it into a readily re-dispersible form. This parameter change in the material's physical structure during storage preparation facilitates easier re-dispersion later with minimal energy input.
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 efficiently produces suspensions with improved tensile strength and viscosity, enabling high loading levels of microfibrillated cellulose and inorganic particulate materials in paper products while maintaining or enhancing their properties, and reduces energy consumption in the microfibrillating process.
Implementation Method 1
Applying ultrasonic energy to dewatered, partially dried, or dried microfibrillated cellulose compositions, either alone or with inorganic particulate materials, to re-disperse and de-agglomerate them
Implementation Method 2
applying ultrasonic energy to such liquid compositions of dewatered, partially dried and dried compositions of microfibrillated cellulose
Data Source
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AI summary
Methods of re-dispersing and de-agglomerating dewatered, partially dried and dried compositions of microfibrillated cellulose and compositions of microfibrillated cellulose and inorganic particulate material, into liquid compositions comprising same, by applying ultrasonic energy to such liquid compositions of dewatered, partially dried and dried compositions of microfibrillated cellulose, or compositions of microfibrillated cellulose and inorganic particulate material. Methods for preparing an aqueous suspension comprising microfibrillated cellulose and, optionally, inorganic particulate material, with enhanced viscosity and tensile strength properties, suitable for use in methods of making paper or coating paper, and to filled and coated papers made from such aqueous suspensions.