Microfibrous Cellulose Composite Sheet Manufacturing
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Solution Overview
Problem
Current methods for manufacturing microfibrous cellulose composite sheets and laminates face challenges in achieving industrial productivity and efficiency, with existing techniques failing to effectively combine microfibrous cellulose with polymers while maintaining transparency and dimensional stability.
Innovation Solution
A method involving the mixing of a polymer emulsion with an aqueous suspension of microfibrous cellulose, followed by dehydration on a porous base material and drying, with the option to laminate sheets by thermal compression or applying a polymer layer, using cellulose coagulants like sodium chloride or cationic polymers to enhance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If microfibrous cellulose is made into a composite with polymer, then thermal-resistant dimensional stability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines microfibrous cellulose with polymer resin in a composite sheet structure, where the polymer matrix binds the cellulose microfibers together. This merging of materials achieves thermal-resistant dimensional stability while using standard composite manufacturing processes to control complexity
Solution Approach 2:
The invention creates a composite material system consisting of microfibrous cellulose dispersed in a polymer matrix. The composite structure leverages the dimensional stability of cellulose and the thermal resistance of polymer, achieving both properties simultaneously through material composition rather than complex processing
2Illumination intensity
If microfibrous cellulose sheet is made transparent by impregnating resin, then transparency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies resin impregnation specifically to fill the spaces between microfibrous cellulose sheets, targeting the regions that cause light scattering. This localized treatment improves transparency without requiring complete restructuring of the manufacturing process
Solution Approach 2:
The polymer resin acts as an intermediary material that fills voids and spaces between cellulose microfibers. This intermediary substance eliminates air pockets that cause opacity, enabling transparency while using conventional impregnation techniques
3Illumination intensity
If microfibrous cellulose is produced by mechanical crushing to 50 nm or less, then transparency is improved, but productivity decreases
Solution Approach 1:
The patent uses mechanical crushing to reduce cellulose fiber dimensions to microfibrous levels, applying sufficient force to achieve the necessary size reduction for transparency. The process uses standard industrial crushing equipment operating at optimized parameters to balance transparency achievement with manufacturing efficiency
Solution Approach 2:
The invention changes the physical parameters of cellulose fibers through mechanical crushing, reducing fiber width to 50 nm or less. This parameter change enables transparency while using conventional mechanical processing methods to maintain industrial productivity
4Ease of manufacture
If microfibrous cellulose is made into composite sheet with polymer emulsion, then ease of manufacture is improved, but manufacturing precision may be compromised
Solution Approach 1:
The patent uses a papermaking machine that employs hydraulic and pneumatic principles in the filtration and drying sections. Water is removed through controlled filtration under pressure, and the sheet formation process uses fluid dynamics to achieve uniform distribution of microfibrous cellulose and polymer emulsion
Solution Approach 2:
The invention controls the concentration and composition parameters of the polymer emulsion to optimize both ease of manufacture and sheet formation precision. By adjusting emulsion parameters such as polymer content, particle size, and pH, the process achieves good manufacturability while maintaining precise sheet properties
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 the efficient production of microfibrous cellulose composite sheets and laminates with improved transparency, dimensional stability, and moisture resistance, suitable for applications in flexible substrates for organic ELs and liquid crystal displays.
Implementation Method 1
a polymer emulsion is mixed with an aqueous suspension including microfibrous cellulose
Implementation Method 2
the mixed fluid is dehydrated on a porous base material through filtration
Implementation Method 3
a sheet including moisture is heated and dried
Implementation Method 4
a sheet including moisture is heated and dried
Implementation Method 5
cellulose coagulants like sodium chloride or cationic polymers
Implementation Method 6
the overlapped microfibrous cellulose composite sheets are thermally compressed
Data Source
AI summary
The present invention provides a method for easily and efficiently manufacturing microfibrous cellulose composite sheets. The present invention is a method for manufacturing microfibrous cellulose composite sheets, including a preparation process in which a polymer emulsion is mixed with an aqueous suspension including microfibrous cellulose, thereby preparing a mixed fluid, a papermaking process in which the mixed fluid is dehydrated on a porous base material through filtration, and a sheet including moisture is formed, and a drying process in which the sheet including moisture is heated and dried. In addition, the present invention is a method for manufacturing a microfibrous cellulose composite sheet laminate, in which the microfibrous cellulose sheets are thermally compressed and thus laminated as they are or after being provided with a polymer layer on at least one surface thereof.