Nanocellulose surface coated support material
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Solution Overview
Problem
Natural fibers used to reinforce polymers face challenges such as variability in dimensions and mechanical properties, low thermal stability, and hydrophilicity, which limits their compatibility with hydrophobic polymer matrices, and existing chemical treatments involve hazardous chemicals and increase production costs.
Innovation Solution
A process involving the production of a surface-coated support material using an aqueous dispersion of nanocellulose, where the nanocellulose is contacted with a support material, and the coated material is dried to form a dense or hairy nanocellulose layer, enhancing the mechanical interlocking with the matrix and improving the material's properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If chemical treatments (silylation, acetylation, benzoylation, maleated coupling agents, isocyanate treatment, polymer grafting) are applied to natural fibers to improve hydrophobicity and compatibility with polymer matrices, then the compatibility and mechanical properties improve, but hazardous chemicals are used and production costs increase
Solution Approach 1:
The patent introduces an intermediary substance (coupling agent or surface treatment layer) that mediates between the hydrophilic natural fiber surface and the hydrophobic polymer matrix. This intermediary layer provides chemical compatibility without requiring harsh chemical treatments of the fibers themselves, reducing harmful chemical usage while maintaining interfacial adhesion
Solution Approach 2:
The patent changes the surface parameters of natural fibers through physical or mild chemical treatments that modify surface energy and wettability without fundamentally altering the fiber chemistry. This allows improvement in polymer compatibility while avoiding the use of hazardous chemicals associated with traditional extensive chemical modifications
2Adaptability or versatility
If natural fibers are used to reinforce polymers, then renewable and biodegradable composite materials are produced, but variability in dimensions and mechanical properties limits practical applications
Solution Approach 1:
The patent applies preliminary surface treatments and size reductions to natural fibers before composite fabrication to standardize their properties. By pre-treating fibers to achieve consistent surface characteristics and dimensions, the variability in mechanical properties is reduced while maintaining the renewable nature of the material
Solution Approach 2:
The patent creates composite materials that combine natural fibers with synthetic components or treatment layers to compensate for the inherent variability of natural fibers. This hybrid approach maintains the renewable advantage while achieving more consistent mechanical properties through the synergistic combination of materials
3Strength
If natural fibers are used to reinforce polymers, then low density and high specific strength are achieved, but low thermal stability reduces tensile properties after processing
Solution Approach 1:
The patent employs temporary protective coatings or sizing agents on natural fibers that provide thermal protection during processing. These sacrificial layers can be applied cheaply and removed or degraded after serving their protective function, allowing the natural fibers to maintain their high specific strength while surviving the thermal processing conditions
Solution Approach 2:
The patent develops composite materials that combine natural fibers with thermally stable matrix materials or treatment layers. This composite structure allows the natural fibers to contribute their high specific strength while the thermally stable components protect them during processing, maintaining both the lightweight advantage and thermal stability
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 process results in enhanced mechanical properties, increased surface area, and improved compatibility between the reinforcement and matrix, leading to stronger, more durable composite materials with increased tensile and flexural properties.
Implementation Method 1
a support material which has been coated with a nanocellulose coating layer
Implementation Method 2
the coated material is dried to form a dense or hairy nanocellulose layer
Data Source
AI summary
The present invention relates to a process for the production of a surface coated support material wherein said process comprises contacting a support material with an aqueous dispersion of nanocellulose. The surface coated support material can be used in a composite material. The invention therefore further relates to the surface coated support material per se, a composite comprising the material, a process for the production of the composite material and an article produced from the composite material.