Mineral Pre-Coating for Polysaccharide Retention in Paper Substrates
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Solution Overview
Problem
The use of nano- or microfibrillar cellulose in paper making is hindered by high costs and inefficiencies due to poor coating holdout and uneven distribution, leading to material loss and reduced structural integrity of paper substrates.
Innovation Solution
A process involving a mineral material pre-coat that absorbs polysaccharides, such as nano-fibrillar cellulose, to enhance surface smoothness, uniformity, and structural stability by forming an in-situ composite layer, preventing material loss and improving the efficiency of polysaccharide use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If polysaccharide material is applied directly to the substrate, then surface treatment is achieved, but coating holdout is poor and material is lost into the fibre void matrix
Solution Approach 1:
A mineral material pre-coat layer is introduced as an intermediary between the substrate and the polysaccharide material. This pre-coat layer acts as a mediator that provides a suitable surface for polysaccharide adhesion, preventing direct penetration into the fibre void matrix and improving coating holdout while reducing material loss.
Solution Approach 2:
The mineral material pre-coat is applied in advance before the polysaccharide material. This preliminary action prepares the substrate surface by creating a porous structure that can effectively retain the polysaccharide material, ensuring better coating performance and reducing subsequent material loss.
2Manufacturing precision
If polysaccharide material is used to improve surface properties, then surface smoothness and uniformity are enhanced, but material distribution is uneven and structural integrity is reduced
Solution Approach 1:
A composite structure is created by combining the mineral material pre-coat layer with the polysaccharide material coating. The mineral pre-coat provides a stable porous framework that enhances surface smoothness and uniformity, while the polysaccharide material fills the porous structure to improve adhesion and maintain structural integrity, achieving both surface quality and strength.
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 approach significantly improves the surface properties and structural stability of paper substrates by ensuring polysaccharides are retained within the mineral material pre-coat, enhancing bending stiffness and surface strength while controlling permeability.
Implementation Method 1
coating the substrate with the at least one mineral material to obtain a pre-coat layer of mineral material... which is able to absorb such polysaccharide material
Data Source
AI summary
The present invention relates to a process for manufacturing coated substrates by providing a substrate, providing at least one mineral material, providing a polysaccharide material comprising one or more polysaccharides, coating the substrate with the at least one mineral material, and coating the resulting pre-coat layer of mineral material with the gel comprising one or more polysaccharides, as well as the coated substrate obtained by this process and its use.