Paper Yarn Composition Using Bagasse Powder Without Strength Loss
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Solution Overview
Problem
Existing paper yarns suffer from reduced strength due to foreign matter contamination, and fibers like sugar cane pulp are often discarded as waste without effective utilization.
Innovation Solution
A method involving granulation of bagasse to produce sugar cane pulp powder without lignin removal, mixing it with lignin-reduced Manila hemp pulp, and processing it into Japanese washi paper for twisting into yarn, which is then woven into paper cloth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If bagasse is mixed with main yarn material, then waste fiber utilization is improved, but paper strength is reduced due to foreign matter contamination
Solution Approach 1:
The invention changes the physical state of bagasse from raw material to granulated powder with controlled particle size (D50: 10-50 μm), and controls the mixing ratio parameter (3-40 mass%) to achieve both waste utilization and maintained strength
Solution Approach 2:
The invention creates a composite paper material combining bagasse granules with traditional paper fibers (Manila hemp with lignin removal), where the composite structure allows waste fiber incorporation while maintaining overall paper strength through the specific composition and processing method
2Reliability
If lignin removing process is performed on bagasse, then fiber quality is improved, but production cost and process complexity increase
Solution Approach 1:
The invention extracts only the necessary function of bagasse (as a filler and structural component) rather than requiring complete lignin removal, thereby simplifying the processing sequence while maintaining paper quality through the composite structure with pre-treated Manila hemp fibers
Solution Approach 2:
The invention performs lignin removal in advance on the Manila hemp fibers before mixing with bagasse granules, so that the bagasse itself does not need to undergo complex lignin removal processes, thereby reducing overall process complexity while ensuring fiber compatibility
3Ease of manufacture
If bagasse is granulated without lignin removal, then production cost is reduced, but mixing uniformity with main yarn material deteriorates
Solution Approach 1:
The invention changes the particle size parameter of bagasse through granulation to D50: 10-50 μm, which optimizes the mixing uniformity with Manila hemp fibers while avoiding the need for expensive lignin removal processes, achieving both cost reduction and acceptable mixing quality
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 produces strong paper yarns and cloths that utilize waste fibers, enhancing strength and deodorizing effects while reducing production costs and waste.
Implementation Method 1
a granulation step of pulverizing bagasse to produce a sugar cane pulp powder of granules
Implementation Method 2
a pulping process for producing pulp from Manila hemp comprising a lignin removing process so that a lignin content of the pulp is reduced to less than 2w%
Implementation Method 3
a mixing step of mixing the sugar cane pulp powder and the pulp after the granulation step and the pulping step
Data Source
Figure 1~2
Figure 3~4(b)
Figure 5~7
AI summary
The object is to prepare useful articles from paper containing different types of fibers. In a granulation step, bagasse is pulverized to produce a sugar cane pulp powder of granules (step S11). In a pulping process, pulp is produced from Manila hemp (step S12). In a mixing step, sugar cane pulp powder, and the pulp produced in preceding steps, are mixed (step S21). In the papermaking process, Japanese washi paper is produced by using a mixture of wude powder and pulp (step S22). In a slitting process, the produced Japanese washi paper is slit (step S23). In a twisting process, the slit Japanese washi paper yarn is twisted to produce a paper yarn (step S24).