Fiberized Pulp Knot Reduction via Moisture Control
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Solution Overview
Problem
Existing methods for fiberizing pulp sheets treated with densifying agents face challenges in achieving low knot content while maintaining density and softness, as the viscous and adhesive nature of these agents complicates the process, especially at lower moisture levels.
Innovation Solution
Fiberizing pulp sheets with hydrogen-bonded cellulose fibers treated with a densifying agent at a moisture content of 0 to 9 percent, where the densifying agent is present in an amount between 1 and 20 weight percent, results in a fiberized pulp with unexpectedly low knot content, maintaining the desired density and softness properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pulp sheets treated with densifying agents are fiberized at conventional moisture levels, then density and softness are maintained, but knot content increases due to the viscous and adhesive nature of the densifying agents
Solution Approach 1:
The patent applies parameter changes by reducing the moisture content of the pulp sheet to a specific range of 5-15% before fiberization. This parameter modification prevents the densifying agent from becoming excessively viscous and adhesive, thereby reducing knot formation while maintaining density and softness properties during the fiberization process
2Strength
If densifying agents are applied to pulp fibers, then density and softness properties are improved, but the agents become viscous and adhesive making fiberization more difficult
Solution Approach 1:
The patent controls the moisture content parameter within 5-15% to optimize the balance between maintaining density/softness properties and facilitating fiberization. This parameter control prevents the densifying agent from becoming too viscous while preserving the desired physical properties of the pulp
Solution Approach 2:
The patent applies preliminary action by pre-treating the pulp sheet with the densifying agent under controlled moisture conditions before fiberization. This preliminary treatment at optimal moisture levels ensures the densifying agent provides density and softness benefits without creating excessive viscosity that would complicate subsequent fiberization
3Manufacturing precision
If moisture content is reduced to improve densifying agent performance, then knot content decreases, but processing at lower moisture levels is challenging
Solution Approach 1:
The patent identifies and applies an optimal moisture content range of 5-15% that balances knot reduction with processing efficiency. Within this parameter range, the densifying agent maintains appropriate viscosity for effective fiberization while still achieving low knot content in the final product
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 effectively reduces knot content in fiberized pulp while maintaining density and softness, contrary to conventional expectations, and allows for easier processing and handling, even at lower moisture levels.
Implementation Method 1
hydrogen-bonded cellulose fibers
Implementation Method 2
cellulose pulp fibers may be treated with a densifying agent
Data Source
AI summary
Disclosed herein are treated pulp sheets comprising cellulose pulp fibers treated with a densifying agent and having a relatively low moisture content. In certain embodiments, the treated pulp sheets are used to produce fiberized pulp having an unexpectedly low knot content, while maintaining density and softness properties usually associated with similarly treated pulp that is fiberized at higher moisture content. Methods of making fiberized pulp from the treated pulp sheets, as well as products comprising the treated pulp sheets or fiberized pulp from the treated pulp sheets, are also provided.