Low-Gelatinization Starch Fiber Binding Method
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Solution Overview
Problem
Existing formed body producing methods using atomized water and sizing agents struggle to achieve strong fiber binding, leading to inconsistent strength in the final product due to regions with weak fiber bonding, which can result in damage and reduced overall strength.
Innovation Solution
A method involving the accumulation, humidification, and heating of a mixture of fibers and starch with a gelatinization temperature of 60° C. or lower, where the starch acts as a binding material to uniformly bind fibers, enhancing the strength and stability of the formed body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a sizing agent is mixed with fiber to produce a formed body, then the formed body can be produced with less water, but the fiber binding strength is insufficient and regions with weak binding are generated
Solution Approach 1:
The patent changes the parameter of gelatinization temperature by selecting starch with a gelatinization temperature of 60°C or lower. This parameter change enables the starch to gelatinize at relatively low temperatures during the forming process, creating strong fiber binding without requiring excessive water, thus resolving the contradiction between water reduction and binding strength
Solution Approach 2:
The patent utilizes the phase transition of starch gelatinization to achieve fiber binding. By controlling the gelatinization temperature to be 60°C or lower, the starch undergoes phase transition from a crystalline to an amorphous state during heating in the forming step, creating a binding matrix that holds fibers together strongly while using minimal water
2Loss of energy
If a small amount of water is provided to the fiber and sizing agent mixture, then energy and time for dehydration are saved, but uniform fiber binding is not achieved and the formed body may be damaged
Solution Approach 1:
The patent changes the gelatinization temperature parameter of the starch to 60°C or lower, which allows the binding process to occur at low temperatures during forming. This eliminates the need for high-temperature dehydration while ensuring uniform fiber binding throughout the formed body, thus saving energy and maintaining reliability
Solution Approach 2:
The patent replaces the mechanical dehydration process (which requires significant energy and time) with a thermal-chemical binding process using low-gelatinization-temperature starch. The starch gelatinizes chemically to bind fibers, eliminating the need for extensive mechanical drying while ensuring uniform binding and preventing damage
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 results in a formed body with improved strength and stability, as the starch effectively binds fibers at a relatively low temperature, preventing fiber deterioration and ensuring uniform bonding throughout the product.
Implementation Method 1
a gelatinization temperature of the starch is 60° C. or lower
Implementation Method 2
a humidifying step of providing the accumulated mixture with water
Implementation Method 3
a forming step of obtaining a formed body by heating and pressurizing the mixture provided with water
Data Source
AI summary
A formed body producing method including an accumulating step of accumulating a mixture including fiber and starch, a humidifying step of providing the accumulated mixture with water, and a forming step of obtaining a formed body by heating and pressurizing the mixture provided with water, wherein a gelatinization temperature of the starch is 60° C. or lower.