Water-Based Cellulose Filament Process Eliminates Chemical Solvents
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Solution Overview
Problem
Current methods for producing cellulose filaments from renewable resources, such as the Lyocell process, require multiple chemical steps, costly solvents, and potential environmental concerns, making them inefficient and costly.
Innovation Solution
A water-based process for forming cellulose filaments using microfibrillar cellulose with minimal chemical additives, eliminating the need for chemical solvents like N-methylmorpholine N-oxide and reducing processing steps, allowing for the use of almost infinite renewable cellulosic sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the Lyocell process is used to produce cellulose filaments, then cellulose filaments can be formed from renewable resources, but the process requires multiple chemical steps, costly solvents, and additional processing steps to remove chemicals
Solution Approach 1:
The invention extracts and eliminates the need for chemical solvents and dissolution steps from the traditional Lyocell process. By using a water-based system with microfibrillar cellulose, the process removes harmful chemical substances (N-methylmorpholine N-oxide) while maintaining the core function of forming cellulose filaments from renewable resources.
Solution Approach 2:
The invention changes the fundamental parameter of the solvent system from a chemical-based dissolution system to a water-based physical dispersion system. This parameter change transforms the process from requiring chemical solvents and multiple washing steps to using simply water, thereby simplifying the manufacturing process and reducing chemical usage.
2Ease of manufacture
If chemical solvents like N-methylmorpholine N-oxide are used to dissolve cellulose, then extrudable fiber dope can be formed, but additional chemicals and washing processes are required to remove formation chemicals
Solution Approach 1:
The invention converts the traditionally harmful chemical dissolution process into a beneficial physical dispersion process. By using water to physically disperse microfibrillar cellulose instead of chemically dissolving it with harmful solvents, the process eliminates environmental concerns while achieving the same end result of forming extrudable fiber dope.
Solution Approach 2:
The water-based system serves its own purpose without requiring additional chemicals for removal. Water acts as both the dispersion medium and the safe, easily removable substance, eliminating the need for separate chemical removal and washing processes that would otherwise be required to address harmful factors.
3Adaptability or versatility
If petroleum-based materials are used in fibrous nonwovens, then fluid absorption and dispensing functions are achieved, but sustainability and resource conservation are compromised
Solution Approach 1:
The invention changes the material source parameter from non-renewable petroleum-based materials to renewable cellulose-based materials. This parameter change maintains the functional properties needed for fluid absorption and dispensing while improving sustainability and resource conservation characteristics.
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 process simplifies the production of cellulose filaments, reducing chemical usage and costs, while enabling the creation of sustainable products suitable for replacing petroleum-based fibers in various applications, including absorbent articles and cleaning products.
Implementation Method 1
about 0.2 to about 3 weight percent of a thickening agent and about 75 to about 95 weight percent of a water-based solvent. The microfibrillar cellulose fibers are dispersed in the water-based solvent while the thickening agent is dissolved in the solvent. The precursor dope has a dynamic viscosity ranging from about 800 to about 3000 Pascal seconds
Data Source
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AI summary
Disclosed herein is a cellulosic textile filament made from microfibrillar cellulose fibers and a thickening agent as well as the precursor dope for forming such filaments, nonwoven webs made from such cellulosic textile filaments and the process for forming such filaments and nonwoven webs including such filaments. One of the advantages of these filaments is the eco-sensitive way in which they are made as they utilize a water- based dope that does not require any chemical solvents unlike other processes such as those used to make Lyocell fibers. In addition, the process does not involve any washing or extraction steps and it employs a cellulosic fiber source that is broadly based and renewable.