Classifications

• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H25/00—After-treatment of paper not provided for in groups D21H17/00 - D21H23/00
  • D21H25/04—Physical treatment, e.g. heating, irradiating
  • D21H25/06—Physical treatment, e.g. heating, irradiating of impregnated or coated paper
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/03—Non-macromolecular organic compounds
  • D21H17/05—Non-macromolecular organic compounds containing elements other than carbon and hydrogen only
  • D21H17/07—Nitrogen-containing compounds
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/20—Macromolecular organic compounds
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/20—Macromolecular organic compounds
  • D21H17/21—Macromolecular organic compounds of natural origin; Derivatives thereof
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/20—Macromolecular organic compounds
  • D21H17/33—Synthetic macromolecular compounds
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/20—Macromolecular organic compounds
  • D21H17/33—Synthetic macromolecular compounds
  • D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/20—Macromolecular organic compounds
  • D21H17/33—Synthetic macromolecular compounds
  • D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • D21H17/35—Polyalkenes, e.g. polystyrene
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/20—Macromolecular organic compounds
  • D21H17/33—Synthetic macromolecular compounds
  • D21H17/46—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/20—Macromolecular organic compounds
  • D21H17/33—Synthetic macromolecular compounds
  • D21H17/46—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D21H17/52—Epoxy resins
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/20—Macromolecular organic compounds
  • D21H17/33—Synthetic macromolecular compounds
  • D21H17/46—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D21H17/53—Polyethers; Polyesters
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/63—Inorganic compounds
  • D21H17/70—Inorganic compounds forming new compounds in situ, e.g. within the pulp or paper, by chemical reaction with other substances added separately
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
  • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
  • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
  • B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
  • D21H21/50—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by form
  • D21H21/52—Additives of definite length or shape
  • D21H21/54—Additives of definite length or shape being spherical, e.g. microcapsules, beads

Definitions

• the present invention relates to a process comprising a non-water sheet forming technology using high concentration of cellulose fibres suspended in a high viscosity liquid.
• fibre flocs[1] The dominant feature of a suspension composed of wood fibres and water is its inherent propensity to form bundles of mechanically entangled fibres, i.e. fibre flocs[1]. This is a feature closely connected to the concentration of fibres in water [2,3], which lies between 0.5-3% since higher concentration are not technically possible.
• the present invention therefore provides a process for producing paper comprising
• paper will be made by applying an innovative non-water sheet forming technology using high concentration of cellulose fibres suspended in a high viscosity liquid.
• the biggest energy saving impact may result from eliminating not only the drying section, but also the needs for refining, vacuums in the process and huge flows in the white water recirculation. This would mean 28% energy saving and 61% CO 2 saving.
• This process enables single or multi-layer structure, thus opening new opportunities for functionalization of paper as well as with significantly reduced capital investments.
• resin as used herein relates to any liquid, solid, semisolid or viscous substances of plant origin, such as copal, rosin, and amber, used principally in lacquers, varnishes, inks, adhesives, synthetic plastics, and pharmaceuticals and any physically similar synthetics, or chemically modified natural resins including thermoplastic materials such as polyvinyl, polystyrene, and polyethylene and thermosetting materials such as polyesters, epoxies, and silicones that may be used with fillers, stabilizers, pigments, and other components to form plastics.
• thermoplastic materials such as polyvinyl, polystyrene, and polyethylene
• thermosetting materials such as polyesters, epoxies, and silicones that may be used with fillers, stabilizers, pigments, and other components to form plastics.
• a "viscous solvent” is a solvent having a dynamic viscosity of 0.01 to 1 kg/ms (Pa. s) measured with a viscometer at 20 °C.
• the invention provides a process for producing paper comprising
• the invention provides a process for producing paper comprising
• a "shear reduction layer” or a drag-reducing (lubricating) layer is implemented to protect the fibres from shear. This may be done by creating a low viscosity layer surrounding the fibre suspended in a high viscosity liquid that will prevent flocculation and allow processing at high concentration.
• the application relates to the use of two main technologies that are combined with the generic process of layered material structures:
• the first technology starts with dry (preferably ⁇ 10% water content) fibres.
• the fibres used in step (i) have a water content of 0 to 20 wt%, preferably 5 to 15 wt%, and more preferably 10 to 12 wt%.
• the fibres used in step (i) may be obtained from recycled or from virgin pulp.
• the fibres are mixed into a high viscosity liquid, i.e. a resin, at high fibre concentration (up to 40% of fibres).
• a high viscosity liquid i.e. a resin
• the suspension obtained in step (ii) may have a fibre concentration of 10 and 45 wt.-%, preferably 20 to 40 wt.-% and more preferably 30 to 40 wt.-%.
• the liquid/resin may be constituted of a bio-based polymer, oligomer or monomer, which can be cross-linked during the curing process in order to form a fixed structure.
• the resin should be seen as a generic technology platform. Similarly to the possibility to choose fibres raw material, the resin will be available in many variants targeted at different needs (bulk, opacity, moldability, printing, barrier properties %) that all fulfils the base requirement for being able to be used to form a sheet structure at very high fibre concentrations without excessive flocculation and without detrimental effects on the fibres.
• the fibres may be modified chemically such that they will give rise to the protective "shear reduction layer" closest to the fibre surface.
• the possibility of modifying the resin to allow processing has been exploited for processing within other areas such as e.g. in paints with excessive concentration of pigments or in biomass extrusion[5].
• the resin and the fibres thus form a compatible system, which is called "DryPulp".
• amino acids may be used to protect the fibres from shear.
• one possible embodiment of this application is to use bio-based substances such as amino acids to functionalize the surface of the cellulosic fibre. These will modify the docking points and introduce bulky side chains that push the individual fibres apart. This will modify the viscosity of the medium in the proximity of the fibres.
• the DryPulp will allow forming of a thin sheet without excessive flocculation due to the high viscosity of the resin.
• a fibre network similar to paper that is made today can be formed with up to 40% fibre content.
• the DryPulp is formed as a sheet, containing up to 40% fibres.
• the solvent is removed.
• the solvent is removed by pressing the sheet e.g. subjected the sheet to a pressing stage where resin is removed similarly to today's pressing operation where water is removed.
• the sheet has a fibre concentration of 50 and 90 wt.-%, preferably 60 to 85 wt.-% and more preferably 70 to 80 wt.-%.
• the web may contain up to 80% fibres.
• the curing may be carried out by chemical additives, ultraviolet radiation, electron beam, heat or any combination thereof.
• the curing may cause cross-linking within the resin as well as between resin and the cellulose fibres. Curing can be made in several steps affecting different properties such as the resin only or the resin-protective layer interface.
• the resin-protective layer-fibre system will allow reversal of the curing, which will allow recycling of the resin as well as of the fibres.
• the use of air or other gases as expanding elements within the sheet may be applied. This could be achieved either by having micro-capsules of air and gas within the resin that are activated during treatment in the pressing (crushed) or through substances that generates gas bubbles under the influence of the curing process or some other external forcing.
• One possibility is to use Sodium Bicarbonate to form gas bubbles[6]. This activation will generate carbon dioxide and the sheet will expand generating a bulky material. This is already used in speciality paper grades where an active energy beam is irradiated onto a foamable composition containing an acid generating agent and Sodium Bicarbonate. The irradiating energy generates an acid that activates the Sodium Bicarbonate that, in turn, generates the bubbles/foam.
• the sheet may be formed as a layered product.
• the layered product is formed by first forming simultaneously, e.g. in one nozzle, or separately at least two layers and then bringing the layers together. This will allow optimization towards desired product properties as well as addition of new functionalities. As an example, if a smooth surface is required, the expansion can be limited to take place within the middle layer of a three layered sheet, i.e. coating will be achieved during the forming process. Micro-bubbles may also be used in the final sheet in order to achieve opacity, which would remove the need for fillers.
• This process for paper and board products will contribute to decarbonisation through the energy savings gained from the elimination of the excessive need for vacuum, the friction losses in pressing and the drying of the base paper as well as drying of coating layers.
• the drying process in paper making alone consumes about half of the energy and today has the largest CO 2 impact.

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• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Inorganic Chemistry (AREA)
• Paper (AREA)

Priority Applications (1)

Applications Claiming Priority (1)

Publications (1)

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Citations (5)

• 2013
  • 2013-11-25 EP EP13194313.6A patent/EP2876207A1/fr not_active Ceased

Patent Citations (5)

Non-Patent Citations (5)

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