Reactor and process for producing nanofibers and method of using nanofibers in web-forming techniques
OwnerEvan KOSLOWinventor
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Abstract
A process for fibrillating a fibrous pulp, and products made using the same. The process comprises providing a fibrous pulp of liquid and staple fibers having a first liquid to fibers ratio of less than or equal to 6:1, applying stress to the pulp to fibrillate the staple fibers; and, during said applying stress, drying the pulp to a second liquid to staple fibers ratio of less than or equal to 0.43:1.
Claims30
A process for fibrillating a fibrous pulp, the process comprising:
- providing a fibrous pulp of liquid and staple fibers having a first liquid to fibers ratio of less than or equal to 6:1;
- applying stress to the pulp to fibrillate the staple fibers;
- and
- during said applying stress, drying the pulp to a second liquid to staple fibers ratio of less than or equal to 0.43:1.
The process of any preceding claim, wherein:
- said drying comprises raising the temperature of the liquid above the boiling point of the liquid by mechanical impaction of the pulp with a rotor.
The process of any preceding claim, further comprising:
- expanding the pulp to a bulk density of less than 0.2 g/cm3.
The process of any preceding claim, wherein:
- the fibrous pulp forms a substantially non-flowing mass during said applying stress.
The process of any preceding claim, wherein:
- said drying comprises removing all free liquid from the pulp by at least one of evaporation or adsorption by the fibers.
A process for fibrillating a fibrous pulp having a Fibrillation Liquid Limit, the process comprising:
- providing a fibrous pulp of liquid and staple fibers having a first liquid content by weight of between 100-200% of the Fibrillation Liquid Limit of the staple fibers;
- applying stress to the pulp to fibrillate the staple fibers;
- and
- during said applying stress, drying the pulp to a second liquid to staple fibers ratio of less than or equal to 0.43:1.
A reactor for fibrillating fibrous pulp, the reactor comprising:
- a vessel for holding the fibrous pulp, the vessel having a vessel axis extending at an angle to vertical,
- a rotor having at least one arm extending into the vessel for impacting the fibrous pulp, and
- a motor drivingly coupled to the rotor for rotating the rotor.
A fibrillated fiber pulp product comprising:
- a plurality of substantially disentangled nanofibers;
- a moisture content of less than or equal to 30% by weight;
- and
- a bulk density of less than or equal to 0.2 g/cm3.
Dependencies are inferred from the claim text.