Highly porous fibre foams - Potential end use applications

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1 VTT TECHNICAL RESEARCH CENTRE OF FINLAND LTD Highly porous fibre foams - Potential end use applications COST Action FP1205 March , Stockholm, Sweden Elina Pääkkönen, Tiina Pöhler, Petri Jetsu, Katariina Torvinen VTT Technical Research Centre of Finland Ltd

2 Future fibre based products? 10/03/2017 2

3 Why foam technology? Two major benefits compared to traditional papermaking Formation sheet uniformity Possibility to highly porous structures Makes material combinations possible From nanoscale to several centimetres long fibres Particles lighter than water Widens the product property window New product possibilities: insulation, filtering, absorbing, packaging 10/03/2017 3

4 Outline Foam forming and testing of porous fiber structures Enhancing mechanical properties and moisture resistance Drying of porous fiber structures Potential applications o Light weight inner packaging o Thermal insulation panels o Acoustic material Pilot environment Conclusions 4 cm Density 22 kg/m 3, Bulk 46 cm 3 /g 10/03/2017 4

5 Basics of foam forming Fibres and other raw materials are mixed with aqueous foam instead of water Foam Consists of water, foaming agent (=surfactant) and air Typical air content % Foam stability can be controlled Typical bubble diameter ~100 µm Material is located in bubble pockets Fibres are frozen in their dispersed state in bubble pockets No fiber flocculation, small bubbles fill the free space 10/03/2017 5

6 Important foam characteristics Foam density (air content) Volume measurement Gravimetric Foam stability Image analysis Half life time (liquid volume reaches half of its initial height) Bubble size distribution Optical microscope and image analysis Sauter mean diameter (area weighted value) 10/03/2017 6

7 Foam forming of high bulk, porous structures in laboratory scale Foaming Water + Fibre + Surfactant Air content % Drainage Mould sizes from A4 up to 50x50 cm Gravity draining or low vacuum Drying In oven C Time depends on pulp type 10/03/2017 7

8 Testing of porous fibre structures Tensile strength EN 1608 Sound absorption coefficient ISO (ACUPRO impedance tube) Compression strength EN 826 standard (at 10% strain) Specific air flow resistance ISO 9053 Filtration efficiency Thermal conductivity EN12667 Water binding capacity EDANA standard Point load test Internal method Water retention capacity ISO modified Fire resistance Ignitability: Single-flame source test ISO :2010 Heat release rate (Cone calorimeter) ISO :2002 Bending strength 10/03/2017 EN standard 8

9 Analysis of pore size distribution Tomographic imaging done at Jyväskylä University Sample size 50x50x50 mm 1E Softwood kraft Softwood kraft +hemp number of pores / dm d < 1 mm 1 mm < d < 3 mm d > 3 mm Softwood Kraft pulp Softwood Kraft pulp & Lignocellulosic fines & # pores /mm 3 0 Softwood Softwood kraft kraft 10/03/ g/m2, 23 kg/m3 Hemp bast fibers fibre type 9 +hemp 800 g/m2, 21 kg/m mm < d < 3 mm Pore size distribution varies depending on

10 Enhancing mechanical properties and moisture resistance Bonding is based on hydrogen bonds sensitivity to humidity and water Material strength Water retention capacity EN 1608 ISO modif. Foam formed material density ~50 kg/m 3 AKD= Alkylketene dimer PAE= Polyamideamine-epichlorohydrin 10/03/

11 Drying of porous structures Drying is a critical process phase o Foam should not collapse or shrink significantly o Efficiency is important, drying is a significant production cost Investigated drying methods o Oven-drying o Impingement drying o Infrared drying o Through-air drying o Microwave drying 10/03/

12 Combined drying methods can give good results IR heater Temp. sensors Fibrous foam in mould Mold support Air impingement box At moisture ratio 2-3 kg/kg drying rate can be increased without risk of structure collapse using through air drying a b Timofeev, O., Jetsu,P., Kiiskinen, H., Keränen, J., Drying of foam formed mats from virgin pine fibres, Drying Technology, Vol. 34 (2016) No: 10, /03/

13 Potential applications

14 Application: Light weight inner packages Light and soft fibrous cushioning element that protects the product from impacts Product shape made in manufacturing phase Replacement of non-biodegradable EPS based inner packages (Europe: 1.6 million tons of EPS waste in 2010, data from CMAI (Chemical Market Associates)) Foam formed inner packages Photos: Harri Kiiskinen and Juha Hakulinen VTT Kiiskinen H., Torniainen E., Kinnunen K., Method of forming a fibrous product, WO 2015/ A1 10/03/

15 Light cellulose fibre material to replace plastic bubble wrap Design: Kaisa Jäntti LAMK Materials and foam forming: VTT Photos: Kaisa Jäntti LAMK and Juha Hakulinen VTT 10/03/

16 Application: Thermal insulation panels New type of semi-rigid 100% wood cellulose fiber based thermal insulation panel Currently competing with mineral wool, EPS and XPS products in thermal conductivity Foam formed thermal insulation panels Foam formed wall element demo 10/03/

17 Application: Thermal insulation panels Thermal conductivity, λ, EN λ at 20 C Effect of pulp type and bulk density on λ Positioning foam formed materials among the competitors (fibrous insulation materials) Pöhler, T., Jetsu, P., Salmén, L., Hornatowska, J., Barraud, V., Fougeron, A., Lecourt, M., Seppänen, R., Larsson, E., 10/03/2017 Comparison and development of wood-based thermal insulation materials. 10th Global Insulation Conference and Exhibition. 17 Istanbul, Turkey, September 2015.

18 Application: Acoustic material, sound absorber Sound absorbers are needed e.g. in construction, automotives, appliances, office & home Lightness of material is a benefit ISO Material Glass wool Foam formed SW kraft Grammage, g/m Thickness, mm Density, kg/m Absorption coefficient = 0, no absorption = 1, full absorption o.d.s. = overall depth of mounting Pöhler, T., Jetsu, P., Isomoisio, H., Benchmarking new wood-fibre based sound 10/03/2017 absorbing material made with a foam-forming technique. Building Acoustics, 18 Vol. 23 (2016) No: 3-4, , DOI: / X

19 Application: Designed decorative sound absorber panels Foam forming and design-driven aspect lead to designed porous structures with special 3D form and sound absorption property Cellulose pulp used as raw material instead of highly processed and disposable materials Kaarna decorative acoustic panels Design: Hannakaisa Pekkala LAMK 3D printed mould: 3D Formtech Materials and foam forming: VTT Photos: Hannakaisa Pekkala LAMK 10/03/

20 Next steps: piloting

21 Target: Expand VTT s foam forming environment to make e.g. unpressed webs possibility to demonstrate highly porous structures continuously A new line will be built at VTT Jyväskylä 2017 Technical information: - Wet & dry reeled samples up to 600 mm width - Machine speed m/min - Basis weight target range g/m 2 - Single & multilayer forming Demonstration for new applications, e.g. nonwoven products, thermal insulations, acoustic materials, composites 10/03/

22 Layout for the first phase / Schematic view Forming Vertical gap/ fourdrinier forming Drying Through-air dryers Reeling 10/03/

23 Conclusions Foam forming enables Very porous and thick structures New raw materials and combinations Possibility to make planar and moulded structures Entering new markets with sustainable and recyclable wood fibre based products New pilot environment starting soon! 10/03/

24 Thank you for your attention! For further information, please contact: Elina Pääkkönen Research Scientist Biomass processing and products VTT Technical Research Centre of Finland Ltd P.O. Box 1603, Jyväskylä FI Jyväskylä, Finland Tel

25 TECHNOLOGY FOR BUSINESS

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