High-consistency foaming process for ultra-low density composites
High-consistency continuous foaming process for ultra-low density composites
As the name implies, ultra-low density composites (ULDC) encompass composite materials that have a very low weight per unit volume, due to their open cell structure; this is a significant advantage in certain applications, such as thermal and acoustic insulation materials in construction and other industries, and protective packaging. While ULDC can be developed for many different applications for various markets and industries, the project team at FPInnovations is mainly focused on the development of ULDC as rigid exterior thermal insulation panels for buildings.
Because of growing environmental concerns, there has been increasing pressure to replace foamed polystyrene and other petroleum-based polymers used in these applications with materials that are renewable, recyclable, and biodegradable. In addition, recent revisions of building codes for energy conservation will soon change the landscape of the construction industry and its practices for improving the thermal insulation performance of buildings. This certainly generates more demand for better quality and cost-competitive thermal insulation materials.
In order to respond to this market need and explore a different approach, a project was initiated by FPInnovations to study the possibility of producing ULDC using wood fibres. In the course of this research, a novel high consistency continuous foaming process has been developed; pilot scale experiments have confirmed the feasibility and possible commercialization of this process. A patent application has been submitted to secure the intellectual property of this process and related technology, which has been published recently by the World Intellectual Property Organization (WIPO). The process involves shredding and disintegrating market pulp (or any other form of fibre source such as recycled paper) in a primary refiner while introducing chemicals, followed by feeding of the pulp into a secondary refiner for continuous foam generation by injection of a foaming agent and air. Foams of uniform consistencies as high as 17% have been achieved, which can lead to reduced drying times and energy use, making commercialization of this process very attractive.
Source: FP Solutions
Because of growing environmental concerns, there has been increasing pressure to replace foamed polystyrene and other petroleum-based polymers used in these applications with materials that are renewable, recyclable, and biodegradable. In addition, recent revisions of building codes for energy conservation will soon change the landscape of the construction industry and its practices for improving the thermal insulation performance of buildings. This certainly generates more demand for better quality and cost-competitive thermal insulation materials.
In order to respond to this market need and explore a different approach, a project was initiated by FPInnovations to study the possibility of producing ULDC using wood fibres. In the course of this research, a novel high consistency continuous foaming process has been developed; pilot scale experiments have confirmed the feasibility and possible commercialization of this process. A patent application has been submitted to secure the intellectual property of this process and related technology, which has been published recently by the World Intellectual Property Organization (WIPO). The process involves shredding and disintegrating market pulp (or any other form of fibre source such as recycled paper) in a primary refiner while introducing chemicals, followed by feeding of the pulp into a secondary refiner for continuous foam generation by injection of a foaming agent and air. Foams of uniform consistencies as high as 17% have been achieved, which can lead to reduced drying times and energy use, making commercialization of this process very attractive.
Source: FP Solutions
