Skip to main content
SpringerLink
Log in

3D-oriented fiber networks made by foam forming

  • Original Paper
  • Published:
Cellulose Aims and scope Submit manuscript

Abstract

In industrial applications, such as paper and nonwovens, cellulose fibers are used in the form of a network where the fibers are oriented more or less in the sheet-plane direction. However, in many biological systems, fibers are instead oriented in a three-dimensional (3D) space, creating a wide variety of functionalities. In this study we created a 3D-oriented fiber network on the laboratory scale and have identified some unique features of its structure and mechanical properties. The 3D fiber network sheets were prepared by using foam-forming as well as modifying consolidation and drying procedures. The fiber orientation and tensile/compression behavior were determined. The resulting sheets were extremely bulky (above 190 cm3/g) and had extremely low stiffness (or high softness) compared to the reference handsheets. Despite this high bulk, the sheets retained good structural integrity. We found that a 3D-oriented fiber network requires much less fiber-fiber contact to create a connected (“percolated”) network than a two-dimensionally oriented network. The compression behavior in the thickness direction was also unique, characterized by extreme compressibility because of its extreme bulk and a long initial increase in the compression load as well as high strain recovery after compression because of its fiber reorientation during compression.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

Notes

  1. Detailed information on the mixer design is available from one of the authors (M. Alimadadi) on request.

  2. The utilized etchant in this work was a mixture of methanol, potassium hydroxide, and propylene oxide, which in essence removes the resin and leaves the fibers intact.

References

  • Al-Qararah AM, Hjelt T, Kinnunen K, Beletski N, Ketoja JA (2012) Exceptional pore size distribution in foam-formed fibre networks. Nord Pulp Pap Res J 27:226

    Article  CAS  Google Scholar 

  • Al-Qararah AM, Hjelt T, Koponen A, Harlin A, Ketoja JA (2013) Bubble size and air content of wet fibre foams in axial mixing with macro-instabilities. Colloids Surf A 436:1130–1139. doi:10.1016/j.colsurfa.2013.08.051

    Article  CAS  Google Scholar 

  • Balberg I, Anderson CH, Alexander S, Wagner N (1984) Excluded volume and its relation to the onset of percolation. Phys Rev B 30:3933–3943

    Article  Google Scholar 

  • Carnaby GA, Pan N (1989) Theory of the compression hysteresis of fibrous assemblies. Text Res J 59:275–284. doi:10.1177/004051758905900505

    Article  CAS  Google Scholar 

  • Cervin NT, Andersson L, Ng JBS, Olin P, Bergström L, Wågberg L (2013) Lightweight and strong cellulose materials made from aqueous foams stabilized by nanofibrillated cellulose. Biomacromolecules 14:503–511. doi:10.1021/bm301755u

    Article  CAS  Google Scholar 

  • Clarke A, Archenhold G, Davidson N (1995) A novel technique for determining the 3D spatial distribution of glass fibres in polymer composites. Compos Sci Technol 55:75–91

    Article  CAS  Google Scholar 

  • Eberhardt C, Clarke A (2001) Fibre-orientation measurements in short-glass-fibre composites. Part I: automated, high-angular-resolution measurement by confocal microscopy. Compos Sci Technol 61:1389–1400

    Article  Google Scholar 

  • Exerowa D, Kruglyakov PM (1998) Foam and foam films: theory, experiment, application studies in interface science, vol 5. Elsevier, Amsterdam

    Google Scholar 

  • Fellers C (2009) Paper products physics and technology. In: Ek M, Gellerstedt G, Henriksson G (eds) Pulp and paper chemistry and technology, vol 4. Walter de Gruyter GmbH & Co. KG, Berlin

    Google Scholar 

  • Gatward APJ, Radvan B (1973) Method and apparatus for forming a non-woven fibrous web from a foamed fiber furnish. United States Patent

  • Jahangiri P et al (2014) On filtration and heat insulation properties of foam formed cellulose based materials. Nord Pulp Pap Res J 29:584–591

    Article  CAS  Google Scholar 

  • Kinnunen K, Lehmonen J, Beletski N, Jetsu P, Hjelt T (2013) Benefits of foam forming technology and its applicability in high MFC addition structures. In: Proceedings of the 15th fundamental research symposium. Advances in pulp and paper research. Cambridge, The Pulp & Paper Fundamental Research Society, pp 837–850. September 2013

  • Komori T, Itoh M (1991) Theory of the general deformation of fiber assemblies. Text Res J 61:588–594. doi:10.1177/004051759106101005

    Article  Google Scholar 

  • Komori T, Makishima K (1977) Numbers of fiber-to-fiber contacts in general fiber assemblies. Text Res J 47:13–17. doi:10.1177/004051757704700104

    Google Scholar 

  • Komori T, Itoh M, Takaku A (1992) A model analysis of the compressibility of fiber assemblies. Text Res J 62:567–574. doi:10.1177/004051759206201002

    Article  Google Scholar 

  • Lappalainen T, Lehmonen J (2012) Determinations of bubble size distribution of foam-fibre mixture using circular hough transform. Nord Pulp Pap Res J 27:930–939. doi:10.3183/NPPRJ-2012-27-05-p930-939

    Article  CAS  Google Scholar 

  • Lappalainen T, Salminen K, Kinnunen K, Järvinen M, Mira I, Andersson L (2014) Foam forming revisited. Part II: effect of surfactant on the properties of foam-formed paper products. Nord Pulp Paper Res J 29:689–699. doi:10.3183/NPPRJ-2014-29-04-p689-699

    Article  CAS  Google Scholar 

  • Lehmonen J, Jetsu P, Kinnunen K, Hjelt T (2013) Potential of foam-laid forming technology in paper applications. Nord Pulp Pap Res J 28:392–398

    Article  CAS  Google Scholar 

  • Madani A, Zeinoddini S, Varahmi S, Turnbull H, Phillion AB, Olson JA, Martinez DM (2014) Ultra-lightweight paper foams: processing and properties. Cellulose 21:2023–2031. doi:10.1007/s10570-014-0197-3

    Article  CAS  Google Scholar 

  • Mira I et al (2014) Foam forming revisited Part I: foaming behaviour of fibre-surfactant systems. Nord Pulp Pap Res J 29:679–689. doi:10.3183/NPPRJ-2014-29-04-p679-689

    Article  CAS  Google Scholar 

  • Pike GE, Seager CH (1974) Percolation and conductivity: a computer study—I. Phys Rev B 10:1421–1434

    Article  Google Scholar 

  • Poranen J, Kiiskinen H, Salmela J, Asikainen J, Keränen J, Pääkkönen E (2013) Breakthrough in papermaking resource efficiency with foam forming. Paper presented at the TAPPI PaperCon 2013, Atlanta, GA

  • Punton VW (1975) Fibre distribution in foam and foam-laid paper. Paper presented at the International Paper Physics Conference, New York. 21–25 Sept

  • Radvan B, Gatward APJ (1972) The formation of wet-laid webs by a foaming process. Tappi J 55:748–751

    CAS  Google Scholar 

  • Rättö P (2005) The influence of surface roughness on the compressive behaviour of paper. Nord Pulp Pap Res J 20:304–307

    Article  Google Scholar 

  • Sander EA, Barocas VH (2009) Comparison of 2D fiber network orientation measurement methods. J Biomed Mater Res A 88:322–331

    Article  CAS  Google Scholar 

  • Smith MK, Punton VW, Rixson AG (1974) The structure and properties of paper formed by a foaming process. Tappi J 57:107–111

    Google Scholar 

  • Stankovic SB (2008) Compression hysteresis of fibrous systems. Polym Eng Sci 48:676–682. doi:10.1002/pen.20994

    Article  CAS  Google Scholar 

  • Ting T, Johnston R, Chiu WK (2000) Compression of paper in the Z-direction: the effects of fibre morphology, wet pressing and refining. Appita J 53:378–384

    Google Scholar 

  • Tsarouchas D, Markaki A (2011) Extraction of fibre network architecture by X-ray tomography and prediction of elastic properties using an affine analytical model. Acta Mater 59:6989–7002

    Article  CAS  Google Scholar 

  • van Wyk CM (1946) 20—Note on the compressibility of wool. J Text Inst Trans 37:T285–T292. doi:10.1080/19447024608659279

    Article  Google Scholar 

  • Zhu Y, Blumenthal W, Lowe T (1997) Determination of non-symmetric 3-D fiber-orientation distribution and average fiber length in short-fiber composites. J Compos Mater 31:1287–1301

    Article  CAS  Google Scholar 

Download references

Acknowledgments

This study was partly financed by the European Regional Development Fund EU-Mål 2, and the authors acknowledge the financial support. The authors also acknowledge various support and help provided by Staffan K. Nyström, Håkan Norberg, and Jan Lövgren from Mittuniversitetet and by Rickard Boman from SCA R&D Centre, Sundsvall. Prof. Bo Westerlind of Mittuniversitetet and Kent Malmgren of SCA R&D are also acknowledged for stimulating discussions and suggestions during the course of this study.

Author information

Authors and Affiliations

  1. Department of Chemical Engineering and FSCN, Mid Sweden University, Sundsvall, Sweden

    Majid Alimadadi & Tetsu Uesaka

Authors
  1. Majid Alimadadi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Tetsu Uesaka
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Majid Alimadadi.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Alimadadi, M., Uesaka, T. 3D-oriented fiber networks made by foam forming. Cellulose 23, 661–671 (2016). https://doi.org/10.1007/s10570-015-0811-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s10570-015-0811-z

Keywords

Search

Navigation