The transition to sustainable, biodegradable, and recyclable materials requires new sources of cellulose fibers that are already used in large volumes by forest industries. Oat and barley straws provide interesting alternatives to wood fibers in lightweight material applications because of their similar chemical composition. Here we investigate processing and material forming concepts, which would enable strong fiber network structures for various applications. The idea is to apply mild pretreatment processing that could be distributed locally so that the logistics of the raw material collection could be made efficient. The actual material production would then combine foam-forming and hot-pressing operations that allow using all fractions of fiber materials with minimal waste. We aimed to study the technical features of this type of processing on a laboratory scale. The homogeneity of the sheet samples was very much affected by whether the raw material was mechanically refined or not. Straw fibers did not form a bond spontaneously with one another after drying the sheets, but their effective bonding required a subsequent hot pressing operation. The mechanical properties of the formed materials were at a similar level as those of the conventional wood-fiber webs. In addition to the technical aspects of materials, we also discuss the business opportunities and system-level requirements of using straw as an alternative source of lignocellulosic fibers.

Paper-based abrasive products are multilayer structures in which the first layer on the paper substrate is usually a latex barrier coating to prevent the migration of adhesive glue into the substrate. The high coat weight (10 g/m²) of latex barrier layers is a cause of environmental concerns. Hence, alternative materials that can provide the barrier function at lower coat weights are desired. In this work, microfibrillated cellulose (MFC) combined with poly(vinyl) alcohol (PVA) were explored as suitable alternatives to the current latex coatings. Barrier coating formulations containing PVA, MFC, and silica (SiO₂) were developed and applied to a paper substrate using a rod coating method on a pilot scale. Coating quality and barrier performance were characterized using scanning electron microscope images, air permeance, surface roughness, water contact angle, KIT test, and oil Cobb measurements. The barrier coatings were also studied for adhesion to the subsequent coating layer. An optimal barrier function was achieved with the developed coatings at a low coat weight of ca. 3 g/m². The adhesion of pure PVA and PVA-MFC barrier coatings to the subsequent coating layer was inadequate; however, silica addition was found to improve the adhesion.

The growth mechanism of Atomic Layer Deposition (ALD) on polymeric surfaces differs from growth on inorganic solid substrates, such as silicon wafer or glass. In this paper, we report the growth experiments of Al₂O₃ and ZnO on nonwoven poly-L-lactic acid (PLLA), polyethersulphone (PES) and cellulose acetate (CA) fibres. Material growth in both ALD and infiltration mode was studied. The structures were examined with a scanning electron microscope (SEM), scanning transmission electron microscope (STEM), attenuated total reflectance-fourier-transform infrared spectroscopy (ATR-FTIR) and ²⁷Al nuclear magnetic resonance (NMR). Furthermore, thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) analysis were used to explore the effect of ALD deposition on the thermal properties of the CA polymer. According to the SEM, STEM and ATR-FTIR analysis, the growth of Al₂O₃ was more uniform than ZnO on each of the polymers studied. In addition, according to ATR-FTIR spectroscopy, the infiltration resulted in interactions between the polymers and the ALD precursors. Thermal analysis (TGA/DSC) revealed a slower depolymerization process and better thermal resistance upon heating both in ALD-coated and infiltrated fibres, more pronounced on the latter type of structures, as seen from smaller endothermic peaks on TA.

When studying the properties of cellulose nanofibrils (CNF) enriched fiber products, it is essential to be able to determine the retention and the spatial distribution of the CNF inside the end-product. That is, to determine how much and where the CNF has been attached. As the CNF and cellulose fibers share the same density and chemical composition, labeling of the CNF is required to distinguish them from each other. In this work, we have applied iron and iron-cobalt -labeling. Labeling with iron is more desirable because of the carcinogenic and toxic properties of cobalt chloride. The benefits of our labeling method are the possibility to determine the retention of the labeled nanocellulose using inductively coupled plasma optical emission spectroscopy (ICP-OES), and to define the spatial distribution using X-ray micro-computed tomographic (XμCT). With XμCT we were able to measure fairly large samples (2 cm × 5 cm × 5 cm). Our study found that the retention of iron-labeled CNF was about 95 % and that of iron-cobalt labeled CNF was 84–94 %. Labeling of CNF improves the contrast of X-ray images. Labeled CNF is attached to fiber network also in the inner structures of the sample. Furthermore, when making thick porous structures using cationic starch, there might be agglomerates in the sample that cannot be visually detected by looking the sample.

Abrasive materials are classified as paper, nonwoven, or plastic-based multilayer structures, which are used for different kinds of surface finishing. Currently, the production of abrasive structures on textiles is carried out by spraying a slurry of binder and abrasive particles, e.g., Al₂O₃or SiC, with subsequent drying and curing of the binder. The drawback of this production method is the poor runnability of the spraying process. Even small variations in the process parameters may lead to an uneven coating. Therefore, a novel coating approach was developed to produce abrasive structures with foam coating on textile substrates. The foam coating method, which is commonly used in the textile industry, has the potential to produce an even coating layer. The runnability and reliability of the foam coating process are good even with high solids. From a workplace safety perspective, another advantage of foam coating is that there are no airborne particles during the coating process. A polyamide woven cloth was foam coated with an aqueous slurry containing abrasive grains (SiC), a water-based UV-curable acrylate binder, and cellulose nanocrystals (CNCs) to adjust the slurry rheology. Stable abrasive-binder foams were generated from the slurries even at high solids of 50% using an anionic foaming agent. The cloth was foam coated and dried, and the resin was cured with a LED-UV lamp on a pilot scale. It was observed that without the addition of CNC the foam did not stay on the surface of the cloth after coating. CNC acts as a rheology modifier and co-binder, which prevent the foam from penetrating deeper into the pores of the cloth. CNC also acted as a dispersing agent: the slurry was effectively stabilized by the CNC to prevent sedimentation of the abrasive grains. An organic solvent-free composition was introduced by combining CNC with a water-based UV-resin.