Methods for manufacture of nanocellulose composite sheet for use as dermatological treatment or medical device

Abstract

A method of manufacturing a two-layer nanocellulose composite sheet is provided. The two-layer nanocellulose composite sheet is comprised of a moisturized nanocellulose material and a fabric. The method includes the steps of dispersing a diluted nanocellulose suspension onto a fabric, and partially drying the diluted nanocellulose suspension until the diluted nanocellulose suspension is transformed to the moisturized nanocellulose material bonded to the fabric. Thereby, a surface of the moisturized nanocellulose material is bonded by mechanical adhesion to a surface of the fabric. The nanocellulose composite sheet manufactured by this method has contour conformability, excellent skin-adhesion, and high capacity for moisture retention and release, and is ideal for dermatological treatments. An apparatus for manufacturing the nanocellulose composite sheet is also provided.

What is claimed is: 
     
         1 . A method of manufacturing a two-layer nanocellulose composite sheet, the method comprising:
 providing a diluted nanocellulose suspension;   dispersing the diluted nanocellulose suspension onto a fabric; and   partially drying the diluted nanocellulose suspension until the diluted nanocellulose suspension is transformed to a moisturized nanocellulose material bonded to the fabric by mechanical adhesion to form the two-layer nanocellulose composite sheet, wherein the two-layer nanocellulose composite sheet comprises the moisturized nanocellulose material and the fabric, and wherein a first surface of the moisturized nanocellulose material and a second surface of the fabric are bonded by mechanical adhesion.   
     
     
         2 . The method of  claim 1 , further comprising:
 infusing the moisturized nanocellulose material with one or more active ingredients.   
     
     
         3 . The method of  claim 2 , wherein the active ingredients are dermatological formulations. 
     
     
         4 . The method of  claim 2 , wherein the active ingredients are cosmetic formulations. 
     
     
         5 . The method of  claim 2 , wherein the active ingredients are selected from the group consisting of hyaluronic acid and hyaluronic acid derivatives. 
     
     
         6 . The method of  claim 2 , wherein the active ingredients are selected from the group consisting of collagen and collagen derivatives. 
     
     
         7 . The method of  claim 2 , wherein the active ingredients are selected from the group consisting of Niacin, tocopherols, ascorbic acid, and vitamin-antioxidants. 
     
     
         8 . The method of  claim 2 , wherein the active ingredients comprise botanical extracts. 
     
     
         9 . The method of  claim 2 , wherein the active ingredients comprise biological materials derived from the group consisting of plant sources, animal sources, and microbial sources. 
     
     
         10 . The method of  claim 1 , wherein the diluted nanocellulose suspension comprises a purified nanocellulose aqueous gel diluted in a suspension medium, and wherein the diluted nanocellulose suspension comprises one of cellulose nanocrystals, cellulose nanofibers, nano-fibrillated cellulose, and bacterial nanocellulose. 
     
     
         11 . The method of  claim 1 , wherein the diluted nanocellulose suspension has a nanocellulose concentration between 0.1 weight % to 3 weight %. 
     
     
         12 . The method of  claim 1 , wherein the partially drying the diluted nanocellulose suspension is performed by applying heat. 
     
     
         13 . The method of  claim 12 , wherein the heat is applied by thermal convection. 
     
     
         14 . The method of  claim 12 , wherein the heat is applied by thermal conduction. 
     
     
         15 . The method of  claim 12 , wherein the heat is applied by thermal radiation. 
     
     
         16 . The method of  claim 12 , wherein the heat is applied by heat transfer by a chemical conversion. 
     
     
         17 . The method of  claim 12 , wherein the heat is applied by a phase change. 
     
     
         18 . The method of  claim 1 , wherein the partially drying the diluted nanocellulose suspension is performed by applying a vacuum differential. 
     
     
         19 . The method of  claim 18 , wherein a pressure of the vacuum differential is increased until drying occurs at a maximal rate. 
     
     
         20 . The method of  claim 1 , wherein the partially drying the diluted nanocellulose suspension is done until a water content of the moisturized nanocellulose material is between 60 and 90 weight %.