Adhesive Laminate Waste Chaff Production for Wood Composites

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Solution Overview

Problem

Current methods for producing wood composite materials are inefficient due to the need for separate extrusion of wood-based and plastic materials, high moisture content issues with sawdust or wood chips, and additional processing steps that increase costs and risk of explosion, as well as the lack of reinforcement from sawdust in the final product.

Innovation Solution

A method and device that process adhesive laminate waste into chaff by crushing in multiple steps while maintaining temperatures below 60°C, eliminating adhesive properties, and mixing with additives before forming a wood composite material without pre-granulation, using a device with crushers, a screen, and a double-screw extruder for extrusion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If sawdust or wood chips are used as fillers in wood-plastic composites, then the product can be manufactured, but the fibre length and shape do not reinforce the profile and instead function merely as filler

Engineering Contradiction:

Improvereinforcement of profileVSAvoidfibre length and shape

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The waste material is divided into multiple segments through multi-step crushing processes, creating chaff with controlled dimensions that can serve both as filler and reinforcement in the composite material

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The physical parameters of the waste material are changed through controlled crushing at specific temperatures below 60°C, transforming the material into chaff with optimized fibre length and shape for reinforcement purposes

Inventive Principle:

Principle #35Parameter changes

2Quantity of substance

If sawdust or wood chips with high moisture content are used, then the processing can proceed, but gas bubbles form in the profile affecting look and mechanical properties

Engineering Contradiction:

Improvemoisture contentVSAvoidmechanical properties and appearance

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The moisture content parameter of the waste material is controlled and maintained at appropriate levels throughout the crushing process, preventing excessive moisture that would cause gas bubble formation while preserving the material's processability

Inventive Principle:

Principle #35Parameter changes

3Reliability

If drying is performed as an additional process to reduce moisture content, then product quality is improved, but additional costs increase and explosion risk occurs

Engineering Contradiction:

Improveproduct qualityVSAvoidnumber of processing steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The harmful adhesive properties are extracted and eliminated through controlled crushing at low temperatures, removing the need for separate drying processes while maintaining product quality and safety

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The adhesive properties of the waste material, which could be harmful, are converted into a benefit by using the crushing process itself to eliminate adhesiveness through temperature control, turning a potential hazard into a quality improvement

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Ease of manufacture

If adhesive laminate waste is crushed without temperature control, then the processing is simpler, but the adhesive properties remain active and cause quality issues

Engineering Contradiction:

Improveprocessing simplicityVSAvoidadhesive property elimination

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The temperature parameter is controlled during crushing to remain below 60°C, which changes the physical state of the adhesive material and eliminates its adhesive properties while maintaining a relatively simple processing procedure

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach simplifies the production process, reduces costs, eliminates the need for separate slip agents, and produces a recyclable, environmentally friendly wood composite material that meets stricter environmental regulations, while utilizing the adhesive laminate waste effectively.

Implementation Method 1

a mixing device for mixing the chaff with predetermined additives

Methodology Applied

Scientific EffectFriction heating: Viscous Heating

Implementation Method 2

a double-screw extruder for extruding the mixture from the mixing device

Methodology Applied

Scientific EffectCompression heating: Compression

Implementation Method 3

a cooling reservoir for cooling the extruded product

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

The product is led to a calibration unit, where it is provided accurate and final dimensions, and further to a water reservoir functioning as a cooler

Methodology Applied

Scientific EffectConvection cooling: Convection

Data Source

PatentEP2079548B1Method and device for producing wood composite material

Publication Date: 2016.12.21 UPM KYMMENE OYJ

Figure 1

AI summary

The invention relates to a method and a device for producing chaff used in the production of a wood composite material. In accordance with the invention, adhesive laminate waste comprising adhesive material, glue and release material is arranged into chaff in multiple steps and the adhesive properties of the glue are killed.