Corn Stover Ethanol Residue Filler for Composite Wood Adhesives
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Solution Overview
Problem
The composite wood industry faces challenges with expensive and environmentally hazardous resin-based adhesives, particularly due to the high cost and unpredictability of wheat flour extenders, which can cause stringing and lumping issues, and the need for more cost-effective and environmentally friendly filler materials that do not compromise adhesive strength or stability.
Innovation Solution
The use of corn stover ethanol residue as a filler in adhesive mixtures for composite wood products, which is produced through yeast-based ethanol fermentation, providing a high protein and cellulosic fiber content that maintains stable viscosity and adhesiveness without the drawbacks of traditional extenders, such as wheat flour.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wheat flour is used as an extender in adhesive mixtures, then the adhesive mixture achieves better adhesiveness and ease of operation, but the cost increases and the mixture exhibits stringing and lumping problems
Solution Approach 1:
The patent replaces expensive wheat flour extender with cheaper corn stover ethanol residue filler. The filler is derived from agricultural waste (corn stover) through ethanol fermentation, providing a cost-effective alternative that eliminates the harmful stringing and lumping issues associated with wheat flour while maintaining adhesive performance.
Solution Approach 2:
The patent modifies the chemical composition parameters of the adhesive mixture by substituting wheat flour with corn stover ethanol residue. This parameter change involves altering the protein and starch content profile, which changes the rheological properties of the adhesive to eliminate stringing and lumping while preserving adhesiveness.
2Strength
If resin solids are used as the adhesive binder, then the adhesive achieves strong bonding and durability, but the cost increases and environmental and health problems arise
Solution Approach 1:
The patent reduces the quantity of expensive resin solids by incorporating corn stover ethanol residue filler, which is derived from renewable agricultural waste. This substitution lowers the cost of resin required while maintaining bonding strength, and simultaneously reduces the environmental and health hazards associated with high resin concentrations and formaldehyde releases.
Solution Approach 2:
The patent creates a composite adhesive system combining resin solids with corn stover ethanol residue filler. This composite material leverages the bonding strength of resin while using the filler to reduce resin content, thereby maintaining strength while reducing harmful effects. The filler acts as a carrier that distributes resin evenly and reduces overall resin concentration.
3Stability of the object's composition
If corn stover ethanol residue is used as a filler, then the adhesive mixture achieves stable viscosity and reduced cost, but the filler must be processed through yeast-based ethanol fermentation
Solution Approach 1:
The patent utilizes the specific compositional parameters of corn stover ethanol residue (derived from yeast-based fermentation of corn stover) to achieve viscosity stability. The filler's specific protein, cellulosic fiber, and starch content profile provides consistent rheological properties in the adhesive mixture, ensuring stable viscosity during storage and application.
Solution Approach 2:
The patent employs a previously waste byproduct (corn stover ethanol residue) from the ethanol fermentation industry to serve as a functional adhesive filler. This self-service approach utilizes an existing industrial byproduct that would otherwise be waste, converting it into a valuable adhesive component without requiring additional processing steps beyond the standard fermentation process.
4Reliability
If wheat flour is used as an extender, then the adhesive mixture achieves acceptable performance, but the cost is high and frequent cleaning of equipment is required
Solution Approach 1:
The patent replaces wheat flour with corn stover ethanol residue filler, which is cheaper and does not require frequent equipment cleaning. The filler's composition (derived from corn stover and yeast) does not promote the same degree of stringing and lumping as wheat flour, reducing maintenance requirements for spray tips and application equipment while maintaining adhesive performance.
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 reduces the quantity of expensive resin needed, provides a stable and clean adhesive performance, and utilizes a previously waste byproduct as a filler, enhancing the manufacturing process with improved viscosity and adhesiveness while minimizing environmental impact.
Implementation Method 1
corn stover ethanol residue, which is produced through yeast-based ethanol fermentation
Implementation Method 2
a filler of adhesives used in bonding cellulose materials
Data Source
AI summary
An improved composite wood adhesive filler, a method of producing such a filler, and an adhesive mixture including such filler are provided, with the filler having performance satisfactory to the manufacturing needs of composite and ply wood products. The adhesive mixture may comprise a filler and one or more extenders. The filler can replace extenders for weight, without introducing instability or viscosity problems. The filler may be drawn from the residue co-product of cellulosic ethanol production using corn stover as feed stock material, which would otherwise be a waste product.