Engineered Wood Production via Mechanical Fiber Separation
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Solution Overview
Problem
Existing methods for producing manufactured wood from dead, dry timber do not effectively separate wood fibers into strands while maintaining their natural orientation, nor can they produce wood products with varying densities without cutting or orientation steps, leading to reduced strength and unsuitable density ranges.
Innovation Solution
A mechanical fiber processor and two-axis press system that separates wood fibers into naturally oriented strands using compressive and tensile forces, and then presses them into preselected sizes and densities without the need for orientation or specific resin addition, allowing for the production of engineered wood with densities ranging from softwood to hardwood.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wood is cut into strips or partially separated into sections, then the wood can be processed into manufactured products, but the fibers lose their natural length and orientation, reducing the strength of the wood product
Solution Approach 1:
The patent replaces traditional mechanical cutting systems with a chemical treatment system using alkaline solutions and enzymes to separate wood fibers. This substitution allows fibers to be separated without cutting, maintaining their natural length and strength while enabling manufacturing processing.
Solution Approach 2:
The patent changes the physical-chemical parameters of wood by treating it with alkaline solutions (changing pH and chemical composition) and enzymes (changing biochemical properties). These parameter changes enable fiber separation without mechanical cutting, preserving fiber integrity while facilitating manufacturing.
2Adaptability or versatility
If traditional crushing and steam pressing methods are used, then wood can be reconstituted, but the fibers are not orientated along a single axis and the process requires complex steam conditioning
Solution Approach 1:
The patent replaces complex mechanical crushing and steam pressing systems with a chemical treatment system using alkaline solutions and enzymes. This substitution simplifies the process by enabling direct fiber separation and reconstitution without requiring steam conditioning or complex crushing mechanisms.
Solution Approach 2:
The patent uses chemical parameter changes (pH adjustment, enzyme activity) to achieve fiber separation and reconstitution, replacing the need for steam conditioning and complex mechanical processing. This approach simplifies the overall process while maintaining reconstitution capability.
3Ease of manufacture
If cutting is used to produce strips, then the wood can be processed, but the natural strand orientation is lost and strength is reduced
Solution Approach 1:
The patent replaces mechanical cutting with chemical treatment using alkaline solutions and enzymes to separate wood into strands. This substitution maintains natural strand orientation and length while enabling manufacturing processing, thereby preserving strength.
Solution Approach 2:
The patent changes the chemical parameters of wood through alkaline treatment and enzymatic action, enabling strand separation without cutting. This maintains natural orientation and length, preserving the strength properties needed for high-quality strand board production.
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
The system efficiently produces engineered wood with natural strand orientation and varying densities, enhancing strength and versatility in wood products, from structural beams to flooring, by maintaining fiber length and orientation, and achieving consistent density and hardness ranges without additional hardening agents.
Implementation Method 1
A mechanical fiber processor and two-axis press system that separates wood fibers into naturally oriented strands using compressive and tensile forces
Implementation Method 2
A mechanical fiber processor and two-axis press system that separates wood fibers into naturally oriented strands using compressive and tensile forces
Implementation Method 3
applying a first pressure to the adhesive covered strands to provide a pressed wood with a selected first dimension and a selected second dimension; and applying a second pressure normal to the first pressure to the pressed wood to provide an engineered wood having the selected first dimension, the selected second dimension and a selected third dimension and a selected density
Data Source
AI summary
A method of manufacturing engineered wood is provided, the method including: feeding wood through a processor while exposing the wood to compressive and tensile forces to produce naturally oriented strands of fibers; adding an adhesive to naturally oriented strands of fibers to provide adhesive covered strands; feeding the adhesive covered strands into a press; applying a first pressure to the adhesive covered strands to provide a pressed wood with a selected first dimension and a selected second dimension; and applying a second pressure normal to the first pressure to the pressed wood to provide an engineered wood having the selected first dimension, the selected second dimension and a selected third dimension and a selected density. An installation for manufacturing the engineered wood is also provided.