Fire-Inhibiting Biochemical Treatment for Composite Wood Panels
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Solution Overview
Problem
Existing methods for treating composite and engineered wood products to provide fire, metal-corrosion, mold/mildew, and moisture protection are inadequate, often leading to structural integrity issues and environmental hazards, particularly with the use of chemical treatments like pMDI resins.
Innovation Solution
Development of environmentally-clean fire inhibiting biochemical compositions using alkali metal salts derived from non-polymerized carboxylic acids (C1-C7) and esters, applied as aqueous solutions or powders to treat lignocellulosic materials, forming alkali metal salt crystalline structures that inhibit fire ignition, flame spread, and protect against corrosion, mold/mildew, and moisture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional chemical treatments like pMDI resins are used to treat composite and engineered wood products, then fire, metal-corrosion, mold/mildew, and moisture protection is provided, but structural integrity issues and environmental hazards occur
Solution Approach 1:
The patent changes the chemical parameters by using alkali metal salts of non-polymerized carboxylic acids (C1-C7) instead of traditional pMDI resins. This parameter change maintains fire and corrosion protection while eliminating the harmful effects and structural integrity issues associated with conventional chemical treatments
Solution Approach 2:
The patent employs simpler, more environmentally benign alkali metal salt compositions that can be effectively applied and then allow the wood product to perform without ongoing harmful effects. The treatment achieves protection without the long-term structural degradation caused by traditional resins
2Object-affected harmful factors
If alkali metal salts of non-polymerized carboxylic acids are used to treat lignocellulosic materials, then fire ignition and flame spread are inhibited, but the complexity of the treatment composition increases
Solution Approach 1:
The patent applies alkali metal salts specifically to the lignocellulosic material surface and structure, creating localized fire inhibition where needed. The esters are used to enhance penetration and distribution, ensuring the protective effect is concentrated where it provides maximum fire protection benefit
Solution Approach 2:
The patent creates a composite treatment system combining alkali metal salts with their corresponding esters. This composite approach leverages the fire-inhibiting properties of the salts while the esters provide enhanced delivery and distribution, achieving effective fire protection through material combination
3Reliability
If alkali metal salt crystalline structures are formed on lignocellulosic materials, then protection against corrosion, mold/mildew, and moisture is enhanced, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies the alkali metal salt treatment to the lignocellulosic material before final product assembly and finishing. This preliminary application allows the crystalline structures to form and provide protection during subsequent manufacturing steps, simplifying the overall process by establishing protection early rather than requiring additional post-processing steps
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 compositions provide high-performance protection against fire, metal-corrosion, mold/mildew, and moisture, enhancing the structural integrity and environmental safety of wood products while overcoming the limitations of traditional chemical treatments.
Implementation Method 1
forming alkali metal salt crystalline structures that inhibit fire ignition, flame spread
Implementation Method 2
forming alkali metal salt crystalline structures that inhibit fire ignition, flame spread
Implementation Method 3
alkali metal ions dispersed in water, for inhibiting fire ignition and flame spread
Implementation Method 4
a dispersing agent, realized as an ester of a non-polymerized saturated carboxylic acid
Implementation Method 5
provide protection against fire, metal-corrosion, mold/mildew and moisture
Implementation Method 6
provide protection against fire, metal-corrosion, mold/mildew and moisture
Data Source
AI summary
Environmentally-clean fire-inhibiting chemical compositions are used to biochemically treat wood furnish material and polymer resin binder material during composite wood product (e.g. oriented strand board (OSB) panel) manufacture, so that alkali metal (i.e. potassium) ions and/or micro-particles associated with the fire inhibiting biochemical treatment compositions are freely available throughout the entire composite wood product so as to inhibit fire ignition, flame spread, smoke development, as well as optionally, inhibit mold, mildew, microbial life and/or moisture. By embodying the environmentally-clean fire inhibiting biochemical compositions of the present invention into the lignocellulosic-based wood furnish material of a composite wood product, and preferably its polymeric resin binder material, during composite product manufacture, it is now possible to safely treat substantially the entire physical structure of the finished composite wood product and its structural components, with environmentally-clean fire inhibiting biochemical composition(s). By doing so, it is possible to provide the entire finished composite wood product with alkali metal ions and/or micro-particles thereof, that are freely available to inhibit fire ignition, flame spread and smoke development in accordance with ASTM Class-A fire-protected standards, as well as, optionally, inhibit metal corrosion, mold/mildew and moisture in a significantly new and improved manner.