Furan Wood Impregnation Composition With pH-Stable Condensate Reuse
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing polymerizable solutions for furan polymer impregnated wood face challenges such as rapid polymerization due to strong acids, environmental concerns with stabilizers, and instability when reusing condensate as a carrier, leading to phase separation and reduced solubility, which affects storage stability and product quality.
Innovation Solution
A polymerizable solution comprising furfuryl alcohol, carboxylic acid as a buffer, maleic anhydride as an initiator, and condensate from a previous curing process, with a pH range of 3 to 5, stabilized by a water-soluble alkali salt, ensuring stability for at least 7 days and improved properties in the final product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If condensate from previous curing process is reused as carrier, then cost is reduced and environmental impact is minimized, but phase separation occurs and storage stability is reduced
Solution Approach 1:
The patent adjusts the pH parameter of the condensate to a specific range (3-5) through controlled neutralization, transforming it into a stable carrier solution that prevents phase separation while maintaining environmental benefits. This parameter optimization resolves the contradiction between reusing condensate and maintaining storage stability.
2Speed
If strong acids are used to initiate polymerization, then polymerization speed is increased, but violent self-condensing polymerization occurs which is difficult to control
Solution Approach 1:
The patent changes the acid strength parameter from strong acids to weak organic acids (pKa 3-6), achieving sufficient polymerization initiation while maintaining controllable reaction rates and avoiding violent self-condensation.
Solution Approach 2:
The patent introduces weak organic acids as intermediary substances that mediate between the need for polymerization initiation and the requirement for controlled reaction, providing gradual and manageable polymerization progress.
3Reliability
If weak organic acids are used as initiators, then violent polymerization is avoided, but the solution becomes unstable and separates during storage
Solution Approach 1:
The patent optimizes the pH parameter to a specific range (3-5) and controls the concentration of weak organic acids, creating a balanced formulation that maintains both polymerization control and storage stability by preventing premature reaction while ensuring adequate initiation capability.
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 solution provides a stable, environmentally friendly, and cost-effective polymerizable solution that maintains reactivity, enhances storage life, and produces furan polymer impregnated wood with improved mechanical strength, dimensional stability, and resistance to leaching, decay, and weathering.
Implementation Method 1
carboxylic acid in the range from 0.01 to 0.15 mol/kg based on the total weight of the solution, water-soluble alkali salt in an amount such that the initial composition comprises a pH in the range from 3 to 5
Implementation Method 2
maleic anhydride as an initiator... the polymerizable compounds of the polymerizable solution are polymerized/cured into a furan polymer in the wood cells
Implementation Method 3
condensate from a previous curing process of wood in the range from 24 to 74 weight% based on the total weight of the solution
Implementation Method 4
thereafter heating and curing the wood such that the polymerizable compounds of the polymerizable solution are polymerized/cured into a furan polymer in the wood cells
Data Source
AI summary
The present invention relates to a polymerizable solution for impregnating wood, a method for impregnating wood with said solution and impregnated wood impregnated with said solution. The polymerizable solution comprises: - furfuryl alcohol in the range from 25 to 75 weight% based on the total weight of the solution, - carboxylic acid in the range from 0.01 to 0.15 mol/kg based on the total weight of the solution, - maleic anhydride in the range from 0.25 to 4 weight% based on the total weight of the solution, - condensate from a previous curing process of wood in the range from 24 to 74 weight% based on the total weight of the solution, and - an amount of water-soluble alkali salt to obtain a pH in the range from 3 to 5 at the time point when the solution is made.