Isocyanate Adhesive Extender for Composite Wood
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Solution Overview
Problem
Existing composite wood products manufactured with isocyanate adhesives do not effectively incorporate fillers or extenders, leading to high costs and inefficient mixing of water and isocyanate, which affects the properties and production efficiency of the final products.
Innovation Solution
The use of interactive extender-filler-containing polymeric, aldehyde-free isocyanate adhesives, where aged tree bark is employed as an interactive filler to facilitate the mixing of water and isocyanate, acting as a compatibilizer to improve the distribution and stability of the adhesive mixture, thereby reducing the amount of costly polymeric isocyanate adhesives required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymeric isocyanate adhesives are used without fillers or extenders, then adhesive performance is maintained, but production cost increases significantly
Solution Approach 1:
The patent applies this principle by replacing expensive polymeric isocyanate adhesive with a cost-effective mixture of water, filler, and small amounts of isocyanate. The filler (such as wood flour or bark) serves as a disposable extender that provides bulk and adhesive functionality at much lower cost, while the small amount of isocyanate ensures sufficient bonding performance.
Solution Approach 2:
The patent creates a composite adhesive system combining water, filler materials (wood flour, bark, or other cellulosic materials), and isocyanate adhesive. This composite approach allows the filler to provide bulk and structural support while the isocyanate provides bonding capability, achieving cost reduction without sacrificing adhesive performance.
2Device complexity
If water and polymeric isocyanate adhesive are mixed directly, then adhesive formulation is simplified, but mixing efficiency decreases and distribution becomes uneven
Solution Approach 1:
The patent uses filler material as an intermediary substance that facilitates the mixing of water and isocyanate adhesive. The filler particles act as a medium that helps distribute the isocyanate uniformly throughout the water-based mixture, preventing uneven distribution and improving mixing efficiency without requiring complex mixing equipment or formulations.
3Quantity of substance
If fillers or extenders are added to isocyanate adhesive systems, then cost is reduced, but mixing and distribution of water and isocyanate becomes inefficient
Solution Approach 1:
The patent optimizes the parameters of the adhesive system by controlling the ratio of water to isocyanate, the type and amount of filler used, and the particle size distribution of the filler. By adjusting these parameters, the system achieves efficient mixing and uniform distribution of components while maintaining cost effectiveness through the use of fillers and extenders.
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 significantly reduces the cost of composite wood products by minimizing the use of polymeric isocyanate adhesives, enhances the adhesive properties, and improves the board properties by ensuring better mixing and distribution of the adhesive, while also reducing the risk of pre-cure reactions and improving the surface finish.
Implementation Method 1
They also include interactive extender-fillers which act as compatibilizers for facilitating the effective and efficient distribution of the water and isocyanate to form a more evenly dispersed polymeric adhesive admixture.
Implementation Method 2
Composite wood particulate products, such as particleboard (PB), medium density fiberboard (MDF), and oriented strand board (OSB) can employ formaldehyde-free isocyanate adhesives instead of formaldehyde-containing adhesives
Data Source
AI summary
The disclosed composite wood particulate products, adhesives contained in such wood particulate products, and methods of making the adhesive and the wood particulate products employ an aldehyde-free adhesive, and more specifically a formaldehyde-free adhesive. The aldehyde-free adhesive includes an inert additive that extends a resin, such as an isocyanate resin, and forms an evenly dispersed, less expensive polymeric adhesive admixture. The extender-filler of the resin is mixed with water to form a slurry. The slurry can then be mixed with a resin, like the isocyanate resin, to form the adhesive. Various rheology modifiers can be added, if desired, to the extender-filler or the slurry. The adhesive can be blended with wood particles to form a mat that is then pressed into a composite wood particulate product.