Lignin Slurry Dispersion for Resin Preparation

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Solution Overview

Problem

Existing methods for preparing lignin-based resins face challenges in fully utilizing lignin reactivity due to splashing issues when adding dry lignin powder to an aqueous medium, which poses safety risks and inefficiencies.

Innovation Solution

A method involving the preparation of a lignin dispersion in an aqueous medium with a pH of 1 to 7, adding lignin as a slurry with a solid content of 30-95 wt-%, and mixing without heating, followed by adding alkali and phenol/formaldehyde at controlled temperatures to form a resin.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If dry lignin powder is added to an aqueous medium, then lignin dispersion is formed, but splashing occurs which poses safety risks

Engineering Contradiction:

Improvelignin dispersion preparationVSAvoidsplashing safety risks

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent changes the physical state parameter of lignin from dry powder to slurry form (30-95 wt% solid content in water). This parameter change eliminates the splashing problem while maintaining effective lignin dispersion in the aqueous medium, directly resolving the safety risk without compromising manufacturing ease

Inventive Principle:

Principle #35Parameter changes

2Reliability

If alkali is added to the aqueous medium to ensure lignin reactivity, then lignin dispersion is formed, but the process complexity increases

Engineering Contradiction:

Improvelignin reactivity utilizationVSAvoidprocess steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-mixing lignin with water to form a slurry before adding it to the aqueous medium. This preliminary preparation ensures adequate suspension and dissolution of lignin, fully utilizing its inherent reactivity without requiring subsequent alkali addition, thereby simplifying the overall process while maintaining reliability

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If heating is applied to the aqueous medium to form lignin dispersion, then dispersion is achieved, but energy consumption increases

Engineering Contradiction:

Improvelignin dispersion stabilityVSAvoidheating energy

Core Design Contradiction:

Stability of the object's compositionVSUse of energy by moving object

Solution Approach 1:

The patent changes the concentration parameter by using high solid content lignin slurry (30-95 wt%). This concentrated form allows the lignin to disperse effectively in the aqueous medium through mixing alone, achieving stable dispersion without requiring heating, thus eliminating energy consumption while maintaining composition stability

Inventive Principle:

Principle #35Parameter changes

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 method enables the safe and efficient preparation of lignin-based resins without alkali addition and heating, facilitating the production of laminates, plywood, and engineered wood products while ensuring lignin reactivity is fully utilized.

Implementation Method 1

adding lignin to the aqueous medium, wherein the lignin is added in the form of a slurry... mixing until a dispersion of lignin in the aqueous medium has been obtained

Methodology Applied

Scientific EffectSuspension: Suspension

Data Source

PatentUS12071518B2Process for preparing a resin

Publication Date: 2024.08.27 STORA ENSO OYJ

AI summary

The present invention relates to an improved process for preparing an aqueous dispersion of lignin and the use of said suspension in the preparation of a resin.