Lignocellulose Board Core with Inhomogeneous Plastic Distribution
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Solution Overview
Problem
Existing lignocellulose-containing materials with evenly distributed foamed polystyrene beads lack sufficient bending strength, screw pull-out strength, and surface quality, and require increased glue and polymer amounts to improve properties, leading to higher costs.
Innovation Solution
Developing lignocellulose-containing materials with a core and two outer layers, where the core contains 30-98% lignocellulose particles, 1-25% expanded plastic particles, and 1-50% binders, and the outer layers contain 70-99% lignocellulose particles and 1-30% binders, with expanded plastic particles inhomogeneously distributed to achieve improved mechanical properties and surface quality without increasing board density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If evenly distributed foamed polystyrene beads are used in the core, then the material structure is simple and manufacturing is easy, but the bending strength, screw pull-out strength and surface quality are insufficient
Solution Approach 1:
The patent applies local quality by creating inhomogeneous distribution of expanded plastic particles in the core, with higher concentration in the inner area and lower concentration in the outer areas. This non-uniform distribution optimizes the local mechanical properties: the inner area with higher plastic content provides enhanced bending strength and screw pull-out strength, while the outer areas maintain better surface quality for coating. This resolves the contradiction by allowing different regions to have different functional characteristics rather than uniform properties throughout.
2Device complexity
If evenly distributed foamed polystyrene beads are used, then the material structure is simple, but the surface quality is poor for coating applications
Solution Approach 1:
The patent implements local quality by spatially varying the concentration of expanded plastic particles, with the outer areas having lower plastic content to preserve surface quality for coating applications, while the inner area has higher plastic content for structural reinforcement. This creates distinct functional zones: the outer layers provide smooth surfaces suitable for lamination and coating, while the inner core provides structural strength. This resolves the surface quality issue without requiring complex overall structure.
3Strength
If glue and polymer amounts are increased to improve properties, then the mechanical properties improve, but the costs increase
Solution Approach 1:
The patent applies parameter changes by optimizing the distribution pattern of expanded plastic particles rather than increasing the total amount of glue and polymer. The inhomogeneous distribution with higher plastic concentration in the inner area and lower concentration in outer areas achieves improved mechanical properties through strategic material placement rather than increased material quantity. This resolves the cost issue by maintaining lower overall material consumption while achieving superior performance through optimized distribution.
4Strength
If inhomogeneous distribution of expanded plastic particles is implemented, then transverse tensile strength and bending strength are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent achieves improved transverse tensile strength through local quality by concentrating expanded plastic particles in the inner area of the core while maintaining lower concentrations in outer areas. This spatial variation in material composition enhances the transverse tensile strength by creating a gradient structure that optimizes strength distribution. The manufacturing complexity is managed by implementing this distribution pattern through controlled mixing and layering processes during fabrication.
5Strength
If board density is increased to improve mechanical properties, then strength improves, but the weight increases and processing properties deteriorate
Solution Approach 1:
The patent applies parameter changes by optimizing the distribution pattern of expanded plastic particles to achieve improved mechanical properties at conventional density levels rather than increasing board density. The inhomogeneous distribution with higher plastic content in the inner area provides structural reinforcement without requiring increased overall density. This resolves the weight issue by maintaining lightweight construction while achieving superior mechanical properties through optimized material distribution.
Data Source
AI summary
Materials which contain lignocellulose, have a core and two covering layers, and contain, in the core, A) 30 to 98 wt. % lignocellulose particles, B) 1 to 25 wt. % expanded plastic particles having a bulk density in the range of 10 to 150 kg/m3, C) 1 to 50 wt. % of one or more binding agents selected from the group consisting of amino resin, phenolic resin and organic isocyanate comprising at least two isocyanate groups, and D) 0 to 10 wt. % additives, and, in the covering layers, E) 70 to 99 wt. % lignocellulose particles, F) 1 to 30 wt. % of one or more binding agents selected from the group consisting of amino resin, phenol formaldehyde resin and organic isocyanate comprising at least two isocyanate groups, and G) 0 to 10 wt. % additives. The lignocellulose particles of the covering layers E contain at least 25 wt. % lignocellulose-containing chips, and the expanded plastic particles B are non-homogeneously distributed in the core.