Lignocellulosic Synthetic Board Using PBS Adhesive

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Solution Overview

Problem

Conventional synthetic boards used for vehicle and building components face issues with environmental friendliness, human safety, and mechanical strength due to the use of oil-derived synthetic resins, which also require high-temperature and pressure processing, and are brittle when using plant-derived resins like polylactic acid, and involve costly manufacturing processes with solvent adhesives.

Innovation Solution

A synthetic board made from lignocellulosic materials treated with steam or explosion processes, bonded with polybutylene succinate-based resin, which is anti-hydrolyzable and anti-biodegradable, and optionally covered with woven or nonwoven fabrics, using a heat-pressing method that reduces processing costs and enhances flexibility and strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If oil-derived synthetic resin is used as adhesive, then binding strength is improved, but environmental friendliness deteriorates and harmful substances are generated

Engineering Contradiction:

Improvebinding strengthVSAvoidenvironmental friendliness

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical composition parameter of the adhesive from oil-derived synthetic resin to plant-derived polybutylene succinate resin, fundamentally altering the material source while maintaining adhesive functionality and eliminating harmful substances

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite adhesive system combining polybutylene succinate resin with lignocellulosic materials, achieving both environmental compatibility and sufficient binding strength through the synergistic properties of the composite materials

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If plant-derived resin is used as adhesive, then environmental friendliness is improved, but flexibility and durability deteriorate

Engineering Contradiction:

Improveenvironmental friendlinessVSAvoidflexibility and durability

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent modifies the chemical structure and physical properties of the plant-derived resin through specific selection of polybutylene succinate and control of its molecular characteristics, achieving adequate flexibility and durability while maintaining environmental benefits

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a biodegradable plant-derived resin that can be safely disposed of or decomposed after use, accepting limited service life in exchange for significant environmental advantages and reduced harm

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Object-affected harmful factors

If steam treatment and heat pressing is carried out, then environmental friendliness is improved, but processing time and energy consumption increase

Engineering Contradiction:

Improveenvironmental friendlinessVSAvoidprocessing time

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The patent optimizes the steam treatment parameters (temperature, pressure, time) and heat pressing conditions to achieve the necessary bonding of lignocellulosic materials with minimal processing time and energy consumption while maintaining environmental compatibility

Inventive Principle:

Principle #35Parameter changes

4Strength

If solvent adhesive is used for fabric lamination, then lamination strength is improved, but manufacturing cost and health hazards increase

Engineering Contradiction:

Improvelamination strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent extracts and eliminates the solvent component from the adhesive system, using pure polybutylene succinate resin that bonds fabric to synthetic board without requiring organic solvents, thereby reducing manufacturing complexity and health hazards while maintaining lamination strength

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs a water-based or solvent-free adhesive system that is simpler, cheaper, and safer to manufacture and apply, eliminating the need for complex solvent recovery processes and reducing health and safety infrastructure requirements

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 resulting synthetic board is environmentally friendly, safe for human use, has improved mechanical properties, and reduces manufacturing costs by eliminating the need for solvent adhesives and high-pressure processing, while maintaining sufficient flexibility and strength for vehicle and building applications.

Implementation Method 1

hemicellulose that is a component of lignocellulose is hydrolyzed by the steam treatment, and the lignocellulosic material is bound through the hydrolysate of the hemicellulose

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Implementation Method 2

The step of producing a synthetic board includes the step of mixing the woody materials with an adhesive and the step of molding an obtained mixture

Methodology Applied

Scientific EffectHeat pressing:

Data Source

PatentUS7524554B2Synthetic board and method of producing the same

Publication Date: 2009.04.28 MITSUBISHI MOTORS CORP

AI summary

A method of producing a synthetic board involves the step of heat-pressing a mixture. The mixture includes lignocellulosic material containing lignocellulose and polybutylene succinate-based resin serving as an adhesive.