NIR Spectroscopy for Online Binder Amount Determination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for determining the application and distribution of isocyanate-containing binders like PMDI on wood particles in wood-based panel production are inadequate, leading to increased costs, material consumption, and difficulty in troubleshooting due to the inability to assess glue distribution visually and the subjective nature of existing monitoring systems.
Innovation Solution
A non-destructive method using Near-Infrared (NIR) spectroscopy with multivariate data analysis to create a calibration model for determining the amount and distribution of binders on wood particles in real-time, enabling continuous monitoring without disrupting the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual assessment methods are used to determine binder distribution, then the process is simple and low-cost, but the measurement is subjective and cannot be performed continuously
Solution Approach 1:
The patent replaces the mechanical/visual assessment system with an optical measurement system (NIR spectroscopy). The NIR measuring head non-contactly measures the reflection or scattering of NIR radiation from wood particles on the conveyor belt, automatically determining binder content and distribution without subjective visual assessment.
Solution Approach 2:
The patent introduces NIR radiation as an intermediary to transfer information about binder distribution. The NIR radiation interacts with the wood particles and binder, and the reflected or scattered radiation carries information about binder content that can be measured and analyzed objectively.
2Difficulty of detecting and measuring
If UV-active substances are added to PMDI to enable visualization, then glue distribution can be detected, but costs increase and continuous monitoring is still not possible
Solution Approach 1:
The patent extracts the detection function from the binder itself (no need to modify PMDI with UV-active substances) and places it in a separate measurement system (NIR measuring head). The NIR system detects binder distribution through non-contact measurement of reflected or scattered radiation, eliminating the need for expensive additives.
Solution Approach 2:
The patent replaces the chemical modification approach (adding UV-active substances) with a physical measurement approach (NIR spectroscopy). This substitution eliminates the need for expensive additives while enabling continuous, objective monitoring of binder distribution.
3Manufacturing precision
If higher binder dosage is applied to ensure even distribution, then glue distribution problems are reduced, but material losses and costs increase
Solution Approach 1:
The patent implements a feedback system where the NIR measuring head continuously measures actual binder distribution on wood particles, and this information is fed back to the control system. The control system can then adjust dosing parameters in real-time to optimize binder distribution and minimize binder consumption while maintaining quality standards.
Solution Approach 2:
The patent performs preliminary measurement of binder distribution on wood particles before they are pressed into panels. This allows detection and correction of distribution problems early in the process, preventing the production of substandard goods and reducing the need for excessive binder dosage as a preventive measure.
4Reliability
If traditional measuring systems are installed to detect abnormalities, then production quality can be monitored, but the root cause of problems cannot be identified and action is delayed
Solution Approach 1:
The patent performs measurement of binder distribution on wood particles immediately after dosing and before the pressing process. This preliminary measurement allows early detection of distribution problems and immediate corrective action, preventing the production of large quantities of substandard goods and reducing time delays in problem response.
Solution Approach 2:
The patent uses NIR radiation as an intermediary to provide direct, real-time information about binder distribution and its relationship to technological values such as transverse tensile strength. This enables immediate identification of root causes rather than just detecting final product abnormalities.
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
Enables accurate, real-time determination of binder application and distribution, reducing material losses, improving production efficiency, and ensuring consistent product quality by correlating binder parameters with technological values such as transverse tensile strength.
Implementation Method 1
recording at least one NIR spectrum of the binder applied to the wood particles by means of at least one NIR measuring head in a wavelength range between 1350 and 2500 nm
Implementation Method 2
The reflected or scattered NIR radiation is detected by the NIR detector
Implementation Method 3
The reflected or scattered NIR radiation is detected by the NIR detector
Data Source
Figure 1
Figure 2(A)~2(B)
AI summary
The present invention relates to a non-destructive measurement method for the online determination of the amount of binder applied to wood particles in a production plant for the manufacture of wood-based panels, comprising the steps of: applying at least one binder in different quantitatively defined quantities to respective samples of wood particles as reference samples and scattering the reference samples onto a conveyor belt; recording at least one NIR spectrum of each of the reference samples scattered onto the conveyor belt using at least one NIR measuring head in a wavelength range between 1000 nm and 2500 nm, preferably between 1350 nm and 2500 nm; and assigning the different quantitative quantities of binder of the reference samples scattered onto the conveyor belt to the recorded NIR spectra of said reference samples.and creation of a calibration model for the relationship between the spectral data of the NIR spectra and the corresponding quantitative amounts of binder of the reference samples scattered on the conveyor belt by means of a multivariate data analysis; application of at least one binder to wood particles (as samples to be measured) and scattering of the wood particles coated with the binder onto a conveyor belt, recording of at least one NIR spectrum of the wood particles coated with the binder and scattered on the conveyor belt using the at least one NIR measuring head in a wavelength range between 1000 and 2500 nm, preferably between 1350 nm and 2500 nm; and determination of the quantitative amount of binder applied to the wood particles scattered on the conveyor belt by comparing the NIR spectrum recorded for the wood particles coated with the binder with the created calibration model.