Oriented Strand Board Core Layer Recycled Wood

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Solution Overview

Problem

Oriented strand boards (OSBs) produced from virgin wood only, as existing technologies have rejected the use of recycled wood due to concerns about mechanical instability, despite recycled wood being suitable only for particleboards or thermal utilization.

Innovation Solution

Development of OSBs with a core layer composed of recycled wood flakes, bonded with surface layers of oriented strands, using a specific configuration that meets mechanical demands as per DIN EN 300:2006, and incorporating virgin wood flakes to enhance properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If recycled wood is used for OSB production, then resource conservation is improved, but mechanical stability deteriorates

Engineering Contradiction:

Improvevirgin wood usageVSAvoidmechanical stability

Core Design Contradiction:

Loss of substanceVSStrength

Solution Approach 1:

The patent applies local quality by using different wood material compositions in different layers of the OSB. Surface layers contain primarily virgin wood strands to ensure mechanical strength and stability, while the core layer uses recycled wood flakes to reduce virgin wood consumption. This spatial differentiation of material quality resolves the contradiction between resource conservation and mechanical stability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent creates a composite structure combining virgin wood strands and recycled wood flakes in specific proportions and arrangements. The surface layers use virgin wood strands (60-100% by weight) while the core layer uses recycled wood flakes (30-70% by weight), creating a composite material system that achieves both resource efficiency and mechanical performance.

Inventive Principle:

Principle #40Composite materials

2Loss of substance

If recycled wood flakes are used in core layer, then resource efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvevirgin wood consumptionVSAvoidproduction process complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The patent segments the OSB into distinct layers with different material compositions - surface layers made from virgin wood strands and a core layer made from recycled wood flakes. This segmentation allows each layer to be optimized independently, simplifying the overall manufacturing process by treating different material types separately rather than mixing them uniformly throughout.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes key parameters including the spatial distribution of materials (surface vs. core layers), the form of wood material (strands vs. flakes), and the proportion of recycled content (30-70% in core layer). These parameter changes enable the use of recycled wood while maintaining production feasibility and mechanical performance.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11969971B2Oriented strand board, process for production of an oriented strand board and apparatus for producing an oriented strand board

Publication Date: 2024.04.30 KRONOSPAN LUXEMBOURG SA

AI summary

A novel oriented strand board (OSB) may be provided comprising recycled wood flakes that have been obtained by flaking of recycled wood at least in a core layer. A process may be provided for producing a corresponding oriented strand board. An apparatus may be provided by which the oriented strand board can be produced.