Oriented Strand Board Toughness via Solid Polyurethane Particles
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Solution Overview
Problem
Current oriented strand boards (OSB) lack improved toughness and impact resistance, and there is a need to reduce the use of hazardous binders like pMDI and PPF during manufacturing, while also seeking to recycle waste polyurethane foam.
Innovation Solution
The development of OSB composite materials incorporating a matrix with solid polyurethane particles and a binder resin, where at least 50% of the composite material is solid reinforcing material, such as wood fibers, and using ground rigid polyurethane foam as a binder replacement, reducing the amount of hazardous chemicals and incorporating recycled waste materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional binders like pMDI or PPF are used during OSB manufacturing, then the panels achieve adequate structural performance, but the manufacturing cost increases and worker exposure to hazardous chemicals increases
Solution Approach 1:
The patent changes the physical state parameter of polyurethane from liquid (hazardous pMDI) to solid particles (ground rigid foam), fundamentally altering how the binder is applied and reducing chemical exposure risks while maintaining binding functionality
Solution Approach 2:
The patent uses recycled rigid polyurethane foam particles from waste materials instead of virgin chemical binders, reducing both cost and hazardous chemical usage while achieving adequate structural performance
2Strength
If more binder resin is used to improve OSB structural performance, then the strength increases, but the manufacturing cost increases
Solution Approach 1:
The patent creates a composite binder system combining solid polyurethane particles with liquid binder resin, where the particles provide structural reinforcement and the liquid provides adhesion, allowing reduced overall binder quantity while maintaining or improving strength
Solution Approach 2:
The binder system is segmented into solid particles (providing structural framework) and liquid resin (providing binding action), allowing each component to perform its function more efficiently and reducing total binder requirements
3Strength
If solid polyurethane particles are incorporated into the OSB matrix, then the toughness and impact resistance improve, but the manufacturing process complexity increases
Solution Approach 1:
The solid polyurethane particles serve dual functions: they act as impact modifiers to improve toughness and simultaneously function as filler material in the matrix, reducing the need for separate additive systems and simplifying the overall formulation
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 approach enhances the toughness and impact resistance of OSB, reduces the use of hazardous chemicals, and recycles waste polyurethane foam, providing an environmentally friendly and cost-effective manufacturing process.
Implementation Method 1
depositing the binder resin and polyurethane foam particles on the solid reinforcing material by spraying a mixture of the binder resin and polyurethane foam particles on the solid reinforcing material
Implementation Method 2
treating the composite precursor to form the composite material comprises treating the composite precursor under heat and pressure
Implementation Method 3
treating the composite precursor under heat and pressure is performed in a mold or an autoclave
Implementation Method 4
a matrix, wherein the matrix comprises a binder resin and solid polyurethane particles
Data Source
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AI summary
The embodiments of the invention are directed to a composite material comprising a fiber reinforcing material, a binder resin and polyurethane foam particles. Other embodiments are related to a process for manufacturing a composite material comprising a fiber reinforcing material, a binder resin and polyurethane foam particles, the method comprising depositing the binder resin and polyurethane foam particles the fiber reinforcing material to form a composite precursor and treating the composite precursor to form the composite material