Sorted Waste Panel Production Without Synthetic Binders
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing building panels from waste materials, such as wood chips and wood fibers, rely on limited raw material sources and environmentally undesirable synthetic binders, whereas sorted communal waste comprising paper and plastic is underutilized for sustainable panel production.
Innovation Solution
A method involving the processing of sorted communal waste using physical and chemical properties of lignocelluloses and low-density polyethylene (LDPE) to form panels without added binders, utilizing a machinery line with specific mechanical and physical features, including pre-pressing and hot/cold pressing stages to achieve the desired thickness and density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wood chips and wood fibers are used as raw material, then panel production is possible, but the raw material source is limited and environmentally undesirable synthetic binders must be added
Solution Approach 1:
The patent changes the physical and chemical parameters of the raw material by sorting and separating communal waste into specific fractions (paper, plastic, textiles) with controlled moisture content (5-20%), transforming it into a suitable form for panel production without requiring synthetic binders
Solution Approach 2:
The patent enables the waste materials themselves to serve as the binding agent through controlled compression and heating processes, where the natural properties of the separated waste fractions allow them to bond together without adding external synthetic binders, thus eliminating harmful factors
2Object-generated harmful factors
If sorted communal waste is used instead of wood waste, then environmental friendliness is improved, but the processing complexity increases due to diverse material composition
Solution Approach 1:
The patent segments the complex communal waste into distinct fractions (paper, plastic, textiles) through sorting mechanisms, allowing each fraction to be processed separately through controlled compression and heating, thereby managing the complexity of diverse materials
Solution Approach 2:
The patent creates a universal processing system that can handle multiple waste fractions (paper, plastic, textiles) through a common compression and heating mechanism, enabling the processing of diverse materials while maintaining a relatively simple overall system structure
3Object-generated harmful factors
If no binder is added to the waste mixture, then environmental friendliness is improved, but the binding strength and panel density may be insufficient
Solution Approach 1:
The patent changes the physical parameters of the waste mixture by controlling moisture content (5-20%), temperature (100-200°C), and pressure during compression, enabling the waste materials to bond together through natural adhesion and compression without requiring additional binders, thus achieving sufficient panel strength
Solution Approach 2:
The patent converts the potentially harmful diversity and variability of communal waste into a benefit by using the natural properties of different waste fractions (paper, plastic, textiles) to create interlocking bonds during compression and heating, where the varied material characteristics contribute to the overall binding strength without needing synthetic additives
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 method effectively converts sorted waste into high-density, water-resistant, and recyclable building panels with enhanced mechanical resilience, suitable for various applications in the building industry, while minimizing waste and environmental impact by eliminating the need for synthetic binders.
Implementation Method 1
The technology can be classified as waste-less, as all scrap, trimmings and fragments can be returned to the manufacturing process. Also used and no longer needed products can be recycled.
Implementation Method 2
The thus formed continual mat passes through a continual belt press to be compacted and cured under pressure and heat effect
Implementation Method 3
The running composite belt is heated from underneath to accelerate solidification of the foam
Implementation Method 4
To provide for water vapour release from the pressed sandwich the pressure is preferably repeatedly short-term reduced in the course of the hot pressing process
Implementation Method 5
The waste is transported by a first conveyor 1 to a shredder 2 for crushing to flake-like particles
Implementation Method 6
The waste is transported by a first conveyor 1 to a shredder 2 for crushing to flake-like particles able to pass though 30mm sieve holes
Data Source
Figure 1
AI summary
A method of processing of sorted communal waste for panels usable in the building industry comprises sorting, crushing, drying, levelling/spreading and pressing of the waste and formatting of the panel. The sorted waste, shredded to pass through sieve hole sizes 20 to 40 mm and dried for the eventual water content of 5 to 10 wt%, whose solid component comprises 60 to 80 wt% of lignocelluloses, e.g. paper, 20 to 40 wt% of low-density polyethylene (LDPE) and maximum 8 wt% of admixtures, such as wood, fabrics, other plastics or metals, is levelled on a running base belt without addition of any adhesive, covered with a cover belt and pressed between the base and the cover belts under a pressure ranging from 0.4 to 1 MPa and temperature of 180 °C to 210 °C, which sandwich formed in this way is subsequently cooled, again under a pressure ranging from 0.4 to 1 MPa, to a formatting temperature.