Two-Part Adhesive for Lignocellulosic Boards
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Solution Overview
Problem
Existing processes for manufacturing multi-layer lignocellulosic articles, such as wood-based composite materials, face challenges with strong odor and eye irritation due to urea in soy flour-based adhesives, which can lead to lower strength in final products and technical constraints in mixing wood chips/particles with fibers, and issues with recycling MDF for OSB and particleboard production.
Innovation Solution
A two-part adhesive composition using ground sunflower or rapeseed meal instead of soy flour, with a solid part and a liquid part containing an amine-based azetidinium-functional cross-linker, reducing water addition and viscosity, and optimizing the use of amine- or amide-based compounds like urea to enhance internal bonding and water resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If soy flour-based adhesive with urea is used, then bonding strength is improved, but strong odor and eye irritation occur due to urease activity
Solution Approach 1:
The patent changes the protein source from soy flour to sunflower or rapeseed meal, which have different urease activity characteristics. This parameter change in the adhesive composition eliminates the harmful urease activity while maintaining bonding strength through the same urea-formaldehyde crosslinking mechanism.
Solution Approach 2:
The patent uses ground sunflower or rapeseed meal as a cost-effective alternative to soy flour. These meal by-products are inexpensive and when used as adhesive base, they provide the necessary protein content without the problematic urease activity, resolving both cost and harmful effects issues.
2Object-affected harmful factors
If soy flour is heat-treated to denature urease, then harmful effects are reduced, but manufacturing complexity and energy consumption increase
Solution Approach 1:
The patent extracts the problematic urease activity by completely replacing soy flour with sunflower or rapeseed meal that naturally lacks this activity. This eliminates the need for the additional heat-treatment step to denature urease, simplifying the manufacturing process while achieving the same harmful effect reduction.
Solution Approach 2:
The patent selects protein sources (sunflower or rapeseed meal) that have already been processed to remove or minimize urease activity before use. This preliminary selection avoids the need for subsequent heat-treatment steps during adhesive preparation, reducing manufacturing complexity.
3Quantity of substance
If two-part adhesive composition is used, then water usage is reduced and viscosity is optimized, but adhesive composition complexity increases
Solution Approach 1:
The patent divides the adhesive composition into two separate parts: a solid protein-based part (sunflower or rapeseed meal) and a liquid crosslinker part (containing urea and formaldehyde). This segmentation allows independent optimization of each component's properties, enabling reduced water usage and optimized viscosity while maintaining effective bonding through controlled mixing before application.
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 process eliminates urease activity, reduces water usage, maintains strength and flexibility of the lignocellulosic boards, and allows for the production of multi-layer wood particleboards with improved internal bonding and water resistance without compromising the manufacturing process.
Implementation Method 1
a liquid part comprising an amine-based azetidinium-functional cross-linker
Implementation Method 2
curing the adhesive compositions impregnating the lignocellulosic material
Data Source
Figure 1
Figure 1
Figure 2~3
AI summary
The present invention relates to a process for preparing a multi-layer lignocellulosic article comprising a core and two surface layers, wherein this process comprises the use of a two-part adhesive compositions comprising a solid part comprising a ground sunflower or rapeseed meal and a liquid part comprising a cross-linker and wherein an amine- or amide-based compound is added and mixed to the lignocellulosic material forming the core layer.