Combustible Waste Panel Fabrication with Calcium Oxide Binding
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Solution Overview
Problem
Conventional wood-based panels for furniture production have high specific weight, moisture absorption issues, toxic emissions, and high environmental impact due to deforestation, while alternative panel methods lack clear material composition and mechanical property definitions.
Innovation Solution
A method using a classified combustible waste material mix (EWC 191210) is micronized, treated with calcium oxide, and formed into a panel with a variable binding agent composition to achieve improved mechanical and environmental properties, using a production apparatus that adjusts layer thickness and binding agent distribution for efficient energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wood chips are used as raw material for panel production, then mechanical properties of panels are improved, but environmental impact increases due to deforestation
Solution Approach 1:
The invention recovers and utilizes combustible waste materials from urban waste sorting that would otherwise be discarded or used for low-value energy recovery. By transforming these discarded materials into construction panels with useful mechanical properties, the invention eliminates the need for virgin wood resources while maintaining panel performance.
Solution Approach 2:
The invention changes the physical and chemical parameters of waste materials through controlled processes including drying to reduce moisture content, micronization to achieve specific particle size distributions, and thermal treatment to enhance bonding characteristics. These parameter transformations enable waste materials to achieve mechanical properties suitable for construction applications.
2Stability of the object's composition
If conventional binding agents are used in panel production, then aggregation of wood chips is improved, but toxic emissions increase due to solvent evaporation
Solution Approach 1:
The invention employs calcium oxide as a binding agent that reacts with moisture and carbon dioxide in the waste materials through oxidation processes to form calcium hydroxide and calcium carbonate. This chemical binding mechanism eliminates the need for organic solvent-based adhesives, thereby preventing toxic emissions while achieving strong aggregation of panel materials.
Solution Approach 2:
The invention uses calcium oxide, a inexpensive and environmentally benign material, as a binding agent that performs its aggregation function during panel formation and then remains as a stable, non-toxic component in the final product. This replaces expensive and harmful synthetic resins with a simple, safe alternative.
3Object-affected harmful factors
If recycled wood scraps are used for panel production, then environmental impact is reduced, but mechanical properties deteriorate due to denaturation
Solution Approach 1:
The invention applies controlled drying and micronization processes to recycled wood scraps and other combustible wastes to restore their physical properties. By optimizing moisture content and particle size distribution, the treatment processes reverse the detrimental effects of previous use and denaturation, enabling the materials to achieve mechanical properties suitable for new construction applications.
Solution Approach 2:
The invention creates composite panel structures by combining treated waste materials with binding agents like calcium oxide. This composite approach allows the use of diverse waste streams including papers, polymers, textiles, and wood scraps, where the binding agent holds together materials that individually would not provide sufficient structural strength.
4Strength
If hot forming process is applied to panels, then mechanical properties are improved, but energy consumption increases
Solution Approach 1:
The invention enables the waste materials to contribute their own thermal energy during the forming process. The combustible waste materials, when subjected to controlled thermal treatment, release energy that assists in the drying and bonding processes, reducing the external energy input required for hot forming while still achieving the necessary mechanical properties.
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 produces panels with enhanced mechanical properties and reduced environmental impact, utilizing low-cost waste materials, minimizing energy consumption, and ensuring health and fire safety while reducing pollution.
Implementation Method 1
a) in a drying unit (1), a mass (2) of combustible waste materials is dried so as to reduce the water content
Implementation Method 2
b) in a micronizing unit (1), the dried mass is micronized
Implementation Method 3
incorporating a binding agent in a quantity that varies depending on the kind of waste material being used and the mechanical properties that the panel is required to have
Implementation Method 4
The mattress thus formed is then pressed
Data Source
Figure 1~4
Figure 5
AI summary
The invention relates to a method for the fabrication of a panel, in particular a panel used in the production of furniture pieces comprising the following steps: a) supplying a first mass of combustible refuse including: - 10 to 30 weight percent of paper-based material, - 0.5 to 6 weight percent of wet refuse, - 20 to 40 weight percent of polymeric material, - 1 to 6 weight percent of inert material; b) drying and micronizing said mass of combustible refuse; c) spreading said mass in one or several layers over a planar surface so as to form a mattress; d) pressing said mattress at a temperature that is equal to or higher than the melting temperature of said polymeric material included in the mass; e) incorporating a first quantity, ranging from 200 kg to 1100 kg per cubic meter of finished product, of binding agent into said mattress; f) drying up the binding agent thus incorporated in the mattress. Also claimed are a panel obtained with said fabrication method and an apparatus for producing g said panel.