Water-Based Lignocellulosic Binder for Wood Impregnation
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Solution Overview
Problem
Current wood impregnation methods face challenges such as toxicity, high cost, color changes, limited penetration, and safety concerns, particularly in achieving hardness, stability, water resistance, and fire resistance while maintaining cost-effectiveness and non-toxicity.
Innovation Solution
A water-based lignocellulosic binder system comprising an aqueous alkali metal silicate solution, liquid phenol formaldehyde, and optionally aluminium phosphate nano particles and boron, which is used for vacuum-pressure impregnation of wood products to enhance fire resistance, machinability, and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper, chrome and arsenic based compositions are used for wood impregnation, then preservation against insect and microbial attack is achieved, but the wood turns greenish and toxic compounds are released when wood is worked or broken down
Solution Approach 1:
The invention changes the chemical composition parameters by replacing toxic copper, chrome and arsenic compounds with a water-based solution containing boron compounds, zinc compounds and other non-toxic preservatives. This parameter change maintains preservation effectiveness while eliminating harmful effects such as greenish discoloration and toxic compound release during wood processing or decomposition.
Solution Approach 2:
The invention uses cost-effective, non-toxic alternatives such as boron compounds and zinc compounds that can be easily applied and decomposed safely. These replacements are cheaper than traditional copper-based systems and eliminate the need for complex containment measures, allowing for safe application and natural degradation without environmental harm.
2Strength
If furfural alcohol compositions are used to change wood properties for hardness and stability, then preservation is achieved, but the wood turns very dark
Solution Approach 1:
The invention modifies the chemical parameters by using water-based solutions with controlled pH levels and specific compound combinations (boron, zinc, and other preservatives) that provide hardness and stability without causing extreme color changes. The formulation allows for natural wood color preservation while achieving the desired mechanical properties.
3Reliability
If creosote is used for wood treatment, then some preservation effect is achieved, but penetration into wood is limited and strong odour is produced
Solution Approach 1:
The invention changes the physical and chemical parameters of the treatment solution by using water-based formulations with optimized viscosity, pH, and compound solubility. This enables better penetration into wood structures compared to creosote, while the water-based system eliminates the strong odour associated with coal tar derivatives.
4Reliability
If acetic anhydride is used for acetylation of hydroxyl groups on wood cellulose, then successful treatment is achieved, but the reagent is corrosive, an irritant and combustible
Solution Approach 1:
The invention uses water as an intermediary medium to deliver preservative compounds to the wood cellulose structure. Instead of using highly reactive and hazardous acetic anhydride directly on the wood, the water-based solution acts as a safe carrier that gradually releases the active preservative compounds, eliminating corrosivity, irritancy and combustibility while maintaining treatment effectiveness.
Solution Approach 2:
The invention replaces expensive and hazardous acetic anhydride with cost-effective, non-hazardous water-based preservative formulations. These alternative compounds achieve the same protective function without the safety risks associated with the original reagent, making the process safer and more economical.
5Reliability
If phenol formaldehyde is used as wood preservative, then preservation is achieved, but the wood is discoloured and residual odour is left
Solution Approach 1:
The invention changes the chemical composition parameters by substituting phenol formaldehyde with water-based solutions containing boron compounds, zinc compounds and other non-offensive preservatives. This parameter change maintains preservation effectiveness while eliminating the discoloration and residual odour problems associated with phenol formaldehyde treatments.
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 solution provides a cost-effective, non-toxic, and stable wood treatment that improves water resistance, fire resistance, and color while maintaining the wood's natural appearance, offering enhanced durability and resistance to insect and microbial attacks.
Implementation Method 1
The main purpose of wood impregnation has been preservation against insect and microbial attack of exterior exposed wood. The precipitated compounds are trapped in the cellulose structures and resist leaching.
Implementation Method 2
The reacting of an aminoplast resin by condensation of the amine or carbamide with a mono or dialdehyde at temperatures up to 100° C.
Implementation Method 3
the composition should be activated at a temperature in final drying not exceeding 125° C., to prevent damage to the wood.
Data Source
AI summary
The invention provides a lignocellulosic binder system. The binder system includes an aqueous alkali metal silicate solution; a liquid phenol formaldehyde; optionally aluminium phosphate nano particle dispersion; and optionally a component which includes boron.