Willow Composite Panels With Built-In Sound Absorption
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Solution Overview
Problem
Existing building materials, such as chipboard, are not environmentally friendly and lack sound-absorbing characteristics, necessitating a more sustainable and acoustically effective alternative.
Innovation Solution
A method involving willow tree chips, powder, or wood-dust mixed with a bio-resin binder, pressed into a composite element without additional layers, optionally with holes for enhanced sound absorption, and finished with a treatment like polishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional chipboard is used, then structural strength is achieved, but environmental friendliness deteriorates
Solution Approach 1:
The patent changes the material parameter from traditional wood chips to willow tree chips, powder, or wood-dust. Willow trees grow rapidly and can be harvested sustainably, improving environmental friendliness while maintaining structural properties through controlled processing and binder selection.
Solution Approach 2:
The patent creates a composite material by combining willow tree chips/powder/dust with a binder. This composite structure maintains structural strength while using sustainable willow material, resolving the contradiction between environmental friendliness and structural reliability.
2Object-affected harmful factors
If traditional chipboard is used, then manufacturing simplicity is maintained, but sound-absorbing characteristics deteriorate
Solution Approach 1:
The patent utilizes the porous structure of willow tree chips, powder, and wood-dust to create sound-absorbing composite elements. The natural porosity of the willow material provides sound absorption capabilities without requiring complex additional structures or layers.
3Stability of the object's composition
If homogeneous mixture is achieved, then material uniformity is improved, but mixing time increases
Solution Approach 1:
The patent changes the physical state parameter of willow tree material to chips, powder, or wood-dust forms. These processed forms have more uniform particle sizes and shapes that facilitate faster and more homogeneous mixing compared to raw wood pieces, reducing mixing time while maintaining composition uniformity.
4Quantity of substance
If willow tree chips with wide size distribution are used, then packing density is improved, but mechanical properties deteriorate
Solution Approach 1:
The patent applies local quality by using a binder to bind willow tree chips, powder, or wood-dust together. The binder provides the necessary mechanical strength at the interfaces between particles, allowing the use of wide size distribution for high packing density while maintaining overall structural integrity through localized bonding.
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 a composite element that is environmentally friendly, reduces CO2 emissions, and provides sound-absorbing properties throughout its thickness, with improved fire resistance and mechanical properties.
Implementation Method 1
mixing the willow tree with a binder, such as a bio-resin
Implementation Method 2
The step of allowing the composite element to solidify may comprise applying cooling, such as by a flow of cooling air, in order to speed-up the solidification
Implementation Method 3
Within this time period, willow tree is considered to be the most COz-absorbing tree grown. The use of this tree for composite elements as according to the present invention will therefore limit the amount of CO 2 emitted into the atmosphere
Data Source
Figure 1
Figure 2~3
Figure 4A~4C
AI summary
The invention relates to a method of manufacturing a composite element (1) comprising willow tree (2). The method comprises providing willow tree in the form of chips, powder, and/or wood-dust (3) which is mixed with a binder (5), such as a bio-resin, and preferably a release agent (6) in a mixer (4). When a homogeneous or substantially homogeneous mixture has been obtained, it is removed from the mixer and arranged in a press (11). The mixture is pressed into a shaped composite element which is allowed to solidity. The invention further relates to a composite element which may have a bowl-shaped overall cross-sectional shape, or which may be a floor panel, ceiling panel, wall panel, furniture panel, and piece of furniture. It also relates to an acoustic element comprising an acoustic batt (14) on which a row or array of composite elements have been arranged with a distance between neighbouring composite elements.