Wood Panel Densification via Hot Pressing and Carbonization
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Solution Overview
Problem
Existing methods for manufacturing artificial wood products, such as compressed wood, face issues like low density, surface hardness, poor corrosion resistance, dimensional instability, and high energy consumption, leading to low yield and susceptibility to cracking and distortion.
Innovation Solution
A manufacturing method involving wood preparation, drying, polishing, hot pressing, pre-carbonization, and carbonization under controlled temperature and pressure conditions, without the use of chemical agents, to enhance the physical and chemical properties of the wood, resulting in improved density, surface hardness, and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If water soaking is used to prepare wood surface before compression, then wood surface becomes soft and pliable, but wood surface contains large amount of water that causes rapid vaporization and internal stress leading to cracking and rebound
Solution Approach 1:
The patent replaces the chemical/water-based softening method with a mechanical compression method. Wood is compressed directly at elevated temperatures (100-200°C) without water soaking, using mechanical pressure to densify the wood structure and achieve the desired dimensional stability and surface hardness.
Solution Approach 2:
The patent changes the processing parameters by eliminating water soaking and instead using controlled temperature (100-200°C) and pressure conditions during compression. This parameter change prevents water-related internal stress while achieving wood densification and stability.
2Stability of the object's composition
If chemical agents are used to process compressed wood to prevent rebound, then wood dimensional stability improves, but environmental pollution increases and product service life decreases
Solution Approach 1:
The patent applies self-service by using the wood's own natural properties and physical processes to achieve dimensional stability. Through controlled compression and drying, the wood structure itself provides the necessary stability without requiring external chemical agents, thereby eliminating environmental pollution.
Solution Approach 2:
The patent converts the potential harm of water content in wood into a benefit by controlling the drying process. The gradual removal of moisture during controlled drying prevents cracking and rebound, transforming what could be a harmful factor (excessive moisture) into a beneficial process feature.
3Volume of stationary object
If traditional compression method is used on fast-growing wood, then wood density increases, but wood rebounds seriously especially under water conditions
Solution Approach 1:
The patent applies preliminary action by conducting compression at elevated temperatures (100-200°C) before final drying. This pre-compression at controlled temperature conditions allows the wood structure to set properly, preventing rebound when the wood is later exposed to water or humidity changes.
Solution Approach 2:
The patent changes the compression parameters by using elevated temperatures (100-200°C) during the compression process. This temperature parameter change modifies the wood's physical properties during compression, allowing for better densification and reduced rebound compared to room temperature compression.
4Productivity
If wood is dried quickly to reduce processing time, then productivity increases, but wood surface cracks and distorts due to uneven moisture removal
Solution Approach 1:
The patent applies periodic action by using staged drying with progressively increasing temperature. The drying process occurs in multiple stages with gradual temperature increases, allowing moisture to be removed systematically from the wood interior to surface, preventing cracking while maintaining efficient processing.
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 achieves high yield, excellent dimensional stability, corrosion resistance, and long service life for the wood products, with the ability to maintain quality and prevent cracking, while being environmentally friendly and suitable for various climates.
Implementation Method 1
hot pressing, pre-carbonization, and carbonization are performed on the panel blank material
Implementation Method 2
compression ratio of panel blank material is controlled at 10-30%, pressure at 20-50 MPa
Implementation Method 3
pre-carbonization step is to raise the hot pressing panels temperature to 170-180 °C and maintain the temperature and pressure for 30min-120min after compression; the said carbonization step is to raise the hot pressing panels temperature to 200-225 °C and maintain the temperature and pressure for 45min-120 min after pre-carbonization
Implementation Method 4
When water vaporizes, the wood surface would quickly contract to produce a large internal stress
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention relates to a method for manufacturing a wood section material, especially with respect to soft wood section material and its manufacturing method. It belongs to the wood processing field. This invention is achieved by the following technical plans: a type of wood section material manufacturing method includes the following steps: (1) wood preparation; (2) drying; (3) polishing; (4) hot pressing, which is to use two hot pressing boards with 140-200 °C to firmly press two surfaces of panel blank material; (5) pre-carbonization, which pre-carbonizes the panel blank material under 160 ∼ 200 °C; (6) carbonization, which carbonizes the panel blank material under 200 ∼ 225 °C; (7) cooling; (8) moisture content control. This invention is particularly suitable to make wooden floor boards and office furniture.