Wood-Plastic Composite Binder Formulation for Controlled Fiber Feeding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge lies in efficiently producing composite wood-plastic products with natural fibers and plastics, as existing methods face difficulties in achieving controlled fiber feeding due to the high volume/low mass nature of fibers, fiber bundling, and hygroscopic properties, leading to issues with fiber entanglements and water content, which affects mechanical properties and processing efficiency.
Innovation Solution
A process involving the application of a liquid or particulate binder formulation comprising a thermoset resin and a thermoplastic polymer to broken-down lignocellulosic or natural fibers, consolidating them into solid products that can be broken down into pellets or granules, allowing for easier dispersion and processing in plastics manufacturing while maintaining superior mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If low bulk density natural or wood fibres are introduced into extruders or injection moulders in a metered or measured way, then the desired fibre volume fractions in compositions can be achieved, but it is difficult to achieve controlled feeding directly into port holes or orifices of plastics processing machinery due to the high volume/low mass nature of fibres, lack of free flowing characteristics, and fibre bundling or entanglements
Solution Approach 1:
The patent applies preliminary action by pre-drying the fibres to reduce moisture content before feeding them into the plastics processing machinery. This pre-treatment step addresses the hygroscopic nature of fibres that would otherwise cause feeding difficulties and processing issues, enabling better control over fibre volume fractions in the final composite material.
2Ease of manufacture
If a high volume-low mass of fibre is used, then the cost and stiffness of the wood-plastic composite can be improved, but the fibres are hygroscopic and retain or reabsorb high levels of water which is undesired and requires substantial removal prior to plastic processing
Solution Approach 1:
The patent implements preliminary action by incorporating a drying step before the fibres are fed into the plastics processing equipment. This pre-drying operation removes excess moisture from the hygroscopic fibres, preventing water-related processing issues while allowing the use of high volume-low mass fibre content to achieve cost-effective and stiff composite materials.
Solution Approach 2:
The patent applies parameter changes by controlling the moisture content parameter of the fibres through drying operations. By adjusting and maintaining fibres at specific moisture levels before processing, the patent enables the use of high fibre content (for cost and stiffness benefits) while eliminating the harmful effects of excessive water retention during plastic processing.
3Strength
If traditional binder systems are used in wood-plastic composite production, then fibre consolidation can be achieved, but thermal degradation risks and cost issues arise
Solution Approach 1:
The patent applies parameter changes by modifying the binder formulation to use alternative materials with different thermal and economic properties. This substitution maintains adequate fibre consolidation strength while reducing both the cost of materials and the risk of thermal degradation during processing, compared to traditional binder systems.
Solution Approach 2:
The patent employs composite materials by using a binder system that combines multiple components with complementary properties. This composite binder approach achieves effective fibre consolidation while mitigating the thermal degradation and cost issues associated with single-component traditional binders.
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
This approach results in wood-plastic composite products with enhanced tensile strength and stiffness, facilitating their use as end products or feedstocks, and reduces the cost and thermal degradation risks associated with traditional binder systems, while providing fire retardancy and improved fiber length preservation.
Implementation Method 1
applying to loose or divided fibres or fibre bundles... a liquid or particulate binder formulation comprising a thermoset resin and a thermoplastic polymer
Data Source
AI summary
A process for producing a composite product comprising fibres of a lignocellulosic material or natural fibres and a plastics material utilises a liquid or particulate binder formulation comprising a thermoset resin and a thermoplastic polymer, monomer, or oligomer. A composite product is formed for use as or in forming a feedstock in plastics manufacture may be broken down under heat and mechanical shearing in a plastics extrusion machine to release the major fraction of the fibres, or the product may be useful as an intermediate product in other form or as an end product.