BRPI0901358A2 - process of obtaining homogeneous particle board using ligno-cellulosic materials mixed with adhesives or polyurethane resins - Google Patents

Abstract

Process of obtaining homogeneous particle boards using lignocellulosic materials, mixed with adhesives or polyurethane resins. The invention relates to obtaining homogeneous panels obtained through the composition of ligno-cellulosic residues from forest thinning, which are: residues from forests, branches and leaves, extraction and harvest residues, such as: husks (of rice, oats, fibers coconut, babassu, among others) and fruit seeds, as well as woodworking residues, furniture and wood industries, mixed with resins or adhesives, such as Urea formaldehyde, Resorcinol formaldehyde, Melanin formaldehyde; Bi and single component castor resin, Polyurethanes such as: Elastomers, Flexible and Rigid Foams.

Description

Process of obtaining Homogeneous Particle Panels using ligno-cellulosic materials, mixed with polyurethane oresine adhesives.

Field of the invention

The present invention relates to a process of obtaining homogeneous particle board (PHP) 1 produced with ligno-cellulosic waste, mixed with adhesives or polyurethane resins, resulting in plates that are applied in various sectors of construction and architecture, furniture sectors, as well as in the formation. of small objects for decoration and packaging.

Background of the invention

There are several patent documents in the literature describing the use of materials from forest thinning, woodworking tailings, furniture industries and grain-processing, sawmills, and the like, in order to create processes for obtaining products derived from these materials, aiming at sustainability and environmental balance. .

In this regard US2006234077-A1 discloses that the wood composite is bonded with an adhesive composition comprising urea-formaldehyde resin and an optionally saturated sulfate8-22C and sulfonate alkaline salt soybean protein according to the formula R2NC (= X ) NR2, or mixtures thereof, with the protein supplied in 1-50 wt.% Solids. The technology focus of this patent document is polymer based and the adhesive composition has formaldehyde with respect to a ratio of 0.6: 1 -1.6: 1. The protein is supplied in 5-40 wt.% Of adhesive solids. Urea - formaldehyde resin is synthesized in formaldehyde in relation to a urea rate of 1.5: 1 -3.2: 1. The modified soy protein chosen is the protein with optionally saturated salts of the alkali metal sulfate and sulfonate 8-22C, or with the composites according to the formula R2NC (= X) NR2.

US2006156954 discloses the use of the Ligno-cellulosic composite (I) comprising two ligno-cellulosic substrates bonded with an adhesive composition. The technology focus disclosed by this patent document comprises the following components: phenolic hydroxide or a thiol and a carboxyl, hydroxyl or amino, preferably an amino group, wherein the deamino group is attached to a covalent functional group of the soy protein carboxylic acid. They are an unsaturated amino which is hydrocarbon and hydroxyl, an amidine, an imine, an amino acid, a polyamide, where it must be an amino group. They are provided by the soy protein product form which has soy flour, soy protein concentrate or soy protein isolation.

They are usable in wood particle board, an OSB board, a wafer board, a wood fiber board, parallel glued lumber, glue laminated lumber, a plywood.

US2003227101-A1 demonstrates a method for forming wood particle board, oriented wood chip panel (OSB), medium density wood fiber board (MDF) and the like products. It involves the equipment adjustments that shape the panels to provide a product based on sampling obtained through the panel density. The method involves taking a sampling of the density through a mat forming the panel by adjusting the panel that forms the equipment to provide a desired product of density based on the sampling obtained from the density within the panel.

US 6,998,078 discloses a process for producing wood fiber panels by pressing wood fibers which have been pulped, boiled and ground at elevated temperature under pressure and steam in a refining unit. It is then transferred to a conveyor belt, dried and finally routed to the desired pressure at elevated temperature to produce plaques, this treatment being performed using a multicomponent, first component A folder containing functional groups that are nonreactive at elevated temperature and a second component B which contain the reactive functional groups at high temperature to component A, which is being added to the refining unit at a temperature of 120 ° C to 200 ° C before or during or shortly after the mincing step and front section of the mattress line. and component B which are being added at a lower temperature not more than 150 ° C at the end of the mattress or during or after drying the wood fibers.

US 5,286,545 discloses a laminated wood product (board), i.e. several wood veneers which are positioned to form the wood laminate with adhesive distributed therebetween and under heat and pressure permanently attach to the surfaces of the wood. blades. The adhesive used is a low melt polyester.

US2002074095 discloses a process for producing wood particle board. This paper presents a process for the production of particulate wood panels in which the emission of pollutants such as formaldehyde is reduced, with high quality in bonding with premature reactions of functional groups which are largely prevented. These and other objectives are achieved by the coating system of the present invention, which comprises a carboxyl containing copolymer, hydroxyl, or NH- functional monomers, and an epoxy adhesive, N-methylol, isocyanate, or ethylene carbonate functional that react with the functional groups of the copolymers.

US 5,538,676 discloses a process whereby the continuous production of particle board having a surface structure with a metal fabric belt on at least one side becomes possible with pressure application, which can be achieved in the manufacture of departmental panels through continuous operation presses. It also features cost-effective pressing in the production of particle board panels for a particle mattress comprising a large area of oriented wood particles which is possible for continuous operation, as well as providing a multitude of metallic fabric belt with different widths to produce particle panels. with different widths. Another object of this invention is to provide a blueprint for accomplishing said process with the above mentioned objectives.

US4,374,791, discloses a process for preparing particle boards which are prepared by treating the particles, e.g. wood chips, with an organic binder comprising polyisocyanate and an internal deliberation agent and then subjecting the treated particles to a forming process involving heat and pressure. The result of particle board generally performed with hot plates in pressing after forming due to the effects of internal deliberation agents, it was found that ease of release is enhanced by pre-coating the hot plate surfaces or plates that are in direct contact with the panels. particle size with a layer of polytetrafluoroethylene with optional layers containing an internal release agent.

US3,969,454, discloses a method for making panels of colored wood particles. Wood particles either make up the entire panel or form a surface layer only.

Some or all particles are colored with one or more different colors. On the other hand, the manufacturing method may be similar to conventional particle board manufacturing methods.

The panels can be sanded to produce a better finished standard surface. A wide variety of effects can be achieved depending on particle size and shape, choice of color, uniformity of individual particle coloration, surface treatment, etc.

DE3342235, reports a process for gluing wood departments. This document proposes that quality defects caused by moisture variation are eliminated, with cost savings. The goal is to provide a process in which the quantities of water added for a non-light water balance do not give homogeneity in moisture content. Additional process of blending for the homogenization of wood particles is avoided.

According to the invention, this objective is achieved by controlling the concentration of the paste that feeds the glue machine, depending on the moisture content of the wood particles, by adding water such that the constant and homogeneous moisture content results in the mixture of wood particles after bonding.

WO9910145 discloses a method for producing wood based panels. According to well-known methods, wood-based panels are made by glue-covering both sides on the plywood blades are scattered in bulk and arranged in a substantially parallel direction to a special device, and finally loaded into a support as a shape. forming a thick particle mattress to be pressed into a panel. The invention allows the steps of the mattress construction process to be improved, including reducing the amount of waste and even achieving regular cuts in the plywood sheets, facilitating glue application homogeneously while ensuring a finished parallel layer as required to form a particulate mattress without additional measures need to be taken. According to the invention, plywood blades continuously supplied in the direction of the fibers in a production line above the mattress formation process and, during working cycles, separated into blades by cuts performed parallel to the fibers, the blades are supplied without stop, covered with glue on both sides during the process and placed particles on the mattress, while the parallel layers of the sheets remain unchanged until the paths to the mattress are established.

GB1113810 demonstrates a process for manufacturing synthetic panel covering. This document describes that Fiberboard and particleboard are covered by the application of a polyurethane layer having in their composition free isocyanate groups for the panels which show moisture and are at least 37.80 ° C. The panels may include fibers, platelets or wood chips or other lignocellulosic materials, with or without synthetic resin, and this is formed with heat and pressure supply. The panels can be coated immediately after removal from the press or afterwards even when they are hot. Moisture curing of the polyurethane coating in its composition generally has free isocyanate groups and end positions in polymeric strands, and may be derived from the prepolymer preparation reaction with polyol such as polyether polyol, vegetable oils such as castor oil, or polyester with polyisocyanates, but the latter in excess. The composition may contain ultraviolet light absorbents, viscosity control agents, inorganic, free moisture pigments and may be applied as a spray, by spraying organic solvents at low temperatures, brushing, dipping, or a coating roller. The panels may be flat or shaped into various shapes, for example a beverage box.

JP2214602 discloses the manufacture of wood particles, to facilitate mold release after compression and to improve water resistance using adhesives composed of a combination of organic and polyolecific compounds or / and manona oil for bonding the wood flakes or fibers. The adhesives consist of organic compounds based on polyisocyanate and polyol (a) or / and manona oil (b), the main chains of molecules are formed only by carbon atoms of the molecule in which there are two or more hydroxyl groups, and the adhesives are employed so that the NCO% of the system is rendered to 1-10% as a filler for wood flakes or fibers. Organic polyisocyanate and polyol (a) and / or polio (b) are premixed before being placed with the chips or wood fibers or polyol (a) to / or polyol (b), is previously mixed with the chips or fibers and organic polyisocyanate and may be mixed by the mixing method. Organic polyisocyanate and polyol (a) and / or polyol (b) are diluted with a solvent and may also be sprayed as an aqueous solution.

Summary of the Invention

In the process of manufacturing the Homogeneous Particle Board (PHP) from ligno-cellulosic waste is specific users or adhesive, able to withstand the various conditions of use. Its main feature is the use of ligno-cellulosic waste from forest thinning, woodworking, furniture and grain processing industries, sawmills, and the like, in the manufacture of low to high density panels, which can be used for various purposes. . It can replace the traditional plates of the market, in the area of civil construction, architecture, furniture production, and small and medium decoration objects, among others. Therefore, adding waste value, generating sustainability and environmental balance, because in the production process there is no need for tree felling to obtain the raw material. This process avoids the use of these residues in coal production, thus sequestering carbon indefinitely, since the process is cyclic, ie the panels are recyclable dozens of times after their useful life. The adhesives or resins used by the The present invention are: Urea formaldehyde, Resorcinol formaldehyde, Melanin formaldehyde, Bic and single component castor resin, Polyurethanes such as: Elastomers, Flexible and Rigid Foams; among others.

Preferably castor bean-based polyurethane resin is used, where the resin content added should be between 9 and 15% of the total weight of the chips used.

Brief Description of the Figures

Figure 1 represents the set of the window retention process, individualizing the logical sequence of each step / process procedure.

Detailed Description of the Invention

The Homogeneous Particle Board (PHP) is produced with ligno-cellulosic waste, preferably using pine and eucalyptus wood residues. Therefore, generating sustainability, environmental balance and adding value to them.

PHP can be made from ligno-cellulosic residues from forest thinning, such as deforestation, branches and leaves. In addition, with residues of extractivism and harvest, such as: husks (rice, oats, coconut fibers, babassu, among others) and fruit seeds, etc. It can also be obtained from woodworking waste, furniture industries, logging, etc.

PHP may have densities ranging from 0.2g / cm3 to 1.3g / cm3, ie low to high density panels.In the PHP production process, Iigno-cellulosic waste from forest thinning or any kind of industries, when necessary, they pass through a chipper to obtain chips of shorter length, thus generating similar dimensions between them. The chips are then screened, where they are vibrated for 10 minutes from the 5.60 mm sieve to the 0.5 m aperture and may vary, depending on the cellulosic material being manufactured up to 0.18 micron sequentially. Table 1 shows an example of selection of wood particles retained fractions up to the chip with chips smaller than 1.18 mm. The selection is made by weighing the chips table 1.

Table 1 - Chip size

<table> table see original document page 11 </column> </row> <table>

After chip selection, the PHP manufacturing process follows these steps:

- Drying in oven with or without air circulation, where the moisture content of the ligno-cellulosic residue should be between 12 and 16%;

- Application of the matrix component - is the step of resin resins. At this stage we carry out the weighing and sizing of the caves. For homogeneous mixtures, there will be only one mixer.

Adhesives or resins may be used such as: Urea formaldehyde, Resorcinol formaldehyde, Melanin formaldehyde; Single component castor resin, Polyurethanes such as: Elastomers, Soft and Rigid Foams; among others, where the contents of these resins should be between 7 and 20% in relation to the weight of the raw material (ligno-cellulosic residue) used. Preferably, castor-based polyurethane aresine is used, where the added content of destaresine should be between 9 and 17% relative to the total weight of the horses;

- Mattress Formation - consists of the distribution of the waste already stuck in a form on a metal plate, where there is no need to organize the direction of the chips or confection of layers in the process of formation of the mattress. Afterwards the particles will be pre-pressed and then forwarded to the press;

- Pressing - After pre-pressing, the mattresses are brought to a hot plate hydraulic press, which reaches a temperature of up to 250 ° C and provides a load of up to 90Kgf / cm2. Many factors influence the production of panels in the pressing process, namely: temperature, humidity, dead type, panel thickness, pressing time and applied load.

For panels produced with adhesives or resins such as: Ureaformaldehyde, Resorcinol formaldehyde, Melanin formaldehyde; Resinade castor and two-component castor, Polyurethanes such as:

Elastomers, Flexible and Rigid Foams; the temperature should be between 90 ° C and 170 ° C, humidity between 12% and 18%, panel thickness between 0.5 mm and 20 mm, for a pressing period between 2 min and 15 min, with a load applied between 40 daN / cm2 and 51 daN / cm 2. For panels produced with castor resin, the temperature should be between 90 ° C and 100 ° C, humidity of the lignocellulosic residue should be between 12% and 16%, panel thickness between 0.5 mm and 16 mm, for a pressing period between 6 min and 15 min, with a load applied between 40 daN / cm2 and 51 daN / cm2 - Finishing - After leaving the press, the plates are stacked for an average period of 65 to 80 hours for daresine or adhesive curing, where to panels made of castor resin, a period of 72 hours is used. The product should, after the final cure, be square and sanded.

Physical and mechanical tests are based on ASTM D 1037/1996 and ABNT 14810-3 / 2002 normative documents.

Thickness (I), water absorption (A), density (p), perpendicular to tensile strength (RTP), and modulus of resistance (MOR) and deelasticity (MOE) values were determined in the static flexion test. according to ABNT 14.810-3 / 2002 and ASTM D1037 / 1996 normative documents.

The average results of the swelling, water absorption and panel density tests are described in Table 1.

Table 1 - Average results of swelling and absorption tests

<table> table see original document page 13 </column> </row> <table>

Table 2 presents the mean values of the modulus of resistance (MOR), modulus of elasticity (MOE) in static flexion and tensile strength perpendicular to the faces (RTP). Table 2 - MOR, MOE and RTP average results. <table> table see original document page 13 </column> </row> <table> <table> table see original document page 14 </column> </row> <table>

It is noteworthy that the results of physical and mechanical properties may vary according to the reduction or increase of panel density.

According to the mechanical physical results and variation of density and thickness, PHP can be applied in various sectors of construction and architecture: coatings, ceilings, partitions, etc. It can also be used in furniture sectors: tables, shelves, chairs, cabinets, etc. It can still be used in small objects for decoration, packaging, etc.

Advantages of the invention

One of the advantages of the manufacture of panels with the technique of homogeneous particles, using any type of Iigno-cellulosic residue from forest thinning, woodworking, furniture and grain processing industries, sawmills, and the like, thus reducing the manufacturing of slabs produced from the clearing of planted forests. Therefore, adding residual value, generating sustainability and environmental balance.

The panel produced by the homogeneous particle process bears no resemblance to the manufacturing process developed with the inventions described in the prior art.

Another factor that differentiates the homogeneous particle board is the raw material origin. In this study, waste is used from any activity that generates Iigno-cellulosic waste, so there is no need to cut down trees specifically for the purpose of producing slabs. preserving the environment. In the prior art, it is described, the manufacture of laminated wood sheets, OSB1 sheets with interlaced fibers, the temperature for the production of the sheets is well higher, the use of different types of resin and bedding.

In addition, there is no formaldehyde emanation or loss of resistance under moisture action.

Bibliographic references:

BRAZILIAN ASSOCIATION OF TECHNICAL STANDARDS (2002) .NBR 14810-3 - Chipboard. Rio de Janeiro.

American Society for Testing and Materials (1996). ASTM D1037 - Standard test methods for evaluating properties of wood-based fiber and particle board materials.Philadelphia. P. 136-165.

Claims (15)

1. - Process for obtaining homogeneous particle boards using ligno-cellulosic materials, mixed with polyurethane oresine adhesives, characterized by being obtained through the composition of ligno-cellulosic residues from forest thinning, namely: forest residues, branches and leaves, extractive residues and harvest, such as: husks (rice, oats, decoc fibers, babassu, among others) and fruit seeds, as well as woodworking, furniture and timber industries, mixed with resins or adhesives such as Urea formaldehyde, Resorcinol formaldehyde, Melanin formaldehyde; Single component castor resin, Polyurethanes such as: Elastomers, Soft and Rigid Foams. 2. A process for obtaining homogeneous particle board using ligno-cellulosic materials mixed with polyurethane oresine adhesives according to claim 1, characterized in that it is preferably produced from pine and eucalyptus wood residues. Process for obtaining homogeneous particle board using ligno-cellulosic materials mixed with polyurethane oresine adhesives according to claim 1, characterized in that the ligno-cellulosic residues pass through a chip to obtain shorter chips, generating similar dimensions. between them. Process for obtaining homogeneous particle board using ligno-cellulosic materials mixed with polyurethane oresine adhesives according to claims 1, 2 and 3, characterized in that the chips are selected by sieves, where they are vibrated for 10 minutes from from the sieve opening 5.60mm to the opening 0.5mm and may also vary, depending on the material cellulosic in manufacturing up to 0.18 micronsequential. Process for obtaining homogeneous particle board using ligno-cellulosic materials mixed with polyurethane oresine adhesives according to claims 1, 2, 3 and 4, characterized by drying the chips in an oven with or without air circulation, where the Moisture content of the ligno-cellulosic residue must be between 12 and 16%. 6. Process for obtaining homogeneous particle board using ligno-cellulosic materials mixed with polyurethane oresine adhesives according to claims 1, 2, 3, 4 and 5, characterized in that the particle resins use a mixer and adhesives or resins may be used. such as: Urea formaldehyde, Resorcinol formaldehyde, Melanin formaldehyde; Single component castor resin, Polyurethanes such as: Elastomers, Soft and Rigid Foams. 7. A process for obtaining homogeneous particle board using lignocellulosic materials mixed with polyurethane oresine adhesives according to claim 6, wherein the contents of such resins must be between 7 and 20% by weight of the raw material. raw material (lignocellulosic residue) used. 8. Process for obtaining homogeneous particle board using ligno-cellulosic materials mixed with polyurethane oresine adhesives according to claim 6, characterized in that the castor-based polyurethane resin is used, the added content of this resin must be between 9 and 17% in relation to the total chip weight. 9. A process for obtaining homogeneous particle board using lignocellulosic materials mixed with polyurethane oresine adhesives according to claims 1, 2, 3, 4, 5 and-6, characterized by the distribution of the residues already bound in a form over a metal plate, where there is no need to organize the direction of the chips or making layers in the process of forming the mattress. Process for obtaining homogeneous particle board using ligno-cellulosic materials mixed with polyurethane oresine adhesives according to claim 9, characterized in that the mattresses are fed to a hot plate hydraulic press, which reaches a temperature of up to 250 ° C and , which provides a load of up to 90 kgf / cm2. 11.- Process for obtaining homogeneous particle board using ligno-cellulosic materials mixed with polyurethane oresine adhesives according to claims 1 to 10, characterized in that they are produced at a temperature between 90 ° C and-170 ° C, humidity between 12% to 18%, panel thickness between 0.5 m and 20 mm, for a pressing period between 2 min and 15 min, with an applied load between 40 daN / cm2 and 51 daN / cm2. Process for obtaining homogeneous particle board using ligno-cellulosic materials mixed with polyurethane oresine adhesives according to claims 1 to 11, characterized in that the panels produced with castor resin are produced at a temperature between 90 ° C and 100% ligno-cellulosic residue should be between 12% and 16%, panel thickness between 0.5 mm and 16 mm, for a pressing period between 6 min and 15 min, with an applied load between 40 daN / cm2 and 51daN / cm2 Process for obtaining homogeneous particle board using ligno-cellulosic materials mixed with polyurethane oresine adhesives according to claims 1 to 12, characterized in that the sheets obtained are stacked for an average period of 65 to 80 hours for resin curing. or sticker. Process for obtaining homogeneous particle board using ligno-cellulosic materials mixed with polyurethane oresine adhesives according to claims 1 to 13, characterized in that the sheets obtained with castor resin are stacked for a period of 72 hours for curing. resin or adhesive. Homogeneous particle board using lignocellulosic materials, mixed with adhesives or polyurethane resins according to claim 1, characterized in that they have densities ranging from 0.2 g / cm3 to 1.3 g / cm3.