EP1914052B1 - Lightweight wooden material - Google Patents

Lightweight wooden material Download PDF

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Publication number
EP1914052B1
EP1914052B1 EP06122557.9A EP06122557A EP1914052B1 EP 1914052 B1 EP1914052 B1 EP 1914052B1 EP 06122557 A EP06122557 A EP 06122557A EP 1914052 B1 EP1914052 B1 EP 1914052B1
Authority
EP
European Patent Office
Prior art keywords
wood
base material
filler
density
weight
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP06122557.9A
Other languages
German (de)
French (fr)
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EP1914052A1 (en
Inventor
Lionel Gehringer
Stephan WEINKÖTZ
Günter Scherr
Frank Braun
Maxim Peretolchin
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BASF SE
Original Assignee
BASF SE
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Application filed by BASF SE filed Critical BASF SE
Priority to PL06122557T priority Critical patent/PL1914052T3/en
Priority to ES06122557.9T priority patent/ES2641263T3/en
Priority to EP06122557.9A priority patent/EP1914052B1/en
Priority to DE200620020503 priority patent/DE202006020503U1/en
Priority to PT61225579T priority patent/PT1914052T/en
Priority to BRPI0717434-9A2A priority patent/BRPI0717434A2/en
Priority to UAA200904960A priority patent/UA96612C2/en
Priority to PT78215308T priority patent/PT2083974T/en
Priority to PT07821531T priority patent/PT2083975E/en
Priority to EP20070821531 priority patent/EP2083975B1/en
Priority to AU2007312218A priority patent/AU2007312218B2/en
Priority to AT07821531T priority patent/ATE493247T1/en
Priority to CN200780042908.7A priority patent/CN101541488B/en
Priority to EP20110152229 priority patent/EP2319670A1/en
Priority to ES07821531T priority patent/ES2357574T3/en
Priority to US12/446,248 priority patent/US9089991B2/en
Priority to CN2007800428544A priority patent/CN101553348B/en
Priority to NZ576290A priority patent/NZ576290A/en
Priority to PL07821530T priority patent/PL2083974T3/en
Priority to EP07821530.8A priority patent/EP2083974B1/en
Priority to NZ576323A priority patent/NZ576323A/en
Priority to EA200900551A priority patent/EA013666B1/en
Priority to CA 2666447 priority patent/CA2666447A1/en
Priority to PCT/EP2007/061167 priority patent/WO2008046892A2/en
Priority to US12/446,245 priority patent/US8304069B2/en
Priority to EA200900550A priority patent/EA013665B1/en
Priority to BRPI0717436-5A2A priority patent/BRPI0717436A2/en
Priority to CA 2666454 priority patent/CA2666454A1/en
Priority to JP2009532808A priority patent/JP5300728B2/en
Priority to AU2007312220A priority patent/AU2007312220B2/en
Priority to UAA200904962A priority patent/UA94123C2/en
Priority to EP07821532A priority patent/EP2083976A2/en
Priority to PCT/EP2007/061165 priority patent/WO2008046890A2/en
Priority to MYPI20091585A priority patent/MY148865A/en
Priority to JP2009532809A priority patent/JP5150638B2/en
Priority to PCT/EP2007/061166 priority patent/WO2008046891A1/en
Priority to MYPI20091588A priority patent/MY148871A/en
Priority to ES07821530.8T priority patent/ES2622883T3/en
Priority to PL07821531T priority patent/PL2083975T3/en
Priority to DE200750006137 priority patent/DE502007006137D1/en
Publication of EP1914052A1 publication Critical patent/EP1914052A1/en
Priority to NO20091522A priority patent/NO20091522L/en
Priority to NO20091523A priority patent/NO20091523L/en
Priority to NO20091516A priority patent/NO20091516L/en
Application granted granted Critical
Publication of EP1914052B1 publication Critical patent/EP1914052B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/005—Manufacture of substantially flat articles, e.g. boards, from particles or fibres and foam
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249971—Preformed hollow element-containing
    • Y10T428/249972—Resin or rubber element
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/253—Cellulosic [e.g., wood, paper, cork, rayon, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/254—Polymeric or resinous material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
    • Y10T428/2991—Coated
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/3188—Next to cellulosic
    • Y10T428/31895—Paper or wood
    • Y10T428/31899—Addition polymer of hydrocarbon[s] only
    • Y10T428/31902—Monoethylenically unsaturated
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31975—Of cellulosic next to another carbohydrate
    • Y10T428/31978—Cellulosic next to another cellulosic
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31975—Of cellulosic next to another carbohydrate
    • Y10T428/31978—Cellulosic next to another cellulosic
    • Y10T428/31982—Wood or paper
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31989—Of wood

Definitions

  • the present invention relates to light wood materials containing 30 to 92.5 wt .-%, based on the wood material, wood particles, wherein the wood particles have a mean density of 0.4 to 0.85 g / cm 3 , 2.5 to 20 wt .-%, based on the wood material, polystyrene and / or styrene copolymer as filler, wherein the filler has a bulk density of 30 to 100 kg / m 3 , and 5 to 50 wt .-%, based on the wood material, binder, wherein the average density of the light wood material is less than or equal to 600 kg / m 3 .
  • Wood-based panels are a cost-effective and resource-saving alternative to solid wood and have gained great importance in particular in furniture construction, laminate flooring and as building materials.
  • Starting materials serve wood particles of different strengths, eg. As wood chips or wood fibers from different woods.
  • wood particles are usually pressed with natural and / or synthetic binders and optionally with the addition of further additives to plate or strand-shaped wood materials.
  • chipboard comes mainly used in the manufacture of doors as an inner layer.
  • a disadvantage of these materials is the too low screw extraction resistance, the difficulty attaching fittings and the difficulties in edging.
  • a light wood material according to the preamble of claim 1 is disclosed, in particular lightweight and pressure-resistant molding materials are described, which consist of wood chips or fibers, a binder and serving as a filler porous plastic.
  • the wood chips or fibers are mixed with binders and foamable or partially foamable plastics, and the resulting mixture is compressed at elevated temperature.
  • binders all conventional binders suitable for the gluing of wood, such as urea-formaldehyde resins, are useful.
  • Suitable fillers are foamable or already foamed plastic particles, preferably expandable thermoplastics such as styrene polymers.
  • the particle size of the plastics used is generally in prefoamed plastics 0.6 to 10 mm.
  • the plastics are used in an amount of 0.5 to 5 weight percent, based on the wood chips.
  • the plates described in the examples have a thickness of 18 to 21 mm, a density of 220 kg / m 3 to 430 kg / m 3 and an average bending strength of 3.6 N / mm 2 to 17.7 N / mm 2 on.
  • the transverse tensile strengths are not specified in the examples.
  • WO 02/38676 describes a process for the preparation of light products, in which 5 to 40 wt .-% foamable or already foamed polystyrene having a particle size of less than 1 mm, 60 to 95 wt .-% lignocellulosic material and binder mixed and at elevated temperature and elevated pressure be pressed into the finished product, wherein the polystyrene melts and on the one hand impregnates the lignocellulosic material and on the other hand by the migration to the surface of the product forms a hard, water-resistant skin.
  • urea-formaldehyde resin or melamine-formaldehyde resin may be used as the binder.
  • the example describes a product with a thickness of 4.5 mm and a density of 1200 kg / m 3 .
  • US 2005/0019548 describes lightweight OSB boards using low density fillers.
  • binder polymeric binders such as 4,4-diphenylmethane diisocyanate resin are described.
  • the fillers described are glass, ceramics, perlite or polymeric materials.
  • the polymeric material is used in an amount of 0.8 to 20 wt .-% based on the OSB board.
  • the polymeric material used in the examples is the material Dualite, which consists of polypropylene, polyvinylidene chloride or polyacrylonitrile. A weight reduction of 5% is described.
  • OSB boards having a density of 607 to 677 kg / m 3 and a transverse tensile strength of 0.31 to 0.59 N / mm 2 are described.
  • US 2003/24443 discloses a material consisting of wood chips, binders and fillers. Fillers include polymers based on styrene. The volume ratio between the wood chips and the binder is advantageously 1: 1. There are also described prior art plates in which the volume ratio of binder to wood shavings is 90:10. These prior art plates have a density of 948 kg / m 3 . As binders among other thermosetting resins are described. In the examples according to the invention plates with a volume ratio of binder to wood chips of 45:55 are described which have a density of 887 kg / m 3 .
  • JP 06031708 describes light wood materials, wherein for the middle layer of a three-layer chipboard, a mixture of 100 parts by weight of wood particles and 5 to 30 parts by weight of particles of synthetic resin foam are used, said resin particles having a specific gravity of not more than 0.3 g / cm 3 and have a compressive strength of at least 30 kg / cm 2 . Further, it is described that the specific gravity of the wood particles should not exceed 0.5 g / cm 3 .
  • a mechanical strength of the produced wood materials of 4.7 to 4.9 kg / cm 3 is achieved using wood particles from the Japanese cedar with a density of 0.35 g / cm 3 . Using Lauan and Kapur wood particles with an average density of 0.6 g / cm 3 , only a mechanical strength of the produced wood materials of 3.7 kg / cm 3 could be achieved.
  • the disadvantage of the prior art is summarized in that on the one hand, the described light (wood) materials for furniture manufacturing too low mechanical strength, such as too low a screw pull-out resistance, have. On the other hand, the wood materials described in the prior art still have a high density of over 600 kg / m 3 . Furthermore, in the prior art for the production of lightweight wood-based materials, woods with an unusually light density of less than 0.5 g / cm 3 are employed for the European market.
  • Too low mechanical strength for example, lead to breaking or cracking of the components. Furthermore, these components tend during drilling or sawing to additional flaking of further wood material. Fastening hardware is difficult with these materials.
  • the object of the present invention was therefore to show light wood materials, which in comparison to the commercial wood materials by 5 bis 40% lower density with the same good mechanical strength.
  • the mechanical strength can be determined, for example, by measuring the transverse tensile strength.
  • these lightweight wood-based materials should be manufacturable using native, European woods. Consequently, the lightweight wood-based materials using heavy woods should have comparable low densities and comparable high mechanical strengths as the wood-based materials according to JP 06031708 made using light woods. Furthermore, the swelling and water absorption of the light wood materials should not be affected by the reduced density.
  • the object was achieved by the features of claim 1.
  • the weight of the binder refers to the solids content of the binder.
  • the average density of the wood particles refers to a wood moisture content of 12%.
  • the average density of the wood particles refers to an average density over all wood particles used.
  • the wood-base materials according to the invention have an average density of 200 to 600 kg / m 3 , preferably 200 to 575 kg / m 3 , particularly preferably 250 to 550 kg / m 3 , in particular 300 to 500 kg / m 3 .
  • the transverse tensile strength of the wood-base materials according to the invention is greater than 0.4 N / mm 2 , more preferably greater than 0.5 and in particular greater than 0.6 N / mm 2 .
  • the determination of the transverse tensile strength is in accordance with EN 319.
  • Wood-based materials are all materials which are made of wood veneers with an average density of 0.4 to 0.85 g / cm 3 , such as veneer sheets or plywood sheets, of wood chips with a mean density of 0.4 to 0.85 g / cm 3 produced wood materials, such as chipboard or OSB boards, and wood fiber materials such as LDF, MDF and HDF boards. Particleboard and fiberboard, in particular chipboard, are preferred.
  • the average density of the wood particles is advantageously 0.4 to 0.8 g / cm 3 , preferably 0.4 to 0.75 g / cm 3 , in particular 0.4 to 0.6 g / cm 3 .
  • spruce for example, spruce, beech, pine, larch or fir wood is used, preferably spruce and / or beech wood, in particular spruce wood.
  • the filler polystyrene and / or styrene copolymer can be prepared by all polymerization processes known to those skilled in the art [see, for example, US Pat. B. Ullmann's Encyclopedia, Sixth Edition, 2000 Electronic Release ]. For example, the preparation is carried out in a conventional manner by suspension polymerization or by extrusion.
  • styrene In the suspension polymerization, styrene, optionally with the addition of further comonomers in aqueous suspension, is polymerized in the presence of a customary suspension stabilizer by means of free-radical-forming catalysts.
  • the blowing agent and, if appropriate, further additives may be introduced during the polymerization or may be added to the batch in the course of the polymerization or after the end of the polymerization.
  • the resulting bead-shaped optionally expandable styrene polymers are separated from the aqueous phase after the end of the polymerization, washed, dried and sieved.
  • the blowing agent is mixed for example via an extruder in the polymer, conveyed through a nozzle plate and granulated into particles or strands.
  • the filler polystyrene or styrene copolymer is particularly preferably expandable.
  • blowing agents are all blowing agents known to those skilled in the art, for example C 3 to C 6 hydrocarbons, such as propane, n-butane, isobutane, n-pentane, isopentane, neopentane and / or hexane, alcohols, ketones, ethers or halogenated hydrocarbons , Preferably, a commercially available pentane isomer mixture is used.
  • the styrenic polymers may contain additives, nucleating agents, plasticizers, flame retardants, soluble and insoluble inorganic and / or organic dyes and pigments, e.g. IR absorber, such as carbon black, graphite or aluminum powder, are added together or spatially separated as additives.
  • additives e.g. IR absorber, such as carbon black, graphite or aluminum powder, are added together or spatially separated as additives.
  • styrene copolymers these styrene copolymers advantageously have at least 50% by weight, preferably at least 80% by weight, of copolymerized polystyrene.
  • comonomers come z. B. ⁇ -methylstyrene, ring-halogenated styrenes, acrylonitrile, esters of acrylic or methacrylic acid of Alcohols having 1 to 8 carbon atoms, N-vinylcarbazole, maleic acid (anhydride), (meth) acrylamides and / or vinyl acetate into consideration.
  • the polystyrene and / or styrene copolymer may contain in copolymerized form a small amount of a chain splitter, i. a compound having more than one, preferably two, double bonds, such as divinylbenzene, butadiene and / or butanediol diacrylate.
  • the branching agent is generally used in amounts of from 0.005 to 0.05 mol%, based on styrene.
  • styrene (co) polymers having molecular weights and molecular weight distributions as described in US Pat EP-B 106 129 and in DE-A 39 21 148 are described. Preference is given to using styrene (co) polymers having a molecular weight in the range from 190,000 to 400,000 g / mol.
  • Mixtures of different styrene (co) polymers can also be used.
  • styrene polymers to glassy polystyrene (GPPS), toughened polystyrene (HIPS), anionically polymerized polystyrene or toughened polystyrene (A-IPS), styrene- ⁇ -methylstyrene copolymers, acrylonitrile-butadiene-styrene polymers (ABS), styrene-acrylonitrile (SAN), Acrylonitrile-styrene-acrylic ester (ASA), methyl acrylate-butadiene-styrene (MBS), methyl methacrylate-acrylonitrile-butadiene-styrene (MABS) polymers or mixtures thereof or used with polyphenylene ether (PPE).
  • GPPS glassy polystyrene
  • HIPS toughened polystyrene
  • A-IPS anionically polymerized polystyrene or toughened polystyrene
  • polystyrene Styropor®, Neopor® and / or Peripor® from BASF Aktiengesellschaft is particularly preferably used.
  • Pre-expanded polystyrene and / or styrene copolymers are advantageously used.
  • the prefoamed polystyrene can be prepared by all methods known to the person skilled in the art (for example DE 845264 ).
  • the expandable styrene polymers are expanded in a known manner by heating to temperatures above their softening point, for example with hot air or preferably steam.
  • the prefoamed polystyrene or styrene copolymer is used in the form of spheres or beads having an average diameter of advantageously 0.25 to 10 mm, preferably 0.5 to 5 mm, in particular 0.75 to 3 mm.
  • the prefoamed polystyrene or styrene copolymer spheres advantageously have a small surface area per volume, for example in the form of a spherical or elliptical particle.
  • the prefoamed polystyrene or styrene copolymer spheres are advantageously closed-celled.
  • the open cell density according to DIN-ISO 4590 is less than 30%.
  • antistatic agents the usual and common in the art substances can be used. Examples are N, N-bis (2-hydroxyethyl) -C 12 -C 18 -alkylamines, fatty acid diethanolamides, choline ester chlorides of fatty acids, C 12 -C 20 -alkyl sulfonates, ammonium salts.
  • Suitable ammonium salts contain on nitrogen in addition to alkyl groups 1 to 3 hydroxyl-containing organic radicals.
  • Suitable quaternary ammonium salts are, for example, those having on the nitrogen cation 1 to 3, preferably 2, identical or different alkyl radicals having 1 to 12, preferably 1 to 10 carbon atoms, and 1 to 3, preferably 2 identical or different hydroxyalkyl or hydroxyalkylpolyoxyalkylene Radicals bound with any anion, such as chloride, bromide, acetate, methyl sulfate or p-toluenesulfonate.
  • hydroxyalkyl and hydroxyalkyl-polyoxyalkylene radicals are those which are formed by oxyalkylation of a nitrogen-bonded hydrogen atom and are derived from 1 to 10 oxyalkylene radicals, in particular oxyethylene and oxypropylene radicals.
  • An antistatic agent which is particularly preferred is a quaternary ammonium salt or an alkali metal salt, in particular the sodium salt of a C 12 -C 20 alkanesulfonate, eg. B emulsifier K30 from Bayer AG, or mixtures thereof.
  • the antistatic agents can generally be added both as a pure substance and in the form of an aqueous solution.
  • the antistatic agent can be added in the process for the preparation of polystyrene or styrene copolymer analogously to the customary additives or applied after the preparation of the polystyrene particles as a coating.
  • the antistatic agent is advantageously used in an amount of 0.05 to 6 wt .-%, preferably 0.1 to 4 wt .-%, based on the polystyrene or styrene copolymer.
  • the filler polystyrene and / or styrene copolymer is advantageously present evenly distributed in the wood material according to the invention.
  • the filler balls are advantageously present after pressing to the wood material in an unmelted state. Optionally, however, it may come to a melting of the filler balls, which are located on the surface of the wood material.
  • binders it is possible to use all binders known to the person skilled in the art for the production of wood-based materials.
  • Formaldehyde-containing adhesives are advantageously used as binders, for example urea-formaldehyde resins or melamine-containing urea-formaldehyde resins. Preference is given to using urea-formaldehyde resins.
  • Kaurit® glue from BASF Aktiengesellschaft is used as the binder.
  • the solids content of the binder is usually from 25 to 100% by weight, in particular from 50 to 70% by weight.
  • the lightweight wood-base materials according to the invention advantageously contain 55 to 92.5% by weight, preferably 60 to 90% by weight, in particular 70 to 85% by weight, based on the wood material, of wood particles, the wood particles having an average density of 0, 4 to 0.85 g / cm 3 , preferably 0.4 to 0.75 g / cm 3 , in particular 0.4 to 0.6 g / cm 3 , preferably 5 to 15 wt .-%, preferably 8 to 12 Wt .-% based on the wood material, polystyrene and / or styrene copolymer filler, wherein the filler has a bulk density of 30 to 100 kg / m 3 , and preferably 5 to 25 wt .-%, in particular 5 to 15 wt .-% , based on the wood material, binder, wherein the average density of the light wood material is less than or equal to 600 kg / m 3 , preferably less than or equal to 575 kg / m
  • the thickness of the wood materials varies with the field of application and is usually in the range of 0.5 to 50 mm.
  • the transverse tensile strength of the lightweight wood-base materials according to the invention having a density of 200 to 650 kg / m 3 is advantageously greater than (0.002 ⁇ D - 0.55) N / mm 2 , preferably greater than (0.002 ⁇ D - 0.45) N / mm 2 , in particular greater than (0.0022 x D - 0.45) N / mm 2 .
  • the swelling values are advantageously 10% smaller, preferably 20% smaller, in particular 30% smaller than the swelling values of a plate of the same density without filler.
  • the present invention relates to a process for the production of lightweight wood-based materials, as defined in claim 1.
  • the wood particle cake is cold pre-sealed before pressing.
  • the pressing can be carried out by all methods known to the person skilled in the art.
  • the wood particle cake is pressed at a press temperature of 150 ° C to 230 ° C to the desired thickness.
  • the pressing time is normally 3 to 15 seconds per mm plate thickness.
  • the present invention relates to the use of the wood-based materials according to the invention for the production of furniture, of packaging materials, in house building or interior work.
  • the advantages of the present invention are the low density of the wood-based materials according to the invention with good mechanical stability. Furthermore, the inventive easily produce wood-based materials; There is no need to retrofit the existing plants for the production of wood-based materials according to the invention.
  • Foamable polystyrene was such.
  • EP 981 574 described prepared. The addition of an antistatic agent during or after production was omitted.
  • the polystyrene particles obtained according to Example A1 were treated with steam in a continuous prefoamer.
  • the bulk density of the prefoamed polystyrene beads was adjusted by varying the vapor pressure and the steaming time.
  • Extruded PS foam available from BASF as Styrodur® (bulk density about 30 kg / m 3 ) was ground in a Pallmann impact mill type PP to an average particle diameter of 0.2 to 2 mm.
  • the glued chips or fibers were cold precompressed in a 30x30 cm mold. It was then pressed in a hot press (pressing temperature 190 ° C, pressing time 210 s). The nominal thickness of the plate was 16 mm in each case.
  • the density was determined 24 hours after preparation according to EN 1058.
  • the determination of the transverse tensile strength is in accordance with EN 319.

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Abstract

Light, wood-containing material (I) with an average density of 200-600 kg/m 3>, comprises wood particles (a) (30-95 wt.%); fillers (b) (1-25 wt.%) with a bulk density of 10-150 kg/m 3>, from foamable plastic particles and plastic particles that are already foamed; binders (c) (0.1-50 wt.%); and optionally additives (d), where (b) contains foaming plastic particles (1-100 wt.%) gained by comminution from molds. Independent claims are included for: (1) a multilayer wood material, comprising at least three layers, where only middle layer or at least one part of the middle layer contains (I), and the external surface layer does not contain fillers; and (2) a preparation of (I) comprising mixing the components (a-d), and subsequently pressing under increased temperature and pressure.

Description

Die vorliegende Erfindung betrifft leichte Holzwerkstoffe enthaltend 30 bis 92,5 Gew.-%, bezogen auf den Holzwerkstoff, Holzpartikel, wobei die Holzpartikel eine mittlere Dichte von 0,4 bis 0,85 g/cm3 aufweisen, 2,5 bis 20 Gew.-%, bezogen auf den Holzwerkstoff, Polystyrol und/oder Styrolcopolymerisat als Füllstoff, wobei der Füllstoff eine Schüttdichte von 30 bis 100 kg/m3 aufweist, und 5 bis 50 Gew.-%, bezogen auf den Holzwerkstoff, Bindemittel, wobei die mittlere Dichte des leichten Holzwerkstoffs kleiner gleich 600 kg/m3 beträgt.The present invention relates to light wood materials containing 30 to 92.5 wt .-%, based on the wood material, wood particles, wherein the wood particles have a mean density of 0.4 to 0.85 g / cm 3 , 2.5 to 20 wt .-%, based on the wood material, polystyrene and / or styrene copolymer as filler, wherein the filler has a bulk density of 30 to 100 kg / m 3 , and 5 to 50 wt .-%, based on the wood material, binder, wherein the average density of the light wood material is less than or equal to 600 kg / m 3 .

Holzwerkstoffe sind eine kostengünstige und Ressourcen schonende Alternative zu Massivholz und haben große Bedeutung insbesondere im Möbelbau, bei Laminatfußboden und als Baumaterialien erlangt. Als Ausgangsstoffe dienen Holzpartikel unterschiedlicher Stärke, z. B. Holzspäne oder Holzfasern aus verschiedenen Hölzern. Solche Holzpartikel werden üblicherweise mit natürlichen und/oder synthetischen Bindemitteln und gegebenenfalls unter Zugabe weiterer Additive zu platten- oder strangförmigen Holzwerkstoffen verpresst.Wood-based panels are a cost-effective and resource-saving alternative to solid wood and have gained great importance in particular in furniture construction, laminate flooring and as building materials. As starting materials serve wood particles of different strengths, eg. As wood chips or wood fibers from different woods. Such wood particles are usually pressed with natural and / or synthetic binders and optionally with the addition of further additives to plate or strand-shaped wood materials.

Der industrielle Bedarf an leichten Holzwerkstoffen ist in den letzten Jahren stetig gestiegen, insbesondere seit Mitnahmemöbel an Beliebtheit gewonnen haben, d.h. das Barzahlen und Selbstabholen von Möbeln durch den Endkunden. Ferner bedingt der steigende Ölpreis, der zu einer fortwährenden Verteuerung von beispielsweise den Transportkosten führt, ein verstärktes Interesse an leichten Holzwerkstoffen.The industrial demand for lightweight wood-based materials has risen steadily in recent years, especially since pick-up furniture has gained in popularity, i. the cash payments and self-picking of furniture by the end customer. Furthermore, the rising price of oil, which leads to a constant increase in, for example, transport costs, has led to an increased interest in lightweight wood-based materials.

Zusammengefasst sind leichte Holzwerkstoffe aus den folgenden Gründen von großer Bedeutung:

  • Leichte Holzwerkstoffe führen zu einer einfacheren Handhabbarkeit der Produkte durch den Endkunden, beispielsweise beim Einpacken, Transportieren, Auspacken oder Aufbauen der Möbel. Leichte Holzwerkstoffe führen zu geringeren Transport- und Verpackungskosten, ferner können bei der Herstellung von leichten Holzwerkstoffen Materialkosten eingespart werden. Leichte Holzwerkstoffe können beispielsweise beim Einsatz in Transportmitteln zu einem geringeren Energieverbrauch dieser Transportmittel führen. Ferner können unter Verwendung von leichten Holzwerkstoffen beispielsweise materialaufwendige Dekorteile, wie derzeit in Mode gekommene dickere Arbeitsplatten und Wangen bei Küchen, kostengünstiger angeboten werden.
In summary, lightweight wood-based materials are of great importance for the following reasons:
  • Lightweight wood-based materials result in easier handling of the products by the end customer, for example when packing, transporting, unpacking or constructing the furniture. Light wood-based materials lead to lower transport and packaging costs, and material costs can be saved in the production of lightweight wood-based materials. Light wood-based panels can, for example, when used in means of transport lead to lower energy consumption of these means of transport. Further, using lightweight wood-based materials, for example, costly decorative parts such as thicker worktops and kitchen cheeks that are currently in vogue can be offered more cheaply.

Im Stand der Technik finden sich vielfältige Vorschläge, die Dichte der Holzwerkstoffe zu verringern.There are many proposals in the state of the art for reducing the density of wood-based materials.

Als leichte (Holz)Werkstoffe sind beispielsweise Röhrenspanplatten und Wabenplatten zu nennen. Durch ihre besonderen Eigenschaften kommen Röhrenspanplatten hauptsächlich bei der Herstellung von Türen als Innenlage zum Einsatz. Nachteilig bei diesen Werkstoffen ist der zu geringe Schraubenauszugswiderstand, das erschwerte Befestigen von Beschlägen und die Schwierigkeiten bei der Bekantung.As light (wood) materials, for example, tube chipboard and honeycomb panels are mentioned. Due to their special properties, chipboard comes mainly used in the manufacture of doors as an inner layer. A disadvantage of these materials is the too low screw extraction resistance, the difficulty attaching fittings and the difficulties in edging.

Ferner finden sich im Stand der Technik Vorschläge, die Dichte der Holzwerkstoffe durch Zusätze zum Leim oder zu den Holzpartikeln zu verringern.Furthermore, there are proposals in the prior art to reduce the density of the wood materials by adding glue or to the wood particles.

In CH 370229 wird ein leichter Holzwerkstoff, gemäß dem Oberbegriff des Anspruchs 1 offenbart, insbesondere werden leichte und gleichzeitig druckfeste Formpressstoffe beschrieben, die aus Holzspänen oder-fasern, einem Bindemittel und einem als Füllstoff dienenden porösen Kunststoff bestehen. Zur Herstellung der Formpressstoffe werden die Holzspäne oder -fasern mit Bindemittel und verschäumbaren oder teilweise verschäumbaren Kunststoffen gemischt, und das erhaltene Gemisch bei erhöhter Temperatur verpresst. Als Bindemittel sind alle für die Verleimung von Holz geeigneten üblichen Bindemittel, wie beispielsweise Harnstoff-Formaldehyd-Harze, brauchbar. Als Füllstoffe kommen verschäumbare oder bereits verschäumte Kunststoffteilchen, bevorzugt expandierbare Thermoplaste wie Styrolpolymerisate, in Frage. Die Teilchengröße der verwendeten Kunststoffe beträgt im allgemeinen bei vorgeschäumten Kunststoffen 0,6 bis 10 mm. Die Kunststoffe werden in einer Menge von 0,5 bis 5 Gewichtsprozent, bezogen auf die Holzspäne, verwendet. Die in den Beispielen beschriebenen Platten weisen bei einer Dicke von 18 bis 21 mm, eine Dichte von 220 kg/m3 bis 430 kg/m3 und eine mittlere Biegefestigkeit von 3,6 N/mm2 bis 17,7 N/mm2 auf. Die Querzugsfestigkeiten werden in den Beispielen nicht angegeben.In CH 370229 a light wood material, according to the preamble of claim 1 is disclosed, in particular lightweight and pressure-resistant molding materials are described, which consist of wood chips or fibers, a binder and serving as a filler porous plastic. To produce the molding materials, the wood chips or fibers are mixed with binders and foamable or partially foamable plastics, and the resulting mixture is compressed at elevated temperature. As binders, all conventional binders suitable for the gluing of wood, such as urea-formaldehyde resins, are useful. Suitable fillers are foamable or already foamed plastic particles, preferably expandable thermoplastics such as styrene polymers. The particle size of the plastics used is generally in prefoamed plastics 0.6 to 10 mm. The plastics are used in an amount of 0.5 to 5 weight percent, based on the wood chips. The plates described in the examples have a thickness of 18 to 21 mm, a density of 220 kg / m 3 to 430 kg / m 3 and an average bending strength of 3.6 N / mm 2 to 17.7 N / mm 2 on. The transverse tensile strengths are not specified in the examples.

WO 02/38676 beschreibt ein Verfahren zur Herstellung von leichten Produkten, in dem 5 bis 40 Gew.-% verschäumbares oder bereits verschäumtes Polystyrol mit einer Teilchengröße von kleiner 1 mm, 60 bis 95 Gew.-% lignocellulosehaltiges Material und Bindemittel vermischt und bei erhöhter Temperatur und erhöhtem Druck zu dem fertigen Produkt verpresst werden, wobei das Polystyrol schmilzt und zum einen das lignocellulosehaltige Material imprägniert und zum anderen durch die Migration zur Oberfläche des Produkts eine harte, wasserresistente Haut bildet. Als Bindemittel kann u.a. Harnstoff-Formaldehyd-Harz oder Melamin-Formaldehyd-Harz verwendet werden. Im Beispiel wird ein Produkt mit einer Dicke von 4,5 mm und einer Dichte von 1200 kg/m3 beschrieben.
US 2005/0019548 beschreibt leichte OSB-Platten unter Verwendung von Füllstoffen mit geringer Dichte. Als Bindemittel werden polymere Bindemittel, beispielsweise 4,4-Diphenyl-methan-diisocyanat-Harz beschrieben. Als Füllstoffe wird Glas, Keramik, Perlit oder polymeres Materialien beschrieben. Das polymere Material wird in einer Menge von 0,8 bis 20 Gew.-% bezogen auf die OSB-Platte eingesetzt. Als polymeres Material wird in den Beispielen das Material Dualite eingesetzt, das aus Polypropylen, Polyvinylidenchlorid oder Polyacrylnitril besteht. Es wird eine Gewichtsreduzierung von 5 % beschrieben. In den Beispielen werden OSB-Platten mit einer Dichte von 607 bis 677 kg/m3 und einer Querzugsfestigkeit von 0,31 bis 0,59 N/mm2 beschrieben. WO 02/38676 describes a process for the preparation of light products, in which 5 to 40 wt .-% foamable or already foamed polystyrene having a particle size of less than 1 mm, 60 to 95 wt .-% lignocellulosic material and binder mixed and at elevated temperature and elevated pressure be pressed into the finished product, wherein the polystyrene melts and on the one hand impregnates the lignocellulosic material and on the other hand by the migration to the surface of the product forms a hard, water-resistant skin. Among others, urea-formaldehyde resin or melamine-formaldehyde resin may be used as the binder. The example describes a product with a thickness of 4.5 mm and a density of 1200 kg / m 3 .
US 2005/0019548 describes lightweight OSB boards using low density fillers. As the binder, polymeric binders such as 4,4-diphenylmethane diisocyanate resin are described. The fillers described are glass, ceramics, perlite or polymeric materials. The polymeric material is used in an amount of 0.8 to 20 wt .-% based on the OSB board. The polymeric material used in the examples is the material Dualite, which consists of polypropylene, polyvinylidene chloride or polyacrylonitrile. A weight reduction of 5% is described. In the examples, OSB boards having a density of 607 to 677 kg / m 3 and a transverse tensile strength of 0.31 to 0.59 N / mm 2 are described.

US 2003/24443 offenbart ein Material, das aus Holzspänen, Bindemittel und Füllstoffen besteht. Als Füllstoffe werden unter anderem Polymere auf Basis von Styrol genannt. Das Volumenverhältnis zwischen den Holzspänen und dem Bindemittel beträgt vorteilhaft 1:1. Es werden ferner Platte aus dem Stand der Technik beschrieben, bei denen das Volumenverhältnis von Bindemittel zu Holzspänen 90:10 beträgt. Diese Platten aus dem Stand der Technik weisen eine Dichte von 948 kg/m3 auf. Als Bindemittel werden unter anderem duroplastische Harze beschrieben. In den erfindungsgemäßen Beispielen werden Platten mit einem Volumenverhältnis von Bindemittel zu Holzspänen von 45:55 beschrieben, die eine Dichte von 887 kg/m3 aufweisen. US 2003/24443 discloses a material consisting of wood chips, binders and fillers. Fillers include polymers based on styrene. The volume ratio between the wood chips and the binder is advantageously 1: 1. There are also described prior art plates in which the volume ratio of binder to wood shavings is 90:10. These prior art plates have a density of 948 kg / m 3 . As binders among other thermosetting resins are described. In the examples according to the invention plates with a volume ratio of binder to wood chips of 45:55 are described which have a density of 887 kg / m 3 .

JP 06031708 beschreibt leichte Holzwerkstoffe, wobei für die Mittelschicht einer Drei-Schichtspanplatte eine Mischung aus 100 Gewichtsteilen Holzpartikeln und 5 bis 30 Gewichtsteilen Partikeln aus synthetischem Harzschaum verwendet werden, wobei diese Harz-Partikel ein spezifisches Gewicht von nicht mehr als 0,3 g/cm3 und eine Druckfestigkeit von mindestens 30 kg/cm2 aufweisen. Ferner wird beschrieben, dass die spezifische Dichte der Holzpartikel einen Wert von 0,5 g/cm3 nicht überschreiten sollte.
In den Beispielen wird eine mechanische Festigkeit der hergestellten Holzwerkstoffe von 4,7 bis 4,9 kg/cm3 unter Verwendung von Holzpartikeln aus der japanischen Zeder mit einer Dichte von 0,35 g/cm3 erreicht. Unter Verwendung von Lauan- und Kapur-Holzpartikeln mit einer mittleren Dichte von 0,6 g/cm3 konnte lediglich eine mechanische Festigkeit der hergestellten Holzwerkstoffe von 3,7 kg/cm3 erreicht werden. JP 06031708 describes light wood materials, wherein for the middle layer of a three-layer chipboard, a mixture of 100 parts by weight of wood particles and 5 to 30 parts by weight of particles of synthetic resin foam are used, said resin particles having a specific gravity of not more than 0.3 g / cm 3 and have a compressive strength of at least 30 kg / cm 2 . Further, it is described that the specific gravity of the wood particles should not exceed 0.5 g / cm 3 .
In the examples, a mechanical strength of the produced wood materials of 4.7 to 4.9 kg / cm 3 is achieved using wood particles from the Japanese cedar with a density of 0.35 g / cm 3 . Using Lauan and Kapur wood particles with an average density of 0.6 g / cm 3 , only a mechanical strength of the produced wood materials of 3.7 kg / cm 3 could be achieved.

Der Nachteil des Stands der Technik besteht zusammengefasst darin, dass zum einen die beschriebenen leichten (Holz)Werkstoffe für die Möbelherstellung eine zu geringe mechanische Festigkeiten, wie beispielsweise einen zu geringen Schraubenauszugswiderstand, aufweisen. Zum anderen weisen die im Stand der Technik beschriebenen Holzwerkstoffe immer noch eine hohe Dichte von über 600 kg/m3 auf. Ferner werden im Stand der Technik zur Herstellung von leichten Holzwerkstoffen Hölzer mit einer für den europäischen Markt ungewöhnlich leichten Dichte von kleiner 0,5 g/cm3 eingesetzt.The disadvantage of the prior art is summarized in that on the one hand, the described light (wood) materials for furniture manufacturing too low mechanical strength, such as too low a screw pull-out resistance, have. On the other hand, the wood materials described in the prior art still have a high density of over 600 kg / m 3 . Furthermore, in the prior art for the production of lightweight wood-based materials, woods with an unusually light density of less than 0.5 g / cm 3 are employed for the European market.

Eine zu geringe mechanische Festigkeit kann beispielsweise zum Brechen oder Reißen der Bauelemente führen. Ferner neigen diese Bauelemente beim Bohren oder Sägen zum zusätzlichen Abplatzen von weiterem Holzmaterial. Bei diesen Werkstoffen ist das Befestigen von Beschlägen erschwert.Too low mechanical strength, for example, lead to breaking or cracking of the components. Furthermore, these components tend during drilling or sawing to additional flaking of further wood material. Fastening hardware is difficult with these materials.

Die Aufgabe der vorliegenden Erfindung bestand demnach darin, leichte Holzwerkstoffe aufzuzeigen, die eine im Vergleich zu den handelsüblichen Holzwerkstoffen um 5 bis 40 % geringere Dichte aufweisen bei gleichbleibenden guten mechanischen Festigkeiten. Die mechanische Festigkeit kann beispielsweise durch die Messung der Querzugsfestigkeit bestimmt werden. Ferner sollten diese leichten Holzwerkstoffe unter Verwendung von heimischen, europäischen Hölzern herstellbar sein. Folglich sollten die leichten Holzwerkstoffe unter Verwendung von schweren Hölzern vergleichbare niedrige Dichten und vergleichbare hohe mechanische Festigkeiten aufweisen wie die Holzwerkstoffe gemäß JP 06031708 , die unter Verwendung von leichten Hölzern hergestellt wurden. Ferner sollten der Quellwert und die Wasseraufnahme der leichten Holzwerkstoffe durch die verringerte Dichte nicht beeinträchtigt werden.The object of the present invention was therefore to show light wood materials, which in comparison to the commercial wood materials by 5 bis 40% lower density with the same good mechanical strength. The mechanical strength can be determined, for example, by measuring the transverse tensile strength. Furthermore, these lightweight wood-based materials should be manufacturable using native, European woods. Consequently, the lightweight wood-based materials using heavy woods should have comparable low densities and comparable high mechanical strengths as the wood-based materials according to JP 06031708 made using light woods. Furthermore, the swelling and water absorption of the light wood materials should not be affected by the reduced density.

Die Aufgabe wurde gelöst durch die Merkmale des Anspruchs 1. Die Gewichtsangabe des Bindemittels bezieht sich auf den Feststoffgehalt des Bindemittels. Die mittlere Dichte der Holzpartikel bezieht sich auf eine Holzfeuchte von 12 %. Ferner bezieht sich die mittlere Dichte der Holzpartikel auf eine gemittelte Dichte über alle eingesetzten Holzpartikel.
Vorteilhaft weisen die erfindungsgemäßen Holzwerkstoffe eine mittlere Dichte von 200 bis 600 kg/m3, bevorzugt 200 bis 575 kg/m3, besonders bevorzugt 250 bis 550 kg/m3, insbesondere 300 bis 500 kg/m3, auf.The object was achieved by the features of claim 1. The weight of the binder refers to the solids content of the binder. The average density of the wood particles refers to a wood moisture content of 12%. Furthermore, the average density of the wood particles refers to an average density over all wood particles used.
Advantageously, the wood-base materials according to the invention have an average density of 200 to 600 kg / m 3 , preferably 200 to 575 kg / m 3 , particularly preferably 250 to 550 kg / m 3 , in particular 300 to 500 kg / m 3 .

Die Querzugsfestigkeit der erfindungsgemäßen Holzwerkstoffe ist größer als 0,4 N/mm2, besonders bevorzugt größer als 0,5 und insbesondere größer als 0,6 N/mm2. Die Bestimmung der Querzugsfestigkeit erfolgt nach EN 319.
Als Holzwerkstoffe kommen alle Werkstoffe in Betracht, die aus Holzfurnieren mit einer mittleren Dichte von 0,4 bis 0,85 g/cm3 gefertigt sind wie beispielsweise Furnierplatten oder Sperrholzplatten, aus Holzspänen mit einer mittleren Dichte von 0,4 bis 0,85 g/cm3 hergestellte Holzwerkstoffe, beispielsweise Spanplatten oder OSB-Platten, sowie Holzfaserwerkstoffe wie LDF-, MDF- und HDF-Platten. Bevorzugt sind Spanplatten und Fasernplatten, insbesondere Spanplatten.The transverse tensile strength of the wood-base materials according to the invention is greater than 0.4 N / mm 2 , more preferably greater than 0.5 and in particular greater than 0.6 N / mm 2 . The determination of the transverse tensile strength is in accordance with EN 319.
Wood-based materials are all materials which are made of wood veneers with an average density of 0.4 to 0.85 g / cm 3 , such as veneer sheets or plywood sheets, of wood chips with a mean density of 0.4 to 0.85 g / cm 3 produced wood materials, such as chipboard or OSB boards, and wood fiber materials such as LDF, MDF and HDF boards. Particleboard and fiberboard, in particular chipboard, are preferred.

Die mittlere Dichte der Holzpartikel liegt vorteilhaft bei 0,4 bis 0,8 g/cm3, bevorzugt bei 0,4 bis 0,75 g/cm3, insbesondere bei 0,4 bis 0,6 g/cm3.The average density of the wood particles is advantageously 0.4 to 0.8 g / cm 3 , preferably 0.4 to 0.75 g / cm 3 , in particular 0.4 to 0.6 g / cm 3 .

Für die Herstellung der Holzpartikel wird beispielsweise Fichten-, Buchen-, Kiefern-, Lärchen-, oder Tannenholz verwendet, bevorzugt Fichten- und/oder Buchen-Holz, insbesondere Fichtenholz.For the production of the wood particles, for example, spruce, beech, pine, larch or fir wood is used, preferably spruce and / or beech wood, in particular spruce wood.

Der Füllstoff Polystyrol und/oder Styrolcopolymerisat kann nach allen den Fachmann bekannten Polymerisierungsverfahren hergestellt werden [siehe z. B. Ullmann's Encyclopedia, Sixth Edition, 2000 Electronic Release ]. Beispielsweise erfolgt die Herstellung in an sich bekannter Weise durch Suspensionspolymerisation oder mittels Extrusionsverfahren.The filler polystyrene and / or styrene copolymer can be prepared by all polymerization processes known to those skilled in the art [see, for example, US Pat. B. Ullmann's Encyclopedia, Sixth Edition, 2000 Electronic Release ]. For example, the preparation is carried out in a conventional manner by suspension polymerization or by extrusion.

Bei der Suspensionspolymerisation wird Styrol, gegebenenfalls unter Zusatz weiterer Comonomere in wässriger Suspension in Gegenwart eines üblichen Suspensionsstabilisators mittels radikalbildender Katalysatoren polymerisiert. Das Treibmittel und gegebenenfalls weitere Zusatzstoffe können dabei bei der Polymerisation mit vorgelegt werden oder im Laufe der Polymerisation oder nach beendeter Polymerisation dem Ansatz zugefügt werden. Die erhaltenen perlförmigen gegebenenfalls expandierbaren Styrolpolymerisate werden nach beendeter Polymerisation von der wässrigen Phase abgetrennt, gewaschen, getrocknet und gesiebt.In the suspension polymerization, styrene, optionally with the addition of further comonomers in aqueous suspension, is polymerized in the presence of a customary suspension stabilizer by means of free-radical-forming catalysts. The blowing agent and, if appropriate, further additives may be introduced during the polymerization or may be added to the batch in the course of the polymerization or after the end of the polymerization. The resulting bead-shaped optionally expandable styrene polymers are separated from the aqueous phase after the end of the polymerization, washed, dried and sieved.

Bei dem Extrusionsverfahren wird das Treibmittel beispielsweise über einen Extruder in das Polymer eingemischt, durch eine Düsenplatte gefördert und zu Partikeln oder Strängen granuliert.In the extrusion process, the blowing agent is mixed for example via an extruder in the polymer, conveyed through a nozzle plate and granulated into particles or strands.

Der Füllstoff Polystyrol oder Styrolcopolymerisat ist besonders bevorzugt expandierbar.The filler polystyrene or styrene copolymer is particularly preferably expandable.

Als Treibmittel können alle dem Fachmann bekannten Treibmittel verwendet werden, beispielsweise C3- bis C6-Kohlenwasserstoffe, wie Propan, n-Butan, Isobutan, n-Pentan, Isopentan, Neopentan und/oder Hexan, Alkohole, Ketone, Ether oder halogenierte Kohlenwasserstoffe. Vorzugsweise wird ein handelsübliches Pentanisomerengemisch verwendet.Suitable blowing agents are all blowing agents known to those skilled in the art, for example C 3 to C 6 hydrocarbons, such as propane, n-butane, isobutane, n-pentane, isopentane, neopentane and / or hexane, alcohols, ketones, ethers or halogenated hydrocarbons , Preferably, a commercially available pentane isomer mixture is used.

Des weiteren können den Styrolpolymerisaten Additive, Keimbildner, Weichmacher, Flammschutzmittel, lösliche und unlösliche anorganische und/oder organische Farbstoffe und Pigmente, z.B. IR-Absorber, wie Ruß, Graphit oder Aluminiumpulver, gemeinsam oder räumlich getrennt als Zusatzstoffe zugegeben werden.Further, the styrenic polymers may contain additives, nucleating agents, plasticizers, flame retardants, soluble and insoluble inorganic and / or organic dyes and pigments, e.g. IR absorber, such as carbon black, graphite or aluminum powder, are added together or spatially separated as additives.

Gegebenenfalls können auch Styrolcopolymerisate eingesetzt werden, vorteilhaft weisen diese Styrolcopolymerisate mindestens 50 Gew.-%, vorzugsweise mindestens 80 Gew.-%, einpolymerisiertes Polystyrol auf. Als Comonomere kommen z. B. α-Methylstyrol, kernhalogenierte Styrole, Acrylnitril, Ester der Acryl- oder Methacrylsäure von Alkoholen mit 1 bis 8 C-Atomen, N-Vinylcarbazol, Maleinsäure(anhydrid), (Meth)acrylamide und/oder Vinylacetat in Betracht.Optionally, it is also possible to use styrene copolymers; these styrene copolymers advantageously have at least 50% by weight, preferably at least 80% by weight, of copolymerized polystyrene. As comonomers come z. B. α-methylstyrene, ring-halogenated styrenes, acrylonitrile, esters of acrylic or methacrylic acid of Alcohols having 1 to 8 carbon atoms, N-vinylcarbazole, maleic acid (anhydride), (meth) acrylamides and / or vinyl acetate into consideration.

Vorteilhaft kann das Polystyrol und/oder Styrolcopolymerisat eine geringe Menge eines Kettenverzweigers einpolymerisiert enthalten, d.h. einer Verbindung mit mehr als einer, vorzugsweise zwei Doppelbindungen, wie Divinylbenzol, Butadien und/oder Butandioldiacrylat. Der Verzweiger wird im Allgemeinen in Mengen von 0,005 bis 0,05 Mol.-%, bezogen auf Styrol, verwendet.Advantageously, the polystyrene and / or styrene copolymer may contain in copolymerized form a small amount of a chain splitter, i. a compound having more than one, preferably two, double bonds, such as divinylbenzene, butadiene and / or butanediol diacrylate. The branching agent is generally used in amounts of from 0.005 to 0.05 mol%, based on styrene.

Vorteilhaft verwendet man Styrol(co)polymerisate mit Molekulargewichten und Molgewichtsverteilungen, wie sie in EP-B 106 129 und in DE-A 39 21 148 beschrieben sind. Bevorzugt werden Styrol(co)polymerisate mit einem Molekulargewicht im Bereich von 190.000 bis 400.000 g/mol eingesetzt.It is advantageous to use styrene (co) polymers having molecular weights and molecular weight distributions as described in US Pat EP-B 106 129 and in DE-A 39 21 148 are described. Preference is given to using styrene (co) polymers having a molecular weight in the range from 190,000 to 400,000 g / mol.

Auch Mischungen verschiedener Styrol(co)polymerisate können verwendet werden.Mixtures of different styrene (co) polymers can also be used.

Bevorzugt werden als Styrolpolymere glasklares Polystyrol (GPPS), Schlagzähpolystyrol (HIPS), anionisch polymerisiertes Polystyrol oder Schlagzähpolystyrol (A-IPS), Styrol-α-Methylstyrol-copolymere, Acrylnitril-Butadien-Styrolpolymerisate (ABS), Styrol-Acrylnitril (SAN), Acrylnitril-Styrol-Acrylester (ASA), Methylacrylat-Butadien-Styrol (MBS), Methylmethacrylat-Acrylnitril-Butadien-Styrol (MABS)-polymerisate oder Mischungen davon oder mit Polyphenylenether (PPE) eingesetzt.Preference is given as styrene polymers to glassy polystyrene (GPPS), toughened polystyrene (HIPS), anionically polymerized polystyrene or toughened polystyrene (A-IPS), styrene-α-methylstyrene copolymers, acrylonitrile-butadiene-styrene polymers (ABS), styrene-acrylonitrile (SAN), Acrylonitrile-styrene-acrylic ester (ASA), methyl acrylate-butadiene-styrene (MBS), methyl methacrylate-acrylonitrile-butadiene-styrene (MABS) polymers or mixtures thereof or used with polyphenylene ether (PPE).

Als Polystyrol wird besonders bevorzugt Styropor®, Neopor® und/oder Peripor® der Firma BASF Aktiengesellschaft eingesetzt.As polystyrene, Styropor®, Neopor® and / or Peripor® from BASF Aktiengesellschaft is particularly preferably used.

Vorteilhaft wird bereits vorgeschäumtes Polystyrol und/oder Styrolcopolymerisate eingesetzt. Generell lässt sich das vorgeschäumte Polystyrol nach allen dem Fachmann bekannten Verfahren herstellen (beispielsweise DE 845264 ). Für die Herstellung von vorgeschäumten Polystyrol und/oder Styrolcopolymerisaten werden die expandierbaren Styrolpolymerisate in bekannter Weise durch Erhitzen auf Temperaturen oberhalb ihres Erweichungspunkts, beispielsweise mit Heißluft oder vorzugsweise Dampf, expandiert.Pre-expanded polystyrene and / or styrene copolymers are advantageously used. In general, the prefoamed polystyrene can be prepared by all methods known to the person skilled in the art (for example DE 845264 ). For the production of prefoamed polystyrene and / or styrene copolymers, the expandable styrene polymers are expanded in a known manner by heating to temperatures above their softening point, for example with hot air or preferably steam.

Das vorgeschäumte Polystyrol oder Styrolcopolymerisat wird in Form von Kugeln oder Perlen mit einem mittleren Durchmesser von vorteilhaft 0,25 bis 10 mm, bevorzugt 0,5 bis 5 mm, insbesondere 0,75 bis 3 mm, eingesetzt.The prefoamed polystyrene or styrene copolymer is used in the form of spheres or beads having an average diameter of advantageously 0.25 to 10 mm, preferably 0.5 to 5 mm, in particular 0.75 to 3 mm.

Die vorgeschäumten Polystyrol- oder Styrolcopolymerisat-Kugeln weisen vorteilhaft eine kleine Oberfläche pro Volumen auf, beispielsweise in Form eines sphärischen oder elliptischen Partikels.The prefoamed polystyrene or styrene copolymer spheres advantageously have a small surface area per volume, for example in the form of a spherical or elliptical particle.

Die vorgeschäumten Polystyrol- oder Styrolcopolymerisat-Kugeln sind vorteilhaft geschlossenzellig. Die Offenzelligkeit nach DIN-ISO 4590 beträgt weniger als 30%.The prefoamed polystyrene or styrene copolymer spheres are advantageously closed-celled. The open cell density according to DIN-ISO 4590 is less than 30%.

Als Antistatikum können die in der Technik üblichen und gebräuchlichen Substanzen verwendet werden. Beispiele sind N,N-Bis(2-hydroxyethyl)-C12-C18-alkylamine, Fettsäurediethanolamide, Cholinesterchloride von Fettsäuren, C12-C20-Alkylsulfonate, Ammoniumsalze.As antistatic agents, the usual and common in the art substances can be used. Examples are N, N-bis (2-hydroxyethyl) -C 12 -C 18 -alkylamines, fatty acid diethanolamides, choline ester chlorides of fatty acids, C 12 -C 20 -alkyl sulfonates, ammonium salts.

Geeignete Ammoniumsalze enthalten am Stickstoff neben Alkylgruppen 1 bis 3 hydroxylgruppenhaltige organische Reste.Suitable ammonium salts contain on nitrogen in addition to alkyl groups 1 to 3 hydroxyl-containing organic radicals.

Geeignete quaternäre Ammoniumsalze sind beispielsweise solche, die am Stickstoff-Kation 1 bis 3, vorzugsweise 2, gleiche oder verschiedene Alkylreste mit 1 bis 12, vorzugsweise 1 bis 10 C-Atomen, und 1 bis 3, vorzugsweise 2 gleiche oder verschiedene Hydroxyalkyl- oder Hydroxyalkylpolyoxyalkylen-Reste gebunden enthalten, mit einem beliebigen Anion, wie Chlorid, Bromid, Acetat, Methylsulfat oder p-Toluolsulfonat.Suitable quaternary ammonium salts are, for example, those having on the nitrogen cation 1 to 3, preferably 2, identical or different alkyl radicals having 1 to 12, preferably 1 to 10 carbon atoms, and 1 to 3, preferably 2 identical or different hydroxyalkyl or hydroxyalkylpolyoxyalkylene Radicals bound with any anion, such as chloride, bromide, acetate, methyl sulfate or p-toluenesulfonate.

Die Hydroxyalkyl- und Hydroxyalkyl-polyoxyalkylen-Reste sind solche, die durch Oxyalkylierung eines Stickstoff-gebundenen Wasserstoffatoms entstehen und leiten sich von 1 bis 10 Oxyalkylenresten, insbesondere Oxyethylen- und Oxypropylen-Resten ab.The hydroxyalkyl and hydroxyalkyl-polyoxyalkylene radicals are those which are formed by oxyalkylation of a nitrogen-bonded hydrogen atom and are derived from 1 to 10 oxyalkylene radicals, in particular oxyethylene and oxypropylene radicals.

Besonders bevorzugt wird als Antistatikum ein quartäres Ammoniumsalz oder ein Alkalisalz, insbesondere Natriumsalz eines C12-C20 Alkansulfonats, z. B Emulgator K30 von Bayer AG, oder Mischungen davon eingesetzt. Die Antistatika können in der Regel sowohl als Reinsubstanz als auch in Form einer wässrigen Lösung zugegeben werden.An antistatic agent which is particularly preferred is a quaternary ammonium salt or an alkali metal salt, in particular the sodium salt of a C 12 -C 20 alkanesulfonate, eg. B emulsifier K30 from Bayer AG, or mixtures thereof. The antistatic agents can generally be added both as a pure substance and in the form of an aqueous solution.

Das Antistatikum kann beim Verfahren zur Herstellung von Polystyrol oder Styrolcopolymerisat analog den üblichen Zusatzstoffen zugesetzt werden oder nach der Herstellung der Polystyrolpartikel als Beschichtung aufgetragen werden.The antistatic agent can be added in the process for the preparation of polystyrene or styrene copolymer analogously to the customary additives or applied after the preparation of the polystyrene particles as a coating.

Das Antistatikum wird vorteilhaft in einer Menge von 0,05 bis 6 Gew.-%, bevorzugt 0,1 bis 4 Gew.-%, bezogen auf das Polystyrol oder Styrolcopolymerisat, eingesetzt.The antistatic agent is advantageously used in an amount of 0.05 to 6 wt .-%, preferably 0.1 to 4 wt .-%, based on the polystyrene or styrene copolymer.

Der Füllstoff Polystyrol und/oder Styrolcopolymerisat liegt vorteilhaft gleichmäßig verteilt in dem erfindungsgemäßen Holzwerkstoff vor.The filler polystyrene and / or styrene copolymer is advantageously present evenly distributed in the wood material according to the invention.

Die Füllstoff-Kugeln liegen vorteilhaft auch nach dem Verpressen zum Holzwerkstoff in einem ungeschmolzenen Zustand vor. Gegebenenfalls kann es allerdings zu einem Schmelzen der Füllstoff-Kugeln, die sich auf der Oberfläche des Holzwerkstoffs befinden, kommen.The filler balls are advantageously present after pressing to the wood material in an unmelted state. Optionally, however, it may come to a melting of the filler balls, which are located on the surface of the wood material.

Als Bindemittel können alle dem Fachmann für die Herstellung von Holzwerkstoffen bekannten Bindemittel verwendet werden. Vorteilhaft werden als Bindemittel formaldehydhaltige Klebstoffe eingesetzt, beispielsweise Harnstoff-Formaldehydharze oder melaminhaltige Harnstoff-Formaldehydharze. Bevorzugt werden Harnstoff-Formaldehydharze verwendet. Beispielsweise wird als Bindemittel Kaurit® Leim der Firma BASF Aktiengesellschaft eingesetzt.As binders it is possible to use all binders known to the person skilled in the art for the production of wood-based materials. Formaldehyde-containing adhesives are advantageously used as binders, for example urea-formaldehyde resins or melamine-containing urea-formaldehyde resins. Preference is given to using urea-formaldehyde resins. For example, Kaurit® glue from BASF Aktiengesellschaft is used as the binder.

Der Feststoffgehalt des Bindemittels liegt üblicherweise bei 25 bis 100 Gew.-%, insbesondere bei 50 bis 70 Gew.-%.The solids content of the binder is usually from 25 to 100% by weight, in particular from 50 to 70% by weight.

Die erfindungsgemäßen leichten Holzwerkstoffe enthaltend vorteilhaft 55 bis 92,5 Gew.-%, bevorzugt 60 bis 90 Gew.-%, insbesondere 70 bis 85 Gew.-%, bezogen auf den Holzwerkstoff, Holzpartikel, wobei die Holzpartikel eine mittleren Dichte von 0,4 bis 0,85 g/cm3, bevorzugt 0,4 bis 0,75 g/cm3, insbesondere 0,4 bis 0,6 g/cm3 aufweisen, vorteilhaft 5 bis 15 Gew.-%, bevorzugt 8 bis 12 Gew.-% bezogen auf den Holzwerkstoff, Polystyrol und/oder Styrolcopolymerisat Füllstoff, wobei der Füllstoff eine Schüttdichte von 30 bis 100 kg/m3, aufweist, und bevorzugt 5 bis 25 Gew.-%, insbesondere 5 bis 15 Gew.-%, bezogen auf den Holzwerkstoff, Bindemittel, wobei die mittlere Dichte des leichten Holzwerkstoffs kleiner gleich 600 kg/m3, bevorzugt kleiner gleich 575 kg/m3, insbesondere kleiner gleich 550 kg/m3 beträgt.The lightweight wood-base materials according to the invention advantageously contain 55 to 92.5% by weight, preferably 60 to 90% by weight, in particular 70 to 85% by weight, based on the wood material, of wood particles, the wood particles having an average density of 0, 4 to 0.85 g / cm 3 , preferably 0.4 to 0.75 g / cm 3 , in particular 0.4 to 0.6 g / cm 3 , preferably 5 to 15 wt .-%, preferably 8 to 12 Wt .-% based on the wood material, polystyrene and / or styrene copolymer filler, wherein the filler has a bulk density of 30 to 100 kg / m 3 , and preferably 5 to 25 wt .-%, in particular 5 to 15 wt .-% , based on the wood material, binder, wherein the average density of the light wood material is less than or equal to 600 kg / m 3 , preferably less than or equal to 575 kg / m 3 , in particular less equal to 550 kg / m 3 .

Alle Gewichtsangaben beziehen sich auf die Trockensubstanz.All weights are based on dry matter.

Gegebenenfalls können in dem erfindungsgemäßen Holzwerkstoff weitere handelsübliche und dem Fachmann bekannte Additive vorliegen.Optionally, further commercially available additives known to the person skilled in the art may be present in the wood-base material according to the invention.

Die Dicke der Holzwerkstoffe variiert mit dem Anwendungsgebiet und liegt in der Regel im Bereich von 0,5 bis 50 mm.The thickness of the wood materials varies with the field of application and is usually in the range of 0.5 to 50 mm.

Die Querzugsfestigkeit der erfindungsgemäßen leichten Holzwerkstoffe mit einer Dichte von 200 bis 650 kg/m3 ist vorteilhaft größer als (0,002 x D - 0,55) N/mm2, bevorzugt größer als (0,002 x D - 0,45) N/mm2, insbesondere größer als (0,0022 x D - 0,45) N/mm2.The transverse tensile strength of the lightweight wood-base materials according to the invention having a density of 200 to 650 kg / m 3 is advantageously greater than (0.002 × D - 0.55) N / mm 2 , preferably greater than (0.002 × D - 0.45) N / mm 2 , in particular greater than (0.0022 x D - 0.45) N / mm 2 .

Die Quellwerte sind vorteilhaft 10 % kleiner, bevorzugt 20 % kleiner, insbesondere 30 % kleiner als die Quellwerte einer Platte gleicher Dichte ohne Füllstoff.The swelling values are advantageously 10% smaller, preferably 20% smaller, in particular 30% smaller than the swelling values of a plate of the same density without filler.

Ferner betrifft die vorliegende Erfindung ein Verfahren zur Herstellung von leichten Holzwerkstoffen, wie im Anspruch 1 definiert. Gegebenenfalls wird der Holzpartikelkuchen vor dem Verpressen kalt vorgedichtet. Das Verpressen kann nach allen dem Fachmann bekannten Verfahren erfolgen. Üblicherweise wird der Holzpartikelkuchen bei einer Press-Temperatur von 150°C bis 230°C auf die gewünschte Dicke gepresst. Die Pressdauer beträgt normalerweise 3 bis 15 Sekunden pro mm Plattendicke.Furthermore, the present invention relates to a process for the production of lightweight wood-based materials, as defined in claim 1. Optionally, the wood particle cake is cold pre-sealed before pressing. The pressing can be carried out by all methods known to the person skilled in the art. Usually, the wood particle cake is pressed at a press temperature of 150 ° C to 230 ° C to the desired thickness. The pressing time is normally 3 to 15 seconds per mm plate thickness.

Ferner betrifft die vorliegende Erfindung die Verwendung der erfindungsgemäßen Holzwerkstoffe zur Herstellung von Möbeln, von Verpackungsmaterialien, im Hausbau oder im Innenausbau.Furthermore, the present invention relates to the use of the wood-based materials according to the invention for the production of furniture, of packaging materials, in house building or interior work.

Die Vorteile der vorliegenden Erfindung liegen in der geringen Dichte der erfindungsgemäßen Holzwerkstoffe bei guter mechanischer Stabilität. Ferner lassen sich die erfindungsgemäßen Holzwerkstoffe leicht herstellen; es besteht kein Bedarf, die bestehenden Anlagen zur Herstellung der erfindungsgemäßen Holzwerkstoffe umzurüsten.The advantages of the present invention are the low density of the wood-based materials according to the invention with good mechanical stability. Furthermore, the inventive Easily produce wood-based materials; There is no need to retrofit the existing plants for the production of wood-based materials according to the invention.

BeispieleExamples A) Herstellung der FüllstoffeA) Preparation of fillers A1.1) Herstellung von schäumbarem Polystyrol mit AntistatikumA1.1) Preparation of foamable polystyrene with antistatic agent

Es werden handelsübliche schäumbare Polystyrole verwendet, die in der Tabelle 1 zusammengefasst sind.Commercially available foamable polystyrenes which are summarized in Table 1 are used.

A1.2) Herstellung von schäumbarem Polystyrol ohne AntistatikumA1.2) Preparation of foamable polystyrene without antistatic agent

Schäumbares Polystyrol wurde wie z. B. in EP 981 574 beschrieben hergestellt. Auf die Zugabe eines Antistatikums während oder nach der Herstellung wurde verzichtet.Foamable polystyrene was such. In EP 981 574 described prepared. The addition of an antistatic agent during or after production was omitted.

A2) Herstellung des vorgeschäumten PolystyrolsA2) Preparation of prefoamed polystyrene

Die gemäß Beispiel A1 erhaltenen Polystyrolpartikel wurden mit Wasserdampf in einem kontinuierlichen Vorschäumer behandelt. Die Schüttdichte der vorgeschäumten Polystyrolkügelchen wurde durch Variation des Dampfdrucks und der Bedampfungszeit eingestellt. Es wurden folgende, in der Tabelle 1 zusammengestellten, vorgeschäumte Polystyrolpartikel hergestellt. Tabelle1: Vorgeschäumte Polystyrolpartikel Füllstoff schäumbares Polystyrol vorgeschäumtes Polystyrol Einsatzstoff Mittlerer Durchmesser [mm] Schüttdichte [kg/m3] 1 Neopor N2400® 0,5 - 0,8 60 2 Neopor N2200® 1,4 - 2,5 60 3 Styropor P426® 0,4 - 0,7 54 4 Beispiel A1.2 0,4 - 0,7 50 5 Neopor N2400® 0,5 - 0,8 10 The polystyrene particles obtained according to Example A1 were treated with steam in a continuous prefoamer. The bulk density of the prefoamed polystyrene beads was adjusted by varying the vapor pressure and the steaming time. The following prefoamed polystyrene particles, which are listed in Table 1, were prepared. Table 1: Preliminary polystyrene particles filler foamable polystyrene prefoamed polystyrene feedstock Mean diameter [mm] Bulk density [kg / m 3 ] 1 Neopor N2400® 0.5 - 0.8 60 2 Neopor N2200® 1.4 - 2.5 60 3 Styrofoam P426® 0.4 - 0.7 54 4 Example A1.2 0.4 - 0.7 50 5 Neopor N2400® 0.5 - 0.8 10

A3) Herstellung von gemahlenem PolystyrolA3) Preparation of ground polystyrene A3.1) Extrudierte Polystyrolschäume (Füllstoff 6)A3.1) Extruded polystyrene foams (filler 6)

Extrudierter PS Schaum verfügbar von Fa. BASF als Styrodur® (Schüttdichte etwa 30 kg/m3) wurde in einer Pallmann Prallmühle Typ PP auf einen mittleren Teilchendurchmesser von 0,2 bis 2 mm gemahlen.Extruded PS foam available from BASF as Styrodur® (bulk density about 30 kg / m 3 ) was ground in a Pallmann impact mill type PP to an average particle diameter of 0.2 to 2 mm.

A3.2) Polyurethanschaum (Füllstoff 7):A3.2) polyurethane foam (filler 7):

Recycelter, handelsüblicher Polyurethanschaum für Isolationen mit einer Größe von 9 cm x 40 cm x 70 cm und einer Dichte von 33 kg/m3 wurde in einer Schneidmühle Retsch SM2000 auf einen mittleren Teilchendurchmesser von 0,2 bis 2 mm gemahlen.Recycled, commercial polyurethane foam for insulation with a size of 9 cm x 40 cm x 70 cm and a density of 33 kg / m 3 was ground in a granulator Retsch SM2000 to a mean particle diameter of 0.2 to 2 mm.

B) Herstellung der HolzwerkstoffeB) Production of wood-based materials B1) Holzwerkstoff gemäß US 2005/0019548B1) wood material according to US 2005/0019548

Die in der US 2005/0019548 offenbarten Eigenschaften sind in der Tabelle 2 zusammengefasst. (Beispiele 1 bis 3)The in the US 2005/0019548 Properties disclosed are summarized in Table 2. (Examples 1 to 3)

B2) Holzwerkstoff gemäß J P 06031708B2) wood material according to J P 06031708

Die in der JP 06031708 offenbarten Eigenschaften sind in der Tabelle 2 zusammengefasst. (Beispiele 4 und 5)The in the JP 06031708 Properties disclosed are summarized in Table 2. (Examples 4 and 5)

B3) Holzwerkstoffe mit und ohne FüllstoffeB3) Wood-based materials with and without fillers B3.1) Mischen der EinsatzstoffeB3.1) Mixing the starting materials

In einem Mischer wurden 450 g Späne, bzw. Fasern gemäß Tabelle 2 und gegebenenfalls Füllstoffe gemäß Tabelle 2 gemischt. Anschließend wurden 58,8 g einer Leimflotte aus 100 Teilen Kaurit®-Leim 340 und 4 Teilen einer 52 % wässrigen Ammoniumnitratlösung und 10 Teilen Wasser aufgebracht.In a mixer 450 g of chips or fibers were mixed according to Table 2 and optionally fillers according to Table 2. Subsequently, 58.8 g of a size liquor of 100 parts of Kaurit® size 340 and 4 parts of a 52% aqueous ammonium nitrate solution and 10 parts of water were applied.

B3.2) Verpressen der beleimten Späne bzw. FasernB3.2) pressing the glued chips or fibers

Die beleimten Späne bzw. Fasern wurden in einer 30x30cm-Form kalt vorverdichtet. Anschließend wurde in einer Heißpresse gepresst (Presstemperatur 190 °C, Presszeit 210 s). Die Solldicke der Platte betrug jeweils 16 mm.The glued chips or fibers were cold precompressed in a 30x30 cm mold. It was then pressed in a hot press (pressing temperature 190 ° C, pressing time 210 s). The nominal thickness of the plate was 16 mm in each case.

C) Untersuchung der HolzwerkstoffeC) Examination of wood-based materials C1) DichteC1) density

Die Bestimmung der Dichte erfolgte 24 Stunden nach Herstellung nach EN 1058.The density was determined 24 hours after preparation according to EN 1058.

C2) QuerzugsfestigkeitC2) transverse tensile strength

Die Bestimmung der Querzugsfestigkeit erfolgt nach EN 319.The determination of the transverse tensile strength is in accordance with EN 319.

C3) Quellwerte und WasseraufnahmeC3) swelling values and water absorption

Die Bestimmung der Quellwerte und der Wasseraufnahme erfolgte nach DIN EN 317. Tabelle 2: Leichte Holzwerkstoffe Beispiel Füllstoff Hölzer; Dichte [kg/m3] Dichte Werkstoff [kg/m3] Querzugsfestigkeit [N/mm2] Wasseraufnahme [%] Quellwerte [%] 1 Dualite 7020 Holzflocken; nicht genannt 622 0,47 - - 2 Dualite 6001 Holzflocken; nicht genannt 617 0,39 - - 3 Glas S22 Holzflocken; nicht genannt 607 0,31 - - 4 10% Polystyrolfüllstoff (Teilchendurchmesser = 3 bis 5 mm; Schüttdichte = 50 kg/m3) japanische Zeder; 340 bis 440 430 0,46 - - 5 20% Polystyrolfüllstoff (Teilchendurchmesser = 3 bis 5 mm; Schüttdichte = 50 kg/m3) japanische Zeder; 340 bis 440 430 0,48 - - 6* PB 5%1 Füllstoff 2 Fichte; etwa 450 500 0,51 118,1 17,4 7* PB 10% Füllstoff 1 Fichte; etwa 450 500 0,61 101,9 13,1 8* PB 10% Füllstoff 2 Fichte; etwa 450 451 0,51 119,5 13,8 9* PB 10% Füllstoff 1 Fichte; etwa 450 433 0,46 130,5 12,8 10* PB 15% Füllstoff 3 Fichte; etwa 450 473 0,75 95,4 15,0 11* PB 15% Füllstoff 3 Fichte; etwa 450 335 0,34 110,7 6,9 12* 10% Füllstoff Fichte; 421 0,49 134,7 11,2 Faserplatte 1 etwa 450 13* Faserplatte 15% Füllstoff 1 Fichte; etwa 450 378 0,52 143,8 10,0 14 10% Füllstoff 4 Es konnte keine homogene Platte hergestellt werden. 15 10 % Füllstoff 5 Die Platte brach bei der Vorverdichtung auseinander. 16 10% Füllstoff 6 Fichte; etwa 450 510 0,35 120,4 21,0 17 10 % Füllstoff 7 Fichte; etwa 450 513 0,19 143,5 27,9 18 Kein Füllstoff Fichte; etwa 450 513 0,26 130,6 20,6 * = erfindungsgemäß
1 = die Gewichtsangabe bezieht sich auf die Holzpartikel The determination of the swelling values and the water absorption was carried out according to DIN EN 317. Table 2: Light wood-based materials example filler woods; Density [kg / m 3 ] Density material [kg / m 3 ] Transverse tensile strength [N / mm 2 ] Water absorption [%] Source values [%] 1 Dualite 7020 Wood flakes; not known 622 0.47 - - 2 Dualite 6001 Wood flakes; not known 617 0.39 - - 3 Glass S22 Wood flakes; not known 607 0.31 - - 4 10% polystyrene filler (particle diameter = 3 to 5 mm, bulk density = 50 kg / m 3 ) Japanese cedar; 340 to 440 430 0.46 - - 5 20% polystyrene filler (particle diameter = 3 to 5 mm, bulk density = 50 kg / m 3 ) Japanese cedar; 340 to 440 430 0.48 - - 6 * PB 5% 1 Filler 2 Spruce; about 450 500 0.51 118.1 17.4 7 * PB 10% filler 1 Spruce; about 450 500 0.61 101.9 13.1 8 * PB 10% filler 2 Spruce; about 450 451 0.51 119.5 13.8 9 * PB 10% filler 1 Spruce; about 450 433 0.46 130.5 12.8 10 * PB 15% filler 3 Spruce; about 450 473 0.75 95.4 15.0 11 * PB 15% filler 3 Spruce; about 450 335 0.34 110.7 6.9 12 * 10% filler Spruce; 421 0.49 134.7 11.2 fibreboard 1 about 450 13 * fiberboard 15% filler 1 Spruce; about 450 378 0.52 143.8 10.0 14 10% filler 4 It could not be made a homogeneous plate. 15 10% filler 5 The plate broke apart during the pre-compression. 16 10% filler 6 Spruce; about 450 510 0.35 120.4 21.0 17 10% filler 7 Spruce; about 450 513 0.19 143.5 27.9 18 No filler Spruce; about 450 513 0.26 130.6 20.6 * = according to the invention
1 = the weight refers to the wood particles

Claims (7)

  1. A light wood-base material comprising
    from 30 to 92.5% by weight, based on the wood-base material, of wood particles, the wood particles having a mean density of from 0.4 to 0.85 g/cm3,
    from 2.5 to 20% by weight, based on the wood-base material, of polystyrene and/or of styrene copolymer as a filler, the filler having a bulk density of from 30 to 100 kg/m3, and
    from 5 to 50% by weight, based on the wood-base material, of a binder, the mean density of the light wood-base material being less than or equal to 600 kg/m3,
    wherein in which prefoamed filler beads or spheres which have a diameter of from 0.25 to 10 mm is used as the filler and in which the filler beads or spheres have an antistatic coating, wherein the wood particles have a mean density of from 0.4 to 0.75 g/cm3 and the transverse tensile strength of the wood-base material is greater than 0.4 N/mm2.
  2. The light wood-base material according to claim 1, the density of the wood-base material being from 250 to 550 kg/m3.
  3. The light wood-base material according to either of claims 1 and 2, comprising from 55 to 92.5% by weight, based on the wood-base material, of wood particles, the wood particles having a mean density of from 0.4 to 0.6 g/cm3, and from 5 to 15% by weight, based on the wood-base material, of polystyrene and/or of styrene copolymer as a filler, the filler having a bulk density of from 15 to 80 kg/m3, and from 2.5 to 40% by weight, based on the wood-base material, of a binder, the mean density of the light wood-base material being less than or equal to 550 kg/m3.
  4. The light wood-base material according to any of claims 1 to 3, the wood-base material being a fibrous wood-base material.
  5. A composite material which comprises at least three wood-base material layers, the middle layer(s) comprising wood-base materials according to any of claims 1 to 3 and 7 and the outer layers comprising no filler.
  6. A process for the production of light wood-base materials as defined in claim 1, wherein from 2.5 to 20% by weight, based on the wood-base material, of prefoamed polystyrene and/or styrene copolymer having a bulk density of from 30 to 100 kg/m3, from 5 to 50% by weight, based on the wood-base material, of a binder and from 30 to 92.5% by weight, based on the wood-base material, of wood particles having a mean density of from 0.4 to 0.85 g/cm3 are mixed and are then molded at elevated temperature and elevated pressure to give a wood-base material as defined in claim 1, where in which prefoamed filler beads or spheres which have a diameter of from 0.25 to 10 mm are used as the filler and in which the filler beads or spheres have an antistatic coating, the wood particles having a mean density of from 0.4 to 0.75 g/cm3 and the transverse tensile strength of the wood-base material being greater than 0.4 N/mm2.
  7. The use of the light wood-base materials according to any of claims 1 to 3 and 7 or of the composite material according to claim 4 for the production of pieces of furniture, of packaging materials, in house construction or in interior trim.
EP06122557.9A 2006-10-19 2006-10-19 Lightweight wooden material Active EP1914052B1 (en)

Priority Applications (43)

Application Number Priority Date Filing Date Title
PL06122557T PL1914052T3 (en) 2006-10-19 2006-10-19 Lightweight wooden material
ES06122557.9T ES2641263T3 (en) 2006-10-19 2006-10-19 Light wood based materials
EP06122557.9A EP1914052B1 (en) 2006-10-19 2006-10-19 Lightweight wooden material
DE200620020503 DE202006020503U1 (en) 2006-10-19 2006-10-19 Light wood materials
PT61225579T PT1914052T (en) 2006-10-19 2006-10-19 Lightweight wooden material
BRPI0717434-9A2A BRPI0717434A2 (en) 2006-10-19 2007-10-18 MATERIAL CONTAINING LIGHT WOOD, MULTI-LAYER WOOD-BASED MATERIAL, PROCESSES FOR THE PRODUCTION OF MATERIALS CONTAINING LIGHT WOOD AND MULTI-LAYER WOOD-BASED MATERIALS AND USE OF LIGHT WOODEN MATERIALS.
UAA200904960A UA96612C2 (en) 2006-10-19 2007-10-18 Light wooden material, method for producing and use thereof (embodiments), multilayer wooden material (embodiments) and method producing and use thereof (embodiments)
PT78215308T PT2083974T (en) 2006-10-19 2007-10-18 Lightweight wooden material
PT07821531T PT2083975E (en) 2006-10-19 2007-10-18 Light wood materials with good mechanical characteristics and method of producing the same
EP20070821531 EP2083975B1 (en) 2006-10-19 2007-10-18 Light wood materials with good mechanical characteristics and method of producing the same
AU2007312218A AU2007312218B2 (en) 2006-10-19 2007-10-18 Light wood-based materials
AT07821531T ATE493247T1 (en) 2006-10-19 2007-10-18 LIGHTWEIGHT WOOD MATERIALS WITH GOOD MECHANICAL PROPERTIES AND PROCESSES FOR PRODUCING THE SAME
CN200780042908.7A CN101541488B (en) 2006-10-19 2007-10-18 Light wood-based materials
EP20110152229 EP2319670A1 (en) 2006-10-19 2007-10-18 Lightweight wooden material
ES07821531T ES2357574T3 (en) 2006-10-19 2007-10-18 LIGHTWEIGHT MATERIAL DERIVED FROM WOOD, WITH GOOD MECHANICAL FEATURES AND THE PROCEDURE FOR OBTAINING IT.
US12/446,248 US9089991B2 (en) 2006-10-19 2007-10-18 Light wood-based materials
CN2007800428544A CN101553348B (en) 2006-10-19 2007-10-18 Light wood-based materials
NZ576290A NZ576290A (en) 2006-10-19 2007-10-18 Light wood-based materials
PL07821530T PL2083974T3 (en) 2006-10-19 2007-10-18 Lightweight wooden material
EP07821530.8A EP2083974B1 (en) 2006-10-19 2007-10-18 Lightweight wooden material
NZ576323A NZ576323A (en) 2006-10-19 2007-10-18 Light wood-based materials
EA200900551A EA013666B1 (en) 2006-10-19 2007-10-18 Light wood-based material
CA 2666447 CA2666447A1 (en) 2006-10-19 2007-10-18 Light wood-base materials having good mechanical properties
PCT/EP2007/061167 WO2008046892A2 (en) 2006-10-19 2007-10-18 Light wood-based materials
US12/446,245 US8304069B2 (en) 2006-10-19 2007-10-18 Light wood-based materials
EA200900550A EA013665B1 (en) 2006-10-19 2007-10-18 Light wood-based materials
BRPI0717436-5A2A BRPI0717436A2 (en) 2006-10-19 2007-10-18 LIGHT WOOD-BASED MATERIAL, COMPOSITE MATERIAL, PROCESS FOR THE PRODUCTION OF LIGHT WOOD-BASED MATERIALS, AND USE OF WOOD-BASED MATERIALS
CA 2666454 CA2666454A1 (en) 2006-10-19 2007-10-18 Light wood-base materials
JP2009532808A JP5300728B2 (en) 2006-10-19 2007-10-18 Lightweight wood material
AU2007312220A AU2007312220B2 (en) 2006-10-19 2007-10-18 Light wood-based materials
UAA200904962A UA94123C2 (en) 2006-10-19 2007-10-18 Light wood-based material, method for manufacturing thereof and multilayer material
EP07821532A EP2083976A2 (en) 2006-10-19 2007-10-18 Lightweight wooden material
PCT/EP2007/061165 WO2008046890A2 (en) 2006-10-19 2007-10-18 Light wood-based materials
MYPI20091585A MY148865A (en) 2006-10-19 2007-10-18 Light wood-based materials
JP2009532809A JP5150638B2 (en) 2006-10-19 2007-10-18 Light weight wood material with good mechanical properties
PCT/EP2007/061166 WO2008046891A1 (en) 2006-10-19 2007-10-18 Light wood materials with good mechanical characteristics
MYPI20091588A MY148871A (en) 2006-10-19 2007-10-18 Light wood-based materials
ES07821530.8T ES2622883T3 (en) 2006-10-19 2007-10-18 Light wood materials
PL07821531T PL2083975T3 (en) 2006-10-19 2007-10-18 Light wood materials with good mechanical characteristics and method of producing the same
DE200750006137 DE502007006137D1 (en) 2006-10-19 2007-10-18 LIGHT WOODEN MATERIALS WITH GOOD MECHANICAL PROPERTIES AND METHOD FOR THE PRODUCTION OF THE SAME
NO20091522A NO20091522L (en) 2006-10-19 2009-04-17 Lightweight wood-based materials
NO20091523A NO20091523L (en) 2006-10-19 2009-04-17 Lightweight wood-based materials
NO20091516A NO20091516L (en) 2006-10-19 2009-04-17 Light wood materials with good mechanical properties

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP06122557.9A EP1914052B1 (en) 2006-10-19 2006-10-19 Lightweight wooden material

Publications (2)

Publication Number Publication Date
EP1914052A1 EP1914052A1 (en) 2008-04-23
EP1914052B1 true EP1914052B1 (en) 2017-06-28

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Family Applications (5)

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EP06122557.9A Active EP1914052B1 (en) 2006-10-19 2006-10-19 Lightweight wooden material
EP07821530.8A Active EP2083974B1 (en) 2006-10-19 2007-10-18 Lightweight wooden material
EP20110152229 Withdrawn EP2319670A1 (en) 2006-10-19 2007-10-18 Lightweight wooden material
EP20070821531 Active EP2083975B1 (en) 2006-10-19 2007-10-18 Light wood materials with good mechanical characteristics and method of producing the same
EP07821532A Withdrawn EP2083976A2 (en) 2006-10-19 2007-10-18 Lightweight wooden material

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EP07821530.8A Active EP2083974B1 (en) 2006-10-19 2007-10-18 Lightweight wooden material
EP20110152229 Withdrawn EP2319670A1 (en) 2006-10-19 2007-10-18 Lightweight wooden material
EP20070821531 Active EP2083975B1 (en) 2006-10-19 2007-10-18 Light wood materials with good mechanical characteristics and method of producing the same
EP07821532A Withdrawn EP2083976A2 (en) 2006-10-19 2007-10-18 Lightweight wooden material

Country Status (18)

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US (2) US8304069B2 (en)
EP (5) EP1914052B1 (en)
JP (2) JP5300728B2 (en)
CN (2) CN101541488B (en)
AT (1) ATE493247T1 (en)
AU (2) AU2007312220B2 (en)
BR (2) BRPI0717436A2 (en)
CA (2) CA2666447A1 (en)
DE (2) DE202006020503U1 (en)
EA (2) EA013666B1 (en)
ES (3) ES2641263T3 (en)
MY (2) MY148865A (en)
NO (3) NO20091516L (en)
NZ (2) NZ576323A (en)
PL (3) PL1914052T3 (en)
PT (3) PT1914052T (en)
UA (2) UA94123C2 (en)
WO (3) WO2008046891A1 (en)

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EP2083974B1 (en) 2017-01-18
EP2083974A2 (en) 2009-08-05
US20100297425A1 (en) 2010-11-25
AU2007312218A1 (en) 2008-04-24
WO2008046890A3 (en) 2008-06-12
PT2083975E (en) 2011-02-03
EA013665B1 (en) 2010-06-30
CN101553348B (en) 2013-08-14
WO2008046892A3 (en) 2008-08-21
NO20091522L (en) 2009-05-18
NZ576290A (en) 2012-02-24
ATE493247T1 (en) 2011-01-15
PL1914052T3 (en) 2017-12-29
US20110003136A1 (en) 2011-01-06
EA200900551A1 (en) 2009-10-30
JP2010506758A (en) 2010-03-04
ES2622883T3 (en) 2017-07-07
AU2007312220B2 (en) 2012-05-03
PT1914052T (en) 2017-10-04
PL2083975T3 (en) 2011-05-31
NO20091523L (en) 2009-04-30
CA2666454A1 (en) 2008-04-24
MY148865A (en) 2013-06-14
CA2666447A1 (en) 2008-04-24
JP5300728B2 (en) 2013-09-25
EP2319670A1 (en) 2011-05-11
EA013666B1 (en) 2010-06-30
US8304069B2 (en) 2012-11-06
NO20091516L (en) 2009-05-14
UA96612C2 (en) 2011-11-25
EP2083975A1 (en) 2009-08-05
JP2010506757A (en) 2010-03-04
EP1914052A1 (en) 2008-04-23
WO2008046892A2 (en) 2008-04-24
AU2007312218B2 (en) 2012-02-09
PL2083974T3 (en) 2017-07-31
CN101553348A (en) 2009-10-07
AU2007312220A1 (en) 2008-04-24
EP2083975B1 (en) 2010-12-29
PT2083974T (en) 2017-03-31
NZ576323A (en) 2012-03-30
ES2641263T3 (en) 2017-11-08
JP5150638B2 (en) 2013-02-20
WO2008046890A2 (en) 2008-04-24
EA200900550A1 (en) 2009-10-30
BRPI0717434A2 (en) 2013-11-12
DE502007006137D1 (en) 2011-02-10
BRPI0717436A2 (en) 2013-11-12
WO2008046891A1 (en) 2008-04-24
MY148871A (en) 2013-06-14
EP2083976A2 (en) 2009-08-05
DE202006020503U1 (en) 2008-10-09
US9089991B2 (en) 2015-07-28
UA94123C2 (en) 2011-04-11
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CN101541488A (en) 2009-09-23
ES2357574T3 (en) 2011-04-27

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