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

Definitions

• the present invention relates to lignocellulose-containing materials having a core and two outer layers, wherein expanded plastic particles are contained in the core, which are distributed inhomogeneous.
• Lightweight and pressure-resistant molding materials consist of wood chips or fibers, a binder and serving as a filler porous foamable or partially expandable plastic.
• a disadvantage of these molding materials is that they have no plastic-free outer layers and therefore conventional coating technologies (for example, lamination with furniture film or short-cycle coating with melamine films) lead to poor results.
• Weight-reduced chipboards are known by combining wood chips and evenly distributed foamed polystyrene beads in the middle layer of the chipboard.
• one- and multi-layer wood materials are known, the wood particles, a filler of polystyrene and / or styrene copolymer having a bulk density of 10 to 100 kg / m 3 and binder.
• the filler is advantageously present uniformly distributed in the wood material.
• WO-A1-2011 / 107365 discloses lignocellulose-containing materials having a core and two outer layers, according to the preamble of claim 1.
• a disadvantage of these materials is that an improvement in the properties at the same plate density can be achieved only with an increase in the amount of glue and / or the amount of polymer and thus with an increase in costs.
• the indication of the weight% of the components A, B, C, D, E, F and G refers to the dry weight of the respective component in the total dry weight.
• the sum of the wt .-% information of components A, B, C and D is 100 wt .-%.
• the sum of components E, F and G also gives 100 wt .-%.
• both the outer layers and the core contain water, which is not taken into account in the weight specifications.
• the water can be obtained from the residual moisture contained in the lignocellulose particles, from the binder, from additionally added water, for example for diluting the binders or for wetting the outer layers, from the additives, for example aqueous hardener solutions or aqueous paraffin emulsions, or from the expanded plastic particles, if these For example, be foamed with steam, come.
• the water content of the core and of the cover layers can be up to 20% by weight, ie 0 to 20% by weight, preferably 2 to 15% by weight, particularly preferably 4 to 10% by weight, based on 100% by weight. Total dry weight amount.
• the ratio of the total dry mass of the core to the total dry mass of the outer layers is generally 100: 1 and 0.25: 1, preferably 10: 1 to 0.5: 1, particularly preferably 6: 1 to 0.75: 1, in particular 4: 1 to 1: 1.
• Inhomogeneously distributed in the core expandable plastic particles B means that the weight ratio X (based on dry matter) of expanded plastic particles B to lignocellulose particles A in the outer regions of the core ("outside") of the weight ratio Y of expanded plastic particles B to lignocellulose particles A in the inner region of the core ("inside”), that is larger or smaller in the outer areas of the core ("outside") than in the inner area of the core ("inside”).
• the inner region of the core is usually separated from the two outer regions of the core by surfaces running parallel to the plane of the plate.
• the inner region of the nucleus is the region of 20 to 80 Wt .-%, preferably 30 to 70 wt .-%, particularly preferably 40 to 60 wt .-%, in particular 45 to 55 wt .-%, most preferably 50 wt .-% of the total dry mass of the core and between the two outer areas lies.
• the two outer regions may be the same, ie in each case 25% by weight or approximately the same, ie 25.01: 24.99 to 25.99: 24.01% by weight, preferably 25.01 to 24.99 25.8: 24.2, more preferably 25.01: 24.99 to 25.6: 24.4, in particular 25.01: 24.99 to 25.4: 24.6 or different mass, based on the total dry mass of the Kerns, ie 26:24 to 40:10 wt .-%, preferably 26:24 to 30:20 wt .-%, particularly preferably 26:24 to 27:23 wt .-%, in particular 26:24 to 26.5 : 23.5% by weight.
• the sum of the inner region and the two outer regions of the core result in 100 wt .-%.
• the weight ratio X of expanded plastic particles B to lignocellulose particles A in the outer regions of the core all expanded plastic particles B and all lignocellulose particles A, which are contained in both outer regions, can be used.
• the ratio X ' which describes the ratio of plastic particles B to lignocellulose particles A in one of the two outer regions, can be the same or equal to the ratio X ", which describes the ratio in the other of the two outer regions.
• lignocellulose-containing materials (lignocellulose materials) according to the invention can be prepared as follows:
• the components for the core and the components for the cover layers are usually mixed separately from each other.
• the components A, B, C and D can each consist of one, two (A1, A2 or B1, B2, or C1, C2 or D1, D2) or several components components (A1, A2, A3, ..., or B1, B2, B3, ..., C1, C2, C3, ..., and D1, D2, D3, ...) exist.
• these component components can be added either as a mixture or separately. In the separate addition of these components components can be added directly behind each other or at different, not directly successive time points. This means, for example, in the case where the component C consists of two components C1 and C2, that C2 is added immediately after C1 or C1 immediately after C2, or that between the addition of C1 and C2 one or more other components or component components, For example, component B will admit. It is also possible to premix components or component components with other components or component components before they are added. For example, an additive component D1 can be added to the binder C or the binder component C1 before this mixture is then added to the actual mixture.
• the expanded plastic particles B are first added to the lignocellulose particles in A, and then this mixture is mixed with a binder C or two or more binder components C1, C2, etc. If two or more binder components are used, they are preferably added separately from one another.
• these components can be added either as a mixture or separately. These components components can be added directly behind each other or at different, not directly successive time points.
• the additives G are preferably partially mixed with the binder F or a binder component and then added.
• the resulting mixtures A, B, C, D and E, F, G are stacked and pressed by a conventional method to a lignocellulose-containing molded body at elevated temperature.
• a mat is produced on a carrier, which consists of these mixtures in the sequence E, F, G / A, B, C, D / E, F, G ("sandwich structure").
• This mat is usually at temperatures of 80 to 300 ° C, preferably, 120 to 280 ° C, more preferably, 150 to 250 ° C and at pressures of 1 to 50 bar, preferably 3 to 40 bar, particularly preferably 5 to 30 bar , Pressed into shaped bodies.
• the mat is precompressed cold before this hot pressing.
• the pressing can be carried out by all methods known to the person skilled in the art (see examples in “ Taschenbuch der Spanplattentechnik "H.-J. Deppe, K. Ernst, 4th ed., 2000, DRW -Verlag Weinbrenner, Leinfelden Echterdingen, pages 232 to 254 , and " MDF Medium Density Fiberboard "H.-J. Deppe, K. Ernst, 1996, DRW-Verlag Weinbrenner, Leinfelden-Echterdingen, pages 93 to 104 .)
• discontinuous pressing methods for example, on single or multi-day presses or continuous pressing method, for example, on double-belt presses used.
• the inhomogeneous distribution of the plastic particles B in the core can be produced as follows: It is possible to prepare several mixtures of components A, B, C and D which have different mass ratios of components A and B. These can be spread one after the other. As a rule, no or only slight mixing of the mixtures with different mass ratios of components A and B should take place.
• both the wood particles A and the plastic particles B can be previously separated into different fractions, for example by sieving.
• Each of the mixtures may contain different fractions of the wood particles A and / or the plastic particles B.
• the inhomogeneous distribution of the plastic particles B in the core can be carried out by separating scattering.
• the scattering is done with a device that ensures that the balls accumulate depending on the size and / or weight in either the outer or inner regions of the core. This can be done, for example, that the mixture A, B, C, D is scattered using a sieve system.
• this system is equipped with screens of different hole sizes, which are arranged mirror-symmetrically.
• a support on which the material for the lower cover layer, passed under a spreader in which a screening system is arranged so that at the beginning of the spreader (in the production direction) sieves are small hole size, the hole size of the sieves to the inside increases towards the middle of the scattering station and decreases again towards the end of the station.
• the arrangement of the screens results in small lignocellulose particles getting into the outer areas of the core close to the cover, and large particles of lignocellulose in the inner area of the core.
• small plastic particles enter the outer regions of the core close to the cover layer and large plastic particles enter the inner region of the core.
• different mass ratios of lignocellulose particles A to plastic particles B are thereby realized.
• Such scattering stations are in EP-B-1140447 and DE-C-19716130 described.
• the lignocellulosic particle scattering station may contain two metering bins, in each of which several backscatter rakes are arranged.
• the ("core mixture") bulk material consisting of different large particles A and components B, C and D can be fed to the metering bunkers (eg from above).
• a bottom band running over two deflection rollers can be arranged, which in each case forms, together with a discharge roller, a discharge unit for the core mixture.
• an endless scraper belt guided over two deflection rollers can be arranged in each case, whose sub-tower can be guided in each case by means of screening devices with different hole sizes, so that different sections of the screening devices are formed.
• the screening devices together with the scraper belts form fractionating devices, by means of which the lignocellulose particles A and the plastic particles B of the core mixture can be fractionated according to their sizes.
• the sections of the screening devices can be arranged so that the fine lignocellulose particles A or plastic particles B are scattered in each case in the transporting direction of the nonwoven outer regions of the scattering station on the lower cover layer, while the coarse lignocellulose particles A or plastic particles B on the inside lying areas of the fractionating on the topcoat are scattered (see in detail: EP-B-1140447 ).
• At least a portion of the Portion michsabête each comprise a Schleifelernent which rests against the surface of the screening device and is guided while moving the Portion michsabroughe dragging over the surface of the screening device.
• the transport device is designed as a particular endless scraper belt.
• the scraper belt is advantageously designed to be permeable to the particles at least over a partial area in a direction perpendicular to the surface of the screening device, so that the particles can be poured out of the dosing hopper via the feed unit through the scraper belt onto the screening device.
• An elaborate design of the feed unit is unnecessary in this way.
• the scraper belt comprises in particular plate-shaped driver, which are preferably provided at regular intervals on an endless chain or band-shaped carrier element.
• the carrier element can be mounted in each case centrally on the drivers.
• the carriers are releasably secured to the carrier element or to the carrier elements and / or formed impermeable to air.
• the grinding elements are each formed by a portion of the drivers.
• the drivers are flexible, for example made of hard rubber, at least in their sections forming the grinding elements.
• the drivers are abrasion resistant at least in their grinding element forming portions and in particular have an abrasion-resistant coating, such as a Teflon coating.
• the sections of the drivers forming the grinding elements can be formed integrally with the drivers as well as separate components. If the grinding elements are designed as separate components, they are preferably detachably attached to the drivers, so that they can be exchanged in the event of wear.
• the drivers are formed, at least in their sections forming the grinding elements, from water-repellent, non-adhesive material. This prevents the binder-crosslinked particles from adhering to the drivers, which could limit the capacity of the portioning sections.
• the sieve device comprises in particular two sieve zones with different sieve openings. In this way it is achieved that particles of different sizes are fractionated through the sieve zones with sieve openings of different sizes.
• the sieve zones are arranged one behind the other along the direction of movement of the portioning sections movable over the surface of the sieve device, wherein preferably the sieve openings of the sieve zone / sieve zones lying in the direction of movement of the portioning sections are larger than the sieve openings of the sieve zone / sieve zones opposite to the direction of movement.
• the endless scraper belt is guided over two deflection rollers, so that a lower belt section directly on the surface of the screening device and an upper band section extends at a certain distance from the surface of the screening device, in particular in each case substantially parallel to the surface of the screening device.
• a particularly compact embodiment of a device according to the invention is possible.
• a receiving device for receiving excreted particles is provided at least at one end of the scraper belt, in particular in the region of the deflection rollers.
• an intermediate bottom is at least partially provided between the upper and the lower band portion, wherein the driver abut with their the sanding elements forming portions opposite ends of the intermediate bottom, so that these ends when moving the Portion michsabête sliding over the Swissgeber be led.
• the intermediate bottom of the one guide roller in the direction of movement of the upper band portion to the opposite other guide roller out extend, wherein between said other guide roller and said other guide roller facing the end of the intermediate floor, a region is formed which is permeable in a direction perpendicular to the surface of the screening device for the particles.
• this region is formed of further screening devices having relatively large sieve openings, a pre-separation of foreign bodies or particles having a size which is greater than the size of these sieve openings can take place here. Only the particles passing through the further screening device fall onto the sieve device below, over which they are moved by means of the transport device.
• two longitudinally successive scraper bands are provided, wherein the scraper bands are arranged in particular mirror-symmetrical to one another.
• the supply unit of the dosing bunker is followed by a distribution device, in particular in the form of a pendulum distributor, with which the particles discharged from the dosing bunker by the supply unit can be supplied to the two scraper belts, in particular alternately.
• the material for the core can be arranged on a moving conveyor belt arranged below the screen devices on which the lower cover layer is already spread are formed in the outer layers of the core, the fine lignocellulose particles A and plastic particles B and in the inner layer of the core, the coarse lignocellulose particles A or plastic particles B are enriched.
• a distribution device for example, two metering bunkers can be provided, through which the two scraper belts are charged with particles.
• the screening device and / or the further screening device is preferably designed as a vibrating screen or as a vibrating vibrating screen. In the process, the bulk material deposited on the sieve device is further loosened up, whereby fine, then medium-sized particles located at a distance from the screen reach the sieve openings faster and faster through them (see in detail: DE-C-197 16 130 ).
• a roller spreading system with specially profiled rollers (roller screen).
• a symmetrical structure is preferably selected so that small lignocellulose particles A or small plastic particles B get into the outer regions of the core close to the cover layer and large lignocellulose particles A or large plastic particles B enter the inner region of the core.
• a particularly preferred embodiment is the use of one or more ClassiFormer TM. Suitable is, for example, the Classiformer CC of Dieffenbacher, which has a symmetrical structure. Alternatively, two Classiformer C can be used, which are arranged behind each other and opposite.
• the lignocellulose materials according to the invention generally have an average density of 300 to 600 kg / m 3 , preferably 350 to 590 kg / m 3 , particularly preferably 400 to 570 kg / m 3 , in particular 450 to 550 kg / m 3 .
• the lignocellulose particles of component A are present in the lignocellulose-containing materials of the core in amounts of from 30 to 98% by weight, preferably from 50 to 95% by weight, more preferably from 70 to 90% by weight, of which the raw material is any kind of wood or its Mixtures, for example, spruce, beech, pine, larch, linden, poplar, eucalyptus, ash, chestnut, fir or their mixtures, preferably spruce, beech or their mixtures, especially spruce, and may, for example Wood parts such as wood layers, wood strips, wood chips, wood fibers, wood dust or mixtures thereof, preferably wood chips, wood fibers, wood dust and mixtures thereof, particularly preferably wood chips, wood fibers or mixtures thereof - as used for the production of chipboard, MDF (medium density fiber) and HDF (High density fiber) - plates - be used.
• MDF medium density fiber
• HDF High density fiber
• the lignocellulose particles may also be derived from wood-containing plants such as flax, hemp, cereals or other annual plants, preferably flax or hemp. Wood chips are particularly preferably used, as used in the production of particleboard. Substituting mixtures of different lignocellus particles, eg mixtures of wood shavings and wood fibers, or wood shavings and wood dust, the proportion of wood shavings is preferably at least 75 wt .-%, ie 75 to 100 wt .-%, particularly preferably at least 90 wt .-% 90 to 100% by weight
• the average density of component A is generally 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 .
• Starting materials for lignocellulose particles are usually roundwoods, thinning woods, residual wood, forest wood waste, industrial wood, used wood, production waste from wood-based material production, used wood-based materials and lignocellulose-containing plants.
• the preparation of the desired lignocellulose-containing particles, for example to wood particles such as wood chips or wood fibers, can be carried out according to known methods (eg M. Dunky, P. Niemz, Holzwerkstoffe und Leime, pages 91 to 156, Springer Verlag Heidelberg, 2002 ).
• the lignocellulose particles E are present in the outer layers in amounts of from 70 to 99% by weight, preferably from 75 to 97% by weight, particularly preferably from 80 to 95% by weight. They consist of at least 25% by weight, ie from 25 to 100% by weight, of lignocellulose-containing chips, in particular wood chips, preferably at least 75% by weight, ie from 75 to 100% by weight, particularly preferably at least 95% by weight , ie 95 to 100 wt .-%, most preferably exclusively, so 100 wt .-%, lignocellulosic shavings, in particular wood chips used.
• lignocellulose-containing materials especially wood from all under component A listed lignocellulosic or wood sources are used.
• the preparation for the desired lignocellulose-containing particles can be carried out as described for component A.
• the average density of component E is generally 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 ,
• Component A may contain the usual small amounts of water from 0 to 10% by weight, preferably 0.5 to 8% by weight, particularly preferably 1 to 5% by weight (in a customary low fluctuation range of 0 to 0.5 Wt .-%, preferably 0 to 0.4 wt .-%, particularly preferably 0 to 0.3 wt .-%).
• This quantity refers to 100% by weight of absolutely dry wood substance and describes the water content of component A after drying (according to customary methods known to the person skilled in the art) immediately before mixing with the first component or the first component component or the first mixture selected from B. , C and D.
• Component E in a preferred embodiment, small amounts of water from 0 to 10 wt .-%, preferably 0.5 to 8 wt .-%, particularly preferably 1 to 5 wt .-% (in a usual small fluctuation range of 0 to 0 , 5 wt .-%, preferably 0 to 0.4 wt .-%, particularly preferably 0 to 0.3 wt .-%).
• This quantity refers to 100% by weight of absolutely dry wood substance and describes the water content of component E after drying (according to customary methods known to the person skilled in the art) immediately before mixing with the first component or component component or mixture selected from F and G.
• expanded plastic particles (component B) are expanded plastic particles, preferably expanded thermoplastic plastic particles having a bulk density of 10 to 150 kg / m 3 , preferably 30 to 130 kg / m 3 , particularly preferably 35 to 110 kg / m 3 , in particular 40 to 100 kg / m 3 (determined by weighing a defined volume filled with the bulk material).
• Expanded plastic particles B are generally in the form of spheres or beads having an average diameter of 0.01 to 50 mm, preferably 0.25 to 10 mm, particularly preferably 0.4 to 8.5 mm, in particular 0.4 to 7 mm inserted.
• the spheres have a small surface per volume, for example in the form of a spherical or elliptical particle, and are advantageously closed-cell.
• the open cell content according to DIN ISO 4590 is generally not more than 30%, ie 0 to 30%, preferably 1 to 25%, particularly preferably 5 to 15%.
• Suitable polymers which are the basis of the expandable or expanded plastic particles are generally all known polymers or mixtures thereof, preferably thermoplastic polymers or mixtures thereof which can be foamed.
• Well-suited such polymers are, for example, polyketones, polysulfones, polyoxymethylene, PVC (hard and soft), polycarbonates, polyisocyanurates, polycarbodiimides, polyacrylimides and polymethacrylimides, polyamides, polyurethanes, aminoplast resins and phenolic resins, styrene homopolymers (im Also referred to hereinafter as "polystyrene” or "styrene polymer”), styrene copolymers, C 2 -C 10 -olefin homopolymers, C 2 -C 10 -olefin copolymers and polyesters.
• the 1-alkenes for example ethylene, propylene, 1-butene, 1-hexene, 1-octene,
• the polymers preferably the thermoplastics which underlie the expandable or expanded plastic particles B
• additives for example UV stabilizers, antioxidants, coating agents, water repellents, nucleating agents, plasticizers, flame retardants, soluble and insoluble inorganic and / or organic dyes , Pigments, and athermane particles, such as carbon black, graphite or aluminum powder, are added together or spatially separated as additives.
• Component B can usually be obtained as follows: Suitable polymers can be expanded with an expandable medium (also called “blowing agent”) or containing an expandable medium by the action of microwave, heat energy, hot air, preferably steam, and / or pressure change (often also referred to as “foamed”) ( Plastics Handbook 1996, Volume 4 "Polystyrene", Hanser 1996, pages 640-673 or US-A-5,112,875 ) become. As a rule, the propellant expands, the particles increase in size and cell structures are formed. This expansion can be carried out in conventional frothing devices, often referred to as "pre-expanders". Such prefoamers can be installed fixed or mobile. The expansion can be carried out in one or more stages.
• pre-expanders Such prefoamers can be installed fixed or mobile. The expansion can be carried out in one or more stages.
• the expandable plastic particles are readily expanded to the desired final size.
• the expandable plastic particles are first expanded to an intermediate size and then expanded in one or more further stages over a corresponding number of intermediate sizes to the desired final size.
• the above-mentioned compact plastic particles also referred to herein as "expandable plastic particles", in contrast to the expanded plastic particles, generally contain no cell structures.
• the expanded plastic particles generally have only a low content of propellant from 0 to 5 wt .-%, preferably 0.5 to 4 wt .-%, particularly preferably 1 to 3 wt .-% based on the total mass of plastic and blowing agent ,
• the resulting expanded plastic particles can be stored temporarily or be used without further intermediate steps for the preparation of the component B according to the invention.
• blowing agents known to those skilled in the art may be used, for example aliphatic C 3 to C 10 hydrocarbons, such as propane, n-butane, isobutane, n-pentane, isopentane, neopentane, cyclo-pentane and / or hexane and its Isomers, alcohols, ketones, esters, ethers or halogenated hydrocarbons, preferably n-pentane, isopentane, neopentane and cyclopentane, more preferably a commercially available pentane isomer mixture of n-pentane and iso-pentane.
• aliphatic C 3 to C 10 hydrocarbons such as propane, n-butane, isobutane, n-pentane, isopentane, neopentane, cyclo-pentane and / or hexane and its Isomers, alcohols
• the content of blowing agent in the expandable plastic particles is generally in the range of 0.01 to 7 wt .-%, preferably 0.01 to 4 wt .-%, particularly preferably 0.1 to 4 wt .-%, in each case based on the propellant-containing expandable plastic particles.
• styrene homopolymer also referred to herein simply as "polystyrene”
• styrene copolymer or mixtures thereof are used as the only plastic in component B.
• Such polystyrene and / or styrene copolymer can be prepared by all known in the art polymerization process, see, for. B. Ullmann's Encyclopedia, Sixth Edition, 2000 Electronic Release or Kunststoff-Handbuch 1996, Volume 4 "Polystyrene", pages 567 to 598 ,
• the production of the expandable polystyrene and / or styrene copolymer is generally 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, can be polymerized in the presence of a customary suspension stabilizer by means of free-radical-forming catalysts.
• the propellant and optionally further customary additives may be initially introduced into the polymerization, added to the batch in the course of the polymerization or after the end of the polymerization.
• the resulting bead-shaped, impregnated with blowing agent, expandable styrene polymers can be separated after the polymerization from the aqueous phase, washed, dried and sieved.
• the blowing agent can be mixed, for example via an extruder in the polymer, conveyed through a nozzle plate and granulated under pressure to particles or strands.
• the preferred or particularly preferred expandable styrene polymers or expandable styrene copolymers described above have a relatively low content of blowing agent. Such polymers are also referred to as "low blowing agent”.
• low blowing agent A well-suited process for producing low-blowing expandable polystyrene or expandable styrene copolymer is disclosed in US Pat US-A-5,112,875 which is incorporated herein by reference.
• styrene copolymers can also be used.
• these styrene copolymers at least 50 wt .-%, ie 50 to 100 wt .-%, preferably at least 80 wt .-%, ie 80 to 100 wt .-%, copolymerized styrene based on the mass of the plastic (without propellant) on , As comonomers come z. B.
• the polystyrene and / or styrene copolymer in copolymerized form contain a small amount of a chain splitter, d. H. 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 0.0005 to 0.5 mol%, based on styrene. Mixtures of different styrene (co) polymers can also be used.
• styrene homopolymers or styrene copolymers are glass clear polystyrene (GPPS), impact polystyrene (HIPS), anionically polymerized polystyrene or impact polystyrene (A-IPS), styrene- ⁇ -methylstyrene copolymers, acrylonitrile-butadiene-styrene polymers (ABS), styrene-acrylonitrile (SAN ), Acrylonitrile-styrene-acrylic esters (ASA), methyl acrylate-butadiene-styrene (MBS), methyl methacrylate-acrylonitrile-butadiene-styrene (MABS) polymers or mixtures thereof or with polyphenylene ether (PPE).
• GPPS glass clear polystyrene
• HIPS impact polystyrene
• A-IPS anionically polymerized polystyrene or impact poly
• Plastic particles particularly preferably styrene polymers or styrene copolymers, in particular styrene homopolymers having a molecular weight in the range from 70,000 to 400,000 g / mol, more preferably 190,000 to 400,000 g / mol, very particularly preferably 210,000 to 400,000 g / mol, are preferably used.
• expanded polystyrene particles or expanded styrenic copolymer particles may be further used without or with further blowing agent reduction measures to produce the lignocellulosic material.
• the expandable polystyrene or expandable Styrolcopoly merisat or the expanded polystyrene or expanded styrene copolymer has an antistatic coating.
• the expanded plastic particles B are usually after pressing to the lignocellulosic material, in unmelted state, which means that the plastic particles B are usually not penetrated into the lignocellulosic particles or these have been impregnated, but are distributed between the Lignocelluloseteilchen.
• the plastic particles B can be separated from the lignocellulose by physical methods, for example after comminution of the lignocellulose material.
• the total amount of the expanded plastic particles B, based on the total dry mass of the core, is generally in the range of 1 to 25 wt .-%, preferably 3 to 20 wt .-%, particularly preferably 5 to 15 wt .-%.
• the Rossin-Rammler-Sperling-Bennet function is described for example in DIN 66145.
• sieve analyzes are first carried out to determine the particle size distribution of the expanded plastic particles B and lignocellulose particles, preferably wood particles A in accordance with DIN 66165, Parts 1 and 2.
• Highly suitable lignocellulose particles A preferably wood particles, have an d 'value according to Rosin-Rammler-Sperling-Bennet (definition and determination of the d value as described above) in the range from 0.1 to 5, preferably 0.3 to 3 and more preferably 0.5 to 2.75.
• the total amount of the binder C, based on the total mass of the core is in the range of 1 to 50 wt .-%, preferably 2 to 15 wt .-%, particularly preferably 3 to 10 wt .-%.
• the total amount of the binder F, based on the total dry mass of the outer layer (s) is in the range of 1 to 30 wt .-%, preferably 2 to 20 wt .-%, particularly preferably 3 to 15 wt .-%.
• the binders of component C or of component F can be selected from the group consisting of aminoplast resin, phenoplast resin and organic isocyanate having at least two isocyanate groups, identical or different binders or binder mixtures of components C and F, preferably the same, more preferably in both cases aminoplast, can be used.
• the weight specification refers to the solids content of the corresponding component (determined by evaporation of the water at 120 ° C., within 2 hours) Günter Zeppenfeld, Dirk Grunwald, adhesives in the wood and furniture industry, 2nd edition, DRW-Verlag, page 268 ) and with regard to the isocyanate, in particular the PMDI (polymeric diphenylmethane diisocyanate), to the isocyanate component per se, that is, for example, without a solvent or emulsifier.
• the isocyanate in particular the PMDI (polymeric diphenylmethane diisocyanate)
• Phenoplasts are synthetic resins that are obtained by condensation of phenols with aldehydes and can be modified if necessary.
• phenol and phenol derivatives can be used for the production of phenoplasts.
• These derivatives can be cresols, xylenols or other alkylphenols, for example p-tert-butylphenol, p-tert-octylphenol and p-tert-nonylphenol, arylphenols, for example phenylphenol and naphthols, or divalent phenols, for example resorcinol and bisphenol A. , be.
• aldehyde The most important aldehyde for the production of phenoplasts is formaldehyde, which can be used in various forms, for example as an aqueous solution, or in solid form as paraformaldehyde, or as a formaldehyde-releasing substance.
• Other aldehydes for example, acetaldehyde, acrolein, benzaldehyde or furfural, and ketones may also be used.
• Phenoplasts can be modified by chemical reactions of the methylol groups or the phenolic hydroxyl groups and / or by physical dispersion in a modifier (EN ISO 10082).
• Preferred phenolic resins are phenol-aldehyde resins, particularly preferably phenol-formaldehyde resins (also called PF resins) are, for example Plastics Handbook, 2nd Edition, Hanser 1988, Volume 10 "Duroplasts", pages 12 to 40 known.
• aminoplast resin it is possible to use all the aminoplast resins known to those skilled in the art, preferably those known for the production of wood-based materials. Such resins and their preparation are, for example, in Ullmann's Encyclopedia of Industrial Chemistry, 4th, revised and expanded edition, Verlag Chemie, 1973, pages 403 to 424 "aminoplasts " and Ullmann's Encyclopedia of Industrial Chemistry, Vol. A2, VCH Verlagsgesellschaft, 1985, pages 115 to 141 "Amino Resins " as in M. Dunky, P. Niemz, wood materials and glues, Springer 2002, pages 251 to 259 (UF resins) and pages 303 to 313 (MUF and UF with a small amount of melamine) described.
• polycondensation products of compounds having at least one, optionally partially substituted by organic radicals, amino group or carbamide group (the carbamide group is also called carboxamide group), preferably carbamide group, preferably urea or melamine, and an aldehyde, preferably formaldehyde.
• Preferred polycondensation products are urea-formaldehyde resins (UF resins), melamine-formaldehyde resins (MF resins) or melamine-containing urea-formaldehyde resins (MUF resins), particularly preferred urea-formaldehyde resins, for example Kaurit® glue types from BASF SE.
• polycondensation products in which the molar ratio of aldehyde to the optionally partially substituted with organic radicals amino group or carbamide group in the range of 0.3: 1 to 1: 1, preferably 0.3: 1 to 0.6: 1, particularly preferably 0.3: 1 to 0.55: 1, very particularly preferably 0.3: 1 to 0.5: 1.
• the aminoplasts are used in combination with isocyanates, the molar ratio of aldehyde to the optionally partially substituted with organic radicals amino group or carbamide group in the range of 0.3: 1 to 1: 1, preferably 0.3: 1 to 0.6 : 1, more preferably 0.3: 1 to 0.45: 1, most preferably 0.3: 1 to 0.4: 1.
• the aminoplast resins mentioned are usually used in liquid form, usually as a 25 to 90% strength by weight, preferably as a 50 to 70% strength by weight solution, preferably in aqueous solution, but can also be used as a solid.
• the solids content of the liquid aqueous aminoplast resin can be determined according to Günter Zeppenfeld, Dirk Grunwald, adhesives in the wood and furniture industry, 2nd edition, DRW-Verlag, page 268.
• the components of the binder C and the binder F can be used alone, so for example aminoplast resin or organic isocyanate or PF resin as the sole constituent of the binder C or the binder F.
• the resin components of the binder C and the binder F but can also are used as a combination of two or more components of the binder C and / or the binder F, preferably these combinations contain an aminoplast resin and / or phenoplast resin.
• the binder C used may be a combination of aminoplast and isocyanate.
• the total amount of the aminoplast resin in the binder C based on the total dry weight of the core in the range of 1 to 45 wt .-%, preferably 4 to 14 wt .-%, particularly preferably 6 to 9 wt .-%.
• the components D and G may each independently or different, preferably the same, known in the art hardener or mixtures thereof. These are usually used when the binder C or F contains aminoplasts or phenoplast resins. These hardeners are preferably added to the binder C or F, for example in the range from 0.01 to 10% by weight, preferably from 0.05 to 5% by weight, particularly preferably from 0.1 to 3% by weight to the total amount of aminoplast resin or phenoplast resin.
• hardener for the aminoplast resin component or for the phenolic resin component herein are meant any chemical compounds of any molecular weight which cause or accelerate the polycondensation of aminoplast resin or phenol formaldehyde resin.
• a well-suited group of curing agents for aminoplast resin or phenolic resin are organic acids, inorganic acids, acid salts of organic acids and acid salts of inorganic acids, or acid-forming salts such as ammonium salts or acid salts of organic amines. The components of this group can of course also be used in mixtures.
• ammonium sulfate or ammonium nitrate or inorganic or organic acids for example sulfuric acid, formic acid or acid regenerating substances, such as aluminum chloride, aluminum sulfate or mixtures thereof.
• a preferred group of curing agents for aminoplast resin or phenoplast resin are inorganic or organic acids such as nitric acid, sulfuric acid, formic acid, acetic acid and polymers with acid groups such as homo- or copolymers of acrylic acid or methacrylic acid or maleic acid.
• Phenoplastharze preferably phenol-formaldehyde resins
• Phenoplastharze can also be cured alkaline.
• Carbonates or hydroxides such as potassium carbonate and sodium hydroxide are preferably used.
• aminoplast resin hardeners are available M. Dunky, P. Niemz, wood materials and glues, Springer 2002, pages 265 to 269 and other examples of curing agents for phenolic resins, preferably phenol-formaldehyde resins are made M. Dunky, P. Niemz, wood materials and glues, Springer 2002, pages 341-352 known.
• the lignocellulose materials according to the invention may contain further commercially available additives known to those skilled in the art as component D or component G independently of one another, identical or different, preferably identical, additives in amounts of 0 to 10% by weight, preferably 0.5 to 5% by weight preferably 1 to 3 wt .-%, for example Water repellents such as paraffin emulsions, antifungal agents, formaldehyde scavengers, for example urea or polyamines, and flame retardants.
• additives known to those skilled in the art as component D or component G independently of one another, identical or different, preferably identical, additives in amounts of 0 to 10% by weight, preferably 0.5 to 5% by weight preferably 1 to 3 wt .-%, for example Water repellents such as paraffin emulsions, antifungal agents, formaldehyde scavengers, for example urea or polyamines, and flame retardants.
• the ratio Z of the weight ratio X of expanded plastic particles to lignocellulose particles in the outer regions of the core is the weight ratio Y of expanded plastic particles to lignocellulose particles in the inner region of the core ("inside") 1.05: 1 to 1000: 1, preferably 1.1: 1 to 500: 1, particularly preferably 1.2: 1 to 200: 1.
• this ratio Z is 0.001: 1 to 0.95: 1, preferably 0.002: 1 to 0.9: 1, particularly preferably 0.005: 1 to 0.8: 1.
• the thickness of the lignocellulosic materials according to the invention with inhomogeneously distributed in the core present expanded plastic particles varies with the field of application and is usually in the range of 0.5 to 100 mm, preferably in the range of 10 to 40 mm, in particular 15 to 20 mm.
• Lignocellulose materials for example wood-based materials, are a cost-effective and resource-saving alternative to solid wood and have gained great importance, in particular in furniture construction, in laminate flooring and as building materials.
• starting materials are usually 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.
• 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. Furthermore, using light wood materials, for example, material-consuming decorative parts, thicker worktops and cheeks in kitchens, can be produced more cheaply.
• lignocellulosic materials For many applications, for example in the bathroom or kitchen furniture sector or in interior design lightweight and economical lignocellulosic materials are sought with improved mechanical properties, such as improved bending strength. In addition, such materials should have the best possible surface quality in order to apply coatings, such as a coating, with good properties can.
• the starting material was the expandable polystyrene Kaurit® Light 200 from BASF SE.
• the polystyrene particles were treated with steam in a batch prefoamer and foamed to a bulk density of 50 g / l.
• the resulting expanded plastic particles (Component B) were stored for 7 days at room temperature in an air-permeable cloth bag prior to further use.
• the component B is omitted, that is, the mixtures 2 and 3 then contain only the components A, C and D.
• the mixtures were each prepared in a laboratory mixer, the solid ingredients are initially presented and mixed.
• the liquid ingredients were premixed in a vessel and then sprayed.
• the binder used was Kaurit® glue 347 with a solids content of 67% from BASF SE (components C and F).
• Kaurit® glue 347 with a solids content of 67% from BASF SE (components C and F).
• For the mixture 10 parts by weight of water and 1 part by weight of 52% strength ammonium nitrate solution were added to the glue before application to the solid constituents of the mixture (in each case based on 100 parts by weight of Kaurit® glue 347).
• 4 parts by weight of 52% ammonium nitrate solution was added to the glue before application to the solid constituents of the mixtures (based on 100 parts by weight of Kaurit® glue 347).
• the amount of size liquor is adjusted to give a degree of gluing of 8.5%, ie 8.5 parts by weight of glue (based on solid substance) per 100 parts by weight of E (based on solid substance) in the mixture 1 or 8.5 parts by weight of glue (based on solid substance) per 100 parts by weight of the mixture of A and B (based on solid substance) in the mixtures 2 and 3.
• mixtures were stacked in a 30 x 30 cm form so that in a symmetrical structure a chip cake with 5 layers was formed (sequence: mixture 1, mixture 2, mixture 3, mixture 2, mixture 1).
• the amounts were chosen such that the weight ratio of the layers (based on dry matter) was 12.5: 18.8: 37.5: 18.8: 12.5.
• the mass ratio of the total amount of Component B contained in the inner three layers to the total amount of Component A contained in the inner three layers is equal to (based on solid substance).
• the total weight of the wood-based material mat was chosen such that at the end of the pressing process the desired density results at a nominal thickness of 16 mm.
• the chip cake was then cold precompressed and pressed in a hot press. In this case, a thickness of 16 mm was set.
• the pressing temperature was 210 ° C, the pressing time 150 s.
• the density was determined 24 hours after preparation according to EN 1058.
• the screw withdrawal resistance was determined according to DIN EN 320. Only the screw withdrawal resistances for the surfaces were measured.
• Examples 1 and 2 Comparative Examples without expanded plastic particles or with homogeneous distribution of the plastic particles in the core

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