WO2002081162A1 - Incorporation d'ignifugeants phosphates ou borates dans des composites a base de bois - Google Patents

Incorporation d'ignifugeants phosphates ou borates dans des composites a base de bois Download PDF

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Publication number
WO2002081162A1
WO2002081162A1 PCT/US2001/049991 US0149991W WO02081162A1 WO 2002081162 A1 WO2002081162 A1 WO 2002081162A1 US 0149991 W US0149991 W US 0149991W WO 02081162 A1 WO02081162 A1 WO 02081162A1
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WO
WIPO (PCT)
Prior art keywords
wood
fire retardant
fire
based composite
binder
Prior art date
Application number
PCT/US2001/049991
Other languages
English (en)
Inventor
Kenneth David Roos
Kevin J. Archer
Original Assignee
Chemical Specialities, Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Chemical Specialities, Inc. filed Critical Chemical Specialities, Inc.
Publication of WO2002081162A1 publication Critical patent/WO2002081162A1/fr

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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
    • B27N9/00—Arrangements for fireproofing

Definitions

  • Another aspect of the invention is the product formed according to the preceding process.
  • aqueously applied fire retardant is not easily leached out of the composite board after treatment. This result is surprising.
  • the fire retardant may also act as a catalyst to cure the binder and thus promote binding; this is also surprising.
  • the addition of the fire retardant in aqueous form to green wood chips, without the need to dry them to a low moisture content first is believed to be novel, and saves the energy which would otherwise be expended by drying the green wood chips before treatment, then applying the aqueous fire retardant (and also rewetting the chips), and finally drying the chips a second time.
  • the present OSB is made by providing a green wood furnish, treating the green wood furnish with a phosphate/borate fire retardant material, treating the furnish with a binder, and pressing the binder-treated furnish to form boards having the desired dimensions.
  • the green wood furnish can be prepared by various conventional techniques.
  • milling, planing, sanding, sawing, or other wood processing waste can be processed into a suitable wood furnish.
  • These furnishes made from processed woods may already be classified adequately in size to avoid the need for classification as outlined above.
  • Flakes longer than about 3.5 inches (9 cm) may tend to curl which hinders proper alignment during mat formation, and it is difficult to insure that flakes shorter than about 0.5 inch (1 cm) do not become aligned with their grain direction cross-wise. Flakes thinner than about 0.01 inch (0.25 mm) tend to require excessive amounts of binder to obtain adequate bonding, and flakes thicker than about 0.05 inch (1.3 mm) are relatively stiff and tend to require excessive compression to obtain the desired intimate contact between them. In any given batch, some of the flakes generally will be shorter than 0.5 inch (1 cm) or longer than 6 inches (15 cm).
  • the wood furnish of oriented wood composite products can be assembled or maintained as one or more strata or layers.
  • the furnish can have a grain direction extending generally parallel to the machine direction - the direction of travel of wood through the process.
  • at least 90% of the particles in the wood furnish are oriented in the recited manner.
  • green wood includes both (1) wood that has not been dried; and (2) wood that has been dried and has been rewetted to a moisture content of at least about 30% MC. The use of a green wood furnish ensures that the penetration of the FRT is maximized.
  • the moisture content may optionally be from about 60% to about 80% by weight, optionally from about 50% to about 70 % by weight, based on the weight of dry wood. Moisture contents outside these ranges that are found in green wood are also contemplated. In contrast, the moisture content to which the furnish is dried traditionally has been in the order of from about 20 weight
  • the fire retardants contemplated herein are phosphate/borate composite compositions.
  • One class of these compositions employs an inorganic monobasic, dibasic, or tribasic phosphate with the borate.
  • suitable phosphates include alkah metal phosphates, alkaline earth metal phosphates, ammonium phosphates, such as monoammonium phosphate or diammonium phosphate, or others.
  • a system for incorporating an ammonium phosphate/borate fire retardant treatment (FRT) into the manufacturing process for wood based composites is disclosed in U.S. Patent No. 4,725,382 (which is hereby incorporated herein by reference in its entirety for its description of fire retardant compositions and their use).
  • Ammonium phosphate/borate fire retardant treatments (FRT) are commercially available from Chemical Specialties, Inc., Charlotte, North Carolina.
  • Yet another alternative is to apply the FRT in dry, powdered form to the green flakes, which has the potential to still further reduce the amount of water that must be dried from the flakes.
  • the water in the green flakes particularly the water expressed when the flakes are pressed to form a board, solubilizes or transports at least part of the FRT into the flakes.
  • the moisture resistance of the structural member can be improved by spraying a liquid wax emulsion onto the particles during or after the stabilizer blending step.
  • the wax can be, for example, the aliphatic or paraffinic petroleum product commonly known as slack wax.
  • Slack wax is the wax recovered from a petroleum hydrocarbon by either solvent or propane dewaxing, and can contain entrained oil in an amount varying up to about 50%, alternatively 35% oil. This is the first waxy material separated in the refining of crude oil.
  • the specific resins that may be used include phenolic, urea formaldehyde (UF), phenol formaldehyde (PF) in a liquid or powder state, liquid melamine urea formaldehyde (MUF), resorcinol-formaldehyde, melamine-formaldehyde, urea- furfural, condensed furfuryl alcohol, acid catalyzed PF resins (commonly known as Novalac resins) isocyanate (MDI), or combinations of those resins.
  • the particular type of binder used depends primarily upon the intended use for the structural member.
  • Addition rates may vary from 1% to 15% resin solids depending on panel type and application.
  • a PMF (Phenol-melamine-formaldehyde) adhesive for example ARC- 9707, is used in the addition rate of 2-15% active. More ideally the resin should be used at an addition rate of 3-8% active. Under normal circumstances the use of this resin dictates the use of an acid catalyst.
  • Catalyst addition rates that are typically recommended for this purpose can vary from 0.5% to 15% on a liquid to liquid basis. Before this invention was made, ideally the addition rate was from 3-9% on a liquid to liquid basis.
  • the catalyst can be reduced, or in some instances eliminated, when practicing the present invention.
  • the particles can be circulated in a rotating drum mixer and sprayed with the FRT, wax, and binder using one or more Coil spinning disc atomizers.
  • the particles are formed by suitable apparatus into a generally flat, loosely- felted mat, having one or more layers, and the mat is placed in a suitable press and compressed to consolidate the wood particles into a structural member of the desired size and cross-sectional shape.
  • the particles can be deposited on a platelike carriage carried on an endless belt or conveyor from one or more hoppers spaced above the belt in the direction of travel.
  • a plurality of hoppers is used with each having a dispensing or forming head extending across the width of the carriage for successively depositing a separate layer of the particles as the carriage is moved beneath the forming heads.
  • the process can be carried out on a batch basis, i.e. individual sheets of the wood composite can be molded by treating an appropriate volume of particles with the binder resin combination and heating and pressing the treated material.
  • the process can be carried out in a continuous manner by feeding treated particles in the form of a continuous web or mat through a heating and pressing zone defined by upper and lower continuous steel belts, through which the necessary heat and pressure are applied.
  • Pressing temperatures, pressures, and times vary widely depending on the thickness and the desired density of the structural member or component, size and type of wood particles, moisture content of the particles, and the type of binder.
  • the pressing temperature used is sufficient to at least partially cure the binder and expel water from the mat within a reasonable time period, without charring the wood.
  • a pressing temperature ranging from ambient (for room temperature- curable binders) up to about 450° F (230° C) can be used. Temperatures above 450° F (230° C) can cause charring of the wood particles.
  • a pressing temperature of about 350° F (175° C) to about 425EF (220° C) is generally preferred for phenol- formaldehyde resin binders.
  • the level of catalyst needed to cure the resin can be reduced, and potentially reduced to zero, while at the same time permitting the manufacture of boards with excellent mechanical and physical properties as will be demonstrated later in Example 3.
  • the dry treated furnish is sprayed with resin and wax, formed and oriented into a mat of the desired thickness and pressed into the final panel.
  • the physical and structural characteristics of the FRT enhanced wood based composite can be equivalent in magnitude to similarly manufactured but untreated composites. Mats are formed to suit the type of composite and desired end use. Formed mats are pressed under heat and pressure conditions appropriate to the final end use of the finished board. Typical press parameters include consolidation pressures ranging
  • Press time may vary from 1 minute to 20 minutes duration.
  • fire resistance of wood based composites can be enhanced if panels that are integrally treated using the invention described above are also surface treated by spray or dip application with an intumescing type fire retardant formulation.
  • panel product Potential uses for this type of panel product include web stock for engineered wood I- beams; sheathing and roofing in commercial buildings; and various uses in multi-unit residential housing applications.
  • the strands were hand formed with a random orientation into 24 inch by 24 inch (61 cm by 61 cm) mats onto tight woven screens to allow off-gassing during the pressing operation.
  • the mats were homogenous, in that there was no differentiation between the core and face layers.
  • Pressing was accomplished using a 100-ton (90 metric ton) Wabash lab press. Press platen temperature was 380°F (190°C). Panels were consolidated to target thickness of 1/2- inch (13 mm) in 30 seconds at 550 psig (380 N/cm 2 ). Pressure was reduced to 250 psig (172 N/cm 2 ) after one minute. Total press time was six minutes with an additional 30 seconds de-gas.
  • the target density was elevated slightly from the industry standard 39 pcf (pounds per cubic foot) (0.63 g/cm ) to 42 pcf (0.67 g/cm ) to compensate for the solids loading of the FRT. Panels were hot stacked for 24 hours to allow for total resin cure prior to testing. Finally the test panels were trimmed to dimensions of 1 inch x 1 inch (25 mm by 25 mm) using a table saw.
  • the addition of the fire retardant changed the appearance of the finished panels in at least two ways.
  • the first observation was that the overall color of the boards became a darker brown. The intensity of the brown increased with increasing fire retardant concentration.
  • a bright yellow particulate deposit was observed randomly distributed on and around the flakes. The amount of the deposit present seemed to increase with increasing fire retardant loading. The yellow material was not easily dislodged by mechanical scraping and could not be washed off the surface of the boards with deionized water. Although they do not intend to be bound to the accuracy of this theory, the inventors believe that the product is formed from a reaction of the fire retardant with the resin/catalyst combination.
  • ComptrolTM was increased from 0-4%, the stiffness increased then tailed off at the 8% loading. This tailing off effect of the stiffness at 8% ComptrolTM loading may or may not be due to the addition rate.
  • the resin used in this Example was an acid catalyzed material. The resin and catalyst levels were held constant for all four combinations. At the 8% loading of Comptrol,TM the addition of this fire retardant is believed to impart a catalytic effect on the resin cure rate given the parameters used in this study. Hence, the inventors contemplate that the catalyst level should be reduced to optimize bending properties at higher ComptrolTM loadings.
  • Example 1 shows that the use of the phosphate/borate fire retardant in combination with the ARC PMF resin system created several very interesting and novel phenomena. In essence it appeared that under the physical conditions generated in the press a new and potentially novel material was created by the combination of resin, catalyst and fire retardant.
  • Example 2 was designed to investigate that interaction in greater detail.
  • European patent application EP0915141A1 describes a novel liquid PMF resin system catalyzed by simple organic acids such as formic acid and citric acid. While the inventors do not intend to limit the claims according to the accuracy of this theory, the inventors believe that similar catalytic properties might be ascribed to simple low molecular weight inorganic acids such as phosphoric acid H 3 (PO 4 ), formed from the fire retardant phosphate components. To evaluate the potential significance of these phenomena to the invention, series of small experiments were conducted as described below.
  • a second series of panels was manufactured using the parameters and procedures defined in Example 1.
  • Mixed aspen and birch flakes were sprayed with sufficient ComptrolTM concentrate such that the final loading in the finished panel was equivalent to 6% m/m P 2 O 5 in both the face and core.
  • After drying the treated flakes were divided into four equal sized batches.
  • ARC 9707 resin was applied to each batch of flakes at an addition rate of 4.5%, based on resin solids and oven-dry weight of the strands and ComptrolTM mix.
  • the amount of wax emulsion applied to each batch of flakes was kept constant at an addition rate of 1.0%.
  • the amount of resin catalyst applied was varied.
  • Treated and untreated panels were conditioned at 90- 95% RH and a temperature of 175°F for a period of 28 days. At the end of the exposure period the panels were removed and tested to determine the residual strength and stiffness. Comparisons were made with matched panels maintained at ambient temperature and humidity in an air-conditioned laboratory. Results are presented in Table 3.
  • the FRT and resin were combined and on a 250 grams solution basis in disposable beakers. Where a catalyst was needed the amount added was based on resin solution, 2.56 grams.
  • the resin and catalyst sample alone was mixed to 250 grams solution basis.
  • the powdered ComptrolTM (made by drying the liquid concentrate) was added to the resin solution then catalyst added if called for. Once thoroughly mixed, part of each sample was poured into a clean glass jar. These jars were placed in a forced air oven at 380°F (193°C) until the jar containing the sampled solidified. This varied from 15 minutes to about 45 minutes depending on the use of a catalyst (or not).

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Wood Science & Technology (AREA)
  • Forests & Forestry (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)

Abstract

La présente invention concerne l'ignifugation d'un composite à base de bois par traitement d'une pièce de bois vert avec une quantité d'ignifugeant phosphaté ou boraté suffisante pour obtenir une meilleure résistance au feu du composite que le même composé non ignifugé. En mélangeant à un liant la pièce de bois vert ignifugée puis en la liant, notamment par pressage, on obtient un composite à base de bois ignifugeant résistant à la lixivation. L'invention concerne également un produit obtenu selon ce procédé. L'ignifugeant peut également servir de catalyseur de polymérisation du liant, favorisant ainsi la liaison. On considère également tenir dans le cadre de l'invention l'adjonction d'ignifugeant à des copeaux de bois vert, sans avoir à abaisser leur teneur en eau par séchage.
PCT/US2001/049991 2000-10-23 2001-10-23 Incorporation d'ignifugeants phosphates ou borates dans des composites a base de bois WO2002081162A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US24250500P 2000-10-23 2000-10-23
US60/242,505 2000-10-23
US27487501P 2001-03-09 2001-03-09
US60/274,875 2001-03-09

Publications (1)

Publication Number Publication Date
WO2002081162A1 true WO2002081162A1 (fr) 2002-10-17

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017144759A1 (fr) * 2016-02-23 2017-08-31 Financiera Maderera, S.A. Procédé de fabrication de panneaux allégés stratifiés multicouches et panneau obtenu selon ledit procédé
EP3727771A4 (fr) * 2017-12-20 2021-11-17 Burnblock Holding APS Imprégnation ignifuge de plaques en bois

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3874990A (en) * 1973-06-13 1975-04-01 Collins Pine Company Flame-retardant particle-board and process for making same
US5064689A (en) * 1989-03-20 1991-11-12 Weyerhaeuser Company Method of treating discontinuous fibers
US5593625A (en) * 1992-08-11 1997-01-14 Phenix Biocomposites, Inc. Biocomposite material and method of making

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3874990A (en) * 1973-06-13 1975-04-01 Collins Pine Company Flame-retardant particle-board and process for making same
US5064689A (en) * 1989-03-20 1991-11-12 Weyerhaeuser Company Method of treating discontinuous fibers
US5593625A (en) * 1992-08-11 1997-01-14 Phenix Biocomposites, Inc. Biocomposite material and method of making

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017144759A1 (fr) * 2016-02-23 2017-08-31 Financiera Maderera, S.A. Procédé de fabrication de panneaux allégés stratifiés multicouches et panneau obtenu selon ledit procédé
EP3727771A4 (fr) * 2017-12-20 2021-11-17 Burnblock Holding APS Imprégnation ignifuge de plaques en bois

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