WO2005023499A1 - Panneau de particules - Google Patents

Panneau de particules Download PDF

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Publication number
WO2005023499A1
WO2005023499A1 PCT/AU2004/001225 AU2004001225W WO2005023499A1 WO 2005023499 A1 WO2005023499 A1 WO 2005023499A1 AU 2004001225 W AU2004001225 W AU 2004001225W WO 2005023499 A1 WO2005023499 A1 WO 2005023499A1
Authority
WO
WIPO (PCT)
Prior art keywords
fibre
accordance
previous
board
manufacturing particle
Prior art date
Application number
PCT/AU2004/001225
Other languages
English (en)
Inventor
John Gorman
Original Assignee
John Gorman
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
Priority claimed from AU2003904904A external-priority patent/AU2003904904A0/en
Application filed by John Gorman filed Critical John Gorman
Priority to AU2004270291A priority Critical patent/AU2004270291A1/en
Publication of WO2005023499A1 publication Critical patent/WO2005023499A1/fr

Links

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
    • B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
    • 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
    • B27N1/00—Pretreatment of moulding material

Definitions

  • This invention relates generally to fibreboard and particleboard and methods of manufacture of fibreboard and particleboard.
  • Fibreboard and particleboard for use as panelling and other structural applications are known and generally comprise wood chips or fibres produced from trees of various types. This material is usually mixed with a binder to form the board or panel.
  • binders currently in use generally include adhesives such as isocyanates, urea formaldehydes and contribute to "sick building syndrome" and, even after curing and use, emit VOCs and other carcinogenic substances. This clearly presents safety hazards.
  • the present invention seeks to ameliorate one or more of the abovementioned disadvantages.
  • a method of manufacturing particle or fibre board including the steps of: preparation of agricultural fibre into fractions of a generally selected size; blending the fractions with an adhesive having selected properties to form a mixture; the blended mixture being pressed into a panel having selected properties.
  • a board or panel which is produced from fractionated agricultural fibre and an adhesive; the adhesive and agricultural fibre being blended together and pressed to form the panel or board.
  • the agricultural fibre is in the form of what is generally considered waste materials, which in one form is crop stubble, the stubble in one form being rice stubble.
  • the agricultural fibre is timber, although it will be appreciated that the requirement for timber plantations and the subsequent harvesting thereof adds to the cost of production of chipboard.
  • the panel includes crop stubble fractions which have been filtered for weeds, and subsequently milled or chopped.
  • the panel includes crop stubble fractions of differing sizes: a first size of crop stubble, having fibres of a size suitable for use with a core of the panel, and a second size of crop stubble having fibres of a size suitable for use with a surface of the panel.
  • the first crop stubble size is larger than the second size of crop stubble; the larger fibres being better suited to maintaining rigidity and structural strength, the smaller fibres providing an acceptable finish for consumers.
  • both sizes of fractionated crop stubble are able to pass through screens having apertures in a range of 1 to 65mm.
  • the first size of fractionated crop stubble pass through screens having apertures of approximately 6.35mm.
  • the second size of stubble is sized so that it will pass through the first screen, but also a further screen having apertures as small as 3.16mm.
  • the proportions of fractions in the panels may vary between 10%/90% first and second sizes respectively, to 90% and 10% of the first and second sizes respectively.
  • the panel includes the first and second fractions sizes in equal proportions.
  • the sizes of fractionated stubble are utilised in laminates comprising only like sizes of fractionated stubble. Any suitable number of laminates are contemplated as required, the laminates having fractionated stubble oriented in any suitable orientation.
  • the preparation step of the crop stubble may further include drying to remove moisture so that the fibres' strength may be properly utilized.
  • This drying in preferred forms is a matter of simply leaving harvested or unharvested stubble until the sun and general atmospheric conditions dry out the stubble, or it may in other preferred forms be commercial processes such as blow line drying or batch processes such as oven drying overnight. Any suitable temperature and humidity may be employed such as for example between 40 and 200 degrees Celsius, however, preferably the temperature is approximately 105°C.
  • the dried crop stubble may be stored in sealed containers until the stubble is blended with the adhesive.
  • the moisture content of the agricultural fibre after drying is in a range of between 0.5% and 10%. In one form contemplated by preferred embodiments of the invention, the moisture content of rice stubble is 1% - 2%.
  • the adhesive may take any suitable form, however it is preferred that phenol formaldehyde (PF) resins are utilised to reduce safety hazards from use of adhesives such as VOCs, isocyanates and other hazardous and carcinogenic compounds such as MDIs.
  • PF phenol formaldehyde
  • PF resins which "wet" surfaces of fractionated crop stubble are utilised to aid the adhesive process.
  • crop stubble such as rice stubble is used as agricultural fibre
  • this type of resin is advantageous because the rice stubble has a high-gloss, waxy, silicacious surface which repels water and has a low surface energy.
  • PF resin such as that described in Australian patent 763697 is utilised.
  • CSIRO Commonwealth Scientific and Industrial Research Organisation
  • cured PF resins have substantially no free formaldehyde emissions, and MDIs are associated with carcinogenic issues when aero-soled and inhaled by workers.
  • Blending of adhesive and agricultural fibre may be performed by any suitable process. First and second sizes of fractionated agricultural fibres are preferably blended with adhesive separately. Blending is preferably performed in a paddle style blender or high velocity blow line blender, or a tumbling drum, or dry air mix in an airless spray blender, so that each fibre is substantially coated with resin about its outside surface.
  • the adhesive is generally applied in a much drier state than typically is performed with other resins or processes, and appears as a powdery coating on the surface of each fractionated agricultural fibre.
  • the adhesive and agricultural fibre may be blended in any suitable proportions, such as for example within a range of between approximately 8% and 15%. In a preferred embodiment the mixture has an approximately 10% adhesive loading, meaning the adhesive is applied at a rate of 10% solids on oven dry straw (weight of water on total weight).
  • the mixture is laid down into a mat. Subsequent to that laying down, pressing takes place.
  • the pressing of the mixture may include heating, and in a preferred form, simultaneous heating and pressing by utilising heated rollers or platens.
  • hot pressing is carried in multiple daylight presses out using platen temperatures in a range of approximately 150 - 250°C, for a time period of between approximately 3 and 10 minutes.
  • One preferred embodiment utilises a temperature of 200°C for 7.5 minutes using position control.
  • Further processing may be performed, after pressing, in the form of cooling. The cooling may, in a preferred form occur slowly by placing the panel between insulated surfaces in a process called "hot stacking".
  • the panel may be any suitable size or density, however in preferred embodiments the thickness of the panels lie in the range of approximately 3 - 50mm. In one preferred form the panel thickness is approximately 15mm and the density is within a range of approximately 500 - 900kg/m 3 .
  • Vibration of the mat may take place to enhance compaction of the mixture before pressing.
  • the mixture is preferably relatively dry, therefore vibrating or patting the mat allows the mixture to settle, reducing the thickness of the mat, increasing its density. In this manner, it is believed that the fractionated fibres are moved into a position normal to the plane of the panel and improve its density.
  • the panel is provided with an ability to tolerate aggressive environments such as elevated temperatures and high humidity and wet environments.
  • the panel emits substantially no VOCs once pressed, and is lighter than chipboard, even though fractions may be packed more tightly than in other boards. It is believed that preferred embodiments of the panel will not allow oxygen to enter the laminate, and the panel will smolder only when placed under fire tests, because the fibre of preferred embodiments comprises starch and cellulose, rather than sugars.
  • Figure 1 is a section view of a panel in accordance with the present invention.
  • a section view of a panel 10 which includes agricultural fibre 11 in the form of fractionated rice stubble 12.
  • the fibre 11 has been blended with binder in the form of phenol formaldehyde (PF) resin (not shown) and pressed utilising a heated mandrel (not shown).
  • the rice stubble 12 has been fractionated into two sizes, a first size 14 suitable to fit through a screen of 6.35mm (not shown).
  • the first size of fractionated rice stubble 14 is disposed in the core 16 of the panel 10, so that increased strength may be obtained.
  • the second size 18 of the fractionated rice stubble 12 in the panel 10 is smaller than the first size 14, being suitable to fit through a screen of 3.16mm (not shown).
  • the second size 18 of rice stubble 12 is smaller and is grouped and utilized on the outside 20 of the panel 10, so as to present an aesthetically pleasing finish to users.
  • the example panel described herein was produced under laboratory conditions and as such, some equipment used was laboratory-scale. Clearly, similar panels would easily be produced using commercial-scale equipment.
  • a particle board panel 10 was manufactured from agricultural fibre in the form of milled rice stubble 12 and binder in the form of phenol formaldehyde (PF) resin. Desired panel density was 675 kg/m 3 . Mean panel density was lower than the desired density, being approximately 630 kg/m . This was likely to have been caused by thickness spring-back on exiting the hot press.
  • PF phenol formaldehyde
  • the stubble was reduced in size to smaller fractions using a chopping action (without creating a hollow drinking-straw effect), in the form of being passed through a
  • Wiley mill (a hammer mill) fitted with screen having apertures of 6.35 mm (1/4 inch). During subsequent milling, the straw was screened through a 3.16 mm (1/8 inch) sieve. This produced two fractions: firstly, a coarse fraction for 'core' material which provides strength and secondly a fine fraction for use in panel faces to provide an acceptable finish to a consumer. The proportion of core material to face material was 1:1.
  • the separated straw fractions were oven dried overnight at 105°C and sealed in plastic bags until used for panel fabrication.
  • a binder was used, which has the ability to "wet" the surface of the stubble to improve the binding process.
  • the binder was in the form of a phenol formaldehyde resin, in the form described by AU patent 763697 and /or CSIRO phenol formaldehyde (PF) resin #779. This was applied to rice straw fractions, each size being mixed with the binder in separate operations using an airless spray in a tumbling drum.
  • the fine fraction was set aside to be used in a lamina at the panel surface layers and the coarse fraction set aside for use in a lamina disposed at the panel core.
  • the blended rice straw furnish was hand-laid into mattresses in a 55x55 cm forming box and transferred to the heated platen press, sandwiched between non-stick mylar sheets (0.1 mm thick) and aluminium caul plates (2.5 mm thick). Hot pressing was carried out using platen temperatures of 200°C for 7.5 minutes using position control. Target panel thickness was 15 mm, with a target density of approximately 675 kg/m 3 . On exiting the press, panels were placed between plywood sheets to facilitate controlled slow cooling. After trimming, the surfaces of panels were lightly sanded with 180 grit paper.
  • the panel is neither standard particle board nor MDF but a highly moisture resistant particle board with fine particle structure and hence suitable for wet area construction and for those items of furniture manufacture normally the domain of MDF.
  • Panels were created using differing amounts of water. It was found that sufficient water is required to be present in the agricultural fibre to initiate a chemical curing reaction, but not so much as to create unstable bonds. Thus, a range of 5% to 15% of residual water in the agricultural fibre was utilised in other examples.
  • the size of the fractions depends on the rate of feed through the mill. Average thicknesses of the first size of fractions were approximately 6.35mm, however, they varied between 4 and 30 mm in other panels which were made. The second size of fractions varied in size between 1 and 7 mm in length, in panels which were made.
  • the mandrels were heated up to temperature so that full curing was initiated, and then pressure was applied.
  • the load required was approximately 200 tonnes. Heating up the mandrels to temperature before pressing ameliorated the problem of hot patches and cold patches within the panel, and provided a more even heating.

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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

Dans un de ses modes de réalisation, l'invention se rapporte à un procédé de fabrication d'un panneau de particules ou de fibres, ledit procédé comprenant les étapes consistant à préparer une fibre d'origine agricole en la divisant en fractions d'une taille généralement sélectionnée; à mélanger les fractions à un adhésif ayant des propriétés sélectionnées de manière à obtenir un mélange; et à comprimer le mélange brassé de manière à obtenir un panneau de particules ayant des propriétés sélectionnées. Dans un autre mode de réalisation, la présente invention se rapporte à une planche ou un panneau qui est produit à partir d'une fibre d'origine agricole fractionnée et d'un adhésif; l'adhésif et la fibre d'origine agricole étant mélangés et comprimés aux fins de la formation du panneau ou de la planche.
PCT/AU2004/001225 2003-09-09 2004-09-09 Panneau de particules WO2005023499A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2004270291A AU2004270291A1 (en) 2003-09-09 2004-09-09 Particle board

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2003904904A AU2003904904A0 (en) 2003-09-09 Particle board
AU2003904904 2003-09-09

Publications (1)

Publication Number Publication Date
WO2005023499A1 true WO2005023499A1 (fr) 2005-03-17

Family

ID=34230087

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU2004/001225 WO2005023499A1 (fr) 2003-09-09 2004-09-09 Panneau de particules

Country Status (1)

Country Link
WO (1) WO2005023499A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN100400254C (zh) * 2006-07-13 2008-07-09 万华生态板业股份有限公司 一种利用农作物秸秆生产板材的方法
EP2337682A1 (fr) * 2008-10-16 2011-06-29 Swedwood International AB Panneaux de particules à couche centrale de particules défibrées
CN106239690A (zh) * 2016-07-20 2016-12-21 山东农业大学 一种杨木与玉米秸秆砖的热空气干燥方法
WO2018018079A1 (fr) * 2016-07-25 2018-02-01 Ampan Naturally Pty Ltd Panneau et son procédé de production

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1653239A1 (de) * 1968-02-10 1971-11-11 Hombak Maschinenfab Kg Verfahren zur Herstellung von Holzwerkstoffen
JPS5276385A (en) * 1975-12-20 1977-06-27 Noda Plywood Mfg Co Ltd Process for manufacturing fiberboard
DD137681A1 (de) * 1978-07-14 1979-09-19 Baumann Rolf Ruediger Verfahren zur verarbeitung von holz-hackschnitzelfeinanteilen fuer die herstellung mehrschichtiger faserplatten mittlerer dichte
US4200430A (en) * 1977-08-06 1980-04-29 Eduard Kusters Apparatus for the manufacture of sheets
CA2039559A1 (fr) * 1990-04-03 1991-10-04 John T. Clarke Structure composite a panneaux a copeaux orientes et methode de fabrication connexe
WO2000009305A1 (fr) * 1998-08-10 2000-02-24 Borden Chemical, Inc. Ameliorations apportees a l'ensimage a la cire et a la liaison a la resine d'un composite lignocellulosique
WO2001007219A1 (fr) * 1999-05-05 2001-02-01 Renshu Lu Plaque en fibre de paille de ble a densite moyenne et son procede d'obtention
US20010017428A1 (en) * 1998-12-16 2001-08-30 Stanislav Klasterka Apparatus and a method for scattering particles to form a mat
WO2002014039A1 (fr) * 2000-08-10 2002-02-21 California Agriboard, Llc. Production d'un panneau de particules a partir de dechets agricoles
WO2002062866A1 (fr) * 2001-02-08 2002-08-15 Battelle Memorial Institute Composites de fibres cellulosiques comprenant des hydrolysats proteiques et procedes de fabrication de ceux-ci

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1653239A1 (de) * 1968-02-10 1971-11-11 Hombak Maschinenfab Kg Verfahren zur Herstellung von Holzwerkstoffen
JPS5276385A (en) * 1975-12-20 1977-06-27 Noda Plywood Mfg Co Ltd Process for manufacturing fiberboard
US4200430A (en) * 1977-08-06 1980-04-29 Eduard Kusters Apparatus for the manufacture of sheets
DD137681A1 (de) * 1978-07-14 1979-09-19 Baumann Rolf Ruediger Verfahren zur verarbeitung von holz-hackschnitzelfeinanteilen fuer die herstellung mehrschichtiger faserplatten mittlerer dichte
CA2039559A1 (fr) * 1990-04-03 1991-10-04 John T. Clarke Structure composite a panneaux a copeaux orientes et methode de fabrication connexe
WO2000009305A1 (fr) * 1998-08-10 2000-02-24 Borden Chemical, Inc. Ameliorations apportees a l'ensimage a la cire et a la liaison a la resine d'un composite lignocellulosique
US20010017428A1 (en) * 1998-12-16 2001-08-30 Stanislav Klasterka Apparatus and a method for scattering particles to form a mat
WO2001007219A1 (fr) * 1999-05-05 2001-02-01 Renshu Lu Plaque en fibre de paille de ble a densite moyenne et son procede d'obtention
WO2002014039A1 (fr) * 2000-08-10 2002-02-21 California Agriboard, Llc. Production d'un panneau de particules a partir de dechets agricoles
WO2002062866A1 (fr) * 2001-02-08 2002-08-15 Battelle Memorial Institute Composites de fibres cellulosiques comprenant des hydrolysats proteiques et procedes de fabrication de ceux-ci

Non-Patent Citations (4)

* Cited by examiner, † Cited by third party
Title
DATABASE WPI Derwent World Patents Index; Class A32, AN 1985-165688 *
DATABASE WPI Derwent World Patents Index; Class A81, AN 1977-56467Y *
DATABASE WPI Derwent World Patents Index; Class A81, AN 1979-88706 *
DATABASE WPI Derwent World Patents Index; Class A81, AN 2001-398715 *

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN100400254C (zh) * 2006-07-13 2008-07-09 万华生态板业股份有限公司 一种利用农作物秸秆生产板材的方法
EP2337682A1 (fr) * 2008-10-16 2011-06-29 Swedwood International AB Panneaux de particules à couche centrale de particules défibrées
EP2337682A4 (fr) * 2008-10-16 2012-03-28 Swedwood Internat Ab Panneaux de particules à couche centrale de particules défibrées
CN106239690A (zh) * 2016-07-20 2016-12-21 山东农业大学 一种杨木与玉米秸秆砖的热空气干燥方法
WO2018018079A1 (fr) * 2016-07-25 2018-02-01 Ampan Naturally Pty Ltd Panneau et son procédé de production

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