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

Definitions

• the present invention relates to the field of wood and / or composites, in particular chipboard and fiberboard, insulation boards, boards and composite materials containing lignocellulose and popcorn.
• Wood and / or composite materials, in particular chipboard or fiberboard have been known for more than a hundred years as an alternative for solid wood in the furniture industry, construction, etc.
• chipboard or fiberboard have been known for more than a hundred years as an alternative for solid wood in the furniture industry, construction, etc.
• For the quality of wood and / or composite materials several factors play a role, in particular the bulk density, the transverse tensile strength and the thickness, but in many applications the flexural strength.
• WO 2008/040747 discloses wood and composites containing popcorn. These have the advantage of a low density. However, it is the task of further improving the wood and / or composite material disclosed therein. This is achieved by a wood and / or composite panel according to the present invention. Accordingly, a wood and / or composite sheet is proposed, comprising an upper and a lower cover layer and an intermediate layer, wherein - the intermediate layer contains popcorn and -
• the upper and the lower cover layer consist of materials which have a modulus of elasticity (modulus of elasticity) of> 1 kN / mm 2 to ⁇ 70 kN / mm 2 .
• wood and / or composite material is understood to mean, in particular, materials which consist mainly of mechanically or thermomechanically, chemo-thermomechanically comminuted lignocellulose-containing material or popcorn, which are shaped after gluing with a synthetic or natural binder and added under temperature and pressure Wood and / or composites are pressed.
• the wood and / or composite board according to the invention may contain even more than the three mentioned layers (upper and lower cover layer and intermediate layer). Usually, and thus according to a preferred embodiment, however, it is a three-layer wood and / or composite board.
• the individual layers of the wood and / or composite board according to the invention are explained in detail: a) Cover layers
• the cover layers of the wood and / or composite board according to the invention - as mentioned - each have a modulus of elasticity (modulus of elasticity) of> 1 kN / mm 2 up to ⁇ 70 kN / mm 2 .
• the modulus of elasticity is preferably from> 1.5 kN / mm 2 to ⁇ 50 kN / mm 2 , more preferably> 2 kN / mm 2 to ⁇ 40 kN / mm 2 , and most preferably> 3 kN / mm 2 to ⁇ 30 kN / mm 2 , and most preferably from> 5 kN / mm 2 to ⁇ 10 kN / mm 2 .
• the modulus of elasticity for wood-based materials is measured according to DIN EN 310.
• the lower and / or upper cover layer preferably has a density of 0,5 0.5 g / cm 3 to ⁇ 3.0 g / cm 3 .
• the lower and / or upper cover layers have a density of 0,8 0.8 g / cm 3 to ⁇ 2.5 g / cm 3 , more preferably from 0 0.9 g / cm 3 to ⁇ 1.5 g / cm 3
• the proportion of the cover layers is from 1 1% to ⁇ 50% of the total wood and / or composite panel according to the invention (% by weight / weight). This has proved to be advantageous, since the density of the wood and / or composite board according to the invention remains low, but nevertheless the surprising increases in flexural strength can be observed. Even more preferably, the proportion of cover layers is from 10 10% to ⁇ 30% of the total wood and / or composite panel of the invention (weight / weight).
• the lower and / or upper cover layer consist predominantly of a material selected from the group consisting of wood chips or fibers, lignocellulose-containing chips and / or fibers (such as, for example, hemp, flax, etc.), or melamine film , HPL (High Pressure Laminate), CPL (Continuous Pressure Laminate), Chipboard (eg Thin Chipboard), Fiberboard (Thin HDF), Aluminum Sheet / Sheet, Metal Sheet / Sheet, Sheet Metal, Plywood, Veneer, Glass Fiber, Carbon Fiber, Carbon fiber, ceramic and possibly other additives such. As hydrophobing agents, anti-flame agents, binders and mixtures of all these materials.
• the intermediate layer contains - as described - popcorn.
• the "popcorn" in the context of the present invention comprises in particular all materials which, like the puffed corn (Zea mays, convar Microsperma), if appropriate after adequate greasing, explode at high temperatures due to rapid heating by the water present in the seed evaporating abruptly Such behavior is known inter alia by quinoa grain, amaranth, rice or even wheat, materials based on these raw materials are explicitly referred to in the context of the present invention as "a foamy consistency.” Popcorn "and includes, the term” popcorn "should not be limited to corn and was chosen especially for reasons of simplicity, clarity and readability.
• the intermediate layer preferably comprises ⁇ 60% (w / w), more preferably ⁇ 80% (w / w), still more preferably ⁇ 90% (w / w) and ⁇ 95% (w / w) of popcorn and otherwise preferably predominantly of wood chips and / or wood fibers, preferably here.
• lignocellulosic chips and / or fibers such as of hemp, flax, etc.
• plastics thermoplastics, thermosets, plastic fibers, such as.
• PP polypropylene
• PE polyethylene
• PVAc polyvinyl acetate
• PP PE supporting fibers
• additives such as.
• the intermediate layer may consist of 100% popcorn.
• the popcorn has a particle size distribution in which ⁇ 50% and ⁇ 90% of the popcorn have a particle size of ⁇ 2 mm and ⁇ 10 mm.
• Popcorn of larger grain size is often less suitable for processing into lignocellulose-containing moldings such as wood and / or composite materials.
• Popcorn of smaller grain size tends to be used in many applications within the present invention in the manufacture of the wood and / or composite material Absorb added binder or glue, which can degrade the quality of the wood and / or composite material.
• the popcorn has a particle size distribution in which> 70% and ⁇ 90% of the popcorn have a particle size of> 2 mm and ⁇ 10 mm.
• the popcorn has a particle size distribution in which> 50% and ⁇ 90%, particularly preferably> 70% and ⁇ 90% of the popcorn have a particle size of> 4 mm and ⁇ 10 mm.
• the popcorn has a particle size distribution in which> 50% and ⁇ 80% of the popcorn have a particle size of> 3 mm and ⁇ 8 mm.
• the popcorn has an average particle size distribution of> 3 mm and ⁇ 6 mm. This has been found to be beneficial for many applications within the present invention.
• the popcorn has an average particle size distribution of> 3.5 mm and ⁇ 5 mm.
• the fat content of the popcorn before processing is ⁇ 10 (wt)%.
• fat content is not understood the total amount of fat in popcorn, but the proportion of fat, which was used to hydrophobize the seed epidermis, which leads to better inclusion of the water contained in the seed.
• the fat content is ⁇ 5 (wt)%.
• the present invention also relates to a method for producing a wood and / or composite board according to the invention, comprising the steps a) (optionally separate) lining of the outer layer and the intermediate layer precursor material
• Step a) can be done by simply sprinkling fibers, chips and / or granules.
• the popcorn granules are preferably either by the Bichsel method (WO 1999042005A1) or by Puffung, z. B. by the microwave method, and then crushed.
• binders are thermoplastics, thermosets, aminoplasts, phenoplasts, isocyanates, proteins, tannins, starch, synthetic binders or natural binders, or mixtures of binders, such as, for example, urea-formaldehyde resin, melamine-formaldehyde resin, melamine-reinforced urea-formaldehyde resin, tannin formaldehyde Resin, phenol-formaldehyde resin, polymeric diphenylmethane diisocyanate or mixtures thereof preferred.
• additives such as hydrophobing agents, anti-flaking agents, etc., are attached.
• Step c) can be carried out according to a preferred embodiment of the invention while introducing hot air / hot steam.
• the present invention also relates to a process for producing a wood and / or composite sheet according to the invention, comprising the steps of a) producing the intermediate layer
• FIG. 1 shows a diagram of a particle size distribution of a popcorn granulate which was used in the examples according to the invention.
• Starting material for the following material examples is grain corn; alternatively, however, other starchy grains may be used as well.
• feed corn kernels are first crushed and the grain fragments are subsequently expanded under pressure and temperature according to the Bichse method (WO 1999042005A1) to a defined process.
• the popcorn granules produced in this way are now fractionated, so that a granulate having particle sizes of 0.5 mm to 8 mm and a bulk density of about 30 kg / m 3 to 70 kg / m 3 is present.
• starchy grains may be expanded by means of a microwave oven or other common methods.
• FIG. 1 shows a grain size distribution suitable for producing expanded corn kernel-based composite materials and as used in the following examples.
• a binder liquor based on urea-formaldehyde resin was used, as is commonly used for the industrial production of wood-based materials.
• these binders liquor contains ammonium sulfate solution (40% - strength) and in some cases water repellents (HYDROWAX 138 ® SASOL GmbH).
• the glue liquor of the material plates described below consisted of popcorn granules, 8.0% UF solid resin relative to ator popcorn granules, 1% ammonium sulfate solution (hardener) based on dry solid resin.
• thermoset-curing binder liquors based on melamine-formaldehyde resin (MUF resin), phenol-formaldehyde resin (PF resin) and mixed resin systems prepared therefrom, natural binder systems based on tannins or proteins and isocyanates such.
• MAF resin melamine-formaldehyde resin
• PF resin phenol-formaldehyde resin
• mixed resin systems prepared therefrom, natural binder systems based on tannins or proteins and isocyanates such.
• B. PMDI used. Two different processes were used to compress the glued popcorn granule cake: a) The glued popcorn granule cake is pressed under heat at 120 ° C. to 200 ° C. with a press time factor of 12 s / mm in a hot press with conductive heat transfer. b) The Popcomgranulatkuchen is pressed cold to the desired final dimensions.
• thermosets this process technology also makes it possible to use thermoplastic binders, such as, for example, PVAC or PP or PE supporting fibers. This process is particularly suitable for slab densities below 200 kg / m 3 , since it must be ensured that the cold pre-pressed granules cake can flow through with hot steam / hot air.
• Tab. 1 Some physico-technological properties of hot-pressed UFC resin (8.0% based on atro) bonded popcorn composite panels with a thickness of 20 mm

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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)

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• 2013
  • 2013-02-27 DE DE102013101937.4A patent/DE102013101937A1/de not_active Withdrawn
• 2014
  • 2014-02-26 HU HUE14706639A patent/HUE040186T2/hu unknown
  • 2014-02-26 WO PCT/EP2014/053743 patent/WO2014131801A1/de active Application Filing
  • 2014-02-26 PT PT147066393T patent/PT2961580T/pt unknown
  • 2014-02-26 SI SI201430813T patent/SI2961580T1/sl unknown
  • 2014-02-26 EP EP18162407.3A patent/EP3366442A1/de not_active Ceased
  • 2014-02-26 PL PL14706639T patent/PL2961580T3/pl unknown
  • 2014-02-26 EP EP14706639.3A patent/EP2961580B1/de active Active
  • 2014-02-26 ES ES14706639.3T patent/ES2675403T3/es active Active

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