WO2020200962A1 - Panneau composite, son procédé de fabrication et utilisations de celui-ci - Google Patents

Panneau composite, son procédé de fabrication et utilisations de celui-ci Download PDF

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Publication number
WO2020200962A1
WO2020200962A1 PCT/EP2020/058374 EP2020058374W WO2020200962A1 WO 2020200962 A1 WO2020200962 A1 WO 2020200962A1 EP 2020058374 W EP2020058374 W EP 2020058374W WO 2020200962 A1 WO2020200962 A1 WO 2020200962A1
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WO
WIPO (PCT)
Prior art keywords
composite panel
weight
parts
rod
panel according
Prior art date
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PCT/EP2020/058374
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German (de)
English (en)
Inventor
Konrad BURLON
Manfred DÖRING
Roland Klein
Lorenz BILGER
Original Assignee
Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V.
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Application filed by Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. filed Critical Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V.
Priority to EP20715800.7A priority Critical patent/EP3946858A1/fr
Publication of WO2020200962A1 publication Critical patent/WO2020200962A1/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
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/02—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from particles
    • 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
    • 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
    • B27N7/00—After-treatment, e.g. reducing swelling or shrinkage, surfacing; Protecting the edges of boards against access of humidity
    • B27N7/005—Coating boards, e.g. with a finishing or decorating layer

Definitions

  • the present invention relates to a composite panel which contains or consists of at least one bioba-based particulate or rod-shaped natural material (excluding wood), at least one thermosetting resin as a binder and at least one inorganic flame retardant.
  • the present invention relates to a method for producing a corresponding composite panel.
  • the present invention also indicates possible uses of the composite panel according to the invention.
  • Effective insulation materials for buildings are an essential part of modern construction to save energy when heating or cooling buildings in order to create a pleasant indoor climate in all climates and in all seasons.
  • the building is insulated, for example, by attaching panels with low thermal conductivity to the walls, roofs or floors of buildings.
  • the Insulation materials can either be attached to the outside or inside.
  • thermal insulation Another possibility for thermal insulation is to fill flea rooms with mats or bulk material with low thermal conductivity.
  • Mineral, petroleum-based or renewable raw materials are used as materials with low thermal conductivity for building insulation.
  • the mineral insulation materials include, for example, glass or rock wool, the production of which is energy-intensive.
  • Insulation materials made from fossil raw materials are mainly foamed plastics such as polystyrene (PS) in the form of panels made of particle foam (EPS) or extruded foam (XPS), which are of great importance on the insulation material market.
  • PS polystyrene
  • EPS particle foam
  • XPS extruded foam
  • Other foams used for this purpose are based on polyurethane, phenol-formaldehyde resin or polyethylene. The has a large market share among insulation materials
  • EPS Polystyrene particle foam
  • Polystyrene foam sheets consist of more than 95% air and still offer good stability with low density, ideal insulation properties and at the same time a low price. Another advantage of polystyrene foam panels is their ease of use, ease of integration into buildings and usability in composite thermal insulation systems.
  • a decisive criterion when evaluating a material that is to be used as an insulating material is its fire behavior.
  • a classification is carried out by DIN EN 13501-1: 2010. Flammability is required for approval in a wide range of applications.
  • Polystyrene foam is per se an easily flammable / combustible material to which a brominated polymer is added as a flame retardant. is set in order to achieve a classification as flame retardant. This ensures the wide use of polystyrene foam as an insulation material.
  • Bio-based insulation materials are described in scientific and patent literature and are also used in practice. Bio-based insulation materials are usually available as bulk or blown insulation, but there are certain reservations about settlement phenomena if they are not installed by a specialist company. Insulation panels made from renewable raw materials are also used, but they also have various disadvantages, such as too low pressure loads. Insulation materials made from renewable raw materials are also considered to be normally flammable (building material class E according to DIN EN 13501-1: 2010). It would therefore be advantageous to have insulating materials made from renewable raw materials available that are easy to handle, that is, available as sheet goods, have acceptable mechanical properties and at the same time are flame retardant.
  • bio-based base materials are described in the specialist literature for use as insulating material, most of which are side streams from forestry and agriculture. Examples of these are fibers from flax, hemp, jute, sisal, kenaf, miscanthur, grass, banana or coconut and straw from grain, rice, flax, hemp, corn or rapeseed or wood chips, coconut pulp, corn husks, peanut shells, pineapple leaves, sunflower stalks , Reeds, cattails, ba gasse, cotton stalks, bark, pecan shells, durian fruit pods, corn slivers, rice hulls, cork, olive pits or seaweed. Overviews of materials from Renewable raw materials that are suitable as insulating material are provided by C. Aciu and N. Corbirzan in ProEnvironment 6 (2013) 472 - 478, H. Wang, P.-C. Chiang, Y. Cai, C.
  • the natural substances described therein are used as insulation in various forms. Loose fibers or particles are introduced into hollow spaces as blown or bulk material. Furthermore, fibers or straw are also stuffed into cavities or frames by hand.
  • insulation panels made of natural fiber-based materials are also known commercially. Jute, flax, hemp, wood fibers as well as white grass are generally used to manufacture insulation boards, mats or fleeces without the use of a binding agent. Wood fiber systems that are suitable for use in thermal insulation composite systems (ETICS) are primarily considered to be pressure-resistant. ETICS-compatible materials can also be produced from hemp in a special process (http://www.caparol.de/im- specific / waermedaemmung / capatect-system-natur.html, accessed on March 27, 2017).
  • Pressed reed mats offer another option for a thermal insulation composite system, but are unsuitable for perimeter and core insulation (https://www.daemmen-und-sanieren.de/daemmung/daemmstoffe/scun, accessed on March 27, 2017).
  • cork granulate is formed into panels under pressure with the supply of steam at around 350 ° C.
  • the natural resin suberin escapes from the cells, causing the Expand cells.
  • the emerging resin binds the individual particles.
  • the insulation properties of natural cork are optimized by the expansion.
  • resin-rich cork is suitable for the manufacture of baking cork, so that the individual particles can be sufficiently connected to one another.
  • this is the so-called primary cork, i.e. the cork from the first peeling of the cork oak. Cork from later peeling periods or recycled cork cannot be used for this process.
  • Another way of producing panels from renewable raw materials that are suitable as insulating material is to bind particulate natural materials with an adhesive, resin or latex.
  • A. Paivaa, S. Pereiraa, A. polea, D. Cruza, H. Varumc and J. Pintoa describe in Energy and Buildings, 45 (2012) 274-279, for example, a board made from corncob meal for building insulation.
  • a wood glue not described in detail, is mentioned as a binder.
  • J. Khedari, S. Charoenvai, J. Hirunlabh in Building and Environment 38 (2003) 435 - 441 describe further plates, consisting of bio-based residue particles, here durian fruit peel. In this study, the particles are mixed with urea-formaldehyde, phenol-formaldehyde - or isocyanate-based adhesives bound.
  • S. Tangjuank describes in Int.
  • DE 2457345 A1 discloses a material made of cork surface-coated with sand and cement which is used in connection with a binding agent, e.g. Mortar, plaster of paris or synthetic resin can be processed into a component with low density and good heat and sound insulating properties.
  • a binding agent e.g. Mortar, plaster of paris or synthetic resin
  • mineral materials such as expanded clay, perlite or calcium silicates are also known from nature as insulation materials. As a rule, they are used as bulk goods. Flat thermal insulation systems are also made from perlite and calcium silicates in particular are used in mineral insulation boards. Fumed silica is currently used as an insulating material in vacuum insulation panels (VIPs). VIPs offer very good insulation te with low structural strengths. However, they are difficult to process, if the vacuum barrier is violated, the insulation performance drops significantly (DE 10 2012 224 201 A1).
  • insulation materials made from renewable raw materials are considered combustible (fire protection class E according to DIN EN 13501-1: 2010).
  • fire protection class E according to DIN EN 13501-1: 2010.
  • cellulose fibers or wood wool boards some of which are classified as flame-retardant, they are all classified as E normally flammable
  • EP 2 721 121 B1 describes, for example, waste paper which, with various mixtures of different flame retardants from the group consisting of aluminum hydroxide, ammonium sulfate, sodium sulfate, monoammonium phosphate, diammonium phosphate, triammonium phosphate, ammonium polyphosphate, aluminum sulfate,
  • Trisodium phosphate, calcium hydroxide and magnesium hydroxide is added.
  • the object of the present invention was therefore to offer a composite panel which does not have the disadvantages indicated above, i.e. meets the requirements for modern, efficient insulation materials with regard to density, thermal conductivity and fire behavior, is self-supporting and is not limited to a class of bio-based raw materials with insulation properties, but can generally be implemented with a wide variety of renewable raw materials and has the potential to be recyclable.
  • the present invention thus relates in a first aspect to a composite panel containing or consisting of
  • thermoset hardened synthetic resin as a binder and at least one inorganic flame retardant.
  • a natural substance in the context of the invention is to be understood as a material that is obtained from a plant, an animal, an alga or a fungus or a part thereof.
  • wood is excluded, so that in particular wood-based composite panels, such as chipboard, OSB, etc., are not included in the subject matter of the invention.
  • the at least one natural substance can be replaced on a subordinate scale by wood chips, such as those used for the production of chipboard (e.g. flat pressed boards, coarse chipboard, etc.).
  • chipboard e.g. flat pressed boards, coarse chipboard, etc.
  • the possible inclusion of wood chips does not qualify the composite panel according to the present invention as a wood-based panel according to the current standards, such as e.g. DIN EN 312, DIN EN 14755 and DIN EN 13986.
  • the composite panel according to the invention thus always contains at least one natural substance different from wood and can additionally contain wood-based materials, but in minor amounts.
  • Particulate natural substances are particles from the natural substance which are spherical or comparable in shape and have an aspect ratio between 1 and 5, the smallest length expansion in all spatial directions preferably being at least 2 mm. The greatest linear expansion in all spatial directions should preferably not exceed 40 mm.
  • the natural substance particles can either occur naturally in this form or be brought into this form by a processing step, such as grinding, cutting, threshing, expanding by heating, etc.
  • natural material sticks are understood to be those which have grown in stick form and can be shortened in length by a processing step, such as chopping, cutting, threshing, etc.
  • the length of the rods must be at least 5 mm, the width preferably at least 2 mm. With a double crochet, however, the length is always greater than the width.
  • the composite panel according to the invention is therefore extremely advantageous from an ecological point of view.
  • the composite panel according to the invention is characterized by a low weight, but at the same time a low thermal conductivity.
  • the composite panel is classified as flame-retardant, so that it is particularly suitable as an insulation material in the construction sector or as a building material.
  • particulate natural substances in particular those which contain cavities
  • the panels made from them have lower densities than those made from fibers or natural materials in the form of chips or whose particle size is well below a millimeter, i.e. are in powder-like form. Similar thermal conductivities can be achieved here, as with panels made of fibers or natural materials in the form of chips.
  • the present invention offers two essential advantages.
  • lower component densities can be achieved than by using fibrous materials.
  • the stable plates obtained with smaller amounts of binding agent, when using particulate and / or rod-shaped natural substances.
  • the panels can also be produced extremely economically.
  • the composite panel according to the present invention can be based on bio-based particulate natural substances alone, or rod-shaped natural substances alone. Mixtures or combinations of particulate or rod-shaped natural substances are also possible.
  • a preferred embodiment provides that the particle size of the at least one bio-based particulate natural substance is at least 2 mm, preferably 2 to 40 mm, particularly preferably 2 to 25 mm.
  • the rod length of the at least one bio-based rod-shaped natural substance is preferably greater than 2 mm, more preferably 5 to 100 mm, particularly preferably 10 to 75 mm.
  • the size fractions of particulate or rod-shaped natural substances that can preferably be used for the purposes of the present invention can be obtained by classification processes known from the prior art, in particular by sieve classification.
  • the at least one bio-based particulate natural substance is preferably selected from the group consisting of cork meal, corncob meal, nutshells (for example peanut shells), nutshell meal, bark granules, fruit kernels, cereal husks, corn husks, crushed pineapple leaves, olive kernels, pecan shells and shredded rice shells, shredded rice as well as mixtures thereof.
  • the at least one bio-based rod-shaped natural substance is preferably selected from the group consisting of sunflower stalks, reeds, cattails, cotton stalks and straw from cereals, rice, flax, hemp, corn or rapeseed and mixtures thereof.
  • the above-mentioned exemplary rod-shaped natural substances can be used as received if the length is suitable; If necessary, it is necessary to shorten the respective rod-shaped natural substances by a suitable process, such as chopping, cutting, threshing, etc. to a desired or suitable length.
  • the at least one bio-based particulate or rod-shaped natural substance is porous.
  • Porous natural substances include, in particular, cork meal, peanut shells, sunflower stalks, pineapple leaves, bark granules, flax straw and hemp.
  • the at least one binder is selected from the group consisting of aqueous phenol-formaldehyde resins, urea-formaldehyde resins, acrylate resins, alkyd resins, melamine-formaldehyde resins, lignin-formaldehyde resins, and tannin Urotropine resins, or 100% systems such as epoxy resins, unsaturated polyester resins, polyurethanes, furan resins, powder resins; as well as mixtures thereof.
  • the at least one flame retardant is particularly preferably selected from the group consisting of inorganic substances, such as aluminum hydroxide (ATH), magnesium hydroxide (MDH), aluminum oxide hydroxide (AOH), ammonium phosphate, such as ammonium polyphosphate (APP) or ammonium diphosphate, but also sheet silicates , such as montmorillionite, kaolinite, talc, mixed-valent hydroxides (LDH; English: Layered double hydroxides) and organic salts such as melamine derivatives, for example melamine polyphosphate or melamine cyanurate, and expandable graphite and mixtures thereof.
  • ATH aluminum hydroxide
  • MDH magnesium hydroxide
  • AOH aluminum oxide hydroxide
  • ammonium phosphate such as ammonium polyphosphate (APP) or ammonium diphosphate
  • sheet silicates such as montmorillionite, kaolinite, talc, mixed-valent hydroxides (LDH; English: Layered double hydroxides)
  • the composite panel according to the invention consists of the aforementioned material components, the composite panel no longer contains any further constituent parts. However, it is also possible for the composite panel according to the invention to have further constituents such as fillers, pigments, dyes, biocides, etc.
  • the composite panel according to the invention can be surface-coated.
  • the surface coating can be designed as a paper or veneer coating, for example.
  • Preferred thicknesses of the composite plate according to the invention range between 5 to 250 mm, preferably from 10 to 150 mm, particularly preferably from 50 to 120 mm.
  • the composite panel according to the invention is characterized in particular by a low bulk density.
  • the density of the composite panels dictate preferably below half 250 kg / m 3 .
  • the composite panel according to the invention has a high insulating capacity.
  • the thermal conductivity, measured in accordance with EN 12667: 2001, is preferably a maximum of 50 mW / mK, preferably from 30 to 45 mW / mK.
  • the composite panel according to the invention can therefore preferably be classified as flame-retardant in accordance with DIN EN 13501-1: 2010.
  • the composite panel can contain small amounts of wood chips.
  • the present invention relates to a method for producing a composite panel described above, in which
  • At least one bio-based particulate or rod-shaped natural material whereby wood is excluded as a natural material
  • thermosetting synthetic resin as a binder and at least one inorganic flame retardant
  • the composite panel being formed.
  • the shaping process comprises heating the mixture to temperatures of 80 to 200 ° C., preferably 100 to 180 ° C., particularly preferably from 120 to 150 ° C., preferably over a period of 10 s to 90 min, more preferably 3 minutes to 60 minutes, particularly preferably 5 minutes to 40 minutes.
  • the heating takes place by applying saturated steam, hot air, microwaves and / or infrared radiation to the mixture.
  • the shaping process can comprise pressing the mixture, wherein the pressing can be carried out in particular on a continuously operating press.
  • B. cutting shavings, chips, wood shavings, sawdust or wooden strands are replaced. It is also possible to add at least one additive to the mixture, in particular one additive selected from the group consisting of fillers, particles and biocides.
  • the present invention relates to the use of the composite panel according to the invention as a thermal insulation material in general and in particular in composite thermal insulation systems for facade insulation, as a building material, as impact sound insulation, as sound insulation.
  • Expanded cork granulate 100 parts by weight of expanded cork granulate are placed in a beaker. Expanded cork granulate is obtained from baked cork residues by regranulating. (http://www.materialarchiv.ch/detail/1866/Daemmkork- expanded # / detail / 1866 / daemmkork-expanded, accessed March 28, 2019). The particle size of the expanded cork is 2 - 10 mm. Beforehand, 21.5 parts by weight of a melamine-formaldehyde resin (MF) with a solids content of 67% are finely dispersed with 21.5 parts by weight of aluminum trihydrate (ATH). The mixture is added to the cork granulate and mixed thoroughly.
  • MF melamine-formaldehyde resin
  • ATH aluminum trihydrate
  • Example 1 according to the invention shows the optimized variant with a pure natural substance.
  • Lower amounts of binder and thus a lower density are possible here than in comparative example 1.
  • an insulation board was made from a material that is used in a similar form in DE 10 2016 121 590 A1.
  • the amount of resin used was chosen so that a dimensionally stable plate is produced which lies in a density range described by DE 10 2016 121 590 A1. Surprisingly, the thermal conductivity remains almost unaffected.
  • an insulation board according to the invention was produced with a mixture of cork granules and straw instead of the wood shavings.
  • a mixture of natural substances 100 parts by weight of a mixture of natural substances are placed in a beaker.
  • the mixture consists of 75 parts of expanded cork granulate with a particle size of 2 - 10 mm and 25 parts of rapeseed straw with a rod length of 2 to 50 mm.
  • 50 parts by weight of a melamine-formaldehyde resin (MF) are finely dispersed with 20 parts by weight of aluminum trihydrate (ATH).
  • MF melamine-formaldehyde resin
  • ATH aluminum trihydrate
  • the mixture is added to the natural product mixture and mixed thoroughly.
  • 2600 ml of the mixture are placed in a 240 ⁇ 240 ⁇ 40 mm frame mold and at a temperature of 130 ° C. for 40 minutes to a height of 34 mm compacted. After demolding, a stable test specimen with a density of 135 kg / m 3 is obtained.
  • the board according to the invention has a significantly lower density.
  • Example 3 shows the possibility of changing the flame retardant and the lower proportion of Ammonium polyphosphate to slightly lower the density and thermal conductivity compared to Example 1 according to the invention.
  • the mixture consists of 72 parts of expanded cork granulate with a particle size of 2 - 10 mm and 28 parts of rapeseed straw with a stick length of 2 to 50 mm. Before this, 21.5 parts by weight of a melamine-formaldehyde resin (MF) are finely dispersed with 10 parts by weight of ammonium polyphosphate (APP). The mixture is added to the natural product mixture and mixed thoroughly. Then 2600 ml of the mixture are placed in a 240 ⁇ 240 ⁇ 40 mm frame and compacted at a temperature of 130 ° C. for 40 minutes to a height of 34 mm. After demolding, a stable test specimen with a density of 141 kg / m 3 is obtained.
  • MF melamine-formaldehyde resin
  • APP ammonium polyphosphate
  • the thermal conductivity of lamda-10 is 42.11 mW / (m K).
  • He inventive example 4 shows the possibility of replacing part of the cork granules with straw. Density and thermal conductivity remain within the same framework as in inventive examples 1 and 2, well below the values for comparative example 1
  • particulate natural product granulates and rod-shaped natural materials can be bound to composite panels in which the natural materials are protected from fire by the flame-retardant resin matrix in the event of fire.
  • the composite panels remain dimensionally stable and burning components do not drip off them. Due to the dispersion of the flame retardants in the resin binder and the subsequent fine distribution on the granules, the flame retardant can be ideally distributed in the composite panels. This means that combustible natural materials can be safely used in insulation materials. Due to the high proportion of renewable raw materials, a low energy requirement and carbon dioxide emissions can be achieved during production.

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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 un panneau composite qui contient au moins un matériau naturel biosourcé particulaire ou en forme de tige (à l'exclusion du bois), au moins une résine thermodurcissable servant de liant et au moins un agent ignifuge minéral, ou qui est constitué de ceux-ci. La présente invention concerne également un procédé de fabrication d'un panneau composite correspondant. La présente invention indique également des utilisations possibles du panneau composite de l'invention.
PCT/EP2020/058374 2019-03-29 2020-03-25 Panneau composite, son procédé de fabrication et utilisations de celui-ci WO2020200962A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP20715800.7A EP3946858A1 (fr) 2019-03-29 2020-03-25 Panneau composite, son procédé de fabrication et utilisations de celui-ci

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102019204436.0A DE102019204436A1 (de) 2019-03-29 2019-03-29 Kompositplatte, Verfahren zu ihrer Herstellung sowie Verwendungen hiervon
DE102019204436.0 2019-03-29

Publications (1)

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WO2020200962A1 true WO2020200962A1 (fr) 2020-10-08

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EP (1) EP3946858A1 (fr)
DE (1) DE102019204436A1 (fr)
WO (1) WO2020200962A1 (fr)

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DE102021111384A1 (de) 2021-05-03 2022-11-03 Schock Gmbh Aushärtbare Gießmasse, daraus hergestellter Formkörper und Verfahren zur Herstellung des Formkörpers
CN113580313A (zh) * 2021-08-05 2021-11-02 优优新材料股份有限公司 一种板材用凝结剂及其应用和应用方法
CN113500678A (zh) * 2021-08-05 2021-10-15 优优新材料股份有限公司 一种阻燃防水无甲醛板及其制备方法
CN114524985B (zh) * 2022-03-23 2023-09-29 安徽森泰木塑集团股份有限公司 一种生物质阻燃地板

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