WO2024062415A1 - Process for the manufacture of boards from reclaimed wooden material - Google Patents

Process for the manufacture of boards from reclaimed wooden material Download PDF

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Publication number
WO2024062415A1
WO2024062415A1 PCT/IB2023/059352 IB2023059352W WO2024062415A1 WO 2024062415 A1 WO2024062415 A1 WO 2024062415A1 IB 2023059352 W IB2023059352 W IB 2023059352W WO 2024062415 A1 WO2024062415 A1 WO 2024062415A1
Authority
WO
WIPO (PCT)
Prior art keywords
mixture
casting
forming mould
fact
forming
Prior art date
Application number
PCT/IB2023/059352
Other languages
French (fr)
Inventor
Paolo Benedetti
Original Assignee
Imal S.R.L.
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 Imal S.R.L. filed Critical Imal S.R.L.
Publication of WO2024062415A1 publication Critical patent/WO2024062415A1/en

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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
    • B27N3/007—Manufacture of substantially flat articles, e.g. boards, from particles or fibres and at least partly composed of recycled material
    • 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
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/08—Moulding or pressing
    • B27N3/18—Auxiliary operations, e.g. preheating, humidifying, cutting-off
    • 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
    • B27N3/08—Moulding or pressing
    • B27N3/20—Moulding or pressing characterised by using platen-presses
    • B27N3/203—Moulding or pressing characterised by using platen-presses with heating or cooling means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/688—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks the inserts being meshes or lattices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
    • B29C70/882—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding
    • B29C70/885—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding with incorporated metallic wires, nets, films or plates

Landscapes

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

Abstract

The process for the manufacture of boards from reclaimed wooden material, comprises at least the following phases: - supplying one mixture (M) comprising wooden material (2) in the form of flakes and/or powders and one binding agent (3); - supplying one forming mould (4) of at least one board (1) from the mixture (M); - casting the mixture (M) within the forming mould (4); - forming the mixture (M) within the forming mould (4) to obtain the board (i); wherein the process comprises at least one phase of arranging one structural reinforcement mesh (7) which can be coupled with the mixture (M) within the forming mould (4).

Description

PROCESS FOR THE MANUFACTURE OF BOARDS FROM RECEAIMED WOODEN MATERIAE
Technical Field
The present invention relates to a process for the manufacture of boards from reclaimed wooden material.
Background Art
It is known that boards are made from a mixture of reclaimed wooden material in the form of flakes and/or powders and from at least one binding agent consisting, e.g., of polymer resins and/or adhesives of various kinds.
Specifically, the term “reclaimed material” as used in this disclosure refers to the wooden material that has already undergone one or more uses and is then subjected to preliminary treatments of chipping and/or shredding, so as to obtain flakes and/or powders, and then subjected to a drying process.
Next, the mixture is cast within a forming mould wherein it undergoes a compaction phase, allowing it to acquire predefined dimensions and densities corresponding to those of the final product.
It is, in addition, known to carry out one or more heating phases of the mixture cast, e.g. at the same time as the compaction phase, to allow the activation of the binding agent.
By heating the mixture, in fact, it is possible to bring the binding agent to its curing temperature and, as a result, join the flakes and/or powders of wooden material which are compacted to each other.
Boards made in this way are characterized by lower mechanical properties (such as, e.g., bending strength) than boards made from solid wood.
Boards made in this way tend, therefore, to deform more than boards made of solid wood or even to break when subjected to high loads, thus being unsuitable for a plurality of uses.
That said, there is an increasing need to make boards from reclaimed wooden material provided with mechanical properties (such as, e.g., bending strength) similar to those typical of boards made from solid wood.
Description of the Invention The main aim of the present invention is to devise a process by which boards can be made from reclaimed wooden material having mechanical properties similar to those typical of boards made from solid wood.
An additional object of the present invention is to devise a process by which boards can be made from reclaimed wooden material which are suitable for a wide range of use and, therefore, significantly more flexible in use than boards made to date from reclaimed wooden material.
Another object of the present invention is to devise a process for the manufacture of boards from reclaimed wooden material which can overcome the aforementioned drawbacks of the prior art within the framework of a simple, rational, easy and effective to use as well as affordable solution.
The aforementioned objects are achieved by this process for the manufacture of boards from reclaimed wooden material having the characteristics of claim 1. Brief Description of the Drawings
Other characteristics and advantages of the present invention will become more apparent from the description of a preferred, but not exclusive, embodiment of a process for the manufacture of boards from reclaimed wooden material, illustrated by way of an indicative, yet non-limiting example, in the attached tables of drawings in which:
Figures 1 to 5 schematically show a first embodiment of the process according to the invention;
Figures 6 to 10 schematically show a second embodiment of the process according to the invention.
Embodiments of the Invention
With particular reference to this figure, reference numeral 1 globally denotes a board made by means of the process for the manufacture of boards from reclaimed wooden material according to the invention.
The process for the manufacture of boards from reclaimed wooden material comprises at least one phase of supplying at least one mixture M comprising wooden material 2 in the form of flakes and/or powders and at least one binding agent 3. In this regard, the supply of the flakes and/or powders of wooden material 2 already mixed with the binding agent 3, or the supply of the flakes and/or powders of wooden material 2 and of the binding agent 3 not yet mixed together can be provided.
In the latter case, one or more pretreatments of the flakes and/or powders of wooden material 2 can be carried out before mixing the latter with the binding agent 3, such as one or more drying processes.
In addition, the process comprises the phase of supplying at least one forming mould 4 of at least one board 1 starting from the mixture M.
In particular, the forming mould 4 is provided with at least one forming cavity 4a which has a conformation corresponding to those of the finished product and can be at least partly filled with the mixture M.
In addition, the forming cavity 4a is bounded inferiorly by at least one bottom wall 4b adapted to hold the mixture M by weight.
Next, the process comprises at least one phase of casting the mixture M within the forming mould 4.
During the aforementioned phase, the mixture M is cast within the forming mould 4 by arranging itself against the bottom wall 4b and filling at least part of the forming cavity 4a.
Casting can be done by means of one or more suitable injectors or by other methods still known to the expert in the field.
The process comprises, at this point, at least one phase of forming the mixture M within the forming mould 4 to obtain the board 1.
Specifically, forming comprises at least the step of heating the mixture M within the forming mould 4.
By heating the mixture M, in fact, it is possible to bring the binding agent 3 to its curing temperature and, in this way, to join the flakes and/or powders of wooden material 2 together.
Heating, in particular, is carried out by heating means 5 associated with the forming mould 4.
The heating means 5 may be of the electrical type (e.g., of the electric resistor type), or they may be of another type known to the expert in the field.
In addition, forming also comprises at least the step of compacting the mixture M within the forming mould 4.
This step is carried out through compaction means 6, e.g. of the hydraulic and/or pneumatic type (e.g., one or more hydraulic and/or pneumatic pistons).
In actual facts, due to the pressure exerted by the compaction means 6 on the mixture M it is clearly possible to obtain a board 1 of the desired size and density. Conveniently, compaction is carried out at the same time as heating.
Thus, in this case, the heating means 5 are built into the compaction means 6 and/or into the forming mould 4.
By doing so, in fact, it is possible to carry out the forming of the board 1 while simultaneously reducing the production time of the same.
The board 1 obtained as a result of forming has a substantially slab-like conformation and is, therefore, provided with a first face la, facing the bottom wall 4b, and with a second face lb, opposite the first face la and facing, therefore, upwards.
According to the invention, the process comprises at least one phase of arranging at least one structural reinforcement mesh 7 which can be coupled to the mixture M within the forming mould 4.
Preferably, the arrangement of the reinforcement mesh 7 is carried out prior to forming.
In fact, in this way, it is clearly possible to join the reinforcement mesh 7 and the mixture M together through the curing of the binding agent 3.
Advantageously, the reinforcement mesh 7 is made at least partly of flexible material in order to ensure adequate bending strength to the resulting board 1.
In addition, the use of a reinforcement mesh 7 made of flexible material allows the mixture M to be formed in a totally safe and efficient manner, avoiding the risk of plasticization or break of the reinforcement mesh itself as a result of the pressure exerted by the compaction means 6.
Usefully, the flexible material is selected from the list comprising: iron, plastic, fiberglass. In all cases, other materials than those just listed should not be ruled out that will, however, give the reinforcement mesh 7 enough flexibility to allow it to deform in a uniquely elastic maimer as a result of the action of the compaction means.
According to a first embodiment of the process, shown in Figures 1 to 4, the arrangement of the reinforcement mesh 7 is carried out prior to casting.
In this case, the reinforcement mesh 7 is bonded within the still-empty forming mould 4, arranging it against the bottom wall 4b.
Once this is done, the mixture M is cast over the reinforcement mesh 7, thus filling at least part of the forming cavity 4a.
It is easy to appreciate that, by doing so, it is possible to obtain a board 1 in which the reinforcement mesh 7 is coupled to the first face la.
Alternatively, in accordance with a second embodiment of the process, shown in Figures 5 to 8, the arrangement of the reinforcement mesh 7 is carried out subsequently to casting.
In actual facts, in this case, the mixture M is cast within the still-empty forming mould 4, filling at least part of the forming cavity 4a.
Once casting is done, the reinforcement mesh 7 is placed inside the forming mould 4, arranging it against the mixture M.
At this point, by forming the mixture M, it is possible to obtain a board 1 in which the reinforcement mesh 7 is coupled to the second face lb.
In accordance with a third embodiment of the process alternative to the previous ones and not shown in the figures, the casting comprises at least one step of first casting of a part of the mixture M within the forming mould 4 and at least one step of second casting, carried out subsequently to the first casting, of the remaining part of the mixture M within the forming mould 4.
In actual facts, this means that the mixture M is cast inside the forming mould 4 at two temporally distinct times corresponding, specifically, to the first casting and to the second casting.
In this regard, in accordance with the third embodiment, the arrangement of the reinforcement mesh 7 is carried out between the first casting and the second casting. This means that once the first part of the mixture M has been cast into the forming mould 4, the reinforcement mesh 7 is positioned resting on the latter, and having done so, the second and remaining part of the mixture M is cast onto the reinforcement mesh itself
It is, therefore, simple to appreciate that the process in accordance with this third embodiment allows obtaining a board 1 containing the reinforcement mesh 7 within it.
It is emphasized, in this regard, that arranging a reinforcement mesh 7 in contact with the mixture M according to any one of the described embodiments allows, once forming has been carried out, obtaining a board 1 having mechanical properties (such as, e.g., bending stiffness) similar to those typical of boards made of solid wood.
In this regard, according to a further aspect of the invention, the present invention also relates to a board 1 which can be made from reclaimed wooden material by means of the process just described.
In detail, the board thus made has at least a first face la and at least a second face lb opposite the first face la and at least one reinforcement mesh 7.
In the present case, the reinforcement mesh 7 can be arranged internally to the board 1 (e.g. by making the arrangement between the first casting and the second casting) or be coupled to one of either the first face la or the second face lb (e.g. by making the arrangement before or after casting, respectively).
It has in practice been ascertained that the described invention achieves the intended objects.
In particular, the fact is emphasized that the special expedient of providing for the arrangement of a reinforcement mesh associated with the mixture makes it possible to obtain boards from reclaimed wooden material having mechanical properties similar to those typical of boards made from solid wood.
In fact, in this way, it is possible to expand the scope of application of the boards thus obtained, thus also employing them for uses requiring good mechanical properties (e.g., good bending strength).

Claims

1) Process for the manufacture of boards from reclaimed wooden material, comprising at least the following phases: supplying at least one mixture (M) comprising wooden material (2) in the form of flakes and/or powders and at least one binding agent (3); supplying at least one forming mould (4) of at least one board (1) from said mixture (M); casting said mixture (M) within said forming mould (4); forming said mixture (M) within said forming mould (4) to obtain said board (i); characterized by the fact that it comprises at least one phase of arranging at least one structural reinforcement mesh (7) which can be coupled with said mixture (M) within said forming mould (4).
2) Process according to claim 1, characterized by the fact that said reinforcement mesh (7) is made at least partly of flexible material.
3) Process according to claim 2, characterized by the fact that said flexible material is selected from the list comprising: iron, plastic, fiberglass.
4) Process according to one or more of the preceding claims, characterized by the fact that said arrangement is carried out prior to said casting.
5) Process according to one or more of claims 1 to 3, characterized by the fact that said arrangement is carried out subsequently to said casting.
6) Process according to claim 5, characterized by the fact that said arrangement is carried out prior to said forming.
7) Process according to one or more of claims 1 to 3, characterized by the fact that: said casting comprises at least one step of first casting of a part of said mixture (M) within said forming mould (4) and at least one step of second casting, carried out subsequently to said first casting, of the remaining part of said mixture (M) within said forming mould (4); and by the fact that said arrangement is carried out between said first casting and said second casting. 8) Process according to one or more of the preceding claims, characterized by the fact that said forming comprises at least the step of heating said mixture (M) within said forming mould (4) and at least the step of compacting said mixture (M) within said forming mould (4). 9) Process according to claim 8, characterized by the fact that said heating is carried out at the same time as said compaction.
PCT/IB2023/059352 2022-09-23 2023-09-21 Process for the manufacture of boards from reclaimed wooden material WO2024062415A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT202200019638 2022-09-23
IT102022000019638 2022-09-23

Publications (1)

Publication Number Publication Date
WO2024062415A1 true WO2024062415A1 (en) 2024-03-28

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998056731A1 (en) * 1997-06-09 1998-12-17 Keiko Kondo Carbonaceous building material and production thereof
DE19810862A1 (en) * 1998-03-13 1999-09-16 Alsen Ag New straw useful in the manufacture of insulating plates
US20030064238A1 (en) * 2001-09-28 2003-04-03 Katuyuki Hasegawa Composite wood and manufacturing method thereof
US20180265705A1 (en) * 2017-03-14 2018-09-20 Multi-Family Building Products Inc. Flax straw fiber based building material

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998056731A1 (en) * 1997-06-09 1998-12-17 Keiko Kondo Carbonaceous building material and production thereof
DE19810862A1 (en) * 1998-03-13 1999-09-16 Alsen Ag New straw useful in the manufacture of insulating plates
US20030064238A1 (en) * 2001-09-28 2003-04-03 Katuyuki Hasegawa Composite wood and manufacturing method thereof
US20180265705A1 (en) * 2017-03-14 2018-09-20 Multi-Family Building Products Inc. Flax straw fiber based building material

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