Patent Application
20240042647
The invention is in the field of a type of engineered wood product known as medium density fibreboard (MDF), and specifically pertains to MDF panels having a length and width of at least 1 m, and an aspect ratio of at least 100. Particularly, the invention pertains to MDF panels possessing a machine direction, as obtainable by commercial-scale continuous processing.
MDF (medium density fibre board) refers to a composite product comprising wood fibres pressed and glued together with an adhesive, typically a phenol-formaldehyde or urea-formaldehyde resin, or a polymeric di-phenylmethane diisocyanate adhesive. Frequently, MDF panels also comprise a wax. MDF is commonly manufactured as flat sheets or boards of various thicknesses (typically from 3 mm to 25 mm) and densities, and may be supplied with a visually-attractive paper- or wood-veneer or plastics surface finish or surface coating. It is a stiff, very rigid, practically inflexible material. This is normally advantageous, since also relatively thin panels at the low end of the aforementioned thickness range—the most typical thicknesses therein being 6 and 9 mm—are highly suitable for use in applications where rigidity is desired. Thus, the panels find wide end use application for example in furniture, decorative interior wall lining, doors, separation walls, and many other typically indoor applications where it is desired to employ panels of good rigidity.
Wood fibreboards come generally in thicknesses ranging from 2 mm to 60 mm and densities ranging from 600-1000 kg/m3. MDF in a strict sense, which is what the invention preferably pertains to, has a density in the range of from 650 kg/m3 and 800 kg/m3. Above 800 kg/m3 it is normally spoken of high-density fibreboard (HDF). Below 650 kg/m3 it is spoken of light MDF, or ultra light MDF (<550 kg/m3).
An important characteristic of wood fibreboard, and thus also of MDF, is the size of the wood fibres used. In this respect different classes of product can be distinguished, each having their own particular fields of use. Thus, wood fibreboard is a different product than, e.g., wood particle board. The latter has larger wood particles, generally having a length of 1.5 to 15 mm, a width of 0.15 mm to 1.30 mm, and a thickness of 0.15 to 1.25 mm. The fibres in fibreboard, such as MDF, are considerably smaller, typically having a length of 7 mm or below, preferably of from 1 mm to 5 mm, a width of 0.05 mm to 0.1 mm, and a thickness also of 0.05 mm to 0.1 mm.
The wood fibres in MDF can originate from basically any fibrous lignocellulosic material, with typically used wood being spruce (genus Picea), various types of pine (genus Pinus), or eucalyptus (genus: Eucalyptus). Just as with other engineered wood products, such as particle board or oriented strand board, fibreboard can also be made of modified wood (e.g. steam-treated wood or acetylated wood).
A reference which provides background on particle board, oriented strand board, and fibreboard made on the basis of acetylated wood, is WO 2011/095824. Therein a range of wood elements is discussed for acetylation, the largest being chips (25-75 mm length), the smallest being fibres (1-5 mm length). Tested are particle board and fibre board panels of 500 mm×500 mm×12 mm (aspect ratio: 41.7). It is shown that, in contrast with regular MDF or regular particle board, the boards made of acetylated wood are capable of sustaining submersion in water. This is shown with reference to thickness swelling behaviour.
The background art on fibreboard panels to which the invention relates, viz. relatively large and thin panels, is limited to the conventional knowledge on wood fibreboard.
MDF panels as they are provided for end-use, and made in commercial scale production, can be characterized as being relatively thin. This is identifiable with reference to an aspect ratio of above 100, wherein the aspect ratio is the ratio between the length (L), and the thickness (D of the panel, i.e. L/D. The length L is to be understood as being the largest side dimension of the panel. i.e. it may be equal to the width in the event of a square panel, or larger, in the event of a rectangular panel.
Conventional MDF, when provided in such large and thin panels, comes with several technical problems.
Some of these problems are believed to be related to the panels' linear swelling behaviour. Linear swelling, which is essentially different from the aforementioned thickness swelling that results from submersion in water, refers to the dimensional changes into the direction of the length and the width of the panel, as a result of fluctuations in temperature and relative humidity. Whilst this may not be a problem for small, relatively thick panels, it presents a true challenge in the event of panels as large as having a length and width of at least 1 m, and being as thin as having an aspect ratio of at least 100. Due to the relative thinness, the linear swelling behaviour (expansion and contraction) is substantially pronounced in these panels.
Whilst this is a technical issue per se, the problems it causes are also more pronounced in the case of large panels, in view of the typical uses of such panels. E.g., to cover a large wall with (aesthetically selected) fibreboard panels will go with a need for seams between the panels in order to accommodate the linear swelling that may occur as a result of subjection to varying degrees of humidity and temperature. These seams need to be relatively large, and are therefore prone to spoiling the desired aesthetic effect, which in many cases is the very reason to employ the panels. It would thus be desired to provide panels that, despite being large and thin, do not require substantial seams in between.
In this respect, it is to be noted that the type of panels referred to, i.e. large and thin panels, as typically produced in continuous, commercial scale processes, have a Machine Direction. The concept of a Machine Direction occurring in fibre-reinforced products is well accepted in the art. This amounts to a degree of orientation imposed on the fibrous material by the direction of producing it. Such a machine direction is recognisable, since the material will inevitably exhibit a degree of “orthogonal inequality”.
As a result of the presence in the material of a Machine Direction, the panels will be prone to exhibit an unintentional unequal response to otherwise random influences of the environment. With reference to the linear swelling that necessitates to inclusion of seams when large panels are built into a wall surface, the effect of Machine Direction results in further inconvenience. For, the effects of expansion and contraction will differ between the machine direction and the cross direction. Thus, in making the seams, one will either need to take into account a pattern of orientation of the panels so as to secure that any linear swelling effect will be equal along the same border of a row of panels, or one will need to select the width of the seams so as to accommodate the direction into which swelling can be expected to be the largest.
Another drawback related to linear swelling, resides in the requirements for handling the traditional fibreboards in construction work: when large, relatively thin panels are used in construction, it is frequently needed to allow the panels to set, i.e. “acclimatise,” at the location where they are to be placed, before they can be further processed. This brings about inconvenience for the constructor, who cannot schedule the work in one go. It would be desired to avoid this, and be able to directly proceed with the construction work.
It will be understood that none of the foregoing drawbacks substantially occurs in small, relatively thick panels, and more particularly in the event that such panels are produced in a process that does not lead to imposing a Machine Direction on the product. For, the effect of linear swelling on a large, thin panel, is not just the expansion or contraction along the length and/or width of the panel as such. Even more importantly, as a result of any non-uniformity in such linear dimensional change of a thin panel (including effects resulting from the presence of a Machine Direction), the panel will be prone to internal movements out of plane. This phenomenon, known as “warping,” puts limits to the use of MDF. Whilst warping can be avoided by using smaller size, thick panels (e.g. having an aspect ratio of 50 or lower and having a surface area of 0.25 m2 or lower), this will not be acceptable for all usages. In fact, in many fields of use it will be desired to employ large panels of length and width of at least 1 m (i.e. having a surface area of 1 m2 or higher), and as thin as 9, or preferably 6 mm (i.e. an aspect ratio as high as 111 or 167, resp.). And particularly in these cases, the MDF panels will frequently be expected to provide an aesthetic view, which means that any substantial risk of warping will not be acceptable.
Another technical issue related to the aesthetic appeal that is frequently expected to achieve from using large MDF panels, is the limited degree of freedom in fixing these panels. Screws, nails, or other fixing means that penetrate the panel, need to be placed well off the edge. A typical distance is 25 mm in both directions from the corner and 12 mm from the edge. It is therefore desired to provide a fibreboard which allows a greater freedom of positioning such fixing means.
In order to better address one or more of the foregoing desires, the invention presents, in one aspect, a panel of medium density fibreboard having a length and width of at least 1 m, and an aspect ratio of at least 100, comprising wood fibres having a length of 7 mm or below, pressed together with an adhesive, wherein the wood fibres are made of acetylated wood.
In another aspect, the invention provides a panel of medium density fibreboard obtainable by a process comprising the steps of providing wood fibres, adding adhesive and, preferably, wax to the fibres; casting the fibres onto a surface, so as to form a mat; cold pre-pressing, and hot pressing, wherein the surface on which the fibres are cast, is a moving belt, and wherein the fibres comprise acetylated wood.
In yet another aspect, the invention provides the use of acetylated wood fibres in making medium density fibreboard panels, the panels having a length and width of at least 1 m, and an aspect ratio of at least 100.
In a further aspect, the invention resides in the use of acetylated wood fibres in making medium density fibreboard panels, the panels having a length and width of at least 1 m, and an aspect ratio of at least 100, for the purpose of reducing warping of the panel as compared to a similar panel made of non-acetylated wood fibres.
In a still further aspect, the invention resides in the use of acetylated wood fibres in making medium density fibreboard panels, the panels having a length and width of at least 1 m, and an aspect ratio of at least 100, for the purpose of enabling the penetration of fixation means at a distance selected from the group consisting of less than 25 mm in both directions from a corner of the panel, less than 12 mm from an edge of the panel, and combinations thereof.
The invention, in a broad sense, is based on the unexpected finding that employing acetylated wood fibres in fibreboard panels of the large and thin type, is capable of reducing or even avoiding typical problems that are normally incurred with traditional MDF, if provided in such large and thin panels.
Hitherto, the art on conventional MDF did not provide acceptable solutions for these longstanding problems. The state of the art on large and thin panels is limited to conventional MDF. The state of the art in respect of acetylated wood is limited to small and thick panels, and does not provide any reason for expectations relating to the pronounced problems in large and thin panels.
The invention expressly relates to panels that are relatively large and thin. The panels of the invention have a length and width of at least 1 m, preferably at least 1.2 m, with most preferred dimensions being 1.22 m×1.22 m, or with either of the two dimensions being 2.44 m. As to thickness, this refers to the low end of the fibreboard product spectrum, and particularly to panels having a thickness of below 10 mm. A preferred thicknesses in this respect is 9 mm, and more preferably 6 mm. It will be understood that, the larger the panel, the greater the thickness can be, whilst still considered thin. The aspect ratio preferably is preferably higher than 122, more preferably higher than 200. Panels of a length of 2.44 m or higher, can have still higher aspect ratio's, e.g., 2440/9 (271) or even 2440/6 (407).
The invention particularly relates to large and thin panels possessing a Machine Direction. The term “Machine Direction” is to be understood as referring to the phenomenon that, as a result of continuous processing of a moving fibre bed, the fibres will assume a degree of orientation.
The concept of a Machine Direction does not imply a man-imposed orientation of fibres (as would be the case in, e.g., oriented strand board or unidirectionally reinforced composites). Rather, the concept of a Machine Direction refers to a degree of orientation that in itself is accidental, but that is the inevitable result of the motion of a bed of fibres into one direction.
This can be viewed as meaning that the fibres, although not strictly oriented, viewed over their population in the board are present a preferred orientation. Thus, a plurality of the fibres will be oriented to a greater extent into the direction of motion during production. Or, put otherwise, a minority of the fibres will be oriented to a greater extent into the cross-direction, i.e. in the same plane orthogonally to said direction of motion. It will be understood that the orientation of a fibre, also in the case of the small fibres used in fibreboard, is viewed with reference to their length.
The fibre orientation in the present invention is tested by the following method by microscopic analysis. In particular, optical microscopy is used to build a pixel digital image with area of 11.3×11.4 mm2 of the surface of each sample. As a measure for the presence of fibre orientation the so-called texture aspect ratio according to ISO 25178/EUR 15178N is calculated from these 11.3×11.4 mm2 images. This calculation yields a value on anisotropy scale between 0 and 1, wherein 0 means fully oriented and 1 no orientation (fully random). In one embodiment of the invention, the degree of fibre orientation in the fibre board of the invention is less than 1, preferably less than 0.95, more preferably in the range 0.6-0.9. The interpretation of the degree of fibre orientation may depend on the length of the fibres. For small fibres having a length under 7 mm, a value of 0.95 may already evidence that a significant non-random orientation is present in the fiber board, which corresponds to the Machine Direction.
Without necessarily analysing the direction of orientation of the fibres, a Machine Direction can also be viewed with reference to certain properties being unequal when measured in the panel along the x axis and the y axis (i.e. the length and width; in other words, the directions perpendicular to the thickness). Properties by measurement of which a Machine Direction can be assessed, are particularly mechanical properties such as tensile modulus, tensile strength, bending modulus, bending strength, compression modulus, or compression strength. These properties are well-known to the skilled person, and art-recognised methods exist to measure them.
Moreover, for establishing the presence of a Machine Direction, it is not important how these mechanical properties are measured, as long as the length and the width of the panel are measured in equal fashion, under the same conditions, and over a sides of equal length (which is a given thing for a square panel). In the event of a rectangular panel it is normally likely that the width represents the production direction, and the length represents the width of the production equipment. It will be understood that the presence of a Machine Direction in a rectangular panel, by measuring a mechanical property over two sides, will be best done if first a part of the longer side of the panel is cut off, so as to avoid any influence of length differences on the measurement of mechanical properties.
It should be noted that it is generally irrelevant to establish which of the directions measured actually represents the production direction and which was, originally the cross-direction. What matters is the fact that a measurable difference is established between the two sides of a square panel. The difference should be measurable and, if a Machine Direction is present, will generally be of the order of 0.5 to 5%.
Small scale panels, produced by batch wise providing the constituents (wood fibres coated with adhesive), will not normally possess a Machine Direction. Large, commercial scale panels produced in a continuous process will typically possess a Machine Direction.
A process of making the panels of the invention will generally be the same as conventionally used in making traditional MDF.
The composition will generally be, in percentages by weight, 75-90% wood, 4-15% adhesive (glue), 0.5-2.5% additives, and 4-10% water.
A great variety of wood-types can be employed for making the acetylated wood fibres. These are not different from the types of wood generally known in the art as possible starting materials for conventional MDF. Preferred types of wood originate from trees in the genera of Pinus, Picea, or Eucalyptus. Other wood types include aspen, poplar, beech, Japanese sugi (cedar), or hemlock. Most preferably the wood is spruce or Radiata pine. It is conceivable to use combinations of wood types as well, such as, e.g., a mixture of Acacia and Eucalyptus.
The adhesive too can generally be selected from the same types of adhesives as are used in making conventional MDF. Preferred adhesives are selected from the group consisting of phenol-formaldehyde resin, melamine urea-formaldehyde resin, or isocyanate based adhesives among which methylene diphenyl diisocyanate (MDI) and polymeric methylene diphenyl diisocyanate (PMDI).
Additives are optional. They are used in small amounts, and for different purposes. The most widely used additive is wax, preferably paraffin, which is added either as a wax melt or in the form of an aqueous emulsion. Paraffin, or other waxes, are mainly added to improve the swelling properties of the MDF. Other additives include colorants (e.g. to indicate different grades of MDF, or so as to fully colour the panel for decorative purposes). Other optional additives, depending e.g. on the geographical area and intended use, include fungicides or insecticides.
The panels of the invention can be generally made in a process comprising the following steps:
cutting the solid wood into wood chips (generally having a size of length and width 15 mm to 75 mm, and a thickness of 1.5 to 15 mm);
optionally, but preferably, purifying the chips by removing small contaminants, such as originating from stones or sand, and metals; —pre-steaming the chips (this involves a hydrothermal pre-treatment, by heating at 100° C. under atmospheric pressure;
refining: transforming the pre-treated wood chips to wood fibres;
subjecting the wood, in at least one of the process stages from solid wood to wood fibres, to acetylation;
casting the fibres onto a surface, so as to form a mat;
cold pre-pressing;
hot pressing;
sanding.
In commercial, continuous processing, the surface on which the fibres are cast will generally be a moving belt, with also the further steps, including the pressing being conducted via a moving belt, e.g. via a double belt press or a calendar. It is conceivable, though, that the mat is provided on a continuously moving belt, and the pressing is conducted in a multidaylight press. In any event, the continuous process of making a fibrous mat will generally impose a Machine Direction on the eventual panel.
In connection herewith, the invention also pertains to the particular type of MDF panel as can be identified with reference to its being obtainable by such a process. Thus, the invention provides a panel of medium density fibreboard obtainable by a process comprising the steps of providing wood fibres, adding adhesive and, preferably, wax to the fibres; casting the fibres onto a surface, so as to form a mat; cold pre-pressing, and hot pressing, wherein the surface on which the fibres are cast, is a moving belt, and wherein the fibres comprise acetylated wood. Preferably, such a panel is obtainable by a process as described above wherein the pressing is conducted via a moving belt, e.g. via a double belt press or a calendar.
The MDF panels of acetylated wood fibres of the invention can be made in accordance with, e.g., the following general processes:
In connection herewith, the invention also pertains to a panel of medium density fibreboard (MDF), comprising wood fibres the largest dimension of which is 5 mm or below, pressed together with an adhesive, the panel having an aspect ratio of at least 100 and a surface area of at least 1 m2, wherein the wood fibres are made of acetylated wood, obtainable by a process comprising the steps of (i) providing dried solid wood; (ii) subjecting the solid wood to acetylation by contact with acetic anhydride; (iii) chipping the acetylated wood and subjecting the chips to a size reduction so as to obtain fibres the largest dimension of which is 5 mm or below.
The acetylation can be conducted in any manner known in the field. Reference is made, inter alia, to WO2011/09852, GB 2 456 915, U.S. Pat. Nos. 5,821,359, 6,632,326, EP 1 718 442; EP 0 680 810.
The MDF panels according to the invention are judiciously provided with a view to reducing or avoiding the effects of linear swelling that normally affect MDF panels of the large and thin type. Particularly, this refers to reduced warping of a panel of the invention as compared to a similar panel made of non-acetylated wood fibres. The reduced warping can be assessed by a challenge test. Accordingly, the reduced warping, being defined as the deviation of the geometry of a panel from an initial state of flatness, can be assessed by a challenge test analogous to NEN-EN 1121. Herein one determines the shape stability of a large panel to expansion and warping when installed between two sets of climate conditions. In this test, the panel is climatised before testing at 65% relative humidity and a temperature of 20° C. The panel is then positioned in a frame of sufficient stiffness and installed between two sets of climatic conditions for a certain period. Climate 1 consists of a temperature of 23° C. and a relative humidity of 30%, and climate 2 consists of a temperature of 3° C. and a relative humidity of 85%. During exposure to both sets of climatic conditions, the distortion of the panel is measured. Optionally radiation with additional Infrared lamps can be conducted to simulate the influence of direct sunlight (as in NEN-EN-1121).
As demonstrated in the examples, the MDF panels according to the invention show a much higher dimensional stability than comparable non-acetylated MDF panels. In addition, the low elongation in the panels is also practically equal in both X and Y directions in the acetylated panels, while non-acetylated panels show different relative elongation in the X direction than the Y direction. This is surprising since both acetylated and non-acetylated panels possess a Machine Direction, which is considered to cause anisotropic behaviour in physical properties of industrially produced panels. Hence, despite the presence of the Machine Direction, the acetylated MDF panels of the present invention are equally dimensionally stable in both X and Y directions. This aspect is particularly important in large and thin panels with a high aspect ratio such as those of the invention.
Moreover, the examples also show that the acetylated panels according to the invention show low distortions on wetting (warping) and the warping stays low even if a twice thinner board of the same dimensions is used.
Conventional, non-acetylated boards of these dimensions show considerable warping already at a thickness of 15 mm, which becomes much worse when thinner boards of 6 mm are used.
In connection herewith, the invention also relates to the use of acetylated wood fibres in making medium density fibreboard panels, the panels having a length and width of at least 1 m, and an aspect ratio of at least 100, for the purpose of reducing warping of the panel as compared to a similar panel made of non-acetylated wood fibres.
Surprisingly, the MDF panels according to the invention allow a greater degree of freedom in using fixation means such as screws, nails, or plugs, that penetrate the panel. The greater degree of freedom is exhibited when such fixation means are provided closer to the edge than is recommendable for conventional MDF.
In connection herewith, the invention further pertains to the use of acetylated wood fibres in making medium density fibreboard panels, the panels having a length and width of at least 1 m, and an aspect ratio of at least 100, for the purpose of enabling the penetration of fixation means at a distance selected from the group consisting of less than 25 mm in both directions from a corner of the panel, less than 12 mm from an edge of the panel, and combinations thereof.
The following can be done to test a panel's fixation ability. The large panels to be tested on fixation are conditioned at 20° C. with a relative humidity of 65%. Such large panel is then rigidly mounted on an inflexible frame of dimensions 122 cm×244 cm with fixation means at less than 25 mm in both directions from the four corners of the panel, or less than 12 mm from the four edges of the panel. The structural integrity of the board area surrounding the fixing means is analysed, by visual inspection, after multiple cycling between 3° C. with a relative humidity of 30% and 40° C. with a relative humidity of 60%. Optionally, the test set-up can be irradiated with an additional IR lamp to simulate the influence of direct sun lighting.
The invention is now illustrated in the following, non-limiting examples.
Three acetylated boards with dimensions 2440×1220×15 mm3 were prepared in a continuous process according to industrial MDF processing. This industrial MDF processing includes continuous mat formation of acetylated wood fibers onto a moving belt, after which continuous pressing is accomplished. The formed fiber mat is passed through a continuous belt press to pre-press the mat to reduced thickness; after this pre-pressing the mat is continuously forwarded into the continuous main press in between two moving steel belts, which pass through the continuous press at high temperature and high pressure. At the end of this continuous pressing the produced MDF panels are sawn to desired length.
The boards were analyzed for fibre orientation by microscopic analysis. Optical microscopy was used to build a pixel digital image with area of 11.3×11.4 mm2 of the surface of each sample. As a measure for the presence of fibre orientation the so-called texture aspect ratio according to ISO 25178/EUR 15178N was calculated from these 11.3×11.4 mm2 images. This calculation yields a value on anisotropy scale between 0 and 1, wherein 0 means fully oriented and 1 no orientation (fully random). The boards scored 0.85, 0.84 and 0.89, which is on average 0.86.
A comparable board produced manually, batch-wise, corresponds to a value of 1 due to the absence of the aforementioned machine direction in the process.
Both acetylated and non-acetylated panels were prepared in the continuous process as described in Example 1, with the difference that in non-acetylated boards non-acetylated fibers were used.
Out of the acetylated and non-acetylated MDF panels with dimensions 2440×1220×12 mm3 (length×width×height) samples with dimensions of 1000×25×12 mm3 are cut in length as well as in width direction of the panel (at least 100 mm away from the perimeter of the panel).
Samples are acclimatized according to EN 318, until all panel samples have reached Equilibrium Moisture Content (EMC) at 65% Relative Humidity, 20° C.). Samples were measured in the length direction of the sample and then emerged for 14 days in water at 20° C., and measured again; then the samples were acclimatized at 65% Relative Humidity, 20° C. again for a period of 37 days (51 days total “emersion+drying time”). The samples were measured again.
The procedure resulted in the following data. All data are calculated from the EMC condition before the start of the emersion test.
The result is shown in
A total of four fibreboards, being acetylated (TRI) and non-acetylated (NA) fibreboards in two thicknesses (15 and 6 mm), were tested on warping. The fibreboards were produced in the continuous process as described in Example 1. The dimensions of the boards are 2440×1220×Z mm3, where Z denotes the thickness of the board as mentioned above.
The distortion of the board in six directions was measured to yield parameters d1-d6. Parameters d1, d2, d3, d4 correspond to the sides of the board in the perimeter order and d5 and d6 to the diagonals of the board.
These were measured by means of an elastic cord fixed at the corners but being free either expand or contract. The measure of the curvature of the board was determined by measuring the distance of the cord (at the center) to the board with a marking gauge. Every subsequent measurement was performed at the same position.
During the test, a board was hung vertically (portrait orientation) using a cord and was sprayed with water with a rate about 0.1 litre per minute on one side during 90 minutes, with a total of 9000 ml. After it was left to dry for at least 24 hours at 20° C. until the mass of the board was equal to the initial mass before testing. The parameters d1-d6 were measured in the dried board. The board was then re-wetted and re-dried according to the same procedure and the parameters were measured again. After another re-wetting cycle, the parameters were measured for the third time.
The results are shown in
| Number | Date | Country | Kind |
|---|---|---|---|
| 11183175.6 | Sep 2011 | EP | regional |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14347568 | Mar 2014 | US |
| Child | 18472722 | US |
