Patent Application
20250050533
The present invention relates to a process of producing a lignocellulosic composite or a product thereof. The invention also relates to a lignocellulosic composite (which is considered as an intermediate product), which is preparable according to a process of the invention, and to a product comprising such lignocellulosic composite. Furthermore, the invention relates (i) to the use of a lignocellulosic composite of the present invention as a building element in a construction product, (ii) to the use of a heat-curable binder composition in a process of producing a lignocellulosic composite and (iii) the use of a dielectric heating and pressing unit in a process of producing a lignocellulosic composite.
The invention is defined in the claims as attached.
More specifically, the present invention according to a first aspect relates to a process of producing a lignocellulosic composite or a product thereof as a part of a continuous production of lignocellulosic composites, wherein a heat-curable binder composition is used comprising as components for hardening the binder via reaction with each other at least one, two or more carbohydrate compounds and one or two compounds having two or more amino groups, comprising hexamethylenediamine and/or polylysine. According to this first aspect of the invention a mixture comprising lignocellulosic particles and said heat-curable binder composition is prepared, and a sheet is formed from said mixture. In a dielectric heating and pressing unit, the resulting formed sheet is at least temporarily simultaneously compacted and dielectrically heated so that the heat-curable binder composition hardens and the lignocellulosic composite results. Preferred embodiments of this process are defined in the claims and described hereinafter.
In specific processes of producing lignocellulosic composites, a mixture of lignocellulosic particles (i.e. particles consisting essentially of lignocellulose) and a binder is provided or prepared. This mixture is typically formed into a sheet. The resulting sheet is then compacted and heated in a manner so that the binder undergoes a hardening process.
The following documents relate to specific features or details of the present invention: WO 2013/150123 A1, US 2016/0304705 A1, WO 2017/207355 A1, and EP 3 359 360 B1 disclose binder compositions based on carbohydrate or carbohydrate-based compounds in combination with nitrogen containing compounds.
WO 2013/150123 A1 discloses a water-soluble pre-reacted binder composition, comprising the reaction product(s) of (i) at least one carbohydrate component, and (ii) at least one nitrogen-containing component.
US 2016/0304705 A1 discloses a curable carbohydrate binder composition comprising: a carbohydrate; a urea compound; and a nitrogen-containing compound, wherein the nitrogen containing compound does not comprise the urea compound.
WO 2017/207355 A1 discloses the use of an amine compound comprising at least one, preferably at least two amine functions, wherein the amine functions are primary or secondary amines, to reduce the level of furfural and/or hydroxymethylfurfural in a carbohydrate-based binder or binder composition and/or escaping in the course of preparation, cross-linking and/or curing of carbohydrate-based binders. Preferably, the carbohydrate-based binder is obtained from a carbohydrate-based binder composition comprising a carbohydrate component and a cross-linker and possibly a reaction product of carbohydrate component and cross-linker, wherein the cross-linker is selected from ammonium salts of inorganic acid, carboxylic acids, salts, ester or anhydride derivatives thereof, and/or combinations thereof.
EP 3 359 360 B1 discloses a multi-layer particle board comprising at least one core layer and a surface layer, the surface layer particles being bonded by a binder comprising carbohydrate based reaction products and the core layer particles being bonded by a binder other than the carbohydrate based binder resin used in the surface layer, wherein the binder comprising carbohydrate based reaction product comprises: reaction products of a reducing sugar and a nitrogen source.
US 2018/0071945 A1 discloses a method for producing single- or multi-layer lignocellulose materials using trialkyl phosphate.
EP 2 137 223 A2 discloses composite Maillard-resole binders to produce or promote cohesion in non-assembled or loosely assembled matter.
WO 2011/138 preparable A1 discloses a binder formulation and materials made therewith comprising a carbohydrate-based binder and a method for preparing the same.
In the technical field of producing lignocellulosic composites, processes known in the state of the art using binders based on carbohydrate compounds typically employ harsh reaction conditions, i.e. typically conductional heating with press plates in a so-called hot press or heated press at high temperatures and long heating periods. Furthermore, these processes require several curing steps in order to harden the binder. As such, carbohydrate based binder systems are considered as challenging materials and are only rarely used in manufacturing processes of making lignocellulosic composites, although carbohydrates can be obtained from natural resources, and are classified as “bio based” and therefore environmentally friendly raw materials.
One multi-step hardening process employing rather harsh reaction conditions is disclosed in EP 2885116 B1. This document discloses a process for manufacturing wood board, comprising the steps: (a) providing wood pieces; (b) applying a carbohydrate binder composition to the wood pieces provided in step (a); (c) forming the wood pieces obtained in step (b) into a sheet; (d) heating and pressing the sheet obtained in step (c) to obtain a cured wood board; and (e) post-curing the wood board obtained in step (d).
EP 2885116 B1 is understood to disclose that post-curing, i.e. a second hardening step, is employed to transform carbohydrates (sugars) which have not been transformed during initial curing, i.e. a first hardening step. Initial curing is performed using conductional heating with press plates at high temperatures and long heating periods. However, even these harsh conditions are considered as not sufficient to react all carbohydrate compounds and to sufficiently harden the binder. From the perspective of the skilled person, quantitative reaction of carbohydrates (sugars) is necessary, as free and unreacted carbohydrates (sugars) would pose a potentially detrimental effect regarding bacterial growth and may negatively contribute to the strength and/or other mechanical properties of the binder and the resulting lignocellulosic composite. This is in particular the case with binder systems comprising carbohydrates (sugars) and amines as reactive components.
The present inventors have considered that initial curing, i.e. heating the sheet with press plates at high temperatures above 190° C. and long heating periods of 140 seconds, has at least three main disadvantages. Firstly, conductional heat transfer appears economically and energetically inefficient, because the sheet is unevenly heated from the surface to the core, and reaction temperatures required for hardening the binder in the core of the sheet are only reached at the very end of long heating periods. Secondly, the surface of the sheet is constantly exposed to the hot press plates, which many times leads to detrimental effects such as burning defects or a very dark colour of the surface. Thirdly, the resulting (intermediate) composite features a strong density deviation within the lignocellulosic composite (low density in the core region and high density in the surface region) and inhomogeneous material characteristics, i.e. fully hardened binder in the surface region and only partially reacted carbohydrate compounds in the core region.
The multi-step hardening process according to EP 2885116 B1 has several disadvantages. Firstly, multiple expensive reaction units must be provided, i.e. at least one hot press unit and at least one post-curing unit. This is economically unattractive and logistically challenging. Secondly, all of the multiple reaction steps require long reaction times, so that the overall manufacturing process is time-consuming. Moreover, it is difficult to ensure high-quality reaction products, i.e. lignocellulosic composites and the (hardened) binder composition therein, with reliable and constant properties in a multi-step hardening process.
There is a demand in industry for an improved process of producing lignocellulosic composites, wherein preferably the binder comprises “bio based” carbohydrate compounds as environmentally friendly raw materials. Preferably, this improved process should allow for an effective one-step hardening of the binder under relatively mild reaction conditions, and should ideally lead to improved properties of the resulting lignocellulosic composites.
Thus, it was a primary object of the present invention to provide for an improved process of producing lignocellulosic composites using binder systems comprising carbohydrate compounds. The improved process should preferably include an effective and mild one-step hardening of the (heat-curable) binder. It was a related object of the present invention to reduce the complexity of the production facilities by providing a process protocol that requires only a single production unit for compacting a formed sheet and for curing the binder composition present within the formed sheet.
The present invention in its interrelated categories relates to
Embodiments, aspects or features disclosed for or in connection with one of these categories in each case analogously apply for each of the other categories of the invention.
If not stated otherwise, preferred embodiments, aspects or features of the present invention can be combined with other embodiments, aspects or features of the present invention, especially with other preferred embodiments, aspects or features, irrespectively of the categories to which the embodiments, aspects or features relate. The combination of preferred embodiments, aspects or features with other preferred embodiments, aspects or features in each case again results in preferred embodiments, aspects or features of the present invention.
In accordance with the primary object of the invention as stated above, the present invention relates to a process of producing a lignocellulosic composite or a product thereof, comprising at least the following steps:
Herein, and throughout the present text, the term “lignocellulosic particles” designates and includes any type, size and shape of lignocellulosic particles, such as fibres, chips, strands, flakes, sawmill shavings and saw dust, and mixtures thereof. In addition, any type of lignocellulosic biomass can be used as a source for said lignocellulosic particles. Mixtures of different types of lignocellulosic particles can be used in the production of a lignocellulosic composite. E.g., lignocellulosic particles from both virgin wood and/or waste wood, such as old furniture, can be used to produce the lignocellulosic composite of the present invention.
Herein, and throughout the present text, the term “heat-curable binder composition” designates binder compositions comprising reactive compounds, which will be reacting with each other when heated so that the binder composition hardens. Relevant hardening reactions include the formation of new chemical bonds by conversion of the functional groups of the binder components. According to the present invention a heat-curable binder composition is employed comprising as components for hardening the binder via reaction with each other at least (ii-a) one, two or more carbohydrate compounds, and (ii-b) one or two compounds having two or more amino groups, comprising hexamethylenediamine and/or polylysine. When such a binder composition is heated to a sufficient temperature chemical reactions take place at a sufficient rate involving in particular the reaction of functional groups of the carbohydrate compounds (e.g. carbonyl groups of reducing sugars) with amino groups of the respective compounds also present in the binder. By such chemical reactions the heat-curable binder composition hardens.
In contrast to conventional urea formaldehyde binders widely employed in lignocellulosic manufacturing processes, the heat-curable binder composition used in the process of the present invention is preferably free of formaldehyde. In corresponding embodiments of the process of the invention detrimental effects are avoided which are associated with the use and/or emissions of formaldehyde.
Herein, and throughout the present text, the term “carbohydrate compound” designates any carbohydrate compounds, which are capable of reacting with amine compounds, and optionally further crosslinkers, in order to form a hardened binder. According to the present invention, the carbohydrate compounds may be selected from the group consisting of monosaccharides, disaccharides, polysaccharides or a carbohydrate reaction product thereof. The carbohydrate compounds may comprise at least one reducing sugar.
The term “reducing sugar” indicates one or more sugars that contain aldehyde groups, or that can isomerize, i.e. tautomerize, to contain aldehyde groups.
Specifically, monosaccharides, disaccharides, or polysaccharides may be (partially) reacted with a precursor to form a carbohydrate reaction product. Such “carbohydrate reaction product” is included in the generic term “carbohydrate compounds”.
For use in the heat-curable binder composition in component (ii-a) such carbohydrate compound(s) must be capable of reacting with the compound(s) having two or more amino groups employed in component (ii-b).
Herein, and throughout the present text, the term “compound having two or more amino groups” (also called “amine co-reactant”) designates any chemical compound containing at least two amino groups, be it a primary or secondary group in each case. For use in the heat-curable binder composition in component (ii-b) such compound must be capable of reacting with the carbohydrate compound(s) employed in component (ii-a). Preferably, one, two or more of the amino groups of the compound having two or more amino groups are primary amino groups.
Herein, and throughout the present text, the term “formed sheet” (as resulting from step (a-ii)) designates a three-dimensional material mixture comprising lignocellulosic particles and a heat-curable binder composition as defined above. In contrast to the situation in the lignocellulosic composite resulting from step b) of the process of the invention, in the formed sheet the lignocellulosic particles are not finally bound by a hardened binder (but formed into a typically predetermined three-dimensional shape). As such the formed sheet can be considered as an intermediate.
Herein, and throughout the present text, the term “dielectric heating and pressing unit” designates a unit (as part of a production plant) comprising means for (at least temporarily simultaneously) pressing (compacting, e.g. with press plates) and dielectrically heating (e.g. with a generator for a high-frequency electrical field) a formed sheet as resulting from step (a-ii). A none limiting example of such a “dielectric heating and pressing unit” is the HLOP 170 press from Hoefer Presstechnik GmbH. The presence of means for simultaneous dielectric heating is the main difference compared to a conventional “hot press” or “heated press” (e.g. the hot press Lab Econ 600 by Fontjine), which does not possess any kind of radiation source and is thus not a “dielectric heating and pressing unit”.
Herein, and throughout the present text, the term “dielectrically heating” designates a process in which a high frequency electrical field, a radio frequency (RF) alternating electric field, or radio wave or microwave electromagnetic radiation or any other kind of electromagnetic radiation is applied for heating a dielectric material such as the heat-curable binder or the mixture comprising lignocellulosic particles and a heat-curable binder composition respectively. In contrast to heat transfer by conduction or convection the energy is transferred to the material by any kind of suitable electromagnetic radiation. A direct contact of the heating means with the (dielectric) material to be heated is thus not necessarily required.
Herein, and throughout the present text, the term “harden” or “hardening” designates a chemical transformation of the heat-curable binder composition by reaction of the reactive components of the binder. The hardening leads to the formation of a binder network in which the reacted binder components are covalently linked and bind the lignocellulosic particles.
Herein, and throughout the present text, the term “lignocellulosic composite” (as resulting in step b)) of the process of the present invention) designates any composite material, which contains lignocellulosic particles and a hardened binder that binds the lignocellulosic particles. Said lignocellulosic composite can be of any (preferably predetermined) shape such as rectangular, square, round, triangular and the like; and may also be of any thickness, density and colour.
In specific preferred embodiments, the lignocellulosic composite may be a “single-layer” lignocellulosic composite, wherein the term “single-layer” specifies that the lignocellulosic composite comprises only one layer of lignocellulosic material and binder, wherein the single layer preferably is produced in a process of the present invention comprising a single step of scattering lignocellulosic particles as part of step a).
Alternatively, in other specific embodiments, the lignocellulosic composite is a “multilayer” lignocellulosic composite. The term “multilayer lignocellulosic composite” used herein designates and includes any multilayered composite, which contains lignocellulosic particles and a hardened binder that binds the lignocellulosic particles, and wherein distinguishable (individual) layers are present within the composite.
A multilayer lignocellulosic composite preferably comprises at least two distinguishable (individual) layers, preferably at least a core layer and an upper and a lower surface layer, or four or more layers within the same composite material. The adjacent layers of the multilayer lignocellulosic composite are distinguishable in terms of their composition, density, colour or any other properties. In a process of the present invention they are preferably prepared in separate steps and/or using different mixtures comprising lignocellulosic particles and heat-curable binder composition. The adjacent layers comprise identical types of lignocellulosic particles and/or binders or different types of lignocellulosic particles and/or binders. The (individual) layers may also comprise or consist of different materials than lignocellulosic particles and/or binders, such as plastics, fabrics, paint coat or the like, for examples derived from foreign matter in waste wood.
The lignocellulosic particles used in the production of an individual layer of a “multilayer lignocellulosic composite” are of the same type or of different types of lignocellulosic biomass. The lignocellulosic particles used in the production of separate (individual) layers of a “multilayer lignocellulosic composite” are of the same type or of different types of lignocellulosic biomass or are identical or different mixtures of two or more of such types of lignocellulosic biomass.
Furthermore, the term “multilayer” specifies that the lignocellulosic composite comprises at least two individual layers, wherein at least one, preferably two or more of these individual layers comprise lignocellulosic material and binder, wherein preferably one or more or all of said layers are produced in a multi-step process comprising for each (individual) layer of lignocellulosic material and binder a step of scattering lignocellulosic particles.
Herein, and throughout the present text, the term “continuous production” has the usual meaning in the art and therefore comprises semi-continuous production processes, wherein specific steps are conducted periodically. A continuous production usually requires a series of discrete unit operations, with the output of one step being the input for the next step. For example, in the continuous production according to the present invention in one step a formed sheet is made by preparing a mixture comprising (i) lignocellulosic particles and (ii) a heat-curable binder composition and by forming (in a forming unit) a sheet from said mixture. Said formed sheet constitutes the input for the next step of at least temporarily simultaneously compacting and dielectrically heating the formed sheet (in a dielectric heating and pressing unit) so that the heat-curable binder composition hardens and the lignocellulosic composite results. Thus, the lignocellulosic composite, is produced in a continuous process starting from said mixture comprising (i) lignocellulosic particles and (ii) a heat-curable binder composition.
Preferably, between process step (a-ii) and process step b) the formed sheet is transported by means of a conveyor belt.
Preferably, in continuous production,
Surprisingly and contrary to the prevailing view on carbohydrate based binder systems the inventors have found a simple and effective method for hardening a heat-curable binder composition comprising as components for hardening the binder via reaction with each other at least one, two or more carbohydrate compounds and one or two compounds having two or more amino groups, comprising hexamethylenediamine and/or polylysine.
This simple and effective method in particular comprises the hardening step b), which is carried out in a dielectric heating and pressing unit and comprises at least temporarily simultaneously compacting and dielectrically heating the formed sheet as resulting in step a). By dielectrically heating (and at least temporarily simultaneously compacting) the formed sheet in step b) the reactive components of the heat-curable binder composition are caused to react with each other and thus harden the binder so that the lignocellulosic composite results.
It is a major advantage of the process according to the present invention that only one hardening (or curing) step is required and no post-hardening (or post-curing) in a separate unit is required. In other words: the process according to the present invention allows for an efficient production of a lignocellulosic composite as a part of a continuous production of lignocellulosic composites without interrupting the process for several different curing steps in several different process (curing) units.
It is another major advantage that the hardening process is initiated or at least supported by electromagnetic radiation, i.e. dielectric heating, and insofar does not need conductional heating with press plates at very high temperatures. The dielectric heating allows for a homogeneous and rapid heating of all regions/areas of the formed (and compacted) sheet, i.e. allows for simultaneously increasing the temperature at the center of the sheet and at the surface of the sheet immediately when starting the dielectric heating.
The process according to the present invention is characterized by at least temporarily simultaneously compacting and dielectrically heating the formed sheet as resulting in step
Also preferred is a process of the present invention wherein in step b) two or more time periods of dielectrically heating the formed sheet are interrupted by time periods wherein no dielectric heating is conducted. The time period(s) of interruption are preferably in the range of from 0.1 sec to 10 min, preferably 0.1 sec to 60 sec, more preferably 0.1 sec to sec.
Furthermore, also and additionally preferred is a process of the present invention wherein before removing the resulting lignocellulosic composite from the dielectric heating and pressing unit the following sequence of steps is conducted: (i) simultaneously compacting and dielectrically heating the formed sheet, followed by (ii) compacting the formed sheet without dielectrically heating the formed sheet, followed by opening the dielectric heating and pressing unit so that the lignocellulosic composite can be removed therefrom.
In a process of the present invention producing the lignocellulosic composite is part of a continuous production of lignocellulosic composites. In such a continuous production it is sometimes preferred to transfer a formed sheet in step b) from a first dielectric heating and pressing unit to a second dielectric heating and pressing unit. During such transfer dielectric heating is typically interrupted.
Preferred is a process of the present invention, wherein the lignocellulosic composite is a multilayer lignocellulosic board comprising at least two distinguishable layers.
The multilayer lignocellulosic board is preferably a board having at least a core layer as well as an upper surface layer and a lower surface layer, the total number of layers is then three or more. More preferably, at least a core layer of the multilayer lignocellulosic board comprises a heat-curable binder composition comprising as components for hardening the binder via reaction with each other at least (ii-a) one, two or more carbohydrate compounds and (ii-b) one or two compounds having two or more amino groups, comprising hexamethylenediamine and/or polylysine.
The multilayer lignocellulosic board is more preferably a three-layer board having one core layer, an upper surface layer and a lower surface layer, wherein preferably at least the core layer comprises a heat-curable binder composition comprising as components for hardening the binder via reaction with each other at least (ii-a) one, two or more carbohydrate compounds and (ii-b) one or two compounds having two or more amino groups, comprising hexamethylenediamine and/or polylysine.
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein the process comprises one or both of the following steps:
It is thus preferred that the individual steps (discrete unit operations) according to the process of the present invention are conducted continuously in themselves. It is accordingly preferred that a formed (yet uncured) sheet is continuously made according to step a) and continuously fed (as input) into the process step of (in a dielectric heating and pressing unit) continuously at least temporarily simultaneously compacting and dielectrically heating (curing) the formed sheet as resulting in step a) so that the heat-curable binder composition hardens and the lignocellulosic composite results. This preferred process hence allows for an advantageous continuous production of lignocellulosic composites.
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein the formed sheet as resulting in step a) is
In a continuous process “termination of step a)” means that the formed sheet as a result of step a) is fully prepared so that the formed sheet exits (as output) the forming unit used in step a).
In particular, in continuous processes in order to allow for the preferred quick transfer from step a) to step b) the spatial distance between the forming unit used in step (a-ii) and the dielectric heating and pressing unit used in step b) should be short. Preferably the spatial distance between the forming unit used in step a-ii) and the dielectric heating and pressing unit used in step b) is below 20 m, preferably below 10 m, more preferably below 5 m.
In some cases it is particularly preferred that the forming unit used in step (a-ii) and the dielectric heating and pressing unit used in step b) are spatially connected, i.e. there is no spatial distance or a spatial distance of at most 10 cm between the forming unit used in step (a-ii) and the dielectric heating and pressing unit used in step b). This is in particular the case, if between process step (a-ii) and process step b) the formed sheet is transported by means of a conveyor belt.
Preferably, the process of the present invention (preferably a process as defined herein above as being preferred) is at least partially conducted in a double belt press.
More preferably the process steps
Herein, and throughout the present text, the term “double belt press” is known in the art and designates a forming/compacting/pressing means/unit, wherein two pressing belts are continuously driven by rollers. The two pressing belts delimit an area for conducting through or transporting through a mixture prepared according to step (a-i) and/or a formed sheet comprising lignocellulosic particles and a heat-curable binder composition according to step (a-ii). The delimiting areas and the two pressing belts are preferably designed such that they exert a pressure on the mixture prepared according to step (a-i) and/or the formed sheet comprising lignocellulosic particles and a heat-curable binder composition according to step (a-ii). Hence, the double belt press is a means for forming the mixture prepared according to step (a-i), i.e. a forming unit for forming a sheet from said mixture obtained in step (a-i), so that the formed sheet results. And preferably the double belt press is also a means for compacting the formed sheet as resulting in step a).
Preferably, the double belt press for compacting the formed sheet as resulting in step a) comprises a dielectric heating unit for dielectrically heating the formed sheet as resulting in step a) so that the heat-curable binder composition hardens and the lignocellulosic composite results according to process step b) of the present invention. Said unit for dielectrically heating the formed sheet in a double belt press preferably comprises a pair of capacitor plates, which are arranged behind the pressing belts. The formed sheet as resulting in step a) is thus conducted or transported through a pair of capacitor plates, with one upper pressing belt being disposed between the formed sheet and the upper capacitor plate, and one lower pressing belt disposed between the formed sheet and the lower capacitor plate. One of the two capacitor plates may be grounded, causing dielectrically heating by a high-frequency electrical field according to the principle of asymmetrical feeding.
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein in step a) and also in step b) before dielectrically heating the formed sheet the maximum temperature within the heat-curable binder composition is below 120° C. preferably below 100° C. more preferably below 80° C. According to this preferred aspect of the present invention, step a) of making a formed sheet is limited to maximum temperatures so that the heat-curable binder typically does not undergo hardening during step a). Heat (thermal energy) might still be transferred to the heat-curable binder and/or the mixture consisting of lignocellulosic particles and a heat-curable binder composition, but due to the maximum temperature restriction only in a limited amount.
Heat transfer during step a) (although limited according to preferred embodiments) may facilitate or support:
A person skilled in the art will understand that a binder system as used in a process of the present invention, i.e. a heat-curable binder comprising as main components for hardening carbohydrate compounds and amine co-reactants, requires a certain minimum temperature of at least 130° C. in order to facilitate a suitable reaction and/or rate of reaction of said main components for hardening the binder. In some cases it might not be possible to completely prevent that small amounts of said reactive components react with each other even at relatively low temperatures in a range of from 20° C. to 120° C. However, hardening of the heat-curable binder composition so that the lignocellulosic composite results is only achieved in step b) of the process of the invention.
Likewise, preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein in step a) and also in step b) before dielectrically heating the formed sheet the maximum temperature at the center of the formed sheet is below 110° C., preferably below 90° C., more preferably below 70° C. The above considerations regarding the maximum temperature within the heat-curable binder composition also apply here, mutatis mutandis.
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein step a) is conducted so that the formed sheet as resulting in step a) has, and wherein preferably also step b) is conducted so that the formed sheet before dielectrically heating has:
According to this preferred aspect of the present invention, step a) is conducted so that the formed sheet as resulting in step a) has certain mechanical properties, namely said above mentioned internal bond strength and/or modulus of elasticity in bending and/or bending strength, that from the perspective of the skilled person classify the formed sheet as an essentially “unhardened” (“uncured”) intermediate material mixture, which is distinctly different from the resulting lignocellulosic composite obtained after step b). The mechanical properties of the formed sheet resulting after step a) of the preferred process, as defined above, are characteristic for an essentially unhardened intermediate material mixture. Correspondingly, the main components of the formed sheet, i.e. the lignocellulosic particles and the heat-curable binder composition are mixed with each other but are not (yet) finally bound.
Also preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein step b) is conducted so that
According to this preferred aspect of the present invention, step b) of at least temporarily simultaneously compacting and dielectrically heating the formed sheet as resulting in step a) in a dielectric heating and pressing unit so that the heat-curable binder composition hardens is conducted so that the resulting lignocellulosic composite has one or more of said mechanical properties as described above.
The inventors have found that surprisingly a single hardening step when properly conducted in a dielectric heating and pressing unit and comprising at least temporarily simultaneously compacting and dielectrically heating the formed sheet as resulting in step a) contrary to prevailing opinion results in the formation of a lignocellulosic composite with excellent mechanical properties as defined above.
Even more preferably step b) is conducted so that the resulting lignocellulosic composite has all of the above-mentioned material properties, i.e. an internal bond strength of at least 0.2 N/mm2 and a modulus of elasticity in bending of at least 1200 N/mm2 and a bending strength of at least 7 N/mm2 (all measured according to EN 310:1993).
According to a related and likewise preferred aspect of the present invention, step b) is conducted so that the internal bond strength (measured according to EN 319:1993) and/or the modulus of elasticity in bending and/or the bending strength (both measured according to EN 310:1993) of the resulting lignocellulosic composite are at least 10 times as high as the respective properties of the formed sheet as resulting in step a).
In a non-limiting example of the above-mentioned preferred aspects of the present invention, the internal bond strength of the formed sheet as resulting in step a) is <0.05 N/mm2 and step b) is conducted (i.e., the process conditions in step b) are selected) so that the resulting lignocellulosic composite has an internal bond strength of at least 0.5 N/mm2, i.e. a bond strength that is at least 10 times as high as the bond strength of the formed sheet present before said step b) (all internal bond strengths measured according to EN 319:1993).
Accordingly, dielectrically heating the formed (yet uncured) sheet in a dielectric heating and pressing unit allows for an efficient and continuous one step hardening protocol in contrast to expensive and elaborate non-continuous two-step hardening protocols utilized in the prior art (e.g. in EP 2 885 116 B1).
The inventors of the present invention have found that upon hardening (curing) of the binder caused by dielectric heating in step b) the mechanical properties are substantially improved in comparison with state of the art processes. Mechanical properties of sheets before and after dielectric heating in step b) of the process of the invention are summarized in the following table:
Preferably, process conditions are set or adjusted in step b) so that the resulting lignocellulosic composite has one, two or all of said above-mentioned mechanical properties, wherein preferably the process conditions are selected from the group consisting of:
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein
In more detail:
(a)—Conversion in Step a):
Preferably, step a) is conducted so that the conversion of said (ii-a) one, two or more carbohydrate compounds after step a) is below 0.2, preferably below 0.1, more preferably below 0.05, based on the respective total amount of the carbohydrate compounds used for preparing the mixture in step (a-i).
And likewise preferably step a) is conducted so that the conversion of said (ii-b) one or two compounds having two or more (preferably primary) amino groups, comprising hexamethylenediamine and/or polylysine, after step a) is below 0.2, preferably below 0.1, more preferably below 0.05, based on the respective total amount of the amine co-reactant compounds used for preparing the mixture in step (a-i).
More preferably, both requirements (relating to the conversion of components (ii-a) and (iib) apply in combination.
(b)—Conversion in Step b) Before Dielectrically Heating is Conducted:
Preferably step b) before dielectrically heating is conducted so that the conversion of said (ii-a) one, two or more carbohydrate compounds before dielectrically heating is below 0.2, preferably below 0.1, more preferably below 0.05, based on the respective total amount of the carbohydrate compounds used for preparing the mixture in step (a-i).
And likewise preferably step b) before dielectrically heating is conducted so that the conversion of said (ii-b) one or two compounds having two or more (preferably primary) amino groups, comprising hexamethylenediamine and/or polylysine, before dielectrically heating is below 0.2, preferably below 0.1, more preferably below 0.05, based on the respective total amount of the amine co-reactant compounds used for preparing the mixture in step (a-i).
More preferably, both requirements (relating to the conversion of components (ii-a) and (ii-b) apply in combination.
(c)—Conversion in Step b):
Preferably step b) is conducted so that the conversion of said (ii-a) one, two or more carbohydrate compounds after step b) is above 0.5, preferably above 0.8, more preferable above 0.9, based on the respective total amount of the carbohydrate compounds used for preparing the mixture in step (a-i).
And likewise preferably step b) is conducted so that the conversion of said (ii-b) one or two compounds having two or more (preferably primary) amino groups, comprising hexamethylenediamine and/or polylysine, after step b) is above 0.5, preferably above 0.8, more preferable above 0.9, based on the respective total amount of the amine co-reactant compounds used for preparing the mixture in step (a-i).
More preferably, both requirements (relating to the conversion of components (ii-a) and (iib) apply in combination.
Preferably, the requirements and provisos according to (a), (b), and (c) (in each case relating to the conversion of components (ii-a) and (ii-b)) apply in combination.
According to this preferred aspect of the present invention, step a) and/or step b) are conducted so that said (ii-a) one, two or more carbohydrate compounds and/or said (ii-b) one or two compounds having two or more (preferably primary) amino groups, comprising hexamethylenediamine and/or polylysine, are only to a limited extent converted in step a) and/or are mainly converted during said hardening step b). I.e., step a) of making a formed sheet is preferably conducted so that said components (ii-a) and/or (ii-b) for hardening the binder via reaction with each other, do not react to a high extent. Vice versa, step b) is preferably conducted so that said components (ii-a) and/or (ii-b) for hardening the binder via reaction with each other, do react to a very considerable extent, and preferably even react quantitatively.
Accordingly, the conversion of said compounds (ii-a) and/or (ii-b) after step a) is preferably below 0.2, more preferably below 0.1, even more preferably below 0.05, based on the respective total amount of the compounds, i.e. compounds (ii-a) and/or compounds (ii-b) respectively, used for preparing the mixture in step (a-i). I.e., in step a) only a small amount of said compounds (ii-a) and/or (ii-b) react.
Correspondingly, the conversion of said compounds (ii-a) and/or (ii-b) after step b) is preferably above 0.5, more preferably above 0.8, even more preferable above 0.9, based on the respective total amount of the compounds, i.e. compounds (ii-a) and/or compounds (iib) respectively, used for preparing the mixture in step (a-i). I.e., a large amount of said compounds (ii-a) and/or (ii-b) react, and preferably almost the total quantity of component(s) (ii-a) and/or (ii-b) for hardening the binder react(s) (with each other).
Herein and throughout the whole text the term “conversion” designates the ratio of how much of a certain component (reactant) has reacted after a specific step or after a set time. E.g., a conversion of 0.1 of said (ii-a) one, two or more carbohydrate compounds after step a) means that 10% of said (ii-a) one, two or more carbohydrate compounds that had been used for preparing the mixture in step (a-i) have reacted at the end of step a).
Herein and throughout the whole text the term “react” or “reacted” or “reaction” means that the molecular structure of a compound has or is changed by conversion of a functional group or by creating a new chemical bond with another molecule.
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein in step b) the formed sheet is dielectrically heated by applying a high frequency electrical field.
EP 3230028 B1 and WO 2016/091918 A1 (BASF SE) disclose a method for producing lignocellulosic materials by hardening in a high frequency electric field. However, the disclosed method has not been applied to a carbohydrate-based binder according to the present invention. The binders in EP 3230028 B1 for example were selected from the group consisting of aminoplastic resin and organic isocyanate having at least two isocyanate groups.
The inventors of the present invention have found out that surprisingly hardening of a mixture comprising (i) lignocellulosic particles and (ii) a heat-curable binder composition comprising as components for hardening the binder via reaction with each other at least (ii-a) one, two or more carbohydrate compounds and (ii-b) one or two compounds having two or more amino groups, preferably primary amino groups, comprising hexamethylenediamine and/or polylysine, wherein said mixture has been formed into a formed sheet can be efficiently carried out in a single step by applying a high frequency electric field.
The term “high-frequency electrical field” used herein designates and includes any kind of high-frequency electrical or electromagnetic field such as microwave irradiation or a high-frequency electrical field, which results after applying a high-frequency alternating voltage at a plate capacitor between two capacitor plates. Preferred frequencies for the high-frequency electrical field are in the range of from 100 kHz to 30 GHz, preferably 6 MHz to 3 GHz, more preferably 13 MHz to 41 MHz. Especially suitable and preferred are the respective nationally and internationally approved frequencies such as 13.56 MHz, 27.12 MHz, 40.68 MHz, 2.45 GHz, 5.80 GHz, 24.12 GHz, more preferably 13.56 und 27.12 MHz. The electrical power used to create such a high-frequency electrical field in the processes of the present invention preferably is in the range of from 10 to 10.000 kWh, more preferably of from 100 to 5.000 kWh, most preferably of from 500 to 2.000 kWh.
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein in step b) the formed sheet is dielectrically heated to a maximum temperature at the center of the formed sheet of at least 130° C., preferably of at least 140° C., more preferably of at least 150° C.
The term “center of the formed sheet” as used in this text designates the location which is approximately in the middle between the surfaces of the three-dimensional object defined by the form of said formed sheet resulting after step a).
Preferably, in a preferred process of the present invention the temperature at the center of the formed sheet is monitored and/or controlled, preferably controlled. It is particularly preferred to control the temperature at the center of the formed sheet, so that the binder hardens via reaction of the (ii-a) one, two or more carbohydrate compounds and the (ii-b) one or two compounds having two or more amino groups, comprising hexamethylenediamine and/or polylysine (amine co-reactants) and binds the lignocellulosic particles in a controlled manner, preferably so that specific mechanical properties (as defined above) result.
It has been found out that a certain temperature is required to sufficiently promote or support the reaction of said carbohydrate compounds and amine co-reactants. The preferred process of the present invention furthermore takes into account that said required temperature has to be reached in the center of the formed sheet in order to facilitate hardening of the binder not only in the surface areas but throughout all regions of the material.
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein the formed sheet is compacted in step b) with press plates having a maximum temperature of below 125° C., preferably below 110° C., at the beginning of the compacting.
According to the present invention step b) is carried out in a dielectric heating and pressing unit comprising dielectric heating means and pressing means, preferably press plates. In this preferred embodiment of the present invention said press plates have a maximum temperature of below 125° C., preferably below 110° C., at the beginning of the compacting. While an increased temperature of the press plates might help to prevent condensation of water and/or electrical discharges on the press plates, the maximum temperature is chosen so that premature hardening is avoided.
Thus, although the press plates might be heated to a maximum temperature of below 125° C., preferably below 110° C., at the beginning of the compacting, this does at least not mean that the heated press plates cause the hardening of the binder in the center of the formed sheet. Rather, said hardening process is primarily initiated and supported by dielectrically heating of the formed sheet, preferably by applying a high frequency electrical field. As stated, this is particularly true for the center of the formed sheet.
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein in step b) of at least temporarily simultaneously compacting and dielectrically heating the formed sheet the maximum temperature at the center of the formed sheet is at least 5° C. higher, preferably at least 10° C. higher, more preferably at least 20° C. higher, than the maximum temperature of the press plates at the beginning of the compacting.
In contrast to processes not according to the present invention comprising multi-step hardening protocols for binder systems based on carbohydrate compounds, which rely on conductional heating with press plates at very high temperatures and heat transfer from the surface to the center of the (formed) sheet, the preferred process according to the present invention relies on a uniform dielectric heating of all areas (volume regions) within the (formed) sheet. It is thus preferred that the maximum temperature at the center of the (formed) sheet is i) sufficiently high to promote reaction of the reactive binder components (hardening) and ii) higher than the maximum temperature of the press plates at the beginning of the compacting. It goes without saying that the surface area of the (formed) sheet is dielectrically heated to a temperature similar to the temperature reached at the center of the (formed) sheet.
In a non-limiting example of a preferred process according to the present invention, the maximum temperature at the center of the sheet reached in step b) may thus be 150° C., while the press plates have a maximum temperature of only 100° C. at the beginning of the compacting. According to this non-limiting example, the maximum temperature at the center of the formed sheet is 50° C. higher than the maximum temperature of the press plates at the beginning of the compacting.
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein step a) of making a formed sheet
Thus, in a preferred process of the present invention step a) of making a formed sheet is conducted in a forming unit not comprising any means for heating the sheet. Correspondingly, preferably the hardening of the heat-curable binder composition exclusively takes place in the dielectric heating and pressing unit of step b).
In another preferred process of the present invention, the formed sheet in step a) is obtained by scattering lignocellulosic particles and mixing said particles with a heat-curable binder composition according to the invention.
More preferably step (a-i) of preparing a mixture comprising (i) lignocellulosic particles and (ii) a heat-curable binder composition comprises one or more of the following steps:
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein step a) of making a formed sheet does not comprise any active heating of the sheet (e.g., by using any heating device) and/or does not comprise any pressing of the sheet (specifically it does not comprise the use of a hot press).
According to this preferred aspect of the present invention, step a) of making a formed sheet leads to a non-hardened and pre-formed intermediate mixture (formed sheet), which has not been actively heated and/or pressed. Correspondingly, a process of the invention is therefore preferred wherein the hardening process is only conducted in the dielectric heating and pressing unit of step b).
In some cases preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein in step b) the formed sheet as resulting in step a) is pre-heated (as defined below) and/or pre-compacted before it is at least temporarily simultaneously compacted and dielectrically heated. According to this preferred aspect of the present invention, it is beneficial to pre-heat and/or pre-compact the formed sheet as resulting in step a) in the dielectric heating and pressing unit of step b). Such a pre-heating and/or pre-pressing step facilitates the hardening process of the mixture comprising (i) lignocellulosic particles and (ii) a heat-curable binder composition as it leads to a denser and more homogenised intermediate mixture.
Pre-heating the formed sheet as resulting in step a) in step b) may preferably be carried out for a period of time in the range of from 10 s to 120 s and/or may preferably lead to a maximum temperature at the center of the formed sheet in the range of from 25° C. to 120° C., preferably 25° C. to 100° C., more preferably 25° C. to 80° C., most preferably 25 to 60° C.
Preferably, the formed sheet is pre-heated using dielectric heating means, more preferably the formed sheet is dielectrically pre-heated by applying a high frequency electrical field. “Pre-heating” as conducted in step b), i.e. in the dielectric heating and pressing unit, designates a heating process wherein the formed sheet is heated to a maximum temperature below the temperature required for starting the hardening reaction of the heat-curable binder composition. I.e., preferably the maximum temperature reached by pre-heating in step b) at the center of the sheet is below 120° C.
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), additionally comprising at least:
post-processing the lignocellulosic composite resulting in step b) so that a product of the lignocellulosic composite results,
wherein preferably the post-processing comprises one or more of the following steps:
According to this preferred aspect of the present invention the lignocellulosic composite resulting in step b) is further processed to result in a product of the lignocellulosic composite. Non-limiting examples of such products are a painted board, a packed board, a stack of grinded and wrapped boards, etc. It is essential to note that none of the above listed post-processing steps includes any kind of post-curing or post-hardening as the process according to the present invention only requires one hardening step, namely said step b) of at least temporarily simultaneously compacting and dielectrically heating in a dielectric heating and pressing unit the formed sheet as resulting in step a).
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), comprising the additional step of:
Industry in general and especially the furniture industry requires specific material properties of lignocellulosic composites (e.g. boards in shelves). It is important that a process of producing a lignocellulosic composite results in high quality products with excellent properties, e.g. results in a lignocellulosic composite that features one, two or all of the parameters listed above.
Accordingly, in a preferred aspect of the present invention, one, two or more parameters (such as internal bond strength, thickness swelling and the like) of the lignocellulosic composite to be produced are determined before step b), preferably before step a). Then, the process conditions for step b) are selected so that said one, two or more parameters are present in the lignocellulosic composite resulting. These process conditions are preferably selected from the group consisting of:
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein the process conditions in step b) are selected so that
According to these preferred aspects of the present invention, the process conditions in step b) are selected to guarantee an effective (one-step) hardening of the heat-curable binder, resulting in a high quality lignocellulosic composite. For preferably selected process conditions see above.
Preferably, the maximum temperature at the center of the formed sheet is reached in a short period of time of less than 200 s, preferably in less than 180 s, more preferably in less than 160 s, after the start of dielectrically heating the formed sheet in step b). Herein, preferably the maximum temperature to be reached at the center of the formed sheet is at least 130° C., more preferably at least 140° C., even more preferably at least 150° C. The short time period needed to reach said maximum temperature once more highlights the effectiveness of dielectric heating. The person skilled in the art is aware that the specific period of time required to reach the maximum temperature at the center of the formed sheet individually depends on several factors such as the kind of lignocellulosic particles and/or heat-curable binder composition used, the thickness of the formed sheet, the water content of the mixture and the power and/or frequency of the electromagnetic radiation applied for dielectric heating.
Preferably, the maximum temperature at the center of the formed sheet is reached in less than 40 s·(d/mm), preferably in less than 30 s·(d/mm), more preferably in less than 20 s·(d/mm) after the start of dielectrically heating the formed sheet, where d is the thickness of the lignocellulosic composite in mm at the end of step b). Preferably the maximum temperature to be reached at the center of the formed sheet is at least 130° C., more preferably at least 140° C., even more preferably at least 150° C. E.g., if the thickness d of the formed sheet is 10 mm, said maximum temperature is preferably reached in less than 400 s, more preferably in less than 300 s, even more preferably in less than 200 s, after the start of dielectrically heating the formed sheet.
The above described preferred processes of the present invention allow for a fast and effective production of a lignocellulosic composite.
It is furthermore preferred that the process conditions in step b) are selected so that more than 95%, preferably more than 97%, more preferably more than 99%, per mole of the total amount of carbohydrate compounds as present in component (ii-a) react and/or more than 95%, preferably more than 97%, more preferably more than 99%, per mole of the total amount of compounds having two or more amino groups as present in component (ii-b) react. This preferred process takes into account that an effective (one-step) hardening of the heat-curable binder requires a quantitative reaction of the major components of the binder in order to guarantee beneficial material properties of the resulting lignocellulosic composite and optimum use of the binder components employed (for the sake of sustainability an inefficient use of binder components should be avoided).
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein the formed sheet resulting after step a) is a
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein the heat-curable binder composition comprises as components for hardening the binder via reaction with each other at least
In some cases the heat-curable binder composition in addition to hexamethylenediamine and/or polylysine additionally comprises one or more other compounds having two or more amino groups selected from the group consisting of
According to this preferred aspect of the present invention, the one or two, preferably bio based, compounds having two or more amino groups, are selected from the group consisting of the amine co-reactants listed above.
Herein and throughout the present text, the term “amine co-reactant” relates to any organic compound having two or more (primary or secondary, preferably primary) amino groups, which may independently be substituted or unsubstituted. Diamines have two amino groups, triamines have three amino groups, tetraamines have four amino groups, oligoamines have 5 to 10 amino groups, and polyamines have more than 10 amino groups. The respective amino groups of the amine co-reactants are preferably part of an alkyl, cycloalkyl, heteroalkyl, or cycloheteroalkyl compound, each of which may be optionally substituted. Herein, the term “optionally substituted” includes the replacement of hydrogen atoms with other functional groups. Such other functional groups include, but are not limited to hydroxy, halo, thiol, alkyl, haloalkyl, heteroalkyl, aryl, arylalkyl, arylheteroalkyl, nitro, sulfonic acids and derivatives thereof, carboxylic acids, and the like. Moreover, according to the present invention, any of, hydroxy, thiol, alkyl, haloalkyl, heteroalkyl, aryl, arylalkyl, arylheteroalkyl, and/or sulfonic acid group may optionally be further substituted.
A non-limiting example of a preferred amine co-reactant according to the present invention is a diamine, preferably said diamine is a molecule having the formula H2N—R—NH2, wherein R is an alkyl, cycloalkyl, heteroalkyl, or cycloheteroalkyl, preferably an alkyl, each of which may be optionally substituted. More preferably the diamine is an aliphatic diamine having the formula H2N—R—NH2, wherein R is preferably an alkyl group selected from C2-C24, more preferably from C3-C16, even more preferably from C4-C10. As used herein, the term “alkyl” includes a chain of carbon atoms, which may optionally be branched and/or unsaturated. It is to be further understood that the alkyl group is preferably of limited length. In particular, shorter alkyl groups may add less lipophilicity to the compound and accordingly will have different reactivity towards the carbohydrate component and solubility in a binder solution.
Preferably the diamine is selected from the group consisting of 1,2-diaminoethane, 1,4-diaminobutane, 1,5-diaminopentane, 1,6-diaminohexane (hexamethylenediamine, HMDA), 1,12-diaminododecane, 1,4-diaminocyclohexane, 1,4-diaminobenzene, 2-methylpentamethylenediamine, 1,3-pentanediamine, and 1,8-diaminooctane, 1,6-diaminohexane and lysine. More preferably the diamine is 1,6-diaminohexane (hexamethylenediamine, HMDA).
According to another preferred aspect, the amine co-reactant is a triamine, preferably selected from the group consisting of diethylenetriamine, 1-piperazineethaneamine, or bis(hexamethylene)triamine. In yet another preferred aspect, the amine co-reactant is a tetraamine, for example triethylenetetramine or an oligoamine, for example tetraethylenepentamine.
In another preferred aspect, the amine co-reactant is a polyether-polyamine. For example, said polyetherpolyamine is a diamine or a triamine. More preferably the polyether-polyamine is a trifunctional primary amine having an average molecular weight of around 400-500, e.g. Jeffamine T-403 Polyetheramine (e.g. Huntsman Corporation).
In a further preferred aspect, the amine co-reactant is a polyamine. Said polyamine is preferably selected from the group consisting of chitosan, polylysine, polyethylene imine, poly(N-vinyl-N-methyl amine), polyaminostyrene and polyvinylamines. In a specific example, the amine co-reactant component comprises a polyvinyl amine. As used herein, the polyvinyl amine can be a homopolymer or a copolymer. The most preferably used polyamine is polylysine.
Polylysine is a polymerization product of the monomer lysine, preferably L-lysine, and optionally further monomers selected from the group consisting of
Preferred are homopolymers of lysine, preferably homopolymers of L-lysine.
Polylysine comprises or consists of dimers (n=2), trimers (n=3), oligomers (n=4-10) and macromolecules (n>10), wherein n is the number of lysine monomers which have been reacted to form the dimers, trimers, oligomers and macromolecules. Additionally, monomers can be present in a limited amount in a mixture with the polylysine due to incomplete conversion of the monomers during the polymerization reaction.
Preferably, the polylysine has a total weight-average molecular weight Mw,total in the range of from 800 g/mol to 10,000 g/mol, preferably 1,000 g/mol to 7,500 g/mol, preferably 1,150 g/mol to 5,000 g/mol, more preferably 1,300 g/mol to 5,000 g/mol, more preferably 2,400 to 5,000 g/mol, most preferably 3,000 to 5,000 g/mol.
In the present text, the term polylysine also includes polylysine derivatives, which are prepared by or can be prepared by a modifying reaction of (i) the amino groups present in the polylysine obtained by polymer synthesis with (ii) electrophiles like carboxylic acid, epoxides, and lactones, wherein the total amount of amino groups reacted in the modifying reaction is 20% or lower, preferably 10% or lower, based on the total amount of amino groups in the polylysine obtained in the polymer synthesis (i.e., before modification).
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein the heat-curable binder composition comprises as components for hardening the binder via reaction with each other at least
According to this preferred aspect of the present invention, the one, two or more, preferably bio based, carbohydrate compounds are selected from the group of compounds listed above.
Preferably, the carbohydrate compound is a monosaccharide in its aldose or ketose form, including a triose, a tetrose, a pentose, a hexose, or a heptose; or a polysaccharide; or combinations thereof.
For example, when a triose serves as the carbohydrate compound, or is used in combination with other reducing sugars and/or a polysaccharide, an aldotriose sugar or a ketotriose sugar may be utilized (including glyceraldehyde and dihydroxyacetone, respectively). When a tetrose serves as the carbohydrate compound, or is used in combination with other reducing sugars and/or a polysaccharide, aldotetrose sugars (including erythrose and threose) and keto-tetrose sugars (including erythrulose), may be utilized. Moreover, when a pentose serves as the carbohydrate compound, or is used in combination with other reducing sugars and/or a polysaccharide, aldopentose sugars (including ribose, arabinose, xylose, and lyxose) and ketopentose sugars (including ribulose, arabulose, xylulose, and lyxulose), may be utilized. When a hexose serves as the carbohydrate compound, or is used in combination with other reducing sugars and/or a polysaccharide, aldohexose sugars (including glucose (i.e. dextrose), mannose, galactose, allose, altrose, talose, gulose, and idose) and ketohexose sugars (including fructose, psicose, sorbose and tagatose), may be utilized. When a heptose serves as the carbohydrate compound, or is used in combination with other reducing sugars and/or a polysaccharide, a ketoheptose sugar (including sedoheptulose) may be utilized. Other stereoisomers of such carbohydrate compounds not known to occur naturally are also contemplated to be useful in the binder compositions as described herein.
Specifically preferred are glucose (i.e. dextrose), fructose and mixtures of carbohydrates comprising or consisting of glucose and fructose, preferably in a weight ratio of glucose to fructose of 60:40 to 40:60.
In another preferred aspect, the carbohydrate component is invert sugar syrup or high fructose corn syrup (HFCS).
As mentioned above, the carbohydrate compound may be a polysaccharide. For example, a polysaccharide with a low degree of polymerization, preferably selected from the group consisting of molasses, starch, cellulose hydrolysates, or mixtures thereof.
According to another preferred aspect, the carbohydrate compound is a starch hydrolysate, a maltodextrin, or a mixture thereof. While carbohydrates of higher degrees of polymerization may not be preferable, they may none the less be useful within the scope of the present invention particularly by in situ depolymerization.
In a particularly preferred aspect of the present invention, at least one of the one, two or more, preferably bio based, carbohydrate compounds, is selected from the group consisting of: ribose, arabinose, xylose, lyxose, glucose (dextrose), mannose, galactose, allose, altrose, talose, gulose, idose, fructose, psicose, sorbose, dihydroxyacetone, sucrose, maltodextrin and tagatose, as well as mixtures thereof,
and
at least one of the one, two or more, preferably bio based, compounds having two or more amino groups is selected from the group consisting of: 1,2-diaminoethane, 1,4-diaminobutane, 1,5-diaminopentane, 1,6-diaminohexane, 1,12-diaminododecane, 1,4-diaminocyclohexane, 1,4-diaminoben-zene, diethylenetriamine, triethylenetetramine, tetraethylenepentamine, 1-piperazine-ethaneamine, 2-methyl-pentamethylenediamine, 1,3-pentanediamine, and bis(hexamethylene)-triamine, 1,8-diaminooctane, lysine and polylysine as well as mixtures thereof.
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein
According to this preferred aspect of the present invention, the at least one mixture of step a) comprises a relatively low amount of the heat-curable binder composition in relation to the amount of the lignocellulosic particles. More particularly, the mass ratio of the weight of the solid content of the heat-curable binder composition to the weight of the lignocellulosic particles in an oven-dry state is less than 0.18, preferably less than 0.16, more preferably less than 0.15. The relatively low preferred amounts of the solid content of the heat-curable binder composition is advantageous as it leads to sustainable processes and/or sustainable products, i.e. lignocellulosic composites mainly consisting of bio based materials.
Surprisingly, in the process of the present invention a relatively low amount of binder suffices to bind a large amount of lignocellulosic particles, as the dielectric heating, preferably by applying a high frequency electrical field, of the formed sheet in step b) of the process allows for a perfect hardening of the heat-curable binder also in the center of the formed sheet, in contrast to other hardening treatments (e.g. the use of a hot press). In otherwords, the binder is used more efficiently in the process of the present invention.
According to another preferred aspect of the present invention, the heat-curable binder composition of step a) comprises as components for hardening the binder via reaction with each other at least (ii-a) one, two or more, preferably bio based, carbohydrate compounds and (ii-b) one or two, preferably bio based, compounds having two or more amino groups, comprising hexamethylenediamine and/or polylysine, wherein none of the compounds having two or more amino groups is polylysine, wherein the ratio of the mass of all compounds present in said component (ii-a) to the mass of all compounds present in said component (ii-b) is in the range of from 90:10 to 50:50, preferably in a range of from 85:15 to 60:40, more preferably in a range of from 82:18 to 70:30. Preferably, the compounds having two or more amino groups are selected from the preferred diamines, triamines or polyetherpolyamines stated above.
This means, that in cases wherein the binder does not comprise polylysine, binder compositions with an excess of the one, two or more, preferably bio based, carbohydrate compounds of component (ii-a) are particularly preferred, because they allow for an efficient hardening process and also for a high content of bio based raw materials within the lignocellulosic composite.
According to another preferred aspect of the present invention, the heat-curable binder composition of step a) comprises as components for hardening the binder via reaction with each other at least (ii-a) one, two or more, preferably bio based, carbohydrate compounds and (ii-b) one or two, preferably bio based, compounds having two or more amino groups, comprising hexamethylenediamine and/or polylysine, wherein the one or one of the two compounds having two or more amino groups is polylysine, wherein the ratio of the mass of all compounds present in said component (ii-a) to the mass of all compounds present in said component (ii-b) is in the range of from 10:90 to 90:10, preferably in the range of from 20:80 to 80:20.
This means, that in cases wherein the heat-curable binder composition comprises polylysine:
It is particularly preferred that the one or one of the two, preferably bio based, compounds having two or more amino groups is polylysine.
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein the (i) lignocellulosic particles are obtained from European tree species,
This preferred aspect of the present invention takes into account that it is desirable to utilize lignocellulosic particles, which have been obtained from regionally available, sustainable sources, i.e. from European tree species instead of rainforest wood from South America, Africa and Asia.
Preferred is a process of the present invention (preferably a process as defined herein above as being preferred), wherein the heat-curable binder composition additionally comprises one, two or more compounds independently selected from the group consisting of:
These additional binder compounds are not components employed for hardening the binder via reaction with each other.
Advantageously, in a process of the present invention (preferably a process as defined herein above as being preferred) the addition of alkali salts and alkaline earth salts, preferably sodium nitrate, to the binder leads to improved properties of the resulting lignocellulosic composite. In particular, the addition of alkali salts and alkaline earth salts, preferably sodium nitrate, to the binder improves the internal bond strength and/or the thickness swelling after 24 hours in water at 20° C. of a resulting lignocellulosic composite. Furthermore, the presence of alkali salts and alkaline earth salts, preferably sodium nitrate, in the binder reduces the time needed to reach the target temperature at the center of the formed sheet, so that the binder hardens more efficiently. Thus, the addition of alkali salts and alkaline earth salts, preferably sodium nitrate, improves the product properties and/or the process parameters, i.e. less time is needed and energy consumption is reduced.
Another preferred additive in a process of the present invention are hydrophobing agents, preferably paraffin and mixtures comprising paraffin, more preferably paraffin emulsions. In particular, the addition of hydrophobing agents, preferably paraffin and mixtures comprising paraffin, more preferably paraffin emulsions, to the binder improves the thickness swelling after 24 hours in water at 20° C. of a resulting lignocellulosic composite. It is preferred that in step a) of the process of the present invention the mass ratio of the weight of paraffin to the weight of the lignocellulosic particles in an oven-dry state (paraffin amount) is in the range of from 0.2% to 1.5%. It is also preferred that the mass ratio of the weight of paraffin to the weight of all binder components present for hardening the binder via reaction with each other (paraffin/binder ratio) is in the range of from 2% to 30%, more preferably in the range of from 3% to 25%, even more preferably in the range of from 4% to 25%.
Further preferred additives in a process of the present invention are described above. The skilled person will select the respective amounts of said additional compounds so that the properties of the resulting binder mixture and/or of the hardened binder and/or the resulting lignocellulosic composite are tailored according to the individual requirements. In particular, the addition of such compounds leads to improved properties of the binder so that the desired viscosity, reactivity, stability and the like can be set. Furthermore, additives are selected in order to improve the properties of the resulting hardened binder and/or the resulting lignocellulosic composite. These properties preferably are, but are not limited to, the colour, durability, density and the like.
The present invention also relates to a lignocellulosic composite, preparable according to a process of the present invention (preferably a process of the invention as defined above or in the attached claims as being preferred), and to a product thereof, wherein the product is preferably a construction product (for a definition see below).
The lignocellulosic composite of the present invention preferably is a lignocellulosic board selected from the group consisting of
A lignocellulosic composite, preferably board, of the present invention, preparable according to a process of the present invention, preferably is a single-layer lignocellulosic board or a multilayer lignocellulosic board, more preferably is a single-layer lignocellulosic board. A multilayer lignocellulosic board of the present invention is a board comprising at least two distinguishable (individual) layers. The multilayer lignocellulosic board is preferably a board having at least a core layer as well as an upper surface layer and a lower surface layer. The total number of layers is then three or more. If the number of layers is four or more, there are one or more intermediate layers. Preferred is a three-layer board having one core layer, an upper surface layer and a lower surface layer. This is specifically relevant if the lignocellulosic composite, preferably board, of the present invention is an element of a construction product of the present invention.
Particularly preferred is a single-layer lignocellulosic board of the present invention that is a medium-density fiberboard (MDF) or a chipboard, even more preferably is chipboard, and a corresponding construction product comprising such single-layer lignocellulosic board.
Particularly preferred is a lignocellulosic board of the present invention, which has a thickness in the range of from 3 to 30 mm, preferably in the range of from 5 to 20 mm. The preferred lignocellulosic board of the present invention preferably is a component (building element) in a construction product, more preferably is a building element in furniture or parts of furniture, and most preferably is a building element in a hollow construction in furniture or parts of furniture.
The present invention also relates to the use of a lignocellulosic composite of the present invention (as defined above or preparable according to a process of the present invention, preferably as defined herein above as being preferred) as a building element in a construction product, preferably as a building element in furniture or parts of furniture, more preferably as a building element in a hollow construction in furniture or parts of furniture.
The term “construction product” as used in this text designates products used for constructions such as decking, doors, windows, floors, panels, furniture or parts of furniture. The construction product of the present invention is preferably selected from the group consisting of furniture and parts of furniture.
The term “furniture” as used in this text designates all kinds of furniture. In the context of the present invention, furniture is preferably selected from the group consisting of chairs, tables, desks, closets, beds and shelves.
The term “building element” as used in this text designates lignocellulosic composite products (e.g., boards, see above) which constitute a part (element) of a construction product (e.g., a part of furniture). Such building elements preferably are parts of furniture, and more preferably such parts of furniture are selected from the group consisting of shelves, table plates, side boards or shelves or doors of cabinets, and side walls of beds.
The term “hollow construction” as used in this text designates construction products, preferably furniture, and building elements, preferably parts of furniture, comprising an amount of enclosed empty space that is not filled with construction material. Such hollow constructions allow for the making of construction products, preferably furniture, and building elements, preferably parts of furniture, which are exceptionally light and strong, although a low amount (by weight) of construction material is used. Board-on-frame (BoF) products are typical examples for such hollow constructions. In a BoF product a frame made from lignocellulosic composite products (e.g. chipboards) is covered with lignocellulosic boards (e.g. thin high-density fiberboard). A further hollow construction is a board-on-stile (BoS) product, in which stripes of lignocellulosic composite products are used instead of a complete frame.
The present invention also relates to the use of a heat-curable binder composition (as defined above) in a process of the present invention (preferably a process as defined herein above as being preferred).
The present invention also relates to the use of a dielectric heating and pressing unit (as defined above) in a process of the present invention (preferably a process as defined herein above as being preferred).
The following examples according to the present invention are meant to further explain and illustrate the present invention without limiting its scope.
The examples relate to boards 1 to 34, which are prepared by using binders 1 to 12. Tables 1 and 2, below, state the number of the respective board and the respective binder used for making it.
The moisture content of the lignocellulosic particles used for preparing a mixture comprising lignocellulosic particles and a binder (see in particular step (a-i) of the process of the invention) was measured according to DIN EN 322:1993-08 by placing the lignocellulosic particles in a drying oven at a temperature of 103±2° C. until constant mass has been reached, i.e. an oven-dry state of the lignocellulosic particles. This method is also used to check the water content of the prepared mixtures comprising lignocellulosic particles and a binder.
For calculating the mass ratios of the weight of the solid content of the heat-curable binder composition to the weight of the lignocellulosic particles in an oven-dry state (binder amount) in the examples according to the present invention considered is the total weight of the sum of the solid contents of the respective binder components present for hardening the binder. Such components are (ii-a) carbohydrate compounds and (ii-b) compounds having two or more amino groups, wherein the components (ii-a) and (ii-b) are capable of reacting with each other. Other additional compounds such as alkali salts and alkaline earth salts, hydrophobing agents, dyes, pigments, antifungal agents, antibacterial agents, rheology modifiers, fillers, release agents, surfactants and tensides are not included, as they do not directly participate in the hardening reaction.
The thickness and the density of the lignocellulosic composites (boards) were measured according to DIN EN 323:1993-08 and are reported as the arithmetic average of ten 50×50 mm samples of the same board.
The internal bond strength of the lignocellulosic composites (boards) was determined according to EN 319:1993-08 and is reported as the arithmetic average of ten 50×50 mm samples of the same lignocellulosic composite (board).
The swelling in thickness after 24 h (“24 h swelling”) of the lignocellulosic composites (boards) was determined according to EN 317:1993-08 and is reported as the arithmetic average of ten 50×50 mm samples of the same lignocellulosic composite (board).
2200 g of L-lysine solution (50% in water, ADM) was heated under stirring in an oil bath (external temperature 140° C.). Water was distilled off and the oil bath temperature was increased by 10° C. per hour until a temperature of 180° C. was reached. The reaction mixture was stirred for an additional hour at 180° C. (oil bath temperature) and then pressure was slowly reduced to 200 mbar. After reaching the target pressure, distillation was continued for another 120 min. The product (Polylysine-2, Mw 2010 g/mol, measured by size exclusion chromatography with calibration against poly(2-vinylpyridine) standards) was hotly poured out of the reaction vessel, crushed after cooling and dissolved in water to give a 50 wt.-% solution.
A heat-curable binder composition was prepared by adding 10.53 g HMDA (70 wt. % in H2O) to a pre-reacted (30 min reaction at 60° C.) solution consisting of 32.44 g dextrose monohydrate (dextrose: 90.9 wt.-%, H2O: 9.1 wt.-%), 29.59 g fructose (100% solid), 10.53 g hexamethylenediamine (70 wt.-% in H2O) and 22.32 g of water. This heat-curable binder composition corresponds to a mass ratio of 40:40:20 of dextrose:fructose:HMDA.
A heat-curable binder composition was prepared by adding 21.06 g HMDA (70 wt. % in H2O) to a solution consisting of 32.44 g dextrose monohydrate (Dextrose: 90.9 wt.-%, H2O: 9.1 wt.-%), 29.59 g fructose (100% solid) and 22.32 g of water. This heat-curable binder composition corresponds to a mass ratio of 40:40:20 of dextrose:fructose:HMDA.
A heat-curable binder composition was prepared by adding 13.7 g HMDA (70 wt.-% in H2O) to a solution consisting of 35.2 g dextrose monohydrate (dextrose: 90.9 wt. %, H2O: 9.1 wt.-%), 32.0 g fructose (100% solid) and 45.0 g of water. This heat-curable binder composition corresponds to a mass ratio of 43.5:43.5:13 of dextrose:fructose:HMDA.
A heat-curable binder composition was prepared by adding 7.95 g HMDA (70 wt.-% in H2O) to a solution consisting of 35.2 g dextrose monohydrate (dextrose: 90.9 wt. %, H2O: 9.1 wt.-%), 32.0 g fructose (100% solid) and 43.8 g of water. This heat-curable binder composition corresponds to a mass ratio of 46:46:8 of dextrose:fructose:HMDA.
A heat-curable binder composition was prepared by adding 31.6 g HMDA (70 wt.-% in H2O) to a solution consisting of 28.3 g dextrose monohydrate (dextrose: 90.9 wt. %, H2O: 9.1 wt.-%), 25.8 g fructose (100% solid) and 40.2 g of water. This heat-curable binder composition corresponds to a mass ratio of 35:35:30 of dextrose:fructose:HMDA.
A heat-curable binder composition was prepared by adding 42.1 g HMDA (70 wt.-% in H2O) to a solution consisting of 24.3 g dextrose monohydrate (dextrose: 90.9 wt. %, H2O: 9.1 wt.-%), 22.1 g fructose (100% solid) and 37.5 g of water. This heat-curable binder composition corresponds to a mass ratio of 30:30:40 of dextrose:fructose:HMDA.
A heat-curable binder composition was prepared by adding 29.4 g polylysine (50 wt.-% in H2O) to a solution consisting of 32.4 g dextrose monohydrate (dextrose: 90.9 wt.-%, H2O: 9.1 wt.-%), 29.6 g fructose (100% solid) and 34.6 g of water. This heat-curable binder composition corresponds to a mass ratio of 40:40:20 of dextrose:fructose:polylysine.
A heat-curable binder composition was prepared by adding 50.2 g polylysine (50 wt. % in H2O) to a solution consisting of 26.8 g dextrose monohydrate (dextrose: 90.9 wt.-%, H2O: 9.1 wt.-%), 24.4 g fructose (100% solid) and 24.9 g of water. This heat-curable binder composition corresponds to a mass ratio of 33:33:34 of dextrose:fructose:polylysine.
A heat-curable binder composition was prepared by adding 20.3 g dextrose monohydrate (dextrose: 90.9 wt.-%, H2O: 9.1 wt.-%) and 18.5 g fructose (100% solid) to a solution consisting of 73.8 g polylysine (50 wt.-% in H2O) and 13.7 g of water. This heat-curable binder composition corresponds to a mass ratio of 25:25:50 of dextrose:fructose:polylysine.
A heat-curable binder composition was prepared by adding 10.2 g dextrose monohydrate (dextrose: 90.9 wt.-%, H2O: 9.1 wt.-%) and 9.25 g fructose (100% solid) to 111 g polylysine (50 wt.-% in H2O). This heat-curable binder composition corresponds to a mass ratio of 12.5:12.5:75 of dextrose:fructose:polylysine.
A heat-curable binder composition was prepared by adding 21.1 g HMDA (70 wt.-% in H2O) to a solution consisting of 28.5 g dextrose monohydrate (dextrose: 90.9 wt. %, H2O: 9.1 wt.-%), 25.9 g fructose (100% solid), 7.38 g maltodextrin and 43.5 g of water. This heat-curable binder composition corresponds to a mass ratio of 35:35:10:20 of dextrose:fructose:maltodextrin:HMDA.
Binder 12 (comparative example):
A heat-curable binder composition was prepared by adding 14.7 g lysine to a solution consisting of 32.4 g dextrose monohydrate (dextrose: 90.9 wt.-%, H2O: 9.1 wt.-%), 29.6 g fructose (100% solid) and 49.4 g of water. This heat-curable binder composition corresponds to a mass ratio of 40:40:20 of dextrose:fructose:lysine.
The spruce wood chips were produced in a disc chipper. Spruce trunk sections (length 250 mm) from Germany were pressed with the long side against a rotating steel disc, into which radially and evenly distributed knife boxes are inserted, each of which consists of a radially arranged cutting knife and several scoring knives positioned at right angles to it. The cutting knife separates the chip from the round wood and the scoring knives simultaneously limit the chip length. Afterwards the produced chips were collected in a bunker and from there they were transported to a cross beater mill (with sieve insert) for reshredding with regard to chip width. Afterwards the reshredded chips were conveyed to a flash drier and dried at approx. 120° C. The spruce wood chips were then screened into two useful fractions (B: ≤2.0 mm×2.0 mm and >0.32 mm×0.5 mm; C: ≤4.0 mm×4.0 mm and >2.0 mm×2.0 mm), a coarse fraction (D: >4.0 mm×4.0 mm), which is reshredded, and a fine fraction (A: ≤0.32 mm×0.5 mm). A mixture of 60 wt.-% of fraction B and 40 wt.-% of fraction C of the spruce wood chips is used for the production of the lignocellulosic composites.
The respective binder composition, spruce wood chips, and optionally water were mixed (cf. 6.1) and formed into a sheet (cf. 6.2), as described hereafter.
In a mixer, 210 g of binder 1 (solid content 70%) and 40.0 g of additional water was sprayed to 1074 g of spruce wood chips (moisture content 2.0%, 1053 g oven dry wood) while mixing. After completion of the spraying, mixing in the mixer was continued for 15 sec.
In a mixer, 150 g of binder 1 or binder 2 (solid content 70%), respectively, and subsequently, 53.0 g of additional water was sprayed to 1074 g of spruce wood chips (moisture content 2.0%, 1053 g oven dry wood) while mixing. After completion of the spraying, mixing in the mixer was continued for 15 sec.
In a mixer, 180 g of binder 3, binder 4, binder 5, binder 6, binder 7, binder 8, binder 9, binder 11 or binder 12 (solid content 58.5%), respectively, and subsequently, 23.4 g of water was sprayed to 1074 g of spruce wood chips (moisture content 2.0%, 1053 g oven dry wood) while mixing. After completion of the spraying, mixing in the mixer was continued for 15 sec.
In a mixer, 186 g of binder 10 (solid content 56.7%), and subsequently, 17.2 g of water was sprayed to 1074 g of spruce wood chips (moisture content 2.0%, 1053 g oven dry wood) while mixing. After completion of the spraying, mixing in the mixer was continued for 15 sec.
In a mixer, 203 g of binder 1 (solid content 70%), and subsequently, 72.0 g of water was sprayed to 1450 g of spruce wood chips (moisture content 2.0%, 1422 g oven dry wood) while mixing. After completion of the spraying, mixing in the mixer was continued for 15 sec.
Binder/Chips Mixture for Board 22 (Binder Amount 10%, with Paraffin):
In a mixer, 203 g of binder 1 (solid content 70%), and subsequently, a mixture of 11.8 g (Hydrowax 138, 60 wt.-% paraffin in water) and 68.0 g of water was sprayed to 1450 g of spruce wood chips (moisture content 2.0%, 1422 g oven dry wood) while mixing. After completion of the spraying, mixing in the mixer was continued for 15 sec.
6.2 Forming a Sheet from the Mixtures so that a Formed Sheet Results:
15 min after preparation of the binder/chips mixture, 834 g of the mixture was scattered into a 320 mm×380 mm mold and pre-pressed under ambient conditions and a pressure of 1.2 N/mm2 resulting in a formed sheet.
15 min after preparation of the binder/chips mixture, 1470 g of the mixture was scattered into a 320 mm×380 mm mold and pre-pressed under ambient conditions and a pressure of 1.2 N/mm2 resulting in a formed sheet.
For monitoring the temperature a fiber-optic sensor (Teflon-coated glass fiber with a gallium arsenide chip) was introduced into the center of a formed sheet, (as prepared in accordance with item 6.2) which was connected with a temperature measuring instrument suitable for measurements in an environment with strong electromagnetic radiation. The formed sheet was compacted and dielectrically heated in a dielectric heating and pressing unit (HLOP 170 press from Hoefer Presstechnik GmbH), whereby birch plywood boards (thickness 6 mm) were placed between the nonwoven separator and the press plate on each side of the sheet, wherein the formed sheet was compacted to a thickness of 10 mm or 18 mm respectively within a period of 2 s and then dielectrically heated by applying a high-frequency electrical field (27.1 MHz, anode current 2.5 A for 10 mm boards, corresponding to ca. 25 kW/m2, or 2.7 A for 18 mm boards) while the press was remaining closed. When a temperature of 150° C. or 170° C., respectively, was reached in the center of the sheet, the press was opened.
One day after conditioning at ambient conditions the board was sanded (0.15 mm was sanded off on each side).
This process of the invention was used for preparing boards 1 to 22 (see Table 1) and boards 23, 24, 27, 28, 31, and 32 (see Table 2).
The formed sheet was heated and compacted in a conventional hot press unit (HLOP 350 from Hoefer Presstechnik GmbH) with heated press plates at a temperature of 195° C. to a thickness of 10 mm to give a cured board. The press factor was 14 s/mm, corresponding to a total press time of 140 seconds.
7.2.2 Post-Curing Step (Heating without Pressing):
5 min after finishing the curing step, the cured board was placed in a radio-frequency post-curing unit and heated with a radio frequency field (27.1 MHz, anode current 2.5 A, corresponding to ca. 25 kW/m2) to a temperature in the center of the board of 150° C. or 170° C., respectively. For monitoring the temperature a fiber-optic sensor was used as described above. For this heating step, the HLOP 170 press from Hoefer Presstechnik GmbH was again used (see item 7.1, above), whereby during heating there was a 1 mm gap between the upper press plate and the surface of the board. Thus, no pressure was applied during heating.
One day after conditioning at ambient conditions the board was sanded (0.15 mm was sanded off on each side).
This process (not according to the invention) was used for preparing boards 25, 26, 29, 30, 33, and 34.
Table 1 shows parameters of production and of the resulting lignocellulosic composites (boards), i.e. of boards no. 1 to 22. Herein, boards 1 to 12 and 14 to 22 were produced in a process according to the present invention, board 13 is a comparative example.
Such parameters of production and of the resulting lignocellulosic composites (boards) are:
i)
i)
i) sample fell apart during measurement
The results show that in each case a lignocellulosic composite was prepared according to a process of the present invention, wherein the individual lignocellulosic composite, i.e. board 1 to 22, is a board with a thickness of 10±0.2 mm or a board with a thickness of 18±0.4 mm, respectively.
All boards that were prepared according to a process of the present invention have a density of more than 600 kg/m3 (measured according to DIN EN 323:1993-08).
All boards 1 to 3, 6 to 12, and 14 to 22 that were prepared according to a process of the present invention have:
Board 4 and 5 were produced in accordance with the present invention, but are not as satisfactory as board 3. As stated in table 1, board 3 is based on binder 2 and comprises HMDA:Dex:Fru (20:40:40). In contrast, board 4 is based on binder 3 and comprises HMDA:Dex:Fru (13:43.5:43.5), and board 5 is based on binder 4 and comprises HMDA:Dex:Fru (8:46:46). The results summarized in table 1 show that binder 4 results in a board 5 having less favourable properties than boards 4 and 3. Similarly, binder 3 results in board 4 having less favourable properties than board 3. Thus, when dextrose and fructose are used in a mass ratio of 1:1 as the carbohydrate component of the heat-curable binder composition, the amount of HMDA should be 10 wt.-% or higher, preferably 15 wt.-% or higher, based on the (total) solid content of the heat-curable binder composition.
More generally, it is preferred that in a process of the present invention the ratio of the mass of all compounds present in component (ii-a), i.e. all carbohydrate compounds, to the mass of all compounds present in component (ii-b), i.e. all compounds having two or more amino groups, is in the range of from 90:10 to 50:50, preferably in a range of from 85:15 to 60:40, more preferably in a range of from 82:18 to 60:40.
Board 13 is based on binder 12 and thus constitutes a comparative example. Lysine is used as the compound having two or more amino groups in binder 12 instead of hexamethylenediamine and/or polylysine. A comparison with board 8 based on binder 7 comprising polylysine as the compound having two or more amino groups shows that the use of polylysine is beneficial in comparison with the use of lysine.
When polylysine is used as the only compound having two or more amino groups or as one of the two or more compounds having two or more amino groups in component (ii-b) of the heat-curable binder composition used in accordance with the present invention, it is generally preferred that the heat-curable binder composition has a ratio of the mass of all compounds present in said component (ii-a) to the mass of all compounds present in said component (ii-b) in the range of from 10:90 to 90:10, preferably in the range of from 20:80 to 80:20.
These results also show that a (carbohydrate based) heat-curable binder composition according to the present invention can be effectively hardened in a simple one step hardening process according to the present invention. Accordingly, a formed sheet comprising lignocellulosic particles and a (carbohydrate based) heat-curable binder composition is effectively hardened in a dielectric heating and pressing unit by at least temporarily simultaneously compacting and dielectrically heating the formed sheet so that the heat-curable binder composition hardens and a lignocellulosic composite with excellent properties results.
The time of dielectric heating (time of applying a high-frequency electrical field) required to reach the target temperature T in the center of the formed sheet of 150° C. (boards no. 1 to 13 and 21 to 22) or 170° C. (boards no. 14 to 20) was in the range of from 141 s to 168 s (for T=150° C.) or in the range of from 153 s to 195 s (for T=170° C.).
The results of boards no. 2 to 22 further show that the ratio of the weight of the solid content of all binder components present for hardening the binder via reaction with each other to the weight of the lignocellulosic particles in an oven-dry state (“binder amount”) can be as low as 10 wt.-%, still resulting in a lignocellulosic composite with excellent properties.
Table 2 shows parameters of production and of the resulting lignocellulosic composites (boards), i.e. of boards no. 23 to 34. Boards 23, 24, 27, 28, 31 and 32 were produced in a process according to the present invention. Boards 25, 26, 29, 30, 33 and 34 were produced in a process not according to the present invention. All of the boards 23 to 34 have a thickness, measured according to DIN EN 323:1993-08, of 10±0.2 mm.
Such parameters of production and of the resulting lignocellulosic composites (boards) depicted in table 2 are:
The results summarized in Table 2 confirm that surprisingly boards obtained in a process of the present invention in direct comparison with boards prepared in a process not according to the invention (because instead of using a dielectric heating and pressing unit, a conventional hot press was used and an additional post-curing step was conducted) have improved properties (in particular internal bond strength and 24 h swelling). Furthermore, these improved properties were obtained within a total time of process that was in each case shorter than the corresponding total time of process for the experiments that were not in accordance with the present invention.
Thus, the process of the present invention is well suited for making boards and is surprisingly better suited than the conventional processes known from the prior art.
| Number | Date | Country | Kind |
|---|---|---|---|
| 21217188.8 | Dec 2021 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/085963 | 12/14/2022 | WO |
