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EP3725481B1 - Matériau sous forme de plaque et son procédé de fabrication - Google Patents

Matériau sous forme de plaque et son procédé de fabrication Download PDF

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Publication number
EP3725481B1
EP3725481B1 EP19170159.8A EP19170159A EP3725481B1 EP 3725481 B1 EP3725481 B1 EP 3725481B1 EP 19170159 A EP19170159 A EP 19170159A EP 3725481 B1 EP3725481 B1 EP 3725481B1
Authority
EP
European Patent Office
Prior art keywords
fibers
binder
board
shaped material
material according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP19170159.8A
Other languages
German (de)
English (en)
Other versions
EP3725481C0 (fr
EP3725481A1 (fr
Inventor
Roger Braun
Joachim Hasch
Volker Schwind
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Swiss Krono Tec AG
Original Assignee
Swiss Krono Tec AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to PL19170159.8T priority Critical patent/PL3725481T3/pl
Application filed by Swiss Krono Tec AG filed Critical Swiss Krono Tec AG
Priority to ES19170159T priority patent/ES3019583T3/es
Priority to EP19170159.8A priority patent/EP3725481B1/fr
Priority to JP2021559135A priority patent/JP2022530186A/ja
Priority to CA3137235A priority patent/CA3137235A1/fr
Priority to EP20701537.1A priority patent/EP3934871A1/fr
Priority to AU2020258486A priority patent/AU2020258486A1/en
Priority to US17/604,544 priority patent/US20220306821A1/en
Priority to PCT/EP2020/050452 priority patent/WO2020211989A1/fr
Priority to CN202080029160.2A priority patent/CN113710441B/zh
Priority to US17/604,532 priority patent/US12441024B2/en
Priority to BR112021020749A priority patent/BR112021020749A2/pt
Priority to EP20701536.3A priority patent/EP3938158A1/fr
Priority to JP2021559130A priority patent/JP2022529410A/ja
Priority to CN202410418823.XA priority patent/CN118181424A/zh
Priority to PCT/EP2020/050451 priority patent/WO2020211988A1/fr
Priority to CA3134193A priority patent/CA3134193A1/fr
Priority to UAA202105798A priority patent/UA129218C2/uk
Priority to BR112021020740A priority patent/BR112021020740A2/pt
Priority to AU2020259631A priority patent/AU2020259631A1/en
Priority to CN202080029521.3A priority patent/CN113840701A/zh
Priority to PL20170128.1T priority patent/PL3736095T3/pl
Priority to EP20170128.1A priority patent/EP3736095B1/fr
Priority to ES20170128T priority patent/ES2992159T3/es
Publication of EP3725481A1 publication Critical patent/EP3725481A1/fr
Application granted granted Critical
Publication of EP3725481B1 publication Critical patent/EP3725481B1/fr
Publication of EP3725481C0 publication Critical patent/EP3725481C0/fr
Priority to US19/330,388 priority patent/US20260001252A1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N1/00—Pretreatment of moulding material
    • B27N1/006—Pretreatment of moulding material for increasing resistance to swelling by humidity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N1/00—Pretreatment of moulding material
    • B27N1/003—Pretreatment of moulding material for reducing formaldehyde gas emission
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/002—Manufacture of substantially flat articles, e.g. boards, from particles or fibres characterised by the type of binder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres

Definitions

  • Board-shaped materials made from lignocellulosic fibers are used in a variety of ways because their production is inexpensive and technically sophisticated.
  • a typical example is the use of high-density fiberboard (HDF), in which wood fibers are pressed into boards using binding agents, which are then usually coated with synthetic resin-impregnated paper. This coating hardens under the influence of pressure and temperature, forming a firmly bonded laminate.
  • This laminate is cut up and the pieces are profiled at the edges, e.g. to be used as a glueless floor covering. However, the material is exposed at the profiled edges. In the presence of water, the wood fibers at the exposed edges begin to swell as a result of water absorption, which leads to a change in the shape of the wood-based panel.
  • the water can be either freely flowing water or even high humidity.
  • High humidity which e.g. B. seasonal or technically caused, can prevent the use of laminate, even if swelling is largely reversible, so that the swelling can be largely reversed by drying.
  • swelling cannot be made completely reversible, so that after the initial swelling an unsightly open joint remains.
  • WPC wood plastic composites
  • an extruded mixture of wood fibers and plastic With a sufficiently high plastic content, WPC is dimensionally stable under the influence of water or moisture.
  • Their production is used, for example, in the DE 10 2007 041 438 A1 , the US 5,985,429 A1 , the CH 109249491 A and the US 2004/0235983 A1
  • the production requires the Use of extruders that are not suitable for the production of sheet-like materials of larger dimensions.
  • non-swelling board materials are available from which non-swelling board materials can be manufactured that do not contain wood fibers or other wood components. This eliminates the need for a renewable, abundantly available raw material that has good strength properties. Examples of raw materials include Stone Plastic Composites (SPC) or polyvinyl chloride (PVC). These typically use halogens or terephthalates, making these products disadvantageous from an environmental perspective.
  • the board material according to the invention is low-emission or emission-free; in particular, the emission of formaldehyde can be largely reduced or avoided, so that the CARB 2 regulations of the State of California regarding formaldehyde emissions can be met. Volatile organic compounds (VOCs) can also be largely or completely avoided.
  • WO2016/071007 discloses a plate-shaped material according to the preamble of claim 1 and a method for producing a plate-shaped material according to the preamble of claim 11.
  • the invention relates to a plate-shaped material comprising fibers and a binder, the proportion of the binder being more than 50% by weight, based on the plate-shaped material.
  • Fibers within the meaning of this invention are solid particles that are elongated, i.e., whose diameter is many times smaller than the longest dimension of the particle.
  • the dimensions of the fibers can be selected within a wide range; they depend in particular on the plate thickness and the specifications for the homogeneity of the plate-shaped material.
  • the diameter of the fibers is from 10 ⁇ m to 5 mm, and the length of the fibers is from 0.05 mm to 100 mm.
  • the sheet-like material therefore has a larger proportion of binder than fibers.
  • the binder content can also be expressed in terms of fibers, i.e., the binder content is specified with reference to the weight of the fibers used.
  • the binder content is specified as fibers dried to constant weight (absolutely dry fibers).
  • the binder content of the sheet-like material is then more than 100 wt.%.
  • Organic or inorganic fibers such as carbon fibers or fibers made from mineral or ceramic raw materials or glass fibers can be used for the sheet-like material according to the invention.
  • Natural fibers e.g., lignocellulosic fibers, or synthetic fibers such as fibers made from thermoplastic materials such as polyethylene or polypropylene, but also from polycarbonate, polyacrylic, polymethacrylic, or polyurethane, can be used to produce the material according to the invention.
  • mixtures of fibers especially mixtures of the aforementioned fibers, can be used to produce the material according to the invention.
  • Mixtures of fibers make it possible to adjust properties of the material according to the invention, e.g., elasticity or flexural properties, dimensional stability, strength, but also manufacturing properties and processability.
  • lignocellulosic fibers e.g., fibers from wood, bamboo, or annual plants
  • inexpensive, easy-to-process fibers are available.
  • the use of hygroscopic fibers is not excluded, especially if they are at least partially dried before the production or pressing of the material according to the invention.
  • the aforementioned lignocellulosic fibers include, in particular, all fibers obtained from plants by chemical or physical processes.
  • Typical examples of physically obtained fibers are softwood fibers, hardwood fibers, or bamboo fibers, or fibers from other organic raw materials obtained by mechanical defibration.
  • An example of chemically obtained fibers are, for example, cellulose fibers from wood, annual plants, or other raw materials.
  • Wood fibers from mechanical defibration are particularly typically used, whereby the aim is to minimize the loss of lignin and hemicelluloses.
  • Fiber blends can also be used, particularly to adjust material properties (strength properties, weight), but also to use the raw material fiber in a cost-optimized manner. Fibers within the meaning of this invention also include fiber bundles; smaller chips are also included, provided their fibers can still be largely coated with a binder.
  • the material according to the invention is plate-shaped, i.e. it generally has two main surfaces, which are also referred to below as the top and bottom.
  • the thickness of the finished plate-shaped material can be from 1 mm to 500 mm, typically between 3 mm and 80 mm, mostly between 5 mm and 30 mm. A typical application may require a thickness of the plate-shaped material of 4 mm to 10 mm.
  • the material according to the invention can have flat main surfaces, but the top and/or bottom can also be embossed or milled or processed in some other way, so that the material has a variable thickness relative to the surface area of the material.
  • the material preferably has an essentially homogeneous composition across its thickness.
  • the edges can be processed using conventional tools. They can be sawn, cut or milled.
  • the plate-shaped material according to the invention has many uses. It can be used, for example, for: B. can be used as floor, ceiling, and/or wall coverings, for the production of interior fittings or furniture, in particular for the interior fittings of vehicles such as vehicle cabins, but also outdoors, both as cladding, e.g., as a curtain wall, and for structural applications.
  • the panel-shaped material according to the invention can be coated, colored, painted, or otherwise decoratively designed. In particular, surface coatings, such as those known, for example, from the field of wood-based materials, can be applied to the surface of the material according to the invention.
  • the material according to the invention differs from the WPC described above in that it is not plastic, in particular thermoplastic plastic, that is formed with fibers into a plate-like material, but rather that a binder is used that enters into a cohesive and/or adhesive interaction with the fibers.
  • binders are known, for example, from the production of wood-based materials. known from the prior art.
  • the binder used according to the invention comprises melamine according to an alternative. Melamine is preferred as a binder because it is non-swelling and non-hygroscopic, as well as resistant to hydrolysis. Melamine can be used either alone as a binder or in combination with one or more other binders, referred to below as binders according to the invention.
  • binders according to the invention can be used, wherein either the mixture of two or more binders is applied to the fiber simultaneously, e.g., as MF resin (melamine-formaldehyde resin). Or a combination of binders according to the invention is used, which are used one after the other, e.g., because they cannot be used as a mixture or because separate application of different binders has an advantageous effect.
  • MF resin melamine-formaldehyde resin
  • the binders mentioned below formaldehyde, phenol, methylene diphenyl isocyanate (MDI), also in emulsified form as eMDI or polymeric diphenylmethane diisocyanate (PMDI), can be used.
  • MDI methylene diphenyl isocyanate
  • PMDI polymeric diphenylmethane diisocyanate
  • two or more of the binders according to the invention can also be used in combination. It is preferred if the binder predominantly comprises melamine. It is further preferred if the proportion of melamine in the binder exceeds 20 wt. %, in particular 50 wt.
  • the binder is preferably urea-free, since urea contributes to the hygroscopicity and thus to the swelling of the lignocellulosic fibers or does not prevent this.
  • Thermoplastic binders are avoided.
  • the board-shaped material according to the invention is preferably free of halogens (e.g. fluorine, chlorine), but also of terephthalates.
  • the binder forms the predominant portion of the plate-shaped material according to the invention.
  • the plate-shaped material based on the fiber content, contains more than 100 wt.%, e.g., 101 wt.% or 102 wt.% up to 120 wt.% binder.
  • the material contains more than 150 wt.% binder, particularly preferably more than 200 wt.% binder, and a maximum of 500 wt.% binder, in each case based on the fiber content.
  • the density of the material is between 1,000 kg/m 3 and 1,800 kg/m 3 , in particular between 1,000 kg/m 3 and 1,600 kg/m 3 , advantageously between 1,000 kg/m 3 and 1,200 kg/m 3 .
  • the material according to the invention has a higher weight, e.g. between 1,000 kg/m 3 and 1,200 kg/m 3 , than, for example, a wood-based material, e.g. an HDF board, which quantitatively predominantly comprises lignocellulosic fibers.
  • the material preferably contains fillers.
  • Fillers can help optimize, and usually minimize, the weight of the plate-shaped material. Fillers can serve alternatively or additionally to optimize certain properties of the plates, e.g., conductivity, insulating properties, or strength properties. Fillers replace fibers in the material according to the invention. Since the material should exhibit minimal swelling in the presence of water, in particular minimized thickness swelling, non-hygroscopic or non-swelling fillers and fillers that are resistant to hydrolysis are preferred.
  • Such fillers can be mineral particles, but also ceramic, synthetic, or glass particles. The size of the particles is preferably no larger than one millimeter, preferably between 10 ⁇ m and 800 ⁇ m. Mixtures of different particles can also be used, e.g., mixtures of different materials or sizes.
  • up to 30 wt.% based on the total weight of the plate-shaped material, is used, particularly preferably up to 20 wt.%, advantageously up to 15 wt.%.
  • the lower limit of the amount used is determined by the detectability of the fillers.
  • the material comprises wet strength agents.
  • Typical wet strength agents are polyamines, polyimines, e.g., polyethyleneimine, polyamides, e.g., polyacrylamides or polyamidoamine-epichlorohydrin (PAAE), polyalcohols, e.g., polyvinyl alcohols, or their copolymers.
  • Wet strength agents further contribute to reducing the swelling of the sheet material according to the invention. They are used in amounts of up to 5% based on the weight of the sheet material, preferably in an amount of 0.05% to 2% by weight of the sheet material.
  • the sheet material comprises hydrophobic agents, e.g., paraffin or wax, which are typically used in amounts of up to 5 wt.% based on the weight of the sheet material, usually in amounts of up to 2 wt.%, often in an amount of 0.1 wt.% to 1 wt.%.
  • hydrophobic agents also contributes to reducing the swelling tendency of the sheet material.
  • the steps of the process correspond to those of a conventional process, e.g., for producing a wood-based panel.
  • a larger amount of binder is used than previously known, so that the weight fraction of the binder is greater than the weight fraction of the fibers.
  • the fibers may be necessary to at least partially dry the binder on the fibers. If the fibers contain moisture, as is common with lignocellulosic fibers, the moisture content should be adjusted before pressing the fiber cake so that after pressing, a dimensionally stable, non-swelling, and non-shrinking board is obtained.
  • the lignocellulosic fibers are often used with a moisture content of up to 120 wt.% or more before gluing.
  • the lignocellulosic fibers can be dried before or after the application of the binder.
  • the lignocellulosic fibers it is preferable for the lignocellulosic fibers to have a moisture content of no more than 15 wt.%. That is, with a water content of up to 15% by weight based on the total weight of the fibers.
  • the moisture content is preferably between 5% and 10%.
  • the binder is usually provided in liquid form. It can be provided in pure form or—more typically—in solution, either in solvent or water.
  • the binder is usually applied to the lignocellulosic fibers by spraying, e.g., through a plurality of spray nozzles that generate a spray of the binder and are arranged around a downward flow of fibers.
  • a typical design for such a drying device is a blowline, for example, used in fiberboard production.
  • the surface of the fibers is wetted with binder droplets.
  • the binder-wetted fibers, after optional drying, are formed into a fiber cake and pressed.
  • the binder hardens during this process, resulting in a board-like material.
  • During curing which occurs under the influence of pressure and temperature, irreversible chemical bonds are formed between the fibers and the binder, but also within the binder itself, unlike with WPC products.
  • the pressing conditions are essentially the same. Pressure, temperature, and pressing time, for example, are within the range of conventional HDF (high-density fiberboard) boards.
  • the material according to the invention can be excellently produced in presses such as those used for the production of wood-based materials. This allows the production of board formats that—unlike WPC—are not limited to the production of narrow plank formats with a width of approximately 30 cm. Rather, conventional board formats, such as those commonly used for wood-based boards, can be provided.
  • the application of large amounts of binder to the fibers can be carried out in a single step or pass.
  • the application of the binder can advantageously be carried out in at least two steps, with a maximum of 50% of the binder being applied to the fiber per step.
  • the step-by-step application of binder has proven particularly effective for lignocellulosic fibers.
  • the fiber can be dried before or after the binder or a portion of the binder has been applied to the fiber. Drying the fiber after the binder or a portion of the binder has been applied prevents the fibers with binder on their surface from sticking to one another.
  • the aim of drying is therefore not to completely remove water or solvent from the binder and/or the fiber.
  • the aim is to prevent the reactivity of the binder from being impaired during curing under the influence of pressure and/or temperature.
  • the aim is simply to ensure that the fibers no longer adhere or stick to one another during conveying or spreading. This makes them pourable and can, for example, be temporarily stored. However, they also become more spreadable because they do not stick to the spreading devices, in particular spreading heads.
  • the fibers are preferably dried after each application of a portion of the binder. Drying is preferably carried out with heated air, e.g., in a drying tunnel located downstream of a gluing device or in a drying shaft, which can be located, for example, below the gluing device.
  • the fiber cake is usually produced by scattering, as is usual with wood-based materials.
  • the fibers either freshly coated with the entire amount of binder or preferably dried, are scattered onto a carrier, usually on a conveyor belt, usually in a homogeneous layer, but alternatively also in several layers.
  • the fiber cake is first passed through a pre-press on the carrier if necessary and then pressed in a press. Any press that applies sufficient pressure and temperature is suitable, both a plate press, in which the material is pressed between two metal sheets, and in particular a continuous press, in which the material is pressed between two circulating metal belts.
  • Suitable pressing temperatures can be selected from 140 °C to 220 °C, preferably from 160 °C to 180 °C, with suitable pressing pressures from 0.3 N/ mm2 to 5.5 N/mm 2 , in particular 1 N/mm 2 to 3 N/mm 2 .
  • the pressing time is advantageously 6 seconds/mm of board thickness (hereinafter: s/mm) to 60 s/mm, usually 10 s/mm to 20 s/mm.
  • the actual pressing process can be preceded by a pre-press for compacting the fiber cake.
  • a device for cooling the board-shaped material can be connected downstream of the press, in particular a device for cooling under a predetermined pressing pressure, which can be lower than the pressing pressure during pressing of the material.
  • the fillers, wet strength agents or hydrophobic agents described above can be added to the material according to the invention, typically before forming the fiber cake.
  • the material produced by the process according to the invention preferably has a surface that essentially comprises binder, particularly preferably a surface consisting of binder.
  • binder particularly preferably a surface consisting of binder.
  • the aim is to have as few fibers as possible in the surface of the material in order to optimize thickness swelling as much as possible. Water in liquid form or, for example, as atmospheric moisture would be absorbed by the hygroscopic fibers, resulting in swelling of the material. This is undesirable.
  • the high or predominant proportion of binder in the plate-shaped material enables a material surface that predominantly or entirely comprises binder, or that has hardly any or no hygroscopic fibers.
  • the material according to the invention can be processed like a wood-based panel, e.g., like an HDF panel.
  • the surface can be coated, embossed, or milled; the edges can be profiled, e.g., for the production of floor panels.
  • the panel-shaped material according to the invention can be laminated with synthetic resin-impregnated paper; it can be printed, painted, varnished, or processed in other ways. It is considered an advantage of this invention that the panel-shaped material can be processed and worked on existing equipment.
  • the invention further includes a device for producing the above-described plate-shaped material, comprising means for applying binder to lignocellulosic fibers, which, according to the invention, has means for applying binder to already pre-glued lignocellulosic fibers.
  • applying binder here refers to the application of binder.
  • the means for applying binder to fibers are advantageously designed as nozzles that generate a spray of liquid binder. Fibers are guided through the spray of binder, onto which binder droplets from the spray are then deposited.
  • Known means for applying binder to lignocellulosic fibers are designed to apply a maximum of 30 wt.% binder based on the fibers to be glued.
  • the method according to the invention can be carried out by passing the fibers to be glued through the known means for applying binder several times until sufficient binder has been applied to the fibers.
  • the invention proposes arranging several of the known gluing means such that the fibers to be glued are conveyed along a plurality of gluing means, each gluing means applying a portion of the binder to the lignocellulosic fibers until the desired total amount of at least more than 50% by weight of the sheet-like material has been applied to the fibers.
  • further means for gluing pre-glued fibers to which a portion of the binder has already been applied are used.
  • the sheet-like material according to the invention can be adapted to various requirements through different combinations of fibers, binders, fillers, and optionally other additives such as waxes. It is therefore expressly pointed out that the features described above can be freely combined with one another.
  • the invention further relates to the use of the above-described panel material.
  • the panel material according to the invention is characterized by its versatility due to minimal swelling, particularly the almost completely reduced thickness swelling in the area of the edges.
  • the panel material can be used, for example, as a floorboard or floor laminate. can be used.
  • use is also possible in damp and wet rooms because the edge profile, where the board core is freely accessible to moisture, no longer swells significantly under the influence of water or high humidity or shrinks during drying. Thickness swelling of less than 2%, preferably less than 1%, is considered insignificant within the meaning of the invention.
  • a board-shaped material that is essentially non-swelling and dimensionally stable against water or humidity can now be produced, which is not limited to narrow formats and which preferably maximizes the use of renewable raw materials.
  • the board-shaped material according to the invention can also be used as a wall or ceiling panel, as a furniture panel, in particular in the construction of damp and wet rooms or of laboratory and technical rooms or workshops, but not limited thereto.
  • the material according to the invention is suitable as a facade panel or for roofing.
  • the panel-shaped material according to the invention can be used, for example, for terrace construction, including decking or outdoor flooring.
  • the panel-shaped material according to the invention can preferably be used for outdoor structures, in particular furniture.
  • the construction of workshops, production halls, or stables, for example, can easily be carried out using the material according to the invention.
  • the figure shows a sheet-like material 1 with a top side 2 and a bottom side 3, as well as an edge 4.
  • the material has fibers 5 embedded in a binder.
  • the binder content is more than 50% by weight of the sheet-like material. Thus, more binder is used than fiber 5.
  • the fibers Natural, synthetic, organic, and inorganic fibers can be used, both individually and in blends. Hygroscopic fibers such as wood, cellulose, or linen fibers can also be used.
  • Melamine is the preferred binder, often in combination with formaldehyde or phenol, but also in a blend with PMDI. Examples of fiber and binder combinations are described below.
  • lignocellulosic fibers in this case softwood fibers
  • the fibers were produced from steamed wood chips by defibringing in a refiner. Alternatively, any other lignocellulosic fibers or mixtures of such fibers can be used.
  • the softwood fibers are used at a moisture content of 120% before gluing; before pressing, they are dried with the binder on them to a residual moisture content of 8%, i.e., one ton of fiber contains 80 kg of water.
  • a binder containing melamine-formaldehyde resin (MF resin) was used.
  • the melamine-formaldehyde resin (MF resin) used had a solids concentration of 60% (measured at 60 min/120°C).
  • “Dry wood” here refers to lignocellulosic fibers that were dried to constant weight at 105°C.
  • “Dry wood” is a common reference measure for formulations containing lignocellulosic fibers. In the following examples, the absolute use of the binder is used.
  • paraffin based on dry wood is used.
  • the binder is applied to the lignocellulosic fibers in four passes, with 27% by weight being applied to the fibers in each pass.
  • the liquid binder is injected through nozzles in a known device for gluing fibers. sprayed.
  • the spray mist generated by the nozzles precipitates on the surface of the fibers, which pass through the spray mist, e.g., falling from top to bottom through the spray mist of binder.
  • the glued fibers are dried in a drying device, such as a warm air tunnel or shaft that applies heated air to the fibers.
  • a drying device such as a warm air tunnel or shaft that applies heated air to the fibers.
  • the goal of drying is not to completely remove all liquid, but rather to dry the binder to the point where it no longer sticks.
  • the reactivity of the binder during curing under the influence of pressure and/or temperature should not be impaired by drying.
  • the fibers can be stored or further glued or processed.
  • a second pass through the gluing device follows, in which another 27 wt.% MF resin is sprayed onto the fibers that have already been pre-glued after the first pass. After the second pass, the glued fibers are also dried until they no longer adhere to one another.
  • a third and fourth pass through the gluing device and the drying agent is carried out in the same way.
  • the 110 wt.% binder can be applied to the fibers in one or two passes, or alternatively in five or more passes. The amount of binder applied to the fibers per pass can vary from pass to pass.
  • a portion of the glued fibers is removed and processed into a 7 mm thick sheet material. This is done by scattering a fiber cake, which is then pressed in a well-known continuously operating double-belt press at 180 °C and a pressure of 2.5 N/ mm2 for a pressing time of 15 s/mm.
  • the resulting sheet has a thickness of 5.5 mm and a density of 1050 kg/ m3 .
  • Table 1, Pass 0 a sheet material produced under the same conditions without increased binder addition is tested (Table 1, Pass 0).
  • Thickness swelling is determined at an edge of the material as an absolute change in mm relative to the initial thickness of 7 mm and also as a relative change (%).
  • the maximum thickness swelling according to Table 1 is approximately 23%, as expected.
  • An exceptionally low edge swelling value of 1.83% is achieved when 108 wt.% binder, based on dry wood, is used.
  • Example 2 uses a 50:50 mixture of different fibers, e.g., wood fibers and carbon fibers, alternatively, e.g., recycled paper fibers and glass wool fibers, or alternatively, mineral fibers and cellulose fibers.
  • the natural fibers wood, recycled paper, cellulose fibers
  • the fibers are preferably dried before gluing; the fibers can be mixed before or after gluing and the optional drying of the binder. Both variants allow the production of a homogeneous mixture of glued fibers, which can then be scattered to form a fiber cake.
  • Example 2 is identical to Example 1 with regard to the use of binder and paraffin.
  • Embodiment 3 relates to a mixture of fibers and binder, in which 50 parts of polyethylene fibers and 20 parts of carbon fibers and 10 parts of filler, e.g. glass particles, mineral or ceramic particles form the fiber portion, which is 115 wt.% Binder, here e.g., with MF resin, is glued.
  • the fiber-binder mixture is otherwise treated as in Example 1.
  • the aim is to produce a board made of fibers and a binder that can be used to create a floor covering, and which can therefore be coated with a decorative surface, particularly either with synthetic resin-impregnated paper or by painting.
  • the material used is 40% by weight of fibers with a density of approximately 550 kg/ m3 and 55% by weight of a binder, in this case an MF resin with a melamine content of more than 60%.
  • 5% by weight of other substances are used, in this case 1.5% by weight of paraffin and 3.5% by weight of a "gray" dye.
  • the dye is used to impart a uniform color to the board-shaped material.
  • the board-shaped material with the above-mentioned composition is produced on an industrial, continuous press and compared with HDF boards made from the same fiber material, but with a binder content of 15 wt.%, and which have a density of 880 kg/m 3 .
  • Table 2 Comparative tests on the swelling of an HDF board and a board according to the invention Attempt Plate thickness (mm) Binder (%) Density (kg/m 3 ) Transverse tensile strength (N/mm 2 ) Swelling of raw board (%) Edge swelling coated (%) Standard HDF 6 15% 880 >1.4 18 - 22 14 - 18 plate-shaped material 5.8 137.5% 1050 >4.5 0.1 - .03 1.0 - 1.2
  • Table 2 above shows a comparison of the two panels, indicating the panel thickness in mm as a gross value (before sanding) and the density in kg/m 3 .
  • the panels were each evaluated according to transverse tensile strength (DIN EN 319), swelling (measured according to EN 317), and edge swelling (measured according to EN 13329).
  • the board according to the invention can be densified more effectively than fiberboard.
  • the binder requirement is approximately nine times higher than for HDF boards.
  • the panel material according to the invention exhibits three times higher transverse tensile strength and a 100-fold reduction in the swelling of the raw panel. After lamination of the top and bottom sides, the edge swelling is measured in the "coated" state. Only the edges are exposed to water, as the top and bottom of the panel are sealed by the lamination and are no longer accessible to water. This test is particularly important for floor coverings because the edges of floor panels generally cannot be sealed and are thus exposed to water. This test shows a one-tenth reduction in edge swelling for the panel material according to the invention compared to a conventional HDF panel. Both the HDF panel and the panel material according to the invention were manufactured on the same industrial production lines.

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

Claims (14)

  1. Matériau en forme de plaque, contenant des fibres lignocellulosiques (5) et un liant, dans lequel la proportion du liant est supérieure à 50 % en poids de la matière en forme de plaque (1).% en poids du matériau en forme de panneau (1), dans lequel le matériau en forme de panneau (1) est fabriqué par pressage et dans lequel la densité du matériau est comprise entre 1 000 kg/m3 et 1 800 kg/m3, caractérisé par le fait que le liant contient de la mélamine, du formaldéhyde, du phénol, du méthylène diphényl isocyanate (MDI), également sous forme émulsifiée (eMDI), du diisocyanate de diphénylméthane polymérique (PMDI) ou des combinaisons ou des mélanges des liants susmentionnés.
  2. Matériau selon la revendication 1, caractérisé par le fait que le matériau (1) comporte des fibres naturelles, des fibres synthétiques, des fibres inorganiques ou organiques ou des mélanges de fibres.
  3. Matériau selon la revendication 1 ou 2, caractérisé par le fait que les fibres organiques et naturelles comprennent des fibres lignocellulosiques, en particulier des fibres de bois tendre, des fibres de bois dur, des fibres de plantes annuelles ou des fibres de bambou.
  4. Matériau selon la revendication 2, caractérisé en ce que les fibres synthétiques comprennent des fibres en matière thermoplastique, en particulier des fibres en polyéthylène ou en polypropylène, mais aussi en polycarbonate, en polyacrylique, en polyméthacrylique ou en polyuréthane.
  5. Matériau selon la revendication 2, caractérisé par le fait que les fibres inorganiques comprennent des fibres minérales, céramiques ou vitreuses.
  6. Matériau selon l'une des revendications précédentes, caractérisé en ce que la proportion de liant par rapport au bois atro est supérieure à 101% en poids, jusqu'à 120% en poids, avantageusement supérieure à 150% en poids, de manière particulièrement préférée supérieure à 200% en poids.
  7. Matériau selon l'une des revendications précédentes, caractérisé par le fait que le matériau en forme de plaque (1) comporte des charges, en particulier des charges non hygroscopiques ou non gonflantes.
  8. Matériau selon la revendication 7, caractérisé par l'utilisation de particules minérales, céramiques, synthétiques ou de verre comme charge.
  9. Matériau selon l'une des revendications précédentes, caractérisé en ce que le matériau en forme de plaque (1) comporte des agents de résistance à l'état humide, en particulier des polyamines, des polyimines, par exemple la polyéthylèneimine, des polyamides, par exemple les polyacrylamides ou la polyamidoamine-épichlorhydrine (PAAE), des polyalcools, par exemple les polyvinylalcools ou des copolymères de ces derniers.
  10. Matériau selon l'une des revendications précédentes, caractérisé par le fait que le matériau en forme de plaque (1) contient des agents d'hydro-phobisation, par exemple de la paraffine ou de la cire.
  11. Procédé de fabrication d'un matériau en forme de panneau comprenant des fibres lignocellulosiques (5) et un liant, dans lequel la proportion du liant est supérieure à 50 % du matériau en forme de panneau (1), et dans lequel le matériau en forme de panneau (1) contient des agents d'hydrophobisation, comprenant les étapes suivantes :
    fournir des fibres lignocellulosiques (5)
    fournir le liant, de préférence sous forme liquide,
    appliquer le liant sur les fibres (5),
    former un gâteau de fibres,
    presser le gâteau de fibres en un matériau en forme de plaque ayant une densité comprise entre 1000 kg/m3 et 1800 kg/m3, tout en durcissant le liant, pour produire un matériau en forme de plaque (1), caractérisé par le fait que le liant contient de la mélamine, du formaldéhyde, du phénol, du méthylène diphényl isocyanate (MDI), également sous forme émulsifiée (eMDI), du diisocyanate de diphénylméthane polymère (PMDI) ou des combinaisons ou des mélanges des liants susmentionnés.
  12. Procédé selon la revendication 11, caractérisé par le fait que l'application du liant se fait en une ou plusieurs étapes.
  13. Procédé selon l'une des revendications 11 ou 12, caractérisé par le fait que la fibre (5) est séchée au moins en sections avant ou après l'application du liant.
  14. Utilisation d'un matériau en forme de plaque selon au moins l'une des revendications 1 à 10, caractérisée par le fait que le matériau en forme de plaque (1) est utilisé dans la construction intérieure, en particulier comme plaque de sol ou stratifié de sol, comme plaque de mur ou de plafond, comme plaque de meuble, dans la finition de pièces humides et mouillées, dans la construction extérieure comme panneau de façade ou pour la couverture de toit, pour les écuries, pour la construction de terrasses, y compris les plaques de terrasse ou les sols et constructions extérieurs, en particulier les meubles pour les espaces extérieurs.
EP19170159.8A 2019-04-18 2019-04-18 Matériau sous forme de plaque et son procédé de fabrication Active EP3725481B1 (fr)

Priority Applications (25)

Application Number Priority Date Filing Date Title
ES19170159T ES3019583T3 (en) 2019-04-18 2019-04-18 Plate-shaped material and method for its manufacture
EP19170159.8A EP3725481B1 (fr) 2019-04-18 2019-04-18 Matériau sous forme de plaque et son procédé de fabrication
PL19170159.8T PL3725481T3 (pl) 2019-04-18 2019-04-18 Materiał płytowy i sposób jego produkcji
CA3134193A CA3134193A1 (fr) 2019-04-18 2020-01-09 Materiau en forme de plaque et son procede de fabrication
EP20701537.1A EP3934871A1 (fr) 2019-04-18 2020-01-09 Procédé pour le revêtement d'une pièce à usiner en forme de plaque
AU2020258486A AU2020258486A1 (en) 2019-04-18 2020-01-09 Method for coating a planar workpiece
US17/604,544 US20220306821A1 (en) 2019-04-18 2020-01-09 Method for coating a planar workpiece
PCT/EP2020/050452 WO2020211989A1 (fr) 2019-04-18 2020-01-09 Procédé pour le revêtement d'une pièce à usiner en forme de plaque
CN202080029160.2A CN113710441B (zh) 2019-04-18 2020-01-09 平面材料和用于生产其的方法
US17/604,532 US12441024B2 (en) 2019-04-18 2020-01-09 Planar material and method for the production thereof
BR112021020749A BR112021020749A2 (pt) 2019-04-18 2020-01-09 Método para revestimento de uma peça de trabalho plana
EP20701536.3A EP3938158A1 (fr) 2019-04-18 2020-01-09 Matériau en forme de plaque et son procédé de fabrication
JP2021559130A JP2022529410A (ja) 2019-04-18 2020-01-09 平面状材料及びその製造方法
CN202410418823.XA CN118181424A (zh) 2019-04-18 2020-01-09 用于涂覆平面工件的方法
JP2021559135A JP2022530186A (ja) 2019-04-18 2020-01-09 平面状ワークピースをコーティングする方法
CA3137235A CA3137235A1 (fr) 2019-04-18 2020-01-09 Procede pour le revetement d'une piece a usiner en forme de plaque
UAA202105798A UA129218C2 (uk) 2019-04-18 2020-01-09 Плоский матеріал і спосіб його виготовлення
BR112021020740A BR112021020740A2 (pt) 2019-04-18 2020-01-09 Material plano e método para a produção do mesmo
AU2020259631A AU2020259631A1 (en) 2019-04-18 2020-01-09 Planar material and method for the production thereof
CN202080029521.3A CN113840701A (zh) 2019-04-18 2020-01-09 用于涂覆平面工件的方法
PCT/EP2020/050451 WO2020211988A1 (fr) 2019-04-18 2020-01-09 Matériau en forme de plaque et son procédé de fabrication
PL20170128.1T PL3736095T3 (pl) 2019-04-18 2020-04-17 Materiał w kształcie płyty i sposób jego produkcji
EP20170128.1A EP3736095B1 (fr) 2019-04-18 2020-04-17 Matière sous forme de plaque et son procédé de fabrication
ES20170128T ES2992159T3 (es) 2019-04-18 2020-04-17 Material en forma de tablero y método para su fabricación
US19/330,388 US20260001252A1 (en) 2019-04-18 2025-09-16 Planar material and method for the production thereof

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP19170159.8A EP3725481B1 (fr) 2019-04-18 2019-04-18 Matériau sous forme de plaque et son procédé de fabrication

Publications (3)

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EP3725481A1 EP3725481A1 (fr) 2020-10-21
EP3725481B1 true EP3725481B1 (fr) 2025-03-12
EP3725481C0 EP3725481C0 (fr) 2025-03-12

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US12441024B2 (en) 2019-04-18 2025-10-14 SWISS KRONO Tec AG Planar material and method for the production thereof
PL3760403T3 (pl) * 2019-07-02 2023-10-02 SWISS KRONO Tec AG Sposób powlekania obrabianego przedmiotu w kształcie płyty
EP4364918A1 (fr) * 2022-11-07 2024-05-08 SWISS KRONO Tec AG Procédé de fabrication d'un panneau de particules ainsi que panneau de particules

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5985429A (en) * 1992-08-31 1999-11-16 Andersen Corporation Polymer fiber composite with mechanical properties enhanced by particle size distribution
KR20060005365A (ko) * 2003-04-23 2006-01-17 시바 스폐셜티 케미칼스 홀딩 인코포레이티드 천연산물 복합체
US7651964B2 (en) * 2005-08-17 2010-01-26 Milliken & Company Fiber-containing composite and method for making the same
DE102007041438A1 (de) * 2007-08-28 2009-03-05 Ami Agrolinz Melamine International Gmbh Verbundwerkstoff, Verwendung eines Verbundwerkstoffes und Verfahren zur Herstellung eines Verbundwerkstoffes
WO2011107900A1 (fr) * 2010-03-04 2011-09-09 Basf Se Matériaux lignocellulosiques présentant des propriétés mécaniques satisfaisantes
CN107206620B (zh) * 2014-11-06 2019-12-31 地板技术有限公司 尤其呈木塑复合材料形式的木质材料板和用于其制造的方法
CN109249491B (zh) * 2018-07-24 2020-09-29 南京林业大学 一种复合材胶合木的制备方法

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PL3736095T3 (pl) 2024-12-02
ES3019583T3 (en) 2025-05-20
ES2992159T3 (es) 2024-12-09
EP3725481C0 (fr) 2025-03-12
EP3725481A1 (fr) 2020-10-21
PL3725481T3 (pl) 2025-07-14

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