Fiber board product comprising a calcium carbonate-containing material

Patent metadata

Field	Value
Publication number	US-10086532-B2
Application number	US-201515305770-A
Country	US
Kind code	B2
Filing date	Apr 28, 2015
Priority date	May 15, 2014
Publication date	Oct 2, 2018
Grant date	Oct 2, 2018

Abstract

The present invention relates to a fiber board product comprising fibers in an amount from 50.0 to 99.0 parts by weight (d/d), at least one particulate calcium carbonate-containing material in an amount from 1.0 to 50.0 parts by weight (d/d), at least one binder in an amount from 0.05 to 25.0 parts by weight (d/d), at least one wax in an amount from 0 to 5.0 parts by weight (d/d), wherein the sum of the fibers and the at least one particulate calcium carbonate-containing material is 100.0 parts by weight (d/d), a process for manufacturing such a fiber board product as well as an use of at least one particulate calcium carbonate-containing material having a weight median particle size d 50 of 0.5 to 150.0 μm as fiber replacement in a fiber board product, preferably in a high-density fiber (HDF) board, medium-density fiber (MDF) board, low-density fiber (LDF) board or particle board.

First claim

The invention claimed is:

1. A fiber board product comprising
a) fibers in an amount from 50.0 to 99.0 parts by weight (d/d), based on the total dry weight of the fibers and at least one particulate calcium carbonate-containing material, wherein the fibers in an amount of
i) 0 to 20.0 wt.-%, based on the total amount of dry fibers, are of a size which is fractioned at a mesh sieve width of 0.05 mm,
ii) 50.0 to 90.0 wt.-%, based on the total amount of dry fibers, are of a size which is fractioned at a mesh sieve width of 1.0 mm, and
iii) 70.0 to 100.0 wt.-%, based on the total amount of dry fibers, are of a size which is fractioned at a mesh sieve width of 3.0 mm, as determined by sieve analysis,

b) at least one particulate calcium carbonate-containing material in an amount from 1.0 to 50.0 parts by weight (d/d), based on the total dry weight of the fibers and the at least one particulate calcium carbonate-containing material, the at least one particulate calcium carbonate-containing material having a weight median particle size d 50 of 0.5 to 150.0 μm,
c) at least one binder in an amount from 0.05 to 25.0 parts by weight (d/d), based on the total dry weight of the fibers and the at least one particulate calcium carbonate-containing material, and
d) at least one wax in an amount from 0 to 5.0 parts by weight (d/d), based on the total dry weight of the fibers and the at least one particulate calcium carbonate-containing material,
wherein the sum of the amount of the fibers and the at least one particulate calcium carbonate-containing material is 100.0 parts by weight (d/d), based on the total dry weight of the fibers and the at least one particulate calcium carbonate-containing material.

2. The fiber board product according to claim 1 , wherein the at least one particulate calcium carbonate-containing material is selected from the group consisting of dolomite, at least one ground calcium carbonate (GCC), at least one precipitated calcium carbonate (PCC), and any mixture thereof.

3. The fiber board product according to claim 1 , wherein the at least one particulate calcium carbonate-containing material is ground calcium carbonate (GCC) selected from the group consisting of marble, chalk, limestone, and any mixture thereof.

4. The fiber board product according to claim 1 , wherein the at least one particulate calcium carbonate-containing material is d precipitated calcium carbonate (PCC) comprising one or more of aragonitic, vateritic and calcitic mineralogical crystal forms.

5. The fiber board product according to claim 1 , wherein the at least one particulate calcium carbonate-containing material has a) a weight median particle size d 50 from 0.7 μm to 100.0 μm, and/or b) a specific surface area of from 0.5 to 200.0 m 2 /g, as measured by the BET nitrogen method.

6. The fiber board product according to claim 1 , wherein the at least one particulate calcium carbonate-containing material has a) a weight median particle size d 50 from 1.0 μm to 50.0 μm, and/or b) a specific surface area of from 0.5 to 100.0 m 2 /g, as measured by the BET nitrogen method.

7. The fiber board product according to claim 1 , wherein the at least one particulate calcium carbonate-containing material has a) a weight median particle size d 50 from 2.1 μm to 40.0 μm, and/or b) a specific surface area of from 0.5 to 50.0 m 2 /g, as measured by the BET nitrogen method.

8. The fiber board product according to claim 1 , wherein the at least one particulate calcium carbonate-containing material consists of calcium carbonate in an amount of ≥50.0 wt.-%, based on the total dry weight of the calcium carbonate-containing material.

9. The fiber board product according to claim 1 , wherein the at least one particulate calcium carbonate-containing material consists of calcium carbonate in an amount of ≥90.0 wt.-%, based on the total dry weight of the calcium carbonate-containing material.

10. The fiber board product according to claim 1 , wherein the at least one particulate calcium carbonate-containing material consists of calcium carbonate in an amount of ≥95.0 wt.-%, based on the total dry weight of the calcium carbonate-containing material.

11. The fiber board product according to claim 1 , wherein the at least one particulate calcium carbonate-containing material consists of calcium carbonate in an amount of ≥97.0 wt.-%, based on the total dry weight of the calcium carbonate-containing material.

12. The fiber board product according to claim 1 , wherein the fibers originate from softwood tree species, hardwood tree species, non-wood fiber plants, and any mixture thereof.

13. The fiber board product according to claim 1 , wherein the fiber board product comprises a fiber material consisting of the fibers and the at least one particulate calcium carbonate-containing material having a weight fraction of fibers in said fiber material from 99.0 to 50.0 wt.-%, based on the total dry weight of the fibers and the at least one particulate calcium carbonate-containing material.

14. The fiber board product according to claim 1 , wherein the fiber board product comprises a fiber material consisting of the fibers and the at least one particulate calcium carbonate-containing material having a weight fraction of fibers in said fiber material from 99.0 to 75.0 wt.-%, based on the total dry weight of the fibers and the at least one particulate calcium carbonate-containing material.

15. The fiber board product according to claim 1 , wherein the fiber board product comprises a fiber material consisting of the fibers and the at least one particulate calcium carbonate-containing material having a weight fraction of fibers in said fiber material from 99.0 to 80.0 wt.-%, based on the total dry weight of the fibers and the at least one particulate calcium carbonate-containing material.

16. The fiber board product according to claim 1 , wherein the fiber board product comprises a fiber material consisting of the fibers and the at least one particulate calcium carbonate-containing material having a weight fraction of fibers in said fiber material from 97.0 to 88.0 wt.-%, based on the total dry weight of the fibers and the at least one particulate calcium carbonate-containing material.

17. The fiber board product according to claim 1 , wherein the fiber board product comprises the fibers in an amount from 75.0 to 99.0 parts by weight (d/d) and the at least one particulate calcium carbonate-containing material in an amount from 1.0 to 25.0 parts by weight (d/d), based on the total dry weight of the fibers and the at least one particulate calcium carbonate-containing material.

18. The fiber board product according to claim 1 , wherein the at least one binder is selected from the group consisting of phenol-formaldehyde resin (PF), urea-formaldehyde resin (UF), melamine-formaldehyde resin (MF), melamine-urea-formaldehyde resin (MUF), urea-melamine-formaldehyde resin (UMF), urea-melamine-phenol-formaldehyde resin (UMPF), epoxy resin, methylene diphenyl diisocyanate resin (MDI), polyurethane resin (PU), and any mixture thereof.

19. The fiber board product according to claim 1 , wherein the fiber board product further comprises at least one compound selected from the group consisting of colorants, filler, dispersants, biocides, hardener, and flame retardants.

20. The fiber board product according to claim 1 , wherein the fiber board product has a density from 35 to 1100 kg/m 3 , and/or a thickness from 1.0 to 300.0 mm.

21. The fiber board product according to claim 1 , wh

Assignees

• Omya Int Ag

Inventors

• Ozyhar Tomasz
• Kritzinger Johannes
• Hunziker Philipp

Classifications

• D21J1/04

  Pressing · CPC title

• B27N3/002

  characterised by the type of binder (compositions of macromolecular compounds C08L) · CPC title

• C04B26/125

  Melamine-formaldehyde condensation polymers · CPC title

• C04B26/14

  Polyepoxides · CPC title

• B27N3/08

  Moulding or pressing (presses in general B30B) · CPC title