Method for producing lignocellulose materials

Patent metadata

Field	Value
Publication number	US-10876001-B2
Application number	US-201716335285-A
Country	US
Kind code	B2
Filing date	Sep 13, 2017
Priority date	Sep 23, 2016
Publication date	Dec 29, 2020
Grant date	Dec 29, 2020

Abstract

The present invention relates to a novel and improved, batchwise or continuous, preferably continuous, process for producing single-layer or multilayer lignocellulose materials, comprising the process steps of
(Ia) producing a mixture M1 and (Ib) optionally one or more mixture(s) M2, (II) scattering mixture M1 and any mixture(s) M2 to give a mat, (III) optionally precompacting the scattered mat and (IV) hot pressing,

in that mixture M1 comprises the lignocellulose particles (component LCP-1) and additionally
a) 0.005% to 0.5% by weight of organic carboxylic acid, carboxylic anhydride, carbonyl chloride or mixtures thereof (component A) b) 0.05% to 3% by weight of organic isocyanates having at least two isocyanate groups (component B) and c) 5% to 15% by weight of binder selected from the group of the amino resins (component C) d) 0% to 2% by weight of hardener (component D) and e) 0% to 5% by weight of additive (component E),

and mixture(s) M2 comprise(s) the lignocellulose particles (component LCP-2) and additionally
f) 0% to 0.3% by weight of organic carboxylic acid, carboxylic anhydride, carbonyl chloride or mixtures thereof (component F), g) 1% to 30% by weight of binder selected from the group consisting of amino resin, phenolic resin, protein-based binder and other polymer-based binders or mixtures thereof (component G-1) and 0% to 3% by weight of organic isocyanate having at least two isocyanate groups (component G-2), h) 0% to 2% by weight of hardener (component H) and i) 0% to 5% by weight of additives (component I),

with the proviso that the following conditions are fulfilled:

a min <a<a max

and

a min =[(−1/6000· T )+(65/6000)1, preferably a min =[(−1/4500· T )+(65/4500)], more preferably a min =[(−1/3500· T )+(65/3500)]

and

a max =[(−1/2000· T )+(75/2000)], preferably a max =[(−1/2500· T )+(75/2500)], more preferably a max =[(−1/3000· T ]+(75/3000)],
where T is the temperature of mixture M1 in ° C. after process step (Ia) and is between 10 and 65° C., preferably 12 and 62° C., more preferably 15 to 60° C., and a is the amount of acid equivalents in component A) in relation to the mass of component C) in mol/100 g.

First claim

The invention claimed is:

1. A process for batchwise or continuous production of a single-layer or multilayer lignocellulose material, comprising the process steps of
(Ia) producing a mixture M1 and
(Ib) optionally one or more mixture(s) M2,
(II) scattering mixture M1 and any mixture(s) M2 to give a mat,
(III) optionally precompacting the scattered mat and
(IV) hot pressing,

wherein mixture M1 comprises lignocellulose particles (LCP-1) and additionally
a) 0.005% to 0.5% by weight of organic carboxylic acid, carboxylic anhydride, carbonyl chloride or mixtures thereof (component A)
b) 0.05% to 3% by weight of organic isocyanates having at least two isocyanate groups (component B) and
c) 5% to 15% by weight of binder selected from the group of the amino resins (component C)
d) 0% to 2% by weight of hardener (component D) and
e) 0% to 5% by weight of additive (component E), and mixture(s) M2 comprise(s) lignocellulose particles (LCP-2) and additionally
f) 0% to 0.3% by weight of organic carboxylic acid, carboxylic anhydride, carbonyl chloride or mixtures thereof (component F),
g) 1% to 30% by weight of binder selected from the group consisting of amino resin, phenolic resin, protein-based binder and other polymer-based binders, and mixtures thereof (component G-1) and 0% to 3% by weight of organic isocyanate having at least two isocyanate groups (component G-2),
h) 0% to 2% by weight of hardener (component H) and
i) 0% to 5% by weight of additives (component I),

with the proviso that the following conditions are fulfilled:
a min < a <a max

and
a min =[(− T/ 6000)+(65/6000)]

and
a max =[(− T/ 2000)+(75/2000)]

where
T is the temperature of mixture M1 in ° C. after process step (Ia) and is between 10 and 65° C., and
a is the amount of acid equivalents in component A) in relation to the mass of component C) in mol/100 g.

2. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 1 , wherein, in process step (Ia), component A) or the mixture of component A) and component B) or the mixture of component A), component B) and component E) and
component C) or
a mixture of component C) with one or more components selected from the group of components B), D) and E)
are applied to the lignocellulose particles (LCP-1)
(1) separately from one another or
(2) as a mixture within 0.1 to 3600 seconds after production of the mixture.

3. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 1 , wherein some or all of component A) is mixed with component B) or a portion of component B) before it is contacted with the lignocellulose particles (LCP-1).

4. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 1 , wherein all of component A) is mixed with component B) or a portion of component B) before it is contacted with the lignocellulose particles (LCP-1).

5. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 1 , wherein a portion or the entire amount, of component A) is mixed with component B) or a portion of component B) and with component E) or a portion of component E) to give a mixture ABE) before it is contacted with component LCP-1).

6. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 1 , wherein component C) which has optionally been mixed in a separate step with one or more components selected from the groups of components B), D) and E), and component A) or the mixture of component A) with component B) or the mixture of component A) with component B) and component E) are added to the lignocellulose particles LCP-1) or to the mixture of lignocellulose particles LCP-1) with one or more components selected from the groups of components B), D) and E) separately from one another or as a mixture within 0.1 to 3600 seconds.

7. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 1 , wherein an initial charge of component LCP-1) is mixed with component C) and component D), together or in any sequence, followed by addition of component E) and then of components A) and B), together or in any sequence, or of components A) and B), together or in any sequence, and then of component E).

8. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 1 , wherein an initial charge of component LCP-1) is mixed with component A) and component B), together or in any sequence, followed by addition of component E) and then of components C) and D), together or in any sequence, or of components C) and D), together or in any sequence, and then of component E).

9. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 1 , wherein an initial charge of component LCP-1) is mixed with component E), followed by addition of component C) and component D), together or in any sequence, then of components A) and B), together or in any sequence, or of components A) and B), together or in any sequence, and then of component C) and component D), together or in any sequence.

10. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 1 , wherein an initial charge of component LCP- 1 ) is mixed with component E), followed by addition of a mixture of components A), B), C) and D).

11. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 1 , wherein an initial charge of component LCP-1) is mixed with a mixture of components A), B), C) and D), followed by addition of component E).

12. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 1 , wherein an initial charge of component LCP-1) is mixed with a portion of component E), followed by addition of a mixture of a further portion of component E) and components A), B), C) and D).

13. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 1 , wherein an initial charge of component LCP-1) is mixed with a mixture of a portion of component E) and components A), B), C) and D), followed by addition of a further portion of component E).

14. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 1 , wherein carboxylic anhydrides are used as component A).

15. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 1 , wherein C 4 to C 8 carboxylic anhydrides are used as component F).

16. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 1 , wherein a portion or the entire amount, of component A) is mixed with component B) or a portion of component B) and with component E) or a portion of component E) to give a mixture ABE) before it is contacted with component LCP-1).

17. The process for batchwise or continuous production of single-layer or multilayer lignocellulose materials according to claim 16 , wherein mixture ABE) comprises 50% to 99% by weigh

Assignees

• Basf Se

Inventors

• Weinkoetz Stephan
• Lindner Jean-Pierre Berkan
• Lunkwitz Ralph
• Fueger Claus

Classifications

• C08L97/02 Primary

  Lignocellulosic material, e.g. wood, straw or bagasse {(manufacture of articles made from lignocellulosic material by dry processes B27N)} · CPC title

• C08K5/29

  Compounds containing {one or more} carbon-to-nitrogen double bonds · CPC title

• C08K5/09

  Carboxylic acids; Metal salts thereof; Anhydrides thereof · CPC title

• C08J5/18

  Manufacture of films or sheets · CPC title

• C08J2397/02

  Lignocellulosic material, e.g. wood, straw or bagasse · CPC title