Panel and method for producing a panel

Abstract

Disclosed is a plate-like panel 1 comprising lignocellulosic material, such as lignocellulosic particles, and comprising a glue and a scavenger, where the lignocellulosic material is pressed and bonded together with the glue, where the panel 1 comprises from top to bottom at least three layers, where at least one of the layers comprises a scavenger, and where the scavenger comprises a binder. And the amounts of scavenger of at least two of the layers are different, and a method for manufacturing the plate 1 is also disclosed.

Description

TECHNICAL FIELD

[0001] The invention relates to a board-shaped board comprising a lignocellulosic material, a glue and a scavenger, and also to a method for producing the board material and the board. BACKGROUND

[0002] The invention relates to boards, such as particle boards, oriented strand boards (OSB) and fibre boards (e.g. wood fibre boards, such as MDF (medium density fibre board) or HDF (high density fibre board), or plant fibre boards, such as flax boards or hemp boards). The invention can also relate to a panel comprising a substrate (such as a particle board substrate) and at least one decorative layer, wherein the panel can be a floor panel, a furniture panel or a wall panel. The decorative layer can comprise one or more paper layers impregnated with resin and / or wood layers and / or thermoplastic layers and / or other layers. Preferably, the invention relates to particle boards. Another term for particle boards is chip boards. Particle boards comprise wood chips that are bound to each other by glue, such as urea-formaldehyde based glue.

[0003] The boards are manufactured by pressing, for example in a continuous press or in a non-continuous press. The pressing conditions, such as time, pressure and temperature, have a major influence on the quality of the board. Of course, also the choice of the raw materials used for forming the board has a major influence. Internal bond, bending strength, density are important properties. The aim is to obtain a board with the desired properties, thus a high quality board, and this is done by pressing as short as possible. Preferably, the production speed is as high as possible. During the production of the board, harmful substances, such as formaldehyde, are emitted. This emission is preferably as little as possible. In addition, when using the board, for example in a room, it is preferred that the emission of harmful substances is as little as possible. For several harmful substances, there are emission guidelines. Formaldehyde is for example such a case. With respect to formaldehyde and particle boards, the particle board is preferably E1 class and even more preferably E0.5 class.

[0004] The formaldehyde emission can be caused by the glue used. The most common glue used in the production of the board is an aminoplastic polymer, which is produced by the polycondensation reaction of urea with formaldehyde to form urea-formaldehyde resin (UF resin). Alternatively, melamine is added and melamine urea-formaldehyde resin (MUF resin) is obtained, or melamine and / or phenol is added (e.g. MUPF resin: melamine urea phenol formaldehyde). A great advantage of these glues is their low cost, due to the universally available and cheap raw materials used in their preparation and their high reactivity, so that a high production speed can be obtained. Such glues can release formaldehyde during and after polymerization, under the influence of changes in temperature, humidity or pH value. Formaldehyde-free glues have been found for the production of the above-mentioned boards, but it is not possible or more difficult to obtain a sufficient production speed, and / or these formaldehyde-free glues can have safety issues.

[0005] Formaldehyde emissions can also be produced from the wood-based material used. The wood-based material can comprise an amount of recycled material. The recycled material can originate from solid wood waste, particle board waste, wood fiber board waste, etc. For the production of particle boards, it is known to utilize wood chips of old particle boards and / or other wood waste. This recycled material often comprises a higher amount of formaldehyde and / or emits a higher amount of formaldehyde. This means that even when formaldehyde-free glue is used, formaldehyde emissions are still a problem.

[0006] To avoid harmful emissions, scavengers are used as raw materials. The scavengers remove / neutralize harmful substances, such as formaldehyde, during production and / or when the board is used. However, the scavengers have a negative impact on the production speed. For example, the formaldehyde scavengers can become active before and / or during pressing of the board, so that the reactivity of the glue decreases. When scavengers are used, the production speed is significantly reduced.

[0007] It is therefore an object of the present invention to obtain a board that solves one or more of the above-mentioned problems and a method for producing the board. SUMMARY

[0008] According to a first aspect, the invention relates to a board-shaped board comprising wood-based material, such as wood-based material particles, and comprising glue and scavengers, wherein the wood-based material is pressed and bound together with glue, wherein the board comprises at least three layers from top to bottom, wherein at least one of the layers comprises scavengers, and the amount of scavengers differs between at least two of the layers. The wood-based material has been pressed and bound together with glue, for example by means of a continuous press or a discontinuous press. For the board-shaped board according to the first aspect of the invention, the scavengers are not proportionally distributed throughout the board, and / or the scavengers are not evenly distributed throughout the board. The amount of scavengers can be expressed as a weight percentage and / or a weight ratio of scavengers. For example, a weight percentage of scavengers to the total weight of the layer, or a weight percentage of scavengers to the total weight of scavengers, glue and wood-based material, or a weight ratio of scavengers to glue. The weight of the scavengers and / or glue and / or wood-based material is preferably the dry matter weight. By having layers with different amounts of scavengers, the scavengers can be present at desired locations and perform their activity, i.e. remove / neutralize harmful substances, at the desired locations, and as little as possible negatively impact other properties, such as board properties of the board and / or production conditions. For example, the scavengers can be positioned so that the board can be produced at a high speed and at the same time the board has the desired technical properties, such as internal bond, density, strength, etc. It is possible that only one of the three layers comprises scavengers and / or that at least one of the three layers does not comprise scavengers. If a layer does not comprise scavengers, this means that there is no scavenger that can negatively impact the layer.

[0009] The scavenger is a chemical substance that removes and / or neutralizes (deactivates) the harmful substance. Preferably, the scavenger is a formaldehyde scavenger that neutralizes formaldehyde.

[0010] The board comprises glue. The glue is a hardened / cured glue. To form the board, glue that has not yet hardened / cured or that has not yet fully hardened / cured is used. During the manufacturing of the board, the glue will (further) harden / cure to result in hardened / cured glue that binds the lignocellulosic material together. The glue of the board means the glue that has undergone hardening / curing during the formation of the board, which is dry enough and binds the lignocellulosic material together. This does not in itself mean that the glue is fully hardened / cured. Here, the hardened / cured glue can or can not be fully hardened / cured glue. By having layers with different scavenger amounts, the scavenger can be present at a desired location and not hinder or less hinder the curing / hardening of the glue, so that the production speed of the board can be high enough.

[0011] The scavenger present in the board can or can not have reacted with the harmful substance, such as formaldehyde, and thus can or can not have removed / neutralized the harmful substance. The scavenger is added during the manufacturing of the board. The board will comprise the scavenger, however it is possible that the scavenger is present in the board in another chemical form than the form in which they are added at the time of forming the board.

[0012] The percentages and amounts of the different components (e.g. lignocellulosic material, glue, scavenger) in the board are preferably expressed based on the amount of dry matter provided by the manufacturing of the board. This is because during the formation of the board, the different components will react with each other and there is also evaporation of e.g. water (formed during production).

[0013] The scavenger preferably comprises one or more of the following: a scavenger comprising a sulfite, such as a metabisulfite and a bisulfite, e.g. sodium metabisulfite, sodium bisulfite, sodium sulfite or potassium metabisulfite, potassium bisulfite or potassium sulfite; and a scavenger comprising urea. It has been found that metabisulfite is a very suitable formaldehyde scavenger. Other possible scavengers include tannins, ammonium salts, melamine, acetoacetamide, polyamines, compounds containing bisulfite anions, compounds containing free or protected primary / secondary amines. The scavenger can also comprise or be a hyperbranched polyamide. Preferably, the hyperbranched polyamide is obtained by polymerization of amino acids, preferably the amino acids are amino acids selected from the group consisting of lysine, histidine, glutamine and asparagine. The scavenger can for example comprise hyperbranched polylysine. The scavenger can be a combination of sodium metabisulfite and urea and hyperbranched polylysine, or a combination of sodium metabisulfite and urea, or a combination of sodium metabisulfite and hyperbranched polylysine.

[0014] By having a formaldehyde scavenger, the glue can be a urea-formaldehyde based glue, such as urea-formaldehyde glue (UF glue), melamine urea-formaldehyde resin (MUF glue), or melamine urea phenol formaldehyde glue (MUPF glue). The glue can also be a phenol formaldehyde glue. These glues are reactive glues, which allow for the production of such boards in a fast way. Of course, other glues can be used, such as polyvinyl acetate glue; polyurethane glue, polyacrylate glue, (poly)polymethylene polyphenylene ester glue, polyvinyl butyral (PVB) glue, polyurethane (PUR) hot-melt glue, polyester glue, bio-based glues based on e.g. saccharides, lignin, hyperbranched polyamides, etc. It is not excluded that the glue comprises additional hardeners to improve the bonding, such hardeners can be based on e.g. isocyanate, carbodiimide, aziridine, epoxy resin, etc. The glue can also be a mixture of two or more types of glue, and / or different layers can comprise different glues.

[0015] By having a formaldehyde scavenger, it is possible to use regenerated materials that comprise formaldehyde and / or emit formaldehyde. For example, if the board is a particle board, it is possible to use old particle boards and other sources of wood waste to manufacture particle boards.

[0016] Preferably, the lignocellulosic material comprises or is lignocellulosic particles. The lignocellulosic particles can be selected from the group consisting of wood chips, wood fibers, shavings, non-wood lignocellulosic fibers such as hemp fibers or flax fibers. The lignocellulosic material can comprise different types of lignocellulosic particles. The lignocellulosic material can comprise or be a wood veneer. For example, the board can be a plywood comprising two or more wood veneers attached to each other with glue layers, wherein for example at least one of these glue layers comprises glue and scavenger, and the wood veneers are the layers of the board.

[0017] The lignocellulosic material can comprise two or more types of material, for example it can comprise wood chips and wood fibers or it can comprise wood chips and wood veneers.

[0018] One of these layers may comprise only a cleaning agent or at least 90 wt% of a cleaning agent. Another layer may not comprise a cleaning agent, or may comprise up to 5 wt% of a cleaning agent, preferably up to 1 wt%, most preferably up to 0.1 wt% of a cleaning agent. For example, the board may comprise three layers having two outer layers and a central layer between the two outer layers. The central layer may not comprise a cleaning agent, or may comprise up to 3 wt% of a cleaning agent, preferably up to 1 wt%, more preferably up to 0.1 wt% of a cleaning agent, while the outer layers comprise a cleaning agent, preferably having a cleaning agent amount at least higher than that in the intermediate layers, preferably at least 0.5 wt% of a cleaning agent, more preferably at least 1 wt% of a cleaning agent. Alternatively, the board may comprise at least two outer layers, an intermediate layer between the two outer layers, and at least one cleaning agent layer sandwiched between the intermediate layer and the outer layers, wherein the cleaning agent layer comprises, for example, at least 80 wt% of a cleaning agent.

[0019] Alternatively, the board may comprise only one or two layers instead of at least three layers, wherein the cleaning agent is unevenly distributed and / or disproportionately distributed throughout the board. This embodiment relates to a first variant of the invention. Preferred / specific embodiments of the first aspect of the invention are applied to this first variant with necessary modifications. For example, the board may be a single-layer board, such as a single-layer wood fiberboard, comprising a hyperbranched polylysine cleaning agent, wherein the cleaning agent is unevenly distributed and / or disproportionately distributed throughout the board.

[0020] In a preferred embodiment, the lignocellulosic material comprises lignocellulosic particles, such as sawdust and / or wood fibers, and the board comprises at least three layers: at least two lignocellulosic layers and a cleaning agent layer. The at least two lignocellulosic layers comprise at least lignocellulosic particles and glue, and the cleaning agent layer comprises at least a cleaning agent. The cleaning agent layer is located between, preferably sandwiched between, the two lignocellulosic layers. The lignocellulosic layers preferably do not contain a cleaning agent, or the weight ratio of the cleaning agent to the glue (dry weight) is less than 5%, preferably less than 3%, more preferably less than 1%, and most preferably less than 0.5%. Here, the cleaning agent's action is largely or entirely performed by the cleaning agent layer. The lignocellulosic layers do not contain a cleaning agent, or may include a small amount of cleaning agent. This means that no cleaning agent needs to be added or only a small amount needs to be added when forming the lignocellulosic layers, and furthermore, there is less contact between the cleaning agent and the glue in the lignocellulosic layers, so that the cleaning agent will not hinder or will less hinder the glue in the lignocellulosic layers from binding the lignocellulosic particles together. Therefore, such a board can be manufactured quickly while still having a small amount of harmful substances (such as formaldehyde) emitted. To form the lignocellulose layers, the glue and lignocellulose particles are preferably mixed together in a mixing device. Since these lignocellulose layers contain little or no cleaning agent, the risk of damage to the mixing device from the cleaning agent is low. The thickness of the cleaning agent layer can be small or even negligible compared to the thickness of the lignocellulose layers. The cleaning agent layer may or may not be a continuous layer. Preferably, the cleaning agent layer is embedded between two lignocellulose layers. If this is the case, direct contact may or may not exist between the lignocellulose layers. If the cleaning agent layer is not completely continuous, direct contact can exist between the lignocellulose layers, such that the cleaning agent layer has little or no negative impact on the internal bonding of the board.

[0021] More preferably, the cleaning agent layer occupies at most 1% of the total thickness of the board, preferably at most 0.5%, and most preferably at most 0.1%. This cleaning agent layer is so thin that the internal bonding of the board (e.g., the bonding strength between different layers) is not negatively affected, and the risk of delamination at the height of the cleaning agent layer can be low.

[0022] Furthermore, and more preferably, the cleaning agent layer comprises between 0.1 wt% and 2 wt% of the total weight of the particleboard, more preferably between 0.2 wt% and 1 wt%, for example, 0.3, 0.5, 0.7, or 1.5 wt%. This indicates that the cleaning agent layer is thin and requires a small amount of cleaning agent. The weight of the cleaning agent layer can be 10 g / m². 2 Up to 60 g / m 2 Plates of varying weights, for example, 20 g / m² 2 Or 30 g / m2 Or 35 g / m 2 A plate-shaped plate of weight, wherein the cleaning agent layer preferably comprises only cleaning agent.

[0023] Furthermore, more preferably, the at least two lignocellulose layers comprise at least two types of lignocellulose layers, namely a core lignocellulose layer and an outer lignocellulose layer forming the outer main surface of the board, wherein the core lignocellulose layer and the outer lignocellulose layer differ in one or more of the following aspects: - The amount of lignocellulose particles, such as the weight percentage of lignocellulose particles in a lignocellulose layer; - The amount of glue, such as the weight percentage of the glue; - Type of adhesive; - The type of lignocellulose particles, such as the lignocellulose particles in the core lignocellulose layer being coarser than those in the outer lignocellulose layer, and / or the lignocellulose particles in the core lignocellulose layer comprising more regenerated lignocellulose particles than those in the outer lignocellulose layer. - The amount and / or type of cleaning agent, such as the weight percentage of the cleaning agent in the lignocellulose layer; -thickness.

[0024] These differences are a result of the desired properties of the board and the way it is manufactured. For example, it is desirable for the core lignocellulose layer to have a lower density than the outer lignocellulose layer, and this is achieved, for example, by using coarser lignocellulose particles, in order to obtain a lighter but still sufficiently strong panel with less material. The lignocellulose particles in the outer lignocellulose layer can be finer than those in the core lignocellulose layer, making the outer main surface of the board more suitable for applying a (decorative) topcoat, such as one or more resin-impregnated papers. The outer lignocellulose layer may include a cleaning agent, while the core lignocellulose layer may not.

[0025] In another preferred embodiment, the board comprises at least five layers: two cleaning agent layers and three lignocellulose layers, of which one is a core lignocellulose layer and two are outer lignocellulose layers. The board, from top to bottom, comprises a first outer lignocellulose layer, a first cleaning agent layer, a core lignocellulose layer, a second cleaning agent layer, and a second outer lignocellulose layer. In this embodiment, the core lignocellulose layer preferably does not contain a cleaning agent, or contains up to 0.5 wt% of a cleaning agent, preferably up to 0.1 wt%. The board is made by pressing. During pressing, the lignocellulose particles are bonded together by the hardening / curing of the adhesive. Because the core lignocellulose layer is embedded between the other layers, it experiences a time delay or less intensity of pressure conditions (e.g., pressure and temperature), for example, resulting in lower maximum temperatures or pressures and / or longer durations of maximum temperatures or pressures. Therefore, the total amount of time required to manufacture a board with the desired properties is determined by the time required for the adhesive in the core lignocellulose layer to fully harden / cur. Because in this embodiment, the core lignocellulose layer contains little or no cleaning agent, the lignocellulose particles can bond together well, even with time delays and / or milder pressure conditions (e.g., lower pressure and / or lower temperature), and this is because there is little or no cleaning agent present that could hinder the curing / hardening of the adhesive. The outer lignocellulose layer may or may not contain a cleaning agent. Since the outer lignocellulose layer is external during pressing, the pressure conditions (e.g., pressure and temperature) increase rapidly, making the negative impact of the presence of the cleaning agent on the bonding of the lignocellulose particles in the outer lignocellulose layer during pressing relatively small. Preferably, the amount of cleaning agent in the outer lignocellulose layer is at most 0.1%. More preferably, the cleaning agent layer comprises at least 80 wt% cleaning agent, preferably at least 99 wt% cleaning agent, or only cleaning agent. The cleaning agent layer may include adhesive, such as at least 1 wt% adhesive and / or at most 20 wt% adhesive, and is used to improve the bonding strength between different layers. The cleaning agent layer may also comprise lignocellulose particles, for example, up to 20 wt% lignocellulose particles, preferably up to 5 wt% lignocellulose particles. The cleaning agent layer may also comprise adhesive, for example, up to 20 wt% adhesive, preferably up to 5 wt% adhesive. The core lignocellulose layer may be a single layer, but may also comprise two or more sublayers, wherein each sublayer may or may not have substantially the same composition. Two core lignocellulose layers may also be present, with the cleaning agent layer located between the two core lignocellulose layers. A reinforcing mesh or grid, such as a glass fiber mesh, may also be present between two layers, for example, as mentioned above.

[0026] In another specific embodiment, the board may have two core lignocellulose layers and three cleaning agent layers, wherein two cleaning agent layers are located between the outer lignocellulose layer and the core lignocellulose layer, and one of the cleaning agent layers is located between the two core lignocellulose layers.

[0027] Furthermore, and more preferably, in the embodiments mentioned above with at least five layers, the outer lignocellulose layer occupies between 4% and 20% of the total board thickness. Preferably, the core lignocellulose layer occupies between 60% and 90% of the total board thickness. Preferably, the thickness of the cleaning agent layer is negligible, for example, less than 0.1% of the total board thickness. In this way, the cleaning agent layer cannot negatively affect the internal bonding of the board.

[0028] Furthermore, and more preferably, the total thickness of the outer lignocellulose layer is between 0.3 mm and 3 mm. In this way, the cleaning agent layer is located inside the board, not near the outer surface, and not near the center. The cleaning agent layer can perform its cleaning agent function well, and the negative impact of the cleaning agent during board manufacturing is negligible or small.

[0029] Furthermore, more preferably, the weight ratio of the scavenger to the glue in the core lignocellulose layer is between 2% and 17%, more preferably between 3% and 9%. Preferably, at least 90 wt% of the scavenger is present in the scavenger layer, more preferably at least 95 wt%, and most preferably at least 99 wt%. Therefore, the weight ratio of the scavenger in the scavenger layer to the glue in the core lignocellulose layer is preferably between 2% and 17%, more preferably between 3% and 9%. The amount of scavenger required will be determined by the thickness of the board. The thicker the board, the more glue and the more lignocellulose particles are required. This means that if the glue is urea-formaldehyde resin, the thicker the board, the more formaldehyde will be present, and therefore the more scavenger will be required. Surprisingly, it has been found that even for thicker boards (e.g., boards with a core lignocellulose layer thicker than 1 cm, 2 cm, or 3 cm), when the core lignocellulose layer is embedded between two scavenger layers, no scavenger is needed in the core lignocellulose layer. The emission of harmful substances from thicker boards can be sufficiently low.

[0030] In a preferred embodiment, the cleaning agent layer comprises at least 10 wt% cleaning agent, preferably at least 30 wt%, more preferably at least 50 wt%, most preferably at least 80 wt%, and most preferably at least 99 wt% cleaning agent, for example, comprising only cleaning agent. The cleaning agent can be provided in powder form. Therefore, the cleaning agent layer can be formed by dispersing / dispersing the cleaning agent in powder form, which ensures easy board production if the cleaning agent layer comprises a large amount of cleaning agent. If the cleaning agent is provided in powder form, a roller disperser or a vibratory spreader can be used. With the aid of a roller disperser, the cleaning agent can be dispersed / dispersed very uniformly. If the cleaning agent is provided in powder form to form the board, the powder is preferably neither too fine nor too coarse. Too fine a powder may result in poor internal bonding of the board, while too coarse a powder may result in lower cleaning agent activity per gram of cleaning agent. Preferably, the particle size of the cleaning agent is such that up to 30% by weight, preferably up to 20% by weight, of the cleaning agent passes through a sieve with an aperture diameter of 160 μm, and / or at least 45% by weight, preferably at least 55% by weight, of the cleaning agent cannot pass through a sieve with an aperture diameter of 300 μm. Preferably, at least 20 wt% by weight, more preferably at least 35 wt% by weight, of the cleaning agent passes through a sieve with an aperture diameter of 300 μm, but cannot pass through a sieve with an aperture diameter of 160 μm. Preferably, the average particle size D90 value is preferably less than 1000 μm, or even less than 700 μm or less than 500 μm, and the average particle size D90 value can be between 100 μm and 500 μm. The average particle size can be measured by various techniques known in the art. Specifically, for larger particles, it may be possible to determine the particle size by sieving techniques, such as those described in EN933-2:2020. The particle size of smaller particles can be determined by laser particle size determination. Specifically, the median particle size D90 can be determined by laser particle size determination, which can be performed according to ISO 13320:2020.

[0031] In a preferred embodiment, the lignocellulose layer comprises up to 1 wt% of a cleaning agent, preferably up to 0.1 wt% of a cleaning agent, and more preferably no cleaning agent. Here, the cleaning agent action is performed substantially by or solely by the cleaning agent layer, enabling the production of boards and / or boards with desirable properties, such as strength, in a rapid manner.

[0032] In a preferred embodiment, the lignocellulose layer comprises at least 97% lignocellulose particles and glue by weight. Here, the lignocellulose material essentially consists of lignocellulose particles and glue. Of course, other materials may also be present, such as colorants, pigments, waxes, flame retardant additives, hardeners, moisture-proof components, antifungal additives, antimicrobial additives, etc.

[0033] The cleaning agent used in the plate can be a water-activated cleaning agent, such as a hydrolyzable cleaning agent.

[0034] In a preferred embodiment, for the board, the weight ratio of the cleaning agent to the adhesive is between 0.5% and 10%, preferably between 1% and 4%. This indicates that with a small amount of cleaning agent, a small amount of harmful substance emissions can be obtained.

[0035] According to a second aspect, the present invention relates to a sheet-like board comprising a lignocellulosic material, adhesive, and a cleaning agent, wherein the lignocellulosic material is pressed and bonded together using the adhesive, and wherein the cleaning agent used in the board is a heat-activated and / or pressure-activated cleaning agent. The lignocellulosic material has been pressed and bonded together using adhesive. The sheet-like board according to the second aspect of the invention may or may not be a sheet-like board according to the first aspect of the invention. This means that the heat- and / or pressure-activated cleaning agent can be uniformly distributed throughout the board, thus meaning that if the board is multilayered, each layer includes the same amount of cleaning agent (e.g., the same weight percentage of cleaning agent), making the sheet-like board not according to the first aspect. If the board is also according to the first aspect, the heat- and / or pressure-activated cleaning agent is not uniformly distributed throughout the board. The advantage of heat- and / or pressure-activated cleaning agents is that, during board production, the cleaning agent only becomes active when needed (e.g., when sufficient heat and / or pressure are present, and therefore when adhesive curing / hardening occurs or is completed), so that they have little or no negative impact on production speed.

[0036] Heat- and / or pressure-activated scavengers can be encapsulated scavengers, meaning the scavenger is encapsulated in a shell or similar material that subsequently decomposes under heat and / or pressure. Encapsulated scavengers may include a shell encapsulating one or more of the following: sulfites, such as metabisulfites and bisulfites, e.g., sodium metabisulfite, sodium bisulfite, sodium sulfite, or potassium metabisulfite, potassium bisulfite, or potassium sulfite; or urea, tannins, ammonium salts, melamine, acetylacetamide, polyamines, compounds containing bisulfite anions, compounds containing free or protected primary / secondary amines, or hyperbranched polyamides (such as hyperbranched polylysine).

[0037] The lignocellulosic material of the board preferably comprises sawdust, and more preferably only sawdust, such that the board is a particleboard. The sawdust may include virgin sawdust and / or recycled sawdust. Particleboard can be made by dispersing different lignocellulosic layers comprising glue and sawdust, such that the formation of a cleaning agent layer can be readily incorporated into the particleboard production process, and this is done by providing a unit that can disperse / apply a cleaning agent to the lignocellulosic layers. Of course, in another embodiment, the lignocellulosic material may include wood fibers, as wood fiberboard may also comprise different layers comprising wood fibers and glue. Of course, in another embodiment, the lignocellulosic material may include wood shavings, as OSB board may also comprise different layers comprising wood shavings and glue. The board may also be a composite board comprising at least two lignocellulosic layers having different lignocellulosic materials selected from: sawdust, wood fibers, wood shavings, and a finish.

[0038] According to a third aspect, the present invention relates to a method for producing a board material, wherein raw materials are provided and production steps are performed to form the raw materials into a board material, the raw materials comprising at least lignocellulosic materials, such as lignocellulosic particles (e.g., sawdust and / or wood fibers), adhesives, and a cleaning agent, wherein the production steps comprise at least the following production steps: -Basic steps, in which raw materials are integrated and transported to the molding unit; - Molding step, wherein the integrated raw materials are pressed into a sheet material by a molding unit to form a sheet material; In the basic step, in order to integrate the raw materials together, at least three base layers are formed on top of each other, wherein at least one of these base layers includes a cleaning agent, and the amount of cleaning agent in at least two of these base layers is different.

[0039] The forming unit is preferably a continuous press (such as a continuous double-belt press) or a portion thereof. Of course, the pressing unit can also be a discontinuous press or a portion thereof. Such a continuous press preferably includes one or more spreaders / dispersers to spread / disperse one or more or all of the substrates in the substrate. Preferably, the substrate is then formed one on top of another, for example, subsequently spread / dispersed one on top of another. Additionally, the continuous press preferably includes a lower belt and an upper belt, on which the substrate is formed one on top of another, wherein the substrate is pressed together between the lower and upper belts.

[0040] Preferably, a sawing unit is provided for sawing the manufactured sheet material into a substrate. The substrate is preferably a sheet according to the first and / or second aspects of the invention, or further processing steps are performed to form a sheet according to the first and / or second aspects of the invention. The layers of the sheet are thus derived from the base layer.

[0041] Thus, the sheet material can be formed into a sheet. Preferably, further processing steps (such as sawing and / or sanding) are performed on the sheet material to form a sheet. Therefore, the method for manufacturing the sheet material is also the method for manufacturing the sheet. Preferably, the sheet is a sheet according to the first and / or second aspects of the invention. Therefore, the advantages and embodiments of the sheet of the first and / or second aspects of the invention also apply to this method, and vice versa.

[0042] In a preferred embodiment, the lignocellulose material comprises lignocellulose particles, and preferably only comprises lignocellulose particles (such as sawdust or plant fibers), wherein at least three base layers comprise at least two lignocellulose base layers and a cleaning agent base layer, the at least two lignocellulose base layers comprising at least lignocellulose particles and a glue, and the cleaning agent base layer comprising at least a cleaning agent, wherein the cleaning agent base layer is located between the two lignocellulose base layers. Preferably, a lignocellulose base layer is first formed (e.g., dispersed), then the cleaning agent base layer is applied (preferably dispersed) onto the lignocellulose base layer, and subsequently another lignocellulose base layer is applied (preferably dispersed) onto the cleaning agent base layer. The cleaning agent may be in granular / powder form and may have a particle size such that up to 30% by weight of the cleaning agent passes through a sieve with an aperture diameter of 160 μm, and / or at least 55% by weight of the cleaning agent cannot pass through a sieve with a diameter of 300 μm. The average particle size D90 value is preferably less than 1000 μm, or even less than 700 μm, and the average particle size D90 value may be between 100 μm and 500 μm. The average particle size can be measured using various techniques known in the art. Specifically, for larger particles, it may be possible to determine the particle size using sieving techniques, such as those described in EN 933-2:2020. The particle size of smaller particles can be determined by laser particle size determination; specifically, the median particle size D90 can be determined using laser particle size determination, which can be performed according to ISO 13320:2020.

[0043] More preferably, the at least two lignocellulose base layers comprise at least two types of lignocellulose base layers, namely a core lignocellulose base layer and an outer lignocellulose base layer, wherein the outer lignocellulose layer of the board material is derived from the outer lignocellulose base layer, and wherein the core lignocellulose base layer and the outer lignocellulose base layer differ in one or more of the following aspects: - Amount of lignocellulose particles; - Amount of glue; - Type of adhesive; - The type of lignocellulose particles, such as the lignocellulose material of the core lignocellulose material being coarser than the lignocellulose material of the outer lignocellulose layer, and / or the lignocellulose material of the core lignocellulose material containing more regenerated lignocellulose material than the lignocellulose material of the outer lignocellulose layer; - The amount and / or type of cleaning agent; -thickness.

[0044] Typically, the thickness of the outer lignocellulose layer is less than that of the core lignocellulose layer. Additionally, the weight percentage of glue in the outer lignocellulose layer is usually higher than that in the core lignocellulose layer. Furthermore, if the board is a particleboard comprising lignocellulose particles as sawdust, the sawdust in the outer lignocellulose layer is generally finer than that in the core lignocellulose layer (no longer coarser). For example, the weight ratio of glue to lignocellulose particles in the outer lignocellulose layer can be between 6% and 15%, and the weight ratio in the core lignocellulose layer can be between 3% and 10%.

[0045] More preferably, at least five substrates (i.e., two cleaning agent substrates and three lignocellulose substrates) are formed on top of each other, wherein one of the three lignocellulose substrates is a core lignocellulose substrate and two are outer lignocellulose substrates, arranged from top to bottom as a first outer lignocellulose substrate, a first cleaning agent substrate, a core lignocellulose substrate, a second cleaning agent substrate, and a second outer lignocellulose substrate. The core lignocellulose substrate can be a single layer or can include two or more sublayers. For example, if the core lignocellulose substrate is being dispersed, two dispersers can be used to obtain a thicker core lignocellulose substrate, or a disperser capable of dispersing thick layers can be used.

[0046] In a highly preferred embodiment, the substrate is then formed (preferably spread or dispersed) as one layer on top of another, and wherein the cleaning agent substrate is applied at a concentration of 5 g / m³. 2 Up to 100 g / m 2 Clearance dose between deposits (preferably dispersed or dispersed), preferably 6 g / m 2 Up to 70 g / m 2 Between, more preferably 10 g / m 2 Up to 30 g / m 2 Between (e.g., 14 g / m) 2 15 g / m 2 16g / m 2 Or 17 g / m 2 ) or 30 g / m 2 Up to 40 g / m 2 Between (e.g., 35 g / m) 2The amount of cleaning agent deposited. Preferably, the cleaning agent base layer substantially comprises the cleaning agent, which is preferably in powder form so that it can be easily dispersed or dispersed. The cleaning agent may also be in liquid form, for example, dissolved in a liquid, and then preferably poured or sprayed.

[0047] By using such a small amount of cleaning agent, pressing can effectively bond the different lignocellulose substrates to the cleaning agent layers between them, resulting in a board material and thus a board with good internal bonding. Preferably, the cleaning agent substrate occupies at most 1% of the total thickness of the substrate formed on top of another before pressing, more preferably at most 0.5%, and more preferably at most 0.1%. Furthermore, preferably, the cleaning agent substrate occupies between 0.1 wt% and 1 wt% of the total weight of the substrate.

[0048] Preferably, the outer lignocellulose layer occupies between 4% and 20% of the total thickness of the layer formed on top of the other. More preferably, the core lignocellulose layer occupies between 60% and 90% of the total thickness of the layer formed on top of the other.

[0049] In a preferred embodiment, the cleaning agent base layer comprises at least 10 wt% of cleaning agent, preferably at least 30 wt%, more preferably at least 50 wt%, and most preferably at least 80 wt% of cleaning agent. The cleaning agent base layer may, for example, comprise only cleaning agent. The cleaning agent layer may also comprise adhesive and / or lignocellulose particles, for example, comprising a small amount of adhesive (e.g., less than 20 wt%, preferably less than 5 wt%), to ensure good bonding between different base layers.

[0050] In a highly preferred embodiment, the lignocellulose base layer comprises up to 1 wt% of a cleaning agent, preferably up to 0.5 wt% of a cleaning agent, and more preferably no cleaning agent. For example, the core lignocellulose base layer comprises up to 0.1% of a cleaning agent or no cleaning agent at all. During pressing, pressure and temperature will gradually increase; however, this will be slower for the core lignocellulose base layer than for the outer lignocellulose base layer. To ensure good curing / hardening of the adhesive, the absence of a cleaning agent and / or the presence of a very small amount of cleaning agent is advantageous. The outer lignocellulose base layer may include a higher amount of cleaning agent; however, the presence of a cleaning agent base layer makes it unnecessary to use a cleaning agent in the outer lignocellulose base layer.

[0051] Preferably, the content of lignocellulose material and glue in the lignocellulose base layer is at least 97 wt%.

[0052] In a highly preferred embodiment, the cleaning agent is water-activated, for example, hydrolyzable. Water / steam can be used / added during pressing. This water will then come into contact with the cleaning agent during pressing, minimizing the risk that the cleaning agent becomes active before it needs activation (and therefore before formaldehyde is formed due to adhesive curing / hardening). As a result, the cleaning agent will have little or no negative impact on the curing / hardening of the adhesive, and a good production rate can be achieved.

[0053] Preferably, the raw materials are assembled into a cake-like structure, which is then pressed into a sheet-like material by a forming unit. Prior to pressing by the forming unit, steam is applied through the cake, for example by steam injection and / or vacuum, the steam preferably comprising at least 95 wt% water. Heat and / or water are added to the cake by means of steam. Therefore, steam is beneficial for heat-activated and / or water-activated cleaning agents. For example, adding steam is very beneficial when the cleaning agent comprises sodium metabisulfite. By adding steam before pressing by the forming unit, the cleaning agent is active from the moment pressing begins.

[0054] According to a fourth aspect, the present invention relates to a method for producing a board material, wherein raw materials are provided and production steps are performed to form the raw materials into a board material, the raw materials comprising at least a lignocellulosic material, such as lignocellulosic particles (e.g., sawdust and / or wood fibers), glue, and a cleaning agent, wherein the production steps comprise at least the following production steps: -Basic steps, in which raw materials are integrated and transported to the molding unit; - Molding step, wherein the integrated raw materials are pressed into a sheet material by a molding unit to form a sheet material; Furthermore, the cleaning agent is a heat- and / or pressure-activated cleaning agent.

[0055] The method according to the fourth aspect of the invention may or may not be based on the third aspect of the invention. This means that the heat- and / or pressure-activated cleaning agent can be uniformly distributed throughout the integrated raw materials, thus meaning that in the case of a multi-layered board, each layer comprises the same amount of cleaning agent (e.g., the same weight percentage of cleaning agent), making the method not based on the third aspect.

[0056] The advantage of heat- and / or pressure-activated cleaners is that they become active only when needed during the production of board material, thus having little or no negative impact on production speed. Heat- and / or pressure-activated cleaners can be encapsulated cleaners, meaning that the cleaner is encapsulated in a shell or similar material, which is subsequently decomposed under the influence of heat and / or pressure.

[0057] In a highly preferred embodiment of the aspects mentioned above or the first variant, the scavenger comprises one or more of the following: scavengers comprising sulfites, such as metabisulfites, bisulfites, for example sodium metabisulfite, sodium bisulfite, sodium sulfite, or potassium metabisulfite, potassium bisulfite, or potassium sulfite; scavengers comprising urea; and scavengers comprising hyperbranched polyamides (e.g., hyperbranched polylysine). The scavenger is a formaldehyde scavenger.

[0058] Preferably, the lignocellulosic material includes wood chips, and the board is particleboard.

[0059] According to a fifth aspect, the invention also relates to a decorative panel, preferably a floor panel, wall panel, or furniture panel, comprising a substrate having one or more substrate layers and a decorative top layer applied to the substrate layers, wherein at least one of the substrate layers is obtained from a board according to the first and / or second aspects of the invention and / or from board material manufactured by the third and / or fourth aspects of the invention. These board / board materials are highly suitable for forming decorative panels because they have low emissions of harmful substances and can possess good technical properties. The decorative top layer may comprise one or more resin-impregnated papers, wherein the resin is, for example, a thermosetting resin (such as melamine resin). For example, the resin-impregnated paper includes (digitally) printed resin-impregnated paper and translucent / transparent resin-impregnated paper (e.g., an abrasion layer), which optionally includes hard particles (such as corundum) to provide additional abrasion resistance. The decorative top layer may also be an HPL (high-pressure laminate), which, in addition to including printed resin-impregnated paper and an abrasion layer, includes one or more resin-impregnated kraft paper. The resin in the resin-impregnated kraft paper may be a phenolic resin.

[0060] In a preferred embodiment, the decorative panel is rectangular and includes two pairs of opposing edges, wherein at least one substrate layer includes an exposed portion at at least one of the edges.

[0061] More preferably, the exposed portion has a contoured structure and at least partially forms a first connecting portion at the corresponding edge, the first connecting portion allowing the edge to connect to a second connecting portion at the opposite edge of a similar decorative panel, wherein, in the connected state, a lock is formed between the corresponding edges in a direction perpendicular to the plane of the connecting panel and / or in the plane of the connecting panel and in a direction perpendicular to the corresponding edge. It has been found that the cleaning agent layer does not negatively affect the technical properties of the board / panel material, making it possible to form the connecting portion in these board / panel materials.

[0062] In the second variant of the first and / or second and / or third and / or fourth and / or fifth aspects of the invention, or in the first variant of the invention, an additive that enhances the specific properties of the board is present, in addition to or besides the cleaning agent. For example, a refractory additive is present, in addition to or besides the cleaning agent. Examples of refractory additives may be selected from the following: phosphates (such as ammonium phosphate, magnesium phosphate, or aluminum phosphate), sulfates, aminosulfonates, aluminum trihydrate, calcium magnesium carbonate, magnesite, and antimony oxide. The refractory additive may be or may not be a combination of the examples mentioned above. In this second variant, the cleaning agent (base) layer is an additive (base) layer, wherein the additive (base) layer comprises at least an additive (such as a refractory additive) that enhances the specific properties of the board and optionally enhances the specific properties of the cleaning agent. The additive (base) layer may, for example, have a cleaning agent to additive ratio between 10:100 and 100:10 by weight. In the prior art, to obtain a refractory board (such as refractory particleboard or refractory fiberboard), a refractory additive is mixed with a lignocellulosic material. Surprisingly, by having an additive (base) layer, as in a variant of the invention, it has been found that the same refractory properties can be obtained with fewer refractory additives. All preferred embodiments of the first and / or second and / or third and / or fourth and / or fifth aspects of the invention also apply to this second variant. Further preferred embodiments of this second variant are listed below.

[0063] Preferably, the board is particleboard.

[0064] In a preferred embodiment, the lignocellulosic material comprises lignocellulosic particles (such as sawdust), and the board comprises at least three layers (i.e., at least two lignocellulosic layers and an additive layer), wherein the at least two lignocellulosic layers comprise at least lignocellulosic particles and glue, and the additive layer comprises at least a refractory additive and is located between the two lignocellulosic layers. Preferably, the additive layer comprises only a refractory additive, or only a refractory additive and a cleaning agent.

[0065] The additive layer may occupy a maximum of 1% of the total thickness of the board, preferably a maximum of 0.5%, and most preferably a maximum of 0.1%.

[0066] The additive layer can account for between 0.1 wt% and 1 wt% of the total weight of the particleboard.

[0067] Preferably, the board comprises at least five layers: two additive layers and three lignocellulose layers, of which one is a core lignocellulose layer and two are outer lignocellulose layers. The board, from top to bottom, comprises a first outer lignocellulose layer, a first additive layer, a core lignocellulose layer, a second additive layer, and a second outer lignocellulose layer. The outer lignocellulose layers can occupy between 4% and 20% of the total thickness of the board, and preferably, the core lignocellulose layer occupies between 60% and 90% of the total thickness of the board. The total thickness of the outer lignocellulose layers can be between 0.3 mm and 3 mm.

[0068] The refractory additive is at most 20 wt% of the board, preferably at most 15 wt% and / or preferably at least 10 wt%.

[0069] The additive layer comprises at least 10 wt% refractory additives, preferably at least 30 wt%, more preferably at least 50 wt%, and most preferably at least 80 wt% refractory additives.

[0070] The core lignocellulose layer includes up to 1 wt% of refractory additives, preferably up to 0.1 wt% of refractory additives, and more preferably no refractory additives.

[0071] The outer lignocellulose layer preferably includes refractory additives, creating a refractory barrier above the additive layer. For example, the outer lignocellulose layer includes between 10 wt% and 20 wt% refractory additives.

[0072] The content of lignocellulose material and gum in the core lignocellulose layer is preferably at least 97 wt%.

[0073] Refractory additives can be dispersed / spread to form an additive base layer. Attached Figure Description

[0074] To better illustrate the features of the present invention, embodiments of the invention are described below with reference to the following schematic diagrams, as examples without any limiting features: - Figure 1 This is a perspective view of the plate according to the present invention; - Figure 2 yes Figure 1 Possible cross-sections of the plate shown; - Figure 3 It is a cross-section of a decorative panel including the substrate of the plate according to the present invention; - Figure 4 It shows the method for manufacturing such as Figure 1 and Figure 2 Possible methods for making particleboard are shown. Detailed Implementation

[0075] Figure 1 A sheet-like board 1 comprising lignocellulose particles, adhesive, and a cleaning agent is shown. The lignocellulose particles may comprise sawdust, wood fibers or other plant fibers, wood shavings, or a combination of two or more types of lignocellulose particles. Preferably, the lignocellulose particles are sawdust, and even more preferably, at least a portion of these sawdust are recycled sawdust derived from, for example, end-of-life wood-based panels / boards. End-of-life panels / boards are those included in the indicated non-exhaustive list: panels / boards already used by end consumers and / or production waste and / or waste from installation, transportation, sales, and / or unsold inventory.

[0076] The lignocellulose material is pressed and bonded together with adhesive, and the board 1 preferably comprises at least three layers from top to bottom, wherein at least one of these layers comprises a cleaning agent, and the amount of cleaning agent is different for at least two of these layers.

[0077] Figure 2 A possible embodiment of the plate 1 according to a first aspect of the invention and optionally a second aspect of the invention is shown. Preferably, the lignocellulose particles are wood chips, but the lignocellulose particles can also be wood fibers or other plant fibers or shavings. Figure 2 As can be seen, board 1 includes, from top to bottom, a first outer lignocellulose layer 2, a first cleaning agent layer 4, a core lignocellulose layer 7, a second cleaning agent layer 4, and a second outer lignocellulose layer 3.

[0078] The core lignocellulose layer 7 comprises lignocellulose particles, glue, and no cleaning agent. The outer lignocellulose layers 2 and 3 have the same composition and comprise lignocellulose particles, glue, and no cleaning agent, or comprise a cleaning agent in an amount less than 5 wt%, preferably less than 3 wt%, more preferably less than 1 wt%. The glue in the outer lignocellulose layers 2 and 3 is the same as that in the core lignocellulose layer 7, and is preferably urea-formaldehyde glue. Other possibilities are melamine-urea-formaldehyde glue, phenolic glue, pMDI glue, and bio-based glue. When the lignocellulose particles are sawdust, the sawdust in the core lignocellulose layer 7 is coarser than that in the outer lignocellulose layers 2-3. The density of the outer lignocellulose layers 2-3 is higher than that of the core lignocellulose layer 7, and the average density is preferably between 500 kg / m³. 3 Up to 1000 kg / m 3 For example, 650 kg / m 3 Up to 750 kg / m 3The cleaning agent layer 4 includes a cleaning agent and optionally includes adhesive, but preferably includes less than 5 wt% adhesive. The adhesive to lignocellulose particles in the core lignocellulose layer 7 has a weight ratio between 5% and 8%. The adhesive to lignocellulose particles in the core lignocellulose layer 7 has a weight ratio between 9% and 12%.

[0079] The scavenger is a sulfite-based scavenger, and preferably a metabisulfite. Metabisulfites are highly effective at neutralizing formaldehyde, resulting in low formaldehyde emissions from board 1. Metabisulfites are water-activated, meaning they are hydrolyzable.

[0080] The cleaning agent layers 4 are preferably substantially identical, meaning they have the same composition and / or thickness. Each cleaning agent layer 4 preferably occupies a maximum of 0.5% of the total thickness of the plate 1, preferably a maximum of 0.1%. The cleaning agent layers 4 preferably occupy 0.1 wt% to 2 wt% of the total weight of the plate 1, preferably 0.2 wt% to 1 wt%.

[0081] The outer lignocellulose layers 2 and 3 can occupy 4% to 20% of the total thickness of board 1, and preferably, the core lignocellulose layer 7 occupies 60% to 90% of the total thickness of board 1. For example, board 1 can have a thickness of 12 mm, including a 9 mm core lignocellulose layer 7, 1.5 mm outer lignocellulose layers 2-3, and a cleaning agent layer 4, the thickness of which is negligible compared to the lignocellulose layers 2, 3, and 7. Figure 2 In the diagram, the cleaning agent layer 4 is indicated by a thick line to show the location where the cleaning agent layer 4 is present. In practice, the cleaning agent layer 4 will be relatively thin.

[0082] The weight ratio of the cleaning agent to the gum in the core lignocellulose layer 7 is preferably between 1.5% and 17%, and more preferably between 3% and 9%.

[0083] The cleaner can be an encapsulated cleaner, such as one included in a casing that has cracked under pressure and / or temperature, wherein, for example, metabisulfite is located inside the casing.

[0084] Figure 3A decorative furniture panel 9 is shown, comprising a substrate of a board 1 according to a first aspect of the invention and optionally according to a second aspect of the invention. Here, panel 9 comprises, from top to bottom, a first decorative layer 8, a substrate, and a second decorative layer 8. The substrate comprises, from top to bottom, a first outer lignocellulose layer 2, a cleaning agent layer 4, a first core lignocellulose layer 7, a cleaning agent layer 4, a second core lignocellulose layer 7, a cleaning agent layer 4, and a second outer lignocellulose layer 3. The decorative layer 8 comprises one or more resin-impregnated papers, wherein the resin is, for example, melamine resin. For example, the resin-impregnated paper comprises (digitally) printed resin-impregnated paper and translucent / transparent resin-impregnated paper (e.g., an abrasion layer), which optionally includes hard particles (such as corundum) to provide additional abrasion resistance. The decorative layer 8 may also be an HPL (high-pressure laminate), which, in addition to comprising the printed resin-impregnated paper and the abrasion layer, comprises one or more resin-impregnated kraft paper. The resin in the resin-impregnated kraft paper may be a phenolic resin. The three cleaning agent layers 4 may be identical layers (e.g., thickness and composition) and may be... Figure 2 The same applies to the embodiments shown. The cleaning agent layer 4 located between the core lignocellulose layers 7 may also differ from the other cleaning agent layers 4. For example, the cleaning agent layer 4 located between the core lignocellulose layers 7 may include an encapsulated cleaning agent.

[0085] Figure 4 Manufacturing process is shown Figure 2 The possible manner in which the plate 1 is shown is as follows. Plate 1 is made by pre-pressing layers sequentially arranged one on top of another and pressing these layers into plate material 10. The plate material 10 is then sawn and optionally sanded to form plate 1. Figure 4 In, such as in Figure 4From left to right, it can be seen that the outer lignocellulose base layer 30 is first dispersed on the lower belt, followed by the dispersion of the first scavenger base layer 40 on the outer lignocellulose base layer 20, then the core lignocellulose base layer 70 is dispersed on the first scavenger base layer 40, followed by the dispersion of the second scavenger base layer 40 on the core lignocellulose base layer 70, and finally another outer lignocellulose base layer 20 is dispersed on the second scavenger base layer 40. When all the base layers 20, 30, 40, and 70 are dispersed one on top of the other, these base layers undergo pre-pressing by means of the first press 5. During pre-pressing, there is no temperature rise or almost no temperature rise. If encapsulated scavengers are present, they will be inactive during pre-pressing. Pre-pressing is followed by actual pressing at a heated dual-belt press 6. During pressing, temperature and pressure rise, and the scavengers (if they are heat- and / or pressure- and / or water-activated) become active, neutralizing the formaldehyde formed during pressing and resulting in low formaldehyde emissions during the manufacture of the board material 10. The amount of scavenger results in low formaldehyde emissions during the use of board 1 derived from board material 10. The composition of the base layers 20, 30, 40, and 70 corresponds to the composition of the corresponding layers 2, 3, 4, and 7 of the corresponding board 1 as described above.

[0086] Preferably, plate 1 has the following characteristics: Transverse tensile strength (according to EN 319): 0.4 N / mm 2 Up to 1.0 N / mm 2 between Bending strength (according to EN 310): 12 N / mm 2 Up to 18.0 N / mm 2 between Young's modulus (according to EN 310): at 2500 N / mm 2 Up to 3500 N / mm 2 between Particleboard 1 can be E1 grade (low formaldehyde) or even E0.5 grade (extremely low formaldehyde).

[0087] The composition of grassroots units at levels 20, 30, 40, and 70 and Figure 2 The corresponding layers 2, 3, 4, and 7 of board 1 are the same.

[0088] This invention is by no means limited to the embodiments described above; rather, this method can be implemented in various variations without departing from the scope of the invention as defined by the appended claims.

Claims

1. A sheet-like board comprising a lignocellulosic material, such as lignocellulosic particles, and comprising an adhesive and a cleaning agent, wherein, The lignocellulose material is pressed and bonded together using the adhesive, wherein the board (1) comprises at least three layers from top to bottom, wherein at least one of the layers contains a cleaning agent, and the amount of cleaning agent in at least two of the layers is different.

2. The plate-shaped plate according to claim 1, wherein, The lignocellulose material comprises lignocellulose particles, such as sawdust and / or wood fibers, and wherein the board (1) comprises at least three layers: at least two lignocellulose layers comprising at least lignocellulose particles and glue; and a cleaning agent layer (4) comprising at least a cleaning agent, wherein the cleaning agent layer (4) is located between the two lignocellulose layers.

3. The plate-shaped plate according to claim 2, wherein, The cleaning agent layer (4) occupies at most 1% of the total thickness of the plate (1), preferably at most 0.5%, and most preferably at most 0.1%.

4. The plate-shaped plate according to claim 2 or 3, wherein, The cleaning agent layer (4) accounts for 0.1 wt% to 2 wt% of the total weight of the plate (1), preferably 0.2 wt% to 1 wt%.

5. The plate-shaped plate according to any one of claims 2 to 4, wherein, The at least two lignocellulose layers comprise at least two types of lignocellulose layers, the at least two types of lignocellulose layers being a core lignocellulose layer (7) and an outer lignocellulose layer (2-3) forming the outer main surface of the board (1), wherein the core lignocellulose layer (7) and the outer lignocellulose layer (2-3) are different in one or more of the following aspects: - Amount of lignocellulose particles; - Amount of glue; - The type of lignocellulose particles, for example, the lignocellulose particles of the core lignocellulose layer (7) can be coarser than the lignocellulose particles of the outer lignocellulose layers (2-3), and / or the lignocellulose particles of the core lignocellulose layer (7) can contain more regenerated lignocellulose particles than the lignocellulose particles of the outer lignocellulose layers (2-3). - Type of adhesive; - The amount and / or type of cleaning agent; -thickness.

6. The plate-shaped plate according to claim 5, wherein, The board (1) comprises at least five layers, which are two cleaning agent layers (4) and three lignocellulose layers. The three lignocellulose layers are a core lignocellulose layer (7) and two outer lignocellulose layers (2-3). The board (1) comprises, from top to bottom, a first outer lignocellulose layer (2), a first cleaning agent layer (4), the core lignocellulose layer (7), a second cleaning agent layer (4), and a second outer lignocellulose layer (3).

7. The plate-shaped plate according to claim 6, wherein, The outer lignocellulose layer (2-3) occupies 4% to 20% of the total thickness of the board (1), and preferably, the core lignocellulose layer (7) occupies 60% to 90% of the total thickness of the board (1).

8. The plate-shaped plate according to claim 6 or 7, wherein, The total thickness of the outer lignocellulose layer (2-3) is between 0.3 mm and 3 mm.

9. The plate-shaped plate according to any one of claims 5 to 8, wherein, The weight ratio of the cleaning agent to the gum of the core lignocellulose layer (7) is between 1.5% and 17%, preferably 3% to 9%.

10. The plate-shaped plate according to any one of claims 2 to 9, wherein, The content of the cleaning agent in the cleaning agent layer (4) is at least 10 wt%, preferably at least 30 wt%, more preferably at least 50 wt%, and most preferably at least 80 wt%.

11. The plate-shaped plate according to any one of claims 2 to 10, wherein, The lignocellulose layer contains up to 0.5 wt% of a cleaning agent, preferably up to 0.1 wt% of a cleaning agent, and more preferably no cleaning agent.

12. The plate-shaped plate according to any one of claims 2 to 11, wherein, The content of lignocellulose material and gum in the lignocellulose layer is at least 97 wt%.

13. The plate-shaped plate according to any one of the preceding claims, wherein, The cleaning agent used in the plate (1) is water-activated, for example, hydrolyzable.

14. The plate-shaped plate according to any one of the preceding claims, wherein, The weight ratio of the cleaner to the adhesive is between 0.5% and 10%, preferably between 1% and 4%.

15. A board-like panel, optionally a board-like panel according to any one of the preceding claims, said board-like panel comprising a lignocellulosic material, an adhesive, and a cleaning agent, wherein, The lignocellulose material is pressed and bonded together using the adhesive, and wherein the cleaning agent used in the board (1) comprises a heat-activated and / or pressure-activated cleaning agent.

16. The plate-shaped plate according to any one of the preceding claims, wherein, The scavenger comprises one or more of the following: a scavenger containing sulfites, such as metabisulfites and bisulfites, for example sodium metabisulfite, sodium bisulfite, sodium sulfite, or potassium metabisulfite, potassium bisulfite, or potassium sulfite; a scavenger containing urea; or a scavenger containing hyperbranched polyamides.

17. The plate-shaped plate according to any one of the preceding claims, wherein, The lignocellulose material comprises wood chips, and wherein the board (1) is a particleboard.

18. A method for producing sheet material, wherein, Raw materials are provided, and production steps are performed to form the board material (10) from the raw materials, wherein the raw materials comprise at least: lignocellulosic materials, such as lignocellulosic particles, such as sawdust and / or wood fibers; glue; and a cleaning agent, wherein the production steps include at least the following production steps: - A basic step in which the raw materials are assembled together and transported to the molding unit; - Molding step, in which the integrated raw materials are pressed into a sheet material by the molding unit to form the sheet material (10). The feature is that, in the basic step, in order to integrate the raw materials together, at least three base layers are formed, one on top of the other, wherein at least one of the base layers contains a cleaning agent, and the amount of cleaning agent in at least two of the base layers is different.

19. The method according to claim 18, wherein, The lignocellulose material comprises lignocellulose particles, and wherein the at least three base layers comprise: at least two lignocellulose base layers, each containing at least lignocellulose particles and adhesive; and a cleaning agent base layer (40), containing at least a cleaning agent, wherein the cleaning agent base layer (40) is located between the two lignocellulose base layers.

20. The method according to claim 19, wherein, The at least two lignocellulose base layers comprise at least two types of lignocellulose base layers, the at least two types of lignocellulose base layers being a core lignocellulose base layer (70) and an outer lignocellulose base layer (20-30), wherein the outer lignocellulose layer of the board material (10) is derived from the outer lignocellulose base layer (20-30), wherein the core lignocellulose base layer (70) and the outer lignocellulose base layer (20-30) differ in one or more of the following aspects: - Amount of lignocellulose material; - Amount of glue; - The type of lignocellulose particles, for example, the lignocellulose particles of the core lignocellulose base layer (70) can be coarser than the lignocellulose particles of the outer lignocellulose base layer (20-30), and / or the lignocellulose particles of the core lignocellulose base layer (70) contain more regenerated lignocellulose particles than the lignocellulose particles of the outer lignocellulose base layer (20-30). - Type of adhesive; - The amount and / or type of cleaning agent; -thickness.

21. The method according to claim 20, wherein, Forming at least five base layers above one of the others, the at least five base layers being two of the cleaning agent base layers (40) and three of the lignocellulose base layers, the three lignocellulose base layers being one of the core lignocellulose base layers (70) and two of the outer lignocellulose base layers (20-30), the at least five base layers from top to bottom being a first outer lignocellulose base layer (20), a first cleaning agent base layer (40), the core lignocellulose base layer (70), a second cleaning agent base layer (40), and a second outer lignocellulose base layer (30).

22. The method according to any one of claims 18 to 21, wherein, The base layer is formed on top of another layer, preferably the base layer is formed on top of another layer by a dispersion method, and wherein the cleaning agent base layer (40) is at 5 g / m 2 Up to 100 g / m 2 The amount of cleaning agent is deposited, preferably dispersed, and preferably the amount of cleaning agent is 6 g / m³. 2 Up to 70 g / m 2 More preferably, the amount of scavenger is 10 g / m³. 2 Up to 30 g / m 2 .

23. The method according to any one of claims 18 to 22, wherein, The cleaning agent content of the cleaning agent base layer (40) is at least 10 wt%, preferably at least 30 wt%, more preferably at least 50 wt%, and most preferably at least 80 wt%.

24. The method according to any one of claims 18 to 23, wherein, The lignocellulose base layer contains up to 1 wt% of a cleaning agent, preferably up to 0.1 wt% of a cleaning agent, and more preferably no cleaning agent.

25. The method according to any one of claims 18 to 24, wherein, The content of lignocellulose material and gum in the lignocellulose base layer is at least 97 wt%.

26. The method according to any one of claims 18 to 25, wherein, The cleaning agent is water-activated, for example, hydrolyzable.

27. The method according to any one of claims 18 to 26, wherein, The integrated raw materials are formed into a cake, wherein the cake is pressed into a sheet material by the forming unit, and wherein steam is applied through the cake, for example by steam injection and / or vacuum, before being pressed by the forming unit, the steam preferably containing at least 95 wt% water.

28. A method for producing sheet material, said method optionally being the method according to any one of claims 18 to 27, wherein, Raw materials are provided, and production steps are performed to form the board material (10) from the raw materials, wherein the raw materials comprise at least: lignocellulosic materials, such as lignocellulosic particles, such as sawdust and / or wood fibers; glue; and a cleaning agent, wherein the production steps include at least the following production steps: - The basic step, in which the raw materials are assembled and transported to the molding unit; - Molding step, in which the integrated raw materials are pressed into a sheet material by the molding unit to form the sheet material (10). Furthermore, the cleaning agent comprises a heat-activated and / or pressure-activated cleaning agent.

29. The method according to any one of claims 18 to 28, wherein, The cleaning agent comprises one or more of the following: a cleaning agent containing sulfites, such as metabisulfites, or sodium metabisulfites, sodium bisulfites, sodium sulfite, or potassium metabisulfites, potassium bisulfites, or potassium sulfite; a cleaning agent containing urea; and a cleaning agent containing hyperbranched polyamides.

30. The method according to any one of claims 18 to 29, wherein, The particle size of the cleaning agent is such that up to 30% by weight of the cleaning agent can pass through a sieve with a mesh diameter of 160 μm, and / or at least 55% by weight of the cleaning agent cannot pass through a sieve with a mesh diameter of 300 μm.

31. The method according to any one of claims 18 to 30, wherein, The lignocellulose material comprises wood chips, and wherein the board material (10) is a particleboard material.

32. A decorative panel, preferably a floor panel, wall panel, or furniture panel, said decorative panel comprising a substrate having one or more substrate layers and a decorative top layer (8) applied to said substrate layers, characterized in that, At least one of the substrate layers is formed from a plate (1) according to any one of claims 1 to 17, or from the plate material (10) manufactured by the method according to any one of claims 18 to 31.

33. The decorative panel according to claim 32, wherein, The decorative panel (9) is rectangular and includes two pairs of opposing edges, wherein the at least one substrate layer includes an exposed portion at at least one of the edges.

34. The decorative panel according to claim 33, wherein, The exposed portion has a contour structure and at least partially forms a first connecting portion at the corresponding edge, the first connecting portion allowing the edge to connect to a second connecting portion at the opposite edge of a similar decorative panel, wherein, in the connected state, a lock is formed between the corresponding edges in a direction perpendicular to the plane of the connecting panel and / or in the plane of the connecting panel and in a direction perpendicular to the corresponding edge.

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