Sheet-shaped material and method for its production

Description

[0001] The invention relates to a plate-shaped material and a method for its production as well as the use of the plate-shaped material.

[0002] Board-shaped materials made from lignocellulosic fibers are used in a variety of ways because their production is inexpensive and technically sophisticated. A typical example is the use of high-density fiberboard (HDF), in which wood fibers are pressed into boards using binding agents, which are then usually coated with synthetic resin-impregnated paper. This coating hardens under the influence of pressure and temperature, forming a firmly bonded laminate. This laminate is cut up and the pieces are profiled at the edges, e.g. to be used as a glueless floor covering. However, the material is exposed at the profiled edges. In the presence of water, the wood fibers at the exposed edges begin to swell as a result of water absorption, which leads to a change in the shape of the wood-based panel. The water can be either freely flowing water or even high humidity. High humidity, which e.g.This can be seasonal or technically caused, and can be counteracted by the use of laminate, even if swelling is largely reversible, meaning that most of the swelling can be reversed by drying. However, swelling cannot be completely reversed, so that after the initial swelling, an unsightly open joint remains. Further alternatives for the production of panel-like materials from lignocellulosic fibers and binders are described in WO 2016 / 071007 A1, WO 2011 / 107900 A1, and US 2007 / 0042664 A1.

[0003] Alternatives to laminate are wood-plastic composites (WPC), an extruded blend of wood fibers and plastic. With a sufficiently high plastic content, WPC is dimensionally stable under the influence of water or moisture. Their production is described, for example, in DE 10 2007 041 438 A1, US 5,985,429 A1, CH 109249491 A, and US 2004 / 0235983 A1. However, their production requires the use of extruders that are not suitable for producing sheet materials of larger dimensions.

[0004] Finally, materials are available from which non-swelling board materials can be manufactured that do not contain wood fibers or other wood components. This eliminates the need for a renewable, abundantly available raw material that exhibits good strength properties. Examples of raw materials include Stone Plastic Composites (SPC) or polyvinyl chloride (PVC). These typically use halogens or terephthalates, making these products disadvantageous from an environmental perspective. The board material according to the invention is low-emission or emission-free; in particular, the emission of formaldehyde can be largely reduced or avoided, thus complying with the California state CARB 2 formaldehyde emission regulations. Volatile organic compounds (VOCs) can also be largely or completely avoided.

[0005] The document WO2016 / 071007 discloses a plate-shaped material according to the preamble of claim 1 and a method for producing a plate-shaped material according to the preamble of claim 11.

[0006] The object of the invention is to provide a plate-shaped material and a method for its production which has reduced swelling by using fibers.

[0007] This object is achieved by a board-shaped wood material according to claim 1 and a method according to claim 11. The use of the board-shaped material according to the invention is covered by claim 14.

[0008] The invention relates to a plate-shaped material comprising fibers and a binder, wherein the proportion of the binder relative to the plate-shaped material is more than 50 wt.%. Fibers within the meaning of this invention are solid particles that are elongated, i.e., whose diameter is many times smaller than the longest dimension of the particle. The dimensions of the fibers can be selected within a wide range; they depend in particular on the plate thickness and the requirements for the homogeneity of the plate-shaped material. The diameter of the fibers is from 10 µm to 5 mm, and the length of the fibers is from 0.05 mm to 100 mm.

[0009] The sheet material therefore has a larger proportion of binder than fibers. The binder content can also be expressed in relation to fibers, i.e., the binder content is specified with reference to the weight of the fibers used. For hygroscopic fibers that can absorb moisture (e.g., lignocellulosic fibers), the fiber content is specified as fibers dried to constant weight (absolutely dry fibers). The binder content of the sheet material is then more than 100 wt.%. Organic or inorganic fibers such as carbon fibers or fibers made from mineral or ceramic raw materials or glass fibers can be used for the sheet material according to the invention. Natural fibers, e.g.Lignocellulosic fibers or synthetic fibers, for example fibers made of thermoplastic material such as polyethylene or polypropylene, but also of polycarbonate, polyacrylic, polymethacrylic or polyurethane, can be used to produce the material according to the invention. In particular, mixtures of fibers, in particular mixtures of the aforementioned fibers, can be used to produce the material according to the invention. Mixtures of fibers make it possible to adjust properties of the material according to the invention, e.g. elasticity or flexural properties, dimensional stability, strength, but also manufacturing properties and processability. If lignocellulosic fibers, e.g. fibers from wood, bamboo or annual plants are used, inexpensive, easy-to-process fibers are available. The use of hygroscopic fibers is not excluded, particularly if these are determined prior to manufacture or processing.Pressing the material according to the invention must be at least partially dried.

[0010] The aforementioned lignocellulosic fibers include, in particular, all fibers obtained from plants through chemical or physical processes. Typical examples of physically obtained fibers are softwood fibers, hardwood fibers, or bamboo fibers, or fibers from other organic raw materials obtained through mechanical defibration. Examples of chemically obtained fibers include cellulose fibers from wood, annual plants, or other raw materials. Wood fibers obtained through mechanical defibration are particularly typically used, with the aim of minimizing the loss of lignin and hemicelluloses as much as possible. Blends of fibers can also be used, particularly to adjust material properties (strength properties, weight), but also to utilize the raw material fiber in a cost-optimized manner.Fibers within the meaning of this invention also include fiber bundles; smaller chips are also included, provided their fibers can still be largely coated with a binder.

[0011] The material according to the invention is plate-shaped, i.e., it generally has two main surfaces, which are also referred to below as the top and bottom. The thickness of the finished plate-shaped material can range from 1 mm to 500 mm, typically between 3 mm and 80 mm, mostly between 5 mm and 30 mm. A typical application may require a plate-shaped material thickness of 4 mm to 10 mm. The material according to the invention can have flat main surfaces, but the top and / or bottom can also be embossed, milled, or machined in some other way, resulting in a variable material thickness relative to the surface area of ​​the material. The material preferably has a substantially homogeneous composition across its thickness. The edges, whose height corresponds to the thickness of the material, can be machined using conventional tools. They can be sawn, cut, or milled.The panel-shaped material according to the invention can be used in a variety of ways. It can be used, for example, as a floor, ceiling, and / or wall covering, for the production of interior fittings or furniture, in particular for the interior fittings of vehicles such as vehicle cabins, but also outdoors, both as cladding, e.g., as a curtain wall, and for structural applications. The panel-shaped material according to the invention can be coated, colored, painted, or otherwise decoratively designed. In particular, surface coatings, such as those known, for example, from the field of wood-based materials, can be applied to the surface of the material according to the invention.

[0012] The material according to the invention differs from the WPC described above in that instead of plastic, in particular thermoplastic plastic, being formed with fibers to form a sheet-like material, a binder is used that enters into a cohesive and / or adhesive interaction with the fibers. Such binders are known, for example, from the prior art in wood-based material production. The binder used according to the invention comprises melamine as an alternative. Melamine is preferred as a binder because it is non-swelling and non-hygroscopic, as well as resistant to hydrolysis. Melamine can be used either alone as a binder or in combination with one or more other binders, hereinafter referred to as binders according to the invention.In the context of this invention, "in combination" means that mixtures of binders according to the invention can be used, wherein either the mixture of two or more binders is applied to the fiber simultaneously, e.g., as MF resin (melamine-formaldehyde resin). Or a combination of binders according to the invention is used, which are used one after the other, e.g., because they cannot be used as a mixture or because separate application of different binders has an advantageous effect. In combination with the melamine mentioned above as being according to the invention, or alternatively, the binders mentioned below, formaldehyde, phenol, methylene diphenyl isocyanate (MDI), also in emulsified form as eMDI or polymeric diphenylmethane diisocyanate (PMDI), can be used. As described above, two or more of the binders according to the invention can also be used in combination.It is preferred if the binder predominantly comprises melamine. It is further preferred if the proportion of melamine in the binder exceeds 20 wt.%, in particular 50 wt. The binder is preferably urea-free, since urea contributes to the hygroscopicity and thus the swelling of the lignocellulosic fibers, or rather does not prevent it. Thermoplastic binders are avoided. The sheet material according to the invention is preferably free of halogens (e.g., fluorine, chlorine), but also of terephthalates.

[0013] The binder forms the predominant portion of the plate-shaped material according to the invention. Preferably, the plate-shaped material, based on the fiber content, contains more than 100 wt.%, e.g., 101 wt.% or 102 wt.% up to 120 wt.% binder. Advantageously, the material contains more than 150 wt.% binder, particularly preferably more than 200 wt.% binder, and a maximum of 500 wt.% binder, in each case based on the fiber content.

[0014] According to the invention, the density of the material is between 1,000 kg / m 3 and 1,800 kg / m 3 , in particular between 1,000 kg / m 3 and 1,600 kg / m 3 , advantageously between 1,000 kg / m 3 and 1,200 kg / m 3 . Due to the high use of binder, the material according to the invention has a higher weight, e.g. between 1,000 kg / m 3 and 1,200 kg / m 3 , than, for example, a wood-based material such as an HDF board, which predominantly contains lignocellulosic fibers.

[0015] The material preferably contains fillers. Fillers can help optimize, and usually minimize, the weight of the plate-shaped material. Fillers can serve alternatively or additionally to optimize certain properties of the plates, e.g., conductivity, insulating properties, or strength properties. Fillers replace fibers in the material according to the invention. Since the material should exhibit minimal swelling in the presence of water, in particular minimized thickness swelling, non-hygroscopic or non-swelling fillers as well as fillers that are resistant to hydrolysis are preferred. Such fillers can be mineral particles, but also ceramic, synthetic, or glass particles. The size of the particles is preferably no larger than one millimeter, preferably between 10 µm and 800 µm. Mixtures of different particles can also be used, e.g., mixtures of different materials or sizes.Preferably, up to 30 wt.% based on the total weight of the sheet-like material is used, particularly preferably up to 20 wt.%, advantageously up to 15 wt.%. The lower limit of the amount used is determined by the detectability of the fillers.

[0016] According to a further development of the invention, the material comprises wet strength agents. Typical wet strength agents are polyamines, polyimines, e.g., polyethyleneimine, polyamides, e.g., polyacrylamides or polyamidoamine-epichlorohydrin (PAAE), polyalcohols, e.g., polyvinyl alcohols, or their copolymers. Wet strength agents further contribute to reducing the swelling of the sheet material according to the invention. They are used in amounts of up to 5% based on the weight of the sheet material, preferably in an amount of 0.05% to 2% by weight of the sheet material.

[0017] According to an advantageous embodiment of the invention, the sheet material comprises hydrophobic agents, e.g., paraffin or wax, which are typically used in amounts of up to 5 wt.% based on the weight of the sheet material, usually in amounts of up to 2 wt.%, often in an amount of 0.1 wt.% to 1 wt.%. The use of hydrophobic agents also contributes to reducing the swelling tendency of the sheet material.

[0018] The invention further relates to a method for producing a plate-shaped material comprising fibers and binder, wherein the proportion of the binder in the plate-shaped material is more than 50% by weight, comprising the steps: Providing fibers, providing the binder, preferably in liquid form, applying the binder to the fibers, forming a fiber cake, pressing the fiber cake while curing the binder to produce a plate-shaped material.

[0019] The steps of the process correspond to those of a conventional process, e.g., for producing a wood-based panel. However, according to the invention, a larger amount of binder is used than previously known, so that the weight fraction of the binder is greater than the weight fraction of the fibers.

[0020] If synthetic or inorganic fibers are used, it may be necessary to at least partially dry the binder on the fibers. If the fibers contain moisture, as is common with lignocellulosic fibers, for example, the moisture content should be adjusted before pressing the fiber cake so that a dimensionally stable, non-swelling and non-shrinking board is produced after pressing. The lignocellulosic fibers are often used with a moisture content of up to 120 wt.% or more before gluing. The lignocellulosic fibers can be dried before or after the application of the binder. During pressing, it is preferred if the lignocellulosic fibers have a moisture content of no more than 15 wt.%, i.e. a water content of up to 15 wt.% based on the total weight of the fibers. The moisture content is preferably between 5% and 10%.

[0021] The binder is usually provided in liquid form. It can be provided in pure form or—more typically—in solution, either in solvent or water. The binder is usually applied to the lignocellulosic fibers by spraying, e.g., through a plurality of spray nozzles that generate a spray of the binder and are arranged around a downward flow of fibers. A typical design for such a drying device is a blowline, for example, used in fiberboard production. The surface of the fibers is wetted with binder droplets. The binder-wetted fibers, after optionally being dried, are formed into a fiber cake and pressed. The binder hardens during this process, resulting in a board-like material.During curing, which occurs under the influence of pressure and temperature, irreversible chemical bonds are formed between the fibers and the binder, but also within the binder, unlike with WPC products.

[0022] Surprisingly, it has been found that the pressing conditions, particularly those for known wood-based materials with a reduced binder content compared to the invention, are essentially the same. Pressure, temperature, and pressing time, for example, are within the range of conventional HDF (high-density fiberboard) boards. The material according to the invention can be excellently produced in presses such as those used for the production of wood-based materials. This allows the production of board formats that—unlike WPC—are not limited to the production of narrow plank formats with a width of approximately 30 cm. Rather, conventional board formats, such as those commonly used for wood-based boards, can be provided.

[0023] The application of large amounts of binder to the fibers can be carried out in a single step or pass. However, it has been found that the application of the binder can advantageously be carried out in at least two steps, with a maximum of 50% of the binder being applied to the fiber per step. Particularly preferred is a maximum of 35%, in particular a maximum of 25%, of the binder being applied to the fiber per step. The step-by-step application of binder has proven particularly effective for lignocellulosic fibers.

[0024] According to a further advantageous embodiment, the fiber can be dried before or after the binder or a portion of the binder has been applied to the fiber. Drying the fiber after the binder or a portion of the binder has been applied prevents the fibers with binder on their surface from sticking to one another. The aim of drying is therefore not to completely remove water or solvent from the binder and / or the fiber. The aim is to prevent the reactivity of the binder from being impaired during curing under the influence of pressure and / or temperature. The aim is simply to ensure that the fibers no longer adhere or stick to one another during conveying or spreading. This makes them pourable and can, for example, be temporarily stored. However, they also become more spreadable because they do not stick to the spreading devices, in particular spreading heads.

[0025] If the binder is applied in at least two steps, the fibers are preferably dried after each application of a portion of the binder. Drying is preferably carried out with heated air, e.g., in a drying tunnel located downstream of a gluing device or in a drying shaft, which can be located, for example, below the gluing device.

[0026] The fiber cake is usually produced by scattering, as is usual with wood-based materials. The fibers, which have been either freshly glued or preferably dried with the entire amount of binder, are scattered onto a carrier, usually on a conveyor belt, usually in a homogeneous layer, but alternatively also in several layers. The fiber cake is first passed through a pre-press on the carrier if necessary and then pressed in a press. Any press that applies sufficient pressure and temperature is suitable, both a plate press in which the material is pressed between two metal sheets and, in particular, a continuous press in which the material is pressed between two circulating metal belts. Suitable pressing temperatures can be selected from 140 °C to 220 °C, preferably from 160 °C to 180 °C, suitable pressing pressures from 0.3 N / mm 2< to 5.5 N / mm 2< , in particular 1 N / mm 2< to 3 N / mm 2< .The pressing time is advantageously between 6 seconds / mm of board thickness (hereinafter: s / mm) and 60 s / mm, usually between 10 s / mm and 20 s / mm. A pre-press for compacting the fiber cake can be installed upstream of the actual pressing process. Optionally, a device for cooling the board-shaped material can be installed downstream of the press, in particular a device for cooling under a predetermined pressing pressure, which can be lower than the pressing pressure during the material pressing process.

[0027] The fillers, wet strength agents or hydrophobic agents described above can be added to the material according to the invention, typically before forming the fiber cake.

[0028] The material produced by the process according to the invention preferably has a surface that essentially comprises binder, particularly preferably a surface consisting of binder. Particularly when using hygroscopic fibers, e.g., lignocellulosic fibers, the aim is to have as few fibers as possible in the surface of the material in order to optimize thickness swelling as much as possible. Water in liquid form or, for example, as atmospheric moisture would be absorbed by the hygroscopic fibers, resulting in swelling of the material. This is undesirable. The high or predominant proportion of binder in the sheet-like material enables a material surface that predominantly or entirely comprises binder, or that has hardly any or no hygroscopic fibers.

[0029] The material according to the invention can be processed like a wood-based panel, e.g., like an HDF board. The surface can be coated, embossed, or milled; the edges can be profiled, e.g., for the production of floor panels. The panel-shaped material according to the invention can be laminated with synthetic resin-impregnated papers; it can be printed, painted, varnished, or processed in other ways. It is considered an advantage of this invention that the panel-shaped material can be processed and processed using existing equipment.

[0030] The invention further includes a device for producing the above-described plate-shaped material, comprising means for applying binder to lignocellulosic fibers, which, according to the invention, has means for applying binder to pre-glued lignocellulosic fibers. The term "applying binder" here refers to the application of binder. The means for applying binder to fibers are advantageously designed as nozzles that generate a spray of liquid binder. Fibers are guided through the spray of binder, onto which binder droplets from the spray are then deposited. Known means for applying binder to lignocellulosic fibers are designed to apply a maximum of 30% by weight of binder, based on the fibers to be glued.The method according to the invention can be carried out by passing the fibers to be glued through the known gluing means several times until sufficient binder is applied to the fibers. However, the invention proposes arranging several of the known gluing means such that the fibers to be glued are conveyed along a plurality of gluing means, each gluing means applying a portion of the binder to the lignocellulosic fibers until the desired total amount of at least more than 50% by weight of the board-shaped material has been applied to the fibers. Thus, in addition to the known means for gluing unglued fibers (fibers without binder), further means for gluing pre-glued fibers are used, to which a portion of the binder has already been applied.

[0031] The sheet-like material according to the invention can be adapted to various requirements through different combinations of fibers, binders, fillers, and optionally other additives such as waxes. It is therefore expressly pointed out that the features described above can be freely combined with one another.

[0032] The invention further relates to the use of the panel-like material described above. The panel-like material according to the invention is distinguished by the fact that it can be used in a variety of ways due to its minimal swelling, in particular the almost completely reduced thickness swelling in the area of ​​the edges. In interior design, the panel-like material can be used, for example, as a floorboard or floor laminate. In contrast to, for example, HDF floor panels, its use is also possible in damp and wet rooms because the edge profile, where the panel core is freely accessible to moisture, no longer swells significantly under the influence of water or high humidity or shrinks during drying. Thickness swelling of less than 2%, preferably less than 1%, is considered insignificant within the meaning of the invention. This means, for example,Using known devices for producing wood-based panels, a panel-shaped, essentially non-swelling material that is dimensionally stable with respect to water or air humidity can now be produced, which is not limited to narrow formats and which preferably maximizes the use of renewable raw materials. Of course, the panel-shaped material according to the invention can also be used as a wall or ceiling panel, as a furniture panel, particularly in the construction of damp and wet rooms or of laboratory and technical rooms or workshops, but not limited thereto. In exterior construction, the material according to the invention is suitable as a facade panel or for roofing. The panel-shaped material according to the invention can be used, for example, for terrace construction, including decking or outdoor flooring. In this way, it is possible to use the same floors or floor coverings for indoor and adjacent outdoor areas (patios, balconies, access routes).The sheet-like material according to the invention can preferably be used for outdoor constructions, in particular furniture. The construction of workshops, production halls, or stables, for example, can easily be carried out using the material according to the invention.

[0033] Details of the invention are explained below using exemplary embodiments. It shows: Fig. 1 a schematic representation of a plate-shaped material according to the invention

[0034] The figure shows a sheet-like material 1 with a top side 2 and a bottom side 3 as well as an edge 4. The material has fibers 5 embedded in a binder. The binder proportion is more than 50% by weight of the sheet-like material. This means that more binder is used than fiber 5. Natural, synthetic, organic and inorganic fibers can be used as fibers, both individually and in mixtures. Hygroscopic fibers such as wood, cellulose or linen fibers can also be used. Melamine is preferred as a binder, frequently in combination with formaldehyde or phenol but also in a mixture with PMDI. Examples of combinations of fibers and binders are described below. Example 1

[0035] For the test, the results of which are presented below in Table 1, lignocellulosic fibers, in this case softwood fibers, were used. The fibers were produced from steamed wood chips by defibringing in a refiner. Alternatively, any other lignocellulosic fibers or mixtures of such fibers can be used. The softwood fibers are used at a moisture content of 120% before gluing; before pressing, they are dried with the binder on them to a residual moisture content of 8%, i.e., one ton of fiber contains 80 kg of water.

[0036] For this experiment, more than 100 wt.%, in this case 108 wt.%, of binder based on dry wood was used. Here, a binder containing melamine-formaldehyde resin (MF resin) was used. The melamine-formaldehyde resin (MF resin) used had a solids concentration of 60% (measured at 60 min / 120°C). Thus, 180 grams of liquid binder containing 108 g of MF resin were applied to 100 grams of dry fiber (dry wood), taking the liquid content into account (108 g at 60% solids concentration = 180 g). "Dry wood" here refers to lignocellulosic fibers that were dried to constant weight at 105°C. "Dry wood" is a common reference measure for formulations containing lignocellulosic fibers. In the following examples, the absolute use of the binder is used.

[0037] Furthermore, 1.2 wt.% paraffin based on dry wood is used.

[0038] The binder is applied to the lignocellulosic fibers in four passes, with 27% by weight being applied to the fibers in each pass. The liquid binder is sprayed through nozzles in a conventional fiber sizing device. The spray mist generated by the nozzles deposits on the surface of the fibers, which pass through the spray mist, e.g., falling from top to bottom through the binder spray.

[0039] The fiber gluing process is followed by drying the glued fibers in a drying device, such as a warm air tunnel or shaft that applies heated air to the fibers. The goal of drying is not to completely remove all liquid, but rather to dry the binder to the point where it no longer sticks. The reactivity of the binder during curing under the influence of pressure and / or temperature should not be impaired by drying.

[0040] After drying, the fibers can be stored or further glued or processed. First, a second pass through the gluing device follows, in which another 27 wt.% MF resin is sprayed onto the fibers that have already been pre-glued after the first pass. After the second pass, the glued fibers are also dried until they no longer adhere to one another. A third and fourth pass through the gluing device and the drying agent is carried out in the same way. Alternatively, the 110 wt.% binder can be applied to the fibers in one or two passes, or alternatively in five or more passes. The amount of binder applied to the fibers per pass can vary from pass to pass.

[0041] After each pass, a portion of the glued fibers is removed and processed into a 7 mm thick sheet material. This is done by scattering a fiber cake, which is then pressed in a well-known continuously operating double-belt press at 180 °C and a pressure of 2.5 N / mm 2 for a pressing time of 15 s / mm. The resulting sheet has a thickness of 5.5 mm and a density of 1050 kg / m 3 . As a reference, a sheet material produced under the same conditions without increased binder addition is tested (Table 1, Pass 0).

[0042] The resulting sheet material is tested for swelling according to DIN 317 and for edge swelling according to DIN 13329. Thickness swelling is determined at one edge of the material as an absolute change in mm relative to the initial thickness of 7 mm and also as a relative change (%). Table 1 Thickness swelling for a plate-shaped material, thickness 7 mm, binder use increasing from 0 to 108 wt.% Passage No. 0 1 2 3 4 Absolute difference (mm) 1,47 0,50 0,25 0,21 0,12 Relative difference (%) 22,92 7,45 3,82 3,05 1,83

[0043] For the board material without added binder (pass 0), the maximum thickness swelling according to Table 1 is approximately 23%, as expected. Each pass, in which 27 wt.% MF resin is applied, reduces the thickness swelling at the edge of the board material. An exceptionally low edge swelling value of 1.83% is achieved when 108 wt.% binder, based on dry wood, is used. Example 2

[0044] For the fiber portion of the sheet-like material, Example 2 uses a 50:50 mixture of different fibers, e.g., wood fibers and carbon fibers, alternatively, e.g., recycled paper fibers and glass wool fibers, or alternatively, mineral fibers and cellulose fibers. The natural fibers (wood, recycled paper, cellulose fibers) are preferably dried before gluing; the fibers can be mixed before or after gluing and the optional drying of the binder. Both variants allow the production of a homogeneous mixture of glued fibers, which can then be scattered to form a fiber cake. Otherwise, Example 2 is identical to Example 1 with regard to the use of binder and paraffin. Example 3

[0045] Example 3 relates to a mixture of fibers and binder, in which 50 parts of polyethylene fibers, 20 parts of carbon fibers, and 10 parts of filler, e.g., glass particles, mineral or ceramic particles, form the fiber portion, which is glued with 115 wt.% binder, in this case, e.g., MF resin. The fiber-binder mixture is otherwise treated as in Example 1. Example 4

[0046] The aim is to produce a board made of fibers and a binder that can be used to create a floor covering, and thus can be coated with a decorative surface, particularly either with synthetic resin-impregnated paper or by painting. The material used is 40% by weight of fibers with a density of approximately 550 kg / m³ and 55% by weight of a binder, in this case an MF resin with a melamine content of more than 60%. In addition, 5% by weight of other substances are used, in this case 1.5% by weight of paraffin and 3.5% by weight of a "gray" dye. The dye is used to impart a uniform color to the board-shaped material.

[0047] The board-shaped material with the above-mentioned composition is produced on an industrial, continuous press and compared with HDF boards made from the same fiber material, but with a binder content of 15 wt.%, and having a density of 880 kg / m 3 . Table 2 Comparative tests on the swelling of an HDF board and a board according to the invention Attempt Plate thickness (mm) Binder (%) Density (kg / m 3< ) Transverse tensile strength (N / mm 2< ) Swelling of raw board (%) Edge swelling coated (%) Standard HDF 6 15% 880 >1,4 18 - 22 14 - 18 plate-shaped material 5,8 137,5% 1050 >4,5 0,1 - ,03 1,0 - 1,2

[0048] Table 2 above compares the two panels, indicating the panel thickness in mm as a gross value (before sanding) and the density in kg / m³. The panels were evaluated for transverse tensile strength (DIN EN 319), swelling (measured according to EN 317), and edge swelling (measured according to EN 13329).

[0049] Due to its high fiber content, the board according to the invention can be densified more effectively than fiberboard. The binding agent used is approximately nine times higher than in the state-of-the-art HDF board. The board-shaped material according to the invention exhibits three times higher transverse tensile strength and a 100-fold reduction in the swelling of the raw board. After laminating the top and bottom sides, the edge swelling is measured in the "coated" state. Only the edges are exposed to water, as the top and bottom sides of the board are sealed by the lamination and are no longer accessible to water. This test is particularly important for floor coverings because the edges of floor panels generally cannot be sealed and are therefore exposed to water. This test shows that the board material according to the invention exhibits a tenth reduction in edge swelling compared to a conventional HDF board.Both the HDF board and the board-like material according to the invention were manufactured on the same industrial production facilities.

Claims

1. Board-shaped material, having lignocellulosic fibers (5) and binder, wherein the proportion of the binder is more than 50 wt.% by weight of the board-shaped material (1), wherein the board-shaped material (1) is manufactured by pressing and wherein the density of the material is between 1,000 kg / m3 and 1,800 kg / m3, characterized in that the binder has melamine, formaldehyde, phenol, methylene diphenyl isocyanate (MDI), also in emulsified form as eMDI, polymeric diphenylmethane diisocyanate (PMDI) or combinations or mixtures of the aforementioned binders.

2. Material according to claim 1, characterized in that the material (1) has natural fibers, synthetic fibers, inorganic or organic fibers or mixtures of fibers.

3. Material according to claim 1 or 2, characterized in that the organic, natural fibers comprise lignocellulosic fibers, in particular softwood fibers, hardwood fibers, fibers from annual plants or bamboo fibers.

4. Material according to claim 2, characterized in that the synthetic fibers comprise fibers of thermoplastic material, in particular fibers of polyethylene or polypropylene, but also of polycarbonate, polyacrylic, polymethacrylic or polyurethane.

5. Material according to claim 2, characterized in that the inorganic fibers comprise fibers of mineral, ceramic or glassy materials.

6. Material according to one of the preceding claims, characterized in that the proportion of binder relative to atro wood is more than 101% by weight, up to 120% by weight, advantageously more than 150% by weight, particularly preferably more than 200% by weight.

7. Material according to one of the preceding claims, characterized in that the board-shaped material (1) has fillers, in particular non-hygroscopic or non-swelling fillers.

8. Material according to claim 7, characterized in that mineral, ceramic, synthetic or glass particles are used as filler.

9. Material according to one of the preceding claims, characterized in that the board-shaped material (1) has wet strength agents, in particular polyamines, polyimines, e.g. polyethyleneimine, polyamides, e.g. polyacrylamides or polyami-doamine-epichlorohydrin (PAAE), polyalcohols, e.g. polyvinylalcohols or copolymers thereof.

10. Material according to one of the preceding claims, characterized in that the board-shaped material (1) has hydrophobizing agents, e.g. paraffin or wax.

11. Method of manufacturing a board-shaped material comprising lignocellulosic fibers (5) and binder, wherein the proportion of the binder is more than 50% of the board-shaped material (1), and wherein the board-shaped material (1) has hydrophobizing agents, comprising the steps of: providing lignocellulosic fibers (5) providing the binder, preferably in liquid form, applying the binder to the fibers (5), forming a fiberboard cake, pressing the fiber cake to form a board-shaped material having a density of between 1,000 kg / m3 and 1,800 kg / m3 while curing the binder to generate a board-shaped material (1), characterized in that the binder has melamine, formaldehyde, phenol, methylene diphenyl isocyanate (MDI), also in emulsified form as eMDI, polymeric diphenylmethane diisocyanate (PMDI) or combinations or mixtures of the aforementioned binders.

12. Method according to claim 11, characterized in that the application of the binder is carried out in one or more steps.

13. Method according to one of claims 11 or 12, characterized in that the fiber (5) is dried at least in sections before or after applying the binder.

14. Use of a board-shaped material according to at least one of claims 1 to 10, characterized in that the board-shaped material (1) is used in interior construction, in particular as a floorboard or floor laminate, as a wall or ceiling board, as a furniture board, in the finishing of damp and wet rooms, in outdoor construction as a facade panel or for roof covering, for stables, for terrace construction including terrace floorboards or outdoor floors and constructions, in particular furniture for outdoor areas.