Binder composition containing a basic substance, respective methods, uses and products for producing a lignocellulose composite

Abstract

A method for producing a lignocellulose composite, a binder composition suitable for use in said method, and a lignocellulose composite that can be produced by the method of the present invention, and its use are described herein. Further, a kit for producing a binder composition for use in the production of a lignocellulose composite, and the respective use of such a binder composition are described herein.

Description

Technical Field

[0001] The present invention relates to a method for producing a lignocellulose composite, a binder composition suitable for use in said method, and a lignocellulose composite that can be produced by the method of the present invention, and its use. Furthermore, the present invention relates to a kit for producing a binder composition according to the present invention for use in the production of a lignocellulose composite, and the respective use of such a binder composition.

Background Art

[0002] Generally, in a method for producing a multi-layer or single-layer lignocellulose composite, a mixture of lignocellulose particles (i.e., particles consisting essentially of lignocellulose) and a binder is provided or prepared. This mixture is typically scattered, for example, to obtain a first layer of a multi-layer mat or to obtain a single-layer mat. When producing a multi-layer composite, two or more mixtures of lignocellulose particles are continuously scattered to obtain a mat having two or more individual layers. The resulting mat is then compressed, and the compressed mat or mixture is cured during or after compression, i.e., the mixture is treated such that the binder undergoes a curing process.

[0003] There is a need in the industry for an improved method for producing multi-layer or single-layer lignocellulose composites that can be obtained to the greatest extent possible from non-petrochemical substances, preferably renewable resources, and that uses a binder component suitable for reducing or avoiding potentially harmful substances such as formaldehyde and isocyanates or substances that release formaldehyde during or after the production process of the composite, such as N-methylol compounds.

[0004] The following documents deal with specific aspects of methods for producing multi-layer or single-layer lignocellulose composites.

[0005] U.S. Patent Application Publication No. 2011 / 0262648 describes durable thermosetting materials from reducing sugars and primary polyamines.

[0006] International Publication No. 2015 / 177114 pamphlet relates to a water-soluble carbohydrate - polyamino acid-based pre-reaction binder composition.

[0007] European Patent No. 3611225 specification deals with a binder composition, an article, and a method for manufacturing the article.

[0008] In light of the existing prior art, there is still a need for an improved method for producing a multi-layer or single-layer lignocellulose composite in which binder components that can be obtained from non-petrochemical resources, preferably renewable resources, are used as much as possible, and harmful or potentially harmful substances are reduced or avoided.

Prior Art Documents

Patent Documents

[0009]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0010] Correspondingly, the main object of the present invention is an improved method for producing a multi-layer or single-layer lignocellulose composite, in particular, when the obtained lignocellulose composite is compared with a similar lignocellulose composite not produced according to the method of the present invention, a method having increased strength, or a lignocellulose composite having a strength comparable to that of a similar lignocellulose composite not produced according to the method of the present invention and having a shorter heating and / or pressing time required to obtain the lignocellulose composite.

[0011] A further object of the present invention was to provide a binder composition suitable for use in an improved method for producing a multi-layer or single-layer lignocellulose composite, and a lignocellulose composite obtained from said method.

[0012] Yet another object of the present invention is that the binder composition reduces or avoids the emission of harmful or other undesirable volatile compounds during or after production, and enables safe disposal and / or reduction of potentially environmentally harmful waste, and provides a method for producing a multi-layer or single-layer lignocellulose composite and its respective binder composition, which should contain the highest possible proportion of bio-based components.

Means for Solving the Problems

[0013] The main and other objects of the present invention are at least the following steps: S1) Providing or preparing a mixture, wherein the mixture comprises at least - lignocellulose particles, and - a binder composition, preferably an aqueous binder composition (i.e., a binder composition containing water), preferably at least as a component for curing the binder or binder composition c1) One or more amino acid polymers having two or more primary amino groups, which are polymerization products of amino acid monomers and optionally other monomers, c2) One or more alpha-hydroxycarbonyl compounds, and pK where pK(OH)<3 B One or more basic substances having a Binder composition containing Including steps S2) Compressing the mixture from step S1) to receive the compressed mixture; S3) Preferably during and / or after compression in step S2), applying heat and / or pressure to the mixture, so that as a result, the binder of the binder composition (preferably, the curable component of the binder or the binder composition) is cured, and a lignocellulose composite (or a layer of a multilayer lignocellulose composite) is obtained; It has been found here that it can be realized by a method for producing a lignocellulose composite comprising one (in particular "single-layer lignocellulose composite") or more lignocellulose composite layers (in particular "multilayer lignocellulose composite").

Embodiments for Carrying out the Invention

[0014] The present invention and its preferred variations and preferred combinations of parameters, characteristics and elements are defined in the appended claims. Preferred embodiments, details, modifications and advantages of the present invention are also defined and described in the following description and the examples shown below.

[0015] Here, the inventors have found that the method for producing a multilayer or single-layer lignocellulose composite according to the present invention described herein shows certain improvements over similar methods known from the prior art (and as shown in the following examples). In particular, the said method according to the present invention results in a lignocellulose composite having increased strength (increased internal bond strength) when compared to similar lignocellulose composites not produced according to the method of the present invention, or the heating and / or pressing time required to obtain a lignocellulose composite having the same strength as similar lignocellulose composites not produced according to the method of the present invention is reduced.

[0016] Unless otherwise specified, the preferred embodiments, aspects or features of the present invention can be combined with other embodiments, aspects or features, particularly other preferred embodiments, aspects or features, regardless of the category to which the embodiments, aspects or features pertain. Combinations of preferred embodiments, aspects or features with other preferred embodiments, aspects or features will in any case result in preferred embodiments, aspects or features.

[0017] As used herein, the term "lignocellulose particle" refers to and includes any type, size and shape of lignocellulose particle, such as fibers, chips, strands, flakes, sawmill waste and wood shavings, or mixtures thereof. In addition, any type of lignocellulosic biomass, such as oak, beech, birch, pine, spruce, larch, eucalyptus, ash, poplar, paulownia, fir, tropical trees, sisal, jute, flax, coconut, kenaf, hemp, banana, straw, cotton stalk, bamboo, etc., can be used as the source of the lignocellulose particles. For generating the lignocellulose composite of the present invention, lignocellulose particles from both unused wood and / or waste wood, such as old furniture, can be used. According to the present invention, it is further possible to use a mixture of different types of lignocellulose particles in the generation of the lignocellulose composite.

[0018] As used herein, the term "single-layer lignocellulose composite" (i.e., a lignocellulose composite comprising one layer of lignocellulose composite) refers to and includes any single-layer composite material containing lignocellulose particles and a cured binder that binds the lignocellulose particles. Further, the term "single-layer" specifies that the lignocellulose composite comprises only one layer of lignocellulose material and binder, and is preferably produced by a method that includes a single step of scattering the lignocellulose particles. The "single-layer lignocellulose composite" can be of any shape, such as rectangular, square, circular, triangular, etc. The "single-layer lignocellulose composite" can also be of any thickness, density, and color as long as it contains lignocellulose particles and a cured binder. The "single-layer lignocellulose composite" can also contain several other compounds different from the lignocellulose particles and the binder. The lignocellulose particles used in the production of the "single-layer lignocellulose composite" are of the same type or different types of lignocellulose biomass (see above for preferred types).

[0019] As used herein, the term "multilayer lignocellulose composite" (i.e., a lignocellulose composite comprising more than one layer of lignocellulose composite) refers to and includes any multilayer composite containing lignocellulose particles and a hardening binder that binds the lignocellulose particles, in which distinguishable (individual) layers are present within the composite. The multilayer lignocellulose composite preferably includes at least two distinguishable (individual) layers, particularly a core layer and an upper and a lower surface layer, or four or more layers within the same composite material. Adjacent layers of the multilayer lignocellulose composite are distinguishable with respect to their composition, density, color, or any other property, and adjacent layers include the same type of lignocellulose particles and / or binder or different types of lignocellulose particles and / or binder. The (individual) layers may also include or consist of materials different from the lignocellulose particles and / or binder, such as plastics, fabrics, paint coats, etc. derived from foreign substances in waste wood. The lignocellulose particles used in the production of the individual layers of the "multilayer lignocellulose composite" are of the same type or different types of lignocellulose biomass (see above for preferred types). The lignocellulose particles used in the production of the separate (individual) layers of the "multilayer lignocellulose composite" are of the same type or different types of lignocellulose biomass (see above for preferred types), or are the same or different mixtures of two or more of such types of lignocellulose biomass. Further, the term "multilayer" specifies that the lignocellulose composite includes at least two individual layers, at least one, preferably two or more, of which contain lignocellulose material and a binder, and one or more or all of said layers are preferably produced by a multi-step process that includes the step of scattering lignocellulose particles for each (individual) layer of lignocellulose material and binder.

[0020] As used herein, the term "amino acid polymer having two or more primary amino groups" (of component c1 of the binder composition) refers to an amino acid (preferably an amino acid monomer, more preferably two or more amino acid monomers), and optionally, preferably a) an amine containing at least two amino groups, which is not an amino acid, b) an organic compound having at least two carboxyl groups, preferably selected from the group consisting of organic dicarboxylic acids and organic tricarboxylic acids, which is preferably not an amino acid, a polymer compound (i.e., one or more polymer compounds) which is a polymerization product (i.e., a polymerization product) with other monomers selected from the group consisting of (the monomers of the polymer compound are preferably connected or bonded to each other via an amide bond), Based on the total (weight) of the monomers forming the amino acid polymer having two or more primary amino groups, preferably at least 50% by weight, preferably at least 75% by weight, preferably at least 85% by weight, preferably at least 90% by weight, preferably at least 95% by weight, preferably at least 97.5% by weight, preferably at least 99% by weight, preferably 100% by weight of amino acids (preferably amino acid monomers) are used as monomers for the polymerization reaction.

[0021] As used herein, the terms "weight %" and "mass %" are used synonymously.

[0022] Generally, and for the purposes of the present invention, the amino acid polymer having two or more primary amino groups may include or consist of dimers (n = 2), trimers (n = 3), oligomers (n = 4 to 10) and / or macromolecules (n>10) (wherein n is the number of monomers (preferably amino acid monomers) that have reacted to form the dimers, trimers, oligomers and macromolecules of the amino acid polymer having two or more primary amino groups).

[0023] One of ordinary skill in the art will select monomers to produce the amino acid polymer having two or more primary amino groups such that the desired amino acid polymer having two or more primary amino groups is received.

[0024] As used herein, the term “amino acid polymer having two or more primary amino groups” also includes derivatives obtained by modification of an amino acid polymer having two or more primary amino groups after polymer synthesis. The modification is carried out by reaction with the following reagents: i) Alkyl carboxylic acids or alkenyl carboxylic acids such as, for example, octanoic acid, nonanoic acid, decanoic acid, dodecanoic acid, hexadecenoic acid, stearic acid, oleic acid, linoleic acid and / or linolenic acid and / or their Li, Na, K, Cs, Ca or ammonium salts, and / or ii) Polyalkylene oxides terminated by amino groups and / or acid groups and having one, two or more functional valences, preferably polyethylene oxide, polypropylene oxide and / or polyethylene - propylene oxide, and / or iii) Alkylene oxides such as, for example, ethylene oxide, propylene oxide and / or butylene oxide, and / or iv) Lactones such as epsilon - caprolactone, delta - valerolactone, gamma - butyrolactone, and / or v) Alcohols such as alkanols such as oleyl alcohol can be effected.

[0025] Amino acids that can be present as monomers in an amino acid polymer having two or more primary amino groups are organic compounds containing at least one primary amine (-NH2) functional group and at least one carboxyl (-COOH) functional group. The amino acids are preferably selected from the group consisting of lysine, histidine, isoleucine, leucine, methionine, phenylalanine, threonine, tryptophan, valine, arginine, aspartic acid, glutamic acid, serine, asparagine, glutamine, cysteine, selenocysteine, glycine, alpha-alanine, beta-alanine, tyrosine, gamma-aminobutyric acid, epsilon-aminocaproic acid, ornithine, diaminopimelic acid, 2,3-diaminopropionic acid, 2,4-diaminobutyric acid, or mixtures thereof. The amino acids can be used in their L- or D- or racemic forms. The amino acids can also be used in their cyclic lactam forms, such as epsilon-caprolactam.

[0026] Preferred amino acids (as monomers for forming the amino acid polymer having two or more primary amino groups) used in the polymerization reaction are diamino acids containing two amine groups, preferably two primary amine groups (-NH2) and at least one carboxyl (-COOH) group. Such diamino acids are preferably selected from the group consisting of ornithine, diaminopimelic acid, 2,3-diaminopropionic acid, 2,4-diaminobutyric acid and lysine. Lysine is preferred as an amino acid monomer for forming the amino acid polymer having two or more primary amino groups. For this purpose, L-lysine is even more preferred.

[0027] Preferably, the amino acid polymer having two or more primary amino groups has 800 g / mol ≤ M w ≤ 10000 g / mol, preferably 1000 g / mol ≤ M w ≤ 8000 g / mol, more preferably 1000 g / mol ≤ M w ≤ 5000 g / mol, even more preferably 1000 g / mol ≤ M wIt has a weight average molecular weight in the range of ≦3500 g / mol.

[0028] The amino acid polymer having two or more primary amino groups may be linear, branched, or partially linear and partially branched.

[0029] Preferred amino acid polymers having two or more primary amino groups for the purposes of the present invention are described below.

[0030] As used herein, the term "(component c2 of the binder composition) 'alpha-hydroxycarbonyl compound'" refers to a compound that can react with an amine compound and optionally an additional crosslinking agent to form a cured binder. The alpha-hydroxycarbonyl compound may contain at least one reducing sugar.

[0031] The term "reducing sugar" refers to one or more sugars that contain a free aldehyde group or that can isomerize, i.e., tautomerize, to contain a free aldehyde group, according to its ordinary meaning in the art.

[0032] For use in the binder composition of component c2), such an alpha-hydroxycarbonyl compound must be able to react with the amino acid polymer having two or more primary amino groups used in component c1).

[0033] The binder composition contains, as components, preferably one or more amino acid polymers having two or more primary amino groups as component c1) and one or more alpha-hydroxycarbonyl compounds as c2) for curing the binder or the binder composition. Components c1) and c2) are also referred to herein as "curable components", preferably "thermosetting components" of the binder or the binder composition. More specifically, components c1) and c2) are also collectively referred to herein as the "binder", and are separately referred to as the "curable components", preferably the "thermosetting components" of the binder.

[0034] For the method of the present invention described herein (or preferably the method of the present invention described herein), it is preferred that at least one of the one or more α-hydroxycarbonyl compounds of component c2) is selected from the group consisting of glycolaldehyde, glyceraldehyde, 1,3-dihydroxyacetone, hydroxyacetone, arabinose, xylose, glucose (dextrose), mannose, fructose, sucrose, ribose, lyxose, galactose, allose, altrose, talose, gulose, idose, psicose, sorbose, maltodextrin, tagatose, and mixtures thereof.

[0035] More preferred α-hydroxycarbonyl compounds for the purposes of the present invention are described below.

[0036] As used herein, the term "basic substance having a pK B value of ≦ 3" includes organic and inorganic substances. For the purposes of the present invention, inorganic basic substances, particularly inorganic hydroxides, having a pK B value of ≦ 3 are preferred. More preferred basic substances having a pK B value of ≦ 3 for the purposes of the present invention are described below.

[0037] One or more amino acid polymers of component c1) of the binder composition contain one or more polylysines, or are one or more polylysines, preferably, one or more polylysines have - a weight average molecular weight M of ≧ 800 g / mol, preferably ≧ 1000 g / mol, more preferably ≧ 1150 g / mol w and; and / or - a weight average molecular weight M of ≦ 10000 g / mol, preferably ≦ 8000 g / mol, more preferably ≦ 5000 g / mol, even more preferably ≦ 3500 g / mol w and; and / or - 800 g / mol ≦ M wM ≤ 10000 g / mol, preferably 1000 g / mol ≤ M w M ≤ 8000 g / mol, more preferably 1000 g / mol ≤ M w M ≤ 5000 g / mol, even more preferably 1000 g / mol ≤ M w The weight-average molecular weight M in the range of ≤ 3500 g / mol w has; and / or - As monomers incorporated into their polymer structures, based on the total mass of the polymer, it contains ≥ 10% by mass, preferably ≥ 20% by mass of lysine monomers; and / or - As monomers incorporated into their polymer structures, based on the total mass of the polymer structure, it contains at least 85% by mass, preferably at least 95% by mass, more preferably at least 99% by mass, even more preferably 100% by mass of lysine monomers, The method of the present invention described herein (or preferably the method of the present invention described herein) is preferred.

[0038] Preferably, the weight percentage (weight percent) or mass percentage (mass percent) of lysine (monomer), preferably L-lysine, in one or more polylysines can be determined by methods known per se, for example, by complete hydrolysis of polylysine and subsequent analysis of the obtained monomers by HPLC / MS.

[0039] The weight-average molecular weight M of one or more amino acid polymers having two or more primary amino groups containing polylysine w is preferably generally known in the art and is determined by size exclusion chromatography (SEC) as specified in more detail in the following Examples section.

[0040] The one or more polylysines can be linear or branched or partially linear and partially branched.

[0041] As used herein, the term "polylysine" refers to a polymerization product of monomer lysine, preferably L-lysine, and optionally, a) an amino acid, b) an amine containing at least two amino groups and not being an amino acid, c) a dicarboxylic acid not being an amino acid and a tricarboxylic acid not being an amino acid, and a further monomer selected from the group consisting of: preferably, based on the total amount of monomers used for the polymerization reaction to produce polylysine, the proportion of lysine in mass % (weight %) used as a monomer for the polymerization reaction to produce polylysine is ≧10 mass %, preferably ≧20 mass %, or or based on the total amount of monomers used, at least 85 mass %, preferably at least 95 mass %, more preferably at least 99 mass %, even more preferably 100 mass % of lysine is used as a monomer for the polymerization reaction to produce said polylysine.

[0042] For the purpose of the present invention, polylysine is preferably a homopolymer of lysine, preferably a homopolymer of L-lysine.

[0043] Generally and for the purpose of the present invention, polylysine may contain or consist of dimers (n = 2), trimers (n = 3), oligomers (n = 4 - 10) and / or macromolecules (n > 10) (wherein n is the number of lysine monomers that have reacted to form dimers, trimers, oligomers and macromolecules of polylysine). Further, lysine monomers may be present in limited amounts in a mixture with polylysine, for example due to incomplete conversion of monomers during the polymerization reaction to produce polylysine.

[0044] In the present text, the term polylysine also preferably includes polylysine derivatives that are prepared by, or can be prepared by, a modification reaction between (i) amino groups present in polylysine obtained by polymer synthesis and (ii) electrophiles such as carboxylic acids, epoxides, and lactones, and the total amount of amino groups reacted in the modification reaction is 20% or less, preferably 10% or less, based on the total amount of amino groups in the polylysine obtained by polymer synthesis (i.e., before modification).

[0045] It has been found in unique experiments that the method according to the invention in which the binder composition comprises, as component c1), an amino acid polymer having two or more primary amino groups, in particular polylysine, is suitable for the production of lignocellulose composites which show increased strength (or require a shorter pressing time to achieve a similar strength) when compared to similar lignocellulose composites in which other amino-functionalized compounds are used in the binder composition. For example, it has been reported in WO 2015 / 177114 that a binder composition containing lysine monomer and hexamethylenediamine (HMDA) as amino-functionalized components could not be fully cured in the presence of reducing sugar and sodium hydroxide.

[0046] - at least one of the one or more alpha-hydroxycarbonyl compounds of component c2) of the binder composition is selected from the group consisting of glycolaldehyde, glyceraldehyde, 1,3-dihydroxyacetone, hydroxyacetone, arabinose, xylose, glucose, mannose, fructose, sucrose, and mixtures thereof, preferably selected from the group consisting of glycolaldehyde, glyceraldehyde, 1,3-dihydroxyacetone, hydroxyacetone, and mixtures thereof; more preferably, at least one of the one or more alpha-hydroxycarbonyl compounds is hydroxyacetone; and / or -(i) The total mass of one or more amino acid polymers of component c1) of the binder composition: (ii) The ratio of the total mass of one or more alpha-hydroxycarbonyl compounds of component c2) of the binder composition, or used in the preparation of the binder composition, is in the range of ≧60:40 to ≦90:10, preferably ≧65:35 to ≦80:20, more preferably ≧65:35 to ≦75:25. The method of the present invention described herein (or preferably the method of the present invention described herein) is also preferred.

[0047] When hydroxyacetone (also known as 1-hydroxy-2-propanone, CAS RN 116-09-6) is used as the alpha-hydroxycarbonyl compound of component c2), it has been found in unique experiments that a particularly high internal bond strength can be achieved in the lignocellulose composite produced by the method according to the present invention, or that the pressing time required to achieve a specified internal bond strength is shortened compared to the use of a similar binder in which an alpha-hydroxycarbonyl compound other than hydroxyacetone is used. Particularly good results (with respect to the shortening of internal bond strength and / or pressing time) are achieved in the method according to the present invention when polylysine is used as component c1) of the binder composition and hydroxyacetone is used as component c2) of the binder composition.

[0048] Similarly, it has been found in unique experiments that the most practical results are achieved for the lignocellulose composite produced by the method according to the present invention when the ratio of (i) the total mass of one or more amino acid polymers of component c1) of the binder composition: (ii) the total mass of one or more alpha-hydroxycarbonyl compounds of component c2) of the binder composition is selected within the preferred range outlined above.

[0049] - pK of ≦3 B One or more basic substances having a value of ≦2.5 pK B Preferably having a pK value of ≦2 B One or more substances having a value; and / or - one or more, preferably all, of the basic substances having a pK value of ≦ 3 B are selected from the group consisting of: ■ preferably an alkali metal hydroxide selected from the group consisting of LiOH, NaOH, KOH and mixtures thereof; more preferably NaOH; and ■ preferably an alkaline earth metal hydroxide selected from the group consisting of Mg(OH)2 and Ca(OH)2 and mixtures thereof, more preferably Ca(OH)2 and are selected from the group consisting of: and / or - the total amount of one or more basic substances (preferably selected from the group consisting of the alkali metal hydroxides and alkaline earth metal hydroxides defined above) having a pK value of ≦ 3, which are component c3) of the binder composition or used in the preparation of the binder composition, is in the range of ≧ 3 to ≦ 9% by mass, preferably ≧ 4 to ≦ 8% by mass, more preferably ≧ 5 to ≦ 7% by mass, based on the total amount of one or more amino acid polymers of the binder composition which are component c1) and one or more alpha-hydroxycarbonyl compounds of the binder composition which are component c2); B The method of the invention described herein (or preferably the method of the invention described herein) is also preferred.

[0050] Furthermore, it has been found in our own experiments that when using one or more basic substances having a pK value of ≦ 3 in the method according to the invention, the internal bond strength of the lignocellulose composite produced by the method of the invention is further improved (or the pressing time for achieving the defined internal bond strength respectively is shortened), regardless of the alpha-hydroxycarbonyl compound used as component c2). B

[0051] Furthermore, the binder composition provided or prepared in step S1) further comprises a carrier liquid, preferably water. Preferably, - One or more amino acid polymers that are component c1) are present in the binder composition in a total amount in the range of ≧20 to ≦50% by mass, preferably ≧25 to ≦45% by mass, more preferably ≧25 to ≦40% by mass, based on the total mass of components c1) to c3) and the carrier liquid, or are used in the preparation of the binder composition; and / or - One or more alpha-hydroxycarbonyl compounds that are component c2) are present in the binder composition in a total amount in the range of ≧3 to ≦20% by mass, preferably ≧5 to ≦15% by mass, more preferably ≧7 to ≦12% by mass, based on the total mass of components c1) to c3) and the carrier liquid, or are used in the preparation of the binder composition. The method of the present invention described herein (or preferably the method of the present invention described herein) is preferred.

[0052] It has been found in unique experiments that when the binder composition has the proportions defined above for component c1) and / or c2), the best practical results of the lignocellulose composite produced by the method according to the invention are achieved.

[0053] Furthermore, in the mixture provided or prepared in step S1) of the method, the total amount of one or more amino acid polymers of the binder composition that are component c1) and one or more alpha-hydroxycarbonyl compounds of the binder composition that are component c2) is present in the binder composition in a range of ≧3 to ≦8% by mass, preferably ≧3.5 to ≦7.5% by mass, more preferably ≧4 to ≦6.5% by mass, based on the total amount of the oven-dried lignocellulose particles of the mixture, or is used in the preparation of the binder composition. The method of the present invention described herein (or preferably the method of the present invention described herein) is preferred.

[0054] Surprisingly, when the total amounts of components c1) and c2) are relatively low as described above, a lignocellulose composite that is sufficiently stable and robust for many applications, such as use as a lignocellulose composite board in the furniture industry, can be obtained.

[0055] Generally, in step S1) for preparing the mixture, the lignocellulose particles may be blended with one or more or all of the components of the binder composition, and / or one or more or all of the components of the binder composition may be sprayed onto the lignocellulose particles. On the other hand, the components of the binder composition may or may not be premixed before blending or spraying.

[0056] However, in step S1), one or more amino acid polymers having two or more primary amino groups as component c1), and one or more basic substances having a pK B value of ≤ 3 as component c3) are premixed with each other, and then the resulting premix is contacted with the lignocellulose particles, preferably sprayed onto the lignocellulose particles. Preferably, one or more alpha-hydroxycarbonyl compounds as component c2) are contacted with the lignocellulose particles separately from the premix, preferably sprayed separately onto the lignocellulose particles. Preferably, the method of the present invention described herein (or preferably the method of the present invention described herein) is preferred, as a result of which the mixture is obtained.

[0057] Preferably, one or more amino acid polymers having two or more primary amino groups as component c1), and a pK of ≤ 3 as component c3) BThe preliminary mixture comprising one or more basic substances having a value and preferably water (thus obtaining an aqueous preliminary mixture) has a pH value (after preparation, preferably immediately after preparation and before bringing said preliminary mixture into contact with said lignocellulose particles and / or component c2)), having a pH value in the range of 10 to 14, preferably 11 to 14, more preferably 11 to 13. Preferably, the pH value of said preliminary mixture, preferably said aqueous preliminary mixture, is determined using an ion-sensitive field effect transistor sensor (preferably of the type "Tophit CPS441" manufactured by Endress+Hauser of Germany) at 22 °C.

[0058] In the process of the present invention, the binder composition may further comprise one, two or more compounds independently selected from the group consisting of alkali salts and alkaline earth salts (preferably sodium nitrate), hydrophobizing agents (preferably paraffin and mixtures containing paraffin, more preferably paraffin emulsions), dyes, pigments, antifungal agents, antibacterial agents, rheology modifiers, fillers, release agents, surfactants and surface-active agents.

[0059] The method of the present invention is preferred which includes steps carried out batchwise and / or steps carried out continuously for producing the lignocellulose composite (preferably as defined as preferred herein). Thus, the method of the present invention is suitable for a wide variety of different production facilities and provides numerous options for the production of the desired lignocellulose composite, i.e., a multi-layer lignocellulose composite or a single-layer lignocellulose composite comprising one or more, preferably two or more, lignocellulose composite layers. As a preferred method of the present invention, batch production is preferably selected for producing individual lignocellulose composites having, for example, different shapes, thicknesses, etc., while a completely continuous method is preferably selected for producing more uniform lignocellulose composites having, for example, similar shapes, thicknesses, etc.

[0060] A preferred method of the present invention can also preferably include one or more steps carried out in a batch mode and one or more steps carried out continuously. One preferred example of such a composite method is the production of a single-layer lignocellulose composite in a continuously carried out method step and the subsequent batch (and preferably individual) production of a multi-layer lignocellulose composite using the continuously produced single-layer lignocellulose composite as a starting material, for example as the core layer of the multi-layer lignocellulose composite.

[0061] The lignocellulose composite is - High-density fiberboard (HDF); - Medium-density fiberboard (MDF); - Low-density fiberboard (LDF); - Wood fiber insulation board; - Oriented strand board (OSB); - Chipboard; and - A natural fiber board preferably having fibers from the group consisting of sisal, jute, flax, coconut, kenaf, hemp, banana and mixtures thereof; a lignocellulose board selected from the group consisting of The lignocellulose board is - A single-layer lignocellulose board, or - A multi-layer lignocellulose board, preferably a multi-layer lignocellulose board having a core layer and upper and lower surface layers, the method of the present invention described herein (or preferably the method of the present invention described herein) is also preferred.

[0062] According to a preferred embodiment of the method according to the invention, the production method results in a lignocellulose composite which is preferably a single-layer lignocellulose board or a multi-layer lignocellulose board, more preferably a multi-layer lignocellulose board. The multi-layer lignocellulose board is more preferably a board having at least a core layer, as well as an upper surface layer and a lower surface layer. In that case, the total number of layers is three or more. If the number of layers is four or more, there is one or more intermediate layers. A three-layer board having one core layer, an upper surface layer and a lower surface layer is preferred.

[0063] Accordingly, a preferred embodiment of the present invention relates to a method for producing a high-density fiber board (HDF), a medium-density fiber board (MDF), a low-density fiber board (LDF), a wood fiber insulation board, an oriented strand board (OSB), a chip board or a natural fiber board, wherein the board is preferably either a single-layer lignocellulose board or a multi-layer lignocellulose board, more preferably a multi-layer lignocellulose board, and most preferably a three-layer lignocellulose board.

[0064] In step S3) of the method according to the invention, preferably during and / or after the compression of the mixture in step S2) (preferably during and after the compression of the mixture in step S2) or after the compression of the mixture in step S2)), heat and / or (preferably "and") pressure is applied to the mixture, as a result of which the binder of the binder composition hardens and a lignocellulose composite is obtained.

[0065] Preferably, a temperature in the range of 80 to 300 °C, more preferably 120 to 280 °C, even more preferably 150 to 250 °C is applied in step S3), and / or (preferably "and") a pressure in the range of 0.1 to 10 MPa, preferably 0.5 to 8 MPa, more preferably 1 to 6 MPa is applied in step S3).

[0066] Preferably, the temperature applied in step S3) is measured at the center of the (three-dimensional) lignocellulose composite obtained at the end of step S3). The lignocellulose composite (“board”) can be cooled more slowly with a stark cooler or by hot lamination. For example, step S3) may be carried out with a conventional hot press.

[0067] The measurement of the temperature at the center of the lignocellulose composite can be carried out according to known methods, in particular according to the methods described in Meyer / Thoemen, Holz als Roh-und Werkstoff [European Journal of Wood and Wood Products] (2007) 65, pages 49-55 or Thoemen, 2010, “Vom Holz zum Werkstoff - grundlegende Untersuchungen zur Herstellung und Struktur von Holzwerkstoffen [From wood to materials - basic investigations for the preparation and the structure of wood - based materials]”, ISBN 978 - 3 - 9523198 - 9 - 5, pages 24 - 30 and 78 - 85. For the wireless measurement of the temperature sensor, for example, the CONTI LOG sensor or the EASYlog sensor of Fagus - Grecon Greten GmbH & Co. KG can be used, which can be inserted into the mixture for producing the lignocellulose composite, for example, during or after step S1).

[0068] In a preferred variant of the method according to the invention, step S3) comprises applying a high - frequency electric field to the mixture so that the binder hardens and binds to the lignocellulose particles, preferably during and / or after compression in step S2), as a result of which a lignocellulose composite (or a layer of a multi - layer lignocellulose composite) is obtained.

[0069] As used herein, the term "high-frequency electric field" refers to and includes any kind of high-frequency electricity or electromagnetic field, such as microwave irradiation or high-frequency electric field generated after applying a high-frequency alternating voltage to a plate capacitor between two capacitor plates. Suitable frequencies for the high-frequency electric field are in the range of 100 kHz to 30 GHz, preferably 6 MHz to 3 GHz, more preferably 13 MHz to 41 MHz. Particularly preferred and favorable are the respective nationally and internationally approved frequencies, such as 13.56 MHz, 27.12 MHz, 40.68 MHz, 2.45 GHz, 5.80 GHz, 24.12 GHz, more preferably 13.56 and 27.12 MHz. The power used to generate such a high-frequency electric field in the method of the present invention is preferably in the range of 10 to 10000 kWh, more preferably 100 to 5000 kWh, and most preferably 500 to 2000 kWh.

[0070] A method for producing a lignocellulose composite comprises the following steps: - preparing a layer of the mixture provided or prepared in step S1), preferably by scattering, and compressing this layer in step S2); - providing or preparing at least first and second individual mixtures for preparing a multi-layer lignocellulose composite comprising one or more lignocellulose composite layers, and using the first and second individual mixtures for making the first and second layers of the multi-layer lignocellulose composite, wherein the first and second layers are preferably in contact with each other and / or the first and second individual mixtures have the same composition or different compositions; - preparing two or more layers for preparing a multi-layer lignocellulose composite, preferably by scattering the individual layers on top of each other, wherein each layer contains lignocellulose particles and a binder, and in two or more layers, the lignocellulose particles and / or the binder are the same or different; - Step S2) is a step of compressing the mixture in two stages. In the first stage, the mixture is pre-compressed to obtain a pre-compressed mat, and in the second stage, this pre-compressed mat is further compressed. - A step of hot pressing the mixture during or after compression in step S2). - In step S3), applying a temperature in the range of 80 to 300 °C and a pressure in the range of 0.1 to 10 MPa to the mixture, preferably the compressed mixture from step S2). Preferably, the method of the present invention described herein (or preferably the method of the present invention described herein) includes one, two, three, more than three, or all of the above.

[0071] According to a preferred embodiment of the method of the present invention, the method of the present invention for producing a lignocellulose composite includes one, two, three, or more preferred steps, each of which is a specific embodiment of step S1), S2), or S3), or any of the additional steps. Each of these preferred steps is optional and can be performed individually or in combination with one or more of the other preferred steps.

[0072] One of the preferred steps relates to step S1) of preparing the mixture comprising or consisting of the lignocellulose particles and the binder composition. According to this preferred embodiment, the lignocellulose particles are blended with one or more or all of the components of the binder composition, or one or more or all of the components of the binder composition are sprayed onto the lignocellulose particles. Specifically, the components of the binder composition are blended or sprayed preferably continuously with the lignocellulose particles simultaneously (e.g., mixed with each other) or continuously, as further specified and outlined above.

[0073] Another preferred step of the present invention is to prepare a layer of the mixture provided or prepared in step S1), preferably by scattering, and to compress this layer in step S2). The preparation of the layer by scattering is a preferred additional step for the production of the lignocellulose composite.

[0074] According to a preferred embodiment of the present invention, at least a first and a second individual mixture are provided or prepared for preparing a multi-layer lignocellulose composite. Then, the first and second individual mixtures are used to produce the first and second layers of the multi-layer lignocellulose composite. Preferably, the first and second layers are in contact with each other. According to this preferred embodiment, the first and second individual mixtures have the same or different compositions, and even more preferably, the first and second individual mixtures have different compositions. Thus, the different individual mixtures and / or layers of the prepared multi-layer lignocellulose composite preferably have different specific properties, such as density, color, etc., and / or they differ with respect to their composition. Different compositions are obtained by using different binders, lignocellulose particles and / or other (additional) components, such as plastics, fabrics, paint coats, etc. derived from foreign substances in waste wood. The individual layers preferably (i) contain different binders and different lignocellulose particles, or (ii) contain the same binder but different lignocellulose particles, or (iii) contain the same binder and the same lignocellulose particles but in different ratios.

[0075] According to a preferred method technically related to the present invention, the preparation of the multi-layer lignocellulose composite includes the preparation of two, three or more layers, and each layer contains lignocellulose particles and a binder. Preferably, the lignocellulose particles and / or the binders in the two, three or more layers are the same or different, and even more preferably, the lignocellulose particles are different and the binders are different.

[0076] Preferably, in step S2) of compressing the mixture provided or prepared in step S1), the compression of the mixture is carried out in two stages. This means that in the first stage, the mixture is pre-compressed to obtain a pre-compressed mat, and in the second stage, this pre-compressed mat is further compressed. Preferably, the first stage of pre-compressing the mixture to obtain a pre-compressed mat is carried out before step S3) of applying heat and / or pressure. The second stage of further compressing the pre-compressed mat is preferably carried out during step S3) of applying heat and / or pressure. This two-stage compression enables a flexible method for generating a lignocellulose composite or a layer of lignocellulose composite.

[0077] In a preferred method of the present invention, the preparation of a single-layer lignocellulose composite or a multi-layer lignocellulose composite comprises the following steps: - providing or preparing a mixture comprising at least one, two or more than two lignocellulose particles and a binder according to the present invention; - scattering this mixture / these mixtures to obtain one, two or more than two layers forming a mat; - in a first compression step, pre-compressing this single-layer or multi-layer mat to obtain a pre-compressed mat; and then, - in a second compression step, compressing the pre-compressed mat while applying heat and / or pressure. This includes.

[0078] The present invention also relates to a binder composition (or preferably each binder composition of the present invention described herein) for use in the method according to the present invention for producing a lignocellulose composite and for producing a lignocellulose composite as defined above in relation thereto.

[0079] Generally, all aspects of the invention discussed herein in the context of the method according to the invention for producing lignocellulose composites are applied with the necessary modifications to the binder composition of the invention, and vice versa.

[0080] The invention further relates to the use of the binder composition according to the invention (or preferably the use of each binder composition according to the invention described herein) in a method for producing a lignocellulose composite.

[0081] Generally, all aspects of the invention discussed herein in the context of the method according to the invention for producing lignocellulose composites and / or in the context of the binder composition of the invention are applied with the necessary modifications to the use of the binder composition of the invention, and vice versa.

[0082] The invention further preferably relates to a lignocellulose composite obtainable or obtained according to the method according to the invention described herein (or preferably according to the method of the invention described herein), or a building product comprising such a lignocellulose composite, wherein the lignocellulose composite preferably is - high - density fiberboard (HDF), - medium - density fiberboard (MDF), - low - density fiberboard (LDF), - xylary fiber insulation board, - oriented strand board (OSB), - chipboard, and - a natural fiber board having fibers selected from the group consisting of preferably sisal, jute, flax, coconut, kenaf, hemp, banana and mixtures thereof, and is a lignocellulose board selected from the group consisting of preferably, the lignocellulose board is - a single - layer lignocellulose board, or - a multi - layer lignocellulose board, preferably a multi - layer lignocellulose board having a core and upper and lower surface layers.

[0083] Generally, all aspects of the invention discussed herein in the context of the method according to the invention for producing lignocellulose composites and / or the binder composition according to the invention and / or the use of the binder composition according to the invention apply with the modifications necessary for the lignocellulose composites of the invention, and vice versa.

[0084] As used herein, the term "construction product" refers to a product used in a construction, such as a floorboard, door, window, floor, panel, furniture or furniture part. The construction products of the invention are preferably selected from the group consisting of furniture and furniture parts.

[0085] As used herein, the term "furniture" refers to any kind of furniture. In the context of the present invention, furniture is preferably selected from the group consisting of chairs, tables, desks, closets, beds and shelves.

[0086] As used herein, the term "building element" refers to a lignocellulose composite product (such as a board, see above) that constitutes a part (element) of a construction product (such as a part of furniture). Such building elements are preferably part of furniture, and more preferably such parts of furniture are selected from the group consisting of shelves, table tops, side panels or cabinet shelves or doors, and the side walls of beds.

[0087] The lignocellulose composites of the invention, specifically boards, when they are particularly elements of the construction products of the invention, preferably comprise lignocellulose particles selected from the group consisting of fibers, chips, strands, flakes, sawmill waste and shavings or mixtures thereof. These lignocellulose particles preferably originate from any type of lignocellulosic biomass, such as oak, beech, walnut, pine, spruce, larch, eucalyptus, paulownia, poplar, kenaf, fir, tropical trees, sisal, jute, flax, coconut, kenaf, hemp, banana, straw, cotton pattern, bamboo, etc. or mixtures thereof.

[0088] The lignocellulose composite of the present invention that can be obtained or is obtained according to the method of the present invention, preferably a board, is preferably a single-layer lignocellulose board or a multi-layer lignocellulose board, more preferably a single-layer lignocellulose board. The multi-layer lignocellulose board of the present invention is a board including at least two distinguishable (individual) layers. The multi-layer lignocellulose board preferably has at least a core layer, an upper surface layer, and a lower surface layer. In that case, the total number of layers is three or more. If the number of layers is four or more, one or more intermediate layers exist. A three-layer board having one core layer, an upper surface layer, and a lower surface layer is preferred. This is particularly relevant when the lignocellulose composite of the present invention, preferably a board, is an element of a building product of the present invention.

[0089] The single-layer lignocellulose board of the present invention which is a medium density fiberboard (MDF) or a chipboard is particularly preferred, and even more preferably, a medium density fiberboard (MDF), and corresponding building products including such single-layer lignocellulose boards.

[0090] The present invention also relates to the use of the lignocellulose composite according to the present invention described herein (or each lignocellulose composite described herein as preferred) as a building element in a building product selected from products used in a building selected from the group consisting of preferably floorboards, doors, windows, floors, panels, furniture, and furniture parts.

[0091] Generally, all aspects of the present invention discussed herein in the context of the method according to the present invention for generating a lignocellulose composite and / or the binder composition of the present invention and / or the use of the binder composition of the present invention and / or the lignocellulose composite of the present invention are applied with the necessary modifications for the use of the lignocellulose composite of the present invention, and vice versa.

[0092] Next, the present invention also relates to a kit for producing a binder composition for use in the production of lignocellulose composites, comprising at least, as spatially separated individual components, k1) one or more amino acid polymers having two or more primary amino groups (or preferably each amino acid polymer described herein), used in the method according to the invention for producing lignocellulose composites and defined above with respect to component c1) of the binder composition; k2) one or more alpha-hydroxycarbonyl compounds (or preferably each alpha-hydroxycarbonyl compound described herein), used in the method according to the invention for producing lignocellulose composites and defined above with respect to component c2) of the binder composition; k3) one or more basic substances having a pK B value of ≦ 3 (or preferably each basic substance described herein), used in the method according to the invention for producing lignocellulose composites and defined above with respect to component c3) of the binder composition and relates to a kit.

[0093] Generally, all aspects of the present invention discussed herein in the context of the method according to the invention for producing lignocellulose composites and / or the binder composition of the present invention and / or the use of the binder composition of the present invention and / or the lignocellulose composite of the present invention and / or the use of the lignocellulose composite of the present invention are applicable with the necessary modifications to the kit of the present invention, and vice versa.

[0094] Examples : The following examples are intended to further illustrate and exemplify the present invention without limiting the scope of the present invention.

[0095] Materials: In the experiments described below, the following materials were used: 1) Dextrose monohydrate, Sigma Aldrich, Spain; 2) L-Lysine solution (50% in water), ADM animal nutrition, USA; 3) Hydroxyacetone (95%), Alfa Aesar (now Thermo Fisher); 4) Sodium hydroxide (97% powder), Sigma Aldrich, USA; 5) Spruce wood chips and fibers (lignocellulose particles) made by Institut fur Holztechnologie Dresden, Germany: The spruce wood chips were produced by a disk chipper. Spruce trunk sections (250 mm in length) from Germany were pressed with their long sides against a rotating steel disk, into which knife boxes were inserted evenly distributed radially. Each of the knife boxes consisted of radially arranged cutting knives and several scoring knives positioned at right angles to them.

[0096] The cutting knives separated chips from the circular wood, and the scoring knives simultaneously limited the chip length. Subsequently, the produced chips were collected in a bunker and then transported to a cross beater mill (with sieve inserts) for re-crushing with respect to chip width. The re-crushed chips were then conveyed to a flash dryer and dried at about 120 °C. The chips were then screened into two useful fractions ( "B": ≤ 2.0 mm × 2.0 mm and > 0.32 mm × 0.5 mm; "C": ≤ 4.0 mm × 4.0 mm and > 2.0 mm × 2.0 mm), a re-crushed coarse fraction ( "D": > 4.0 mm × 4.0 mm), and a fine fraction ( "A": ≤ 0.32 mm × 0.5 mm). Fraction B was suitable for use as surface layer chips (surface layer chips) for three-layer chipboards, and a mixture of 60 wt% fraction B and 40 wt% fraction C was used as chips for single-layer chipboards, but was also suitable as core layer chips (core layer chips) for three-layer chipboards.

[0097] Methods: 1. Measurement of the residual particle moisture content The moisture content of the lignocellulose particles (chips or fibers, see above) before applying the binder was measured in accordance with EN 322:1993 by placing the particles in a drying oven at a temperature of (103 ± 2) °C until a constant mass was reached. The water content of the particle / binder composition mixture obtained in step S1) was determined in a similar manner. For this purpose, samples of each mixture (approx. 20 g) were weighed in the wet state (m1) and after drying (m0). The mass m0 is determined by drying to a constant mass at 103 °C. The water content was calculated as follows: water content [wt%] = [(m1 - m0) / m0]·100.

[0098] 2. Measurement of the pressing time coefficient To determine the "pressing time coefficient", a conventional hot press was used. For the purposes of the present invention, the "pressing time coefficient" was determined as the "pressing time" (i.e., the time from closing to opening of the press) divided by the "target thickness" of the lignocellulose composite (board). The target thickness refers to the thickness of the lignocellulose composite at the end of step S3) and was adjusted by the pressing conditions, i.e., the distance between the upper press plate and the lower press plate, which is adjusted by the automatic distance control of the press.

[0099] The pressing time coefficient is given below in units of [seconds / mm], i.e., the time from closing to opening of the press [seconds]: the target thickness of the press board [mm]. For example, if a 10 mm chip board is produced with a pressing time of 120 seconds, a pressing time coefficient of 12 seconds / mm results.

[0100] 3. Measurement of the density of the lignocellulose composite The density of the lignocellulose composite (board) was measured in accordance with EN 323:1993 and reported herein as the arithmetic mean of 10 samples of 50 × 50 mm of the same lignocellulose composite (board).

[0101] 4. Measurement of the cross-tensile strength ("internal bond strength") of the lignocellulose composite The cross-tensile strength ("internal bond strength") of the lignocellulose composite (board) is determined in accordance with EN 319:1993 and reported herein as the arithmetic mean of 10 samples of 50×50 mm of the same lignocellulose composite (board).

[0102] 5. Determination of the amount of binder or binder composition The amount of binder or binder composition in the examples shown below is reported as the total weight (weight %) of the respective components of the binder or binder composition, based on the total dry weight of the lignocellulose particles (wood particles).

[0103] 6. Weight-average molecular weight (M w ) of polylysine The weight-average molecular weight (M w ) of the polylysine prepared according to this example was determined by size exclusion chromatography generally known under the following conditions: Solvent and eluent: 0.1% (w / w) trifluoroacetate, 0.1 M NaCl in distilled water Flow rate: 0.8 ml / min Injection volume: 100 μl The sample was filtered through a Sartorius Minisart RC25 (0.2 μm) filter Column material: hydroxylated polymethacrylate (TSKgel G3000PWXL) Column size: inner diameter 7.8 mm, length 30 cm Column temperature: 35 °C Detector: DRI Agilent 1100 UV GAT-LCD503 [232 nm]

[0104] Calibration was carried out using poly(2-vinylpyridine) standards (manufactured by Polymer Standard Service GmbH, Mainz, Germany) in the molar mass range of 620 - 2890000 g / mol and pyridine (79 g / mol).

[0105] The integration upper limit was set to 29.01 mL.

[0106] M w The calculation of

[0107] Example 1: Synthesis of Polylysine Example 1a :M w Poly-L-lysine having 2100 2200 g of an L-lysine solution was heated with stirring in an oil bath (outer temperature 140 °C). Water was distilled off, and the temperature of the oil bath was raised at 10 °C / h until it reached 180 °C. The reaction mixture was stirred at 180 °C (oil bath temperature) for an additional 1 hour, and then the pressure was slowly reduced to 200 mbar. After reaching the target pressure, distillation was continued for 2 hours. The product was poured out of the reaction vessel while it was hot, ground after cooling, and dissolved in water to obtain a 50 wt% aqueous solution of poly-L-lysine (hereinafter, "polylysine solution 1a"). The weight average molecular weight of the obtained poly-L-lysine was 2100 (see above for the measurement method).

[0108] Example 1b :M w Poly-L-lysine having 3690 The experiment of Example 1a above was repeated. Different from Example 1a, distillation after reaching the target pressure was continued for 4 hours (instead of 2 hours). A 50 wt% aqueous solution of poly-L-lysine (hereinafter, "polylysine solution 1b") was finally obtained. The weight average molecular weight of the obtained poly-L-lysine was 3690 (see above for the measurement method).

[0109] Example 1c :M w Poly-L-lysine having 6270 The experiment of Example 1a above was repeated. Different from Example 1a, distillation after reaching the target pressure was continued for 4.5 hours (instead of 2 hours). A 50 wt% aqueous solution of poly-L-lysine (hereinafter, "polylysine solution 1c") was finally obtained. The weight average molecular weight of the obtained poly-L-lysine was 6270 (see above for the measurement method).

[0110] Example 2: Single-Layer Lignocellulose Composite Poly-L-Lysine / Hydroxyacetone (for Comparison) Example 2a :M w Single-layer lignocellulose composite containing 2100 poly-L-lysine / hydroxyacetone (for comparison) In a mixer, 499 g of polylysine solution 1a (see Example 1a above for preparation) was sprayed while mixing with 5.56 kg (5.40 kg dry weight + 160 g water from residual particle moisture content) of corn cob layer chips (moisture content 3.0 wt%). Immediately, 149 g of hydroxyacetone solution (50 wt% in water) was sprayed while mixing into the mixture. Finally, 90 g of water was sprayed while mixing into the mixture to adjust the final moisture of the resinified chips. After the addition of water, mixing was continued for 3 minutes.

[0111] The term "resinified chip" is used herein for the mixture of chips and binder composition and further added water (similarly for "resinification").

[0112] The binder amount (or the proportion of binder in the finished lignocellulose composite) was calculated as follows: [499 g of component c1) × 0.5] + [149 g of component c2) × 0.5] : 5400 g of lignocellulose particles = 6.0% The ratio of the binder components was calculated as follows: [499 g of component c1) × 0.5] : [149 g of component c2) × 0.5] = 77:23

[0113] The moisture content of the mixture provided or prepared in step S1) was calculated as follows: Total weight of water = 499 g × 0.5 (from polylysine solution 1a) + 149 g × 0.5 (from hydroxyacetone solution) + 90 g (from additional water) + 160 g (from chip moisture) = 574 g Total weight of solids = 499 g × 0.5 (from polylysine solution 1a) + 149 g × 0.5 (from hydroxyacetone solution) + 5400 g (dry chips) = 5724 g The resulting moisture content = 574 g / 5724 g = 10.0%

[0114] This water content was checked and confirmed by a method carried out in the same manner as EN 322:1993, and a water content of 10% was obtained.

[0115] Immediately after resinification, 1.10 kg of the mixture was scattered into a 30×30 cm mold and pre-pressed under ambient conditions (0.4 N / mm 2 ). Subsequently, the pre-pressed chip mat thus obtained was removed from the mold, transferred to a hot press, and pressed to a thickness of 16 mm to obtain a chipboard as a single-layer lignocellulose composite (referred to as "SLC 2a C(HA)" in Table 1) (temperature of the press plate: 210 °C, maximum pressure: 4 N / mm 2 , and the pressing time indicated by the pressing time coefficient in Table 1 below).

[0116] Example 2b :M w Single-layer lignocellulose composite containing poly-L-lysine / hydroxyacetone of 3690 (for comparison) The experiment of Example 2a above was repeated. Different from Example 2a, 499 g of polylysine solution 1b (see Example 1b above for preparation) was used. From this experiment, a single-layer lignocellulose composite (referred to as "SLC 2b C(HA)" in Table 1) was obtained.

[0117] Example 2c Single-layer lignocellulose composite containing poly-L-lysine / hydroxyacetone of Mw = 6270 (for comparison) The experiment of Example 2a above was repeated. Different from Example 2a, 499 g of polylysine solution 1c (see Example 1c above for preparation) was used. From this experiment, a single-layer lignocellulose composite (referred to as "SLC 2c C(HA)" in Table 1) was obtained.

[0118] Example 3: Single-Layer Lignocellulose Composite Poly_L-Lysine / Hydroxyacetone (According to the Invention) Example 3a :M w Single-layer lignocellulose composite containing poly-L-lysine / hydroxyacetone of 2100 (according to the present invention) 20.0 g of sodium hydroxide was added to 499 g of polylysine solution 1a, and the mixture was stirred to obtain polylysine solution 1a-NaOH.

[0119] In a mixer, 519 g of polylysine solution 1a-NaOH was sprayed while being mixed with 5.56 kg (5.40 kg dry weight + 160 g of water from the residual particle moisture content) of douglas fir core chips (moisture content 3.0 wt%). Immediately, 149 g of hydroxyacetone solution (50 wt% in water) was sprayed while being mixed into the mixture. Finally, 90 g of water was sprayed into the mixture while being mixed to adjust the final moisture content of the resinified chips. After the addition of water, mixing was continued for 3 minutes.

[0120] From the binder composition prepared above, a single-layer lignocellulose composite (referred to as "SLC 3a I(HA)" in Table 1) was prepared as described in Example 2a.

[0121] Example 3b :M w Single-layer lignocellulose composite containing poly-L-lysine / hydroxyacetone 3690 (according to the present invention) The experiment of Example 3a above was repeated. Different from Example 3a, 499 g of polylysine solution 1b (see Example 1b above for preparation) was used (instead of polylysine solution 1a). From this experiment, a single-layer lignocellulose composite (referred to as "SLC 3b C(HA)" in Table 1) was obtained.

[0122] Example 3c :M w Single-layer lignocellulose composite containing poly-L-lysine / hydroxyacetone 6270 (according to the present invention) The experiment of Example 3a above was repeated. Different from Example 3a, 499 g of polylysine solution 1c (see Example 1c above for preparation) was used (instead of polylysine solution 1a). From this experiment, a single-layer lignocellulose composite (referred to as "SLC 3c C(HA)" in Table 1) was obtained.

[0123] Example 4: Single-Layer Lignocellulose Composite Polylysine / Dextrose (for Comparison) In a mixer, 499 g of polylysine solution 1a (50 wt% in water) was sprayed while mixing with 5.56 kg of douglas fir core chips (moisture content 3.0 wt%) (5.40 kg dry weight + 160 g of water from the residual particle moisture content). Immediately, 149 g of dextrose solution (50 wt% in water) was sprayed while mixing into the mixture. Finally, 90 g of water was sprayed into the mixture while mixing to adjust the final moisture content of the resinified chips. After the addition of water, mixing was continued for 3 minutes.

[0124] From the binder composition prepared above, a single-layer lignocellulose composite (referred to as "SLC 4 C(DEX)" in Table 1) was prepared as described in Example 2.

[0125] Example 5: Single-Layer Lignocellulose Composite Polylysine / Dextrose (According to the Invention) In a mixer, 519 g of polylysine solution 1a-NaOH (see Example 3 above for preparation) was sprayed while mixing with 5.56 kg of douglas fir core chips (moisture content 3.0 wt%) (5.40 kg dry weight + 160 g of water from the residual particle moisture content). Immediately, 149 g of dextrose solution (50 wt% in water) was sprayed while mixing into the mixture. Finally, 90 g of water was sprayed into the mixture while mixing to adjust the final moisture content of the resinified chips. After the addition of water, mixing was continued for 3 minutes.

[0126] From the binder composition prepared above, a single-layer lignocellulose composite (referred to as "SLC 5 I(DEX)") was prepared as described in Example 2.

[0127] Example 6: Determination of Parameters of the Lignocellulose Composite For the single-layer lignocellulose composites prepared according to Examples 2 to 5, specific board parameters were determined and are shown in Table 1 below:

[0128]

Table 1

[0129] The "without board" in Table 1 above means that the material obtained after pressing was not a sound chipboard but showed cracks, dents and / or ruptures.

[0130] From the data shown in Table 1 above, when a basic substance (NaOH) having a pK B value of ≤ 3 is present in the binder composition used in the method of the present invention, it is particularly found that the internal bond strength of the lignocellulose composite produced by the method increases.

Claims

1. A method for producing a lignocellulose composite comprising one or more lignocellulose composite layers, comprising at least the following steps: S1) Providing or preparing a mixture, wherein the mixture comprises at least - lignocellulose particles, and - a binder composition comprising as components at least c1) one or more amino acid polymers having two or more primary amino groups, c2) one or more alpha-hydroxycarbonyl compounds, and pK of c3) ≤ 3 Ｂ one or more basic substances having a value a binder composition; and S2) Compressing the mixture from step S1) to obtain a compressed mixture; S3) Applying heat and / or pressure to the mixture, whereby the binder of the binder composition cures to obtain a lignocellulose composite. A method comprising the above steps.

2. The one or more amino acid polymers of component c1) of the binder composition comprise or are one or more polylysines, preferably, the one or more polylysines - A weight average molecular weight M of ≧ 800 g / mol, preferably ≧ 1000 g / mol, more preferably ≧ 1150 g / mol ｗ having; and / or - having a weight average molecular weight M of ≤ 10,000 g / mol, preferably ≤ 8,000 g / mol, more preferably ≤ 5,000 g / mol, even more preferably ≤ 3,500 g / mol ｗ ; and / or -800 g / mol ≤ M ｗ ≤ 10000 g / mol, preferably 1000 g / mol ≤ M ｗ ≤ 8000 g / mol, more preferably 1000 g / mol ≤ M ｗ ≤ 5000 g / mol, even more preferably 1000 g / mol ≤ M ｗ having a weight average molecular weight M in the range of ≤ 3500 g / mol ｗ ; and / or - as monomers incorporated into their polymer structure, comprise lysine monomers in an amount of ≧ 10% by mass, preferably ≧ 20% by mass, based on the total mass of the polymer; and / or - as monomers incorporated into their polymer structure, comprise at least 85% by mass, preferably at least 95% by mass, more preferably at least 99% by mass, even more preferably 100% by mass of lysine monomers, based on the total mass of the polymer structure. The method according to claim 1.

3. - At least one of the one or more alpha-hydroxycarbonyl compounds of component c2) of the binder composition is selected from the group consisting of glycolaldehyde, glyceraldehyde, 1,3-dihydroxyacetone, hydroxyacetone, arabinose, xylose, glucose, mannose, fructose, sucrose and mixtures thereof, preferably selected from the group consisting of glycolaldehyde, glyceraldehyde, 1,3-dihydroxyacetone, hydroxyacetone and mixtures thereof; more preferably, at least one of the one or more alpha-hydroxycarbonyl compounds is hydroxyacetone; and / or - (i) the total mass of the one or more amino acid polymers of component c1) of the binder composition; (ii) the ratio of the total mass of the one or more alpha-hydroxycarbonyl compounds of component c2) of the binder composition or used in the preparation of the binder composition is in the range of ≧60:40 to ≦90:10, preferably ≧65:35 to ≦80:20, more preferably ≧65:35 to ≦75:25, The method according to claim 1 or 2.

4. - pK of ≤ 3 Ｂ wherein the one or more basic substances having a pK value of ≤ 2.5 Ｂ preferably having a pK value of ≤ 2 Ｂ are one or more substances; and / or - pK of ≤ 3 Ｂ at least one of said one or more, preferably all of the basic substances having a ■ preferably an alkali metal hydroxide selected from the group consisting of LiOH, NaOH, KOH and mixtures thereof; more preferably NaOH; and ■Preferably Mg(OH) ２ and Ca(OH) ２ and an alkaline earth metal hydroxide selected from the group consisting of mixtures thereof, more preferably Ca(OH) ２ selected from the group consisting of; and / or pK of ≤ 3 which is the - component c3) Ｂ The total amount of the one or more basic substances having a value is ≥ 3 to ≤ 9% by mass, preferably ≥ 4 to ≤ 8% by mass, more preferably ≥ 5 to ≤ 7% by mass, based on the total amount of the one or more amino acid polymers of the binder composition which is component c1) and the one or more alpha-hydroxycarbonyl compounds of the binder composition which is component c2). The method according to any one of claims 1 to 3.

5. The binder composition provided or prepared in step S1) further comprises a carrier liquid, preferably water, preferably, - the one or more amino acid polymers that are component c1) are present in the binder composition or used in the preparation of the binder composition in a total amount in the range of ≧20 to ≦50% by mass, preferably ≧25 to ≦45% by mass, more preferably ≧25 to ≦40% by mass, based on the total mass of components c1) to c3) and the carrier liquid; and / or - the one or more alpha-hydroxycarbonyl compounds that are component c2) are present in the binder composition or used in the preparation of the binder composition in a total amount in the range of ≧3 to ≦20% by mass, preferably ≧5 to ≦15% by mass, more preferably ≧7 to ≦12% by mass, based on the total mass of components c1) to c3) and the carrier liquid, The method according to any one of claims 1 to 4.

6. In the mixture provided or prepared in step S1) of the method, the total amount of the one or more amino acid polymers of the binder composition that are component c1) and the one or more alpha-hydroxycarbonyl compounds of the binder composition that are component c2) is in the range of ≧3 to ≦8% by mass, preferably ≧3.5 to ≦7.5% by mass, more preferably ≧4 to ≦6.5% by mass, based on the total amount of the oven-dried lignocellulose particles of the mixture. The method according to any one of claims 1 to 5.

7. In step S1), component c1) and component c3) are premixed with each other, and then the resulting premix is brought into contact with the lignocellulose particles, preferably sprayed onto the lignocellulose particles. Preferably, component c2) is brought into contact with the lignocellulose particles separately from the premix, preferably sprayed onto the lignocellulose particles. Preferably, as a result, the mixture is obtained. The method according to any one of claims 1 to 6.

8. The lignocellulose composite is - High - density fiberboard (HDF); - Medium - density fiberboard (MDF); - Low - density fiberboard (LDF); - Wood fiber insulation board; - Oriented strand board (OSB); - Chipboard; and - A natural fiber board having fibers selected from the group consisting of preferably sisal, jute, flax, coconut, kenaf, hemp, banana and mixtures thereof. A lignocellulose board selected from the group consisting of The lignocellulose board is - A single - layer lignocellulose board, or - A multi - layer lignocellulose board, Preferably, it is a multi - layer lignocellulose board having a core layer, an upper surface layer and a lower surface layer. The method according to any one of claims 1 to 7.

9. The method for producing the lignocellulose composite comprises the following steps: - Preparing a layer of the mixture provided or prepared in step S1), preferably by scattering, and compressing this layer in step S2); and - Providing or preparing at least a first and a second individual mixture to prepare a multi - layer lignocellulose composite comprising one or more lignocellulose composite layers, using the first and second individual mixtures to form the first and second layers of the multi - layer lignocellulose composite, wherein the first and the second layers preferably contact each other and / or the first and the second individual mixtures have the same composition or different compositions. - To prepare a multi-layer lignocellulose composite, a step of preparing two or more layers, preferably by scattering the individual layers on top of each other, wherein each layer contains lignocellulose particles and a binder, and in the two or more layers, the lignocellulose particles and / or the binder are the same or different; - In step S2), a step of compressing the mixture in two stages, wherein in the first stage, the mixture is pre-compressed to obtain a pre-compressed mat, and in the second stage, this pre-compressed mat is further compressed; - A step of hot pressing the mixture during or after compression in step S2); - In step S3), applying a temperature in the range of 80 to 300 °C and a pressure in the range of 0.1 to 10 MPa to the compressed mixture from step S2); including one, two, three, more than three or all of the above; The method according to any one of claims 1 to 8.

10. A binder composition for producing a lignocellulose composite as defined in any one of claims 1 to 6.

11. Use of the binder composition according to claim 10 in a method for producing a lignocellulose composite.

12. Preferably, the lignocellulose composite is - High-density fiberboard (HDF) - Medium-density fiberboard (MDF) - Low-density fiberboard (LDF) - Wood fiber insulation board - Oriented strand board (OSB) - Chipboard, and - Preferably a natural fiber board having fibers from the group consisting of sisal, jute, flax, coconut, kenaf, hemp, banana and mixtures thereof; a lignocellulose board selected from the group consisting of; Preferably, the lignocellulose board is - A single-layer lignocellulose board, or - A multi-layer lignocellulose board, preferably a multi-layer lignocellulose board having a core and upper and lower surface layers; A lignocellulose composite obtainable or obtained according to the method of any one of claims 1 to 9, or a building product comprising such a lignocellulose composite.

13. Use of the lignocellulose composite according to claim 12 as a building element in a building product selected from building products used in a structure selected from the group consisting of floorboards, doors, windows, floors, panels, furniture and furniture parts.

14. A kit for generating a binder composition for use in said generation of a lignocellulose composite, comprising at least as spatially separated individual components k1) one or more amino acid polymers having two or more primary amino groups as defined in any of claims 1 or 2; k2) one or more alpha-hydroxycarbonyl compounds as defined in any of claims 1 or 3; k3) one or more basic substances having a pK value of ≦ 3, as defined in any of claims 1 or 4 Ｂ and A kit comprising.

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