Measuring method for the online determination of an amount of binder applied to wood particles in a production facility for producing wood-based material boards

Abstract

The present invention relates to a nondestructive measuring method for the online determination of an amount of formaldehyde-free binder applied to wood particles in a production facility for producing wood-based material boards, comprising the following steps: applying in each case different quantitatively defined amounts of at least one formaldehyde-free binder to respective samples of wood particles as reference samples and sprinkling the reference samples onto a conveyor belt; recording at least one NIR spectrum of each of the reference samples sprinkled onto the conveyor belt, using at least one NIR measuring head in a wavelength range of between 1000 nm and 2500 nm, preferably between 1350 nm and 2500 nm; assigning the different quantitative amounts of formaldehyde-free binder of the reference samples sprinkled onto the conveyor belt to the recorded NIR spectra of said reference samples; and creating a calibration model for the relationship between the spectral data of the NIR spectra and the associated quantitative amounts of formaldehyde-free binder of the reference samples sprinkled onto the conveyor belt, by means of a multivariate data analysis; applying at least one formaldehyde-free binder to wood particles (as samples to be measured) and sprinkling the wood particles provided with the formaldehyde-free binder onto a conveyor belt, recording at least one NIR spectrum of the wood particles provided with the formaldehyde-free binder and sprinkled onto the conveyor belt, using the at least one NIR measuring head in a wavelength range of between 1000 and 2500 nm, preferably between 1350 nm and 2500 nm; and determining the quantitative amount of the formaldehyde-free binder applied to the wood particles sprinkled onto the conveyor belt, by comparing the NIR spectrum recorded for the wood particles provided with the binder with the created calibration model.

Description

[0001] Measurement method for the online determination of a binding agent quantity applied to wood particles in a production plant for the manufacture of wood-based panels

[0002] The present invention relates to a method for determining a quantity of binder applied to wood particles in a production plant for the manufacture of wood-based panels, in particular OSB panels.

[0003] Description

[0004] To manufacture wood-based panels, such as HDF boards, OSB, or particleboard, wood particles are coated with a binder or glue, the glued wood particles are scattered onto a conveyor belt, and pressed into panels. Liquid, usually aqueous formulations, such as melamine-formaldehyde resin or urea-formaldehyde resin, are often used as binders. For HDF boards in particular, formaldehyde-containing binders are typically used in quantities of more than 10 wt%, e.g., 12-20 wt% (based on the quantity of wood particles) in the wood-based panels. In the case of OSB, formaldehyde-containing binders can be used in quantities of around 10 wt%, particularly in the top layer.

[0005] However, there are also glue systems that do not contain water. One such glue system is PMDI (polymeric diphenylmethane diisocyanate). This glue system has several advantages over traditional water-based glue systems, such as those based on urea formaldehyde. The first advantage is that these glues do not emit formaldehyde. The second advantage is that this glue can be used to create water-resistant bonded joints / boards, and the third advantage is that relatively little glue is needed to produce boards. Typically, 2-5% by weight is sufficient for various wood materials.

[0006] This small amount, however, creates a problem, as increased care must be taken to ensure the glue is evenly distributed. This is even more important the larger the wood particles to be glued are. For example, with smaller wood chips, such as the face layer chips for particleboard, it is much easier to achieve a homogeneous bond in a trough mixer, for example, than it is to bond larger, flat wood strands, such as the face layer strands for OSB (oriented strand board), in a coil (rotating drum). A particular problem here is that the glue distribution on the wood particles cannot be assessed visually. For example, PMDI is only slightly brownish and therefore cannot be detected on yellow strands of softwood, for example.

[0007] In addition, if problems arise, it is difficult to determine the cause, as only the dosage is known, but nothing about the glue distribution. Attempts to address this problem by adding UV-active substances to the PMDI have shown some success, as UV lamps can be used to visualize the glue distribution. However, the dyes are expensive and thus increase costs. Furthermore, the assessment still has to be done visually, which makes it subjective. Continuous monitoring is not possible with this system anyway.

[0008] The use of binders such as PMDI from different manufacturers with different glue properties (viscosity, wetting, etc.) also complicates production. The use of additives (e.g., flame retardants) can also significantly alter the glue distribution, but is undetectable. All of this results in higher costs and increased raw material consumption due to the slightly higher dosage.

[0009] In general, it must be stated that significantly higher demands are placed on the dosage and distribution of the glue on the wood particles. Furthermore, it must be noted that troubleshooting is significantly more difficult. While problems can be detected by the measuring systems installed on the production lines (crack detection, thickness measurement, etc.), this does not identify the root cause. Furthermore, a measuring device must first detect an abnormality before action is taken. This means that larger quantities of substandard goods may be produced.

[0010] This results in various disadvantages, such as a lack of in-line control, readjustment with a time delay, material losses or undetectable fluctuations in the composition.

[0011] The invention is therefore based on the technical problem of developing a non-destructive method that can determine the application rate and, in particular, the distribution of a formaldehyde-free binder, such as PMDI, on wood particles. The method is to be installed in-line in production lines and deliver as many measurements as possible per unit of time in the direction of production and across it. The measurements should not disrupt the production process. Furthermore, irregularities regarding glue application and distribution should be detected earlier or eliminated as a cause of the irregularities.

[0012] This object is achieved according to the invention by a method having the features of claim 1.

[0013] Accordingly, a measuring method for the online determination of the amount of a formaldehyde-free binder applied to wood particles, in particular OSB strands, in a production plant for the manufacture of wood-based panels is provided, the method comprising the following steps:

[0014] - applying at least one formaldehyde-free binder in different quantitatively defined quantities to respective samples of wood particles as reference samples and sprinkling the reference samples onto a conveyor belt of the production plant;

[0015] - Recording of at least one NIR spectrum of each of the reference samples scattered on the conveyor belt using at least one NIR measuring head in a wavelength range between 1000 nm (10,000 cm- 1 ) and 2500 nm (4000 cm- 1 ), preferably between 1350 nm (7400 cm- 1 ) and 2500 nm (4000 cm- 1); particularly preferably between 1800 (5555 cm- 1 ) and 2500 nm (4000 cm- 1 ); most preferably between 2000 and 2200 nm,

[0016] - Allocation of the different quantitative amounts of formaldehyde-free binders of the reference samples sprinkled on the conveyor belt to the recorded NIR spectra of the said reference samples; and

[0017] - Creation of a calibration model for the relationship between the spectral data of the NIR spectra and the corresponding quantitative amounts of formaldehyde-free binder of the reference samples sprinkled onto the conveyor belt using multivariate data analysis; - Application of at least one formaldehyde-free binder to wood particles (as samples to be measured) and sprinkling the wood particles coated with the binder onto a conveyor belt,

[0018] - Recording at least one NIR spectrum of the wood particles provided with the formaldehyde-free binder and scattered onto the conveyor belt using at least one NIR measuring head in a wavelength range between 1000 nm (10,000 cm- 1 ) and 2500 nm (4000 cm- 1 ), preferably between 1350 nm (7400 cm- 1 ) and 2500 nm (4000 cm- 1 ); particularly preferably between 1800 (5555 cm- 1 ) and 2500 nm (4000 cm- 1 ); most preferably between 2000 and 2200 nm, and

[0019] - Determination of the quantitative amount of formaldehyde-free binder by comparing the NIR spectrum recorded for the wood particles containing the binder with the created calibration model.

[0020] The amount of formaldehyde-free binder applied to the wood particles is between 0.5 and 5.0 wt% (based on the amount of wood particles).

[0021] The present method therefore enables the determination of the amount of binder applied to wood particles in a production plant for wood-based panels, where the wood particles coated with the formaldehyde-free binder are scattered onto a conveyor belt. This means that the formaldehyde-free binder is applied, in particular sprayed, to the wood particles, and the glued wood particles are scattered onto a conveyor belt and measured immediately after scattering. Thus, the NIR measurement is performed directly on the conveyor belt in the production line after the particles leave a device for scattering the wood particles.

[0022] The present method allows not only a determination of the application quantity but also a statement about the distribution of the formaldehyde-free binder, such as PMDI, on the wood particles, in particular a distribution of the formaldehyde-free binder on (flat) OSB strands.

[0023] As described, NIR spectra are first created for various amounts of the binder applied to wood particles. Strands and chips can be used as wood particles. These are sprayed with the binder, e.g., PMDI, under defined conditions. NIR spectra are then recorded from these reference samples. Calibration models are then created, which can then be used to determine unknown quantities and compositions. A further advantage is that other parameters (e.g., moisture content, wood species, etc.) can also be analyzed from the NIR spectra, facilitating potential problem analysis.

[0024] Although the analysis of mixtures of wood particles and binders using spectroscopic methods is known, in these cases the measurements are carried out at different times in the production process or on individual samples.

[0025] For example, US 2003 / 0048440 A1 describes a method for the continuous determination of wood fiber properties (such as fiber length distribution, resin content in the stream of resin-coated fibers) in a wood fiber stream for the production of wood fiberboard. The method uses NIR radiation to determine the various properties of the wood fiber stream immediately after defibration, before the fibers are scattered onto a conveyor belt.

[0026] US 2007 / 131862A1 describes the use of NIR spectroscopy for the quantitative analysis of resin-wood composites. Concentrations of various components in a sample of a resin-wood composite are measured simultaneously. For example, the components resin, wax, polyols, and inorganic hardeners are mixed with OSB strands and then measured using NIR spectroscopy, and calibration models are created. The calibration models are then used for the quantitative analysis of unknown resin-wood samples. A mandatory prerequisite for the measurement is comminution (grinding) of the samples to be analyzed outside of the production process. An assessment of the quantity and distribution of binder applied to wood particles (such as wood strands) on a conveyor belt in a production line, as required by the invention, is therefore not possible.

[0027] In one embodiment, the present method is carried out in a production plant with a plant speed between 200 and 500 mm / sec, preferably between 300 and 400 mm / sec.

[0028] In a further embodiment of the present method, the at least one NIR measuring head moves transversely to the running direction of the conveyor belt sprinkled with the glued wood particles and traverses the entire width of the conveyor belt. Furthermore, it is advantageously provided that the at least one NIR measuring head records several spectra per minute, preferably up to eight spectra per minute or more, from which an average value is calculated based on the number of recorded spectra.

[0029] The NIR measuring head used should also be insensitive to temperature fluctuations, dust and emissions from wood components.

[0030] This method enables the measured values ​​to be provided quickly (online, preferably without disruptive time delays). The measured data can be used for quality assurance, research and development, process control, process regulation, process control, etc. The measurement process does not reduce production speed, etc. Fundamentally, it improves production monitoring. Furthermore, downtimes due to quality control and system adjustments are reduced.

[0031] The determination of the amount of binder applied to wood particles, which is possible with this method, is preferably carried out exclusively using NIR measurements. A combination with other spectroscopic methods, especially those using wavelengths outside the NIR range, is not intended.

[0032] According to the invention, an NIR measuring head, preferably an NIR multi-measuring head, is used, which allows the amount and distribution of binder applied to wood particles to be determined by recording spectral data (spectra) in the near-infrared range (1000-2500 nm, preferably 1350-2500 nm). The NIR radiation interacts with the organic functional groups, such as OH, CH, and NH, present in the binder, such as PMDI. The isocyanate groups typical of isocyanate-containing binders, such as PMDI, exhibit peaks at 2040-2050 nm, for example.

[0033] During the interaction, the NIR radiation is scattered and reflected by the sample being measured. The reflected NIR radiation is received by an NIR detector, generating an NIR spectrum. This measurement involves numerous individual NIR measurements within a second, ensuring statistical reliability of the values. NIR spectroscopy, combined with multivariate data analysis (described below), offers a way to establish a direct correlation between the spectral information (NIR spectra) and the parameters of the applied binder to be determined.

[0034] The present method exploits the fact that NIR radiation is reflected or scattered at the particle surface. The reflected or scattered NIR radiation is detected by the NIR detector, and the resulting NIR spectrum is used to determine the desired parameters (in this case, the application rate of binder).

[0035] To determine the amount of binder applied, spectral data from the entire recorded spectral range are preferably used, i.e. not a single, discrete wavelength but rather a whole range of several wavelengths is used.

[0036] According to the method according to the invention, reference samples of wood particles provided with a binder are first prepared. To prepare the reference samples, various amounts of binder, e.g., 0.05 wt%, 1.0 wt%, 2.0 wt%, 3.0 wt%, 4.0 wt%, 5.0 wt% (based on the amount of wood particles), are applied to the wood particles.

[0037] It is also important to ensure that the reference sample is similar to the sample being measured; that is, the binder and wood particles of the reference sample have the same composition as the binder and wood particles being measured. The similarity of the sample being measured and the reference sample is particularly important when using binders with additives such as flame retardants, fibers, and other additives.

[0038] From these reference samples, at least one NIR spectrum is measured in a wavelength range between 1000 nm (10,000 cm- 1 ) and 2500 nm (4000 cm-1 ), preferably between 1350 nm (7400 cm- 1 ) and 2500 nm (4000 cm- 1 ); particularly preferably between 1800 nm (5555 cm- 1 ) and 2500 nm (4000 cm- 1 ). It is also possible to use a wavelength range between 1350 nm (7407 cm' 1 ) and 1600 nm (6250 cm' 1 ) alone or in combination with a wavelength range between 1800 (5555 cm -1 ) and 2500 nm (4000cm -1 ), particularly preferably between 2000 and 2200 nm.

[0039] The different quantitative amounts of binder in the reference samples are then assigned to the recorded NIR spectra of these reference samples, and a calibration model is created for the relationship between the spectral data of the NIR spectra of the reference samples and the corresponding binder amounts as parameter values ​​using multivariate data analysis. This means that for each parameter value of the reference sample, an NIR spectrum of the reference sample corresponds. The calibration models created for the various parameters are stored in a suitable data storage system.

[0040] Subsequently, at least one measurement sample comprising a formaldehyde-free binder applied to wood particles is provided, and at least one NIR spectrum of the binder applied to the wood particles is recorded. The quantitative amount of binder applied to the wood particles can be determined by comparing the NIR spectrum recorded for the measurement sample with the created calibration model.

[0041] A comparison and interpretation of the NIR spectra is best performed across the entire recorded spectral range. This is best done using a well-known multivariate data analysis (MDA). Multivariate analysis methods typically examine several statistical variables simultaneously in a well-known manner. To achieve this, these methods typically reduce the number of variables contained in a data set without simultaneously diminishing the information contained therein.

[0042] In this case, the multivariate data analysis is performed using partial least squares regression (PLS), which allows for the creation of a suitable calibration model. The obtained data is preferably evaluated using suitable analysis software, such as SIMCA-P from Umetrics AB or The Unscrambler from CAMO.

[0043] In a further embodiment, spectral data from the NIR spectral range between 1350 (7400 cm- 1 ) and 2500 nm (4000 cm- 1 ) which are pretreated using appropriate mathematical methods and then subjected to multivariate data analysis. It is also possible to use a wavelength range between 1350 nm (7407 cm -1 ) and 1600 nm (6250 cm' 1) alone or in combination with a wavelength range between 1800 (5555 cm' 1 ) and 2500 nm (4000cm -1 ), most preferably between 2000 and 2200 nm.

[0044] The significance of a wavelength for predicting parameters, such as the amount of binder, from the NIR spectrum is illustrated by the regression coefficients. Regions with large coefficient values ​​have a strong influence on the regression model. Thus, the representation of the regression coefficients in a PLS regression model for determining the amount of binder shows that the wavelength range between 1800 nm (5555 cm- 1 ) and 2500 nm (4000 cm- 1 ), with maxima at 1980 nm (5050 cm -1 ) and 2500 nm (4000 cm- 1), particularly preferably between 2000 and 2200 nm, is the most important for calculating the model, as the regression coefficients are largest here. Although the other ranges in the spectrum have less information content with respect to the NIR measurement, they nevertheless contribute to considering or minimizing other information or interfering factors (such as the transparency of the binder, the surface texture of the wood particles, etc.).

[0045] To eliminate interfering influences (such as the nature of the surface of the wood particles, the color of the samples, light scattering by the wood particles or other additives, etc.), it is necessary to process the spectral data using mathematical pretreatment methods (e.g., derivative data pretreatment, standardization according to SNVT (Standard Normal Variate Transformation), multiplicative signal correction (EMSC, Extended Multiplicative Signal Correction, etc.). This removes the baseline effects, which are mainly caused by the different colors of the samples, from the spectra, separates overlapping bands, and takes into account the dependence of light scattering by the wood particles.

[0046] As already mentioned above, the present method not only enables the determination of the amount of binder applied to the wood particles, but also provides information about the distribution of the binder over or between the wood particles sprinkled onto the conveyor belt.

[0047] By comparing the actual amount of binder or glue applied to the wood particles with the amount of binder measured on the conveyor belt for the sprinkled, glued wood particles, it is possible to determine the distribution of the binder across the wood particles. If the binder is poorly distributed, the mean value of the measurement signal decreases, and an average lower binder content is measured than originally applied, which can be seen as an indication of poor binder distribution. Thus, if the binder is poorly distributed across the wood particles, the measured binder amount can deviate by up to 10-20% from the actual binder amount applied.

[0048] Poor binder distribution is also associated with significant fluctuations in the measured binder quantity. Thus, with poor binder distribution, the measured binder values ​​can fluctuate between 35-40% around an average value, whereas with good binder distribution, the measured binder values ​​fluctuate between 15-30%, preferably between 18-28%, and particularly preferably between 20-25% around an average value.

[0049] Determining the distribution of the binder is important because inhomogeneous application and thus inhomogeneous distribution of the binder on wood particles, especially with larger wood particles such as wood strands, can lead to fluctuating transverse tensile strength of the pressed wood-based panels. The present method opens up the possibility of relating the binder quantity and binder distribution determined by NIR spectroscopy to technological values, such as the transverse tensile strength, of a wood-based panel produced after pressing the glued wood particles; i.e., there is a correlation between the measured binder quantity and the transverse tensile strength. Thus, poor distribution (indicated by a strong fluctuation) of the measured binder quantity results in reduced transverse tensile strength and greater fluctuation in the transverse tensile strength of the pressed wood-based panels.

[0050] A larger fluctuation in transverse tensile strength therefore requires a higher binder dosage to achieve the standardized values ​​of transverse tensile strength for wood-based panels, such as OSB or particleboard. The transverse tensile strength of OSB should typically be in a range between 0.3 and 0.6 N / mm 2 , preferably between 0.4 and 0.6 N / mm 2 , particularly preferably between 0.45 and 0.55 N / mm 2 lay.

[0051] Of course, the recorded NIR spectra can also be used to analyze other parameters of the wood particles, in particular the size distribution of the wood particles and the moisture content of the wood particles.

[0052] In one embodiment of the present process, an isocyanate-containing binder, preferably based on aromatic polyisocyanates, in particular polydiphenylmethane diisocyanate (PMDI), tolylene diisocyanate (TDI) and / or diphenylmethane diisocyanate (MDI), is used as formaldehyde-free binder, with PMDI being particularly preferred.

[0053] The amount of formaldehyde-free binder applied to the wood particles is in one embodiment between 1.0 and 5.0 wt%, preferably between 1.5.0 and 4.0 wt%, particularly preferably between 2.5 and 3.5 wt%, very particularly preferably between 2.5 and 3.0 wt%, even more preferably between 2.5 and 2.9 wt% based on the amount of wood particles, in particular wood strands. In particular, the amount of formaldehyde-free binder is less than 3.0 wt%.

[0054] As already mentioned, at least one isocyanate-containing compound is used as the formaldehyde-free binder. Preferably, the formaldehyde-free binder contains only one isocyanate-containing compound.

[0055] In a further embodiment, however, it can also be provided that the formaldehyde-free binder comprises at least two components, i.e., a mixture of two components. Here, the first component is an isocyanate-containing compound, and the second component is a biodegradable adhesive component. The addition of biodegradable binders to isocyanate-containing binders reduces the amount of isocyanate-containing binders used and forms a sustainable component in the adhesive system.

[0056] In such a combination, for example, up to 20% by weight of the isocyanate-containing binder can be replaced by the biodegradable binder. Preferred amounts of biodegradable binder in a binder mixture are between 5 and 20% by weight, preferably between 10 and 15% by weight.

[0057] Biodegradable binders can be either naturally occurring binders or synthetic binders.

[0058] If a natural binder is used as a biodegradable binder, it is selected from a group consisting of starch, cellulose derivatives such as carboxymethyl cellulose, chitosan, gluten-containing binders such as hide glue, bone glue, and leather glue; milk protein-containing binders, particularly from the casein group; and plant protein-containing binders, particularly from the soy binder group; agar-agar, alginate, gelatin, guar gum, gum arabic, xanthan gum, pectins, locust bean gum, and polysaccharides such as carrageenan, lignin, or rapeseed residue. The use of starch and soy flour is particularly preferred.

[0059] In one embodiment of the present process, the starch used as a binding agent is selected from the group consisting of potato starch, corn starch, wheat starch, and rice starch. Starch is a polysaccharide with the formula (CeH Os)^ which consists of aD-glucose units. The macromolecule is therefore classified as a carbohydrate. Starch can physically bind, swell, and gelatinize many times its own weight in water when exposed to heat. When heated with water, the starch swells at 47-57 °C, the layers burst, and at 55-87 °C (potato starch at 62.5 °C, wheat starch at 67.5 °C), starch paste is formed. This paste has different stiffening capacities depending on the type of starch (corn starch paste greater than wheat starch paste, which is greater than potato starch paste) and decomposes more or less easily under acidification.

[0060] Starch can be used as a binder in both its native and modified (derivatized) form. Thus, at least one starch can be present in the wood fiber mat in its native or modified (derivatized) form. DuraBind from Ecosynthetix is ​​the preferred starch-based binder.

[0061] In the case of the use of modified or derivatized starch as a binder, this can be selected from a group containing cationic or anionic starch, carboxylated starch, carboxy-methylated starch, sulfated starch, phosphorylated starch, etherified starch such as hydroxyalkylated starch (e.g. hydroxyethylated starch, hydroxypropylated starch), oxidized starch containing carboxyl or dialdehyde groups and hydrophobic starches such as acetate, succinate, half or phosphate esters.

[0062] It is also generally conceivable to use a mixture of a natural starch and a derivatized starch or of several natural starches and / or several derivatized starches.

[0063] The particle size of the starch is between 20 and 100 pm, preferably between 30 and 80 pm, particularly preferably between 40 and 60 pm, e.g. 50 pm.

[0064] In one embodiment of the present method, when starch is used as the second binder component (in addition to the preferred wavelength range of the isocyanate-containing component), spectral data from the NIR spectral range between 900 nm and 1800 nm, preferably between 1100 nm and 1650 nm, particularly preferably between 1300 nm and 1650 nm, and most preferably between 1400 nm and 1550 nm are used. Two types of wood-based panels and their production processes, in which the measurement method according to the invention can be used, are described below. As already mentioned, wood strands and wood chips, e.g., recycled chips, are preferably used as wood particles with the present method. Wood strands are used to produce OSB, and wood chips are used to produce particle boards.

[0065] The wood strands used here can have a length between 50 and 200 mm, preferably 70 to 180 mm, particularly preferably 90 to 150 mm; a width between 5 and 50 mm, preferably 10 to 30 mm, particularly preferably 15 to 20 mm; and a thickness between 0.1 and 2 mm, preferably between 0.3 and 1.5 mm, particularly preferably between 0.4 and 1 mm. In one embodiment, the wood strands have, for example, a length between 150 and 200 mm, a width between 15 and 20 mm, a thickness between 0.5 and 1 mm, and a moisture content of max. 50%.

[0066] As mentioned, the strands are used to produce OSB. OSB production is a multi-stage process, beginning with the strands of debarked roundwood, preferably softwood, being stripped lengthwise using rotating knives. In the subsequent drying process, the strands' natural moisture content is reduced at high temperatures. The moisture content of the strands can vary depending on the adhesive used, but it should be well below 10% to avoid cracking due to excessive vapor pressure in the board during subsequent pressing. Depending on the adhesive, wetting on relatively moist strands or on dry strands may be more beneficial.

[0067] After the strands have dried, they are introduced into a gluing device in which the glue or adhesive is applied in a fine distribution to the strands.

[0068] A gluing device in the form of a coil used for the present process consists of a rotating cylinder and at least one supply bar for the supply of adhesive and compressed air with spray discs, which are driven by pneumatic drive motors arranged in housings. Such a gluing device is described in DE 10 2008 046 637 A1.

[0069] A suitable trough mixer is available from Dieffenbacher, for example. These glue mixers ensure even glue distribution thanks to their large chamber volume and optimal material residence time. To ensure optimal gluing results, the mixer's constant fill level is maintained by an outlet flap.

[0070] After gluing, the glued strands are spread in spreading devices alternately lengthwise and crosswise to the production direction, so that the strands are arranged crosswise in at least three layers (lower cover layer - middle layer - upper cover layer). The spreading direction of the lower and upper cover layers is the same, but differs from the spreading direction of the middle layer. The strands used in the cover layer and middle layer also differ from one another. For example, the strands used in the cover layers are flat, while those used in the middle layer are less flat and even have a chip-like appearance. The strands in the middle layer can be of lower quality, as the flexural strength is essentially generated by the cover layers. Therefore, fines created during machining can also be used in the middle layer of OSB boards.Following the scattering of the strands, they are continuously pressed under high pressure and high temperature of e.g. 200 to 250°C.

[0071] Suitably, the NIR measurement of the present method for determining the amount and distribution of the binder on the strands is performed after the last spreading device, i.e., the NIR measuring head is positioned after the last spreading device. However, it is also conceivable for NIR measurements to be performed after each individual layer (i.e., lower cover layer, middle layer, upper cover layer) has been spread; i.e., one NIR measuring head is positioned after each of the first, second, and third spreading devices.

[0072] The particle boards (OSB) produced with it have a transverse tensile strength of greater than 0.3 N / mm 2 , preferably greater than 0.4 N / mm 2 , preferably greater than 0.45 N / mm 2 , particularly preferably greater than 0.5 N / mm 2The transverse tensile strength can be in a range between 0.3 and 0.6 N / mm 2 , preferably between 0.4 and 0.6 N / mm 2 , particularly preferably between 0.45 and 0.55 N / mm 2 lay.

[0073] Furthermore, particle boards (OSB) have longitudinal elastic moduli between 3200 and 4000 MPa, preferably between 3400 and 3800 MPa, and transverse elastic moduli between 1400 and 1800 MPa, preferably between 1500 and 1600 MPa.

[0074] This OSB wood-based panel can have a density between 300 and 1000 kg / m 3 , preferably between 500 and 800 kg / m 3 , particularly preferably between 600 and 700 kg / m 3 The thickness of the present OSB wood-based panel can be between 5 and 50 mm, preferably between 8 and 40 mm, with a thickness between 8 and 30 mm being particularly preferred.

[0075] As mentioned, glued wood chips, e.g., recycled wood chips, can also be measured using this method. Wood chips are produced in a machining process and divided into fine and coarse chip material. The larger wood chips are preferably used in the middle layer of a particle board, and the smaller wood chips are preferably used in the surface layers.

[0076] After gluing, the glued wood chips are scattered onto a conveyor belt, forming a chip cake. In the case of wood chips, a wind-dispersed method is typically used, with a first top layer being scattered, followed by the middle layer, and finally a second top layer.

[0077] In the case of particleboard production, the NIR measurement is also suitably carried out after the last scattering device, i.e., the NIR measuring head is positioned after the last scattering device. However, it is also conceivable that NIR measurements are carried out after the scattering of the individual layers (i.e., lower surface layer, middle layer, upper surface layer); i.e., one NIR measuring head is positioned after each of the first, second, and third scattering devices.

[0078] The chip cake is then first pre-pressed and then hot-pressed at temperatures between 100°C and 250°C, preferably 130°C and 220°C, in particular at 200°C.

[0079] In both cases (OSB, particle board), the NIR measuring heads are each connected to a control system with an evaluation unit and database for processing and storing the determined NIR data. If the measured actual values ​​deviate from the target values, the system control or regulation makes automatic adjustments. In principle, all NIR measuring heads used in a production line send their measured actual values ​​to the central control and evaluation unit, which regulates or predictively controls the production process accordingly if the measured actual values, for example from a single one of the NIR measuring heads, deviate from the corresponding target specifications. This provides a method in which, by using an NIR measuring head, the quantity and distribution of a binding agent applied to wood particles can be determined from a single NIR spectrum or the reflection orScattering of NIR radiation can be determined using a non-contact measurement. In an advantageous embodiment of the invention, the data acquired with the measuring head(s) are used directly for system control or regulation.

[0080] Furthermore, in a further advantageous embodiment of the invention, storing the data enables improved quality control. The stored data can also advantageously contribute to the evaluation of system tests, e.g., commissioning of a system during a new installation or after maintenance or repair, or for in-situ testing of new production or measurement processes. The immediate availability of the measured values ​​and the high measurement frequency enable very close monitoring, control, or regulation of the systems.

[0081] The advantages of this method are manifold: non-contact multi-parameter determination ("real-time" measurement) with significantly reduced time delay in the evaluation of the measured parameter values; improved plant control, reduction of scrap, improvement in the quality of the products manufactured on the plant, cost reduction, and improved plant availability.

[0082] The control system of each production facility includes at least one computer-based evaluation unit (or processor unit) and a database. The evaluation unit compares or compares the NIR spectrum measured for the product (i.e., coated substrate) with the calibration models created for the individual parameters. The parameter data thus determined is stored in the database.

[0083] The data determined using this spectroscopic method can be used to control the respective production line. The non-contact measured parameter values ​​of the NIR multi-sensor head ("actual values") can, as previously described, be used directly and in real time for the control or regulation of the respective system. For example, by storing the measured actual values ​​in a database, e.g., a relational database, and comparing them with the target values ​​of these parameters available there. The resulting differences are then used to control or regulate the production line.

[0084] For the calibration and control of the respective production line, a computer-implemented method and a computer program comprising instructions that, when executed by a computer, cause the computer to execute the computer-implemented method are provided. The computer program is stored in a memory unit of the control system of the respective production line.

[0085] The invention is explained in more detail below using exemplary embodiments with reference to the figures. They show:

[0086] Figure 1 NIR spectra recorded from wood strands sprayed with PMDI with a blank sample; and

[0087] Figure 2 A, B the distribution of PMDI on wood strands.

[0088] Example 1: Creating a calibration model

[0089] PMDI was sprayed onto top layer strands (1, 3, and 5 wt% on wood) in a rotatably mounted drum using a spray device. The strands, which were made of pinewood, were taken from an industrial production facility after drying. During spraying, the drum was manually rotated using a crank. This process was repeated five times for each concentration.

[0090] Strands (five strands) were taken from the individual experiments and NIR spectra were recorded using a Perkin Elmer NIR measuring device. Five individual spectra were created for each strand sampled. For this purpose, the strand was moved beneath the measuring head. The individual spectra were then combined into an averaged spectrum. A calibration model was then developed using software. The software used a multivariate data analysis.

[0091] For this purpose, NIR spectra were recorded between 700 and 2500 nm. The range between 1350 and 2500 nm was used in particular to create the calibration model. A blank sample without PMDI was also analyzed (see). The NIR spectra shown in the diagram in Figure 1 show a good correlation between the amount of PMDI applied (0, 1, 3, 5 wt%) and the measured signal strength.

[0092] Example 2: Determination of PMDI content in middle layer strands

[0093] From an OSB production line, middle layer strands were taken after gluing in a trough mixer and tested for their PMDI content. According to the formulation, the target value was 2.9 wt%. Spectra were recorded for the ten samples taken using an NIR measuring head, and the PMDI content was determined using the calibration model. It was between 2.6 and 3.2 wt%.

[0094] Example 3: Determination of the PMDI content in recycled chips

[0095] Recycled wood chips were used in the middle layer of an OSB line. These chips differed significantly in color from the top layer strands made from forest wood. Some were gray, brownish, or reddish in color. These strands were glued with 3.5 wt% PMDI in a trough mixer. Samples were taken and analyzed with the NIR measuring head. This resulted in differently colored samples (sorting). Despite the discoloration, values ​​between 3.1 and 3.6 wt% were determined. No significant outliers were observed.

[0096] Example 4: Determination of PMDI content of OSB strands on a production line for the manufacture of OSB

[0097] An NIR measuring head was installed centrally above an OSB line, just before the continuous press. During production, NIR spectra of the PMDI-glued strands were continuously recorded. Eight spectra were generated per minute. The spectra were displayed using software as an average over a specific number of spectra. The PMDI content of 2.9 wt% was confirmed on average. The gluing was then increased from 2.9 wt% to 3.5 wt%. This increase was replicated using the NIR measuring head.

[0098] Uneven gluing was simulated using unglued strands. During a production run in which the top layer strands were glued with 2.9 wt% PMDI, unglued strands were thrown onto the strand cake at regular intervals, directly in front of the measuring head. It was observed that the mean value of the measurement signal gradually decreased, thus indicating a lower mean glue content. In addition, a greater fluctuation in the measurement signal was also observed.

[0099] The fluctuation of the measurement signal depending on the binder distribution on the wood particles is shown as an example in Figures 2 A,B.

[0100] The diagram in Figure 2A shows a poor binder distribution. In the example shown in Figure 2A, the average measured binder amount is 2.8 wt%. The measured values ​​fluctuate around this mean between 35.7% (largest downward deviation at 1.8 wt%) and 39.3% (largest upward deviation at 3.9 wt%).

[0101] The diagram in Figure 2B, on the other hand, shows a good binder distribution. In the example shown in Figure 2B, the average measured binder amount is 3.1 wt%. The measured values ​​fluctuate around this mean between 19.3% (largest downward deviation at 2.5 wt%) and 25.8% (largest upward deviation at 3.9 wt%).

[0102] The data obtained through online measurement can be archived to determine whether any deviations occurred in the event of product problems later. Of course, glue dosing can also be controlled in combination with the determination of technological values. Of particular interest, of course, is the comparison of different glues in terms of their performance. The analyses described above can help optimize the production line in terms of costs and productivity.

[0103] There are advantages:

[0104] In-line analysis

[0105] Better process optimization possible

[0106] - Analysis of glue distribution Easier error analysis

[0107] - Cost reduction Example 5: Determination of PMDI content in a mixture with starch on middle layer strands

[0108] From an OSB production line, middle layer strands were taken after gluing with a binder mixture of PMDI and starch in a ratio of 9:1 in a trough mixer and tested for their PMDI content. According to the formulation, the target PMDI content was 2.5 wt%. Spectra were recorded for the ten samples taken using an NIR measuring head, and the PMDI content was determined using the calibration model. It was between 2.2 and 2.8 wt%.

Claims

Patent claims 1. A measuring method for the online determination of an amount of a formaldehyde-free binder applied to wood particles in a production plant for the manufacture of wood-based panels, comprising the steps - applying at least one formaldehyde-free binder in different quantitatively defined amounts to respective samples of wood particles as reference samples and scattering the reference samples onto a conveyor belt; - Recording at least one NIR spectrum of each of the reference samples scattered onto the conveyor belt using at least one NIR measuring head in a wavelength range between 1000 nm and 2500 nm, preferably between 1350 nm and 2500 nm, particularly preferably between 1800 nm and 2500 nm, most preferably between 2000 and 2200 nm, - Allocation of the different quantitative amounts of formaldehyde-free binders of the reference samples sprinkled on the conveyor belt to the recorded NIR spectra of the said reference samples; and - Creation of a calibration model for the relationship between the spectral data of the NIR spectra and the corresponding quantitative amounts of formaldehyde-free binder of the reference samples sprinkled onto the conveyor belt using a multivariate data analysis; - applying at least one formaldehyde-free binder to wood particles and scattering the wood particles coated with the formaldehyde-free binder onto a conveyor belt, - Recording at least one NIR spectrum of the wood particles provided with the formaldehyde-free binder and scattered onto the conveyor belt using the at least one NIR measuring head in a wavelength range between 1000 nm and 2500 nm, preferably between 1350 nm and 2500 nm; particularly preferably between 1800 nm and 2500 nm, most preferably between 2000 and 2200 nm, and - Determining the quantitative amount of formaldehyde-free binder applied to the wood particles by comparing the NIR spectrum recorded for the wood particles coated with the binder with the created calibration model, whereby the amount of formaldehyde-free binder applied to the wood particles is between 0.5 and 5.0 wt%, 2. Method according to claim 1, characterized in that the method is carried out in a production plant with a plant speed between 200 and 500 mm / sec, preferably between 300 and 400 mm / sec.

3. Method according to one of the preceding claims, characterized in that the at least one NIR measuring head moves transversely to the running direction of the conveyor belt sprinkled with the glued wood particles and traverses over the entire width of the conveyor belt.

4. Method according to one of the preceding claims, characterized in that the at least one NIR measuring head records several spectra per minute, preferably up to eight spectra per minute, from which an average value is formed over the number of recorded spectra.

5. Method according to one of the preceding claims, characterized in that the amount of binder determined by means of NIR spectroscopy is related to the technological values, preferably transverse tensile strength, of a wood-based panel produced after pressing the glued wood particles.

6. Method according to one of the preceding claims, characterized in that spectral data from the entire recorded spectral range are used to determine the amount of binder applied.

7. Process according to one of the preceding claims, characterized in that the formaldehyde-free binder is an isocyanate-containing binder, preferably based on aromatic polyisocyanates, in particular Polydiphenylmethane diisocyanate (PMDI), toluene diisocyanate (TDI) and / or diphenylmethane diisocyanate (MDI), with PMDI being particularly preferred.

8. Process according to one of the preceding claims, characterized in that the formaldehyde-free binder comprises at least two components, one component being a biodegradable binder.

9. The method according to claim 8, characterized in that the formaldehyde-free binder comprises an isocyanate-containing binder and a biodegradable binder.

10. The method according to any one of the claims, characterized in that the biodegradable binder is selected from a group comprising starch, cellulose derivatives such as carboxymethyl cellulose, chitosan, gluten-containing binders such as hide glue, bone glue, leather glue; milk protein-containing binders, in particular from the group of caseins, and plant protein-containing binders, in particular from the group of soy binders, agar-agar, alginate, gelatin, guar gum, gum arabic, xanthan gum, pectins, locust bean gum, polysaccharides such as carrageenan, lignin or rapeseed residue, with starch and soy flour being particularly preferred.

11. Method according to one of the preceding claims, characterized in that the amount of formaldehyde-free binder applied to the wood particles is between 1.0 and 5.0 wt%, preferably between 1.5 and 4.0 wt%, particularly preferably between 2.0 and 3.5 wt%, very particularly preferably between 2.5 and 3.0 wt%, even more preferably between 2.5 and 2.9 wt%, based on the wood particles.

12. Method according to one of the preceding claims, characterized in that wood strands and wood chips are used as wood particles.

13. Method according to one of the preceding claims, characterized in that wood strands with a length between 50 and 200 mm, preferably 70 to 180 mm, particularly preferably 90 to 150 mm; a width between 5 and 50 mm, preferably 10 to 30 mm, particularly preferably 15 to 20 mm; and a thickness between 0.1 and 2 mm, preferably between 0.3 and 1.5 mm, particularly preferably between 0.4 and 1 mm are used as wood particles.

14. Method according to one of the preceding claims, characterized in that the recorded NIR spectra are used to determine the distribution of the formaldehyde-free binder on the wood particles.

15. Method according to claim 14, characterized in that the distribution of the formaldehyde-free binder on the wood strands is determined.

16. Method according to one of the preceding claims, characterized in that the recorded NIR spectra are used to analyze further parameters of the wood particles, in particular size distribution of the wood particles, moisture content of the wood particles.

17. Method according to one of the preceding claims, characterized in that the determination of the amount of binder applied to the wood particles takes place in the production line after leaving a device for scattering the wood particles.

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