Method and device (system) for producing a material panel

Abstract

The invention relates to a method for producing a material panel having at least one layer which has at least a portion of natural fibres, wherein at least one of the at least one layer comprises a useful product which is produced from a raw material comprising natural fibres, wherein the method comprises at least the following steps: i) providing a system for producing a material panel, at least comprising: material preparation, gluing, shaping, pressing, finishing, iii) breaking down the raw material, under the action of a pressure shock wave having a pulse duration and a pulse frequency, into useful product having at least a first, oddly indexed component and a second, evenly indexed component using at least one device for breaking down the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency, iv) separating the first, oddly indexed component and the second, evenly indexed component on the basis of at least one parameter v) providing the (at least one) obtained oddly indexed component for use in at least one further process step of the method. In order to be able to produce material panels, inter alia, in an environmentally friendly and cost-effective manner, the invention proposes providing the following step: vi) breaking down at least one of the evenly indexed component under the action of a pressure shock wave having a pulse duration and a pulse frequency in such a way that at least one further oddly indexed component is produced.

Description

[0001] Method and device (plant) for producing a material plate

[0002] The invention relates to a method for producing a material board having at least one layer comprising at least a portion of natural fibers, wherein at least one of the at least one layer comprises a useful product made from a raw material comprising natural fibers, wherein the method comprises at least the following steps: i) providing a system for producing a material board, at least comprising material preparation, gluing, forming, pressing, and finishing, iii) breaking down the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency into at least a first, odd-indexed component and a second, even-indexed component using at least one device for breaking down the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency, iv) separating the first,odd-indexed component and the second, even-indexed component based on at least one parameter v) making the at least one obtained odd-indexed component available for utilization in at least one further process step of the method.

[0003] The invention further relates to a plant for producing a material board having at least one layer comprising at least a proportion of natural fibers, wherein at least one of the at least one layer comprises a useful product which is produced from a raw material comprising natural fibers, wherein the plant comprises at least the following: a material preparation with at least one device for breaking down the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency a gluing a shaping a pressing a finishing process.

[0004] The production of material sheets takes place either in a cyclical or continuous manner, so that corresponding processes and devices, or systems, are designed accordingly. In cyclical production, the material sheets are produced as flat objects with finite dimensions in all three spatial directions, whereas the material sheets produced in a continuous process represent cut-to-length sections of a web material with finite dimensions in only two spatial directions. The operation of the joining and / or compacting unit determines whether the overall process is described as a cyclical or continuous process. Since the compacting units, or the combined joining and compacting units, generally operate with significant pressures during material sheet production, these units are usually referred to by experts as "press sections" in reference to the overall system.When producing material plates as defined in this document, the working pressures are usually in the range of approximately 50 N / cm, depending on the material and size of the material plate to be produced. 2 and approx. 500 N / cm 2 and there advantageously between 100 N / cm 2 and 400 N / cm 2 .

[0005] Both from an economic perspective and with regard to their technical applicability, material boards containing at least one layer containing a natural fiber component occupy a special position among material boards. For the purposes of this document, natural fibers or fiber components are understood to mean fibers and fiber components that have a natural origin, i.e., originate from an annual or perennial plant, regardless of whether the fibers or fiber components are present as pure fibers, for example, for the production of MDF / HDF boards or their layer types, or form components of chips, long chips, or wafers, which are traditionally used for the production of particleboard or OSB boards or their layer types. The term "wood particles," also used below, therefore always includes at least natural fibers or fiber components.

[0006] Such material boards are often simply referred to by experts as "wood-based panels," even if they contain one or more layers that are not based on a raw material obtained from a perennial plant. Even material boards that comprise only one or more layers that consist at least partially of fibers and / or fiber components obtained from annual plants are usually referred to as wood-based panels and only very rarely are they correctly referred to as "bast or grass-based panels."

[0007] Such wood-based panels are manufactured in a wide variety of forms for different applications. Particularly widespread are particleboard, OSB, and MDF or HDF panels, as well as hybrid panels constructed from individual layers of such composites. The name of the material panels depends on the shape and size of the wood particles used to construct the panel or layer. Experts refer to a particleboard when it is made from "fine" wood particles, while an OSB panel is used when it is made from coarse wood particles. Experts generally understand fine wood particles to be particles whose maximum dimension in one spatial direction does not exceed 60 mm; these particles, described as chips, are usually even formed with a maximum dimension of 25 mm or even 20 mm.In general, experts understand coarse wood particles to be particles whose maximum dimension in one spatial direction is at least 60 mm. These particles, described as long chips, are usually formed with a maximum dimension of 60 mm to 185 mm, especially 80 mm to 140 mm. MDF and HDF boards, or their individual layers, are made of (medium-density or high-density compressed) fibers, which are usually extracted from the raw material through a chemical process, usually a type of cooking.

[0008] Hybrid panels consist of several layers of different types and are often particularly suitable when the material panel has to meet different requirements for its intended use.

[0009] Such material boards are still referred to as wood-based panels even if they contain individual layers that do not contain any natural fibers and / or fiber components. These are usually laminated material boards, i.e., wood-based panels that are laminated on one or both sides. Plastics are typically used for the lamination. So-called coated particle boards are particularly well-known.

[0010] The types and types of wood-based panels mentioned are therefore made from wood particles (chips, long chips or fibers) of different shapes and sizes, whereby the wood particles are bonded by stimulating their own adhesion mechanisms and adding adhesives (usually a glue) in the so-called press section of a material panel production plant under the influence of pressure and temperature.

[0011] Recently, efforts have been made to use annual plants, particularly grass-like plants, for the production of composite panels, in addition to wood materials, which take many years to regrow. These annual plants have the great advantage of rapid growth. Thus, their use is particularly resource-efficient and fits better with the growing environmental awareness worldwide. Furthermore, the increasing prosperity in many countries, such as Asia, requires meeting a large demand for composite panels for housing construction, particularly interior design or furniture construction. Since annual plants do not shed bark, their harvested products initially form a homogeneous raw material from a production perspective, the fibers of which can be extracted for composite panel production through a splicing process.Single- or multi-layer material panels are also known from the state of the art, the individual layers of which consist of annual plants.

[0012] However, the processing of annual plants is significantly more complicated than wood particle-based material boards. The high release of silicates during the manufacturing process, which have an abrasive effect on plant construction, poses a major obstacle.

[0013] This requires significantly increased effort, particularly with regard to plant construction, for example, due to additional process steps, the reinforcement of certain plant components, and an increased need for spare parts. There is also the risk of production downtime. All of this makes the production of panels made from annual plants significantly more expensive. Furthermore, these factors counteract the fundamental advantage of lower environmental impact, as not only is the energy required to operate the plant significantly higher, but the service life of the entire plant, and in particular of the individual devices or equipment contained therein that form process sections, is usually significantly reduced. Last but not least, the mechanical properties of panels (layers) made from annual plant particles differ from those of their wood particle-based counterparts.

[0014] These problems are significantly slowing the development of composite panel use in growth markets and thus also slowing overall economic growth in the respective market. On the other hand, especially in Asian countries, large forests with a sufficient density of mature trees are often not available everywhere in sufficient quantities for economic production by current standards.

[0015] For these reasons, initial efforts are underway to make woody grass-like plants, particularly woody grasses, accessible for the production of material panels. The most widespread representatives of this species, bamboo plants, are perennial, woody grass-like plants characterized by rapid growth and high strength. Due to their widespread distribution, they are available in sufficient quantities, especially in regions with rapidly growing economies. For example, approximately 6 million hectares in China are populated by bamboo species, and in India, the figure is as high as 9 million hectares.

[0016] However, initial studies have shown that the strength properties observed in bamboo constructions used in full stalks are not transferable to material panels made from the resulting fiber material.

[0017] Another approach to producing and marketing material panels in an environmentally friendly and cost-effective manner, also with regard to energy consumption and the overall process, is to produce material panels in hybrid forms and / or to use raw materials from different plant bases or different mixtures of raw materials from different plant bases for different layers.

[0018] Unfortunately, considerable difficulties have arisen in this area as well, so that it still seems hardly possible to produce material panels in a resource-saving manner, also in an environmentally friendly and cost-effective manner with regard to energy consumption and the overall process, and to supply them to the market in sufficient quantities.

[0019] Accordingly, one object of the invention is to improve the current problem situation at least with regard to one of the aspects mentioned.

[0020] In a method for producing a material board having at least one layer comprising at least a proportion of natural fibers, wherein at least one of the at least one layer comprises a useful product which is made from a raw material comprising natural fibers, the method comprising at least the following steps: i) Providing a system for producing a material board, at least comprising material preparation, gluing, shaping, pressing and finishing iii) Decomposing the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency into at least a first, odd-indexed component and a second, even-indexed component containing useful product, iv) Separating the first, odd-indexed component and the second, even-indexed component based on at least one parameter v) Providing the at least one,obtained odd-indexed components for utilization in at least one further process step of the method, as well as in a method for producing a material board having at least one layer comprising at least a proportion of natural fibers, wherein at least one of the at least one layer comprises a useful product made from a raw material comprising natural fibers, the method comprising at least the following steps: i) Providing a system for producing a material board, at least comprising material preparation, gluing, shaping, pressing, and finishing, ii) Mechanically contacting pre-shredding of the raw material, iii) Decomposing the (pre-shredded) raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency into at least a first, odd-indexed component and a second, even-indexed component,iv) Separation of the first, odd-indexed component and the second, even-indexed component based on at least one parameter, v) Provision of the at least one obtained odd-indexed component for utilization in at least one further process step of the method, at least one aspect of the object underlying the present invention is achieved by providing the following process step: vi) Decomposition of at least one of the even-indexed components under the action of a pressure shock wave having a pulse duration and a pulse frequency, such that at least one further odd-indexed component is created.

[0021] The individual steps mentioned in the proposed method, and in some cases also the additional steps mentioned in the preferred embodiments, can preferably be carried out chronologically, at least in sections. Particularly significant advantages can result if at least steps i) to vi) are carried out chronologically one after the other, even if step ii) is preferably not carried out in some cases. In some cases, it may be preferable for the steps to be carried out chronologically one after the other, but not directly one after the other, i.e., a step mentioned in the preferred embodiments can be carried out between two steps, without, however, changing their priority.In exceptional cases, it may also be preferable, in addition to or in deviation from this, for a temporal priority within steps i) to vi) and / or within the steps mentioned in the preferred embodiments to change from one another. However, since this is at least associated with significant disadvantages, only individual cases are possible, which may arise, for example, in certain compositions of recycled fibers and fresh fibers, in particular fibers obtained from grass-like plants.

[0022] Furthermore, it may be advantageous in certain cases if step ii) is carried out using a rotor chipper. Since the mechanically contacting comminution then comprises not only an effective cutting component but also an effective crushing component in the separation process, the fibers extending across both sides of the separation plane to be created in the undivided plant (the raw material comprising natural fibers) are not all separated, but rather partially merely deflected, so that overall a larger proportion of undamaged fibers remains—and thus still usable for the formation of strength and binding properties. This can form a good starting point in this case. In other cases, however, it may also be advantageous if step ii) is carried out using a knife-shaft chipper.Deviating from the implementation of process step ii) using a rotor chipper, this results in fewer transverse forces overall loading the raw material, which, in conjunction with the basic idea of ​​the present invention, can lead to special symbioses when processing raw materials obtained from certain plant varieties. In any case, it is advantageous that, when providing process step ii), the resulting raw material particles, i.e., the cuttings or wood chips, move in a size range characterized by a length—measured along the fiber direction—between 20 mm and 200 mm, in particular between 30 mm and 100 mm, most particularly between 35 mm and 80 mm, or even more advantageously between 40 mm and 65 mm.For verification purposes, it is always necessary that when a volume of material, for example one cubic meter, is extracted, at least 90% of the relevant raw material components—here the wood chips or cuttings—fall under the relevant definition. Regardless of the clearly distinct design variants described here, the provision of the characteristic process step vi) decomposition of at least one of the even-indexed components under the action of a pressure shock wave having a pulse duration and a pulse frequency, such that at least one further odd-indexed component is created, always results in the great advantage that the properties inherent in the raw materials contained in natural fibers derived from a particular plant species are retained to a previously unattainable extent. This applies primarily to their mechanical properties, in particular tensile and compressive strength and flexural strength.But also the fatigue strength of individual fibres obtained in this way, as well as of the fabrics or mixtures formed from them, which is considered much less frequently, increases considerably due to the high preservation of undamaged or at least almost undamaged natural fibres.Although it is known from earlier publications by the applicant that contactless disintegration of pre-shredded plant parts preserves the cell structure of their fibers during further disintegration considerably better than is possible using mechanically contacting process steps, it is also known that contactless processes, i.e. the disintegration of raw materials comprising natural fibers under the influence of a pressure shock wave having a pulse duration and a pulse frequency, are considerably inferior to the achievable throughput, measured in mass or volume flows, of mechanically contacting processes - in some cases by a factor of 5 or 6, in some cases even more significantly.In order to improve a process of the type mentioned at the beginning in such a way that it leads, among other things, to a particularly economical production of material boards, it is therefore far-fetched to anchor the repetition of such a "bottleneck" in an overall process. This makes it seem remote from the objective of the present task to be achieved. However, the inventors have recognized, on the one hand, that achievable results of the fiber properties measured using at least one parameter can be improved and, on the other hand, that the described positive effects and their derivatives more than compensate for the disadvantage of the low throughput, also from an economic point of view.If a large number of fibers and their cell structures remain undamaged, they individually contribute significantly more to the achievable strength of a material board produced from them, but they are also much more likely to bond with other (healthy) cells of natural fibers. Consequently, it may be possible, for example, to achieve the desired strength properties of a material board by using a lower thickness and / or a lower density. This, combined with, among other things, lower energy consumption, ultimately leads to a particularly resource-saving, environmentally friendly, and cost-effective production process for material boards, also with regard to energy consumption and the overall process.

[0023] In addition, it has surprisingly been shown that repeated treatment of the raw material containing natural fibers with pressure waves not only allows for finer and more repeatable shapes of fibers or, in particular, chips, wafers and pellets to be obtained without their cell structure showing any (technically relevant) greater damage, but also, depending on the plant variety, increases the binding capacity of the fibers, sometimes even very impressively.

[0024] It is therefore preferred that step iv) is repeated multiple times, in particular 2 to 6 times, very particularly 2 to 4 times or 3 to 4 times. It is irrelevant whether, in the repetition steps, at least one of the even-indexed components is decomposed under the influence of a pressure shock wave having a pulse duration and a pulse frequency, such that at least one further odd-indexed component is created, and / or whether at least one of the (then) odd-indexed components is decomposed under the influence of a pressure shock wave having a pulse duration and a pulse frequency, such that at least one further even or odd-indexed component is created. Thus, if the process is repeated twice, at least portions of the components have undergone a decomposition process 3 times under the influence of a pressure shock wave having a pulse duration and a pulse frequency.However, experiments have surprisingly shown that the quality gain hardly increases or does not increase at all after a few repetitions, so that from an energetic point of view, repetitions of more than 6 times (or more than 7 times) do not seem to be advisable.

[0025] To design the process, it may be preferable in certain cases that step iii) and

[0026] Step vi) using, and preferably within, the same device for decomposing the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency.

[0027] In other words, at least a portion of the raw material that has already passed through step iii) is returned via a ring line to the same device for decomposing the raw material under the influence of a pressure shock wave having a pulse duration and a pulse frequency. Fractionation can be provided so that, based on at least one parameter, it can be decided which portion of the raw material should be returned to the device for decomposing the raw material under the influence of a pressure shock wave having a pulse duration and a pulse frequency and which portion should be fed to subsequent process steps. This creates a type of "loop operation" that returns at least a portion of the raw material that has already passed through step iii) via a ring line to the same device for decomposing the raw material under the influence of a pressure shock wave having a pulse duration and a pulse frequency.Such a ring line can advantageously include a type of "bypass circuit".

[0028] It is preferred that the same device for breaking down the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency for carrying out step iii) and step vi) is also operated in the same, or at least approximately the same, mode of operation. Preferably, the mode of operation is defined by the respectively provided pulse duration and pulse frequency of the pressure shock wave(s), which, in devices having at least one rotor for generating the pressure shock waves, can be influenced in their simple designs primarily by adjusting the provided rotor speed(s). In the preferred embodiment, these rotor speed(s) are to be kept constant or at least approximately constant. In such devices, it is therefore sufficient if the provided speed for carrying out step iii) and step vi) simply remains constant.The term "constant" in this context preferably means actually constant, at least in the technical sense, i.e., the same nominal speed, without any controlling intervention and merely disregarding possible grid fluctuations or motor inaccuracies. Technically insignificant adjustments of less than 10%, preferably less than 5%, and most preferably less than 3% deviation of the nominal speed or the nominal speeds for several - especially two - rotors should, however, be included in a broad interpretation, regardless of whether they would result in an increase or a decrease in speed.

[0029] In addition to lower construction costs, such a design is characterized primarily by particularly short paths for the raw material to be reprocessed, i.e., the raw material processed in at least one loop. This is not unimportant, since natural fibers that undergo an overall process consisting of multiple process steps also function – so to speak, from within themselves – and thus do not change their properties or at least their value alter solely due to external influences. However, such internally controlled processes usually proceed at lower speeds, so that with short paths and, consequently, short residence times of the natural fibers between two treatment steps, the process sequence can be defined more precisely, and in turn, from an environmental point of view, undesirable auxiliary measures can be reduced or even dispensed with in some cases.This may include re-moistening or drying, temperature increases or accelerations or decelerations of the ongoing mass or volume flow that would otherwise have to be provided, which at least unnecessarily increase the overall energy requirement.

[0030] In order to counteract the bottleneck aspect already mentioned, which is to be expected by providing a step iii) and in particular in conjunction with a step vi), it can therefore be advantageous to provide at least two devices arranged next to one another for breaking down the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency for carrying out step iii) and step vi), which devices are each suitable for closed loop operation by means of corresponding ring lines and are connected next to one another, i.e. in a parallel circuit.

[0031] In other cases, however, it may be preferred that step iii) is carried out using, and preferably within, a first device for decomposing the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency for carrying out step iii) and step vi) and step vi) is carried out using, and preferably within, a second device for decomposing the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency for carrying out step iii) and step vi).

[0032] In contrast to the previously described embodiment, this embodiment represents a "series connection".

[0033] In this case, it is preferred that the first device for carrying out step iii) and the second device for carrying out step vi) are also operated in the same, or at least approximately the same, mode. The mode is preferably defined by the respective intended pulse duration and pulse frequency of the pressure shock wave(s). In devices that have at least one rotor for generating the pressure shock waves, these can be influenced, in their simple designs, primarily by adjusting the intended rotor speed(s). In such devices, it is sufficient if the intended speed for carrying out step iii) and step vi) is simply set to a constant speed. In this context, the term "constant" preferably means truly constant, at least in the technical sense, i.e., an identical nominal speed without any controlling intervention.However, technically insignificant adjustments of less than 10%, preferably less than 5%, most preferably less than 3% deviation from the nominal speed should be included in a broad interpretation, regardless of whether they would result in an increase or a decrease in speed.

[0034] However, when operating at a constant rated speed, as previously described, the loop operation design is preferable unless, for example, structural requirements, for example coupled with a minimum throughput to be achieved, speak in favor of the design described here.

[0035] However, the series connection described here offers the advantage that pressure shock waves with different pulse durations and pulse frequencies are used to carry out step iii) and step vi).

[0036] This can lead to the great advantage, particularly when applied to woody grasses, for example various bamboo species, that larger-sized raw material parts can be treated in a first cycle and smaller raw material particles can be treated in a subsequent cycle, and the pressure shock waves can be individually designed and / or adjusted to the resulting different requirements, so that work can be carried out in a particularly energy-efficient manner.

[0037] Of course, the combination of a series connection and a parallel connection can also lead to significant advantages, for example, enabling both an energy-efficient and highly productive implementation of the process. Furthermore, it may be preferred that steps iii) and iv) are carried out using, and preferably within, the same device for separating the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency. This device, in terms of the device, therefore comprises a separating unit and is thus suitable for separating the first, odd-indexed component from the second, even-indexed component based on at least one parameter.

[0038] The separating unit can, for example, be designed according to the centrifugal force principle and move heavier, larger components (here: even-indexed component) which are to be fed to process step vi) into compartments, shafts or channels provided for this purpose, while components which have already been reduced to an acceptable nominal size (here: odd-indexed component) are fed to the further process flow.

[0039] If the facility has two shock wave generating units or an internal bypass, the device (plant) is also suitable for carrying out the present method in such a way that steps iii), iv), and vi) are carried out using, and preferably within, the same facility. The advantages resulting from the aforementioned embodiments relate in particular to achieving a higher overall efficiency, since the acceleration energy expended in connection with the implementation of process step iii) to decompose the raw material can also be used in part to carry out process step iv) and subsequently, if necessary, also in part to carry out process step vi). In addition, the short distances result in synergy effects.A particular advantage, however, is that even and odd indexed components are separated from each other at a very early stage, which reduces the effort required to separate the components and also achieves better allocation rates, particularly above 98% and even above 99.6%, with less energy consumption. In certain cases, it may be preferable for the moisture content of the natural fibers during the execution of step iii) and step vi) to be within a range of above 200% to 20%, preferably from 160% to 25%, and most preferably from 135% to 45%.

[0040] ("Wet area")

[0041] The moisture content present in raw materials comprising natural fibers is consistently formed by the retention of water and / or aqueous solutions. Since water (and, at least to a first approximation, solutions formed from it) are incompressible, they transmit any pressure waves that occur in all spatial directions. While this results in a certain damping effect through heat loss and thus a certain reduction in the efficiency of the process, experiments have surprisingly shown that a high moisture content strongly promotes a type of internal splitting between the fibers.

[0042] Alternatively, however, it may also be preferred in certain cases that the moisture content of the natural fibers during the implementation of step iii) and step vi) is within a range of a maximum of 18.5% to less than 1.0%, preferably from 16% to 2% and most preferably from 13% to 2%.

[0043] Analyses of test results have surprisingly shown that, in particular, fillers made from raw materials containing natural fibers tend to experience brittle fractures in some plant varieties and species, while the fiber cell structures remain stable. Thus, at least for certain plant varieties, the process can be operated in a particularly energy-saving and efficient manner.

[0044] To combine both advantages and achieve additional synergy effects, it may also be preferred that the moisture content of the natural fibers during step iii) is within a range of more than 200% to 20%, preferably from 160% to 25%, and very preferably from 135% to 45%, and during step vi) is within a range of a maximum of 18.5% to less than 1%, preferably from 16% to 2%, and very preferably from 13% to 2%. In other words, a step vii) to reduce the moisture content of the natural fibers is carried out between step iii) and step vi). Such a process step is usually referred to as "drying." Consequently, at least a first pass takes place in the wet section and at least a second pass in the dry section of the plant.It is therefore also possible to provide several passes in one of the two areas and to combine them with at least one pass in the other area.

[0045] It is very advantageous to carry out a step viii) between the execution of step iii) and step vi) to separate out undesirable raw material components, in particular silicates.

[0046] Silicates are found in many plant species. However, due to their concentration and the different ways they are deposited within the cell structure, their presence is particularly hazardous when processing raw materials derived from certain plant varieties and can rapidly reduce the lifespan of a plant for the production of material panels and / or its individual components. Therefore, increased accessibility of undesirable raw material components, such as the silicates mentioned above, within and / or directly downstream of a non-contact comminution system is particularly advantageous for initiating their removal.

[0047] It can also lead to significant advantages if, between the implementation of step iii) and step vi), a step ix) is carried out to enrich and / or combine the natural fibres with at least one additive.

[0048] An additive can be understood, in particular, as so-called additives that are not absolutely necessary for the formation of a material board under conventional standards, but are intended to improve certain properties. In particular, flame retardants, pesticides, mold inhibitors, odor additives, or agents that reduce the swelling tendency of a natural fiber, and thus of a material board made at least partially from natural fibers, can be suitable and specifically intended. In individual cases, an additive can also be understood as an adhesion-promoting additive, such as a glue, even if its effect on further processing is fundamentally different. This exception can, however, apply in particular if the glue has a particularly long setting time or, for example, only one component of an adhesion-promoting additive (an "adhesive") is used or added—which is not yet active in itself.

[0049] Accordingly, various advantages can arise if the high binding capacity of the natural fibres present between steps iii) and vi) is exploited.

[0050] Furthermore, it may be preferred that the method further comprises a further step: x) passing on a volume flow of at least two odd-indexed components to a subsequent process step, wherein at least one of the two passed on odd-indexed components and the portion of the volume flow formed therefrom is obtained from a previously even-indexed component, preferably at least in step iv).

[0051] The process can be operated particularly precisely and effectively through targeted forwarding of the volume flow in a defined step. The forwarding of a volume flow of at least two odd-indexed components to a subsequent process step, wherein at least one of the two passed-on odd-indexed components and the portion of the volume flow formed therefrom is obtained from a previously even-indexed component, preferably at least in step iv), also makes it possible for subsequent process steps to be supplied with a volume flow whose natural fibers contain a high percentage, for example 100% or almost 100%, but at least (significantly) over 90%, e.g.over 93% or over 96% correspond exactly or at least approximately exactly to the desired configurations, which could be measured using at least one parameter and, for example, fall exactly within the desired size or weight range, whereby each—or at least most, for example 100% or approximately 100%, but at least (significantly) over 90%, for example over 93% or over 96%—of the natural fibers forwarded to the downstream process steps were exposed to the pressure waves used for pulping only as often as necessary. This not only leads to the achievement of truly exceptional quality, but also ensures minimal or at least almost minimal energy consumption.A subsequent process step can be one of the steps vii) to x) referred to as a process step, but it can also be a process step resulting from the execution of a subsequent arrangement, for example, the pressing process step when passing through the press. A subsequent process step can therefore be in direct or indirect succession.

[0052] In some cases, it may be preferable that the proportion of the volume flow consists of natural fibers in fiber form and is between 27 m 3 / h and 3 m 3 / h, preferably between 20 m 3 / h and 4 m 3 / h, especially preferably between 16 m 3 / h and 4 m 3 / h, especially preferably between 12.5 m 3 / h and 5 m 3 / h and most preferably between 11 m 3 / h and 5.5 m 3 / h.

[0053] These values ​​were surprisingly obtained in experiments.

[0054] It may also be preferable in some cases that the proportion of the volume flow consists of natural fibres in chip form and lies between J and 3 m 3 / h, preferably between 20 m 3 / h and 4 m 3 / h, especially preferably between 16 m 3 / h and 4 m 3 / h, especially preferably between 12.5 m 3 / h and 5 m 3 / h and most preferably between 11 m 3 / h and 5.5 m 3 / h.

[0055] These values ​​also emerged surprisingly in experiments.

[0056] In some cases, it may also be preferable that the proportion of the volume flow consists of natural fibres formed in long chip form and is between 27 m 3 / h and 3 m 3 / h, preferably between 20 m 3 / h and 4 m 3 / h, especially preferably between 16 m 3 / h and 4 m 3 / h, especially preferably between 12.5 m 3 / h and 5 m3 / h and most preferably between 11 m 3 / h and 5.5 m 3 / h.

[0057] These values ​​also surprisingly emerged from experiments.

[0058] In some cases, it may also be preferable that the proportion of the volume flow consists of natural fibres in pellet form and is between 27 m 3 / h and 3 m 3 / h, preferably between 20 m 3 / h and 4 m 3 / h, especially preferably between 16 m 3 / h and 4 m 3 / h, especially preferably between 12.5 m 3 / h and 5 m 3 / h and most preferably between 11 m 3 / h and 5.5 m 3 / h.

[0059] These values ​​also surprisingly emerged from experiments.

[0060] Preferably, the method can be further developed such that at least a part of the just indexed components, in particular at least 30%, preferably at least 55%, very preferably at least 75% of the just indexed components are used to form a core layer of a material plate.

[0061] Such a design of the present process offers a good compromise between quality and productivity. The even-indexed components can be used to form the core volume of a material sheet. The core layer, i.e., the middle layer of a material sheet, is often surrounded on both sides by one or two flanking cover layers, but nevertheless often occupies more than 20% of the volume (calculated for a 5-layer material sheet) or more than 33% of the volume (calculated for a 3-layer material sheet). Since the even-indexed components forwarded to subsequent process steps—at least in the context of a larger quantity, such as (at least) one cubic meter—do not achieve the quality of the odd-indexed components, but also require less production time and energy, this method supports the achievement of increased productivity.

[0062] Independently of this or in addition thereto, it can also be particularly advantageous if at least a part of the odd-indexed components, in particular at least 30%, preferably at least 55%, very preferably at least 75% of the odd-indexed components are used to form a cover layer of a material plate.

[0063] Such a development of the present process can also at least indirectly contribute to a good compromise between quality and productivity, because the cover layers are crucial for achieving the usually decisive strength values ​​and are also visually perceived by the customer. Furthermore, they often form the basis for possible finishing processes, such as sanding processes and / or lamination with real wood or plastic layers or with decorative papers.Since, as already described, it has surprisingly been shown that repeated treatment of the raw material containing natural fibers with pressure waves not only produces finer and more repeatable shapes of fibers, or in particular chips, wafers, and pellets, without causing significant (technically relevant) damage to their cell structure, but also increases the fibers' ability to bond – sometimes significantly, depending on the plant variety. This allows the production of covering layers with outstanding quality and surface finish. In conjunction with the aforementioned embodiment, this results in particularly high-quality material panels with low energy consumption and reasonable production costs.

[0064] Particular advantages are achieved when raw material from the grass family (Poaceae), in particular from their subfamilies Arundinarieae and / or Bambuseae, is used.

[0065] Bamboo plants are woody grasses. Experiments have surprisingly shown that they can be spliced ​​or compressed into long-fiber cell structures using non-contact processes, particularly using pressure pulses, with low energy levels and high repeatability, with good distribution and yield, if the raw material is subjected to this process step at least twice. Surprisingly, this process step can be carried out under the same or even identical boundary conditions, which seems counterintuitive, since one cannot usually expect a different comminution result (such as "grinding result") with the same or even identical settings of a comminution unit, and one certainly cannot expect to achieve greater suitability, in particular better splicing, fiberization, suitable length, or the like, after a second run.

[0066] Thus, raw material originating from the grass family (Poaceae), in particular from its subfamilies Arundinarieae and / or Bambuseae, is surprisingly particularly well suited to creating a basis for a particularly ecological product, since plants of this species grow quickly even with a low nutrient supply, their fiber extraction can be made very energy-efficient with the present process and material panels with high strength can be produced, since the repeated passage of the raw material through the contactless disassembly can, although fibers of the desired size can be obtained, the cell structure is at least almost completely preserved and the fibers obtained in this way can contribute far greater proportions to the achievable strength values ​​of a material panel than fibers of comparable dimensions obtained in other ways.

[0067] Preferably in addition, but in some cases also alternatively, it may also be particularly advantageous if raw material originating from the coniferous and / or myrtle family, in particular eucalyptus, is used.

[0068] The plant species mentioned also belong to the fast-growing plants and are therefore particularly well suited to a concept of resource-saving material panel production and, surprisingly, respond particularly well to repeated exposure to pressure shock waves, thus producing particularly good results when used in the present process.

[0069] In a plant for producing a material board having at least one layer comprising at least a proportion of natural fibers, wherein at least one of the at least one layer comprises a useful product which is produced from a raw material comprising natural fibers, wherein the plant comprises at least the following: a material preparation with at least one device for breaking down the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency a gluing a shaping a pressing a finishing at least one aspect of the object(s) on which the present invention is based is achieved by providing a line for re-feeding the raw material comprising natural fibers into one of the at least one devices for contactless comminution.

[0070] Such a plant offers the advantage that raw material comprising natural fibers, after a first treatment within a device for breaking down the raw material under the influence of a pressure shock wave having a pulse duration and a pulse frequency, can be fed at least in part to a second treatment within a device for breaking down the raw material under the influence of a pressure shock wave having a pulse duration and a pulse frequency.

[0071] This results in the significant advantage that the system is designed in such a way that the raw materials it processes, which contain natural fibers derived from a specific plant species and contain them, can be subjected to a pressure shock wave with a specific pulse duration and frequency, at least in part, within a single manufacturing process for a material sheet. This allows the properties inherent in natural fibers to be preserved to a previously unattainable degree. This primarily applies to their mechanical properties, particularly their tensile and compressive strength and flexural strength. However, the fatigue strength of individual fibers obtained in this way—as well as the fabrics or mixtures formed from them—is also significantly increased due to the high degree of preservation of undamaged or at least virtually undamaged natural fibers.In addition, their willingness to bond both with each other and with third raw materials increases, which leads to further increased strength and the reducibility of binding agents, as well as to lower energy requirements, since in order to achieve sufficient bonding capacity, especially between natural fibers, lower temperatures and / or pressures are necessary to maintain the health of the fibers in order to meet the requirements placed on a (layer of a) material board.

[0072] As a result, it may be possible, for example, to provide a lower strength (thickness) of the material plate and / or a lower density of the material plate in order to achieve the desired strength properties of a material plate, which in combination, among other things, with the lower energy consumption and resource consumption of the plant ultimately leads to a particularly resource-saving, environmentally friendly and cost-effective production process for material plates within the plant, also with regard to energy consumption and the overall process.

[0073] In the following, reference is made to the description of the advantages of the present method and its embodiments, which are applicable analogously to the present invention. It is therefore preferable to design and / or configure the system for carrying out a method according to at least one of claims 1 to 16, i.e., the system for carrying out the method according to claim 1 and / or its advantageous embodiments is designed according to one of claims 2 to 16. The resulting advantages are analogously apparent from the description therein.

[0074] For the design of the system, it can be particularly advantageous if the line is designed and arranged as a ring line around the same facility and / or as a transfer line between two separate facilities.

[0075] In other words, on the plant side, it is made possible by at least a portion of the raw material that has already undergone step iii) within a device for contactless comminution being able to be fed back via a ring line to the same device for contactless comminution under the action of a pressure shock wave having a pulse duration and a pulse frequency and / or to a second device for contactless comminution. Fractionation can be provided so that, based on at least one parameter, a decision can be made as to which portion of the raw material should be returned to the device for comminution of the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency and / or fed to a second device for contactless comminution, and which portion should be fed to subsequent process steps, such as scattering.

[0076] This creates a type of "loop operation" and / or "series operation" which returns or forwards at least part of the raw material which has already passed through step iii) via a ring line and / or a transfer line to the same device for decomposing the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency and / or to a second device for decomposing the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency.

[0077] In the case of an embodiment that includes a ring line, this can advantageously include a type of "bypass circuit".

[0078] It is preferred that the same device for breaking down the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency for carrying out step iii) and step vi) is also operated in the same, or at least approximately the same, mode of operation. The mode of operation is preferably defined by the respectively provided pulse duration and pulse frequency of the pressure shock wave(s), which in devices which have at least one rotor for generating the pressure shock waves, in their simple designs, can be influenced primarily by adjusting the provided rotor speed(s). In the preferred embodiment here, these rotor speed(s) should be kept constant or at least approximately constant. In such devices, it is therefore sufficient if the provided speed for carrying out step iii) and step vi) is simply set to a constant level.The term "constant" in this context preferably means actually constant, at least in the technical sense, i.e., the same nominal speed, without any controlling intervention and merely disregarding possible grid fluctuations or motor inaccuracies. Technically insignificant adjustments of less than 10%, preferably less than 5%, and most preferably less than 3% deviation of the nominal speed or the nominal speeds for several - especially two - rotors should, however, be included in a broad interpretation, regardless of whether they would result in an increase or a decrease in speed.

[0079] In addition to lower construction costs and minimal space requirements, such a design is characterized above all by particularly short paths for the raw material to be processed again, i.e., the raw material processed in at least one loop. This is not unimportant, since natural fibers that undergo an overall process consisting of multiple process steps also function - so to speak, from within themselves - and thus their properties do not change or at least alter their value solely due to external influences. However, such processes - controlled from within - usually proceed at lower speeds, so that with short paths and, derived from this, short residence times of the natural fibers between two treatment steps, the process sequence can be defined more precisely and, in turn, unwanted auxiliary measures can be reduced or even dispensed with in some cases from an environmental point of view.This could include otherwise required re-moistening or drying, temperature loading, or acceleration or deceleration of the ongoing mass or volume flow, which would at least unnecessarily increase the overall energy demand and require corresponding system design. It remains to be seen whether the required aggregates would significantly disrupt or even render impossible the operation of the raw material separation facility under the influence of a pressure surge wave with a specific pulse duration and frequency.

[0080] In order to counteract the bottleneck aspect already mentioned, which is to be expected by providing a step iii) and in particular in conjunction with a step vi), it can therefore be advantageous to provide at least two devices arranged next to one another for breaking down the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency in the layout of the plant for carrying out step iii) and step vi), which devices are each suitable for closed loop operation by means of corresponding ring lines and are connected next to one another, i.e. in a parallel circuit.

[0081] In other cases, however, it may be preferable to perform step iii) using, and preferably within, a first device for breaking down the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency for carrying out step iii) and step vi), and to perform step vi) using, and preferably within, a second device, provided in the layout of the system, for breaking down the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency for carrying out step iii) and step vi). As already explained, such an embodiment then represents a system with a "series connection" of at least two devices for breaking down the raw material under the action of a pressure shock wave having a pulse duration and a pulse frequency.

[0082] In this case, it is preferred that the first device for carrying out step iii) and the second device for carrying out step vi) also be operable in the same, or at least approximately the same, mode of operation. The mode of operation is preferably defined by the respective intended pulse duration and pulse frequency of the pressure shock wave(s). In devices that have at least one rotor for generating the pressure shock waves, these pulse frequency can be influenced, in their simple designs, primarily by adjusting the intended rotor speed(s). In such devices, it is sufficient if the intended speed for carrying out step iii) and step vi) is simply set to a constant value. In this context, the term "constant" preferably means truly constant, at least in the technical sense, i.e., an identical nominal speed without any controlling intervention.Technically insignificant adjustments of less than 10%, preferably less than 5%, most preferably less than 3% deviation from the nominal speed should, however, be included in a broad interpretation, regardless of whether they would result in an increase or a decrease in the speed. However, when operating at a constant nominal speed, as previously described, the loop operation embodiment is preferable, unless, for example, structural requirements, for example coupled with a minimum throughput to be achieved, speak in favor of the design described here. The series connection described here, however, offers the advantage that pressure shock waves with different pulse durations and pulse frequencies are used to carry out step iii) and step vi).This can lead to the significant advantage, particularly when applied to woody grasses, such as various bamboo species, that larger raw material components can be treated in a first cycle and smaller raw material particles in a subsequent cycle. The pressure shock waves can be individually designed and / or adjusted to the resulting different requirements, allowing the system to be operated with particularly high energy efficiency, among other things. Of course, the combination of a series and parallel connection can also lead to significant advantages, for example, enabling both an energy-efficient and highly productive implementation of the process.

[0083] Furthermore, there are great advantages if the system (additionally) includes at least one of the following devices:

[0084] Device for mechanically contacting pre-crushing of the raw material,

[0085] Fractionation facility

[0086] Classification facility,

[0087] Interim storage facility,

[0088] drying device,

[0089] Pressurization device, first temperature application device,

[0090] grinding device,

[0091] assembly facility,

[0092] Stacking device, second temperature application device, in particular cooling device, ripening storage device, preferably with output storage device

[0093] Cleaning and / or

[0094] Pelletizing.

[0095] In this way, the individual facilities can contribute to the production of a high-quality material board and improve the economically and ecologically sensible implementation options of a process based on this type of advanced technology.

[0096] The invention is explained in more detail below with reference to a drawing that merely represents an exemplary embodiment. In the figures, identical objects and circumstances, such as process steps, parameters, spatial directions, and the like, are designated by identical reference numerals and need not be shown and / or named in all figures. The drawing shows: Figure 1: A system for producing a material plate.

[0097] Figure 2: A flow chart illustrating a process for producing a

[0098] Material plate

[0099] Figure 1 shows a plant 100 for producing a material plate 10 comprising at least one layer 15, 16, 17 comprising at least a portion A of natural fibers F, wherein at least one of the at least one layer 15, 16, 17 comprises a useful product 11 which is produced from a raw material 14 comprising natural fibers F, wherein the plant 100 comprises at least the following: a material preparation 110 with at least one device 111, 113, 114 for contactless disassembly of the raw material 14 under the action of a pressure shock wave W having a pulse duration ID and a pulse frequency IF a gluing 120 a forming 130 a pressing 140 a finishing 150 and which is connected by a line 112 for the renewed feeding of the raw material 14 comprising natural fibers F into one of the at least one device 111, 113, 114 is characterized for contactless comminution.The system comprises a further device for contactless disassembly of raw material 115. Two of the devices 111 and 115 are arranged in a wet area N, and two of the devices 113 and 114 are arranged in a dry area T of the system 100.

[0100] The system 100 is for carrying out a method for producing a material board 10 comprising at least one layer 15, 16, 17 having at least a proportion A of natural fibers F, wherein at least one of the at least one layer 15, 16, 17 comprises a useful product 11 made from a raw material 14 comprising natural fibers F, wherein the method comprises at least the following steps: i) Providing a system 100 for producing a material board 10, comprising at least a material preparation 110, a gluing 120, a forming 130, a pressing 140, and a finishing 150; iii) Breaking down the raw material under the action of a pressure shock wave W having a pulse duration ID and a pulse frequency IF into at least one first, odd-indexed component K1, K3, K5,...K2n+l and a second, even-indexed component K2, K4, K6, K2n, using at least one device 111 for decomposing the raw material 14 under the influence of a pressure shock wave W having a pulse duration ID and a pulse frequency IF, iv) separation of the first, odd-indexed component K1, K3, K5,...K2n+l and the second, even-indexed component K2, K4, K6, K2n on the basis of at least one parameter PI v) provision of the (at least one) obtained odd-indexed components K1, K3, K5,...K2n+l for utilization in at least one further process step vii to x of the method, vi) decomposition of at least one of the even-indexed components K2, K4, K6, K2n under the influence of a pressure shock wave W having a pulse duration ID and a pulse frequency IF, such that at least one further odd indexed component Kl, K3, K5,...K2n+l is formed and / or at least one of its advantageous embodiments mentioned in connection with the figures or disclosed in the general descriptive part.

[0101] For this purpose, it can be advantageous, as shown in Figure 1, for the two devices 111 and 115 arranged in the wet area N to be arranged one behind the other in a series circuit and connected by means of a line 112 designed as a transfer line, while the two devices 113 and 114 arranged in the dry area T are arranged in parallel and each have their own lines 112 designed as a ring line. In embodiments not shown, however, the two devices 111 and 115 arranged in the wet area N can also be arranged in parallel and each have their own lines 112 designed as a ring line and correspond within a system 100 with two devices 113 and 114 arranged in the dry area T, which are either - according to the embodiment shown here - also connected in parallel or in series.

[0102] To implement the method, it is of course sufficient if the system has only two devices 111 and 113, which are connected to themselves and / or to one another via a line 112 - regardless of whether the two devices are located in the wet area N or the dry area T, or distributed across the two areas. Furthermore, to implement the method and in the sense of the system 100 shown here as an example, it is also sufficient if the system 100 has only a single device for contactless comminution 111, provided that it has a line 112, specifically a line 112 designed as a ring line.

[0103] In order to optimize individual process steps i) to x) and / or to improve the efficiency and / or economic effectiveness of the system 100, the system comprises, in a manner shown or not shown, in particular at least one of the following further devices:

[0104] Device 160 for mechanically contacting pre-crushing of the raw material 14, fractionation device 170, classification device 180, intermediate storage device 190, drying device 200, pressurization device 210, first temperature application device 220, grinding device 230, packaging device 240, stacking device 250, second temperature application device, in particular cooling device 260, maturing storage device 270, preferably with output storage device 280, cleaning 290 and / or pelletizing 300.

[0105] The provision of the aforementioned inputs and devices 160 to 280 within illustrated or non-illustrated embodiments of the system can depend, among other things, heavily on the raw material 14 to be processed within the system using a method described in the present document and its properties, in particular its natural properties, and / or the objectives of the material panel 10 to be produced. For example, it is highly important whether an MDF / HDF board, a particle board, a long-chip board, or a hybrid board with layers of different fiber shapes is to be produced on the system 100 using a method described here. Thus, the system and method are also designed so that the material panel to be produced can be designed as—according to the established market classification—"flexible" or "inflexible" insulation board(s). 32

[0106] As shown in the embodiment illustrated in Figure 1, a device 160 for mechanically contacting pre-shredding the raw material 14 is provided, in which step ii) of the method can be carried out. Such a device 160 can be designed, for example, as a knife-shaft chipper or, as in the present embodiment, as a rotor chipper. As long as the mechanically contacting pre-shredding remains coarse enough, natural fibers with an undamaged or at least barely damaged cell structure can be produced in sufficient quantities in the system 100 and / or when carrying out the method. By providing a device 160 for mechanically contacting pre-shredding raw material 14, the productivity of the system 100 can be significantly increased.When designing the plant 100 for the processing of annual or perennial grass-like plant species and varieties, the provision of at least one cleaning 300 - also shown in Figure 1 - is of great advantage, in particular in the entrance area of ​​the plant, i.e. relatively early in the production process, for example before carrying out step iii) and / or - if provided - step ii) and / or even before carrying out step i).

[0107] The method preferably to be carried out within a system 100 is shown in Figures 1 and 2 individually and in their overview in a particularly clear manner, even if not all individual method steps are shown in their different linkability and / or variants.

[0108] Specifically, it is shown that step iii) and step vi) are carried out using, and preferably within, the same device 111. It is also shown that step iii) is carried out using, and preferably within, a first device 113 and step vi) is carried out using, and preferably within, a second device 114. The moisture content M of the natural fibers F during the execution of step iii) and step vi) can be within a range of over 200% to 20%, preferably from 160% to 25%, and very preferably from 135% to 45%, if the device 111, 115 - for example, as also shown in Figure 1 - is arranged within a wet area N of the system 100 and the moisture content M of the raw materials 14 comprising the natural fibers F is possibly additionally increased by a cleaning 300 using water, steam, or the like.Additionally or alternatively, the moisture content M of the natural fibers F during the execution of step iii) and step vi) can be within a range of a maximum of 18.5% to less than 1%, preferably from 16% to 2% and most preferably from 13% to 2%, if the device 113 and / or 114 - for example as also shown in Figure 1 - is arranged within a wet area T of the system 100.From the above, it can also be directly deduced from Figure 1 - although not explicitly shown - that the moisture content M of the natural fibers F during the implementation of step iii) can be within a range of more than 200% to 20%, preferably from 160% to 25% and very preferably from 135% to 45%, and during the implementation of step vi) can be within a range of a maximum of 18.5% to less than 1%, preferably from 16% to 2% and very preferably from 13% to 2%, if both devices, for example 111 and 113, are connected via a line 112 designed as a transfer line and one device, for example 111, is arranged in the wet area N of the system 100 and the other device, for example 113, is arranged in the dry area of ​​the system 100. In some cases, the line 112 can then comprise a drying device 200 or lead through a drying device 200.As shown, between the execution of steps iii) and vi), a step viii) for the removal of undesirable raw material components, in particular silicates, is provided on the plant side and is carried out by the process. Furthermore, it is shown that plant 100 and the process (optionally) provide that between the execution of steps iii) and vi), a step ix) for enriching and / or combining the natural fibers F with at least one additive ADI, AD2 is carried out.

[0109] Furthermore, the described and illustrated method (optionally) comprises a further step x) for passing on a volume flow VI, V3, V5,...V2n+l of at least two odd-indexed components Kl, K3, K5,...K2n+l to a subsequent process step, wherein at least one of the two passed on odd-indexed components Kl, K3, K5,...K2n+l and the portion VA of the volume flow VI, V3, V5,...V2n+l formed therefrom is obtained from a previously even-indexed component K2, K4, K6, K2n.

[0110] By means of measures not explicitly shown in detail, the system 100 shown and the method shown therein and in Figure 2 can be developed in such a way that the proportion VA of the volume flow consists of natural fibres F formed in fibre form FF and is between 27 m 3 / h and 3 m 3 / h, preferably between 20 m 3 / h and 4 m 3 / h, especially preferably between 16 m 3 / h and 4 m 3 / h, especially preferably between 12.5 m 3 / h and 5 m 3 / h and most preferably between 11 m 3 / h and 5.5 m 3 / h or that the proportion VA of the volume flow consists of natural fibres F formed in chip form FS and is between 27 m 3 / h and 3 m 3 / h, preferably between 20 m 3 / h and 4 m 3 / h, especially preferably between 16 m 3 / h and 4 m 3 / h, especially preferably between 12.5 m 3 / h and 5 m 3 / h and most preferably between 11 m 3 / h and 5.5 m 3 / h or that the proportion VA of the volume flow consists of natural fibres F formed in long chip form FL and is between 27 m 3 / h and 3 m 3 / h, preferably between 20 m 3 / h and 4 m 3 / h, especially preferably between 16 m 3 / h and 4 m 3 / h, especially preferably between 12.5 m 3 / h and 5 m 3 / h and most preferably between 11 m 3 / h and 5.5 m 3 / h.

[0111] As described above, the system 100 in the illustrated embodiment has a forming unit 130 which includes a scattering in order to be able to specifically form the individual layers 15, 16, 17 of the material plate 10 produced in the system or in the process. In this case, the forming and the method in the illustrated embodiment are designed such that at least a portion of the even-indexed components K2, K4, K6, K2n, in particular at least 30%, preferably at least 55%, very preferably at least 75% of the even-indexed components K2, K4, K6, K2n is used to form a core layer 15 of a material plate 10 and / or that at least a portion of the odd-indexed components K1, K3, K5, K2n+1, in particular at least 30%, preferably at least 55%, very preferably at least 75% of the odd-indexed components K1, K3, K5, K2n+1 is used to form a cover layer 16, 17 of a material plate 10.To simplify the achievement of sufficient repeatability, the system 100 also has a fractionation device 170, a classification device 180 and an intermediate storage device 190. Following the forming process, the layout of the system 100 comprises a pressing unit 140 in which the resulting material plate 10 is subjected in particular to pressure p and temperature t, with an adjoining finishing device 150, a maturing storage device 270, a stacking device 250, a grinding device 230 and a removal device 280. The pressing unit can comprise an (upstream) pressure application device 210 with a first temperature application device 220 and, within the pressing unit, also a second temperature application device 260 for cooling, although the pressing unit is operated at high pressures and temperatures in large sections along its longitudinal direction X.

[0112] In the method described, raw material 14 originating from the grass family (Poaceae), in particular from their subfamilies Arundinarieae and / or Bambuseae, is used. Alternatively or additionally, raw material 14 originating from the coniferous family and / or the myrtle family, in particular the eucalyptus family, is used. The illustrated embodiment of the system 100 is designed for this purpose.

[0113] The illustrated embodiment can be deviated from in many ways without departing from the scope of the present invention. In particular, the person skilled in the art will also read the description of the drawings for possible variations not explicitly mentioned, which are obvious or at least obvious from different combinations of individual features disclosed within the present specification and within the scope of the invention.

[0114] List of reference symbols

[0115] 10 Material plate

[0116] 11 Goods

[0117] 14 Raw material

[0118] 15 layer, core layer

[0119] 16 layer, top layer

[0120] 17th layer, top layer

[0121] 100 system

[0122] 110 Material processing

[0123] 111 Device for contactless cutting of raw material, first device

[0124] 112 line, ring line, transfer

[0125] 113 Device for contactless cutting of raw material, separate

[0126] Furnishings

[0127] 114 Device for contactless cutting of raw material, separate

[0128] Furnishings

[0129] 115 Device for contactless cutting of raw material, second

[0130] Furnishings

[0131] 120 Gluing

[0132] 130 Forming

[0133] 140 pressing

[0134] 150 assembly

[0135] 160 Device for mechanical contact pre-crushing of raw material

[0136] 170 fractionation facility

[0137] 180 Classification device

[0138] 190 Interim storage facility

[0139] 200 drying device

[0140] 210 Pressurization device

[0141] 220 first temperature application device

[0142] 230 grinding device

[0143] 240 assembly facility

[0144] 250 stacking device

[0145] 260 second temperature application device, in particular cooling device

[0146] 270 ripening storage facility

[0147] 280 outsourcing facility

[0148] 290 Cleansing

[0149] 300 Pelletizing

[0150] A proportion of AD, ADi, AD2 additive F natural fiber(s)

[0151] FF fiber shape FS chip shape FL long chip shape FP pellet shape ID pulse duration IF pulse frequency

[0152] Ki, K3, K5,...K 2n+i odd indexed component

[0153] K2, K4, K6, K2n even indexed component

[0154] M moisture content

[0155] N Wet area P Parameters

[0156] Pi first parameter

[0157] P pressure

[0158] T Drying area t Temperature

[0159] Vl, V3, Vs,...V2n+l Volume flow (of at least two odd indexed

[0160] components)

[0161] V A Share of a volume flow W pressure shock wave

[0162] X First spatial direction, longitudinal direction Y Second spatial direction, width direction z Third spatial direction, height direction i) Step, first process step ii) Step, second process step iii) Step, third process step iv) Step, fourth process step v) Step, fifth process step vi) Step, sixth process step vii) Step, seventh process step viii) Step, eighth process step ix) Step, ninth process step x) Step, tenth process step

Claims

Patent claims 1. A method for producing a material board (10) comprising at least one layer (15, 16, 17) comprising at least a portion (A) of natural fibers (F), wherein at least one of the at least one layer (15, 16, 17) comprises a useful product (11) made from a raw material (14) comprising natural fibers (F), the method comprising at least the following steps: i) providing a system (100) for producing a material board (10), comprising at least a material preparation (110), a gluing (120), a forming (130), a pressing (140), and a finishing (150); iii) breaking down the raw material into at least one first, odd-indexed component (Ki, K3, Ks,...) under the action of a pressure shock wave (W) having a pulse duration (ID) and a pulse frequency (IF).K2n+i) and a second, even-indexed component (K2, K4, Ke, K2n), using at least one device (111) for breaking down the raw material (14) under the action of a pressure shock wave (W) having a pulse duration (ID) and a pulse frequency (IF), iv) separating the first, odd-indexed component (Ki, K3, Ks,...K2n+i) and the second, even-indexed component (K2, K4, Ke, K2n) on the basis of at least one parameter (Pi), v) making the (at least one) obtained odd-indexed components (Ki, K3, Ks,...K2n+i) available for utilization in at least one further process step of the method, characterized by vi) breaking down at least one of the even-indexed components (K2, K4, Ke, K2n) under the action of a pulse duration (ID) and a pulse frequency. (IF) having a pressure shock wave (W), such that at least one further odd-indexed component (Ki, K3, Ks,...K2n+i) is created.

2. Method according to claim 1, characterized in that step iii) and step vi) are carried out using, and preferably within, the same device (111, 113, 114, 115).

3. Method according to claim 1, characterized in that step iii) is carried out using, and preferably within, a first device 111 and step vi) is carried out using, and preferably within, a second device 115.

4. Process according to one of claims 1 to 3, characterized in that the moisture content (M) of the natural fibers (F) during the implementation of step iii) and step vi) is within a range of more than 200% to 20%, preferably from 160% to 25% and very preferably from 135% to 45%.

5. Process according to one of claims 1 to 3, characterized in that the moisture content (M) of the natural fibers (F) during the implementation of step iii) and step vi) is within a range of at most 18.5% to less than 1%, preferably of 16% to 2% and most preferably of 13% to 2%.

6. The method according to any one of claims 1 to 5, characterized in that the moisture content (M) of the natural fibers (F) during the implementation of step iii) is within a range of more than 200% to 20%, preferably from 160% to 25% and very preferably from 135% to 45% and during the implementation of step vi) is within a range of at most 18.5% to less than 1%, preferably from 16% to 2% and very preferably from 13% to 2%.

7. Method according to one of the preceding claims, characterized in that between the implementation of step iii) and step vi) a step viii) for the Separation of undesirable raw material components, especially silicates, is carried out.

8. Method according to one of the preceding claims, characterized in that between the implementation of step iii) and step vi) a step ix) for enriching and / or combining the natural fibers (F) with at least one additive (ADi, AD2) is carried out.

9. Method according to one of the preceding claims, characterized in that the method further comprises a further step: x) passing on a volume flow (Vi, V3, Vs,...V2n+i) of at least two odd-indexed components (Ki, K3, Ks,...ton+i) to a subsequent process step, wherein at least one of the two passed on odd-indexed components (Ki, K3, Ks,...ton+i) and the portion (VA) of the volume flow (Vi, V3, Vs,...V2n+i) formed therefrom is obtained from a previously even-indexed component (K2, K4, Ke, ton).

10. Method according to claim 9, characterized in that the portion (VA) of the volume flow consists of natural fibers (F) formed in fiber form (FF) and is between 27 m 3 / h and 3 m 3 / h, preferably between 20 m 3 / h and 4 m 3 / h, especially preferably between 16 m 3 / h and 4 m 3 / h, especially preferably between 12.5 m 3 / h and 5 m 3 / h and most preferably between 11 m 3 / h and 5.5 m 3 / h.

11. Method according to claim 9, characterized in that the portion (VA) of the volume flow consists of natural fibers (F) formed in chip form (FS) and is between 27 m 3 / h and 3 m 3 / h, preferably between 20 m 3 / h and 4 m 3 / h, especially preferably between 16 m 3 / h and 4 m 3 / h, especially preferably between 12.5 m 3 / h and 5 m 3 / h and most preferably between 11 m 3 / h and 5.5 m 3 / h.

12. Method according to claim 9, characterized in that the proportion (V A ) of the volume flow consists of natural fibres (F) formed in long chip form (FL) and is between 27 m 3 / h and 3 m 3 / h, preferably between 20 m 3 / h and 4 m 3 / h, especially preferably between 16 m 3 / h and 4 m 3 / h, especially preferably between 12.5 m 3 / h and 5 m 3 / h and most preferably between 11 m 3 / h and 5.5 m 3 / h.

13. Method according to one of the preceding claims, characterized in that at least a part of the just indexed components (K2, K4, Ke, K2n), in particular at least 30%, preferably at least 55%, very preferably at least 75% of the just indexed components (K2, K4, Ke, K2n) is used to form a core layer (15) of a material plate (10).

14. Method according to one of the preceding claims, characterized in that at least a part of the odd-indexed components (Ki, K3, K5, K2n+i), in particular at least 30%, preferably at least 55%, very preferably at least 75% of the odd-indexed components (Ki, K3, Ks, K2n+i) is used to form a cover layer (16, 17) of a material plate (10).

15. Method according to one of the preceding claims, characterized in that raw material (14) originating from the family of sweet grasses (Poaceae), in particular from their subfamilies Arundinarieae and / or Bambuseae, is used.

16. Method according to one of the preceding claims, characterized in that raw material (14) originating from the family of conifers and / or myrtle plants, in particular eucalyptus, is used.

17. Plant (100) for producing a material plate (10) comprising at least one layer (15, 16, 17) comprising at least a portion (A) of natural fibers (F), wherein at least one of the at least one layer (15, 16, 17) comprises a useful product (11) produced from a raw material (14) comprising natural fibers (F), wherein the system (100) comprises at least the following: a material preparation (110) with at least one device (111) for contactless disintegration of the raw material (14) under the action of a pressure shock wave (W) having a pulse duration (ID) and a pulse frequency (IF), a gluing (120), a shaping (130), a pressing (140), a finishing (150), and by a line (112) for re-feeding the raw material (14) comprising natural fibers (F) into one of the at least one device (111, 113, 114) for contactless comminution.

18. Plant (100) according to claim 17, characterized in that the plant is designed to carry out the method according to claim 1 and / or its advantageous embodiments according to one of claims 2 to 16.

19. System (100) according to claim 17 or 18, characterized in that the line (112) is designed and arranged as a ring line around the same device (111) and / or as a transfer line between two separate devices (111, 113, 114).

20. System (100) according to claim 17 to 19, characterized in that the system (100) comprises at least one of the further devices: Device (160) for mechanically contacting pre-crushing of the raw material (14), Fractionation facility (170) Classification facility (180), Interim storage facility (190), - drying device (200), pressure application device (210), first temperature application device (220), Grinding device (230), Assembly facility (240), - stacking device (250), second temperature application device, in particular cooling device (260) Ripening storage facility (270), preferably with exit storage facility (280) Cleanup (290) and / or Pelleting (300).

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