First and second aqueous binder compositions comprising reducing sugars, hydroxymethylfurfural and polylysines, respective processes, products and uses

Abstract

Described herein is a process for producing a first and a second aqueous binder composition, each comprising reducing sugars, hydroxymethylfurfural and polylysines, the respective aqueous binder compositions per se, as well as their uses in wood technology. Moreover is described herein a process for producing a lignocellulosic article, selected from a lignocellulosic composite and a lignocellulosic element, and a process for producing a lignocellulosic article, all involving said first and / or said second aqueous binder compositions. Furthermore is described herein said lignocellulosic article, including said lignocellulosic composite and said lignocellulosic element.

Description

[0001] BASF SE

[0002] Carl-Bosch-StraBe 38, 67056 Ludwigshafen am Rhein Germany

[0003] First and second aqueous binder compositions comprising reducing sugars, hydroxymethylfurfural and polylysines, respective processes, products and uses

[0004] The present invention relates to a process for producing a first and a second aqueous binder composition, each comprising reducing sugars, hydroxymethylfurfural and polylysines, to the respective aqueous binder compositions per se, as well as to their uses in wood technology. Moreover, the present invention relates to a process for producing a lig- nocellulosic article, selected from a lignocellulosic composite and a lignocellulosic element, and to a process for producing a lignocellulosic article, all involving said first and / or said second aqueous binder compositions. Furthermore, the present invention relates to said lignocellulosic article, including said lignocellulosic composite and said lignocellulosic element. Generally, in a process of producing a multilayer or single-layer lignocellulosic composite, a mixture comprising lignocellulosic particles (i.e. particles consisting essentially of lignocellulose) and a binder composition is provided or prepared. This mixture is typically arranged (e.g. scattered) in such a way that a first layer of a multilayer mat or the only one layer of a single-layer mat results. When producing a multilayer composite, successively two or more mixtures of lignocellulosic particles, usually comprising a binder composition, are arranged on top of each other in a way so that a mat with two or more individual layers BASF SE 240806 results. The resulting mat is then usually compacted, and the compacted mat is cured (viz. hardened) during or after compaction, i.e. the mat (or the compacted mixture forming said mat) is treated in a manner so that the binder of the binder composition undergoes a hardening process.

[0005] There is a demand in industry for an economic, safe and sustainable process of producing a multilayer or single-layer lignocellulosic composite, wherein binder components can be used which can be obtained to the highest possible extent from non-petrochemical, preferably from renewable, resources, and which are suitable to reduce or avoid potentially hazardous substances like formaldehyde and isocyanates, or substances which emit formaldehyde, during or afterthe production process of the composites. It is furthermore desirable that respective binder components for use in said process are available in sufficient quantities and that multilayer or single-layer lignocellulosic composites resulting from said process have satisfactory mechanical properties, in particular have sufficient internal bond strength and show a low tendency for swelling when in contact with aqueous moisture.

[0006] Similar demands exist in industry for processes for producing lignocellulosic elements like e.g. gluelam, plywood, cross-laminated timber, blockboards and solid wood boards, as well as for products resulting from said processes.

[0007] The following literature deals with certain aspects of processes of producing composite materials which may comprise lignocellulosic particles or lignocellulosic components:

[0008] Document EP 3611225 A2 deals with a binder composition, an article and a method for manufacturing an article.

[0009] Document WO 2022 / 13661 1 A1 describes a binder composition comprising amino acid polymers as well as carbohydrates, for composite articles.

[0010] In document WO 2022 / 136612 A1 , a binder composition comprising poly(amino acids) for fiber composite articles is described.

[0011] Document WO 2022 / 136613 A1 pertains to a binder composition comprising polyamines as well as 1 ,3-dihydroxyacetone, glycolaldehyde and / or glyceraldehyde for composite articles. BASF SE 240806

[0012] In document WO 2022 / 136614 A1 , the authors report of a binder composition comprising polyamines and hydroxyacetone for composite articles.

[0013] Document WO 2023 / 117648 A1 describes a process of producing a lignocellulosic composite or a product thereof, using dielectric heating.

[0014] Document WO 2023 / 247431 A1 deals with a binder composition, comprising basic substances, for producing a lignocellulosic composite, a respective process as well as respective uses and products.

[0015] Document WO 2023 / 247437 A1 discusses a binder for wood-based panels comprising an amino acid polymer and a polyaldehyde compound.

[0016] Document WO 2014 / 086775 A2 relates to binder compositions with improved amine components and a method of manufacturing a collection of matter bound by said binder compositions.

[0017] Document 2015 / 177114 A1 describes a water-soluble carbohydrate-polyamino acid-based pre-reacted binder composition for making a collection of matter bound by a polymeric binder.

[0018] C. Rosenfeld et al. report in Industrial Crops & Products 187 (2022) 115536 of hydroxymethylfurfural as a key to increased reactivity and performance of fructose-based adhesives for particle boards.

[0019] In the light of the existing prior art, there is still a need for an economic, safe and sustainable process of producing a lignocellulosic article, in particular a lignocellulosic composite or a lignocellulosic element (as is further described herein), where the products from said processes have satisfactory mechanical properties and are environmentally friendly to the highest possible extent.

[0020] A similar need also still exists for a process for producing lignocellulosic products, where lignocellulosic composites and / or lignocellulosic elements are bonded or joined together, like e.g. bonded gluelam elements, or where lignocellulosic composites or articles are coated with veneers, like e.g. veneered particle boards or veneered medium density fiberboards. BASF SE 240806

[0021] Correspondingly, it was a primary object of the present invention to provide an economic and sustainable process of producing a lignocellulosic article, in particular a lignocellulosic composite or a lignocellulosic element, wherein binder components are used as much as possible which can be obtained from non-petrochemical resources, preferably from renewable resources and which pose as little hazard as possible to human health. Moreover, the products from said process should have satisfactory mechanical properties, in particular single-layer and multilayer lignocellulosic composites from said process should have sufficient internal bond strength and show a low tendency for swelling when in contact with aqueous moisture. A further object of the present invention was to provide respective products from said processes, in particular respective lignocellulosic composites or lignocellulosic elements.

[0022] It was a more specific object of the present invention to provide binder compositions which would be useful as intermediates in processes for producing lignocellulosic articles, in particular lignocellulosic composites or lignocellulosic elements.

[0023] It has now been found that the primary object and other objects of the present invention can be accomplished by a process for producing a first aqueous binder composition (i.e. a binder composition comprising water), comprising at least the following steps:

[0024] 51) providing or preparing an activated aqueous carbohydrate component (i.e. the activated carbohydrate component comprises water) comprising as constituents: c1) one or more monomeric reducing sugars, wherein the one or at least one of the more monomeric reducing sugars is fructose, and c2) hydroxymethylfurfural;

[0025] 52) providing or preparing a first polylysine component, comprising one or more polylysines; and

[0026] 53) reacting the activated aqueous carbohydrate component from step S1) with the first polylysine component from step S2) at a temperature of > 35 °C, to receive a first aqueous binder composition. BASF SE 240806

[0027] The invention as well as preferred variants and preferred combinations of parameters, properties and elements thereof are defined in the appended claims. Preferred aspects, details, modifications and advantages of the present invention are also defined and explained in the following description and in the examples stated below.

[0028] If not stated otherwise, preferred embodiments, aspects or features of the present invention can be combined with other embodiments, aspects or features, especially with other preferred embodiments, aspects or features, irrespective of the categories to which the embodiments, aspects or features relate. The combination of preferred embodiments, aspects or features with other preferred embodiments, aspects or features in each case again results in preferred embodiments, aspects or features.

[0029] It has been found in own experiments that the first aqueous binder composition resulting from the process as defined above is a particularly useful intermediate in economic and sustainable processes for producing lignocellulosic articles, in particular lignocellulosic composites or lignocellulosic elements. It has also been found that said first aqueous binder composition is suited as intermediate for preparing a second aqueous binder composition as is described in more detail below.

[0030] As used herein, the term "monomeric reducing sugar" (e.g. of constituent c1) of the activated aqueous carbohydrate component as defined here above in step S1) of the process of the present invention) indicates one or more monomeric sugars that contain free aldehyde groups, or that can isomerize, i.e. tautomerize, to contain free aldehyde groups, in accordance with the usual meaning in the technical field. The one or more monomeric reducing sugars of constituent c1) can consist of fructose (only), or they can comprise a mixture comprising fructose and one or more reducing sugars which are different from fructose (as is explained in more detail below).

[0031] Hydroxymethylfurfural (also abbreviated to “HMF” hereinafter) of constituent c2) of the activated aqueous carbohydrate component as defined here above in step S1) of the process of the present invention is also known as 5-(hydroxymethyl)furfural or 5-(hydroxymethyl)fu- ran-2-carbaldehyde (preferred IUPAC name; CAS Registry number 67-47-0).

[0032] An “activated aqueous carbohydrate component” as used herein means a carbohydrate component which comprises constituents c1) and c2) as defined herein and further comprises water. BASF SE 240806

[0033] In a variant of the process for producing a first aqueous binder composition according to the present invention, the activated aqueous carbohydrate component, in addition to the one or more monomeric reducing sugars, comprises further carbohydrates, preferably selected from the group consisting of non-reducing polysaccharides (preferably selected from the group consisting of starch and cellulose), non-reducing disaccharides (preferably selected from the group consisting of saccharose and trehalose), non-reducing monosaccharides and mixtures thereof.

[0034] As used herein, the term “poylysine(s)” designates a polymerization product of the monomer lysine, preferably of L-lysine, and optionally further monomers selected from the group consisting of a) amino acids, b) amines comprising at least two amino groups, wherein the amines are no amino acids, and c) dicarboxylic acids, which are no amino acids and tricarboxylic acids, which are no amino acids, wherein preferably

[0035] - the proportion of lysine in mass-% (wt.-%), which is used as monomer for the polymerization reaction for producing the polylysine, based on the total mass of monomers used in the polymerization reaction for producing the polylysine (i.e. the mass of the monomers which have become part of the polymerization product), is > 50 mass-%, preferably > 75 mass-%, more preferably > 85 mass-%, even more preferably > 90 mass-%, yet even more preferably > 95 mass-%, yet even more preferably > 95 mass-%, yet even more preferably > 97.5 mass-%, yet even more preferably > 99 mass-% and yet even more preferably 100 mass-%, and / or

[0036] - at least 50 mass-%, preferably at least 75 mass-%, more preferably at least 85 mass- %, even more preferably at least 90 mass-%, yet even more preferably at least 95 mass- %, yet even more preferably at least 95 mass-%, yet even more preferably at least 97.5 mass-%, yet even more preferably at least 99 mass-% and yet even more preferably BASF SE 240806

[0037] 100 mass-% of lysine, is used as the monomer for the polymerization reaction for producing said polylysine, based on the total mass of monomers used in the polymerization reaction (i.e. the mass of the monomers which have become part of the polymerization product).

[0038] As used herein, the terms “wt.-%” and “mass-%” are used synonymously.

[0039] Generally and for the purpose of the present invention, a polylysine may comprise or consist of (or comprises or consists of) dimers (n=2), trimers (n=3), oligomers (n = 4-10) and / or macromolecules (n > 10), wherein n is the number of monomers which have been reacted to form the dimers, trimers, oligomers and macromolecules of the polylysine(s). Additionally, lysine monomers and optionally further monomers which are not lysine monomers may be present in a limited amount in a mixture with the polylysine, e.g. due to incomplete conversion of the monomers during the polymerization reaction for producing polylysine.

[0040] Preferred as polylysine(s) forthe purpose of the present invention (i.e. for use in component c1) of the mixture provided or prepared in step S1) of the process according to the present invention) are homopolymers of lysine.

[0041] In the preferred variant of the process of the present invention where the one or more polylysines of component c1) of the mixture provided or prepared in step S1) comprise or are homopolymers, such polylysine homopolymer(s) may comprise or consist of dimers (n=2), trimers (n=3), oligomers (n = 4-10) and / or macromolecules (n > 10), wherein n is the number of lysine monomers which have been reacted to form the dimers, trimers, oligomers and macromolecules of the polylysine(s).

[0042] The one or more polylysines of the first and second aqueous binder compositions as described herein can be linear or branched or partially linear and partially branched.

[0043] In preferred variants of the process for producing the first aqueous binder composition, the first polylysine component, comprising one or more polylysines, is prepared or provided as an aqueous solution or an aqueous mixture (i.e. as a solution or mixture comprising water) of the one or more polylysines.

[0044] It has been observed by the present inventors that no carbon dioxide is formed or set free in the process for producing the first aqueous binder composition according to the present invention. BASF SE 240806

[0045] The present invention also pertains to a process for producing a second aqueous binder composition (i.e. the second binder composition comprises water), comprising at least the following steps:

[0046] 54) providing or preparing a first aqueous binder composition according to the present invention as defined herein (or a first aqueous binder composition according to the present invention as described herein as being preferred),

[0047] 55) providing or preparing a second polylysine component, comprising one or more polylysines and

[0048] 56) mixing, preferably reacting, the first aqueous binder composition from step S4) with the second polylysine component from step S5) at a temperature in the range of from > 15 °C to < 60 °C, preferably of from > 15 °C to < 40 °C, to receive a second aqueous binder composition.

[0049] Generally, all aspects of the present invention discussed herein in the context of the process for producing the first aqueous binder composition according to the present invention as defined herein apply mutatis mutandis to the process for producing the second aqueous binder composition according to the present invention as defined herein, and vice versa.

[0050] The second polylysine component as provided or prepared in step S5) may be different from the first polylysine component as provided or prepared in step S2) with regard to the type(s) (e.g. characterized by their weight-average molecular weight Mw) and / orthe amount of polylysines used, or said second polylysine component can be the same as said first polylysine component in one or more aspects.

[0051] In preferred variants of the process for producing the second aqueous binder composition, the second polylysine component, comprising one or more polylysines, is prepared or provided as an aqueous solution or an aqueous mixture (i.e. as a solution or mixture comprising water) of the one or more polylysines.

[0052] In a preferred variant of the process for producing a first aqueous binder composition according to the present invention, the pH of the activated aqueous carbohydrate component BASF SE 240806 provided or prepared in step S1) is adjusted to a value in the range of from > 7 to < 9 before it is used in step S3).

[0053] In a further preferred variant of the process for producing a second aqueous binder composition according to the present invention, step S6) is carried out within 24 hours, preferably within 12 hours, more preferably within six hours, after the first aqueous binder composition has been provided or prepared in step S4). In a particularly preferred variant of the process for producing a second aqueous binder composition according to the present invention, step S6) is carried out within 2 hours, preferably within 1 hour, after the first aqueous binder composition has been provided or prepared in step S4).

[0054] In step S6) of the process for producing a second aqueous binder composition according to the present invention as defined here above, the first aqueous binder composition is mixed with the second polylysine component at a temperature in the range or preferred range as defined above. It has been found in own experiments that an observable reaction between said both components is not necessarily required in order to make the resulting second aqueous binder composition suited for producing a lignocellulosic article, in particular a lignocellulosic composite or a lignocellulosic element.

[0055] It has been observed by the present inventors that no carbon dioxide is formed or set free in the process for producing the second aqueous binder composition according to the present invention.

[0056] Without wishing to be bound by theory, it is assumed that the first and second aqueous binder compositions as described herein comprise the reaction products of Maillard reactions (see e.g. article “A review of Maillard reaction in food and implications to kinetic modelling” by S. I.F.S. Martins et al. in Trends in Food Science & Technology 11 (2001) 364- 373 and references cited therein).

[0057] The present invention then also pertains to a process for producing a lignocellulosic composite comprising one or more lignocellulosic composite layers, comprising at least the following steps:

[0058] S7) providing or preparing an aqueous mixture, comprising at least lignocellulosic particles, BASF SE 240806 and

[0059] - (i) a first aqueous binder composition according to the present invention as defined herein (or a first aqueous binder composition according to the present invention as described herein as being preferred), or

[0060] (ii) a second aqueous binder composition according to the present invention as defined herein (or a second aqueous binder composition according to the present invention as described herein as being preferred), and

[0061] S8) applying heat and pressure to the aqueous mixture from step S7), so that the binder of the first aqueous binder composition hardens, orthe binder of the second aqueous binder composition hardens, and a lignocellulosic composite results.

[0062] Generally, all aspects of the present invention discussed herein in the context of the process for producing the first aqueous binder composition according to the present invention as defined herein and of the process for producing the second aqueous binder composition according to the present invention as defined herein apply mutatis mutandis to the process for producing a lignocellulosic composite comprising one or more lignocellulosic composite layers according to the present invention as defined herein, and vice versa.

[0063] The first aqueous binder composition produced by the process of the present invention comprises curable, preferably heat-curable, components and water. The (heat-) curable components of the first aqueous binder composition are also referred to herein as “binder” of the first aqueous binder composition. Without wishing to be bound by theory, the present inventors assume that the (heat-) curable components of the first aqueous binder composition comprise (1) the reaction product(s) of (i) constituent c1), the one or more monomeric reducing sugars, wherein the one or at least one of the more monomeric reducing sugars is fructose, (ii) constituent c2), hydroxymethylfurfural, and (iii) the one or more polylysines of the first polylysine component used in step S2), and (2) any unreacted amounts of said components (i), (ii) and / or (iii) which may still be present in the first aqueous binder composition.

[0064] The second aqueous binder composition produced by the process of the present invention comprises curable, preferably heat-curable, components and water. The (heat-) curable BASF SE 240806 components of the second aqueous binder composition are also referred to herein as “binder” of the second aqueous binder composition. Without wishing to be bound by theory, the present inventors assume that the (heat-) curable components of the second aqueous binder composition comprise (a) the first aqueous binder composition (viz. the (heat-) curable components of the first aqueous binder composition as defined above) and (p) the one or more polylysines of the second polylysine component used in step S5).

[0065] For the purposes of the present invention, "lignocellulosic particles" are preferably selected from the group consisting of fibers, chips, strands, flakes, sawmill shavings, saw dust and mixtures thereof, more preferably from the group consisting of fibers, chips, strands and mixtures thereof, and even more preferably selected from the group consisting of fibers, chips and mixtures thereof. In one particularly preferred variant of the present invention, the lignocellulosic particles comprise or are (lignocellulosic) chips.

[0066] Any type of lignocellulosic biomass such as birch, beech, alder, pine, spruce, larch, eucalyptus, linden, poplar, ash, fir, tropical wood, sisal, jute, flax, coconut, kenaf, hemp, banana, straw, cotton stalks, bamboo and the like can be used as a source for said lignocellulosic particles. Lignocellulosic particles from both virgin wood and / or waste wood, such as old furniture, can be used to produce the lignocellulosic composite of the present invention. According to the present invention, it is further possible to use mixtures of different types of lignocellulosic particles in the production of a lignocellulosic composite.

[0067] For the purposes of the present invention, the lignocellulosic composites made from lignocellulosic particles, preferably from wood particles, may belong to one of the categories “chip / strand composites” (e.g. chipboard, oriented strand board) or “fiber composites” (e.g. medium density fiber board MDF, high density fiberboard HDF, or wood fiber insulation board WFIB) as listed in the well-known book by M. Dunky, P. Niemz, “Holzwerkstoffe und Leime” [Wood Materials and Glues], Springer Verlag Heidelberg, 2002, e.g. on page 7. Methods for producing these composites and the use of these composites are known to the person skilled in the art and are described for example in said book by M. Dunky et al., 2002, e.g. in Part 1 , Chapters 4 and 5.

[0068] As used herein, chips may be used for the production of chipboards. Chips needed for this purpose can be classified according to size by means of sieve analysis as described in said book by M. Dunky et al., 2002, e.g. on pages 665 and 666. Appropriate sieves are defined in DIN ISO 3310-1 :2017-1 1 . Preferably, the average size of such chips (as defined in M. Dunky, Holzforschung und Holzverwertung, 1988, 40, pages 126 -133) may be 0.01 to 30 mm, preferably 0.05 to 25 mm, particularly preferably 0.1 to 20 mm. BASF SE 240806

[0069] As used herein, fibers may be wood fibers, hemp fibers, bamboo fibers, miscanthus fibers, bagasse fibers or mixtures thereof, preferably wood fibers. The length of the fibers may be 0.01 to 20 mm, preferably 0.05 to 15 mm, particularly preferably 0.1 to 10 mm.

[0070] As used herein, strands may be wood strands, hemp strands, bamboo strands, bagasse strands or mixtures thereof, preferably wood strands. The length of the strands may be 20 to 500 mm, preferably 50 to 200 mm, particularly preferably 100 to 150 mm. The width of the strands may be 1 to 50 mm, preferably 5 to 30 mm, particularly preferably 10 to 15 mm. The thickness of the strands may be 0.2 to 2 mm, preferably 0.4 to 1 .2 mm, particularly preferably 0.6 to 0.8 mm. Strands may also be called flakes.

[0071] As used herein, a “lignocellulosic component” belongs to the group of lignocellulosic pieces which are larger in size than lignocellulosic particles. For the purposes of the present invention, lignocellulosic components are preferably selected from the group consisting of beams, lamellas, blanks, panels and veneers. Any type of lignocellulosic biomass can be used as a source for said lignocellulosic components, preferably wood.

[0072] According to the present invention, lignocellulosic elements made from lignocellulosic components, preferably from wood components, may belong to one of the categories “solid wood composite” (e.g. glulam) or “veneer composite” (e.g. plywood), as listed in the book by M. Dunky et al., 2002, e.g. on page 7. Preferred lignocellulosic elements for the purposes of the present invention are described above and below.

[0073] As used herein, the term “single-layer(ed) lignocellulosic composite” (i.e. a lignocellulosic composite comprising one lignocellulosic composite layer) designates and includes any single-layered composite which contains lignocellulosic particles and a hardened binder that binds the lignocellulosic particles, the latter of which has been produced by a process of the present invention as disclosed herein. Furthermore, the term “single-layer” specifies that the lignocellulosic composite comprises only one layer of lignocellulosic particles and binder, wherein the single layer preferably is produced by a process comprising a single step of scattering the aqueous mixture comprising lignocellulosic particles and first or second aqueous binder composition. The “single-layer lignocellulosic composite” can be of any shape such as rectangular, square, round, triangular and the like. The “single-layer lignocellulosic composite” can also be of any thickness, density and colour as long as it contains lignocellulosic particles and a hardened binder as specified above. The “single-layer lignocellulosic composite” can also comprise several other compounds different from lignocel- BASF SE 240806 lulosic particles and binders. The lignocellulosic particles used in the production of a “single-layer lignocellulosic composite” are of the same type, or of different types of lignocellulosic biomass (see above for preferred types).

[0074] As used herein, the term “multilayer lignocellulosic composite” (i.e. a lignocellulosic composite comprising more than one lignocellulosic composite layers) designates and includes any multi-layered composite which contains lignocellulosic particles and a hardened binder that binds the lignocellulosic particles and wherein distinguishable (individual) layers are present within the composite. In a multilayer lignocellulosic composite according to the present invention, at least one layer is obtainable or obtained by a process for producing a lignocellulosic composite according to the present invention as described herein (or according to a process of the present invention as described herein as being preferred). A multilayer lignocellulosic composite as described herein comprises at least two distinguishable (individual) layers, preferably comprises three such layers, i.e. a core layer and an upper and a lower surface layer; or comprises four or more such layers, within the same multilayer lignocellulosic composite. The adjacent layers of the multilayer lignocellulosic composite are distinguishable in terms of their composition, density, thickness, colour or any other properties, and adjacent layers comprise identical types of lignocellulosic particles and / or binders or different types of lignocellulosic particles and / or binders. The (individual) layers may also comprise or consist of different materials than lignocellulosic particles and / or binders, such as plastics, fabrics, paint coat or the like, for examples derived from foreign matter in waste wood.

[0075] The lignocellulosic particles used in the production of an individual layer of a “multilayer lignocellulosic composite” are of the same type or of different types of lignocellulosic biomass (see above for preferred types). The lignocellulosic particles used in the production of separate (individual) layers of a “multilayer lignocellulosic composite” are of the same type or of different types of lignocellulosic biomass (see above for preferred types) or are identical or different mixtures of two or more of such types of lignocellulosic biomass. Furthermore, the term “multilayer” specifies that the lignocellulosic composite comprises at least two individual layers, wherein at least one, preferably two or more of these individual layers comprise lignocellulosic particles and binder, wherein one or more or all of said layers preferably are produced in a multi-step-process comprising for each (individual) layer of lignocellulosic particles and binder a step of arranging (e.g. by scattering) the aqueous mixture comprising lignocellulosic particles and first or second aqueous binder composition. BASF SE 240806

[0076] For example, for the purposes of the present invention, a multilayer lignocellulosic composite may comprise a core layer which is obtainable or obtained by a process for producing a lignocellulosic composite according to the present invention as described herein (or according to a process of the present invention as described herein as being preferred) and an upper and a lower surface layer which both may comprise binders which are different from the binder of the present invention, e.g. conventional urea-formaldehyde binders, or vice versa.

[0077] In the process for producing a lignocellulosic composite according to the present invention, the aqueous mixture provided or prepared in step S7) may additionally comprise one, two or more auxiliary compounds independently selected from the group consisting of alkali salts and alkaline earth salts (also see below for the preferred presence of alkali or earth alkaline hydroxides), hydrophobizing agents (preferably paraffin and mixtures comprising paraffin more preferably paraffin emulsions), dyes, pigments, antifungal agents, antibacterial agents, rheology modifiers, fillers, release agents, surfactants and tensides.

[0078] In a variant of the process for producing a lignocellulosic composite according to the present invention, the aqueous mixture provided or prepared in step S7), in addition to the one or more monomeric reducing sugars, comprises further carbohydrates, preferably selected from the group consisting of non-reducing polysaccharides (preferably selected from the group consisting of starch and cellulose), non-reducing disaccharides (preferably selected from the group consisting of saccharose and trehalose), non-reducing monosaccharides and mixtures thereof.

[0079] Particularly preferred is a process of the present invention as described herein (i.e. including a process for producing a first aqueous binder composition, a process for producing a second aqueous binder composition and a process for producing a lignocellulosic composite, or a respective process of the present invention as described herein as being preferred), wherein the activated aqueous carbohydrate component of step S1) is prepared in a step S1 a), comprising: reacting a first amount of one or more monomeric reducing sugars, wherein the one or at least one of the more monomeric reducing sugars is fructose, in the presence of water and an acid, at a temperature of > 50 °C, and preferably removing any solid precipitate which may have formed, preferably comprising BASF SE 240806 reacting the first amount of the one or more monomeric reducing sugars, wherein the one or at least one of the more monomeric reducing sugars is fructose, at a temperature in the range of from > 100 °C to < 180 °C, preferably of from > 120 °C to < 180 °C and more preferably of from > 130 °C to < 170 °C, preferably at a pressure above atmospheric pressure, more preferably at a pressure of > 150 kPa and even more preferably in the range of from > 200 kPa to < 400 kPa, and preferably for a time in the range of from 15 min. to 120 min., more preferably of from 30 min. to 90 min.

[0080] It has been found in own experiments that a solid precipitate may sometimes form in the process variant of the present invention as described here above, wherein the activated aqueous carbohydrate component of step S1) is prepared in a step S1 a). Preferred is therefore a respective process variant, wherein said solid precipitate is removed before the first aqueous binder composition resulting from the process is used in step S4) or in step S7) of the processes of the present invention as described herein.

[0081] It has also been found in own experiments that the formation of said solid precipitate in the process variant of the present invention as described here above, wherein the activated aqueous carbohydrate component of step S1) is prepared in a step S1 a), can be reduced or avoided when a reducing agent, preferably sodium dithionite, is added in step S1 a) and / or when a pressure above atmospheric pressure (or a preferred pressure above atmospheric pressure as explained above) is applied, preferably when furtherthe first amount of the one or more monomeric reducing sugars is reacted at a temperature in the range of from > 100 °C to < 180 °C (or at a preferred temperature as explained above).

[0082] Preferred is therefore the process of the present invention as described herein, wherein the activated aqueous carbohydrate component of step S1) is prepared in a step S1 a), wherein a reducing agent, preferably sodium dithionite, is added in step S1 a).

[0083] In a variant of the process for producing a lignocellulosic composite according to the present invention, wherein the activated aqueous carbohydrate component of step S1) is prepared in a step S1 a), further carbohydrates may be present in step S1 a) in addition to the first amount of one or more monomeric reducing sugars, wherein preferably said further carbohydrates are selected from the group consisting of non-reducing polysaccharides BASF SE 240806

[0084] (preferably selected from the group consisting of starch and cellulose), non-reducing disaccharides (preferably selected from the group consisting of saccharose and trehalose), non-reducing monosaccharides and mixtures thereof.

[0085] One particularly preferred aspect of the present invention therefore pertains to a process for producing a first aqueous binder composition, comprising at least the following steps:

[0086] S1 a) reacting a first amount of one or more monomeric reducing sugars, wherein the one or at least one of the more monomeric reducing sugars is fructose, in the presence of water and an acid, at a temperature of > 50 °C, and preferably removing any solid precipitate which may have formed, so that an activated aqueous carbohydrate component results, comprising as constituents: c1) one or more monomeric reducing sugars, wherein the one or at least one of the more monomeric reducing sugars is fructose, and c2) hydroxymethylfurfural;

[0087] 52) providing or preparing a first polylysine component, comprising one or more polylysines; and

[0088] 53) reacting the activated aqueous carbohydrate component from step S1 a) with the first polylysine component from step S2) at a temperature of > 35 °C, to receive a first aqueous binder composition.

[0089] A further aspect of the present invention therefore pertains to a process for producing a second aqueous binder composition, comprising at least the following steps:

[0090] S1 a) reacting a first amount of one or more monomeric reducing sugars, wherein the one or at least one of the more monomeric reducing sugars is fructose, in the presence of water and an acid, at a temperature of > 50 °C, and preferably removing any solid precipitate which may have formed, so that an activated aqueous carbohydrate component results, comprising as constituents: BASF SE 240806 c1) one or more monomeric reducing sugars, wherein the one or at least one of the more monomeric reducing sugars is fructose, and c2) hydroxymethylfurfural;

[0091] 52) providing or preparing a first polylysine component, comprising one or more polylysines;

[0092] 53) reacting the activated aqueous carbohydrate component from step S1 a) with the first polylysine component from step S2) at a temperature of > 35 °C, to receive a first aqueous binder composition;

[0093] 55) providing or preparing a second polylysine component, comprising one or more polylysines and

[0094] 56) mixing, preferably reacting, the first aqueous binder composition from step S3) with the second polylysine component from step S5) at a temperature in the range of from > 15 °C to < 60 °C, preferably of from > 15 °C to < 40 °C, to receive a second aqueous binder composition.

[0095] Preferred is then also a process of the present invention as described herein (i.e. including a process for producing a first aqueous binder composition, a process for producing a second aqueous binder composition and a process for producing a lignocellulosic composite, or a respective process of the present invention as described herein as being preferred), wherein

[0096] - the activated aqueous carbohydrate component is prepared according to the process of the present invention as defined herein (or according to the process of the present invention as described herein as being preferred), wherein in step S1 a) the activated aqueous carbohydrate component is cooled to a temperature in the range of from > 0 °C to < 60 °C, preferably in the range of from > 10 °C to < 50 °C, more preferably in the range of from > 20 °C to < 40 °C, before it is reacted in step S3) with the first polylysine component and preferably before any solid precipitate is removed; and / or BASF SE 240806

[0097] - the one or more monomeric reducing sugars of constituent c1) of the activated aqueous carbohydrate component provided or prepared in step S1) or in step S1 a) which are not fructose, are independently selected from the group consisting of ribose, arabinose, xylose, glucose, mannose, galactose and mixtures thereof, preferably are selected from the group consisting of xylose, glucose and mixtures thereof; and / or

[0098] - a second amount of one or more monomeric reducing sugars, preferably wherein the one or at least one of the more monomeric reducing sugars is fructose, or a part of said second amount, is added to (i) the activated aqueous carbohydrate component from step S1) or (preferably) from step S1 a), or to a part thereof, and / or is added to (ii) the first polylysine component of step S2), or to a part thereof, and / or to their mixture (i.e. the mixture of (i) and (ii)), before or during, preferably before, reacting the activated aqueous carbohydrate component with the first polylysine component in step S3); and / or

[0099] - a third amount of one or more monomeric reducing sugars, preferably wherein the one or at least one of the more monomeric reducing sugars is fructose, or a part of said third amount, is added to the first aqueous binder composition as received in step S3) and / or as provided or prepared in step S4); and / or

[0100] - the total amount of hydroxymethylfurfural of constituent c2) present in the activated aqueous carbohydrate component provided or prepared in step S1) or in step 1 a) is in the range of from > 3 to < 30 mol-%, preferably of from > 4 to < 25 mol-%, more preferably of from > 5 to < 20 mol-% and even more preferably of from > 6 to < 15 mol-%, relative to the molar amount of the one or more monomeric reducing sugars of constituent c1), preferably as determined by1H-NMR spectroscopy.

[0101] In the variant of the process of the present invention as described above, wherein a second amount of one or more monomeric reducing sugars (or a part thereof) is added before (or during) reacting the activated aqueous carbohydrate component with the first polylysine component in step S3), the one or more monomeric reducing sugars of said second amount are preferably selected from the group consisting of ribose, arabinose, xylose, glucose, BASF SE 240806 fructose, mannose, galactose and mixtures thereof. Preferably, the second amount of one or more monomeric reducing sugars comprises fructose.

[0102] Since said second amount of one or more monomeric reducing sugars is added before or during reacting the activated aqueous carbohydrate component with the first polylysine component in step S3), the one or more reducing sugars of said second amount may participate in the reaction of step S3).

[0103] In the variant of the process of the present invention as described above, wherein a third amount of one or more monomeric reducing sugars (or a part thereof) is added to the first aqueous binder composition as received in step S3) and / or as provided or prepared in step S4), the one or more monomeric reducing sugars of said third amount are preferably selected from the group consisting of ribose, arabinose, xylose, glucose, fructose, mannose, galactose and mixtures thereof. Preferably, the third amount of one or more monomeric reducing sugars comprises fructose.

[0104] Since said third amount of one or more monomeric reducing sugars is added after reacting the activated aqueous carbohydrate component with the modified polylysine component in step S3), the one or more reducing sugars of said third amount do not participate in the reaction of step S3).

[0105] In the variant of the process of the present invention as described above, wherein the total amount of hydroxymethylfurfural of constituent c2) present in the activated aqueous carbohydrate component provided or prepared in step S1) is in the range of from > 3 to < 30 mol- %, said total amount of hydroxymethylfurfural of constituent c2) is preferably determined by1H-NMR spectroscopy in case the activated aqueous carbohydrate component is prepared in a step S1 a).

[0106] In a variant of the process of the present invention as described above, wherein the activated aqueous carbohydrate component provided or prepared in step S1) is obtained by mixing the separate constituents c1) and c2) with each other, the total amount of hydroxymethylfurfural of constituent c2) can simply be determined by specifying the amount of hydroxymethylfurfural which is or was used for preparing the activated aqueous carbohydrate component provided or prepared in step S1). BASF SE 240806

[0107] Preferred is moreover a process of the present invention as described herein (i.e. including a process for producing a first aqueous binder composition, a process for producing a second aqueous binder composition and a process for producing a lignocellulosic composite, or a respective process of the present invention as described herein as being preferred), wherein

[0108] - the mass ratio of the total amount (mass) of the one or more polylysines of the first polylysine component used in step S2) to the total amount (mass) of the one or more monomeric reducing sugars of constituent c1) present in or used for the preparation of the activated aqueous carbohydrate component in step S1) is in the range of from > 0.5 : 1 to < 2.5 : 1 , preferably of from > 0.8 : 1 to < 2.0 : 1 and more preferably of from > 0.8 : 1 to < 1 .5 : 1 ; and / or

[0109] - the mass ratio of the total amount (mass) of the one or more polylysines of the first polylysine component used in step S2) to the total amount (mass) of (i) the first amount of the one or more monomeric reducing sugars which is used for preparing the activated aqueous carbohydrate component in step S1) or in step S1 a) according to the process of the present invention (or according to a process of the present invention as described herein as being preferred), and of (ii) any second amount of one or more monomeric reducing sugars, is in the range of from > 0.5 : 1 to < 2.5 : 1 , preferably of from > 0.8 : 1 to < 2.0 : 1 and more preferably of from > 0.8 : 1 to < 1 .5; and / or

[0110] - in step S3), the activated aqueous carbohydrate component from step S1) or from step S1 a) is reacted with the first polylysine component of step S2) at a temperature of > 35 °C, preferably at a temperature in the range of from > 35 °C to < 90 °C, more preferably of from > 38 °C to < 80 °C, even more preferably of from > 38 °C to < 60 °C, and / or

[0111] - in step S3), the activated aqueous carbohydrate component from step S1) or from step S1 a) is reacted with the first polylysine component of step S2) for a time in the range of from > 20 to < 180 min., preferably of from > 30 to < 150 min. and more preferably of from > 40 to < 120 min.; BASF SE | 240806 and / or

[0112] - in step S3), the activated aqueous carbohydrate component from step S1) or from step S1 a) is reacted with the first polylysine component of step S2) until the apparent viscosity of the first aqueous binder composition, measured at a concentration of 50 wt.-% solids, preferably as determined according to DIN EN 827:2005, test conditions for amino resins (“Prufbedingungen fiir Synthetische Klebstoffe / Aminoharze”), has reached a value in the range of from > 80 to < 1000 mPa ■ s, preferably of from > 100 to < 800 mPa ■ s, more preferably of from > 120 to < 650 mPa ■ s and even more preferably of from > 140 to < 500 mPa ■ s, preferably determined according to method No. 8 as described in the methods section (see below).

[0113] Unless otherwise stated, all masses (weights) and mass ratios (weight ratios) of monomeric reducing sugars and of polylysines given herein refer to their dry masses (weights).

[0114] In the variant of the process of the present invention as described above, wherein the mass ratio of the total amount of the one or more polylysines of the first polylysine component used in step S2) to the total amount of the one or more monomeric reducing sugars of constituent c1) present in or used for the preparation of the activated aqueous carbohydrate component in step S1) or in step S1 a) is in the range of from > 0.5 : 1 to < 2.5 : 1 , said total amount of the one or more monomeric reducing sugars of constituent c1) comprises any second amount of one or more monomeric reducing sugars (and includes any first amount of one or more monomeric reducing sugars in variants of the process of the present invention the activated aqueous carbohydrate component is prepared in a step S1 a)).

[0115] Preferably, at least 90 mass-%, more preferably at least 95 mass-%, of the total solids content present in the first aqueous binder composition as received in step S3) and / or as provided or prepared in step S4) originates from (i) the activated aqueous carbohydrate component, (ii) the first polylysine component and (iii) any first and second amounts of one or more monomeric reducing sugars, wherein the one or at least one of the more monomeric reducing sugars is fructose (as were used in the process), or from reaction products of any of the foregoing, which may occur during the process of the present invention.

[0116] A process of the present invention as described herein is also preferred (i.e. including a process for producing a first aqueous binder composition, a process for producing a second aqueous binder composition and a process for producing a lignocellulosic composite, or a BASF SE 240806 respective process of the present invention as described herein as being preferred), wherein

[0117] - the first aqueous binder composition as received in step S3) and / or as provided or prepared in step S4) has a solid content in the range of from > 35 to < 85 mass-%, preferably of from > 40 to < 75 mass-% and more preferably of from > 45 to < 60 mass-%, preferably determined according to DIN EN 827:2005, test conditions for amino resins (“Prufbedingungen fiir Synthetische Klebstoffe / Aminoharze”); and / or

[0118] - in step S6), the mass ratio of the total mass of the first aqueous binder composition provided or prepared in step S4) to the total mass of the one or more polylysines of the second polylysine component provided or prepared in step S5) is in the range of from > 1 : 1 to < 15 : 1 , preferably in the range of from > 1.5 : 1 to < 10 : 1 and more preferably in the range of from > 2 : 1 to < 5 : 1 ; and / or

[0119] - the mass ratio of the total mass of the one or more polylysines of the first polylysine component provided or prepared in step S2) to the total mass of the one or more polylysines of the second polylysine component provided or prepared in step S5) is in the range of from > 30 : 70 to < 90 : 10, preferably of from > 35 : 65 to < 85: 15 and more preferably of from > 40 : 60 to < 80 : 20.

[0120] Furthermore, a process of the present invention as described herein is preferred (i.e. including a process for producing a first aqueous binder composition, a process for producing a second aqueous binder composition and a process for producing a lignocellulosic composite, or a respective process of the present invention as described herein as being preferred), wherein the one or more polylysines of the first polylysine component and the one or more polylysines of the second polylysine component

[0121] - independently have a weight-average molecular weight Mw in the range of 800 g / mol < Mw < 10000 g / mol, preferably of 1000 g / mol < MW£ 8000 g / mol and more preferably of 1200 g / mol < MW2 7000 g / mol, preferably as determined by size exclusion chromatography, preferably according to method No. 8 as described in the methods section (see below); BASF SE 240806 wherein preferably the one or more polylysines of the first polylysine component have a weight-average molecular weight Mw in the range of 1000 g / mol < Mw5000 g / mol, preferably of 1200 g / mol < MW2 3500 g / mol, preferably as determined by size exclusion chromatography, preferably according to method No. 7 as described in the methods section (see below); and / or the one or more polylysines of the second polylysine component have a weightaverage molecular weight Mwin the range of 1500 g / mol < Mw7000 g / mol, preferably of 1500 g / mol < MW2 6000 g / mol, more preferably of 2000 g / mol < Mw< 5000 g / mol, preferably as determined by size exclusion chromatography, preferably according to method No. 7 as described in the methods section (see below); and / or

[0122] - independently comprise as monomers integrated in their polymer structure > 85 mass- %, preferably > 95 mass-%, more preferably > 99 mass-%, and yet even more preferably 100 mass-%, of lysine monomers, based on the total mass of the polymer structure; and / or

[0123] - independently and measured as a 50 mass-% solution in water, preferably as determined according to DIN EN 827:2005, test conditions for amino resins (“Priifbed- ingungen fiir Synthetische Klebstoffe / Aminoharze”), have an apparent viscosity in the range of from > 50 mPa ■ s to < 2000 mPa ■ s, preferably of from > 55 mPa ■ s to < 1000 mPa ■ s, more preferably of from > 60 mPa ■ s to < 800 mPa ■ s, even more preferably of from > 65 mPa ■ s to < 600 mPa ■ s and yet even more preferably of from > 70 mPa ■ s to < 400 mPa ■ s, preferably as determined according to method No. 8 as described in the methods section (see below).

[0124] Preferably, the wt.-% proportion (weight percentage) or mass-% proportion (mass percentage) of lysine (monomers), preferably of L-lysine, in the one or more polylysines can be BASF SE 240806 determined in a manner known per se, e.g. by synthesizing (polymerizing) a particular polylysine from defined monomers and subsequently determining the type(s) and amount(s) of remaining monomers which have not been polymerized. From said type(s) and amount(s) of remaining monomers which have not been polymerized it, can be concluded that all (previous) monomers, which are not found as remaining monomers have become part of the synthesized polylysine.

[0125] Weight-average molecular weights Mw of the one or more polylysines as described herein are preferably determined by size exclusion chromatography (SEC), as is generally known in the field and as is specified in more detail in the methods section below.

[0126] It has been found in own experiments that a process according to the present invention as disclosed herein results in lignocellulosic composites with particularly beneficial mechanical properties, in particular in high internal bond strengths and in low tendency for swelling in the presence of aqueous moisture, when the preferred one or more polylysines of the first polylysine component are used and / or when the preferred one or more polylysines of the second polylysine component are used. More specifically, it has been found that lignocellulosic composites with particularly beneficial mechanical properties are obtained when the one or more polylysines of the first polylysine component are used and / or when the preferred one or more polylysines of the second polylysine component are used, which have the above-explained preferred weight-average molecular weights Mw and / or apparent viscosities.

[0127] Moreover, a process of the present invention as described herein is preferred (i.e. including a process for producing a first aqueous binder composition, a process for producing a second aqueous binder composition and a process for producing a lignocellulosic composite, or a respective process of the present invention as described herein as being preferred), wherein

[0128] - the mass ratio of (i) the total amount (mass) of the one or more polylysines of the first polylysine component of step S2) and (ii) any present polylysines of the second polylysine component of any step S5) to the total amount (mass) of the one or more monomeric reducing sugars used in step S1) and in step S3), is in the range of from > 5 : 95 to < 90 : 10, preferably of from > 10 : 90 to < 80 : 20, more preferably of from > 15 : 85 to < 70 : 30, still more preferably of from > 20 : 80 to < 60 : 40 and yet more preferably of from > 25 : 75 to < 55 : 45. BASF SE 240806 and / or

[0129] - the one or more monomeric reducing sugars, wherein the one or at least one of the more monomeric reducing sugars is fructose, of constituent c1), as well as of the first amount of one or more monomeric reducing sugars (as specified above), each independently comprise > 20 mass-%, preferably > 25 mass-%, more preferably > 35 mass- % and yet more preferably > 45 mass-% of fructose, based on the total mass of the respective one or more monomeric reducing sugars; and / or

[0130] - the one or more monomeric reducing sugars of constituent c1) of the activated aqueous carbohydrate component provided or prepared in step S1) or in step S1 a), or a part thereof, are provided by fructose-containing syrups which are selected from the group consisting of fructose syrup, inverted sugar syrup, corn syrup, high fructose corn syrup, glucose-fructose syrup, fructose-glucose syrup and mixtures thereof.

[0131] In a preferred variant of the process of the present invention as described above, the one or more monomeric reducing sugars of constituent c1) of the activated aqueous carbohydrate component and the first amount of one or more monomeric reducing sugars, as used in a step S1 a) both independently comprise > 60 mass-%, preferably > 75 mass-%, of fructose, based on the total mass of the respective one or more monomeric reducing sugars. In one preferred variant of the process of the present invention as described above, the one or more monomeric reducing sugars of constituent c1) of the activated aqueous carbohydrate component and the first amount of one or more monomeric reducing sugars, as used in a step S1 a) independently consist of fructose.

[0132] In the variant of the process of the present invention as described above, wherein the one or more monomeric reducing sugars of constituent c1) of the activated aqueous carbohydrate component provided or prepared in step S1) or in step S1 a), or a part thereof, are provided by fructose-containing syrups, commercially available fructose-containing syrups like high fructose corn syrups (commonly abbreviated to “HFCS”), in particular such comprising fructose in a dry weight of about 42 % (“HFCS 42”) or of about 55 % (“HFCS 55”) may be used. It was found in own experiments that such fructose-containing syrups are excellently suited for providing the monomeric reducing sugars of constituent c1) of said activated aqueous carbohydrate component in a process according to the present invention. Surprisingly, although fructose was found to be a particularly preferred reducing sugar BASF SE 240806 for the purposes of the present invention, it was also found that even mixtures comprising a proportion of fructose as specified here above usually result in lignocellulosic composites with excellent mechanical properties.

[0133] A process for producing a lignocellulosic composite of the present invention as described herein is preferred (or a respective process of the present invention as described herein as being preferred), wherein

[0134] - the process further comprises a step S7a) comprising compacting the aqueous mixture from step S7) to receive a compacted mixture, and wherein step S8) comprises applying heat and pressure to the compacted mixture from step S7a), so that the binder of the first aqueous binder composition hardens, or the binder of the second aqueous binder composition hardens, and a lignocellulosic composite results, wherein preferably step 7a) comprises compacting the mixture at a pressure in the range of from of > 0.01 to < 4 MPa, preferably in the range of from > 0.1 to < 1 MPa; and / or

[0135] - step S8) comprises applying to the aqueous mixture from step S7) or to the compacted mixture from step S7a) a temperature in the range of from > 80 °C to < 300 °C, preferably in the range of from > 120 °C to < 270 °C, and a pressure in the range of from > 0.1 to < 10 MPa, preferably in the range of from > 1 to < 7 MPa; and / or

[0136] - step S8) comprises pressing the aqueous mixture from step S7) or the compacted mixture from step S7a) in a hot-press, preferably with a press-time factor in the range of from > 3 s / mm to < 10 s / mm, preferably in the range of from > 3.5 s / mm to < 9 s / mm, more preferably in the range of from > 4 s / mm to < 8 s / mm.

[0137] In a preferred variant of the process for producing a lignocellulosic composite of the present invention as described above, wherein a temperature in the range of from > 80 °C to < 300 °C is applied in step S8) to the aqueous mixture from step S7) or to the compacted mixture from step S7a), the temperature is applied by heating with a hot press and the temperature in the range of from > 80 °C to < 300 °C (or a temperature in the preferred temperature BASF SE 240806 ranges as defined above) in this case designates the temperature of the plates of the hot press.

[0138] In a further variant of the process for producing a lignocellulosic composite of the present invention as described above, wherein a temperature in the range of from > 80 °C to < 300 °C is applied in step S8) to the aqueous mixture from step S7) or to the compacted mixture from step S7a), the temperature (or a temperature in the preferred temperature ranges as defined above) is applied by heat transfer via high frequency electromagnetic waves, preferably by heating with a high frequency press. In this case the temperature in the range of > 80 °C to < 300 °C (or a temperature in the preferred temperature ranges as defined above) designates the maximum temperature reached in step S8) in the center of the aqueous mixture which is derived from step S7) or the compacted mixture which is derived from step S7a). Applying the temperature by heating with a hot press is, however, preferred.

[0139] In a preferred variant of the process for producing a lignocellulosic composite of the present invention as described above, the temperature (or a temperature in the preferred temperature ranges as defined above) is therefore not applied by heat transfer via high-frequency electromagnetic waves and / or is not applied by heating with a high-frequency press.

[0140] In a further preferred variant of the process for producing a lignocellulosic composite of the present invention as described above, the mass ratio of the total (mass of the) solids content of the first aqueous binder composition provided or prepared in step S7) (preferably determined according to DIN EN 827:2005, test conditions for amino resins (“Priifbed- ingungen fiir Synthetische Klebstoffe / Aminoharze”) to the total (dry) mass of the lignocellulosic particles provided or prepared in step S7) is in the range of from > 3 to < 12 %, preferably of from > 4 to < 10 %.

[0141] In a still further preferred variant of the process for producing a lignocellulosic composite of the present invention as described above, the mass ratio of the total (mass of the) solids content of the second aqueous binder composition provided or prepared in step S7) (preferably determined according to DIN EN 827:2005, test conditions for amino resins (“Priif- bedingungen fiir Synthetische Klebstoffe / Aminoharze”) to the total (dry) mass of the lignocellulosic particles provided or prepared in step S7) is in the range of from > 3 to < 12 %, preferably of from > 4 to < 10 %. BASF SE 240806

[0142] It is then also preferred a process of the present invention for producing a lignocellulosic composite as described herein (or a respective process of the present invention as described herein as being preferred), wherein

[0143] - the temperature of the lignocellulosic particles has been set to a temperature in the range of from > 30 °C to < 80 °C, preferably of from > 35 °C to < 70 °C, more preferably in the range from > 38 °C to < 62 °C before the lignocellulosic particles are combined with the first aqueous binder composition or with the second binder composition, to provide or prepare the aqueous mixture of step S7); and / or

[0144] - wherein the aqueous mixture provided or prepared in step S7) comprises as further constituent one or more basic substances having a pKs-value of < 3, preferably having a pKs-value of < 2,5, more preferably having a pKs-value of < 2; wherein preferably

[0145] - the one or at least one of the more, preferably all of the more, basic substances having a pKs-value of < 3 are selected from the group consisting of: alkali metal hydroxides, preferably selected from the group consisting of LiOH, NaOH, KOH and mixtures thereof; more preferably the one or at least one of the more basic substances having a pKs-value of < 3 is NaOH; and earth alkali metal hydroxides, preferably selected from the group consisting of Mg(OH)2 and Ca(OH)2 and mixtures thereof, more preferably Ca(OH)2.

[0146] In the preferred variant of the process for producing a lignocellulosic composite according to the present invention as described herein, the temperature of the lignocellulosic particles has been set or adjusted to a temperature in the range of from > 30 °C to < 80 °C (or in a preferred range as is explained in more detail below), right before said lignocellulosic particles are combined with the first aqueous binder composition or with the second binder composition, to provide or prepare the aqueous mixture of step S7), i.e. the temperature of the lignocellulosic particles is in the range of from > 30 °C to < 80 °C (or in a preferred BASF SE 240806 range as is explained in more detail below) just when the lignocellulosic particles are brought into contact with the first aqueous binder composition or with the second binder composition, to provide or prepare the aqueous mixture of step S7) of the process.

[0147] It has been found in own experiments that, when lignocellulosic particles whose temperature has been set or adjusted to a temperature in the range of from > 30 °C to < 80 °C (or in a preferred range as is explained in more detail below), right before said lignocellulosic particles are combined with the first aqueous binder composition or with the second binder composition, to provide or prepare the aqueous mixture of step S7), a lignocellulosic composite produced by such process according to the present invention has unexpected beneficial properties when compared to a similar process, in which, however, the lignocellulosic particles used therein have not been set to a temperature in the range of from > 30 °C to < 80 °C (but have a temperature below 30 °C or below a preferred temperature as further discussed herein). In particular, it has been observed by the present inventors that lignocellulosic composites produced by said variant of the process of the present invention as disclosed herein show particularly high internal bond strengths and also show a particularly low tendency for swelling when in contact with aqueous moisture.

[0148] Preferred is a process for producing a lignocellulosic composite of the present invention as described herein (or a respective process of the present invention as described herein as being preferred), wherein the lignocellulosic particles (still) have a temperature within the range of from > 30 °C to < 80 °C to which they have been set, when the lignocellulosic particles are contacted or combined with the first aqueous binder composition or with the second binder composition, to provide or prepare the aqueous mixture of step S7).

[0149] It has been found that it is beneficial or even necessary for achieving the best results, that, at the time when the lignocellulosic particles are contacted or combined with the first aqueous binder composition or with the second binder composition (e.g. when the aqueous binder compositions or their components are sprayed onto the cellulosic particle), the lignocellulosic particles then have a temperature in the specified range of from > 30 °C to < 80 °C. Once contacting or combining the aqueous binder compositions or its components with the lignocellulosic particles progresses, the temperature of the lignocellulosic particles may gradually drop or be lowered again, for example by (passive) heat exchange with the environment. Under such circumstances, no significant negative effect is observed on the mechanical properties of a lignocellulosic composite resulting from such process.

[0150] Preferred is, however, a process for producing a lignocellulosic composite of the present invention as described herein (ora respective process of the present invention as described BASF SE | 240806 herein as being preferred), wherein the aqueous mixture provided or prepared in step S7) has a temperature in the range of from > 30 °C to < 80 °C, preferably in the range of from > 35 °C to < 70 °C and more preferably in the range of from > 38 °C to < 62 °C and preferably has about the same temperature as the temperature to which the lignocellulosic particles have been set. For this purpose, the (first or second) aqueous binder composition may be heated to a temperature in the range of from > 25 °C to < 80 °C, preferably in the range of from > 30 °C to < 70 °C and more preferably in the range of from > 33 °C to < 62 °C before it is contacted with the lignocellulosic particles in step S7) (so that the aqueous binder composition has a temperature in the range or in a preferred range as specified above when it is contacted with the lignocellulosic particles). Preferably the (first or second) aqueous binder composition is heated to a temperature which does not deviate by more than 10 °C, preferably does not deviate by more than 5 °C, from the temperature to which the lignocellulosic particles have been set before the aqueous binder composition is contacted with the lignocellulosic particles to provide or prepare the aqueous mixture in step S7). Preferably the heated (first or second) aqueous binder composition is contacted with the lignocellosic particles within 5 min, more preferably within 1 min, after the (first or second) aqueous binder composition has reached the desired temperature, to provide or prepare the aqueous mixture in step S7). Preferably the (first or second) aqueous binder composition is heated to a temperature which does not deviate more than 10 °C, preferably does not deviate more than 5 °C, from the temperature to which the lignocellulosic particles have been set, before, the aqueous binder composition is contacted with the lignocellulosic particles in step S7).

[0151] Preferred is, however, a process of the present invention as described herein (or a process of the present invention as described herein as being preferred), wherein the aqueous binder composition provided or prepared in step S1), or one or more parts, preferably all parts, of the aqueous binder composition (when components c1) and c2) of the aqueous binder composition, or parts thereof, are contacted separately with the lignocellulosic particles), has a temperature in the range of from > 10 °C to < 35 °C, preferably in the range of from > 15 °C to < 30 °C and more preferably in the range of from > 18 °C to < 28 °C.

[0152] In the preferred variant of the process for producing a lignocellulosic composite according to the present invention as described herein, wherein the aqueous mixture provided or prepared in step S7) comprises as further constituent one or more basic substances having a pKs-value of < 3, the total amount of the one or more basic substances having a pKs- value of < 3, (preferably selected from the group consisting of alkali metal hydroxides and earth alkali metal hydroxides as defined above) of the aqueous mixture or used for the preparation of the aqueous mixture in step S7) is in the range of from > 0.05 to < 1 mass- BASF SE 240806

[0153] %, preferably of from > 0.1 to < 0.8 mass-% and more preferably in the range of from > 0.15 to < 0.6 mass-%, relative to the total mass of the aqueous mixture.

[0154] The one or more basic substances having a pKs-value of < 3 (preferably selected from the group consisting of alkali metal hydroxides and earth alkali metal hydroxides as defined above) is preferably added to the first or second aqueous binder composition used in step S7) in an amount in the range of from > 0.3 to < 10 mass-%, preferably of from > 1 to < 8 mass-% and more preferably in the range of from > 0.5 to < 6 mass-%, relative to the solid content of the respective first or second aqueous binder composition, wherein the solid content of the respective first or second aqueous binder composition is preferably determined according to DIN EN 827:2005, test conditions for amino resins (“Prufbedingungen fiir Synthetische Klebstoffe / Aminoharze”)

[0155] Preferably, the pH of the first and / or the second aqueous binder composition used in step S7) is adjusted to a pH in the range of from > 8 to < 14, more preferably in the range of from > 9 to < 13 (preferably before said first and / or second aqueous binder composition is used in step S7).

[0156] It has furthermore been found in own experiments that the use of one or more basic substances having a pKs-value of < 3 in the process for producing a lignocellulosic composite according to the present invention resulted in a further improvement of internal bond strengths of lignocellulosic composites (or a reduction in press times for achieving a defined internal bond strength, respectively) produced by the process for producing a lignocellulosic composite according to the present invention. NaOH is a particularly preferred basic substance having a pKs-value of < 3 for use in the in the process for producing a lignocellulosic composite according to the present invention.

[0157] A process for producing a lignocellulosic composite of the present invention as described herein is also preferred (or a respective process of the present invention as described herein as being preferred), wherein the lignocellulosic composite is a lignocellulosic board selected from the group consisting of high-density fiberboard; medium-density fiberboard; low-density fiberboard; wood fiber insulation board; BASF SE 240806 oriented strand board; chipboard; and natural fiber board, preferably comprising fibers from the group consisting of sisal fibers, jute fibers, flax fibers, coconut fibers, kenaf fibers, hemp fibers, banana fibers, and mixtures thereof; wherein the lignocellulosic board is a single-layer lignocellulosic board or a multilayer lignocellulosic board, preferably chipboard, wherein preferably the multilayer lignocellulosic board is a three-layered board having a core layer and an upper surface layer and a lower surface layer, wherein at least one layer, preferably at least the core layer, has been produced from an aqueous mixture as provided or prepared in step S7) as defined herein.

[0158] Under a preferred aspect of the process for producing a lignocellulosic composite according to the present invention, the process results in a lignocellulosic composite, that is preferably a single-layer lignocellulosic board or a multilayer lignocellulosic board, more preferably is a multilayer lignocellulosic board. The multilayer lignocellulosic board is preferably a board having at least a core layer as well as an upper surface layer and a lower surface layer. The total number of layers is then three or more. If the number of layers is four or more, there are one or more intermediate layers. Preferred is a three-layer board having one core layer, an upper surface layer and a lower surface layer, wherein at least one layer is prepared from an aqueous mixture as provided or prepared in step S7) of the process of the present invention as disclosed herein.

[0159] A process of the present invention for producing a lignocellulosic composite as described herein is also preferred (or a respective process of the present invention as described herein as being preferred), wherein the process of producing a lignocellulosic composite comprises one, two, three, more than three, or all of the following steps: preparing a layer of the aqueous mixture provided or prepared in step S7), and in step S7a) compacting or pre-compacting this layer, for preparing a multilayer lignocellulosic composite comprising one or more lignocellulosic composite layers: BASF SE 240806 providing or preparing at least a first and a second individual mixture, wherein at least one of said first and second individual mixtures is an aqueous mixture as defined in step S7), and using said first and second individual mixtures for making a first and a second layer of the multilayer lignocellulosic composite, wherein preferably the first and the second layer are in contact with each other, and / or wherein the first and the second individual mixtures have the same composition or have different compositions, preferably have different compositions; for preparing a multilayer lignocellulosic composite, preparing two or more layers, preferably preparing two or more layers by applying individual layers on top of each other, each layer comprising lignocellulosic particles and an aqueous binder composition, wherein at least one of the two or more layers comprises the lignocellulosic particles and the binder in the form of an aqueous mixture as defined in step S7), and wherein in the two or more layers the lignocellulosic particles and / or the binders are the same or different, in step S7a) compacting the aqueous mixture in two stages, wherein in the first stage the mixture is pre-compacted to give a pre-compacted mat, and wherein in the second stage this pre-compacted mat is further compacted; and during or after, preferably after compacting in step S8), applying heat and pressure to the mixture.

[0160] According to preferred aspects of the process for producing a lignocellulosic composite of the present invention, said process comprises one, two, three or more preferred steps, which are either specific embodiments of steps S7), S7a) or S8), respectively, or are additional steps. Each of these preferred steps is optional and can be conducted individually or in combination with one or more of the other preferred steps.

[0161] According to a preferred aspect of the present invention, for preparing a multilayer lignocellulosic composite, at least a first and a second individual (first or second) aqueous mixture are provided or prepared. Said first and second individual (first or second) aqueous BASF SE 240806 mixtures are then used for making a first and a second layer of the multilayer lignocellulosic composite. Preferably, the first and the second layer are in contact with each other. According to this preferred aspect, the first and the second individual (first or second) aqueous mixture have the same or have different composition, even more preferably the first and the second individual (first or second) aqueous mixture have different compositions. Thus, the different individual aqueous mixtures and / or layers of the prepared multilayer lignocellulosic composite preferably differ in specific properties such as density, thickness, color and / or they differ in terms of their composition, wherein differing compositions are obtained by using different binders, lignocellulosic particles and / or other (additional) components such as plastics, fabrics or paint coat for example derived from foreign matter in waste wood. Individual layers preferably (i) comprise different binders (resulting from different aqueous binder compositions) and different lignocellulosic particles, or (ii) comprise identical binders (resulting from the same or identical aqueous binder compositions), but different lignocellulosic particles or (iii) comprise identical binders and identical lignocellulosic particles, but in different ratios. Preferably, the individual mixtures for preparing the individual layers of a multilayer lignocellulosic composite are processed jointly in step S7a) and / or in step S8) of the process of the present invention.

[0162] According to a variant of the process of the present invention, the preparation of a multilayer lignocellulosic composite comprises the preparation of two, three or more layers, each layer comprising lignocellulosic particles and a binder. Preferably the lignocellulosic particles and / or the binders in said two, three or more layers are the same or different, even more preferably the lignocellulosic particles are different and the binders are different.

[0163] Preferably, in step S7a) of compacting the mixture provided or prepared in step S7) (if said compacting is applied), the compacting of the mixture is conducted in two stages. This means, that in a first stage the aqueous mixture is pre-compacted to give a pre-compacted mat, and in a second stage this pre-compacted mat is further compacted. Preferably, the first stage of pre-compacting the aqueous mixture to give a pre-compacted mat is carried out before step S8) of applying heat and pressure.

[0164] In a preferred process for producing a lignocellulosic composite of the present invention, the preparation of a single-layer lignocellulosic composite or a multilayer lignocellulosic composite comprises the following steps: providing or preparing one, two or more than two mixtures at least comprising lignocellulosic particles and an aqueous binder composition according to the present invention, BASF SE 240806 scattering this mixture / these mixtures to give one, two or more than two layers, wherein the layer(s) form a mat, in a first compacting step pre-compacting this single-layer or multilayer mat to give a pre-compacted mat, and thereafter in a second compacting step compacting the pre-compacted mat while applying heat and pressure.

[0165] The present invention furthermore pertains to a process for producing a lignocellulosic element, preferably selected from the group consisting of gluelam, plywood, finger-joint lumber, laminated veneer lumber, cross-laminated timber, parallel-laminated timber, blockboards solid wood beams and solid wood boards, comprising at least the following steps:

[0166] S7-1) providing or preparing a first lignocellulosic component (of a lignocellulosic element) wherein said first lignocellulosic component has at least one surface;

[0167] S7-2) providing or preparing a second lignocellulosic component (of a lignocellulosic element), wherein said second lignocellulosic component has at least one surface;

[0168] S7-3) providing or preparing

[0169] (i) a first aqueous binder composition according to the present invention as defined herein (or a first aqueous binder composition according to the present invention as described herein as being preferred), and / or

[0170] (ii) a second aqueous binder composition according to the present invention as defined herein (or a second aqueous binder composition according to the present invention as described herein as being preferred),

[0171] S7-4) applying the first aqueous binder composition and / or the second aqueous binder composition from step S7-3) to the at least one surface of the first lignocellulosic component from step S7-1) and / orto the at least one surface of the second lignocellulosic component from step S7-2);

[0172] S7-5) joining the surface of the first lignocellulosic component to which the first aqueous binder composition and / or the second aqueous binder composition was previously BASF SE 240806 applied in step S7-4) with the at least one surface of the second lignocellulosic component as prepared or provided in step S7-2), to which the first aqueous binder composition and / or the second aqueous binder composition was optionally previously applied, or joining the surface of the second lignocellulosic component to which the first aqueous binder composition and / or the second aqueous binder composition was previously optionally applied in step S7-4) with the at least one surface of the first lignocellulosic component as prepared or provided in step S7-1), to which the first aqueous binder composition and / or the second aqueous binder composition was previously applied; and

[0173] S8-1) applying pressure and optionally heat to the joint surfaces of the first and second lignocellulosic components, preferably so that the binder of the first aqueous binder composition and / or the binder of the second aqueous binder composition hardens and the first and second lignocellulosic components are permanently joint, and preferably a lignocellulosic element results.

[0174] Generally, all aspects of the present invention discussed herein in the context of the process for producing a lignocellulosic composite comprising one or more lignocellulosic composite layers according to the present invention as defined herein and / or the process for producing the first aqueous binder composition according to the present invention as defined herein and of the process for producing the second aqueous binder composition according to the present invention as defined herein apply mutatis mutandis to the process for producing a lignocellulosic element according to the present invention as defined herein, and vice versa.

[0175] Preferably, the first lingocellulosic component as provided or prepared in step S7-1) as defined above and the second lignocellulosic component as provided or prepared in step S7-2) as defined above are independently selected from the group consisting of wood beams, wood lamellas, wood blanks, wooden panels, wood veneers, and wood composites. In a preferred variant of the process for producing a lignocellulosic element according to the present invention, the first and second lignocellulosic components are selected from the same type, e.g. both are selected from wood lamellas or both are selected from wood veneers. BASF SE 240806

[0176] In one variant of the present invention, a lignocellulosic composite can be used as lignocellulosic component in the process for producing a lignocellulosic element according to the present invention. The first lignocellulosic component may be a chipboard (or fiberboard) to which the first aqueous binder composition or the second aqueous binder composition is applied. The second lignocellulosic component may be a veneer which is joined to the chipboard resulting in a veneered chipboard (or fiberboard).

[0177] Preferably, step S8-1) of the process for producing a lignocellulosic element according to the present invention as defined here above comprises applying to the joint surfaces of the first and second components of the lignocellulosic element a pressure in the range of from > 1 to < 10 MPa, preferably in the range of from > 2 to < 9 MPa and preferably a temperature in the range of from > 30 °C to < 200 °C, preferably in the range of from > 50 °C to < 160 °C.

[0178] The present invention then also pertains to a lignocellulosic composite comprising one or more lignocellulosic composite layers, obtainable or obtained by a process for producing a lignocellulosic composite according to the present invention as described herein (or by a respective process of the present invention as described herein as being preferred), or a construction product thereof.

[0179] Generally, all aspects of the present invention discussed herein in the context of the process for producing a lignocellulosic element according to the present invention and / or to the process for producing a lignocellulosic composite comprising one or more lignocellulosic composite layers according to the present invention as defined herein and / or the process for producing the first aqueous binder composition according to the present invention as defined herein and of the process for producing the second aqueous binder composition according to the present invention as defined herein apply mutatis mutandis to the lignocellulosic composite of the present invention as defined herein, and vice versa.

[0180] Preferably, the lignocellulosic composite of the present invention may be used in a construction product (e.g. as building element in such construction product) selected from the group consisting of deckings; walls; ceilings; doors; windows, preferably window frames; floors; panels, preferably selected from the group consisting of acoustic panels and insulation panels; and furniture and parts of furniture, wherein preferably the furniture is selected from the group consisting of bookshelves, wardrobes, cabinets, vitrines, kitchen cabinets, tables, chairs, upholstered furniture, office furniture and desks. BASF SE 240806

[0181] The term “building element” as used herein designates lignocellulosic composite products (e.g., boards, see above) which constitute a part (element) of a construction product (e.g., a part of furniture). Such building elements may be parts of furniture, preferably such parts of furniture are selected from the group consisting of shelves, table plates, side boards, doors of cabinets and side walls of beds.

[0182] A lignocellulosic composite according to the present invention as defined herein is preferably characterized by one, more than one, or all of the following parameters: a formaldehyde emission measured according to EN717-2, which is lower than 2.0 mg / m2h; preferably lowerthan 1 .0 mg / m2h; more preferably lowerthan 0.5 mg / m2h and even more preferably lowerthan 0.25 mg / m2h; even yet more preferably lowerthan 0.1 mg / m2h and / or a surface screw holding, measured according to IKEA specification no. IOS-TM-0057, Date: 2018-07-13, Version no: AA-2120821 -1 , of at least 250 N, preferably of least 300 N, more preferably of least 450 N; and / or an edge screw holding, measured according to IKEA specification no. IOS-TM-0057, Date: 2018-07-13, Version no: AA-2120821 -1 , of at least 600 N, preferably of at least 800 N; and / or an internal bond strength, determined according to DIN EN 319:1993-08, of at least 0.3 N / mm2, preferably of at least 0.35 N / mm2, more preferably of at least 0.4 N / mm2, and / or a thickness swelling after 24 hours in water at 20 °C, determined according to DIN EN 317:1993-08, of less than 60 %, preferably of less than 50 %, more preferably of less than 40 %. BASF SE 240806

[0183] The present invention moreover pertains to a lignocellulosic element, preferably selected from the group consisting of wood beams, wood lamellas, wood blanks, wooden panels and wood veneers, obtainable or obtained by a process for producing a lignocellulosic element according to the present invention as described herein (or to a respective lignocellulosic element of the present invention as described herein as being preferred).

[0184] Generally, all aspects of the present invention discussed herein in the context of the lignocellulosic composite of the present invention as defined herein and / or of the process for producing a lignocellulosic element according to the present invention and / orto the process for producing a lignocellulosic composite comprising one or more lignocellulosic composite layers according to the present invention as defined herein and / orthe process for producing the first aqueous binder composition according to the present invention as defined herein and / or of the process for producing the second aqueous binder composition according to the present invention as defined herein apply mutatis mutandis to the lignocellulosic element of the present invention as defined herein, and vice versa.

[0185] In a further aspect, the present invention pertains to a first aqueous binder composition, obtainable or obtained by a process for producing a first aqueous binder composition according to the present invention as described herein (or by a respective process of the present invention as described herein as being preferred).

[0186] Generally, all aspects of the present invention discussed herein in the context of the lignocellulosic element of the present invention as defined herein and / orthe lignocellulosic composite of the present invention as defined herein and / or of the process for producing a lignocellulosic element according to the present invention and / orto the process for producing a lignocellulosic composite comprising one or more lignocellulosic composite layers according to the present invention as defined herein and / or the process for producing the first aqueous binder composition according to the present invention as defined herein and / or of the process for producing the second aqueous binder composition according to the present invention as defined herein and / or of the lignocellulosic composite of the present invention as defined herein, apply mutatis mutandis to the first aqueous binder composition of the present invention as defined herein, and vice versa.

[0187] In a still further aspect, the present invention also pertains to a second aqueous binder composition, obtainable or obtained by a process for producing a second aqueous binder composition according to the present invention as described herein (or by a respective process of the present invention as described herein as being preferred). BASF SE 240806

[0188] Generally, all aspects of the present invention discussed herein in the context of the first aqueous binder composition of the present invention as defined herein and / or of the lignocellulosic element of the present invention as defined herein and / orthe lignocellulosic composite of the present invention as defined herein and / or of the process for producing a lignocellulosic element according to the present invention and / or to the process for producing a lignocellulosic composite comprising one or more lignocellulosic composite layers according to the present invention as defined herein and / or the process for producing the first aqueous binder composition according to the present invention as defined herein and / or of the process for producing the second aqueous binder composition according to the present invention as defined herein and / or of the lignocellulosic composite of the present invention as defined herein, apply mutatis mutandis to the second aqueous binder composition of the present invention as defined herein, and vice versa.

[0189] In yet a further aspect, the present invention further pertains to the use of a first aqueous binder composition of the present invention as defined herein (or of a first aqueous binder composition of the present invention as defined herein as being preferred) and / or to the use of a second aqueous binder composition of the present invention as defined herein (or of a second aqueous binder composition of the present invention as defined herein as being preferred),

[0190] - in a process for producing a lignocellulosic composite (preferably a lignocellulosic composite according to the present invention as defined herein) or a lignocellulosic element (preferably a lignocellulosic element according to the present invention as defined herein), and / or

[0191] - as a binder, adhesive or glue for permanently joining lignocellulosic (preferably wooden) parts, wherein preferably the lignocellulosic parts are selected from lignocellulosic particles (preferably as further defined herein), lignocellulosic elements (preferably as further defined herein) and lignocellulosic components (preferably as further defined herein).

[0192] Generally, all aspects of the present invention discussed herein in the context of the second aqueous binder composition of the present invention as defined herein and / or of the first aqueous binder composition of the present invention as defined herein and / or of the ligno- BASF SE 240806 cellulosic element of the present invention as defined herein and / orthe lignocellulosic composite of the present invention as defined herein and / or of the process for producing a lignocellulosic element according to the present invention and / or to the process for producing a lignocellulosic composite comprising one or more lignocellulosic composite layers according to the present invention as defined herein and / or the process for producing the first aqueous binder composition according to the present invention as defined herein and / or of the process for producing the second aqueous binder composition according to the present invention as defined herein and / or of the lignocellulosic composite of the present invention as defined herein, apply mutatis mutandis to the use of a first aqueous binder composition of the present invention as defined herein and / or of a second aqueous binder composition of the present invention as defined herein, and vice versa.

[0193] Under a broader aspect, the present invention also pertains to a process for producing a lignocellulosic article, selected from the group consisting of

[0194] - a lignocellulosic composite, comprising one or more lignocellulosic composite layers, and

[0195] - a lignocellulosic element, preferably selected from the group consisting of gluelam, plywood, finger-joint lumber, laminated veneer lumber, cross-laminated timber, parallel- laminated timber, blockboards, solid wood beams and solid wood boards, comprising at least the following steps:

[0196] 5700) providing or preparing lignocellulosic pieces selected from the group consisting of lignocellulosic particles and lignocellulosic components,

[0197] 5701) providing or preparing at least one aqueous binder composition, selected from the group consisting of

[0198] (i) a first aqueous binder composition according to the present invention as described herein (or a first aqueous binder composition according to the present invention as described herein as being preferred), and

[0199] (ii) a second aqueous binder composition according to the present invention as described herein (or a second aqueous binder composition according to the present invention as described herein as being preferred), BASF SE 240806

[0200] S702) applying one or both of the aqueous binder compositions from step S701) to at least one of the lignocellulosic pieces from step S700), and joining said at least one of the lignocellulosic pieces with at least one further lignocellulosic piece, and

[0201] S800) applying pressure and optionally heat to the at least two joined lignocellulosic pieces from step S702), so that the binder of the first aqueous binder composition and / or the binder of the second aqueous binder composition hardens and a lignocellulosic article results.

[0202] Generally, all aspects of the present invention discussed herein in the context of the use of a first aqueous binder composition of the present invention as defined herein and / or of a second aqueous binder composition of the present invention as defined herein and / or of the second aqueous binder composition of the present invention as defined herein and / or of the first aqueous binder composition of the present invention as defined herein and / or of the lignocellulosic element of the present invention as defined herein and / or the lignocellulosic composite of the present invention as defined herein and / or of the process for producing a lignocellulosic element according to the present invention and / or to the process for producing a lignocellulosic composite comprising one or more lignocellulosic composite layers according to the present invention as defined herein and / orthe process for producing the first aqueous binder composition according to the present invention as defined herein and / or of the process for producing the second aqueous binder composition according to the present invention as defined herein and / or of the lignocellulosic composite of the present invention as defined herein, apply mutatis mutandis to the process for producing a lignocellulosic article of the present invention as defined herein, and vice versa.

[0203] In step S702) of the a process for producing a lignocellulosic article as described above, joining said at least one of the lignocellulosic pieces with at least one further lignocellulosic piece preferably means that the lignocellulosic pieces are joined (connected) via (or by) the aqueous binder composition which was applied to at least one of the lignocellulosic pieces.

[0204] Examples:

[0205] The following examples are meant to further explain and illustrate the present invention without limiting its scope. BASF SE 240806

[0206] Materials:

[0207] The following materials were used in the experiments described below:

[0208] 1) Dextrose monohydrate, Sigma Aldrich, Spain;

[0209] 2) Fructose (> 99 %), Sigma Aldrich, USA

[0210] 3) Fructose FF100, Cargill, Germany

[0211] 4) Sugar Syrup FF95, Cargill, Germany (content: 67.0 wt.-% fructose, 3.5 wt.-% other sugars, and 29.5 wt.-% water)

[0212] 5) Hydroxymethylfurfural (HMF), BLD Pharmatech GmbH, Germany (> 98.5%)

[0213] 6) L-Lysine solution (50 % in water), ADM animal nutrition, USA;

[0214] 7) Sulfuric acid (96 %), Carl Roth

[0215] 8) Sodium hydroxide (pellets), Carl Roth

[0216] 9) Sodium dithionite, Merck

[0217] 10) Spruce wood chips (lignocellulosic particles) from Germany, Institut fiir Holztechnol- ogie Dresden:

[0218] Spruce wood chips were produced in a disc chipper. Spruce trunk sections (length 250 mm) from Germany were pressed with the long side against a rotating steel disc, into which radially and evenly distributed knife boxes were inserted, each of which consisted of a radially arranged cutting knife and several scoring knives positioned at right angles to it.

[0219] The cutting knife separated the chip from the round wood and the scoring knives simultaneously limited the chip length. Afterwards the produced chips were collected in a bunker and were subsequently transported to a cross beater mill (with sieve insert) for re-shredding with regard to chip width. Then, the re-shredded chips were conveyed to a flash drier and dried at approx. 120 °C. The chips were then screened into two useful fractions (“B”: < 2.0 mm x 2.0 mm and > 0.32 mm x 0.5 mm; “C”: < 4.0 mm x 4,0 mm and > 2.0 mm x 2.0 mm), a coarse fraction (“D”: > 4.0 mm x 4.0 mm), which was re-shredded, and a fine fraction (“A”: < 0.32 mm x 0.5 mm). In the examples, a mixture of 60 wt.-% of fraction B and 40 wt.-% of fraction C was used as chips (lignocellulosic particles) for single-layered chipboards (lignocellulosic composites). | BASF SE | 240806 | 240806WQ01 ~

[0220] The moisture content of the chips was measured to be 4.6 % (according to the method described below).

[0221] 11) Industrial wood chips (lignocellulosic particles)

[0222] Industrial wood chips were received from an industrial chipboard producer in Austria. They were made from about. 40 % fresh wood (mixture of hard and soft wood) and about 60 % recycled wood.

[0223] The industrial wood chips were characterized by determination of the particle size distribution by sieve analysis. The used sieves and the resulting size distribution are given in the following table 1 . Table 1 : Characterization of industrial wood chips (lignocellulosic particles)

[0224] The moisture content of the industrial wood chips was measured to be 1 .7 % (according to the method described below).

[0225] Methods: 1 . Measuring of residual moisture content of lignocellulosic particles

[0226] The moisture content of the lignocellulosic particles (wood chips) before their combination with the aqueous mixture and the moisture content of the lignocellulosic particles (wood chips) in the aqueous mixture were measured according to EN 322:1993 by placing the particles in a drying oven at a temperature of (103 ± 2) °C until constant mass was reached. BASF SE 240806

[0227] For this, a sample of the respective mixture (ca. 20 g) was weighed in moist condition (rm) and after drying (mo). The mass mo is determined by drying at 103 °C to constant mass. Water content was calculated as follows: water content [in wt.-%] = [(rm - mo) / mo] • 100.

[0228] 2. Measuring of press time factor

[0229] For determining the “press time factor”, a conventional hot press was used. For the purposes of the present invention, the “press time factor” was determined as the “press time” (i.e. the time from closing to opening of the hot press) divided by the “target thickness” of the lignocellulosic composite (board). The target thickness refers to the thickness of the lignocellulosic composite at the end of step S8) and was adjusted by the press conditions, i.e. by the distance between the top and bottom press plates, which is adjusted by the distance control of the press.

[0230] The press time factor is given below in units of “[s / mm]”, i.e. the time from closing to opening of the press in [s] : target thickness of the pressed board in [mm]. For example, when a 16 mm chipboard is made with a press time of 160 s, a press time factor of 10 s / mm results.

[0231] 3. Measuring of densities of lignocellulosic composites

[0232] The density of lignocellulosic composites (boards) was measured according to EN 323 :1993 and is reported herein as the arithmetic average of ten 50 mm x 50 mm samples of the same lignocellulosic composite (board).

[0233] 4. Measuring of transverse tensile strength of lignocellulosic composites (“internal bond strength”)

[0234] Transverse tensile strength (“internal bond strength”) of lignocellulosic composites (boards) was determined according to EN 319:1993 and is reported herein as the arithmetic average of ten 50 mm x 50 mm samples of the same lignocellulosic composite (board).

[0235] 5. Determination of the swelling thickness after 24 hours

[0236] The swelling in thickness after 24 h (“24 h swelling”) of the lignocellulosic composites (boards) was determined according to DIN EN 317:1993-08 and is reported herein as the arithmetic average of ten 50 mm x 50 mm samples of the same lignocellulosic composite (board). BASF SE 240806

[0237] 6. Determination of the amount of binder composition

[0238] The amount of binder composition in the examples shown below is reported herein as the total weight (mass) of the solids of the first or second aqueous binder composition in wt.- %, based on the total dry weight of the lignocellulosic particles (wood particles) used. For example, if 100 g of a first or second aqueous binder composition with a solid content of 50 wt.-% is added to 1046 g of wood chips (lignocellulosic particles, with a residual moisture content of 4.6 wt.-%, i.e. corresponding to 1000 g of dry wood chips), the amount of binder composition is 5.0 wt.-%.

[0239] 7. Determination of the weight-average molecular weight (Mw) of polylysines

[0240] The weight-average molecular weight (Mw) of polylysines as prepared according to the present examples was determined by generally known size exclusion chromatography (SEC) under the following conditions:

[0241] Solvent and eluent: 0.1 % (w / w) trifluoroacetate, 0.1 M NaCI in distilled water

[0242] Flow: 0.8 mL / min

[0243] Injection volume: 100 pL

[0244] Samples were filtrated with a Sartorius Minisart RC 25 (0,2 pm) filter

[0245] Column material: hydroxylated polymethacrylate (TSKgel G3000PWXL)

[0246] Column size: inside diameter 7.8 mm, length 30 cm

[0247] Column temperature: 35 °C

[0248] Detector: DRI Agilent 1100 UV GAT-LCD 503 [232nm]

[0249] Calibration was done with poly(2-vinylpyridine) standards in the molar mass range from 620 to 2890000 g / mole (from Polymer Standards Service GmbH, Mainz, Germany) and pyridine (79 g / mol).

[0250] The upper integration limit was set to 29.01 mL.

[0251] The calculation of Mw included the lysine oligomers and polymers as well as the monomer lysine. - M -

[0252] BASF SE 240806

[0253] 8. Determination of the apparent viscosities of polylysines

[0254] A mixture of polylysine in deionized water (50 wt.-% polylysine and 50 wt.-% water) is prepared by mixing with a shaker for 24 h at 23 °C. For the rheological measurement, a modular compact rheometer MCR 302 by Anton Paar, equipped with a circulating water bath thermostat system DC10-K10 by Thermo Scientific HAAKE, is used with the measuring cone CP50-1 (diameter 50 mm, angle 1 °) by Anton Paar and the rheometer software RheoCompass, version 1 .30, by Anton Paar. The measuring cone is mounted and automatically the right program is selected for the specific measuring cone. 1 mL of the mixture is transferred as sample by a pipette onto the middle of the measuring plate. Then, the cone is lowered to a gap of 0.05 mm. In case of overfilling, the excess liquid sample is whipped off. The device temperature is set to 23.0 °C. The measurement is undertaken at the set gap under ambient air with a constant shear rate of 250 s-1. Every six seconds, a data point is recorded and in total 20 data points are recorded. The last data point is taken to give the value for the apparent viscosity of the polylysine sample in mPa s.

[0255] 9. Determination of the apparent viscosities of first and second aqueous binder compositions

[0256] The apparent viscosities of the first and second aqueous binder compositions are measured at concentrations of 50 wt.-% solids (as determined according to DIN EN 827:2005, test conditions for amino resins I “Prufbedingungen fiir Synthetische Klebstoffe / Amino- harze”, see below) in a similar manner as described in method No. 8 above, using a MCR 302 rheometer (gap was set to 0.1 mm instead of 0.05 ppm). The mean values of the apparent viscosities were calculated on the basis of 10 measurements at a shear rate of 100 / s.

[0257] 10. Determination of the solid content of first and second aqueous binder compositions

[0258] The solid content of the first and second aqueous binder compositions was determined according to DIN EN 827:2005, test conditions for amino resins (see above). An aluminium cup of appropriate size was accurately weighed (0.1 mg accuracy, ml = weight of cup). A 2 g ± 0.2 g sample was weighed into the cup (m2 = weight of sample). The sample was heated for 2 hrs at 120 °C in a ventilated oven (± 1 °C). The sample was then removed from the oven and cooled to room temperature for 15 min. in a desiccator. After that, the sample was weighed again (m3 = weight of sample after heating + weight of cup). The solid content was calculated according to the following equation: (m3 - ml) / m2 * 100 [%]. BASF SE 240806

[0259] 11 . Determination of the HMF content of the activated aqueous carbohydrate component

[0260] A 500 pl sample of the activated aqueous carbohydrate component to be analyzed were diluted with 2500 pl deionized water and thoroughly mixed utilizing a Vortex mixer. 500 pL of the diluted sample solution so received was then mixed with 30 pL of 0.34 mM NaOAc as the internal standard and 100 pL of D2O (99.8% D, Eurisotop, Saint-Aubin, France). Subsequently,1H-NMR spectra were recorded from the samples prepared in this manner at room temperature on a Bruker Avance II 400 instrument (resonance frequency 400 MHz for1H), equipped with a 5 mm liquid N2-cooled probe head (Prodigy) with z gradients. A relaxation delay of 2 s was used. The HMF content was determined by setting the (integrated area of the) HMF aldehyde signal and the (integrated area of the) known signal of the internal standard in relation to each other. Molar yields of HMF were then calculated based on the initial fructose amount which was used for preparing the activated aqueous carbohydrate component.

[0261] 12. Determination of the “gel point” of aqueous binder compositions

[0262] Rheological measurements were performed to determine the gel point as the crossover of the storage modulus (G') and loss modulus (G"). All measurements were carried out on an Anton Paar MCR 302 oscillatory rheometer using a parallel-plate measuring system (PP25 with exchangeable plate). A 0.5 mm measurement gap was used. Approximately 0.5 g of a sample was loaded onto the lower plate. Care was taken to avoid air entrapment and to ensure full contact with the plates.

[0263] The measurement protocol was as follows:

[0264] • Step 1 (initial hold): The sample was held at 20 °C for 150 s under oscillatory shear with a shear deformation (strain) of 5% (y = 5%) and a frequency of 1 Hz (f = 1 Hz). Data were recorded every 10 seconds

[0265] • Step 2 (temperature ramp): The temperature was increased from 20 °C to 80 °C over 504 s, corresponding to a heating rate of ~7.1 K min-1 , while maintaining oscillatory shear at y = 5% and f = 1 Hz. G' and G" were recorded continuously during the ramp. Data were recorded every 2.1 seconds BASF SE 240806

[0266] • Step 3 (isothermal hold): After the ramp, the sample was held at 80 °C for 900 s under the same oscillatory conditions (y = 5%, f = 1 Hz) with continuous recording of G' and G". Data were recorded every 5 seconds.

[0267] Gelation time was defined and reported as the elapsed time after the start of the temperature ramp (Step 2) to the G' / G" crossover.

[0268] 13. Determination of the apparent viscosities of reaction mixtures before and after condensation

[0269] For the rheological measurement of the apparent viscosities of reaction mixtures before and after condensation (see example 5 and table 7), a modular compact rheometer MCR 302 by Anton Paar, equipped with a circulating water bath thermostat system DC10-K10 by Thermo Scientific HAAKE, was used, with the measuring cone CP50-1 (diameter 50 mm, angle 1 °) by Anton Paar and the rheometer software RheoCompass, version 1.30, by Anton Paar. The measuring cone was mounted and automatically the right program was selected for the specific measuring cone. 1 mL of the mixture (reaction mixture before or after condensation) was transferred as sample by a pipette onto the middle of the measuring plate. Then, the cone was lowered to a gap of 0.05 mm. In case of overfilling, the excess liquid sample is whipped off. The device temperature was set to 23.0 °C. The measurement was undertaken at the set gap under ambient air with a constant shear rate of 250 s-1. Every six seconds, a data point was recorded (in total 20 data points were recorded). The last data point was taken to give the value for the apparent viscosity of the polylysine sample in mPa ■ s.

[0270] Example 1 : Synthesis of polylysines

[0271] Example 1 a: 50 wt.-% solution of Polylysine with Mw2750

[0272] 2200 g of L-lysine solution (50 wt.-% in water) was heated under stirring in an oil bath (external temperature 140 °C). Water was distilled off and the oil bath temperature was increased by 10 °C per hour until a temperature of 180 °C was reached. The reaction mixture was stirred for an additional hour at 180 °C (oil bath temperature) and then pressure was slowly reduced to 200 mbar (200 hPa). After reaching the target pressure, distillation was continued for 3 hours. The product was hotly poured out of the reaction vessel, crushed after cooling and dissolved in water to give a 50 wt.-% aqueous solution of polylysine (the “Polylysine Solution 1 a” hereinafter). The weight-average molecular weight of the resulting BASF SE 240806 polylysine was 2750 g / mol, the apparent viscosity 124 mPa ■ s (as determined by the respective methods described above).

[0273] Example 1 b:60 wt.-% solution of Polylysine with Mw 2750

[0274] 2200 g of L-lysine solution (50 wt.-% in water) was heated under stirring in an oil bath (external temperature 140 °C). Water was distilled off and the oil bath temperature was increased by 10 °C per hour until a temperature of 180 °C was reached. The reaction mixture was stirred for an additional hour at 180 °C (oil bath temperature) and then pressure was slowly reduced to 200 mbar. After reaching the target pressure, distillation was continued for 3 hours. The product was hotly poured out of the reaction vessel, crushed after cooling and dissolved in water to give a 60 wt.-% aqueous solution of polylysine (the “Polylysine Solution 1 b” hereinafter). The weight-average molecular weight of the resulting polylysine was 2750 g / mol, the apparent viscosity 124 mPa ■ s (as determined by the respective methods described above).

[0275] Example 1 c: 50 wt.-% solution of Polylysine with Mw 6517

[0276] The experiment of example 1 a as described above was repeated. Different from example 1 a, the distillation after reaching the target pressure was continued for 4.5 hours (instead of for 3 hours). A 50 wt.-% aqueous solution of polylysine (the “Polylysine Solution 1 c” hereinafter) was finally obtained. The weight-average molecular weight of the resulting polylysine was 6517 g / mol, the apparent viscosity 286 mPa ■ s (as determined by the respective methods described above).

[0277] Example 2: Synthesis of first aqueous binder compositions (Part 1)

[0278] Example 2a: Preparing an activated aqueous carbohydrate component (AACC-1)

[0279] 281 g fructose syrup FF95 (1 .04 mol) was mixed with 27.9 g deionized water. 1 .30 g sulfuric acid (96%) was diluted with 20.0 g of deionized water and subsequently added to the reaction solution. Thereafter, 1.65 g sodium dithionite were added, and the resulting mixture was stirred for 5 min. The reaction mixture was transferred to a pressure reactor (Parr Instruments GmbH, Germany), and a pressure of 3.5 bar N2 was applied to the closed reaction system. The reaction mixture was heated under intense stirring to 160 °C within 15 min. The pressure increased to 6 bar (0.6 MPa) during the heating. After 40 min. at 160 °C, the reaction was cooled down to 30 °C within 8 min. | BASF SE | 240806

[0280] The HMF content of the reaction mixture was determined as 14.3 mol-%, the levulinic acid content as 1 .3 mol-% and the formic acid content as 3.3 mol-%, each based on the total amount of fructose used as starting material (measured by the above-described1H-NMR method). The pH of the activated aqueous carbohydrate solution so received was set to 8.0 by addition of 50 % (wt. / wt.) aqueous NaOH solution and named “AACC-1 ”.

[0281] Example 2b: Preparing first aqueous binder compositions with Polylysine Solution 1 a

[0282] Four different first aqueous binder compositions were prepared, which were only differing in the applied condensation time (30, 50, 90 or 110 min., respectively, named “first aqueous binder compositions 2biABc-30, 2biABc-50, 2biABc-90 and 2biABc-110”, respectively).

[0283] In each of the preparations, 228 g of the activated aqueous carbohydrate component prepared as described in example 2a above (AACC-1) were mixed with 130 g of fructose FF100 (“second amount of one or more monomeric reducing sugars”) and 18.2 g of deionized water in a 1000-ml three necked flask, equipped with magnetic stirring and a reflux condenser. The resulting mixture was heated to 60 °C under constant stirring at 200 rpm. At 40 °C (after 12 min) 393 g Polylysine Solution 1 a (50 wt.-% in water, for preparation see example 1 a above) were added within 3 min. The condensation time (see above) was counted from the end of the addition of the polylysine solution. The reaction mixture was then further heated to 60 °C within 20 min. and kept at 60 °C. When the planned condensation time was reached, the reaction mixture was cooled in an ice bath.

[0284] The solid content of the first aqueous binder compositions was adjusted to 50 wt.-% by adding water (for determining solid content see method No. 10 as described above), and the apparent viscosities were measured (for determining apparent viscosities of aqueous binder compositions see method No. 9 above) and are listed in table 2 below.

[0285] Table 2: Apparent viscosities of first aqueous binder compositions (with Polylysine Solutions 1 a and 1 b) | BASF SE | 240806 n.a.: not applicable (no condensation done)

[0286] *: comparative example, not according to the present invention

[0287] Example 2c: Preparing an activated aqueous carbohydrate component (AACC-2)

[0288] 300 g fructose (solid, see above), 180 g water and 20 g sulfuric acid (10 wt.-% aqueous solution) were placed in a 1 L four-neck flask equipped with a reflux condenser. The mixture was heated under stirring to the reflux temperature within 30 min. Stirring under reflux was continued for 180 min. Thereafter, the mixture was cooled down to room temperature using an ice bath and filtered to remove a solid precipitate (black colour, 58 g; after drying at 120 °C for 2 hours: 48 g). The obtained filtrate (442 g, named “AACC-2”) was analysed and used for the preparation of aqueous binder compositions.

[0289] The HMF content of the filtrate AACC-2 was determined as 10 mol-%, the levulinic acid content as 1.5 mol-% and the formic acid content as 2 mol-%, each based on the total amount of fructose used at starting material (measured by the above-described1H-NMR method).

[0290] Example 2d: Preparing first aqueous binder compositions with Polylysine Solution 1 b

[0291] Two different first aqueous binder compositions were prepared, only differing in the applied condensation time (60 or 90 min., respectively, named “first aqueous binder compositions 2diABc-60 and 2diABc-90”, respectively).

[0292] In each of the preparations, a mixture of 150 g of the activated aqueous carbohydrate component prepared as described in example 2c above (AACC-2) and 150 g Polylysine Solution 1 b (60 wt.-% in water) was placed in a 1 L four-neck flask equipped with a reflux condenser. The mixtures were heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 60 min or 90 min.

[0293] When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. The solid content of the first aqueous binder compositions were adjusted to 50 | BASF SE | 240806 wt.-% by adding water (for determining solid content see method No. 10 as described above), and the apparent viscosities were measured (for determining apparent viscosities of aqueous binder compositions see method No. 9 above) and are listed in table 3 below.

[0294] Table 3: Apparent viscosities of first aqueous binder compositions (with Polylysine Solution 1 b)

[0295] Example 2e: Preparing an activated aqueous carbohydrate component (AACC-3)

[0296] 281 g fructose syrup FF95 (1 .04 mol) was mixed with 27.9 g deionized water. 1 .30 g sulfuric acid (96 %) was diluted with 20.0 g of deionized water and subsequently added to the reaction solution. Thereafter, 1.65 g sodium dithionite were added, and the resulting mixture was stirred for 5 min. The reaction mixture was transferred to a pressure reactor (Parr Instruments GmbH, Germany), and a pressure of 3.5 bar N2 was applied to the closed reaction system. The reaction mixture was heated under intense stirring to 140 °C within 20 min. The pressure increased to 5 bar (0.5 MPa) during the heating. After 30 min. at 140 °C, the reaction was cooled down to below 100 °C within 20 min.

[0297] The HMF content of the reaction mixture was determined as 14.5 mol-%, the levulinic acid content as 0.8 mol-% and the formic acid content as 0.9 mol-%, each based on the total amount of fructose used as starting material (measured by the above-described1H-NMR method). The pH of the activated aqueous carbohydrate solution so received was set to 8.0 by addition of 50 % (wt. / wt.) aqueous NaOH solution and named “AACC-3”.

[0298] Example 2f: Preparing a first aqueous binder composition with Polylysine Solution 1 b

[0299] 459 g of the activated aqueous carbohydrate component prepared as described in example 2e above (AACC-3) were mixed with 203 g fructose syrup FF95 (“second amount of one or more monomeric reducing sugars”) and 25 g of deionized water in a 1000-ml three necked flask, equipped with mechanical stirring and a reflux condenser. The resulting mixture was heated to 60 °C under constant stirring at 200 rpm. At 40 °C (after 12 min.) 443 g BASF SE 240806

[0300] Polylysine solution 1 b (60% in water) were added within 3 min. The condensation time was counted from the end of the addition of the polylysine solution. The reaction mixture was then further heated to 60 °C and kept at 60 °C. When the planned condensation time of 90 min was reached, the reaction mixture was cooled in an ice bath.

[0301] The solid content of the first aqueous binder composition was adjusted to 50 wt.-% (for determining solid content see method No. 10 as described above), and the apparent viscosities were measured (for determining apparent viscosities of aqueous binder compositions see method No. 9 above) and are listed in table 2 above as first aqueous binder composition “2fiABc-90”.

[0302] Example 2q: Preparing a comparative aqueous binder composition with Polylysine Solution 1 b (no condensation step S3))

[0303] 459 g of the activated aqueous carbohydrate component prepared as described in example 2e above (AACC-3) were mixed, under cooling in an ice bath, with 203 g fructose syrup FF95 (“second amount of one or more monomeric reducing sugars”), 443 g Polylysine solution 1 b (60% in water) and 25 g of deionized water. The mixing was done in an ice bath to avoid the rise of the temperature of the mixture above 20 °C.

[0304] The solid content of the resulting aqueous binder composition was adjusted to 50 wt.-% (for determining solid content see method No. 10 as described above), and the apparent viscosities were measured (for determining apparent viscosities of aqueous binder compositions see method No. 9 above) and are listed in table 2 above as comparative aqueous binder composition “2gCABc”.

[0305] Example 3: Synthesis of second aqueous binder compositions

[0306] Example 3a: Preparing a second aqueous binder composition from first aqueous binder compositions 2biABc and Polylysine Solution 1 a

[0307] Each of the first aqueous binder compositions 2biABc-30, 2biABc-50, 2biABc-90 and 2biABc -1 10 (for preparation see example 2b above), respectively, was mixed with Polylysine Solution 1 a (for preparation see example 1 a above) in a weight ratio of 85 : 15 (283 g of respective first aqueous binder composition 2biABc and 49.4 of Polylysine Solution 1 a) at room temperature by thorough stirring to obtain the second aqueous binder compositions 3a2ABc-30, 3a2ABc-50, 3a2ABc-90 and 3a2ABc-1 10. The solid content of all second aqueous BASF SE 240806 binder compositions so prepared was measured according to the above-described method No. 10 to be 50 wt.-%.

[0308] Example 3b: Preparing a second aqueous binder composition from first aqueous binder compositions 2diABc and Polylysine Solution 1 a

[0309] Each of the first aqueous binder compositions 2diABc-60 and 2diABc-90 (for preparation see example 2d above) was mixed with Polylysine Solution 1 a (for preparation see example 1 a above) in a weight ratio of 67 : 33 (284 g of respective first aqueous binder composition 2diABc and 142 g of Polylysine Solution 1 a) at room temperature by thorough stirring to obtain the second aqueous binder compositions 3b2ABc-60 and 3b2ABc-90. The solid content of all second aqueous binder compositions so prepared was measured according to the above-described method No. 10 to be 50 wt.-%.

[0310] Example 3c: Preparing a second aqueous binder composition from first aqueous binder compositions 2diABc and Polylysine Solution 1 c

[0311] Each of the first aqueous binder compositions 2diABc-60 and 2diABc-90 (for preparation see example 2d above) was mixed with Polylysine Solution 1 c (for preparation see example 1 c above) in a weight ratio of 67 : 33 (284 g of respective first aqueous binder composition 2diABc and 142 g of Polylysine Solution 1 c) at room temperature by thorough stirring to obtain the second aqueous binder compositions 3C2ABC-60 and 3C2ABC-90. The solid content of all second aqueous binder compositions so prepared was measured according to the above-described method No. 10 to be 50 wt.-%.

[0312] Example 3d: Preparing a second aqueous binder composition from first aqueous binder compositions 2diABc, Polylysine Solution 1 a and a third amount of one or more monomeric reducing sugars

[0313] Each of the first aqueous binder compositions 2diABc-60 and 2diABc-90 (for preparation see example 2d above) was mixed with Polylysine Solution 1 a (for preparation see example 1 a above) (284 g of respective first aqueous binder composition 2diABc and 142 g of Polylysine Solution 1 c) and with a 50 wt.-% aqueous solution of fructose (third amount of one or more monomeric reducing sugar) in a weight ratio of 61 : 35 : 4 (284 g of respective first aqueous binder composition 2diABc, 162 g of Polylysine Solution 1 a and 20 g of aqueous fructose solution) at room temperature by thorough stirring to obtain the second aqueous binder compositions 3d2ABc-60 and 3d2ABc-90. The solid content of all second aqueous binder BASF SE 240806 compositions so prepared was measured according to the above-described method No. 10 to be 50 wt.-%.

[0314] Example 3e: Preparing a second aqueous binder composition from first aqueous binder composition 2fiABc-90 and Polylysine Solution 1 a

[0315] The first aqueous binder composition 2fiABc-90 (for preparation see example 2f above) was mixed with Polylysine Solution 1 a (for preparation see example 1 a above) in a weight ratio of 86 : 16 (310 g of respective first aqueous binder composition 2fiABc-90 and 50.0 g of Polylysine Solution 1 a) at room temperature by thorough stirring, to obtain the second aqueous binder composition 362ABC-90. The solid content of the second aqueous binder composition so prepared was measured according to the above-described method No. 10 to be 50 wt.-%.

[0316] Example 4: Producing liqnocellulosic composites

[0317] Example 4a: 16 mm Chipboards (lignocellulosic composites) produced with second aqueous binder compositions 3a2ABc and 362ABC-90, and with first aqueous binder composition 2fiABc-90

[0318] 1432 g of industrial wood chips (lignocellulosic particles; 1408 g dry weight plus 24.0 g water from residual chip moisture content of 1 .7%) were filled per lignocellulosic composite to be produced into a drum mixer equipped with an industrial spraying pistol. Mixing was started (60 rpm) and 282 g (corresponding to an amount of second aqueous binder composition of 10 wt.-% solids based on the dry weight of the wood chips) of the second aqueous binder composition 3a2ABc-30, 3a2ABc-50, 3a2ABc-90, 3a2ABc-1 10 or 362ABC-90, respectively, was sprayed onto the wood chips within 3 min. while continuing mixing. The mixing was further continued, so that the total time from start of addition of second aqueous binder composition until end of mixing amounted to 210 s.

[0319] Thereafter, 1587 g of the mixture of the chips and the second aqueous binder composition (i.e. an aqueous mixture as defined in step S7)) was scattered into a 39 cm x 39 cm mold and pre-compacted under ambient conditions (pressure 0.4 N / mm2). Subsequently, the pre-compacted chip mat thus obtained was removed from the mold, transferred into a hot press (laboratory press by G. Siempelkamp GmbH & CO. KG., Krefeld, Germany) and pressed to a thickness of 16 mm to give a chipboard (temperature of the press plates 220 BASF SE 240806

[0320] °C, pressure 3.5 N / mm2, press time factor 10 s / mm) as a single-layered lignocellulosic composite.

[0321] The resulting lignocellulosic composites were named SLCI-1 to SLCI-4, respectively (for lignocellulosic composites produced with second aqueous binder composition 3a2ABc-30, 3a2ABc-50, 332ABC-90, 332ABC-110) and SLCI-17 (for lignocellulosic composite produced with second aqueous binder composition 3e2ABc-90).

[0322] Under the same conditions as outlined here above, a 16 mm chipboard was produced with first aqueous binder composition 2fiABc-90 (amount of first aqueous binder composition 10 wt.-% based on the dry weight of the wood chips) and named SLCI-18.

[0323] Example 4b: 16 mm Chipboards (lignocellulosic composites) produced for comparison (SLCC-1)

[0324] For comparison, a chipboard (lignocellulosic composite) was produced in the same manner as described above in example 4a, with the differences explained hereinafter: For this board, a mixture of Polylysine Solution 1 a, fructose, and water was used as the binder ("PL- 1 / Fru"). The amounts of polylysine and fructose used were the same as the amounts employed in the production of adhesive formulations 332ABC (weight ratio fructose : polylysine = 50 : 50, on a solid basis). The amounts of water and the quantity of sprayed PL-1 / Fru were chosen so that both the amount of binder composition and the moisture content of the resinated chips were the same as for the boards of Example 4a.

[0325] The resulting lignocellulosic composite was named SLCC-1 .

[0326] Example 4c: 16 mm Chipboards (lignocellulosic composites) produced for comparison (SLCC-2)

[0327] For comparison, a chipboard (lignocellulosic composite) was produced in the same manner as described above in example 4a, with the differences explained hereinafter: 1432 g of industrial wood chips (lignocellulosic particles; 1408 g dry weight plus 24.0 g water from residual chip moisture content of 1 .7%) were filled per lignocellulosic composite to be produced into a drum mixer equipped with an industrial spraying pistol. Mixing was started (60 rpm) and 282 g (corresponding to an amount of comparative aqueous binder composition of 10 wt.-% based on the dry weight of the wood chips) of the comparative aqueous binder composition 2gCABc was sprayed onto the wood chips within 3 min. while continuing mixing. | BASF SE | 240806

[0328] The mixing was further continued, so that the total time from start of addition of second aqueous binder composition until end of mixing amounted to 210 s.

[0329] The resulting lignocellulosic composite was named SLCC-2.

[0330] For the single-layered lignocellulosic composites of examples 4a and 4b certain board parameters were determined according to the methods as described above and are shown in table 4 below.

[0331] Table 4: Parameters measured for 16 mm single-layered lignocellulosic composites

[0332] PL-1 a: Polylysine solution 1 a

[0333] Example 4c: 10 mm Chipboards (lignocellulosic composites) produced with first aqueous binder composition 2diABc or with second aqueous binder compositions 3b2ABC, 3C2ABC, or 3d2ABC

[0334] A Plougshare® mixer L20 (Lbdige Maschinenbau GmbH, Paderborn) was attached to a circulating water bath thermostat system. The water bath was set to the temperature which is given in the table 5 below (“Temperature LP”). 1046 g (1000 g dry weight plus 46.0 g water (from residual chip moisture content) of spruce core layer chips (lignocellulosic particles, moisture content 4.6%) were filled into the mixer. Mixing was started (80 rpm) to bring the chips to the specified temperature (i.e. “Temperature LP”, see table 5). After 5 min., 120 g of the respective aqueous (50 wt.%) binder composition (corresponding to a BASF SE 240806 binder amount of 6 wt.-% binder solids referred to dry chips) was sprayed onto the tempered chips within 1 min. while continuing mixing. Immediately thereafter, additional water was sprayed onto the mixture (aqueous mixture) while continuing mixing, whereas the amount of water is selected to achieve a final moisture content of the resinated chips of 10%. The mixing was continued at the given temperature, so that the total time from start of addition of adhesive or adhesive formulation until end of mixing amounted to 3 min.

[0335] The resulting aqueous mixtures were either used directly (for temperature LP = 20 °C) or were stored at the given temperature (of the respective aqueous mixture) for 15 min (for temperature LP = 40 °C). Thereafter, 625 g of each aqueous mixture were scattered into a 30 cm x 30 cm mold and pre-compacted in a pneumatic press under ambient conditions (0.4 N / mm2). Subsequently, the pre-compacted chip mat thus obtained was removed from the mold, transferred into a hot press (hydraulic lab press, model LaboPress P400XT by Vogt Labormaschinen GmbH) and pressed to a thickness of 10 mm to give a chipboard (temperature of the press plates 210 °C., maximum pressure 4 N / mm2, press time 80 s) as a single-layered lignocellulosic composite.

[0336] The resulting single-layered lignocellulosic composites were named SLCI-5 to SLCI-16.

[0337] For the single-layered lignocellulosic composites of example 4c certain board parameters were determined according to the methods as described above and are shown in table 5 below.

[0338] Table 5: Parameters measured for 10 mm single-layered lignocellulosic composites | BASF SE | 240806

[0339] From the examples shown in tables 2 to 5 here above it can be seen that lignocellulosic composites which were produced by a process according to the present invention, i.e. involving a first aqueous binder composition and / or a second aqueous binder composition which were prepared involving a pre-condensation reaction of their components, show excellent mechanical properties.

[0340] In particular, said lignocellulosic composites which were produced by a process according to the present invention show excellent internal bond strengths and excellent 24 hours swelling properties. Said mechanical properties of lignocellulosic composites produced by a process according to the present invention are significantly better than the respective mechanical properties of a lignocellulosic composite for comparison, which was produced from comparable components but where the respective process for the production of said lignocellulosic composite for comparison did not involve a pre-condensation reaction of its components.

[0341] Example 5: Synthesis of first aqueous binder compositions (Part 2) and of comparative aqueous binder compositions x g of Polylysine solution 1 b (60% in water), y g Fructose solution (60% in water) and z g of HMF solution (60% in water) were mixed at room temperature (for values of “x”, “y” and “z” see table 6 below). The apparent viscosity of the resulting mixture was measured in each case according to method No. 13 above (for results see table 7 below, “viscosities before condensation”). Each mixture was heated to 60 °C within 20 minutes under constant stirring at 200 rpm. Each mixture was then stirred at 60 °C for further 30 minutes. Thereafter, the reaction mixture was cooled in an ice bath and the apparent viscosity was measured again (method No. 13; for results see table 7, “viscosity after condensation”). The resulting first aqueous binder compositions were named 53IABC to 56IABC, respectively. BASF SE 240806

[0342] The solid content of the first aqueous binder compositions produced in this way was adjusted to 50 wt.-% (for determining solid content see method No. 10 as described above), and the apparent viscosities were measured (for determining apparent viscosities of aqueous binder compositions see method No. 9 above) and are listed in table 7 below.

[0343] The gel point of the first aqueous binder compositions was determined as described above (method No. 12). The values so determined are listed in table 8 below.

[0344] The following comparative aqueous binder compositions were also synthesized: x g of Polylysine solution 1 b (60% in water), y g Fructose solution (60% in water) and z g of HMF solution (60% in water) were mixed at room temperature, (for values of “x”, “y” and “z” see table 6 below). The resulting comparative aqueous binder compositions were named 5aCABc to 5eCABc, respectively.

[0345] The gel point of the resulting comparative aqueous binder compositions was determined as described above (method No. 12). The values so determined are listed in table 8 below.

[0346] Table 6: First aqueous binder compositions 53IABC to 56IABC and comparative aqueous binder compositions 5aCABc to 5eCABc

[0347] Fru: fructose

[0348] HMF: hydroxymethylfurfural

[0349] PL-1 b: Polylysine solution 1 b BASF SE | 240806

[0350] Table 7: Certain parameters of first aqueous binder compositions 53IABC to 56IABC

[0351] *: after condensation at 50 wt.-% solid content

[0352] Example 6: Producing liqnocellulosic composites (Part 2)

[0353] 10 mm Chipboards (single layered lignocellulosic composites) were produced with first aqueous binder compositions 53IABC to 56IABC or with comparative aqueous binder compositions 5aCABc to 5eCABc, respectively.

[0354] A Plougshare® mixer L20 (Lbdige Maschinenbau GmbH, Paderborn) was attached to a circulating water bath thermostat system. The water bath was set to 40 °C. 1046 g (1000 g dry weight plus 46.0 g water (from residual chip moisture content) of spruce core layer chips (lignocellulosic particles, moisture content 4.6%) were filled into the mixer. Mixing was started (80 rpm) to bring the chips to 40 °C. After 5 min., 120 g of the respective aqueous (50 wt.%) binder composition (corresponding to a binder amount of 6 wt.-% binder solids referred to dry chips) was sprayed onto the tempered chips within 1 min. while continuing mixing. Immediately thereafter, additional water was sprayed onto the mixture (aqueous mixture) while continuing mixing, whereas the amount of water was selected to achieve a final moisture content of the resinated chips of 10 %. The mixing was continued at 40 °C, so that the total time from start of addition of the aqueous binder composition until end of mixing amounted to 3 min.

[0355] Thereafter, 625 g of each aqueous binder composition were scattered into a 30 cm x 30 cm mold and pre-compacted in a pneumatic press under ambient conditions (0.4 N / mm2). Subsequently, the pre-compacted chip mat thus obtained was removed from the mold, BASF SE | 240806 transferred into a hot press (hydraulic lab press, model LaboPress P400XT by Vogt Labor- maschinen GmbH) and pressed to a thickness of 10 mm to give a chipboard (temperature of the press plates 210 °C, maximum pressure 4 N / mm2, press time 60 s and 80 s) as a single-layered lignocellulosic composite.

[0356] The resulting single-layered lignocellulosic composites were named SLCI-19 to SLCI-23 (for chipboards made from first aqueous binder compositions 53IABC to 56IABC) and SLCC- 3 to SLCC-7 (for chipboards made from comparative aqueous binder compositions 5aCABc to 5eCABc).

[0357] For the single-layered lignocellulosic composites of this example 6 certain board parameters were determined according to the methods as described above and are shown in table 8 below.

[0358] Table 8: Parameters measured for 10 mm single-layered lignocellulosic composites and gel points of the respective aqueous binder compositions

[0359] *: press time 60 s

[0360] **: press time 80 s

[0361] From the data in table 8 above it can be seen that first binder compositions made by a process according to the present invention showed earlier gelling than respective comparative binder compositions not made by a process according to the present invention. It was found that such earlier gelling behaviour correlated with better (higher) internal bond BASF SE 240806 strengths of the lignocellulosic composites produced with said first binder compositions made by a process according to the present invention and that this technical effect was already pronounced at short(er) press times (60 s vs. 80 s press time).

[0362] Example 7: Synthesis of first aqueous binder compositions (Part 3) and of comparative aqueous binder compositions

[0363] Example 7a: First aqueous binder compositions 73IABC and comparative aqueous binder composition 7aCABc

[0364] A mixture of 300 g of the activated aqueous carbohydrate component AACC-2 (for preparation see example 2d above) and 100 g Polylysine Solution 1 b (60 wt.-% in water, for preparation see example 1 b above) was prepared and named “comparative aqueous binder composition 7aCABc“.

[0365] Comparative aqueous binder composition 7aCABc was then placed in a 1 L four-neck flask equipped with a reflux condenser and was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 45 min or 60 min (condensation time), to produce first aqueous binder compositions 73IABC-45 or 73IABC-60, respectively.

[0366] General procedure for determining apparent viscosities of the first aqueous binder compositions of this example 7:

[0367] When the planned condensation time was reached, each reaction mixture was cooled in an ice bath (for planned condensation times see table 9 below). The solid content of the first aqueous binder compositions so obtained was adjusted to 50 wt.-% by adding water (for determining solid content see method No. 10 as described above), and the apparent viscosity was measured in each case (for determining apparent viscosities of aqueous binder compositions see method No. 9 above) and is listed in table 9 below.

[0368] Example 7b: First aqueous binder compositions 7biABc and comparative aqueous binder composition 7bCABc

[0369] A mixture of 263 g of the activated aqueous carbohydrate component AACC-2 (for preparation see example 2d above) and 113 g Polylysine Solution 1 b (60 wt.-% in water, for preparation see example 1 b above) was prepared named “comparative aqueous binder composition 7bCABc”. BASF SE 240806

[0370] Comparative aqueous binder composition 7bCABc was then placed in a 1 L four-neck flask equipped with a reflux condenser and was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 45 min or 60 min (condensation time), to produce first aqueous binder compositions 7biABc-45 or 7biABc-60, respectively.

[0371] The apparent viscosities of the first aqueous binder compositions so obtained were determined according to the general procedure provided in example 7a above are shown in table 9 below.

[0372] Example 7c: First aqueous binder compositions 7CIABC and comparative aqueous binder composition 7CCABC

[0373] A mixture of 150 g of the activated aqueous carbohydrate component AACC-2 (for preparation see example 2d above) and 150 g Polylysine Solution 1 b (60 wt.-% in water, for preparation see example 1 b above) was prepared named “comparative aqueous binder composition 7CCABC”.

[0374] Comparative aqueous binder composition 7CCABC was then placed in a 1 L four-neck flask equipped with a reflux condenser and was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 45 min or 60 min (condensation time), to produce first aqueous binder compositions 7CIABC-45 or 7ciABc-60, respectively.

[0375] The apparent viscosities of the first aqueous binder compositions so obtained were determined according to the general procedure provided in example 7a above and are shown in table 9 below.

[0376] Example 7d: First aqueous binder compositions 7diABc and comparative aqueous binder composition 7dCABc

[0377] A mixture of 105 g of the activated aqueous carbohydrate component AACC-2 (for preparation see example 2d above) and 189 g Polylysine Solution 1 b (60 wt.-% in water, for preparation see example 1 b above) was prepared named “comparative aqueous binder composition 7dCABc”.

[0378] Comparative aqueous binder composition 7dCABc was then placed in a 1 L four-neck flask equipped with a reflux condenser and was heated under stirring to 60 °C within 30 min. | BASF SE | 240806

[0379] Stirring at 60 °C was continued for 45 min or 60 min (condensation time), to produce first aqueous binder compositions 7diABc-45 or 7diABc-60, respectively.

[0380] The apparent viscosities of the first aqueous binder compositions so obtained were determined according to the general procedure provided in example 7a above and are shown in table 9 below.

[0381] Example 7e: First aqueous binder compositions 76IABC and comparative aqueous binder composition 7eCABc

[0382] A mixture of 100 g of the activated aqueous carbohydrate component AACC-2 (for preparation see example 2d above) and 260 g Polylysine Solution 1 b (60 wt.-% in water, for preparation see example 1 b above) was prepared named “comparative aqueous binder composition 7eCABc”.

[0383] Comparative aqueous binder composition 7eCABc was then placed in a 1 L four-neck flask equipped with a reflux condenser and was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 45 min or 60 min (condensation time), to produce first aqueous binder compositions 76IABC-45 or 7eiABc-60, respectively.

[0384] The apparent viscosities of the first aqueous binder compositions so obtained were determined according to the general procedure provided in example 7a above and are shown in table 9 below.

[0385] Table 9: Apparent viscosities of first aqueous binder compositions and comparative aqueous binder compositions (with Polylysine Solution 1 b) | BASF SE 240806

[0386] PL-1 b: Polylysine solution 1 b

[0387] Example 8: Producing liqnocellulosic composites (Part 3)

[0388] 10 mm Chipboards (single-layered lignocellulosic composites) were produced by the method provided above in example 6 with first aqueous binder compositions 73IABC-45 to 7eiABc-60, or with comparative aqueous binder compositions 7aCABc to 7eCABc, respectively.

[0389] The resulting single-layered lignocellulosic composites were named SLCI-24-1 to SLCI-28- 2 (for chipboards made from first aqueous binder compositions 73IABC-45 to 7eiABc-60) and SLCC-8 to SLCC-12 (for chipboards made from comparative aqueous binder compositions 7aCABc to 7eCABc).

[0390] For the single-layered lignocellulosic composites of this example 8 certain board parameters were determined according to the methods as described above and are shown in table 10 below.

[0391] Table 10: Parameters measured for 10 mm single-layered lignocellulosic composites | BASFSE 240806 press time 60 s press time 80 s

[0392] PL-1b: Polylysine solution 1b

Claims

BASF SE240806Claims:

1. Process for producing a first aqueous binder composition, comprising at least the following steps:51) providing or preparing an activated aqueous carbohydrate component comprising as constituents: c1) one or more monomeric reducing sugars, wherein the one or at least one of the more monomeric reducing sugars is fructose, and c2) hydroxymethylfurfural;52) providing or preparing a first polylysine component, comprising one or more polylysines; and53) reacting the activated aqueous carbohydrate component from step S1) with the first polylysine component from step S2) at a temperature of > 35 °C, to receive a first aqueous binder composition.

2. Process for producing a second aqueous binder composition, comprising at least the following steps:54) providing or preparing a first aqueous binder composition according to claim 1 ,55) providing or preparing a second polylysine component, comprising one or more polylysines and56) mixing, preferably reacting, the first aqueous binder composition from step S4) with the second polylysine component from step S5) at a temperature in the range of from > 15 °C to < 60 °C, preferably of from > 15 °C to < 40 °C, to receive a second aqueous binder composition.BASF SE2408063. Process for producing a lignocellulosic composite, comprising one or more lignocellulosic composite layers, comprising at least the following steps:57) providing or preparing an aqueous mixture, comprising at least- lignocellulosic particles, and- (i) a first aqueous binder composition according to claim 1 , or(ii) a second aqueous binder composition according to claim 2, and58) applying heat and pressure to the aqueous mixture from step S7), so that the binder of the first aqueous binder composition hardens, or the binder of the second aqueous binder composition hardens, and a lignocellulosic composite results.

4. Process according to any of the preceding claims, wherein the activated aqueous carbohydrate component of step S1) is prepared in a step S1 a), comprising reacting a first amount of one or more monomeric reducing sugars, wherein the one or at least one of the more monomeric reducing sugars is fructose, in the presence of water and an acid, at a temperature of > 50 °C, and preferably removing any solid precipitate which may have formed, preferably comprising reacting the first amount of the one or more monomeric reducing sugars, wherein the one or at least one of the more monomeric reducing sugars is fructose, at a temperature in the range of from > 100 °C to < 180 °C, preferably of from > 120 °C to < 180 °C and more preferably of from > 130 °C to < 170 °C,BASF SE240806preferably at a pressure above atmospheric pressure, more preferably at a pressure of > 150 kPa and even more preferably in the range of from > 200 kPa to < 400 kPa, and preferably for a time in the range of from 15 min. to 120 min., more preferably of from 30 min. to 90 min.

5. Process according to any of the preceding claims, wherein- the activated aqueous carbohydrate component is prepared according to the process of claim 4, wherein in step S1 a) the activated aqueous carbohydrate component is cooled to a temperature in the range of from > 0 °C to < 60 °C, preferably in the range of from > 10 °C to < 50 °C, more preferably in the range of from > 20 °C to < 40 °C, before it is reacted in step S3) with the first polylysine component and preferably before any solid precipitate is removed; and / or- the one or more monomeric reducing sugars of constituent c1) of the activated aqueous carbohydrate component provided or prepared in step S1) or in step 1 a) which are not fructose, are independently selected from the group consisting of ribose, arabinose, xylose, glucose, mannose, galactose and mixtures thereof, preferably are selected from the group consisting of xylose, glucose and mixtures thereof; and / or- a second amount of one or more monomeric reducing sugars, preferably wherein the one or at least one of the more monomeric reducing sugars is fructose, or a part of said second amount, is added to (i) the activated aqueous carbohydrate component from step S1) or - preferably - from step S1 a), or to a part thereof, and / orto (ii) the first polylysine component of step S2), orto a part thereof, and / or to their mixture, before or during reacting the activated aqueous carbohydrate component with the first polylysine component in step S3); and / orBASF SE240806- a third amount of one or more monomeric reducing sugars, preferably wherein the one or at least one of the more monomeric reducing sugars is fructose, or a part of said third amount, is added to the first aqueous binder composition as received in step S3) and / or as provided or prepared in step S4); and / or- the total amount of hydroxymethylfurfural of constituent c2) present in the activated aqueous carbohydrate component provided or prepared in step S1) or in step 1 a) is in the range of from > 3 to < 30 mol-%, preferably of from > 4 to < 25 mol-%, more preferably of from > 5 to < 20 mol-% and even more preferably of from > 6 to < 15 mol-%, relative to the molar amount of the one or more monomeric reducing sugars of constituent c1), preferably as determined by1H-NMR spectroscopy.

6. Process according to any of the preceding claims, wherein- the mass ratio of the total amount of the one or more polylysines of the first polylysine component used in step S2) to the total amount of the one or more monomeric reducing sugars of constituent c1) present in or used for the preparation of the activated aqueous carbohydrate component in step S1) is in the range of from > 0.5 : 1 to < 2.5 : 1 , preferably of from > 0.8 : 1 to < 2.0 : 1 and more preferably of from > 0.8 : 1 to < 1 .5 : 1 ; and / or- the mass ratio of the total amount of the one or more polylysines of the first polylysine component used in step S2) to the total amount of (i) the first amount of the one or more monomeric reducing sugars which is used for preparing the activated aqueous carbohydrate component in step S1) or in step S1a) according to claim 4, and of (ii) any second amount of one or more monomeric reducing sugars, is in the range of from > 0.5 : 1 to < 2.5 : 1 , preferably of from > 0.8 : 1 to < 2.0 : 1 and more preferably of from > 0.8 : 1 to < 1.5; and / orBASF SE240806- in step S3), the activated aqueous carbohydrate component from step S1) orfrom step S1 a) is reacted with the first polylysine component of step S2) at a temperature of > 35 °C, preferably at a temperature in the range of from > 35 °C to < 90 °C, more preferably of from > 38 °C to < 80 °C, even more preferably of from > 38 °C to < 60 °C, and / or- in step S3), the activated aqueous carbohydrate component from step S1) orfrom step S1 a) is reacted with the first polylysine component of step S2) for a time in the range of from > 20 to < 180 min., preferably of from > 30 to < 150 min. and more preferably of from > 40 to < 120 min.; and / or- in step S3), the activated aqueous carbohydrate component from step S1) orfrom step S1 a) is reacted with the first polylysine component of step S2) until the apparent viscosity of the first aqueous binder composition, measured at a concentration of 50 wt.-% solids, preferably as determined according to DIN EN 827:2005, test conditions for amino resins (“Prufbedingungen fiir Synthetische Klebstoffe / Aminoharze”), has reached a value in the range of from > 80 to < 1000 mPa ■ s, preferably of from > 100 to < 800 mPa ■ s, more preferably of from > 120 to < 650 mPa ■ s and even more preferably of from > 140 to < 500 mPa ■ s, preferably determined according to method No. 8 as described in the present methods section.

7. Process according to any of the preceding claims, wherein- the first aqueous binder composition as received in step S3) and / or as provided or prepared in step S4) has a solid content in the range of from > 35 to < 85 mass- %, preferably of from > 40 to < 75 mass-% and more preferably of from > 45 to < 60 mass-%, preferably determined according to DIN EN 827:2005, test conditions for amino resins (“Prufbedingungen fiir Synthetische Klebstoffe / Aminoharze”); and / orBASF SE240806- in step S6), the mass ratio of the total mass of the first aqueous binder composition provided or prepared in step S4) to the total mass of the one or more polylysines of the second polylysine component provided or prepared in step S5) is in the range of from > 1 : 1 to < 15 : 1 , preferably in the range of from > 1.5 : 1 to < 10 : 1 and more preferably in the range of from > 2 : 1 to < 5 : 1 ; and / or- the mass ratio of the total mass of the one or more polylysines of the first polylysine component provided or prepared in step S2) to the total mass of the one or more polylysines of the second polylysine component provided or prepared in step S5) is in the range of from > 30 : 70 to < 90 : 10, preferably of from > 35 : 65 to < 85: 15 and more preferably of from > 40 : 60 to < 80 : 20.

8. Process according to any of the preceding claims, wherein the one or more polylysines of the first polylysine component and the one or more polylysines of the second polylysine component- independently are polymerization products of the monomer lysine, preferably of L-lysine, and optionally further monomers selected from the group consisting of amino acids, amines comprising at least two amino groups, wherein the amines are no amino acids, and dicarboxylic acids, which are no amino acids and tricarboxylic acids, which are no amino acids, wherein preferably the proportion of lysine in mass-% which is used as monomer for the polymerization reaction for producing the polylysine, based on the total mass of monomers used in the polymerization reaction for producing the polylysine is > 50 mass-%, and wherein preferably a polylysine may comprise or consist of dimers with n=2, trimers with n=3, oligomers with n = 4-10 and / or macromolecules withBASF SE240806n > 10, wherein n is the number of monomers which have been reacted to form the dimers, trimers, oligomers and macromolecules of the polylysine(s); and / or- independently have a weight-average molecular weight Mwin the range of 800 g / mol < Mw 2 10000 g / mol, preferably of 1000 g / mol < Mw8000 g / mol and more preferably of 1200 g / mol < Mw7000 g / mol, preferably as determined by size exclusion chromatography, preferably according to the method as described in method No. 7 as described in the present methods section; wherein preferably the one or more polylysines of the first polylysine component have a weightaverage molecular weight Mwin the range of 1000 g / mol < Mw5000 g / mol, preferably of 1200 g / mol < Mw3500 g / mol, preferably as determined by size exclusion chromatography, preferably according to the method as described in method No. 7 as described in the present methods section; and / or the one or more polylysines of the second polylysine component have a weight-average molecular weight Mw in the range of 1500 g / mol < Mw7000 g / mol, preferably of 1500 g / mol < Mw6000 g / mol, more preferably of 2000 g / mol < Mw S 5000 g / mol, preferably as determined by size exclusion chromatography, preferably according to the method as described in method No. 7 as described in the present methods section; and / or- independently comprise as monomers integrated in their polymer structure > 85 mass-%, preferably > 95 mass-%, more preferably > 99 mass-%, and yet even more preferably 100 mass-%, of lysine monomers, based on the total mass of the polymer structure; and / orBASF SE240806- independently and each measured as a 50 mass-% solution in water, preferably as determined according to DIN EN 827:2005, test conditions for amino resins (“Prufbedingungen fiir Synthetische Klebstoffe / Aminoharze”), have an apparent viscosity in the range of from > 50 mPa ■ s to < 2000 mPa ■ s, preferably of from > 55 mPa ■ s to < 1000 mPa ■ s, more preferably of from > 60 mPa ■ s to < 800 mPa ■ s, even more preferably of from > 65 mPa ■ s to < 600 mPa ■ s and yet even more preferably of from > 70 mPa ■ s to < 400 mPa ■ s, preferably as determined according to the method as described in method No. 8 as described in the present methods section.

9. Process according to any of the preceding claims, wherein- the mass ratio of (i) the total amount of the one or more polylysines of the first polylysine component of step S2) and (ii) any present polylysines of the second polylysine component of any step S5) to the total amount of the one or more monomeric reducing sugars used in step S1) and in step S3), is in the range of from > 5 : 95 to < 90 : 10, preferably of from > 10 : 90 to < 80 : 20, more preferably of from > 15 : 85 to < 70 : 30, still more preferably of from > 20 : 80 to < 60 : 40 and yet more preferably of from > 25 : 75 to < 55 :

45. and / or- the one or more monomeric reducing sugars, wherein the one or at least one of the more monomeric reducing sugars is fructose, of constituent c1), as well as of the first amount of one or more monomeric reducing sugars, each independently comprise > 20 mass-%, preferably > 25 mass-%, more preferably > 35 mass-% and yet more preferably > 45 mass-% of fructose, based on the total mass of the respective one or more monomeric reducing sugars. and / or- the one or more monomeric reducing sugars of constituent c1) of the activated aqueous carbohydrate component provided or prepared in step S1), or a part thereof, are provided by fructose-containing syrups which are selected from the group consisting of fructose syrup, inverted sugar syrup, corn syrup, high fructose corn syrup, glucose-fructose syrup, fructose-glucose syrup and mixtures thereof.BASF SE24080610. Process for producing a lignocellulosic composite according to any of claims 3 to 9, wherein- the process further comprises a step S7a) comprising compacting the aqueous mixture from step S7) to receive a compacted mixture, and wherein step S8) comprises applying heat and pressure to the compacted mixture from step S7a), so that the binder of the first aqueous binder composition hardens, or the binder of the second aqueous binder composition hardens, and a lignocellulosic composite results, wherein preferably step 7a) comprises compacting the mixture at a pressure in the range of from of > 0.01 to < 4 MPa, preferably in the range of from > 0.1 to < 1 MPa; and / or- step S8) comprises applying to the aqueous mixture from step S7) or to the compacted mixture from step S7a) a temperature in the range of from > 80 °C to < 300 °C, preferably in the range of from > 120 °C to < 270 °C, and a pressure in the range of from > 0.1 to < 10 MPa, preferably in the range of from > 1 to < 7 MPa; and / or- step S8) comprises pressing the aqueous mixture from step S7) orthe compacted mixture from step S7a) in a hot-press, preferably with a press-time factor in the range of from > 3 s / mm to < 10 s / mm, preferably in the range of from > 3.5 s / mm to < 9 s / mm, more preferably in the range of from > 4 s / mm to < 8 s / mm.11 . Process for producing a lignocellulosic composite according to any of claims 3 to 10, wherein- the temperature of the lignocellulosic particles has been set to a temperature in the range of from > 30 °C to < 80 °C, preferably of from > 35 °C to < 70 °C, more preferably in the range from > 38 °C to < 62 °C, before the lignocellulosic particles are combined with the first aqueous binder composition or with the second binder composition, to provide or prepare the aqueous mixture of step S7);BASF SE240806and / or- wherein the aqueous mixture provided or prepared in step S7) comprises as further constituent one or more basic substances having a pKs-value of < 3, preferably having a pKs-value of < 2,5, more preferably having a pKs-value of < 2; wherein preferably- the one or at least one of the more, preferably all of the more, basic substances having a pKs-value of < 3 are selected from the group consisting of: alkali metal hydroxides, preferably selected from the group consisting of LiOH, NaOH, KOH and mixtures thereof; more preferably the one or at least one of the more basic substances having a pKs-value of< 3 is NaOH; and earth alkali metal hydroxides, preferably selected from the group consisting of Mg(OH)2 and Ca(OH)2 and mixtures thereof, more preferably Ca(OH)2.

12. Process for producing a lignocellulosic composite according to any of claims 3 to 1 1 , wherein the lignocellulosic composite is a lignocellulosic board selected from the group consisting of high-density fiberboard; medium-density fiberboard; low-density fiberboard; wood fiber insulation board; oriented strand board; chipboard; andBASF SE240806natural fiber board, preferably comprising fibers from the group consisting of sisal fibers, jute fibers, flax fibers, coconut fibers, kenaf fibers, hemp fibers, banana fibers, and mixtures thereof; wherein the lignocellulosic board is a single-layer lignocellulosic board or a multilayer lignocellulosic board, preferably chipboard, wherein preferably the multilayer lignocellulosic board is a three-layered board having a core layer and an upper surface layer and a lower surface layer, wherein at least one layer, preferably at least the core layer, has been produced from an aqueous mixture as defined in any of claims 3 to 9.

13. Process for producing a lignocellulosic element, preferably selected from the group consisting of gluelam, plywood, finger-joint lumber, laminated veneer lumber, crosslaminated timber, parallel-laminated timber, blockboards, solid wood beams and solid wood boards, comprising at least the following steps:S7-1) providing or preparing a first lignocellulosic component t, wherein said first lignocellulosic component has at least one surface;S7-2) providing or preparing a second lignocellulosic component, wherein said second component has at least one surface;S7-3) providing or preparing(i) a first aqueous binder composition according to any of claims 1 to 9, and / or(ii) a second aqueous binder composition according to any of claims 2 to 9,S7-4) applying the first aqueous binder composition and / or the second aqueous binder composition from step S7-3) to the at least one surface of the first lignocellulosic component from step S7-1) and / or to the at least one surface of the second lignocellulosic component from step S7-2);BASF SE24080657-5) joining the surface of the first lignocellulosic component to which the first aqueous binder composition and / or the second aqueous binder composition was previously applied in step S7-4) with the at least one surface of the second lignocellulosic component as prepared or provided in step S7-2), to which the first aqueous binder composition and / or the second aqueous binder composition was optionally previously applied, or joining the surface of the second lignocellulosic component to which the first aqueous binder composition and / or the second aqueous binder composition was previously optionally applied in step S7-4) with the at least one surface of the first lignocellulosic component as prepared or provided in step S7-1), to which the first aqueous binder composition and / or the second aqueous binder composition was previously applied; and58-1 ) applying pressure and optionally heat to the joint surfaces of the first and second lignocellulosic components, preferably so that the binder of the first aqueous binder composition and / or the binder of the second aqueous binder composition hardens and the first and second lignocellulosic components are permanently joint, and preferably a lignocellulosic element results.

14. Lignocellulosic composite comprising one or more lignocellulosic composite layers, obtainable or obtained by a process according to any of claims 3 to 12, or construction product thereof, wherein preferably the lignocellulosic composite is characterized by one, more than one, or all of the following parameters: a formaldehyde emission measured according to EN717-2, which is lower than 2.0 mg / m2h; preferably lower than 1.0 mg / m2h; more preferably lower than 0.5 mg / m2h and even more preferably lower than 0.25 mg / m2h; even yet more preferably lower than 0.1 mg / m2h and / orBASF SE240806a surface screw holding, measured according to IKEA specification no. IOS-TM- 0057, Date: 2018-07-13, Version no: AA-2120821-1 , of at least 250 N, preferably of least 300 N, more preferably of least 450 N; and / or an edge screw holding, measured according to IKEA specification no. IOS-TM- 0057, Date: 2018-07-13, Version no: AA-2120821-1 , of at least 600 N, preferably of at least 800 N; and / or an internal bond strength, determined according to DIN EN 319:1993-08, of at least 0.3 N / mm2, preferably of at least 0.35 N / mm2, more preferably of at least 0.4 N / mm2, and / or a thickness swelling after 24 hours in water at 20 °C, determined according to DIN EN 317:1993-08, of less than 60 %, preferably of less than 50 %, more preferably of less than 40 %.

15. Lignocellulosic element, obtainable or obtained by a process according to claim 13.

16. First aqueous binder composition, obtainable or obtained by a process according to any of claims 1 or 4 to 9, wherein preferably the apparent viscosity of the first aqueous binder composition, measured at a concentration of 50 wt.-% solids, preferably as determined according to DIN EN 827:2005, test conditions for amino resins (“Prufbedingungen fiir Synthe- tische Klebstoffe / Aminoharze”), has a value in the range of from > 80 to < 1000 mPa ■ s, preferably of from > 100 to < 800 mPa ■ s, more preferably of from > 120 to < 650 mPa ■ s and even more preferably of from > 140 to < 500 mPa ■ s, preferably determined according to method No. 8 as described in the present methods section.

17. Second aqueous binder composition, obtainable or obtained by a process according to any of claims 2 or 4 to 9.BASF SE | 240806 | 240806WQ01 ~18. Use of a first aqueous binder composition according to claim 16 and / or of a second aqueous binder composition according to claim 17,- in a process for producing a lignocellulosic composite or a lignocellulosic element and / or - as a binder, adhesive or glue for permanently joining lignocellulosic parts.

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