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

Abstract

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

Description

[0001] BASF SE

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

[0003] Germany

[0004] First and second aqueous binder compositions comprising reducing sugars and polylysines, respective processes, articles and uses

[0005] The present invention relates to a process for producing a first and a second aqueous binder composition, each comprising reducing sugars and polylysines, to the respective aqueous binder compositions per se, as well as to the uses of said aqueous binder compositions in wood technology. Moreover, the present invention relates to a process for pro- ducing a lignocellulosic article selected from a lignocellulosic composite and a lignocellulosic element, involving said first and / or said second aqueous binder compositions. Furthermore, the present invention relates to said lignocellulosic article.

[0006] Generally, in a process of producing a multilayer or single-layer lignocellulosic composite, a mixture comprising lignocellulosic particles (i.e. particles consisting essentially of ligno- cellulose) 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 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 BASF SE 241255 mat) is treated in a manner so that the binder of the binder composition undergoes a hardening process.

[0007] There is a demand in industry for an economic, safe and sustainable process of producing lignocellulosic articles like lignocellulosic elements or multilayer or single-layer lignocellulosic composites, 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 after the production process of said lignocellulosic articles.

[0008] It is furthermore desirable that respective binder components for use in said economic and sustainable process are available in sufficient quantities and that lignocellulosic elements or multilayer or single-layer lignocellulosic composites resulting from said process have satisfactory mechanical properties, in particular that respective multilayer or single-layer lignocellulosic composites have sufficient internal bond strength and show a low tendency for swelling when in contact with aqueous moisture.

[0009] 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 related elements resulting from said processes.

[0010] The following literature deals with certain aspects of processes of producing certain materials which may comprise lignocellulosic composites or lignocellulosic elements:

[0011] Document EP 3 61 1 225 A2 deals with a binder composition, an article and a method for manufacturing an article.

[0012] Document WO 2022 / 13661 1 A1 describes a binder composition comprising amino acid polymers as well as carbohydrates, for composite articles.

[0013] In document WO 2022 / 136612 A1 , a binder composition comprising poly(amino acids) for fiber composite articles is described.

[0014] 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 241255

[0015] In document WO 2022 / 136614 A1 , the authors report of a binder composition comprising polyamines and hydroxyacetone for composite articles.

[0016] Document WO 2023 / 1 17648 A1 describes a process of producing a lignocellulosic composite or a product thereof, using dielectric heating.

[0017] 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.

[0018] Document WO 2023 / 247437 A1 discusses a binder for wood-based panels comprising an amino acid polymer and a polyaldehyde compound.

[0019] Document WO 2014 / 086775 A2 relates to binder compositions with amine components and a method of manufacturing a collection of matter bound by said binder compositions.

[0020] 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.

[0021] 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 like a lignocellulosic composite or a lignocellulosic element, e.g. a cellulosic element selected from gluelam, plywood, finger-joint lumber, laminated veneer lumber, cross-laminated timber, parallel-laminated timber, blockboards, solid wood beams and solid wood boards, where the products from said process have satisfactory mechanical properties and are environmentally friendly to the highest possible extent.

[0022] 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.

[0023] Correspondingly, it was a primary object of the present invention to provide an economic, safe and sustainable process of producing a lignocellulosic article like a lignocellulosic composite or a lignocellulosic element, wherein binder components are used as much as BASF SE 241255 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 where respective multilayer or single-layer lignocellulosic composites 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, viz. respective lignocellulosic articles, including lignocellulosic composites and lignocellulosic elements.

[0024] 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, including lignocellulosic composites and lignocellulosic elements.

[0025] 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:

[0026] 51) providing or preparing a carbohydrate component, preferably an aqueous carbohydrate component, comprising a first amount of one or more monomeric reducing sugars,

[0027] 52) providing or preparing a first polylysine component, comprising one or more polylysines; and

[0028] 53) reacting the carbohydrate component (preferably the aqueous carbohydrate component) from step S1) with the first polylysine component from step S2) at a temperature of > 40 °C, to receive (or obtain) a first aqueous binder composition.

[0029] 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. BASF SE 241255

[0030] 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.

[0031] 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, including lignocellulosic composites and 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.

[0032] Preferably, the carbohydrate component provided or prepared in step S1) of the process of the present invention is an aqueous carbohydrate component, i.e. a carbohydrate component comprising water. When said carbohydrate component is provided or prepared in step S1) of the process of the present invention as aqueous carbohydrate component, it is preferably provided or prepared as an aqueous solution or dispersion comprising the first amount of one or more monomeric reducing sugars.

[0033] As used herein, the term "monomeric reducing sugar" of the carbohydrate component (preferably of the 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. More preferred monomeric reducing sugars for the purposes of the present invention are defined below.

[0034] In a variant of the process for producing a first aqueous binder composition according to the present invention, the carbohydrate component (preferably the aqueous carbohydrate component), in addition to the first amount of one or more monomeric reducing sugars, may comprise further carbohydrates, preferably selected from the group consisting of nonreducing disaccharides (preferably sucrose), reducing disaccharides (preferably selected from the group consisting of maltose, lactose and mixtures thereof), oligosaccharides (preferably maltotriose), polysaccharides (preferably selected from the group consisting of starch and starch hydrolysates) and mixtures of any of the foregoing. BASF SE 241255

[0035] Preferably, said further carbohydrates may be present in the carbohydrate component (preferably in the aqueous carbohydrate component) provided or prepared in step S1) in a total amount of < 50 wt.-%, preferably of < 30 wt.-% and more preferably of < 15 wt.-%, relative to the first amount of one or more monomeric reducing sugars which is present in the carbohydrate component (preferably in the aqueous carbohydrate component) provided or prepared in step S1). 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

[0036] - 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 is 100 mass-%, and / or

[0037] - 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 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 BASF SE 241255 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 / or macromolecules of the polylysine(s). Additionally, lysine monomers (and in certain cases 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) for the purpose of the present invention of the first polylysine component provided or prepared in step S2) 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 the first polylysine component provided or prepared in step S2) 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 or second polylysine components 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 of the one or more polylysines.

[0044] In own experiments, it was not observed that carbon dioxide was formed or was set free in the process for producing the first aqueous binder composition according to the present invention (including in step S3) thereof). BASF SE 241255

[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 > 0 °C to < 100 °C, preferably of from > 15 °C to < 60 °C, more preferably of from > 15 °C to < 40 °C, to receive (or obtain) 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 of the one or more polylysines (i.e. a solution or mixture comprising water).

[0052] 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, prefer- BASF SE 241255 ably 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).

[0053] 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, including a lignocellulosic composite and a lignocellulosic element.

[0054] In own experiments, it was not observed that carbon dioxide was formed or was set free in the process for producing the second aqueous binder composition according to the present invention (including in step S6) thereof).

[0055] 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).

[0056] The present invention then also pertains to a process for producing a lignocellulosic article selected from the group consisting of

[0057] - a lignocellulosic composite, comprising one or more lignocellulosic composite layers, and 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: BASF SE 241255

[0058] 57) providing or preparing lignocellulosic pieces selected from the group consisting of lignocellulosic particles and lignocellulosic components,

[0059] 58) providing or preparing at least one aqueous binder composition, selected from the group consisting of

[0060] (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

[0061] (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), preferably providing or preparing a first aqueous binder composition (i),

[0062] 59) applying one or both of the aqueous binder compositions from step S8) to at least one of the lignocellulosic pieces from step S7), and joining said at least one of the lignocellulosic pieces with at least one further lignocellulosic piece, and

[0063] S10) applying pressure and optionally heat to the at least two joined lignocellulosic pieces from step S9), 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.

[0064] 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 / or 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 article according to the present invention as defined herein, and vice versa.

[0065] 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 BASF SE 241255 inventors assume that the (heat-) curable components of the first aqueous binder composition comprise (1) the reaction product(s) of (i) the first amount of the one or more monomeric reducing sugars of the aqueous carbohydrate compound used in step S1) and (ii) the one or more polylysines of the first polylysine component used in step S2), and (2) any unreacted amounts of said components (i) and / or (ii) which may still be present in the first aqueous binder composition.

[0066] The second 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 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).

[0067] 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.

[0068] 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.

[0069] 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 BASF SE 241255 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.

[0070] 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 :2017-11 . 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.

[0071] 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.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] In step S9) of the 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 the aqueous binder composition which was applied to at least one of the lignocellulosic pieces. BASF SE 241255

[0076] Preferred is a process for producing a lignocellulosic composite, comprising one or more lignocellulosic composite layers, of the present invention as described herein (or a respective process of the present invention as described herein as being preferred), comprising at least the following steps:

[0077] S7a) providing or preparing an aqueous mixture, comprising at least

[0078] - lignocellulosic particles, and

[0079] - (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), or

[0080] (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), and

[0081] S1 Oa) applying heat and pressure to the aqueous mixture from step S7a), so that the binder of the first aqueous binder composition hardens or the binder of the second binder composition hardens, and a lignocellulosic composite results.

[0082] 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 the 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- BASF SE 241255 layer lignocellulosic composite” can also comprise several other compounds different from lignocellulosic 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).

[0083] 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.

[0084] 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 241255

[0085] 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.

[0086] In the process of the present invention, the aqueous mixture provided or prepared in step S7a) 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.

[0087] In a variant of the process for producing a lignocellulosic composite according to the present invention, the aqueous mixture provided or prepared in step S7a) in addition may comprise further carbohydrates, preferably selected from the group consisting of non-reducing disaccharides (preferably sucrose), reducing disaccharides (preferably selected from the group consisting of maltose, lactose and mixtures thereof), oligosaccharides (preferably maltotriose), polysaccharides (preferably selected from the group consisting of starch and starch hydrolysates) and mixtures of any of the foregoing.

[0088] One aspect of the present invention pertains to a process for producing a second aqueous binder composition, comprising at least the following steps:

[0089] 51) providing or preparing a carbohydrate component (preferably an aqueous carbohydrate component) comprising a first amount of one or more monomeric reducing sugars,

[0090] 52) providing or preparing a first polylysine component, comprising one or more polylysines;

[0091] 53) reacting the carbohydrate component (preferably the aqueous carbohydrate component) from step S1) with the first polylysine component from step S2) at a temperature of > 40 °C, to receive (or obtain) a first aqueous binder composition; BASF SE 241255

[0092] 55) providing or preparing a second polylysine component, comprising one or more polylysines and

[0093] 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 > 0 °C to < 100 °C, preferably of from > 15 °C to < 60 °C, more preferably of from > 15 °C to < 40 °C, to receive (or obtain) a second aqueous binder composition.

[0094] 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 article, including a lignocellulosic composite, or a respective process of the present invention as described herein as being preferred), wherein

[0095] - the one or at least one of the more, or all of the more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) are selected from the group consisting of fructose, ribose, arabinose, xylose, glucose, mannose, galactose and mixtures thereof; preferably the one or at least one of the more, or all of the more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) are selected from the group consisting of fructose, xylose, glucose and mixtures thereof, and / or

[0096] - the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) comprise fructose; preferably all of the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) are fructose; BASF SE 241255 and / or

[0097] - the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) comprise > 25 mass-%, preferably > 35 mass-%, more preferably > 45 mass-% and yet more preferably > 60 mass-% of fructose, based on the total mass of the first amount of one or more monomeric reducing sugars. and / or

[0098] - the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1 ) , or a part thereof, are provided by fructose-containing syrups which are preferably selected from the group consisting of fructose syrup, inverted sugar syrup, corn syrup, high fructose corn syrup, glucosefructose syrup, fructose-glucose syrup and mixtures thereof.

[0099] In the variant of the process of the present invention as described above, wherein the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1 ) , 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 total dry weight of the syrup of about 42 % (“HFCS 42”), of about 44 % (e.g. “TruSweet 01750”), 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 first amount of monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) in a process according to the present invention. Surprisingly, although fructose was found to be a particularly preferred reducing sugar for the purposes of the present invention, it was also found that even mixtures comprising a proportion of fructose as specified here above or below usually result in lignocellulosic composites with excellent mechanical properties.

[0100] It has been found in own experiments that lignocellulosic composites can be produced which show particularly high internal bond strengths when the first amount of one or more BASF SE 241255 monomeric reducing sugars for providing or preparing the carbohydrate component (preferably the aqueous carbohydrate component) in step S1) of the process for producing a first aqueous binder composition according to the present invention comprises fructose. It has also been found in own experiments that higher proportions of fructose in said first amount of one or more monomeric reducing sugars often lead to further increased internal bond strengths of the resulting lignocellulosic composites in a process for producing a lignocellulosic composite according to the present invention.

[0101] In a preferred variant of the process of the present invention as described above, in particular of the process for producing a lignocellulosic composite of the present invention as described above, the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) comprises > 70 mass-%, preferably > 85 mass-%, more preferably > 90 mass-%, of fructose, based on the total mass of the respective one or more monomeric reducing sugars. In one preferred variant of the process for producing a lignocellulosic composite according to the present invention, the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) consists of fructose.

[0102] 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 article, including a lignocellulosic composite, or a respective process of the present invention as described herein as being preferred), wherein

[0103] - in step S3), the carbohydrate component (preferably the aqueous carbohydrate component) from step S1) is reacted with the first polylysine component from step S2) at a temperature of > 45 °C, preferably of from > 45 °C to < 120 °C, more preferably of from > 45 °C to < 95 °C, even more preferably of from > 45 °C to < 80 °C and yet even more preferably of from > 50 °C to < 70 °C; and / or

[0104] - in step S3), the carbohydrate component (preferably the aqueous carbohydrate component) from step S1) is reacted with the first polylysine component from step S2) for a time in the range of from > 1 to < 180 min., preferably of from > 10 to < 150 min. and more preferably of from > 30 to < 120 min.; BASF SE 241255 and / or

[0105] - in step S3), the carbohydrate component (preferably the aqueous carbohydrate component) from step S1) is reacted with the first polylysine component from step S2) until the apparent viscosity of the first aqueous binder composition, measured at a theoretical solid content of 50 wt.-%, has reached a value in the range of

[0106] - from > 40 to < 150 mPa ■ s, preferably of from > 45 to < 120 mPa ■ s and more preferably of from > 50 to < 100 mPa ■ s, preferably determined according to method No. 9 as described in the methods section; or

[0107] - from > 40 to < 200 mPa ■ s, preferably of from > 45 to < 175 mPa ■ s and more preferably of from > 50 to < 150 mPa ■ s, preferably determined according to method No. 9 as described in the methods section; and / or

[0108] - in step S3), the carbohydrate component (preferably the aqueous carbohydrate component) from step S1) is reacted with the first polylysine component of step S2) until the weight-average molecular weight Mwof the first aqueous binder composition has increased by 2 to 35%, preferably by 3 to 30%, more preferably by 5 to 25%, relative to the weight-average molecular weight Mwof the first aqueous binder composition at the start of the reaction in step S3), wherein preferably the weight-average molecular weight Mw of the first aqueous binder composition is determined by size exclusion chromatography, preferably according to method No. 7 as described in the methods section.

[0109] The term ..theoretical solid content" of the first aqueous binder composition as used herein preferably means the mass (or weight) ratio of (i) the total mass of carbohydrates of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) and the total mass of the one or more polylysines of the first polylysine component provided or prepared in step S1). to (ii) the total mass (or weight) of the first aqueous binder composition (including the water). The total mass of carbohydrates of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) forthe purposes of determining the theoretical solid content of the first aqueous binder composition comprises the total mass of the first amount of one or more BASF SE 241255 monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) and the total mass of any additional further carbohydrates of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) (as defined above).

[0110] The expression ..measured at a theoretical solid content of 50 wt.-%” (in water) as used herein means that the theoretical solid content of the first aqueous binder composition (or the theoretical solid content of the second aqueous binder composition, respectively) is adjusted to a value of 50 wt.-% before measuring its apparent viscosity, either by increasing or by reducing the water content of the first binder composition (or of the second aqueous binder composition, respectively), as may be necessary.

[0111] For example, if a first aqueous binder composition is produced according to the process of the present invention from 50 g fructose (as carbohydrate component comprising a first amount of one or more monomeric reducing sugars), 50 g polylysine (dry) and 100 g water, then the “theoretical solid content” of the resulting first aqueous binder composition is 50 %.

[0112] Preferably, in step S3) of the process for producing a first aqueous binder composition according to the present invention as defined herein, the theoretical solid content of further carbohydrates of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) in the first aqueous binder composition is < 40 wt.-%, more preferably is < 30 wt.-%, even more preferably is < 20 wt.-%, yet even more preferably is < 10 wt.-% and particularly preferably is < 1 wt.-%.

[0113] In the process for producing a first aqueous binder composition according to the present invention, a condensation reaction occurs in step S3) between the (first amount of) one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) and the one or more polylysines of the first polylysine component, which results in formation of the first aqueous binder composition. It has been found in own experiments that said first aqueous binder composition is particularly suited for (i) preparing a second aqueous binder composition (as further explained herein) and / or for producing a lignocellulosic article (in particular for producing a lignocellulosic composite), when the first aqueous binder composition has reached the apparent viscosity and / or the weight-average molecular weight Mw(or the respective preferred values) as specified above. These target values of the parameters “apparent viscosity” or “weight-average molecular weight Mw“ of the first aqueous binder composition are usually reached when the reaction times and reaction temperatures are applied as are also specified here above. BASF SE 241255

[0114] There is also preferred 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 article, including a lignocellulosic composite, or a respective process of the present invention as described herein as being preferred), wherein

[0115] - the mass ratio of the total mass of the one or more polylysines of the first polylysine component used in step S2) to the total mass of the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) is in the range of from > 0.4 : 1 to < 3.5 : 1 , preferably of from > 0.4 : 1 to < 2.7 : 1 , more preferably of from > 0.5 : 1 to < 2.5 : 1 and yet more preferably of from > 1 : 1 to < 2.5 : 1 ; and / or

[0116] - the mass ratio of the total mass of the one or more polylysines of the first polylysine component used in step S2) and of any present one or more polylysines of the second polylysine component used in any step S5) to the total mass of the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) is in the range of from > 0.7 : 1 to < 3.5 : 1 , preferably of from > 1 : 1 to < 3.0 : 1 and more preferably of from > 1 .5 : 1 to < 2.5 : 1 ; and / or

[0117] - 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 any present one or more polylysines of the second polylysine component provided or prepared in any step S5) is in the range of from > 0.2 : 1 to < 1 .5 : 1 , preferably of from > 0.3 : 1 to < 1 : 1 and more preferably of from > 0.35 : 1 to < 0.75 : 1 .

[0118] Unless otherwise stated, all masses and mass ratios of monomeric reducing sugars and of polylysines given herein refer to their dry masses.

[0119] It has been found in own experiments that lignocellulosic articles, preferably lignocellulosic composites, can be produced which show particularly beneficial mechanical properties BASF SE 241255 when the aqueous binder compositions used fortheir production show the above-described ratios or preferred ratios of the one or more monomeric reducing sugars and / or of the one or more polylysines

[0120] The term ..theoretical solid content" of the second aqueous binder composition as used herein means the mass (or weight) ratio of (i) the total mass of carbohydrates of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1), of the total mass of the one or more polylysines of the first polylysine component provided or prepared in step S1) and of the total mass of the one or more polylysines of the second polylysine component provided or prepared in step S5) to (ii) the total mass (or weight) of the second aqueous binder composition (including the water). The total mass of carbohydrates of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) for the purposes of determining the theoretical solid content of the first aqueous binder composition comprises the total mass of the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) and the total mass of any additional further carbohydrates of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) (as defined above).

[0121] 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 article, including a lignocellulosic composite, or any respective process of the present invention as described herein as being preferred) has been found to be particularly preferred, comprising at least the following steps:

[0122] S1) providing or preparing a carbohydrate component (preferably an aqueous carbohydrate component) comprising a first amount of one or more monomeric reducing sugars, wherein the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars comprise > 25 mass-%, preferably > 35 mass-%, more preferably > 45 mass-% and yet more preferably > 60 mass-% of fructose, based on the total mass of the first amount of one or more monomeric reducing sugars;

[0123] S2) providing or preparing a first polylysine component, comprising one or more polylysines, wherein BASF SE 241255 the mass ratio of the total mass of the one or more polylysines of the first polylysine component : the total mass of the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the aqueous carbohydrate component provided or prepared in step S1) is in the range of from > 0.4 : 1 to < 3.5 : 1 , preferably of from > 0.4 : 1 to < 2.7 : 1 more preferably of from > 0.5 : 1 to < 2.5 : 1 and yet more preferably of from > 1 : 1 to < 2.5 : 1 ; and

[0124] S3) reacting the carbohydrate component (preferably the aqueous carbohydrate component) from step S1) with the first polylysine component from step S2) at a temperature of > 40 °C, to receive (or obtain) a first aqueous binder composition.

[0125] In one preferred variant of the process for producing a lignocellulosic article according to the present invention, said process therefore comprises the following steps:

[0126] 51) providing or preparing a carbohydrate component (preferably an aqueous carbohydrate component) comprising a first amount of one or more monomeric reducing sugars, wherein the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars comprise > 25 mass-%, preferably > 35 mass-%, more preferably > 45 mass-% and yet more preferably > 60 mass-% of fructose, based on the total mass of the first amount of one or more monomeric reducing sugars;

[0127] 52) providing or preparing a first polylysine component, comprising one or more polylysines, wherein the mass ratio of the total mass of the one or more polylysines of the first polylysine component : the total mass of the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) is in the range of from > 0.4 : 1 to < 3.5 : 1 , preferably of from > 0.4 : 1 to < 2.7 : 1 more preferably of from > 0.5 : 1 to < 2.5 : 1 and yet more preferably of from > 1 : 1 to < 2.5 : 1 ; BASF SE 241255

[0128] S3) reacting the carbohydrate component (preferably the aqueous carbohydrate component) from step S1) with the first polylysine component from step S2) at a temperature of > 40 °C, to receive (or obtain) a first aqueous binder composition;

[0129] S7) providing or preparing lignocellulosic pieces selected from the group consisting of lignocellulosic particles and lignocellulosic components,

[0130] S9d) applying the first aqueous binder composition from step S3) to at least one of the lignocellulosic pieces from step S7), and joining said at least one of the lignocellulosic pieces with at least one further lignocellulosic piece, and

[0131] S1 Od) applying pressure and optionally heat to the at least two joined lignocellulosic pieces from step S9d), so that the binder of the first aqueous binder composition hardens and a lignocellulosic article results.

[0132] Furthermore is preferred 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 article, including a lignocellulosic composite, or a respective process of the present invention as described herein as being preferred), wherein

[0133] - the first aqueous binder composition as received (or obtained) 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 as determined according to DIN EN 827:2005, test conditions for amino resins (“Prufbedingungen fur Synthetische Klebstoffe / Aminoharze”); and / or

[0134] - in step S6), the mass ratio of the total mass of the first aqueous binder composition provided or prepared in step S4) (i.e. including the water) 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 < 6 : 1 , preferably in the range of from > 1.5 : 1 to < 5 : 1 and more preferably in the range of from > 2 : 1 to < 4 : 1 ; and / or BASF SE 241255

[0135] - the second aqueous binder composition as received (or obtained) in step S6) has an apparent viscosity, measured at a theoretical solid content of 50 wt.-%, in the range of from > 70 to < 250 mPa ■ s, preferably of from > 80 to < 200 mPa ■ s and more preferably of from > 85 to < 150 mPa ■ s, preferably determined according to method No. 9 as described in the methods section; and / or

[0136] - a second amount of one or more monomeric reducing sugars is added to the first aqueous binder composition as received in step S3) and / or as provided or prepared in step S4), preferably wherein the mass ratio of the total mass of the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) to the total mass of the one or more monomeric reducing sugars of the second amount of one or more monomeric reducing sugars added to the first aqueous binder composition is in the range of from > 1 : 1 to < 20 : 1 , preferably in the range of from > 1 .5 : 1 to < 5 : 1 , more preferably in the range of from > 1.5 : 1 to < 3 : 1 ; and / or the mass ratio of (i) the total mass of the one or more polylysines of the first polylysine component used in step S2) and of any present one or more polylysines of the second polylysine component used in any step S5) to (ii) the total mass of the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) and of the one or more monomeric reducing sugars of the second amount of one or more monomeric reducing sugars added to the first aqueous binder composition is in the range of from > 0.35 : 1 to < 3.3 : 1 , preferably in the range of from > 0.5 : 1 to < 2.85 : 1 , more preferably in the range of from > 0.75 : 1 to < 2.4 : 1 . BASF SE 241255

[0137] In the variant of the process of the present invention as described above wherein a second amount of one or more monomeric reducing sugars is added to the first aqueous binder composition as received (or obtained) in step S3) and / or as provided or prepared in step S4), the one or more monomeric reducing sugars of said second amount are preferably selected from the group consisting of fructose, ribose, arabinose, xylose, glucose, fructose, mannose, galactose and mixtures thereof. Preferably, the second amount of one or more monomeric reducing sugars comprises fructose. In a preferred variant of the process of the present invention as described above, the same preferences apply to the one or more monomeric reducing sugars of the second amount as were described here above for the first amount of one or more monomeric reducing sugars of step S1).

[0138] Since said second amount of one or more monomeric reducing sugars is added to the first aqueous binder composition before step S6), the one or more reducing sugars of said second amount may participate in any reaction which may occur in step S6).

[0139] Preferably, at least 80 mass-%, more preferably at least 90 mass-%, and even more preferably at least 95 mass-%, of the total solids content present in the first aqueous binder composition as received (or obtained) in step S3) and / or as provided or prepared in step S4) originates from (i) the carbohydrate component (preferably the aqueous carbohydrate component), (ii) the first polylysine component and (iii) any second amounts of one or more monomeric reducing sugars (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.

[0140] In one further variant of a process of the present invention as described herein, including a process for producing a second aqueous binder composition and a process for producing a lignocellulosic article, a further amount of carbohydrate compounds may be added in step S6) or to the second aqueous binder composition received (or obtained) in step S6). The carbohydrate compounds of said further amount of carbohydrate compounds can be selected from monomeric reducing sugars (as defined above), from further carbohydrates (as defined above) and from mixtures thereof.

[0141] 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 article, including a lignocellulosic composite, or a respective process of the present invention as described herein as being preferred) is also preferred, wherein the one or more polylysines of the first polylysine component and the one or more polylysines of the second polylysine component BASF SE 241255

[0142] - independently have a weight-average molecular weight Mwin the range of 800 g / mol < Mw ^ 10000 g / mol, preferably of 1000 g / mol < Mw^ 8000 g / mol, more preferably of 1200 g / mol < Mw S 7000 g / mol, preferably as determined by size exclusion chromatography, preferably according to method No. 7 as described in the methods section; wherein preferably the one or more polylysines of the first polylysine component have a weight-average molecular weight Mwin the range of 1000 g / mol < Mw< 5000 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; and / or the one or more polylysines of the second polylysine component have a weightaverage molecular weight Mw in the range of 1500 g / mol < M« < 7000 g / mol, preferably of 1500 g / mol < Mw2 6000 g / mol, more preferably of 2000 g / mol < Mw5000 g / mol, preferably as determined by size exclusion chromatography, preferably according to method No. 7 as described in the methods section; and / or

[0143] - 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

[0144] - independently and each as a 50 mass-% solution in water, preferably as determined according to DIN EN 827:2005, test conditions for amino resins, have an apparent viscosity in the range of from > 25 mPa ■ s to < 1000 mPa ■ s, preferably of from > 50 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 determined according to method No. 8 as described in the methods section BASF SE 241255 wherein preferably the one or more polylysines of the first polylysine component have an apparent viscosity in the range of > 25 mPa ■ s to < 300 mPa ■ s, preferably of > 40 mPa ■ s to < 200 mPa ■ s and / or the one or more polylysines of the second polylysine component have an apparent viscosity in the range of 40 mPa ■ s to < 350 mPa ■ s and / or preferably of > 80 mPa ■ s to < 250 mPa ■ s.

[0145] Preferably, the wt.-% proportion (weight percentage) or mass-% proportion (mass percentage) of lysine (monomers), preferably of L-lysine, in the one or more polylysines of the first and of the second polylysine component can be 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.

[0146] Weight-average molecular weights Mwof 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 (see in particular method No. 7).

[0147] It has been found in own experiments that a process according to the present invention as disclosed herein results in lignocellulosic articles with particularly beneficial mechanical properties, preferably in lignocellulosic composites with particularly high internal bond strengths and a 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 Mwand / or apparent viscosities. BASF SE 241255

[0148] 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

[0149] - the process further comprises a step S9a), comprising compacting the aqueous mixture from step S7a) to receive (or obtain) a compacted mixture, and wherein step S10a) comprises applying heat and pressure to the compacted mixture from step S9a), 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 9a) 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

[0150] - step S10a) comprises applying to the aqueous mixture from step S7a) or to the compacted mixture from step S9a) heat of a temperature in the range of from > 80 °C to < 300 °C, preferably in the range of from > 120 °C to < 270 °C, and pressure in the range of from > 0.1 to < 10 MPa, preferably in the range of from > 1 to < 7 MPa, preferably wherein heat and pressure are applied using a hot press and wherein the temperature in the range of from > 80 °C to < 300 °C is the temperature of the plates of the hot press; and / or

[0151] - step S10a) comprises pressing the aqueous mixture from step S7a) or the compacted mixture from step S9a) in a hot-press, 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.

[0152] 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 S10a) to the aqueous mixture from step S7a) or to the compacted mixture from step S9a), 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 BASF SE 241255 temperature ranges as defined above) in this case designates the temperature of the plates of the hot press.

[0153] 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 S10a) to the aqueous mixture from step S7a) or to the compacted mixture from step S9a), 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. Applying the temperature by heating with a hot press is, however, preferred.

[0154] 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 (glue) press.

[0155] 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) solid content of the first aqueous binder composition provided or prepared in step S7a) (preferably determined according to DIN EN 827:2005, test conditions for amino resins (“Prufbed- ingungen fur Synthetische Klebstoffe / Aminoharze”) to the total (dry) mass of the lignocellulosic particles provided or prepared in step S7a) is in the range of from > 3 to < 12 wt.-%, preferably of from > 4 to < 10 wt.-%.

[0156] 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) solid content of the second aqueous binder composition provided or prepared in step S7a) (preferably determined according to DIN EN 827:2005, test conditions for amino resins (“Pruf- bedingungen fur Synthetische Klebstoffe / Aminoharze”) to the total (dry) mass of the lignocellulosic particles provided or prepared in step S7a) is in the range of from > 3 to < 12 wt.- %, preferably of from > 4 to < 10 wt.-%.

[0157] There is also preferred 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 BASF SE 241255

[0158] - 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 S7a); and / or

[0159] - wherein the aqueous mixture provided or prepared in step S7a) comprises as further constituent one or more basic substances having a pKe-value of < 3, preferably having a pKs-value of < 2,5, more preferably having a pKe-value of < 2; wherein preferably

[0160] - the one or at least one of the more, preferably all of the more, basic substances having a pKe-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 pKe-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.

[0161] 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 S7a), i.e. the temperature of the lignocellulosic particles is in the range of from > 30 °C to < 80 °C (or in a preferred 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 S7a) of the process. BASF SE 241255

[0162] 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 S7a), 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.

[0163] 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 S7a).

[0164] 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.

[0165] Preferred is, however, 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 aqueous mixture provided or prepared in step S7a) 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 BASF SE 241255 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 to prepare or provide the aqueous mixture in step S7a). Preferably, the heated (first or second) aqueous binder composition is contacted with the lignocellulosic 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 S7a). 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 S7a).

[0166] 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 S7a) or in step S8) 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 S7a) is in the range of from > 0.05 to < 1 mass-%, 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.

[0167] 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 of the aqueous mixture provided or prepared in step S7a) in a total 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 preferably the solid content of the respective first or second aqueous binder composition is determined according to DIN EN 827:2005, test conditions for amino resins (“Prufbedingungen fur Synthetische Klebstoffe / Aminoharze”).

[0168] Preferably the pH of the first or second aqueous binder composition of the aqueous mixture provided or prepared in step S7a) is adjusted to a pH in the range of from > 8 to < 14, more preferably in the range of from > 9 to < 13 before it in step S7). BASF SE 241255

[0169] 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 substances having a pKs-value of < 3 for use in the in the process for producing a lignocellulosic composite according to the present invention.

[0170] 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; 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 S7a) as defined herein. BASF SE 241255

[0171] 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 S7a) of the process of the present invention as disclosed herein.

[0172] 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 S7a), and in step S9a) compacting or pre-compacting this layer, for preparing a multilayer lignocellulosic composite comprising one or more lignocellulosic composite layers: 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 S7a), 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 S7a), BASF SE 241255 and wherein in the two or more layers the lignocellulosic particles and / or the binders are the same or different, in step S9a) compacting the aqueous mixture in two stages, wherein in the first stage the aqueous mixture is pre-compacted to give a pre-compacted mixture or mat, and wherein in the second stage this pre-compacted mixture or mat is further compacted; and after compacting in step S9a), applying heat and pressure to the compacted mixture.

[0173] 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 S7a), or S9a), 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.

[0174] 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 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 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 (first or second) aqueous mixtures and / or individual 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 S9a) and / or in step S10a) of the process for producing a lignocellulosic composite of the present invention. BASF SE 241255

[0175] According to a variant of the process for producing a lignocellulosic composite 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.

[0176] Preferably, in step S9a) of compacting the mixture provided or prepared in step S7a) (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 mixture or mat, and in a second stage this pre-compacted mixture or mat is further compacted. This two-stage compacting allows for a flexible process for the production of a lignocellulosic composite or a layer of a lignocellulosic composite.

[0177] 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 aqueous mixtures at least comprising lignocellulosic particles and an aqueous binder composition according to the present invention, scattering this aqueous mixture / these aqueous 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.

[0178] Moreover is preferred 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, of the present invention as described herein (or a respective process of the present invention as described herein as being preferred), comprising at least the following steps: BASF SE 241255

[0179] S7b) providing or preparing a first lignocellulosic component (of a lignocellulosic element), wherein said first lignocellulosic component has at least one surface;

[0180] S7c) providing or preparing a second lignocellulosic component (of a lignocellulosic element), wherein said second lignocellulosic component has at least one surface;

[0181] S8) providing or preparing an aqueous binder composition, selected from the group consisting of

[0182] (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 / or

[0183] (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),

[0184] S9b) applying the first aqueous binder composition and / or the second aqueous binder composition from step S8) to the at least one surface of the first lignocellulosic component from step S7b) and / or to the at least one surface of the second lignocellulosic component from step S7c);

[0185] S9c) 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 S9b) with the at least one surface of the second lignocellulosic component as prepared or provided in step S7c), 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 applied in step S9b) with the at least one surface of the first lignocellulosic component as prepared or provided in step S7c), to which the first aqueous binder composition and / or the second aqueous binder composition was optionally previously applied; BASF SE 241255

[0186] S1 Ob) 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.

[0187] Preferably, the first lignocellulosic component as provided or prepared in step S7b) as defined above and the second lignocellulosic component as provided or prepared in step S7c) 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 of the lignocellulosic element are selected from the same type, e.g. both are selected from wood lamellas or both are selected from wood veneers.

[0188] 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).

[0189] Preferably, step S10b) 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 lignocellulosic 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.

[0190] The present invention also pertains to a lignocellulosic article, obtainable or obtained by a process for producing a lignocellulosic article according to the present invention as described herein (or by a respective process of the present invention as described herein as being preferred).

[0191] 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 BASF SE 241255 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 process for producing a lignocellulosic article (including the process for producing a lignocellulosic composite and the process for producing a lignocellulosic element) according to the present invention as defined herein, apply mutatis mutandis to the lignocellulosic article according to the present invention as defined herein, and vice versa.

[0192] 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, 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, even more preferably lower than 0.25 mg / m2h and yet even more preferably lower than 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 03

[0193] N / mm2, preferably of at least 0.35 N / mm2, more preferably of at least 0.4 N / mm2, BASF SE 241255 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 less than 40%.

[0194] 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 / or of the process for producing the second aqueous binder composition according to the present invention as defined herein and / or of the process for producing a lignocellulosic article (including the process for producing a lignocellulosic composite and the process for producing a lignocellulosic element) according to the present invention as defined herein and / or of the lignocellulosic article according to the present invention as defined herein, apply mutatis mutandis to the lignocellulosic composite according to the present invention as defined herein, and vice versa.

[0195] 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.

[0196] 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.

[0197] The present invention furthermore pertains to a lignocellulosic element, obtainable or obtained by a process for producing a lignocellulosic element according to the present invention as described herein (or by a respective process of the present invention as described herein as being preferred).

[0198] 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 BASF SE 241255 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 process for producing a lignocellulosic article (including the process for producing a lignocellulosic composite and the process for producing a lignocellulosic element) according to the present invention as defined herein and / or of the lignocellulosic article according to the present invention as defined herein and / or of the lignocellulosic composite according to the present invention as defined herein, apply mutatis mutandis to the lignocellulosic element according to the present invention as defined herein, and vice versa.

[0199] Under 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).

[0200] 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 / or of the process for producing the second aqueous binder composition according to the present invention as defined herein and / or of the process for producing a lignocellulosic article (including the process for producing a lignocellulosic composite and the process for producing a lignocellulosic element) according to the present invention as defined herein and / or of the lignocellulosic article according to the present invention as defined herein and / or of the lignocellulosic composite according to the present invention as defined herein and / or of the lignocellulosic element according to the present invention as defined herein, apply mutatis mutandis to the first aqueous binder composition according to the present invention as defined herein, and vice versa.

[0201] Under 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).

[0202] 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 / or of the process for producing the second aqueous binder composition according to the present invention as defined herein and / or of the process for producing a lignocellulosic article (including the process for producing a lignocellulosic composite and the process for producing a lignocellulosic element) according to the present invention as defined herein and / or of the lignocellulosic article according to the present BASF SE 241255 invention as defined herein and / or of the lignocellulosic composite according to the present invention as defined herein and / or of the lignocellulosic element according to the present invention as defined herein and / or of the first aqueous binder composition according to the present invention as defined herein, apply mutatis mutandis to the second aqueous binder composition according to the present invention as defined herein, and vice versa.

[0203] Under yet a further aspect, the present invention also 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),

[0204] - in a process for producing a lignocellulosic article, preferably selected from the group consisting of a lignocellulosic composite and a lignocellulosic element; and / or

[0205] - 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 components (preferably as further defined herein), and lignocellulosic elements (preferably as further defined herein).

[0206] 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 / or of the process for producing the second aqueous binder composition according to the present invention as defined herein and / or of the process for producing a lignocellulosic article (including the process for producing a lignocellulosic composite and the process for producing a lignocellulosic element) according to the present invention as defined herein and / or of the lignocellulosic article according to the present invention as defined herein and / or of the lignocellulosic composite according to the present invention as defined herein and / or of the lignocellulosic element according to the present invention as defined herein and / or of the first aqueous binder composition according to the present invention as defined herein and / or of the second aqueous binder composition according to 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 to the BASF SE 241255 use of a second aqueous binder composition of the present invention as defined herein, and vice versa.

[0207] Examples:

[0208] The following examples are meant to further explain and illustrate the present invention without limiting its scope.

[0209] Materials:

[0210] The following materials were used in the experiments described below:

[0211] 1) Glucose monohydrate, Sigma Aldrich, Spain;

[0212] 2) Fructose (> 99%), Sigma Aldrich, USA

[0213] 3) Dextrose monohydrate, Sigma Aldrich, Spain

[0214] 4) TruSweet 01750, Cargill, Italy (71 % dry substance, which is mainly (> 95%) fructose and glucose in a weight ratio of 44 to 56)

[0215] 5) L-Lysine solution (50% in water), ADM animal nutrition, USA;

[0216] 6) Sodium hydroxide (pellets), Carl Roth

[0217] 7) Hexamethylenediamine (“HMDA”), Sigma Aldrich

[0218] 8) Spruce wood chips (lignocellulosic particles) from Germany, Institut fur Holztechnol- ogie Dresden:

[0219] 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.

[0220] 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 BASF SE 241255 mm), which was re-shredded, and a fine fraction (“A”: < 0.32 mm x 0.5 mm). Fraction B was suitable for use as surface layer chips for three-layered chipboards (surface layer chips), 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) but was also suitable as core layer chips for three-layered chipboards (core layer chips).

[0221] The moisture content of the surface layer chips was measured to be 4.6 %, and the moisture content of the core layer chips was measured to be 4.6 % (according to the method described below).

[0222] Methods:

[0223] 1 . Measuring of residual moisture content of lignocellulosic particles

[0224] The moisture content of the lignocellulosic particles (chips) before application of the binder and the moisture content of the mixtures of the chips with the binder 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. For this, a sample of the respective mixture (ca. 20 g) was weighed in moist condition (m-i) 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.-%] = [(mi - mo) / mo] • 100.

[0225] 2. Determination of press time factor

[0226] 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 a lignocellulosic composite (board). The target thickness refers to the thickness of a lignocellulosic composite at the end of step S10a) 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.

[0227] 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 10 mm chipboard is made with a press time of 80 sec, a press time factor of 8 s / mm results. BASF SE 241255

[0228] 3. Measuring of densities of lignocellulosic composites

[0229] 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).

[0230] 4. Measuring of transverse tensile strength of lignocellulosic composites (“internal bond strength”)

[0231] 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).

[0232] 5. Determining the swelling thickness after 24 hours

[0233] 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 as the arithmetic average of ten 50 mm x 50 mm samples of the same lignocellulosic composite (board).

[0234] 6. Determining the amount of binder composition

[0235] The amount of aqueous 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 of 4.6 wt.-%, i.e. 1000 g of dry wood chips), the amount of aqueous binder composition is 5.0 wt.-%.

[0236] 7. Determining the weight-average molecular weight (Mw) of polylysines

[0237] The weight-average molecular weight (Mw) of polylysines as prepared according to the present examples was determined by generally known size exclusion chromatography under the following conditions:

[0238] Solvent and eluent: 0.1 % (w / w) trifluoroacetate, 0.1 M NaCI in distilled water BASF SE 241255

[0239] Flow: 0.8 mL / min

[0240] Injection volume: 100 pL

[0241] Samples were filtrated with a Sartorius Minisart RC 25 (0,2 pm) filter

[0242] Column material: hydroxylated polymethacrylate (TSKgel G3000PWXL)

[0243] Column size: inside diameter 7.8 mm, length 30 cm

[0244] Column temperature: 35 °C

[0245] Detector: DRI Agilent 1100 UV GAT-LCD 503 [232nm]

[0246] 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).

[0247] The upper integration limit was set to 29.01 mL.

[0248] The calculation of Mwincluded the lysine oligomers and polymers as well as the monomer lysine.

[0249] 8. Determining the apparent viscosities of polylysines

[0250] 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 Rhe- oComPass, 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 by a pipette as sample 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 thevalue for the apparent viscosity of the polylysine sample in mPa ■ s. BASF SE 241255

[0251] 9. Determining the apparent viscosities of first and second aqueous binder compositions

[0252] The apparent viscosities of the first and second aqueous binder compositions are measured at theoretical solid contents (for definition see above) of 50 wt.-% 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.

[0253] 10. Determining the solid content of first and second aqueous binder compositions

[0254] 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). 2 g ± 0.2 g sample were weighed into the cup (m2 = weight of sample). The sample was heated for 2 h at 120°C in a ventilated oven (± 1 °C). The sample was removed from the oven and cooled down 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 [%].

[0255] 11 . Primary and secondary amine group nitrogen content:

[0256] The primary and secondary amine group nitrogen contents are measured by potentiometric titration according to EN ISO 9702:1998.

[0257] Example 1 : Synthesis of polylysines

[0258] Example 1 a: Preparing a 60 wt.-% Solution of Polylysine with Mw2750

[0259] 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 and crushed after cooling. The weight-average molecular weight of the resulting polylysine (Polylysine-1 a) was 2750 g / mol and the apparent viscosity was 124 mPa ■ s (for determination methods BASF SE 241255 see above). The polylysine was dissolved in water to give a 60 wt.-% aqueous solution of polylysine (the “Polylysine Solution 1 a” hereinafter).

[0260] Example 1 b: Preparing a 50 wt.-% Solution of Polylysine with Mw6517

[0261] 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 fer 3 hours). The weight-average molecular weight of the resulting polylysine (Polylysine- 1 b) was 6517 g / mol and the apparent viscosity was 286 mPa ■ s (for determination methods see above). The polylysine was dissolved in water to give a 50 wt.-% aqueous solution of polylysine (the “Polylysine Solution 1 b” hereinafter).

[0262] Example 1 c: Preparing a 60 wt.-% Solution of Polylysine with Mw4065

[0263] 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 3.5 hours (instead of fer 3 hours). The weight-average molecular weight of the resulting polylysine (Polylysine- 1 c) was 4065 g / mol and the apparent viscosity was 199 mPa ■ s (for determination methods see above). The polylysine was dissolved in water to give a 60 wt.-% aqueous solution of polylysine (the “Polylysine Solution 1 c” hereinafter).

[0264] Example 2: Preparing aqueous mixtures of polylysine and reducing sugar as aqueous binder composition (for comparison)

[0265] The following examples 2a to 2d were prepared with aqueous mixtures of polylysine and reducing sugars for comparison, in a process not according to the present invention.

[0266] Example 2a: Mixture of polylysine-1 a and glucose (67 : 33)

[0267] 200 g Polylysine Solution 1 a (solid content 60 wt.-%) was mixed with 100 g of a 60 wt.-% solution of glucose in water (made by solving 66.0 g glucose monohydrate in 34 g water) resulting in comparative aqueous binder composition 23CABC.

[0268] Example 2b: Mixture of polylysine-1 a and glucose (50 : 50)

[0269] 150 g Polylysine Solution 1 a (solid content 60 wt.-%) was mixed with 150 g of a 60 wt.-% solution of glucose in water resulting in comparative aqueous binder composition 2bcABc. BASF SE 241255

[0270] Example 2c: Mixture of polylysine-1 a and TruSweet 01750 (67 : 33)

[0271] 200 g Polylysine Solution 1 a (solid content 60 wt.-%) was mixed with 100 g of a 60 wt.-% solution of TruSweet 01750, which is made by diluting 84.5 g TruSweet 01750 syrup (71 wt.-% dry content) with 15.5 g water, resulting in comparative aqueous binder composition 2CCABC.

[0272] Example 2d: Mixture of polylysine-1 a and TruSweet 01750 (50 : 50)

[0273] 150 g Polylysine Solution 1 a (solid content 60 wt.-%) was mixed with 150 g of a 60 wt.-% solution of TruSweet 01750, which is made by diluting 127 g TruSweet 01750 syrup (71 wt.-% dry content) with 23.0 g water, resulting in comparative aqueous binder composition 2dcABC.

[0274] Example 3: Synthesis of first aqueous binder compositions

[0275] Example 3a: Preparing first aqueous binder composition 3aiABc, made by condensation of Polylysine Solution 1 a and glucose (67 : 33)

[0276] A mixture of 200 g Polylysine Solution 1 a (solid content 60 wt.-%) and 100 g of a 60 wt.-% solution of glucose in water was placed in a 1 L four-neck flask equipped with a reflux condenser. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 60 min (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. 60 g water was added to adjust a theoretical solid content (for definition see above) of 50 wt.-% [(200*0.6 + 100*0.6) I (200 + 100 + 60)], and the apparent viscosity was measured to be 92 mPa ■ s (see methods above).

[0277] The weight-average molecular weight Mw of the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mw had increased by 4.5 % after reaction and cooling. BASF SE 241255

[0278] Example 3b: Preparing first aqueous binder composition 3biABc, made by condensation of Polylysine Solution 1 a and glucose (50 : 50)

[0279] A mixture of 150 g Polylysine Solution 1 a (solid content 60 wt.-%) and 150 g of a 60 wt.-% solution of glucose in water was placed in a 1 L four-neck flask equipped with a reflux condenser. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 60 min (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. 60 g water was added to adjust a theoretical solid content of 50 wt.-% [(150*0.6 + 150*0.6) / (150 + 150 + 60)], and the apparent viscosity was measured to be 104 mPa ■ s (see methods above).

[0280] The weight-average molecular weight Mwof the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mwhad increased by 6.9 % after reaction and cooling.

[0281] Example 3c: Preparing first aqueous binder composition 3CIABC, made by condensation of Polylysine Solution 1 a and glucose (37 : 63)

[0282] A mixture of 112 g Polylysine Solution 1 a (solid content 60 wt.-%) and 188 g of a 60 wt.-% solution of glucose in water was placed in a 1 L four-neck flask equipped with a reflux condenser. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 60 min (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. 60 g water was added to adjust a theoretical solid content of 50 wt.-%, and the apparent viscosity was measured to be 60 mPa ■ s (see methods above).

[0283] The weight-average molecular weight Mw of the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mw had increased by 7.0 % after reaction and cooling.

[0284] Example 3d: Preparing first aqueous binder composition 3diABc, made by condensation of Polylysine Solution 1 a and TruSweet 01750 (67 : 33)

[0285] A mixture of 200 g Polylysine Solution 1 a (solid content 60 wt.-%) and 100 g of a 60 wt.-% solution of TruSweet 01750 (which is made by diluting 84.5 g TruSweet 01750 syrup (71 BASF SE 241255 wt.-% dry content) with 15.5 g water) was placed in a 1 L four-neck flask equipped with a reflux condenser. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 30 min (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. 60 g water was added to adjust a theoretical solid content of 50 wt.-%, and the apparent viscosity was measured to be 81 mPa ■ s (see methods above).

[0286] The weight-average molecular weight Mwof the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mwhad increased by 9.0 % after reaction and cooling.

[0287] Example 3e: Preparing first aqueous binder composition 36IABC, made by condensation of Polylysine Solution 1 a and TruSweet 01750 (50 : 50)

[0288] A mixture of 150 g Polylysine Solution 1 a (solid content 60 wt.-%) and 150 g of a 60 wt.-% solution of TruSweet 01750 (see example 3d above) was placed in a 1 L four-neck flask equipped with a reflux condenser. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 30 min (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. 60 g water was added to adjust a theoretical solid content of 50 wt.-%, and the apparent viscosity was measured to be 92 mPa ■ s (see methods above).

[0289] The weight-average molecular weight Mw of the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mw had increased by 8.9 % after reaction and cooling.

[0290] Example 3f: Preparing first aqueous binder composition STABC, made by condensation of Polylysine Solution 1 a and TruSweet 01750 (37 : 63)

[0291] A mixture of 112 g Polylysine Solution 1 a (solid content 60 wt.-%) and 188 g of a 60 wt.-% solution of TruSweet 01750 (see example 3d above) was placed in a 1 L four-neck flask equipped with a reflux condenser. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 30 min (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. 60 g water BASF SE 241255 was added to adjust a theoretical solid content of 50 wt.-%, and the apparent viscosity was measured to be 53 mPa ■ s (see methods above).

[0292] The weight-average molecular weight Mwof the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mwhad increased by 7.3 % after reaction and

[0293] Example 3g: Preparing first aqueous binder composition 3giABc, made by condensation of Polylysine Solution 1 a and fructose (67 : 33)

[0294] A mixture of 200 g Polylysine Solution 1 a (solid content 60 wt.-%) and 100 g of a 60 wt.-% solution of fructose in water was placed in a 1 L four-neck flask equipped with a reflux condenser. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 30 min (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. 60 g water was added to adjust a theoretical solid content of 50 wt.-%, and the apparent viscosity was measured to be 64 mPa ■ s (see methods above).

[0295] The weight-average molecular weight Mw of the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mw had increased by 18.1 % after reaction and cooling.

[0296] Example 3h: Preparing first aqueous binder composition 3hiABc, made by condensation of Polylysine Solution 1 a and fructose (50 : 50)

[0297] A mixture of 150 g Polylysine Solution 1 a (solid content 60 wt.-%) and 150 g of a 60 wt.-% solution of fructose in water was placed in a 1 L four-neck flask equipped with a reflux condenser. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 30 min (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. 60 g water was added to adjust a theoretical solid content of 50 wt.-%, and the apparent viscosity was measured to be 101 mPa ■ s (see methods above).

[0298] The weight-average molecular weight Mw of the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method BASF SE 241255

[0299] No. 7 (see above). It was found that the Mwhad increased by 23.0 % after reaction and cooling.

[0300] Example 3i: Preparing first aqueous binder composition 3HABC, made by condensation of Polylysine Solution 1 a and fructose (37 : 63)

[0301] A mixture of 112 g Polylysine Solution 1 a (solid content 60 wt.-%) and 188 g of a 60 wt.-% solution of fructose in water was placed in a 1 L four-neck flask equipped with a reflux condenser. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 30 min (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. 60 g water was added to adjust a theoretical solid content of 50 wt.-%, and the apparent viscosity was measured to be 56 mPa ■ s (see methods above).

[0302] The weight-average molecular weight Mwof the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mw had increased by 22.2 % after reaction and cooling.

[0303] Example 3j: Preparing first aqueous binder composition 3JIABC, made by condensation of Polylysine Solution 1 a and TruSweet 01750 (43 : 57)

[0304] A mixture of 112 g Polylysine Solution 1 a (solid content 60 wt.-%) and 149 g of a 60 wt.-% solution of TruSweet 01750 (see example 3d above) was placed in a 1 L four-neck flask equipped with a reflux condenser. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 30 min (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. 60 g water was added to adjust a theoretical solid content of 50 wt.-% by adding water, and the apparent viscosity was measured to be 65 mPa ■ s (see methods above).

[0305] The weight-average molecular weight Mw of the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mw had increased by 7.8 % after reaction and cooling. BASF SE 241255

[0306] Example 3k: Preparing comparative first aqueous binder composition 3K*IABC, made by condensation of HMDA and Glucose / Fructose (12 : 88)

[0307] A mixture of 33.3 g of an aqueous solution of hexamethylenediamine (60 wt.-% in water), 80.0 g fructose, 80.0 g glucose monohydrate (corresponding to 72.7 g glucose) and 107 g water was placed in a 1 L four-neck flask equipped with a reflux condenser. The viscosity of this mixture was measured to be 55 mPa ■ s . The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 20 min. (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. The apparent viscosity of the reaction of the final reaction mixture was measured to be 75 mPa ■ s. Water was added to adjust a theoretical solid content of 50 wt.-%, and the apparent viscosity was measured to be 18 mPa ■ s (see methods above).

[0308] Example 3I: Preparing first aqueous binder composition 3IIABC, made by condensation of Polylysine Solution 1 a and Glucose / Fructose (24 : 76)

[0309] In this example 3I, the amount of polylysine was selected in such way, that the number of primary amine groups (determined as described above) corresponded to the number of primary amine groups in the HMDA used in Example 3k above.

[0310] A mixture of 82.3 g of Polylysine Solution 1 a (60 wt.-% in water), 80.0 g fructose, 80.0 g glucose monohydrate (corresponding to 72.7 g glucose) and 107 g water was placed in a 1 L four-neck flask equipped with a reflux condenser. The apparent viscosity of this mixture was measured to be 83 mPa ■ s. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 20 min. (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. The apparent viscosity of the final reaction mixture was measured to be 118 mPa ■ s. Water was added to adjust the theoretical solid content of the first aqueous binder composition to 50 wt.-%, and the apparent viscosity was measured to be 29 mPa ■ s (see methods above).

[0311] Example 3m: Preparing first aqueous binder composition 3ITIIABC, made by condensation of Polylysine Solution 1 a and Glucose / Fructose (24 : 76)

[0312] In this example 3m, the amount of polylysine was selected in such a way that the number of primary amine groups (determined as described above) corresponded to the number of primary amine groups in the HMDA used in Example 3k above. BASF SE 241255

[0313] A mixture of 82.3 g of Polylysine Solution 1 a (60 wt.-% in water), 80.0 g fructose, 80.0 g glucose monohydrate (corresponding to 72.7 g glucose) and 94.5 g water was placed in a 1 L four-neck flask equipped with a reflux condenser. The apparent viscosity of this mixture was measured to be 89 mPa ■ s. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 20 min. (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. The apparent viscosity of the final reaction mixture was measured to be 133 mPa ■ s. Water was added to adjust the theoretical solid content of the first aqueous binder composition to 50 wt.-%, and the apparent viscosity was measured to be 31 mPa ■ s (see methods above).

[0314] The weight-average molecular weight Mwof the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mwhad increased by 7.3 % after reaction and cooling.

[0315] Example 3n: Preparing first aqueous binder composition 3niABc, made by condensation of Polylysine Solution 1 a and TruSweet 01750 (24 : 76)

[0316] A mixture of 73.2 g of Polylysine Solution 1 a (60 wt.-% in water), 227 g of of a 60 wt.-% solution of TruSweet 01750 (TruSweet 01750 was diluted from a solid content of 71 wt.-% to 60 wt.-% by adding water) was placed in a 1 L four-neck flask equipped with a reflux condenser. The apparent viscosity of this mixture was measured to be 88 mPa ■ s. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 30 min. (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. The apparent viscosity of the final reaction mixture was measured to be 153 mPa ■ s. Water was added to adjust the theoretical solid content of the first aqueous binder composition to 50 wt.-%, and the apparent viscosity was measured to be 36 mPa ■ s (see methods above).

[0317] The weight-average molecular weight Mw of the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mw had increased by 8.3 % after reaction and cooling. BASF SE 241255

[0318] Example 3o: Preparing first aqueous binder composition 3o made by condensation of Polylysine Solution 1 a and TruSweet 01750 (77 : 23)

[0319] A mixture of 231 g of Polylysine Solution 1 a (60 wt.-% in water), 69 g of a 60 wt.-% solution of TruSweet 01750 (see example 3d above) was placed in a 0.5L four-neck flask equipped with a reflux condenser. The apparent viscosity of this mixture was measured to be 450 mPa ■ s. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 30 min. (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. The apparent viscosity of the final reaction mixture was measured to be 783 mPa ■ s. Water was added to adjust the theoretical solid content of the first aqueous binder composition to 50 wt.-%, and the apparent viscosity was measured to be 130 mPa ■ s (see methods above).

[0320] The weight-average molecular weight Mwof the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mwhad increased by 7.7 % after reaction and cooling.

[0321] Example 3p: Preparing first aqueous binder composition 3p made by condensation of Polylysine Solution 1 a and TruSweet 01750 (50 : 50)

[0322] A mixture of 150 g of Polylysine Solution 1 a (60 wt.-% in water), 150 g of a 60 wt.-% solution of TruSweet 01750 (see example 3d above) was placed in a 0.5L four-neck flask equipped with a reflux condenser. The apparent viscosity of this mixture was measured to be 246 mPa ■ s. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 30 min. (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. The apparent viscosity of the final reaction mixture was measured to be 462 mPa ■ s. Water was added to adjust the theoretical solid content of the first aqueous binder composition to 50 wt.-%, and the apparent viscosity was measured to be 85 mPa ■ s (see methods above).

[0323] The weight-average molecular weight Mw of the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mw had increased by 5.8 % after reaction and cooling. BASF SE 241255

[0324] Example 3q: Preparing first aqueous binder composition 3q made by condensation of Polylysine Solution 1 a and Xylose (50 : 50)

[0325] A mixture of 150 g of Polylysine Solution 1 a (60 wt.-% in water), 150 g of a 60 wt.-% solution of Xylose was placed in a 0.5L four-neck flask equipped with a reflux condenser. The apparent viscosity of this mixture was measured to be 222 mPa ■ s. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 30 min. (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. The apparent viscosity of the final reaction mixture was measured to be 546 mPa ■ s. Water was added to adjust the theoretical solid content of the first aqueous binder composition to 50 wt.-%, and the apparent viscosity was measured to be 121 mPa ■ s (see methods above).

[0326] The weight-average molecular weight Mwof the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mwhad increased by 22.7 % after reaction and cooling.

[0327] Example 3r: Preparing first aqueous binder composition 3r made by condensation of Polylysine Solution 1 c and TruSweet 01750 (50 : 50)

[0328] A mixture of 150 g of Polylysine Solution 1 c (60 wt.-% in water), 150 g of a 60 wt.-% solution of TruSweet 01750 (see example 3d above) was placed in a 0.5L four-neck flask equipped with a reflux condenser. The apparent viscosity of this mixture was measured to be 307 mPa ■ s. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 15 min. (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. The apparent viscosity of the final reaction mixture was measured to be 517 mPa ■ s. Water was added to adjust the theoretical solid content of the first aqueous binder composition to 50 wt.-%, and the apparent viscosity was measured to be 88 mPa ■ s (see methods above).

[0329] The weight-average molecular weight Mw of the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mw had increased by 7.1 % after reaction and cooling. BASF SE 241255

[0330] Example 3s: Preparing first aqueous binder composition 3s made by condensation of Polylysine 1 c and Fructose (50 : 50)

[0331] A mixture of 150 g of Polylysine Solution 1 c (60 wt.-% in water), 150 g of a 60 wt.-% solution of Fructose was placed in a 0.5L four-neck flask equipped with a reflux condenser. The apparent viscosity of this mixture was measured to be 239 mPa ■ s. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 15 min. (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. The apparent viscosity of the final reaction mixture was measured to be 701 mPa ■ s. Water was added to adjust the theoretical solid content of the first aqueous binder composition to 50 wt.-%, and the apparent viscosity was measured to be 129 mPa ■ s (see methods above).

[0332] The weight-average molecular weight Mwof the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mwhad increased by 23.3 % after reaction and cooling.

[0333] Example 3t: Preparing first aqueous binder composition 3t made by condensation of Polylysine Solution 1 a and Glucose (17 : 83)

[0334] A mixture of 50 g of Polylysine Solution 1 a (60 wt.-% in water), 250 g of a 60 wt.-% solution of Glucose was placed in a 0.5L four-neck flask equipped with a reflux condenser. The apparent viscosity of this mixture was measured to be 75 mPa ■ s. The mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 60 min. (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. The apparent viscosity of the final reaction mixture was measured to be 103 mPa ■ s. Water was added to adjust the theoretical solid content of the first aqueous binder composition to 50 wt.-%, and the apparent viscosity was measured to be 27 mPa ■ s (see methods above).

[0335] The weight-average molecular weight Mw of the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mw had increased by 2.8 % after reaction and cooling. BASF SE 241255

[0336] Example 3u: Preparing first aqueous binder composition 3hiABc, made by condensation of Polylysine Solution 1 a and fructose (50 : 50)

[0337] A mixture of 150 g Polylysine Solution 1 a (solid content 60 wt.-%) and 150 g of a 60 wt.-% solution of fructose in water was placed in a 0.5L four-neck flask equipped with a reflux condenser. The apparent viscosity of this mixture was measured to be 187 mPa ■ sThe mixture was heated under stirring to 60 °C within 30 min. Stirring at 60 °C was continued for 35 min (condensation time). When the planned condensation time was reached, the reaction mixture was cooled in an ice bath. The apparent viscosity of the final reaction mixture was measured to be 496 mPa ■ s. Water was added to adjust the theoretical solid content of the first aqueous binder composition to 50 wt.-%, and the apparent viscosity was measured to be 110 mPa ■ s (see methods above).

[0338] The weight-average molecular weight Mwof the mixture before heating and after reaction and cooling (then a first aqueous binder composition) were measure according to method No. 7 (see above). It was found that the Mwhad increased by 21.5 % after reaction and cooling.

[0339] Example 4: Synthesis of second aqueous binder compositions

[0340] Example 4a: Preparing second aqueous binder composition 4a2ABc from first aqueous binder composition 3biABc and Polylysine Solution 1 a

[0341] 300 g of first aqueous binder composition 3biABc, 125 g of Polylysine Solution 1 a (solid content 60 wt.-%) and 25 g water were mixed at 20 °C under thorough stirring to provide second aqueous binder composition 4a2ABc. The apparent viscosity of this binder composition (at a theoretical solid content of 50 wt.-%) was measured (as described above) to be 110 mPa ■ s. The total mass ratio of polylysine to glucose is 67 : 33.

[0342] Example 4b: Preparing second aqueous binder composition 4b2ABc from first aqueous binder composition 3CIABC and Polylysine Solution 1 a

[0343] 300 g of first aqueous binder composition 3CIABC, 218 g of Polylysine Solution 1 a (solid content 60 wt.-%) and 43 g water were mixed at 20 °C under thorough stirring to provide second aqueous binder composition 4b2ABc. The apparent viscosity of this binder composition (at a theoretical solid content of 50 wt.-%) was measured (as described above) to be 103 mPa ■ s. The total mass ratio of polylysine to glucose is 67 : 33. BASF SE 241255

[0344] Example 4c: Preparing second aqueous binder composition 4C2ABC from first aqueous binder composition 36IABC and Polylysine Solution 1 a

[0345] 300 g of first aqueous binder composition 36IABC, 125 g of Polylysine Solution 1 a (solid content 60 wt.-%) and 25 g water were mixed at 20 °C under thorough stirring to provide second aqueous binder composition 4C2ABC. The apparent viscosity of this binder (at a theoretical solid content of 50 wt.-%) was measured (as described above) to be 97 mPa ■ s. The total mass ratio of polylysine to glucose / fructose is 67 : 33.

[0346] Example 4d: Preparing second aqueous binder composition 4d2ABc from first aqueous binder composition 3fiABc and Polylysine Solution 1 a

[0347] 300 g of first aqueous binder composition STABC, 218 g of Polylysine Solution 1 a (solid content 60 wt.-%) and 43 g water were mixed at 20 °C under thorough stirring to provide second aqueous binder composition 4d2ABc. The apparent viscosity of this binder (at a theoretical solid content of 50 wt.-%) was measured (as described above) to be 92 mPa ■ s. The total mass ratio of polylysine to fructose / glucose is 67 : 33.

[0348] Example 4e: Preparing second aqueous binder composition 462ABC from first aqueous binder composition 3hiABc and Polylysine Solution 1 a

[0349] 300 g of first aqueous binder composition 3hiABc, 125 g of Polylysine Solution 1 a (solid content 60 wt.-%) and 25 g water were mixed at 20 °C under thorough stirring to provide second aqueous binder composition 462ABC. The apparent viscosity of this binder (at a theoretical solid content of 50 wt.-%) was measured (as described above) to be 115 mPa ■ s . The total mass ratio of polylysine to fructose is 67 : 33.

[0350] Example 4f: Preparing second aqueous binder composition 4f2ABc from first aqueous binder composition 3iiABc and Polylysine Solution 1 a

[0351] 300 g of first aqueous binder composition 3iiABc, 218 g of Polylysine Solution 1 a (solid content 60 wt.-%) and 43 g water were mixed at 20 °C under thorough stirring to provide second aqueous binder composition 4f2ABc. The apparent viscosity of this binder (at a theoretical solid content of 50 wt.-%) was measured (as described above) to be 98 mPa ■ s. The total mass ratio of polylysine to fructose is 67 : 33. BASF SE 241255

[0352] Example 4g: Preparing second aqueous binder composition 4g2ABc from first aqueous binder composition 3iiABc and Polylysine Solution 1 b

[0353] 300 g of first aqueous binder composition 3iiABc, 261 g of Polylysine Solution 1 b (solid content 50 wt.-%) were mixed at 20 °C under thorough stirring to provide second aqueous binder composition 4g2ABc. The apparent viscosity of this binder (at a theoretical solid content of 50 wt.-%) was measured (as described above) to be 92 mPa ■ s. The total mass ratio of polylysine to fructose / glucose is 67 : 33.

[0354] Example 4h: Preparing second aqueous binder composition 4I12ABC from first aqueous binder composition 3JIABC, Polylysine Solution 1 a and TruSweet 01750

[0355] 261 g of first aqueous binder composition 3JIABC, 218 g of Polylysine Solution 1 a (solid content 60 wt.-%), 26.4 g TruSweet 01750 and 54 g water were mixed at 20 °C under thorough stirring to provide second aqueous binder composition 4h2ABc. The apparent viscosity of this binder (at a theoretical solid content of 50 wt.-%) was measured (as described above) to be 93 mPa ■ s. The total mass ratio of polylysine to fructose / glucose is 67 : 33.

[0356] Example 4i: Preparing comparative second aqueous binder composition 4i*2ABc from first aqueous binder composition 3KIABC and HMDA

[0357] 288 g of comparative first aqueous binder composition 3K*IABC, and 31 .9 g of an aqueous solution of hexamethylenediamine (60 wt.-% in water) were mixed at 20 °C under thorough stirring to provide comparative second aqueous binder composition 4i*2ABc. The apparent viscosity of this binder composition (at a theoretical solid content of 50 wt.-%) was measured (as described above) to be 18 mPa ■ s. The total mass ratio of hexamethylenediamine to fructose / glucose is 21 : 79.

[0358] Example 4i*: Preparing comparative second aqueous binder composition 4j2ABc from first aqueous binder composition 3IIABC and HMDA

[0359] 335 g of first aqueous binder composition 3IIABC, and 31 .9 g of an aqueous solution of hexamethylenediamine (60 wt.-% in water) were mixed at 20 °C under thorough stirring to provide comparative second aqueous binder composition 4J*2ABC. The apparent viscosity of this binder composition (at a theoretical solid content of 50 wt.-%) was measured (as described above) to be 30 mPa ■ s. The total mass ratio of hexamethylenediamine to polylysine to fructose / glucose is 9 : 22 : 69. BASF SE 241255

[0360] Example 4k: Preparing second aqueous binder composition 4k2ABc from first aqueous binder composition 3IIABC and Polylysine Solution 1 a

[0361] 333 g of first aqueous binder composition 3IIABC, and 78.6 g of Polylysine Solution 1 a (60 wt.-% in water) were mixed at 20 °C under thorough stirring to provide second aqueous binder composition 4k*2ABc. The apparent viscosity of this binder composition (at a theoretical solid content of 50 wt.-%) was measured (as described above) to be 47 mPa ■ s . The total mass ratio of polylysine to fructose / glucose is 39 : 61 .

[0362] Example 5: Producing liqnocellulosic composites (chipboards)

[0363] Example 5a: 10 mm Chipboards (lignocellulosic composites) with comparative aqueous binder compositions

[0364] A Plougshare® mixer L20 by 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 tables 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 wt.-%) were filled into the mixer. Mixing was started (80 rpm) to bring the chips to the specified temperature (i.e. “Temperature LP”). 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 after that, additional water was sprayed onto the mixture while continuing mixing, whereas the amount of water is selected to achieve a final moisture of the resinated chips of 10 wt.-%. The mixing was continued at the given temperature, so that the total time from start of addition of aqueous binder composition until end of mixing amounted to 3 min.

[0365] The resulting chips / binder mixture is either used directly or is stored at the given temperature (the temperature of the chips / binder mixture) for 15 min. Thereafter 625 g of the chips / binder mixture were scattered into a 30 cm x 30 cm mold and pre-compacted in a pneumatic press under ambient conditions (0.4 N / mm21 0.4 MPa). Subsequently, the precompacted 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. BASF SE | 241255

[0366] The single-layered lignocellulosic composites made from comparative aqueous binder compositions of examples 2a to 2d produced by the process as described here above were named SLCC2a to SLCC2d.

[0367] For the single-layered lignocellulosic composites SLCC2a to SLCC2d made from comparative aqueous binder compositions of examples 2a to 2d, certain board parameters were determined according to the methods as described above and are shown in table 1 below.

[0368] Table 1 : Parameters measured for 10 mm single-layered lignocellulosic composites

[0369] SLCC2a to SLCC2d made from comparative aqueous binder compositions

[0370] *: Comparative example, not according to the present invention

[0371] Example 5b: 10 mm Chipboards (lignocellulosic composite) with first aqueous binder compositions according to the invention

[0372] Single-layered lignocellulosic composites were produced from first aqueous binder compositions of examples 3a, 3b, 3d, 3e, 3g, 3h, 3i, 3j, 3I, 3o, 3q, 3r, 3s, 3t and 3u (as described above) by the process as described in example 5a above and were named SLCI3a, SLCI3b, SLCI3d, SLCI3e, SLCI3g, SLCI3h, SLCI3i, SLCI3j, SLCI3I, SLCI3o, SLCI3q, SLCI3r, SLCI3s, SLCI3t and SLCI3u, respectively.

[0373] For the single-layered lignocellulosic composites SLCI3a, SLCI3b, SLCI3d, SLCI3e, SLCI3g, SLCI3h, SLCI3i, SLCI3j, SLCI3I, SLCI3o, SLCI3q, SLCI3r, SLCI3s, SLCI3t and SLCI3u made from the respective first aqueous binder compositions, certain board parameters were determined according to the methods as described above and are shown in table 2 below. | BASF SE | 241255

[0374] Table 2: Parameters measured for 10 mm single-layered lignocellulosic composites SLCI3a to SLCI3h, made from first aqueous binder compositions according to the invention n.a.: not applicable - the internal bond strength of the respective single-layered lignocellulosic composites was to weak to be measurable. | BASF SE | 241255

[0375] Example 5c: 10 mm Chipboards (lignocellulosic composites) with second aqueous binder compositions

[0376] Single-layered lignocellulosic composites were produced from second aqueous binder compositions of examples 4a to 4h (as described above) by the process as described in example 5a above and were named SLCI4a to SLCI4h, respectively.

[0377] For the single-layered lignocellulosic composites SLCI4a to SLCI4h made from the respective second aqueous binder compositions, certain board parameters were determined according to the methods as described above and are shown in table 3 below.

[0378] Table 3: Parameters measured for 10 mm single-layered lignocellulosic composites SLCI4a to SLCI4h, made from second aqueous binder compositions BASF SE 241255

[0379] Example 5d: 10 mm Chipboards (lignocellulosic composites) with comparative second aqueous binder compositions and second aqueous binder composition according to the invention

[0380] Single-layered lignocellulosic composites were produced from comparative second aqueous binder compositions of examples 4i to 4k (as described above) by the process as described in example 5a above and were named SLCC4i to SLCC4k, respectively.

[0381] For the single-layered lignocellulosic composites SLCC4i, SLCC4j and SLCI4k, made from the respective comparative second aqueous binder compositions, certain board parameters were determined according to the methods as described above and are shown in table 4 below.

[0382] Additional lignocellulosic composites SLCC4i, SLCC4j and SLCI4k were also produced according to the methods as described above, where, however, a press time factor of 16 s / mm was applied (instead of 8 s / mm). Also for these additional lignocellulosic composites board parameters were determined according to the methods as described above and are shown in table 4 below.

[0383] Table 4: Parameters measured for 10 mm single-layered lignocellulosic composites SLCC4i, SLCC4j and SLCI4k , made from second aqueous binder compositions (Temperature LP was 20 °C for all experiments shown in table 4 below)

[0384] Comparative example, not according to the present invention

Claims

BASF SE241255Claims:

1. Process for producing a first aqueous binder composition, comprising at least the following steps:51) providing or preparing a carbohydrate component comprising a first amount of one or more monomeric reducing sugars,52) providing or preparing a first polylysine component, comprising one or more polylysines; and53) reacting the carbohydrate component from step S1) with the first polylysine component from step S2) at a temperature of > 40 °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 > 0 °C to < 100 °C, preferably of from > 15 °C to < 60 °C, more preferably of from > 15 °C to < 40 °C, to receive a second aqueous binder composition.

3. Process for producing a lignocellulosic article selected from the group consisting ofBASF SE241255- a lignocellulosic composite, comprising one or more lignocellulosic composite layers, and- 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:57) providing or preparing lignocellulosic pieces selected from the group consisting of lignocellulosic particles and lignocellulosic components,58) providing or preparing at least one aqueous binder composition, selected from the group consisting of(i) a first aqueous binder composition according to claim 1 , and(ii) a second aqueous binder composition according to claim 2,59) applying one or both of the aqueous binder compositions from step S8) to at least one of the lignocellulosic pieces from step S7), and joining said at least one of the lignocellulosic pieces with at least one further lignocellulosic piece, andS10) applying pressure and optionally heat to the at least two joined lignocellulosic pieces from step S9), so that the binderofthe first aqueous binder composition and / or the binder of the second aqueous binder composition hardens and a lignocellulosic article results.

4. Process for producing a lignocellulosic composite, comprising one or more lignocellulosic composite layers, preferably according to claim 3, comprising at least the following steps:S7a) providing or preparing an aqueous mixture, comprising at least lignocellulosic particles,BASF SE241255and- (i) a first aqueous binder composition according to claim 1 , or(ii) a second aqueous binder composition according to claim 2, andS10a) applying heat and pressure to the aqueous mixture from step S7a), so that the binder of the first aqueous binder composition hardens or the binder of the second binder composition hardens, and a lignocellulosic composite results.

5. 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 are a polymerization product 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 %, 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 with n > 10, wherein n is the number of monomers which have been reacted to form the dimers, trimers, oligomers and / or macromolecules of the polylysine(s).BASF SE2412556. Process according to any of the preceding claims, wherein the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component, preferably of the aqueous carbohydrate component, provided or prepared in step S1) comprise > 25 mass-%, preferably > 35 mass-%, more preferably > 45 mass-%, yet more preferably > 60 mass-% and yet even more preferably > 70 mass-% of fructose, based on the total mass of the first amount of one or more monomeric reducing sugars.

7. Process according to any of the preceding claims, wherein- the carbohydrate component comprising a first amount of one or more monomeric reducing sugars provided or prepared in step S1) is an aqueous carbohydrate component; and / or- the one or at least one of the more, or all of the more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component, preferably of the aqueous carbohydrate component, provided or prepared in step S1) are selected from the group consisting of fructose, ribose, arabinose, xylose, glucose, mannose, galactose and mixtures thereof; preferably the one or at least one of the more, or all of the more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component, preferably of the aqueous carbohydrate component, provided or prepared in step S1) are selected from the group consisting of fructose, xylose, glucose and mixtures thereof, and / or- the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component, preferably of the aqueous carbohydrate component, provided or prepared in step S1) comprise fructose; preferably all of the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component, preferably of the aqueous carbohydrate component, provided or prepared in step S1) are fructose;BASF SE241255and / or- the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component, preferably of the aqueous carbohydrate component, provided or prepared in step S1 ), or a part thereof, are provided by fructose-containing syrups which are preferably 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.

8. Process according to any of the preceding claims, wherein- in step S3), the carbohydrate component, preferably the aqueous carbohydrate component, from step S1) is reacted with the first polylysine component from step S2) at a temperature of > 45 °C, preferably of from > 45 °C to < 120 °C, more preferably of from > 45 °C to < 95 °C, even more preferably of from > 45 °C to < 80 °C and yet even more preferably of from > 50 °C to < 70 °C; and / or- in step S3), the carbohydrate component, preferably the aqueous carbohydrate component, from step S1) is reacted with the first polylysine component from step S2) for a time in the range of from > 1 to < 180 min, preferably of from > 10 to < 150 min. and more preferably of from > 30 to < 120 min.; and / or- in step S3), the carbohydrate component (preferably the aqueous carbohydrate component) from step S1) is reacted with the first polylysine component from step S2) until the apparent viscosity of the first aqueous binder composition, measured at a theoretical solid content of 50 wt.-%, has reached a value in the range of- from > 40 to < 150 mPa ■ s, preferably of from > 45 to < 120 mPa ■ s and more preferably of from > 50 to < 100 mPa ■ s, preferably determined according to method No. 9 as described in the methods section; orBASF SE241255- from > 40 to < 200 mPa ■ s, preferably of from > 45 to < 175 mPa ■ s and more preferably of from > 50 to < 150 mPa ■ s, preferably determined according to method No. 9 as described in the methods section; and / or- in step S3), the carbohydrate component, preferably the aqueous carbohydrate component) from step S1) is reacted with the first polylysine component of step S2) until the weight-average molecular weight Mwof the first aqueous binder composition has increased by 2 to 35%, preferably by 3 to 30%, more preferably by 5 to 25%, relative to the weight-average molecular weight Mwof the first aqueous binder composition at the start of the reaction in step S3), wherein preferably the weight-average molecular weight Mw of the first aqueous binder composition is determined by size exclusion chromatography, preferably according to method No. 7 as described in the methods section.

9. Process according to any of the preceding claims, wherein the mass ratio of the total mass of the one or more polylysines of the first polylysine component used in step S2) : the total mass of the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component, preferably of the aqueous carbohydrate component, provided or prepared in step S1) is in the range of from > 0.4 : 1 to < 3.5 : 1 , preferably of from > 0.4 : 1 to < 2.7 : 1 , more preferably of from > 0.5 : 1 to < 2.5 : 1 and yet more preferably of from > 1 : 1 to < 2.5 : 1.

10. Process according to any of the preceding claims, wherein- the mass ratio of the total mass of the one or more polylysines of the first polylysine component used in step S2) and of any present one or more polylysines of the second polylysine component used in any step S5) : the total mass of the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component, preferably of the aqueous carbohydrate component, provided or prepared in step S1) is in the range of from > 0.7 : 1 to < 3.5 : 1 , preferably of from > 1 : 1 to < 3.0 : 1 and more preferably of from > 1 .5 : 1 to < 2.5 : 1 ; and / orBASF SE241255- 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 any present one or more polylysines of the second polylysine component provided or prepared in any step S5) is in the range of from > 0.2 : 1 to < 1 .5 : 1 , preferably of from > 0.3 : 1 to < 1 : 1 and more preferably of from > 0.35 : 1 to < 0.75 : 1 .11 . 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 total solids 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 as determined according to DIN EN 827:2005, test conditions for amino resins; and / or- in step S6), the mass ratio of the total mass of the first aqueous binder composition provided or prepared in step S4) : 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 < 6 : 1 , preferably in the range of from > 1 .5 : 1 to < 5 : 1 and more preferably in the range of from > 2 : 1 to < 4 : 1 ; and / or- the second aqueous binder composition as received in step S6) has an apparent viscosity, measured at a theoretical solid content of 50 wt.-%, in the range of from > 70 to < 250 mPa ■ s, preferably of from > 80 to < 200 mPa ■ s and more preferably of from > 85 to < 150 mPa ■ s, preferably determined according to method No. 9 as described in the methods section; and / or a second amount of one or more monomeric reducing sugars is added to the first aqueous binder composition as received in step S3) and / or as provided or prepared in step S4), preferably whereinBASF SE241255the mass ratio of (i) the total mass of the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) to (ii) the total mass of the one or more monomeric reducing sugars of the second amount of one or more monomeric reducing sugars added to the first aqueous binder composition is in the range of from > 1 : 1 to < 20 : 1 , preferably in the range of from > 1 .5 : 1 to < 5 : 1 , more preferably in the range of from > 1 .5 : 1 to < 3 : 1 ; and / or wherein the mass ratio of (i) the total mass of the one or more polylysines of the first polylysine component used in step S2) and of any present one or more polylysines of the second polylysine component used in any step S5) to (ii) the total mass of the one or more monomeric reducing sugars of the first amount of one or more monomeric reducing sugars of the carbohydrate component (preferably of the aqueous carbohydrate component) provided or prepared in step S1) and of the one or more monomeric reducing sugars of the second amount of one or more monomeric reducing sugars added to the first aqueous binder composition is in the range of from > 0.35 : 1 to < 3.3 : 1 , preferably in the range of from > 0.5 : 1 to < 2.85 : 1 , more preferably in the range of from > 0.75 : 1 to < 2.4 : 1 .

12. 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 have a weight-average molecular weight Mwin the range of 800 g / mol < Mw £ 10000 g / mol, preferably of 1000 g / mol < Mw< 8000 g / mol, more preferably of 1200 g / mol < MW2 7000 g / mol, preferably as determined by size exclusion chromatography, preferably according to method No. 7 as described in the methods section; wherein preferably the one or more polylysines of the first polylysine component have a weightaverage molecular weight Mw in the range of 1000 g / mol < MW2 5000 g / mol, preferably of 1200 g / mol < Mw3500 g / mol, preferably as determined by sizeBASF SE241255exclusion chromatography, preferably according to method No. 7 as described in the methods section; and / or the one or more polylysines of the second polylysine component have a weight-average molecular weight Mwin the range of 1500 g / mol < Mw< 7000 g / mol, preferably of 1500 g / mol < MW2 6000 g / mol, more preferably of 2000 g / mol < Mw S 5000 g / mol, preferably as determined by size exclusion chromatography, preferably according to method No. 7 as described in the 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 / or- independently and each as a 50 mass-% solution in water, preferably as determined according to DIN EN 827:2005, test conditions for amino resins, have an apparent viscosity in the range of from > 25 mPa ■ s to < 1000 mPa ■ s, preferably of from > 50 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 determined according to method No. 8 as described in the methods section wherein preferably the one or more polylysines of the first polylysine component have an apparent viscosity in the range of > 25 mPa ■ s to < 300 mPa ■ s, preferably of > 40 mPa ■ s to < 200 mPa ■ sBASF SE241255and / or the one or more polylysines of the second polylysine component have an apparent viscosity in the range of 40 mPa ■ s to < 350 mPa ■ s and / or preferably of > 80 mPa ■ s to < 250 mPa ■ s.

13. Process for producing a lignocellulosic composite according to any of claims 4 to 12, wherein- the process further comprises a step S9a) comprising compacting the aqueous mixture from step S7a) to receive a compacted mixture, and wherein step S10a) comprises applying heat and pressure to the compacted mixture from step S9a), 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 9a) 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 S10a) comprises applying to the aqueous mixture from step S7a) or to the compacted mixture from step S9a) heat of a temperature in the range of from > 80 °C to < 300 °C, preferably in the range of from > 120 °C to < 270 °C, and pressure in the range of from > 0.1 to < 10 MPa, preferably in the range of from > 1 to < 7 MPa, preferably wherein heat and pressure are applied using a hot press and wherein the temperature in the range of from > 80 °C to < 300 °C is the temperature of the plates of the hot press; and / or step S10a) comprises pressing the aqueous mixture from step S7a) or the compacted mixture from step S9a) in a hot-press, with a press-time factor in the rangeBASF SE241255of 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.

14. Process for producing a lignocellulosic composite according to any of claims 4 to 13, 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 S7a); and / or- wherein the aqueous mixture provided or prepared in step S7a) 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 ofthe 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.

15. Process for producing a lignocellulosic composite according to any of claims 4 to 14, wherein the lignocellulosic composite is a lignocellulosic board selected from the group consisting ofBASF SE241255- high-density fiberboard;- medium-density fiberboard;- low-density fiberboard;- wood fiber insulation board;- 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 defined in any of claims 4 to 12.

16. 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, preferably according to claim 3, comprising at least the following steps:S7b) providing or preparing a first lignocellulosic component of a lignocellulosic element, wherein said first lignocellulosic component has at least one surface;S7c) providing or preparing a second lignocellulosic component, wherein said second lignocellulosic component has at least one surface;S8) providing or preparing an aqueous binder composition, selected from the group consisting ofBASF SE241255(i) a first aqueous binder composition according to claim 1 and 6 to 12, and / or(ii) a second aqueous binder composition according to claim 2 and 6 to 12,S9b) applying the first aqueous binder composition and / or the second aqueous binder composition from step S8) to the at least one surface of the first lignocellulosic component from step S7b) and / or to the at least one surface of the second lignocellulosic component from step S7c);S9c) 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 S9b) with the at least one surface of the second lignocellulosic component as prepared or provided in step S7c), 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 applied in step S9b) with the at least one surface of the first lignocellulosic component as prepared or provided in step S7c), to which the first aqueous binder composition and / or the second aqueous binder composition was optionally previously applied;S1 Ob) 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 of a lignocellulosic element are permanently joint, and preferably a lignocellulosic element results.

17. Lignocellulosic article, obtainable or obtained by a process according to any of claims 3 to 16.

18. Lignocellulosic composite, obtainable or obtained by a process according to any of claims 4 to 15, or construction product thereof,BASF SE241255wherein 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, whcih is lower than 2.0 mg / m2h, preferably lower than 1.0 mg / m2h; more preferably lower than 0.5 mg / m2h, even more preferably lower than 0.25 mg / m2h and yet even more preferably lower than 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 03 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 less than 40%.

19. Lignocellulosic element, obtainable or obtained by a process according to claim 16.

20. First aqueous binder composition, obtainable or obtained by a process according to any of claims 1 and 5 to 12.I BASF SE 1 241255 | 241255WOQ1 ~~21 . Second aqueous binder composition, obtainable or obtained by a process according to any of claims 2 and 5 to 12.

22. Use of a first aqueous binder composition according to claim 20 and / or of a second aqueous binder composition according to claim 21 , - in a process for producing a lignocellulosic article, preferably selected from the group consisting of a lignocellulosic composite and a lignocellulosic element; and / or- as a binder, adhesive or glue for permanently joining lignocellulosic parts.

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