Lignocellulose Material Production via Temperature-Controlled Binder Reaction
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Solution Overview
Problem
Existing processes for producing lignocellulose materials, such as those disclosed in EP-B-1 852 231 and WO-A-2015/000913, fall short in terms of efficiency and effectiveness, particularly in the use of additives and binders during the hot pressing stage.
Innovation Solution
A novel process involving the production of mixtures M1 and M2 with specific compositions and temperature conditions, including the use of organic carboxylic acids, isocyanates, amino resins, and hardeners, where the temperature of mixture M1 is controlled to optimize the reaction kinetics, ensuring proper bonding and structural integrity of lignocellulose materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional processes are used for producing lignocellulose materials, then the production can proceed with standard additives and binders, but the bonding strength and structural consistency are insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling the temperature of mixture M1 within the range of 10-65°C during the mixing stage, and then controlling the hot pressing temperature to be higher than the mixing temperature. This temperature parameter optimization enables the acid equivalents to react effectively with the amino resins, forming strong bonds between lignocellulose particles while maintaining structural consistency, thereby resolving the contradiction between bonding strength and process complexity
Solution Approach 2:
The patent uses a composite binder system comprising amino resins (component C) combined with organic carboxylic acids, carboxylic anhydrides, or carbonyl chlorides (component A). This composite material approach creates a multi-functional binding system where the acid equivalents react with the amino groups to form crosslinked structures, significantly enhancing bonding strength while maintaining ease of manufacture through the use of conventional materials in optimized combinations
2Productivity
If the temperature of mixture M1 is not controlled, then the mixing process is simpler, but the reaction kinetics are suboptimal and bonding is insufficient
Solution Approach 1:
The patent implements parameter changes by establishing specific temperature ranges for mixture M1 (10-65°C) during mixing, which optimizes the reaction kinetics between acid equivalents and amino resins. The temperature control system, while adding some complexity, enables significantly improved reaction efficiency and bonding quality, justifying the increased device complexity through enhanced productivity
Solution Approach 2:
The patent applies preliminary action by controlling the temperature of mixture M1 before the hot pressing stage. The mixing is performed at the optimized temperature range of 10-65°C to ensure proper reaction kinetics and binder activation. This preliminary temperature control prepares the mixture for subsequent hot pressing, ensuring that the bonding reactions proceed efficiently when the material is formed, thereby improving overall reaction efficiency
3Strength
If higher amounts of binders and hardeners are used, then bonding strength improves, but the production cost and process complexity increase
Solution Approach 1:
The patent uses parameter changes to optimize the amounts of binders and hardeners. By controlling the temperature of mixture M1 at 10-65°C and the hot pressing temperature to be higher, the patent achieves effective bonding with optimized quantities of amino resins (5-15% by weight) and hardeners (0-2% by weight). This temperature optimization ensures that the chemical reactions proceed efficiently, reducing the need for excessive amounts of additives while maintaining high bonding strength
Solution Approach 2:
The patent applies self-service through the in-situ formation of crosslinked structures during the hot pressing stage. The acid equivalents in component A react with the amino groups in component C to form crosslinked networks that provide self-reinforcing bonding. This self-service mechanism reduces the need for additional hardeners and additives, as the system generates its own bonding strength through the controlled chemical reactions, thereby reducing the total quantity of substances required
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process enhances the production of single-layer or multilayer lignocellulose materials by improving bonding strength and structural consistency, leading to higher quality products with enhanced mechanical properties.
Implementation Method 1
mixture M1 comprises... a) 0.005% to 0.5% by weight of organic carboxylic acid, carboxylic anhydride, carbonyl chloride or mixtures thereof (component A)... c) 5% to 15% by weight of binder selected from the group of the amino resins (component C)... d) 0% to 2% by weight of hardener (component D)
Implementation Method 2
mixture M1 comprises... b) 0.05% to 3% by weight of organic isocyanates having at least two isocyanate groups (component B)
Implementation Method 3
process steps of (Ia) producing a mixture M1 and (Ib) optionally one or more mixture(s) M2, (II) scattering mixture M1 and any mixture(s) M2 to give a mat, (III) optionally precompacting the scattered mat and (IV) hot pressing
Data Source
AI summary
The present invention relates to a novel and improved, batchwise or continuous, preferably continuous, process for producing single-layer or multilayer lignocellulose materials, comprising the process steps of(Ia) producing a mixture M1 and(Ib) optionally one or more mixture(s) M2,(II) scattering mixture M1 and any mixture(s) M2 to give a mat,(III) optionally precompacting the scattered mat and(IV) hot pressing,in that mixture M1 comprises the lignocellulose particles (component LCP-1) and additionallya) 0.005% to 0.5% by weight of organic carboxylic acid, carboxylic anhydride, carbonyl chloride or mixtures thereof (component A)b) 0.05% to 3% by weight of organic isocyanates having at least two isocyanate groups (component B) andc) 5% to 15% by weight of binder selected from the group of the amino resins (component C)d) 0% to 2% by weight of hardener (component D) ande) 0% to 5% by weight of additive (component E),and mixture(s) M2 comprise(s) the lignocellulose particles (component LCP-2) and additionallyf) 0% to 0.3% by weight of organic carboxylic acid, carboxylic anhydride, carbonyl chloride or mixtures thereof (component F),g) 1% to 30% by weight of binder selected from the group consisting of amino resin, phenolic resin, protein-based binder and other polymer-based binders or mixtures thereof (component G-1) and 0% to 3% by weight of organic isocyanate having at least two isocyanate groups (component G-2),h) 0% to 2% by weight of hardener (component H) andi) 0% to 5% by weight of additives (component I),with the proviso that the following conditions are fulfilled:amin<a<amax andamin=[(−1/6000·T)+(65/6000)1, preferably amin=[(−1/4500·T)+(65/4500)], more preferably amin=[(−1/3500·T)+(65/3500)]andamax=[(−1/2000·T)+(75/2000)], preferably amax=[(−1/2500·T)+(75/2500)], more preferably amax=[(−1/3000·T]+(75/3000)],whereT is the temperature of mixture M1 in ° C. after process step (Ia) and is between 10 and 65° C., preferably 12 and 62° C., more preferably 15 to 60° C., anda is the amount of acid equivalents in component A) in relation to the mass of component C) in mol/100 g.