EP4126484A1

EP4126484A1 - Production of a lignocellulose-containing, plastic-coated and printable molding

Info

Publication number: EP4126484A1
Application number: EP20717100.0A
Authority: EP
Inventors: Max Zaher; Volker Thole
Original assignee: Polymertrend LLC
Current assignee: Polymertrend LLC
Priority date: 2020-03-24
Filing date: 2020-03-24
Publication date: 2023-02-08
Also published as: WO2021190728A1; US20230130260A1

Abstract

A process for producing a lignocellulose-containing, plastic-coated and printable molding (26), in particular in sheet form, comprising the steps of: a) producing a layer (A, B') containing lignocellulose-containing particles according to the shape of the molding to be produced (26); b) applying a layer (C) of particles containing electron beam-reactive thermoplastic onto the layer produced according to the preceding feature; c) heating the layers (A, C) produced according to the preceding features such that thermoplastic particles melt into the layer containing lignocellulose-containing particles (Cs); d) pressing the layers heated according to feature (1c); and e) irradiating the layers pressed according to the feature (1d) with electrons in the energy range from 1 MeV to 10 MeV. The process is for example elucidated with reference to an MDF sheet one-sidedly provided with a polymer layer.

Description

Production of a lignocellulose-containing, plastic-coated and printable molded part

The invention relates to methods and devices for producing a lignocellulose-containing, plastic-coated, printable molded part.

The methods and devices use lignocellulosic particles. Substances made from wood or from non-wood-containing plants or else a mixture of such, e.g. B. in the form of chips, fibers, so-called strands or flakes. The particles mentioned here therefore include, in particular, wood-containing and wood-like chips and fibers.

Wood chips or wood fibers or wood-like chips or fibers are to be understood here in particular as meaning native cellulose-containing raw materials, such as wood from various tree species and provenance (fresh, old or recycled).

Further examples of wood-like chips or fibers in the context of this description are bamboo, straw from maize or cereals, fiber plants such as flax or jute.

The use of ionizing radiation for treatment, in particular for the digestion of native cellulose-containing raw materials for various further processing purposes, is known as such. Examples are pest decontamination, the facilitation of so-called refining or fiber disruption in paper production or the acceleration of saccharification and fermentation, e.g. B. in the production of bioethanol.

In particular, the invention relates to the production of chipboard and MDF / HDF boards.

Known in the prior art is the use of a chopper for comminuting the wood-like starting materials, a chipper for generating chips, a sieve for determining the chip or fiber sizes, a washing system, a so-called defibrator (in the case of MDF production), a dryer, a Mixer for mixing the chips or fibers with a binding agent, in particular the component formaldehyde, a system for producing fleece, a prepress, and a full press with heating. B. 220 ° C and means for aftertreatment of the chipboard or MDF / HDF panels. The use of formaldehyde is problematic in terms of health protection and fire hazard. The state of the art needs to be improved in particular with regard to the following properties and parameters:

Productivity in manufacturing, energy expenditure, required temperatures, mixing and binding times, cooling times, thickness swelling, abrasion and bending strength (Modulus of elasticity), transverse pull ^¬ strength, further processing relief, printability, UV protection, Wechselklima- and moisture resistance, bioresistance products against Spores, fungi, insects, fire protection, health protection, etc.

The international patent application PCT / EP 2019/074883 of the inventors, the knowledge of which is assumed here, describes the production of a lignocellulose-containing molded part, with at least some of the above-mentioned objectives being at least partially achieved.

The present application also relates to the problem of printing lignocellulose-containing molded parts, that is to say in particular chipboard and MDF / HDF boards.

In the prior art, the printing, for example with laser printing or inkjet printing, of lignocellulose-containing molded parts, in particular chipboard and MDF / HDF boards, is very complex. The molded parts or panels must be painted several times with regard to their surface, typically in more than 3 stages. The device is technically and procedural ^¬ renstechnisch consuming and expensive.

Accordingly, the present invention has the object to provide methods and devices to which a lignocellulose molding with minimal equipment and process engineering effort is preparable insbeson ^¬ particular so that it can be printed and optionally printed.

According to the invention, a method for producing a lignocellulose-containing plastic-coated and printable molded part, in particular in panel form and as an MDF / HDF panel, includes the following steps: molded part to be produced (26); b) applying a layer (C) of particles which contain electron beam-reactive thermoplastic to the layer produced according to the above feature; c) heating the layers (A, C) produced according to the above features in such a way that thermoplastic particles melt into the layer containing lignocellulose-containing particles (Cs); d) pressing the layers heated according to feature (lc); and e) irradiating the layers pressed according to feature (ld) with electrons in the energy range from 1 MeV to 10 MeV.

With such a method, MDF / HDF molded parts, in particular panels, can advantageously be produced with regard to the above-mentioned problems / goals in such a way that they have an outer polymer layer that can be easily printed, in particular with laser printing or with inkjet printing.

According to one embodiment of the above-mentioned method, in particular for the production of MDF / HDF molded parts provided on both sides with an outer polymer layer, in particular panels, according to FIGS. 7, 8, a layer of particles is to be produced before the above-mentioned step a), ^{which contain an electron beam reactive} thermoplastic and to which the layer containing the lignocellulose-containing particles is applied in accordance with step a) above. Said particles containing electron beam reactive thermoplastic preferably consist essentially of thermoplastic.

The above-mentioned method steps are preferably carried out one after the other in the specified order. Here, the heating according to data ^¬ can times lc) and the pressing in accordance with feature d) are carried out wholly or partly overlapping in time.

To produce an MDF / HDF molded part in which the surface arranged at the bottom during production is provided with the polymer layer that is easy to print, the process is as follows:

- Generating a layer of particles which ^{contain electron beam reactive} thermoplastic;

- Application of a layer containing lignocellulose-containing particles corresponding to the shape of the molded part to be produced;

Heating the layers produced according to the above features in such a way that thermoplastic particles melt into the layer containing lignocellulose-containing particles;

Pressing the layers heated according to the above feature; and Irradiating the layers pressed according to the above feature with electrons in the energy range from 1 MeV to 10 MeV.

The above-mentioned "melting down" of thermoplastic particles, which can also consist entirely of thermoplastic particles, means that not the entire layer of thermoplastic particles melts, but only part of it into the adjacent lignocellulose-containing particles (i.e. in particular wood particles ) containing layer penetrate melted by the heating and thus bring about an optimal connection of the layers, while on the outside of the molded part a smooth layer of essentially thermoplastic material is created, which can be printed without further complex measures, in particular in inkjet printing or laser printing.

To produce chipboard with a polymer coating on one side, the layer according to feature a) contains lignocellulose-containing fine particles and after step a) and before step b) the following steps are carried out: aa) applying a layer (A ') containing lignocellulose-containing coarse particles.

When a "layer corresponding to the shape of the molded part to be produced" is mentioned here, this means that the layer shape is not necessarily identical to the final shape of the molded part, but only depends on the last-mentioned shape.

The invention also relates to apparatuses for carrying out the above Ver ^¬ drive being provided for the individual process steps mentioned above in each case a ^¬ A device for performing the method step.

The methods of the invention can also be used to bring a product made in her ^¬ kömmlicher manner mold part, such as a chipboard or an MDF / HDF plate in a well-printable state. For this purpose, a layer of particles can be sprinkled on the conventionally produced chipboard or the MDF / HDF board, which contain electron beam reactive thermoplastic or essentially consist of it, after which the intermediate product produced in this way is heated in such a way that some of the thermoplastic particles enter the fitting, lignocellulose-containing particles containing layer penetrate melting, whereupon the so it is pressed ^¬ sired intermediate product and is subsequently irradiated with electrons in said energy range. The above-mentioned heating of the layers produced in such a way that thermoplastic particles melt into the layer containing lignocellulose-containing particles is preferably carried out at temperatures from 100.degree. C. to 180.degree. C., in particular at 160.degree. C. to 170.degree.

The above-mentioned pressing process takes place in particular with pressures of 30 bar to 50 bar.

Above, layers containing electron beam reactive thermoplastics are mentioned on the one hand and layers containing lignocellulose-containing particles on the other hand. These are preferably, on the one hand, essentially thermoplastic-containing layers and, on the other hand, layers essentially containing wood-like particles. The particles are each suitable for scattering in the area.

A polymer (also in particle form) can be added to the layers containing lignocellulose-containing particles, these added polymer particles bringing about an overall crosslinking including the lignocellulose particles and the polymers when irradiated with electrons.

The lignocellulose-containing particles can also be irradiated with electrons in the energy range from 1 MeV to 10 MeV before or when they are used for the first time in one of the processes mentioned here. Two such irradiations then take place in the process.

In this case, 5% to 30% by weight of a thermoplastic can be added to the layers of lignocellulose-containing particles (wood particles). To produce a so-called WPC molded part (wood-plastic composite), preferably 30% to 60% by mass of a polymer of the type mentioned above are mixed in.

Exemplary embodiments of the invention are described in more detail below with reference to the accompanying figures.

FIG. 1 shows the production of a particle board without a polymer coating;

FIG. 2 shows a standard chipboard in section, as it is produced with an apparatus and a method according to FIG. 1; FIG. 3 shows the production of a chipboard with a polymer layer on both sides;

FIG. 4 shows a chipboard produced with a device according to FIG. 3 with polymer layers on both sides;

FIG. 5 shows the production of a particle board with a one-sided polymer layer;

FIG. 6 shows a chipboard with a one-sided polymer layer produced with a device according to FIG. 5;

FIG. 7 shows the production of an MDF / HDF board with polymer layers on both sides;

FIG. 8 shows an MDF / HDF board produced with a device according to FIG. 7 with polymer layers on both sides;

FIG. 9 shows the production of an MDF / HDF board with a polymer layer on one side; and

FIG. 10 shows an MDF / HDF board produced with a device according to FIG. 9 with a one-sided polymer layer.

1 generally illustrates an apparatus and method 10 for making conventional particle board as a starting point of the present invention.

The method in FIG. 1 runs from left to right in terms of time and space.

"Lignocellulose-containing particles" are, by way of example, "wood particles" below.

First, a wood fine particle spreader spreads over a large area in a manner known as such

Wood fine particles on a conveyor belt 24 to produce a layer of wood

Fine particles. The term "wood flour" is also used for such fine wood particles.

A wood coarse particle spreader 14 scatters a layer of wood coarse particles on the layer of wood fine particles. The coarse wood particles can also be used as wood shavings are designated. Subsequently, a further wood fine particle spreader 16 scatters a layer of wood fine particles on the layer of wood coarse particles. The fine particles and the coarse particles as used here have dimensions that are customary in the manufacture of three-layer chipboard. The fine particles therefore have smaller dimensions than the coarse particles.

The conveyor belt 24 conveys the three layers thus scattered on top of one another into a preheater 18 and from there the layers pass into a press 20. After the press 20, the pressed molded parts 26 are conveyed to an electron gun 22, where they are filled with electrons in the energy range between 1 MeV and 10 MeV are irradiated.

2 shows a standard chipboard produced in this way with a central wood coarse particle layer A, an upper wood fine particle layer B and with a lower wood fine particle layer B '.

This is the basic structure on which the present invention is based.

In the figures, corresponding components are each provided with chen same Bezugszei ^¬ wherein gegebe at various points components used ^¬ are appropriate, provided with a bar or with two strokes.

3 shows an apparatus and a method for producing a particle board which is provided with a polymer layer on both sides. A ^polymer which is thermoplastically deformable and meltable by the action of heat is referred to below as a thermoplastic.

A thermoplastic particle spreader 30 scatters a layer of fine thermoplastic particles onto the conveyor belt 24. A wood fine particle spreader 12 then scatters a layer of wood fine particles onto the layer of thermoplastic particles. A coarse wood particle spreader then scatters a layer of coarse wood particles onto the above-mentioned layer of fine wood particles. Then another wood fine particle spreader 12 'scatters a layer of wood fine particles on the layer of wood coarse particles. Subsequently, a further thermoplastic particles spreaders 30 ', a layer of fine thermoplastic particles scattered on the produced layer of wood fine ^¬ particles. The layer thicknesses of the thermoplastic particle layers mentioned are preferably in the range from 100 to 500 micrometers (μm). In all the double-sided coatings described here, the thickness of the polymer layers produced with the thermoplastic particles is preferably the same on both sides of the molded part. This has the advantage that warping (deformation) of the molded part is counteracted (the so-called "banana effect" is avoided).

After the thermoplastic particle spreader 30 'according to FIG. 3, the intermediate product with the five layers mentioned is conveyed into a preheating device 18, where, depending on the polymers or thermoplastics used, heating to temperatures in the range from 100 to 180 ° C., typically takes place in the range from 160 to 170 ° C. The thermoplastic particles melt and the molten thermoplastic partially penetrates the adjacent layer of fine wood particles and thus creates an intimate connection between the polymer layer and the wood particle layer. The intermediate product processed in this way is then fed into a press 20, where the plates are pressed with pressures between 30 and 50 bar. The intermediate products are then fed into the electron gun 22 and irradiated over the entire area with electrons in the energy range between 1 MeV and 10 MeV. The plates are then turned through 180 ° and the other side of the plates is also irradiated with electrons in the energy range between 1 MeV and 10 MeV.

4 shows the molded part 26 produced in this way in section. A central wood coarse ^¬ particle layer A has on both sides of timber fine particle layers as the outside, lie on either side polymer layers C, C. The outer-side polymer layers C, C are each connected by fusion bonding layers Cs with the respective adjacent timber fine particle layer. When heated molten thermo plast ^¬ particulate flowing fine particles interposed between the timber.

Fig. 5 shows a device for producing a chipboard with a polymer ^¬ layer on one side. Following a first wood fine particle spreader 12, a wood coarse particle spreader 14 and a second wood fine particle spreader 12 ', a thermoplastic particle spreader 30 applies an upper layer of thermoplastic particles and then preheating and pressing with a preheating ^device 18 or one Press 20 and electron irradiation of the molded parts 26 in an electron gun 22, as described above with reference to FIG. 3. The statements made above in connection with FIGS. 3 and 4 with regard to layer thicknesses, added polymers to the wooden parts, etc. apply to all exemplary embodiments.

The molded part 26 produced with the device according to FIG. 5 is shown in section in FIG. 6. A central wood coarse particle layer A 'has wood fine particle layers B' on both sides and a polymer layer C on one side, which is firmly connected to the wood fine particle layer B ’below it via a fusion bonding layer Cs.

Fig. 7 shows an apparatus for the production of an MDF / HDF board (medium density fiber board / high density fiber board) with a polymer layer on both the top and the bottom.

A thermoplastic particle spreader 30 scatters a layer of thermoplastic particles onto the conveyor belt. A wood fiber spreader 32 scatters a layer of wood fibers from said layer of thermoplastic particles. A mat former 34 forms the two mentioned layers into a fleece. A second thermoplastic particle spreader 30 'scatters a layer of thermoplastic particles thereon. Thereafter, the thus Herge ^¬ passes presented intermediate in the manner already described in a preheater 18 and into a press 20 and an electron gun 22 in the above with reference to for example Fig. Manner described. 5

8 shows the molded part produced in this way and is self-explanatory due to the reference symbols already explained above.

Fig. 9 shows an apparatus for producing an MDF board with a polymer layer on only one side. A wood fiber spreader 332 spreads a layer of Holzfa ^¬ fibers. A mat former 34 forms the wood fiber layer produced in this way. A thermoplastic particle spreader 30 scatters a layer of thermoplastic particles thereon. From there, the intermediate product passes into the preheater 18, the press 20 and the electron gun 22, as described above.

Fig. 10 shows the MDF board thus prepared with a single-side coated poly ^¬ cell layer. In all of the exemplary embodiments described above, the wood fine particle layers and the wood coarse particle layers can be mixed with polymers which crosslink under electron bombardment. The references in the claims to figures serve to facilitate the assignment to the exemplary embodiments and are not part of the claims.

REFERENCE SIGNS LIST 10 Chipboard manufacture

12 Wood fine particle spreader 14 Wood coarse particle spreader

16 wood fine particle spreader

18 preheating

20 press

22 electron gun 24 conveyor belt

26 molded part (chipboard)

30 thermoplastic particle dispensers

12 'wooden fine particle spreader

14 'Wood coarse particle spreader 30' Thermoplastic particle spreader 12 "Wood fine particle spreader

14 "wood particle spreader

30 "thermoplastic particle spreader

A Wood coarse particle layer B Wood fine particle layer

B 'wood fine particle layer

C polymer layer

Cs fusion bond layer

C polymer layer 32 wood fiber dispenser

34 Mat former

Claims

1. A method for producing a lignocellulose-containing, plastic-coated and printable molded part (26), in particular in plate form, comprising the following steps: a) producing a layer (A, B ') which contains lignocellulose-containing particles corresponding to the shape of the molded part (26) to be produced; b) applying a layer (C) of particles which contain electron beam-reactive thermoplastic to the layer produced according to the above feature; c) heating the layers (A, C) produced according to the above features in such a way that thermoplastic particles melt into the layer containing lignocellulose-containing particles (Cs); d) pressing the layers heated according to feature (lc); and e) irradiating the layers pressed according to feature (ld) with electrons in the energy range from 1 MeV to 10 MeV.

(Fig. 9, 10; MDF, one-sided, thermoplastic, top)

2. The method according to claim 1, wherein before step la) a layer (C) is produced from particles which contain electron beam reactive thermoplastic and to which the layer containing the lignocellulose-containing particles is applied according to step la).

(Figures 7, 8; MDF, thermoplastic on both sides)

3. The method according to any one of claims 1 or 2, wherein the layer produced according to feature la) contains electron beam reactive powdery thermoplastic polymer with powder particle sizes <2000 micrometers (pm) or a liquid containing electron beam reactive polymer.

4. The method according to claim 2, wherein step lb) is omitted.

(MDF, one-sided, thermoplastic below)

5. The method according to any one of the preceding claims, wherein said layer production takes place by particle scattering.

6. The method according to any one of claims 1 or 3, wherein the process steps la) and lb) are interchanged in the order.

(MDF, thermoplastic on one side, below)

7. The method according to any one of claims 1 to 5, wherein the layer (B ') produced according to feature la) contains lignocellulose-containing fine particles and the following steps are carried out after step la) and before step lb): aa) applying a layer containing lignocellulose-containing coarse particles ( A ¹ ); and ab) applying a layer (B ') containing lignocellulose-containing fine particles.

(Figures 5, 6; chipboard, thermoplastic on one side, top)

8. The method according to claim 7, wherein the layers applied according to feature 7aa) and / or according to feature 7ab) contain powdered thermoplastic polymer with powder particle sizes <2000 micrometers (pm) or a liquid containing electron beam reactive polymer.

9. Apparatus for producing a lignocellulose-containing plastic-coated and printable molded part (26), in particular in plate form, comprising: a) a particle spreader (32) for producing a layer (A, B ') which contains lignocellulosic particles corresponding to the shape of the molded part to be produced (26); b) a particle scatterer (30) for applying a layer (C) of particles which contain electron beam-reactive thermoplastic to the layer produced according to the above feature; c) a heater (18) for heating the layers (A, C) produced according to the above features in such a way that thermoplastic particles melt into the layer containing lignocellulose-containing particles (Cs); d) a press (20) for pressing the layers heated according to feature (1c); and e) an electron emitter (22) for irradiating the layers pressed according to feature (ld) with electrons in the energy range from 1 MeV to 10 MeV.

(Fig. 9, 10; MDF, one-sided, thermoplastic, top)

10. The device according to claim 9, wherein in front of the particle spreader according to feature 9a) a particle spreader (30) is arranged for generating a layer (C) from particles which contain electron beam reactive thermoplastic.

(Figures 7, 8; MDF, thermoplastic, both sides)

11. Device according to one of claims 9 or 10, wherein the layer produced with the particle scatterer according to feature 9a) contains electron beam reactive powdery thermoplastic polymer with powder particle sizes <2000 micrometers (pm) or a liquid containing electron beam reactive powder.

12. The device according to claim 10, wherein the particle spreader according to feature 9b) is omitted.

13. Device according to one of claims 9 or 11, wherein the particle scatterers according to features 9a) and 9b) are interchanged in the order of the arrangement.

14. Device according to one of claims 9 to 13, wherein the ^{layer (B ') produced with the powder ¬} sprinkler according to feature 9a) contains lignocellulose-containing fine particles and in the arrangement of said particle spreader after the particle spreader according to feature 9a) and before the particle spreader according to feature 9b) comprises at ^¬ is ordered: aa) a particle spreader (14) for applying a coarse ^¬ lignocellulose particle-containing layer (a '); and ab) a particle spreader (12 ') for applying a lignocellulose-containing fine-particle-containing layer ^¬ (B').

(Figures 5, 6; chipboard, thermoplastic on one side, top)

15. The apparatus of claim 14, wherein the according to feature 14aa) and / or according to feature 14ab) applied layers powdered thermoplastic polymer included with powder particle sizes <2000 microns (pm) or a elekt ^¬ Ronen beam reactive polymer-containing liquid.

16. The method or device according to any one of the preceding claims, characterized by printing the molded part produced by laser beam printing or inkjet printing.