EP2083975B1 - Light wood materials with good mechanical characteristics and method of producing the same - Google Patents

Light wood materials with good mechanical characteristics and method of producing the same Download PDF

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Publication number
EP2083975B1
EP2083975B1 EP20070821531 EP07821531A EP2083975B1 EP 2083975 B1 EP2083975 B1 EP 2083975B1 EP 20070821531 EP20070821531 EP 20070821531 EP 07821531 A EP07821531 A EP 07821531A EP 2083975 B1 EP2083975 B1 EP 2083975B1
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EP
European Patent Office
Prior art keywords
wood
weight
containing material
light wood
range
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EP20070821531
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German (de)
French (fr)
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EP2083975A1 (en
Inventor
Michael Schmidt
Michael Finkenauer
Günter Scherr
Frank Braun
Stephan WEINKÖTZ
Maxim Peretolchin
Jürgen von Auenmüller
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BASF SE
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BASF SE
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Priority to EP20070821531 priority Critical patent/EP2083975B1/en
Priority to PL07821531T priority patent/PL2083975T3/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/005—Manufacture of substantially flat articles, e.g. boards, from particles or fibres and foam
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249971—Preformed hollow element-containing
    • Y10T428/249972—Resin or rubber element
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/253—Cellulosic [e.g., wood, paper, cork, rayon, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/254—Polymeric or resinous material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
    • Y10T428/2991—Coated
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/3188—Next to cellulosic
    • Y10T428/31895—Paper or wood
    • Y10T428/31899—Addition polymer of hydrocarbon[s] only
    • Y10T428/31902—Monoethylenically unsaturated
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31975—Of cellulosic next to another carbohydrate
    • Y10T428/31978—Cellulosic next to another cellulosic
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31975—Of cellulosic next to another carbohydrate
    • Y10T428/31978—Cellulosic next to another cellulosic
    • Y10T428/31982—Wood or paper
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31989—Of wood

Definitions

  • the present invention relates to a light wood-containing material having an average density in the range of 200 to 600 kg / m 3 according to claim 1.
  • the present invention relates to a multilayer wood material containing the wood-containing material according to the invention according to claim 7, a process for the preparation of light wood-containing materials according to claim 10, a process for producing a multilayer wood material according to claim 11, the use of light wood-containing material according to the invention and of the multilayer wood material according to the invention according to claims 12 and 13.
  • Wood-based materials in particular multilayer wood-based materials, are a cost-effective and resource-saving alternative to solid wood and have gained great importance in particular in furniture construction, in laminate flooring and as building materials.
  • As starting materials serve wood particles of different strengths, eg. As wood chips or wood fibers from different woods. Such wood particles are usually pressed with natural and / or synthetic binders and optionally with the addition of further additives to plate or strand-shaped wood materials.
  • Light wood-based materials lead to lower transport and packaging costs, and material costs can be saved in the production of lightweight wood-based materials.
  • Light wood-based panels can, for example, when used in means of transport lead to lower energy consumption of these means of transport. Further, using lightweight wood-based materials, for example, costly decorative parts such as thicker worktops and kitchen cheeks that are currently in vogue can be offered more cheaply.
  • tube chipboard and honeycomb panels are mentioned. Due to their special properties, tube chipboards are mainly used in the manufacture of doors as an inner layer.
  • honeycomb panel for example, the too low screw extraction resistance, the difficulty attaching fittings and the difficulties in edging.
  • Lightweight and pressure-resistant molding materials consist of wood chips or fibers, a binder and serving as a filler porous plastic.
  • the wood chips or fibers are mixed with binders and foamable or partially foamable plastics, and the resulting mixture is compressed at elevated temperature.
  • Binders are all customary binders for gluing wood, such as urea-formaldehyde resins.
  • Suitable fillers are foamable or already foamed plastic particles, preferably expandable thermoplastics such as styrene polymers.
  • the plates described in the examples have a thickness of 18 to 21 mm, a density of 220 kg / m 3 to 430 kg / m 3 and an average bending strength of 3.6 N / mm 2 to 17.7 N / mm 2 on. Cross tensile strengths are not specified. Foamed plastic particles obtained by comminution of moldings are expressed CH 370229 Not.
  • WO 02/38676 describes a process for the preparation of light products, in which 5 to 40 wt .-% foamable or already foamed polystyrene having a particle size of less than 1 mm, 60 to 95 wt .-% lignocellulosic material and binder mixed and at elevated temperature and elevated pressure be pressed to the finished product. The usual binders are mentioned. Foamed plastic particles obtained by comminution of moldings are expressed WO 02/38676 Not.
  • JP 06031708 describes light wood materials, wherein for the middle layer of a three-layer chipboard, a mixture of 100 parts by weight of wood particles and 5 to 30 parts by weight of synthetic resin foam particles are used, these resin particles having a specific gravity of not more than 0.3 g / cm 3 and compressive strength of at least 30 kg / cm 2 . Further, it is described that the specific gravity of the wood particles should not exceed 0.5 g / cm 3 .
  • the binders are loud JP 06031708 no restrictions. Foamed plastic particles obtained by comminution of moldings are expressed JP 06031708 Not.
  • Too low mechanical strength for example, lead to breaking or cracking of the components. Furthermore, these components tend during drilling or sawing to additional flaking of further wood material. Fastening hardware is difficult with these materials.
  • the object of the present invention was to show light wood-containing materials and light wood materials, which in comparison to the commercial
  • Wood materials have lower density with good mechanical strength and good processing properties.
  • the mechanical strength can be determined, for example, by measuring the transverse tensile strength according to DIN EN 319 or the bending strength according to DIN EN 310.
  • these lightweight wood-based materials should preferably be producible using domestic European woods.
  • the swelling value of the light wood materials should not be adversely affected by the reduced density.
  • the object has been achieved by a light wood-containing material having an average density in the range from 200 to 600 kg / m 3 according to claim 1.
  • the sum of components A) to D) is 100% by weight and is based on the solids of the wood-containing substance.
  • the wood-containing substance may contain the usual small amounts of water (in a usual small range of variation); This water is not included in the weight of the present application.
  • the weight of the wood particles refers to, in the usual manner known to those skilled, dried wood particles.
  • the weight specification of the binder C relates to the solids content of the corresponding component (determined by evaporation of the water at 120 ° C., within 2 h, for example, Günter Zeppenfeld, Dirk Grunwald, Klebstoffe in Wood and furniture industry, 2nd edition, DRW-Verlag, page 268).
  • the weight of the binder C) refers to this Sustanz in terms of organic isocyanate having at least two isocyanate groups per se, ie without consideration of, for example, solvent.
  • the light wood-containing substances according to the invention have an average density of 200 to 600 kg / m 3 , preferably 200 to 575 kg / m 3 , particularly preferably 250 to 550 kg / m 3 , in particular 300 to 500 kg / m 3 .
  • the transverse tensile strength of the light wood-containing materials according to the invention or preferably of the multilayer wood-base materials according to the invention is in the range from 0.1 N / mm 2 to 1.0 N / mm 2 , preferably 0.3 to 0.8 N / mm 2 , particularly preferably 0 , 30 to 0.6 N / mm 2 .
  • the flexural strength of the light wood-containing materials according to the invention or preferably of the multilayer wood-base materials according to the invention is in the range of 3 N / mm 2 to 30 N / mm 2 , preferably 5 to 25 N / mm 2 , particularly preferably 9 to 20 N / mm 2 .
  • the determination of the bending strength is according to DIN EN 310.
  • multilayer wood materials are all materials into consideration, which are made of wood veneer, preferably with an average density of the wood veneer from 0.4 to 0.85 g / cm 3 , for example, veneer or plywood boards or Laminated Veneer Lumber (LVL).
  • wood veneer preferably with an average density of the wood veneer from 0.4 to 0.85 g / cm 3 , for example, veneer or plywood boards or Laminated Veneer Lumber (LVL).
  • VLL Laminated Veneer Lumber
  • multilayer wood materials are particularly all materials into consideration, which are made of wood chips, preferably with a mean density of wood chips from 0.4 to 0.85 g / cm 3 , for example chipboard or OSB boards, and wood fiber materials such as LDF, MDF and HDF plates. Particleboard and fiberboard, in particular chipboard, are preferred.
  • the average density of the wood particles of component A) is generally 0.4 to 0.85 g / cm 3 , preferably 0.4 to 0.75 g / cm 3 , in particular 0.4 to 0.6 g / cm 3 .
  • spruce, beech, pine, larch, linden, poplar, ash, chestnut or fir wood are very suitable; spruce and / or beech wood, in particular spruce wood, are preferred.
  • the dimensions of the wood particles are not critical according to the current state of knowledge and, as usual, are based on the wood material to be produced, for example the wood-based materials mentioned above, such as chipboard or OSB.
  • filler B are foamable yet compact or already foamed plastic particles, preferably thermoplastic plastic particles in question. But it can also be used plastic particles that are in any intermediate stage of foaming.
  • Filler B contains plastic foam particles which can be obtained from moldings, for example from polyurethane foam moldings, polyethylene foam moldings, polypropylene foam moldings or preferably polystyrene foam moldings, by comminution, preferably grinding, in an amount in the range from 15% by weight to 85% by weight. -%, particularly preferably in the range of 25 wt .-% to 75 wt .-%, most preferably in the range of 40 wt .-% to 60 wt .-%, each based on the component B).
  • plastic particles according to the invention are referred to below as plastic particles according to the invention.
  • foamed plastic or especially foam is explained, for example, in DIN 7726: 1982-05.
  • Suitable polymers on which the plastic particles according to the invention are based are all polymers, preferably thermoplastic polymers, which can be foamed. These are known to the person skilled in the art.
  • Highly suitable such polymers are, for example, PVC (hard and soft), polycarbonates, polyisocyanurates, polycarbodiimides, polyacrylimides and polymethacrylimides, polyamides, polyurethanes, aminoplast resins and phenolic resins, styrene homopolymers, styrene copolymers, C 2 -C 10 -olefin homopolymers, C 2 -C 10 -olefin copolymers and polyester.
  • the 1-alkenes for example ethylene, propylene, 1-butene, 1-hexene, 1-octene, are preferably used for the preparation of said olefin polymers.
  • the plastic particles of component B) according to the invention have a bulk density of from 10 to 150 kg / m 3 , preferably from 15 to 80 kg / m 3 , particularly preferably from 20 to 70 kg / m 3 , in particular from 30 to 60 kg / m 3 .
  • the bulk density is usually determined by weighing a volume filled with the bulk material.
  • Foamed plastic particles according to the invention are generally used in the form of spheres or beads having an average diameter of advantageously 0.25 to 10 mm, preferably 0.5 to 5 mm, in particular 0.75 to 3 mm.
  • Prefabricated plastic particle beads according to the invention advantageously have a small surface area per volume, for example in the form of a spherical or elliptical particle.
  • the prefoamed plastic particle beads according to the invention are advantageously closed-celled.
  • the open cell density according to DIN-ISO 4590 is usually less than 30%.
  • Plastic foam particles which can be obtained from shaped articles, for example from polyurethane foam moldings, polyethylene foam moldings, polypropylene foam moldings or preferably polystyrene foam moldings, by comminution, preferably grinding, are generally irregular in shape but can also be spherical.
  • filler B from different types of polymers, so polymer types which are based on different monomers (for example, polystyrene and polyethylene or polystyrene and homo-polypropylene or polyethylene and homo-polypropylene), they may be present in different weight ratios, however, according to the current state of the Knowledge, not critical.
  • thermoplastics of the invention additives, nucleating agents, plasticizers, flame retardants, soluble and insoluble inorganic and / or organic dyes and pigments, for.
  • IR absorbers such as carbon black, graphite or aluminum powder, are added together or spatially separated as additives.
  • Polystyrene and / or styrene copolymer in each case including those which are obtained by comminution of shaped bodies, are preferably used as the sole inventive plastic particle component in filler B).
  • the filler polystyrene and / or styrene copolymer can be prepared by all polymerization processes known to those skilled in the art [see, for example, US Pat. B. Ullmann's Encyclopedia, Sixth Edition, 2000 Electronic Release]. For example, the preparation is carried out in a conventional manner by suspension polymerization or by extrusion.
  • styrene In the suspension polymerization, styrene, optionally with the addition of further comonomers in aqueous suspension, is polymerized in the presence of a customary suspension stabilizer by means of free-radical-forming catalysts.
  • the propellant and optionally further additives may be included in the polymerization be added to the batch in the course of the polymerization or after completion of the polymerization.
  • the resulting bead-shaped expandable styrene polymers are separated from the aqueous phase after the end of the polymerization, washed, dried and sieved.
  • the blowing agent is mixed for example via an extruder in the polymer, conveyed through a nozzle plate and granulated into particles or strands.
  • blowing agents are all blowing agents known to those skilled in the art, for example C 3 to C 6 hydrocarbons, such as propane, n-butane, isobutane, n-pentane, isopentane, neopentane and / or hexane, alcohols, ketones, ethers or halogenated hydrocarbons , Preferably, a commercially available pentane isomer mixture is used.
  • styrene polymers additives, nucleating agents, plasticizers, flame retardants, soluble and insoluble inorganic and / or organic dyes and pigments, for.
  • IR absorbers such as carbon black, graphite or aluminum powder, are added together or spatially separated as additives.
  • styrene copolymers these styrene copolymers advantageously have at least 50% by weight, preferably at least 80% by weight, of copolymerized styrene.
  • comonomers come z.
  • ⁇ -methyl styrene ring halogenated styrenes, acrylonitrile, esters of acrylic or methacrylic acid of alcohols having 1 to 8 carbon atoms, N-vinylcarbazole, maleic acid (anhydride), (meth) acrylamides and / or vinyl acetate into consideration.
  • the polystyrene and / or styrene copolymer in copolymerized form contain a small amount of a chain splitter, d. H. a compound having more than one, preferably two, double bonds, such as divinylbenzene, butadiene and / or butanediol diacrylate.
  • the branching agent is generally used in amounts of from 0.005 to 0.05 mole percent, based on styrene.
  • styrene (co) polymers having molecular weights and molecular weight distributions as described in US Pat EP-B 106 129 and in DE-A 39 21 148 are described. Preference is given to using styrene (co) polymers having a molecular weight in the range from 190,000 to 400,000 g / mol.
  • Mixtures of different styrene (co) polymers can also be used.
  • styrene polymers are glassy polystyrene (GPPS), impact polystyrene (HIPS), anionically polymerized polystyrene or toughened polystyrene (A-IPS), styrene- ⁇ -methylstyrene copolymers, acrylonitrile-butadiene-styrene polymers (ABS), styrene-acrylonitrile (SAN), acrylonitrile-styrene-acrylic esters (ASA), methyl acrylate-butadiene-styrene (MBS), methyl methacrylate-acrylonitrile-butadiene-styrene (MABS) polymers or mixtures thereof or with polyphenylene ether (PPE).
  • GPPS glassy polystyrene
  • HIPS impact polystyrene
  • A-IPS anionically polymerized polystyrene or toughened polystyrene
  • ABS acrylonit
  • polystyrene Neopor ® and / or Peripor ® from BASF Aktiengesellschaft is particularly preferred ® Styrofoam used.
  • Pre-expanded polystyrene and / or styrene copolymers are advantageously used.
  • the prefoamed polystyrene can be prepared by all methods known to the person skilled in the art (for example DE 845 264 ).
  • the expandable styrene polymers are expanded in a known manner by heating to temperatures above their softening point, for example with hot air or preferably steam.
  • the prefoamed polystyrene or prefoamed styrene copolymer of component B) and the plastic particles of component B according to the invention obtained by comminution of corresponding polystyrene or styrene copolymer molded articles advantageously have a bulk density of 10 to 150 kg / m 3 , preferably 15 to 80 kg / m 3 , more preferably 20 to 70 kg / m 3 , in particular 30 to 60 kg / m 3 .
  • the prefoamed polystyrene or prefoamed styrene copolymer is advantageously used in the form of spheres or beads having an average diameter of advantageously 0.25 to 10 mm, preferably 0.5 to 5 mm, in particular 0.75 to 3 mm.
  • the prefoamed polystyrene or prefoamed styrene copolymer spheres advantageously have a small surface area per volume, for example in the form of a spherical or elliptical particle.
  • the prefoamed polystyrene or prefoamed styrene copolymer spheres are advantageously closed-cell.
  • the open cell density according to DIN-ISO 4590 is usually less than 30%.
  • foamed polystyrene or foamed styrene copolymer moldings of foamed styrene polymer or styrene copolymer can serve. These can be comminuted with the usual comminution methods to the degree of the individual styrene polymer or styrene copolymer particles, preferably spherical. A well suited and preferred shredding method is milling.
  • Moldings of foamed styrene polymer or styrene copolymer can be prepared by the known methods and serve, for example, as packaging material or insulating material.
  • foamed styrene polymer or styrene copolymer molded articles intended for disposal for example, styrene polymer or styrene copolymer packaging waste or styrene polymer or styrene copolymer insulating waste, may be used.
  • the polystyrene or styrene copolymer or the prefoamed polystyrene or prefoamed styrene copolymer has an antistatic coating.
  • antistatic agents the usual and common in the art substances can be used. Examples are N, N-bis (2-hydroxyethyl) -C 12 -C 18 -alkylamines, fatty acid diethanolamides, choline ester chlorides of fatty acids, C 12 -C 20 -alkyl sulfonates, ammonium salts.
  • Suitable ammonium salts contain on nitrogen in addition to alkyl groups 1 to 3 hydroxyl-containing organic radicals.
  • Suitable quaternary ammonium salts are, for example, those having on the nitrogen cation 1 to 3, preferably 2, identical or different alkyl radicals having 1 to 12, preferably 1 to 10 carbon atoms, and 1 to 3, preferably 2 identical or different hydroxyalkyl or hydroxyalkylpolyoxyalkylene Radicals bound with any anion, such as chloride, bromide, acetate, methyl sulfate or p-toluenesulfonate.
  • hydroxyalkyl and hydroxyalkyl-polyoxyalkylene radicals are those which are formed by oxyalkylation of a nitrogen-bonded hydrogen atom and are derived from 1 to 10 oxyalkylene radicals, in particular oxyethylene and oxypropylene radicals.
  • An antistatic agent which is particularly preferred is a quaternary ammonium salt or an alkali metal salt, in particular the sodium salt of a C 12 -C 20 alkanesulfonate, eg. B emulsifier K30 from Bayer AG, or mixtures thereof.
  • the antistatic agents can generally be added both as a pure substance and in the form of an aqueous solution.
  • the antistatic agent can be added in the process for the preparation of polystyrene or styrene copolymer analogously to the customary additives or applied after the preparation of the polystyrene particles as a coating.
  • the antistatic agent is advantageously used in an amount of 0.05 to 6 wt .-%, preferably 0.1 to 4 wt .-%, based on the polystyrene or styrene copolymer.
  • the filler particles B) are advantageous even after pressing to light wood material, preferably multi-layer wood material, in a state in which their original shape is still recognizable.
  • the total amount of filler B), based on the light wood-containing material, is in the range of 1 to 25 wt .-%, preferably 2 to 15 wt .-%, particularly preferably 3 to 12 wt .-%.
  • the total amount of filler B) with polystyrene and / or styrene copolymer, in each case including that which is obtained by comminuting shaped bodies, as the only plastic particle component, based on the light wood-containing substance, is in the range from 1 to 25% by weight, preferably 2 to 15 wt .-%, particularly preferably 3 to 12 wt .-%.
  • binder C it is possible to use all binders known to the person skilled in the art for the production of wood-based materials, for example aminoplast resins and / or organic isocyanates, such as PMDI.
  • the binder C) contains the substances generally known to the person skilled in the art for aminoplast resins and commonly referred to as hardeners, such as ammonium sulfate or ammonium nitrate or inorganic or organic acids, for example sulfuric acid, formic acid or acid regenerating substances, such as aluminum chloride, aluminum sulfate in the usual, small amounts, for example in the range of 0.1 wt .-% to 3 wt .-%, based on the total amount of aminoplast resin in the binder C).
  • hardeners such as ammonium sulfate or ammonium nitrate or inorganic or organic acids, for example sulfuric acid, formic acid or acid regenerating substances, such as aluminum chloride, aluminum sulfate in the usual, small amounts, for example in the range of 0.1 wt .-% to 3 wt .-%, based on the total amount of aminoplast resin in the binder C).
  • aminoplast resin are here polycondensation products of compounds having at least one, optionally partially substituted with organic radicals, carbamide group (the carbamide group is also called carboxamide) and an aldehyde, preferably formaldehyde understood.
  • aminoplast resins As a suitable aminoplast resin, all of the specialist, preferably known for the production of wood materials, aminoplast resins can be used. Such resins and their preparation are, for example, in Ullmann's Encyclopedia of Industrial Chemistry, 4th, revised and expanded edition, Verlag Chemie, 1973, pages 403 to 424 "aminoplasts " and Ullmann's Encyclopedia of Industrial Chemistry, Vol. A2, VCH Verlagsgesellschaft, 1985, pages 115 to 141 "Amino Resins " as in M. Dunky, P. Niemz, wood materials and glues, Springer 2002, pages 251 to 259 (UF resins) and pages 303 to 313 (MUF and UF with a small amount of melamine).
  • Preferred aminoplast resins are polycondensation products of compounds having at least one, also partially substituted by organic radicals, carbamide group and formaldehyde.
  • aminoplast resins are urea-formaldehyde resins (UF resins), melamine-formaldehyde resins (MF resins) or melamine-containing urea-formaldehyde resins (MUF resins).
  • UF resins urea-formaldehyde resins
  • MF resins melamine-formaldehyde resins
  • UMF resins melamine-containing urea-formaldehyde resins
  • urea-formaldehyde resins for example Kaurit ® glue types from BASF Aktiengesellschaft.
  • very preferred aminoplast resins are polycondensation products of compounds having at least one, also partially substituted by organic radicals, amino group and aldehyde, wherein the molar ratio of aldehyde: optionally partially substituted with organic groups amino group in the range of 0.3 to 1.0, preferably 0.3 to 0.60, more preferably 0.3 to 0.45, most preferably 0.30 to 0.40.
  • very preferred aminoplast resins are polycondensation products of compounds having at least one amino group -NH 2 and formaldehyde, wherein the molar ratio of formaldehyde: -NH 2 group in the range of 0.3 to 1.0, preferably 0.3 to 0.60, especially preferably 0.3 to 0.45, very particularly preferably 0.30 to 0.40.
  • very preferred amino resins are urea-formaldehyde resins (UF resins), melamine-formaldehyde resins (MF resins) or melamine-containing urea-formaldehyde resins (MUF resins), wherein the molar ratio of formaldehyde: -NH 2 group in the range of 0.3 to 1.0, preferably 0.3 to 0.60, more preferably 0.3 to 0.45, most preferably 0.30 to 0.40.
  • UF resins urea-formaldehyde resins
  • MF resins melamine-formaldehyde resins
  • MMF resins melamine-containing urea-formaldehyde resins
  • very preferred aminoplast resins are urea-formaldehyde resins (UF resins), wherein the molar ratio of formaldehyde: -NH 2 group in the range of 0.3 to 1.0, preferably 0.3 to 0.60, particularly preferably 0.3 to 0.45, most preferably 0.30 to 0.40.
  • UF resins urea-formaldehyde resins
  • aminoplast resins mentioned are usually suspended in liquid form, usually in a liquid suspending agent or dissolved, preferably in aqueous suspension or solution, but can also be used as a solid.
  • the solids content of the aminoplast resin suspensions is usually from 25 to 90% by weight, preferably from 50 to 70% by weight.
  • the solids content of the aminoplast resin in aqueous suspension can be determined according to Günter Zeppenfeld, Dirk Grunwald, adhesives in the wood and furniture industry, 2nd edition, DRW-Verlag, page 268.
  • To determine the solids content of aminoplast glues 1 g of aminoplast glue is weighed exactly into a weighing dish, finely distributed on the bottom and dried for 2 hours at 120 ° C. in a drying oven. After tempering to room temperature in a desiccator, the residue is weighed and calculated as a percentage of the initial weight.
  • the aminoplast resins are prepared by known processes (see above Ullmann-Literatur “Aminoplasts” and “Amino Resins”, as well as literature Dunky et al.) By reacting the carbamido-containing compounds, preferably urea and / or melamine, with the aldehydes, preferably formaldehyde, in the desired molar ratios carbamide group: aldehyde, preferably in water as a solvent.
  • aldehyde preferably formaldehyde: optionally partially substituted with organic radicals amino group
  • NH 2 group-carrying monomers are preferably urea, melamine, more preferably urea.
  • the total amount of the binder C), based on the light wood-containing substance is in the range from 0.1 to 50% by weight, preferably 0.5 to 15% by weight, particularly preferably 0.5 to 10% by weight. ,
  • the total amount of the aminoplast resin (always based on the solid), preferably the urea-formaldehyde resin and / or melamine-urea-formaldehyde resin and / or melamine-formaldehyde resin, particularly preferably urea-formaldehyde resin, in the binder C), based on the light wood-containing Substance in the range of 1 to 45 wt .-%, preferably 4 to 14 wt .-%, particularly preferably 6 to 9 wt .-%.
  • an organic isocyanate is a single or further constituent of the binder C
  • the total amount of the organic isocyanate preferably of the oligomeric isocyanate having 2 to 10, preferably 2 to 8 monomer units and an average of at least one isocyanate group per monomer unit, more preferably PMDI, in the binder C), based on the light wood-containing material in the range of 0.1 to 5 wt .-%, preferably 0.25 to 3.5 wt .-%, particularly preferably 0.5 to 1.5 wt .-%.
  • Preferred embodiments of the light wood-containing material contain (i) 55 to 92.5 wt .-%, preferably 60 to 90 wt .-%, in particular 70 to 88 wt .-%, based on the light wood-containing material, wood particles A), wherein the wood particles A) have an average density of 0.4 to 0.85 g / cm 3 , preferably 0.4 to 0.75 g / cm 3 , in particular 0.4 to 0.6 g / cm 3 ; (Ii) 1 to 25 wt .-%, preferably 2 to 15 wt .-%, in particular 3 to 12 wt .-% based on the light wood-containing material, polystyrene and / or styrene copolymer filler B), wherein the filler B) a Bulk density of 10 to 150 kg / m 3 , preferably 20 to 80 kg / m 3 , in particular 30 to 60 kg / m 3 and wherein the filler B) by
  • component D) in the light wood-containing substance or multilayer wood material according to the invention for example water repellents, such as paraffin emulsions, antifungal agents and flame retardants.
  • the average density of the multilayer, preferably of the three-layer, wood material according to the invention is in the range of 300 kg / m 3 to 600 kg / m 3 , preferably in the range of 350 kg / m 3 to 600 kg / m 3 , particularly preferably in the range of 400 kg / m 3 to 500 kg / m 3 .
  • Middle layers in the sense of the invention are all layers that are not the outer layers.
  • the outer layers (usually called “cover layer (s)" have no fillers.
  • the multilayer wood material according to the invention contains three layers of wood pulp, wherein the outer cover layers together make up 1 to 25% of the total thickness of the multilayer wood material according to the invention, preferably 3 to 20%, in particular 5 to 15%.
  • the binder used for the outer layers is usually an aminoplast resin, for example urea-formaldehyde resin (UF), melamine-formaldehyde resin (MF), melamine-urea-formaldehyde resin (MUF) or the binder C according to the invention.
  • the binder used for the outer layers is an aminoplast resin, more preferably a urea-formaldehyde resin, most preferably an aminoplast resin wherein the molar formaldehyde: -NH 2 group ratio is in the range of 0.3 to 1.0.
  • the thickness of the multilayer wood material according to the invention varies with the field of application and is generally in the range of 0.5 to 100 mm; preferably in the range of 10 to 40 mm, in particular 15 to 20 mm.
  • the present invention relates to a method for producing multilayer wood products according to the invention as defined above, wherein the components for the individual layers are stacked and pressed under elevated temperature and elevated pressure.
  • the chips After cutting the wood, the chips are dried. Thereafter, if necessary, coarse and fines are removed. The remaining chips are sorted by sieving or sifting in the air stream.
  • the coarser material is used for the middle layer, the coarser material for the cover layers.
  • Middle layer and outer layer chips are glued separately from each other with the components B) (only the middle layer (s)), C) (middle layer) and optionally D) (middle layer and / or outer layers) and with an aminoplast resin (top layer), or mixed and then scattered.
  • the cover layer material is scattered on the forming belt, then the middle layer material - containing the components B), C) and optionally D) - and finally once more cover layer material.
  • the three-layer chip cake thus produced is precompressed cold (usually at room temperature) and then pressed hot.
  • the pressing can be carried out by all methods known to the person skilled in the art. Usually, the wood particle cake is pressed at a press temperature of 150 ° C to 230 ° C to the desired thickness.
  • the pressing time is normally 3 to 15 seconds per mm plate thickness. This gives a three-layer chipboard.
  • Preferred parameter ranges and preferred embodiments with regard to the average density of the light wood-containing material, the multilayer wood-based material and with regard to the components A), B), C) and optionally D) and the combination of the features correspond to those described above.
  • the pre-foamed or non-pre-foamed polystyrene and / or styrene copolymer is provided with an antistatic coating prior to mixing with the binder and / or the wood particles.
  • an antistatic coating the above applies.
  • the present invention relates to the use of the light wood-containing material according to the invention and the multilayer wood material according to the invention for the production of objects of all kinds, for example furniture, furniture parts or packaging materials, the use of light wood-containing material according to the invention and the multilayer wood material according to the invention in the construction sector.
  • objects of all kinds for example furniture, furniture parts or packaging materials
  • items of all kinds include furniture, furniture parts and packaging materials, wall and ceiling panels, doors and floors.
  • Examples of furniture or furniture parts are kitchen furniture, cabinets, chairs, tables, countertops, for example for kitchen furniture, desk tops.
  • packaging materials are boxes, boxes. '
  • Examples of the construction sector are structural engineering, civil engineering, interior construction, tunneling, where the wood-containing materials or multilayer wood-based materials according to the invention can be used as shuttering panels or as a carrier.
  • the advantages of the present invention lie in the low density of the light wood-containing material or multilayer wood material according to the invention, wherein a good mechanical stability is maintained.
  • the wood-containing material according to the invention or the multilayer wood-based material according to the invention exhibits good transverse tensile values in conjunction with good flexural strength values.
  • the light wood-containing material and multi-layer wood material according to the invention can be easily produced; there is no need to retrofit the existing plants for the production of the multilayer wood-based materials according to the invention.
  • the Bekant zucchini the light wood-containing materials according to the invention or especially of the multilayer wood materials adheres particularly well and is not uneven or wavy, the narrow surface, in particular of the multilayer wood material, is not characterized by the edge through, the edge is pressure-stable and edging can be done with the usual machines of plate making and edging.
  • the swelling values of the multilayer wood-base materials according to the invention are advantageously 10% smaller, preferably 20% smaller, in particular 30% smaller than the swelling values of an analogous plate of the same density without filler.
  • glues was urea-formaldehyde glue (glue Kaurit ® 340 from BASF Aktiengesellschaft) were used. The solids content was adjusted in each case with water to 67 wt .-%. For details see also in the table.
  • a mixer 450 g of chips (component A)) were mixed according to the table and optionally component B) according to the table. Subsequently, 58.8 g of a glue liquor comprising 100 parts Kaurit ® -Leim 340 and 4 parts of a 52% aqueous ammonium nitrate solution and 10 parts of water were applied.
  • the glued chips were cold pre-compacted in a 30x30cm-form. It was then pressed in a hot press (pressing temperature 190 ° C, pressing time 210 s). The nominal thickness of the plate was 16mm in each case.
  • the density was determined 24 hours after preparation according to DIN EN 1058.
  • the determination of the bending strength was carried out according to DIN EN 310.
  • the quantities always refer to the dry matter.
  • the dry wood or the sum of the dry wood and the filler is set to 100 parts.
  • the wt .-% the sum of all dry constituents of the light wood-containing substance is equal to 100%.

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  • Manufacturing & Machinery (AREA)
  • Wood Science & Technology (AREA)
  • Forests & Forestry (AREA)
  • Dry Formation Of Fiberboard And The Like (AREA)
  • Chemical And Physical Treatments For Wood And The Like (AREA)
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Abstract

Light, wood-containing material (I) with an average density of 200-600 kg/m 3>, comprises wood particles (a) (30-95 wt.%); fillers (b) (1-25 wt.%) with a bulk density of 10-150 kg/m 3>, from foamable plastic particles and plastic particles that are already foamed; binders (c) (0.1-50 wt.%); and optionally additives (d), where (b) contains foaming plastic particles (1-100 wt.%) gained by comminution from molds. Independent claims are included for: (1) a multilayer wood material, comprising at least three layers, where only middle layer or at least one part of the middle layer contains (I), and the external surface layer does not contain fillers; and (2) a preparation of (I) comprising mixing the components (a-d), and subsequently pressing under increased temperature and pressure.

Description

Die vorliegende Erfindung betrifft einen leiche holzhaltigen Stoff mit einer mittleren Dichte im Bereich von 200 bis 600 kg/m3 gemäß dem Anspruch 1. tigen Stoff:The present invention relates to a light wood-containing material having an average density in the range of 200 to 600 kg / m 3 according to claim 1. tigen substance:

Weiterhin betrifft die vorliegende Erfindung einen mehrschichtigen Holzwerkstoff enthaltend den erfindungsgemäßen holzhaltigen Stoff gemäß dem Anspruch 7 ein Verfahren zur Herstellung von leichten holzhaltigen Stoffen gemäß dem Anspruch 10, ein Verfahren zur Herstellung eines mehrschichtigen holzwerkstoffes gemäß dem Anspruch 11, die Verwendung des erfindungsgemäßen leichten holzhaltigen Stoffs und des erfindungsgemäßen mehrschichtigen Holzwerkstoffs gemäß dem Anspruchen 12 und 13.Furthermore, the present invention relates to a multilayer wood material containing the wood-containing material according to the invention according to claim 7, a process for the preparation of light wood-containing materials according to claim 10, a process for producing a multilayer wood material according to claim 11, the use of light wood-containing material according to the invention and of the multilayer wood material according to the invention according to claims 12 and 13.

Holzwerkstoffe, insbesondere mehrschichtige Holzwerkstoffe, sind eine kostengünstige und Ressourcen schonende Alternative zu Massivholz und haben große Bedeutung insbesondere im Möbelbau, bei Laminatfußboden und als Baumaterialien erlangt. Als Ausgangsstoffe dienen Holzpartikel unterschiedlicher Stärke, z. B. Holzspäne oder Holzfasern aus verschiedenen Hölzern. Solche Holzpartikel werden üblicherweise mit natürlichen und/oder synthetischen Bindemitteln und gegebenenfalls unter Zugabe weiterer Additive zu platten- oder strangförmigen Holzwerkstoffen verpresst.Wood-based materials, in particular multilayer wood-based materials, are a cost-effective and resource-saving alternative to solid wood and have gained great importance in particular in furniture construction, in laminate flooring and as building materials. As starting materials serve wood particles of different strengths, eg. As wood chips or wood fibers from different woods. Such wood particles are usually pressed with natural and / or synthetic binders and optionally with the addition of further additives to plate or strand-shaped wood materials.

Um gute mechanische Eigenschaften der Holzwerkstoffe zu erzielen, werden diese mit einer Dichte von ca. 650 kg/m3 und mehr hergestellt. Anwendern, insbesondere Privatkonsumenten, sind Holzwerkstoffe dieser Dichte oder die entsprechenden Teile, wie Möbel, oft zu schwer.In order to achieve good mechanical properties of the wooden materials, these are produced with a density of about 650 kg / m 3 and more. Users, especially private consumers, are often too heavy with wood-based materials of this density or the corresponding parts, such as furniture.

Der industrielle Bedarf an leichten Holzwerkstoffen ist daher in den letzten Jahren stetig gestiegen, insbesondere seit Mitnahmemöbel an Beliebtheit gewonnen haben. Ferner bedingt der steigende Ölpreis, der zu einer fortwährenden Verteuerung von beispielsweise den Transportkosten führt, ein verstärktes Interesse an leichten Holzwerkstoffen.The industrial demand for lightweight wood-based materials has therefore risen steadily in recent years, especially since pick-up furniture has gained in popularity. Furthermore, the rising price of oil, which leads to a constant increase in, for example, transport costs, has led to an increased interest in lightweight wood-based materials.

Zusammengefasst sind leichte Holzwerkstoffe aus den folgenden Gründen von großer Bedeutung:

  • Leichte Holzwerkstoffe führen zu einer einfacheren Handhabbarkeit der Produkte durch den Endkunden, beispielsweise beim Einpacken, Transportieren, Auspacken oder Aufbauen der Möbel.
In summary, lightweight wood-based materials are of great importance for the following reasons:
  • Lightweight wood-based materials result in easier handling of the products by the end customer, for example when packing, transporting, unpacking or constructing the furniture.

Leichte Holzwerkstoffe führen zu geringeren Transport- und Verpackungskosten, ferner können bei der Herstellung von leichten Holzwerkstoffen Materialkosten eingespart werden.Light wood-based materials lead to lower transport and packaging costs, and material costs can be saved in the production of lightweight wood-based materials.

Leichte Holzwerkstoffe können beispielsweise beim Einsatz in Transportmitteln zu einem geringeren Energieverbrauch dieser Transportmittel führen. Ferner können unter Verwendung von leichten Holzwerkstoffen beispielsweise materialaufwendige Dekorteile, wie derzeit in Mode gekommene dickere Arbeitsplatten und Wangen bei Küchen, kostengünstiger angeboten werden.Light wood-based panels can, for example, when used in means of transport lead to lower energy consumption of these means of transport. Further, using lightweight wood-based materials, for example, costly decorative parts such as thicker worktops and kitchen cheeks that are currently in vogue can be offered more cheaply.

Vor diesem Hintergrund besteht der Wunsch leichte Holzwerkstoffe mit geringerer Formaldehydemission aber nach wie vor guter Anwendungs- und Verarbeitungseigenschaften zur Verfügung zu stellen.Against this background, there is a desire to provide lightweight wood materials with lower formaldehyde emission but still good application and processing properties available.

Im Stand der Technik finden sich vielfältige Vorschläge, die Dichte der Holzwerkstoffe zu verringern.There are many proposals in the state of the art for reducing the density of wood-based materials.

Als leichte Holzwerkstoffe, die erhältlich sind durch konstruktive Maßnahmen, sind beispielsweise Röhrenspanplatten und Wabenplatten zu nennen. Durch ihre besonderen Eigenschaften kommen Röhrenspanplatten hauptsächlich bei der Herstellung von Türen als Innenlage zum Einsatz.As light wood materials, which are available by constructive measures, for example, tube chipboard and honeycomb panels are mentioned. Due to their special properties, tube chipboards are mainly used in the manufacture of doors as an inner layer.

Nachteilig bei der Wabenplatte ist zum Beispiel der zu geringe Schraubenauszugswiderstand, das erschwerte Befestigen von Beschlägen und die Schwierigkeiten bei der Bekantung.A disadvantage of the honeycomb panel, for example, the too low screw extraction resistance, the difficulty attaching fittings and the difficulties in edging.

Ferner finden sich im Stand der Technik Vorschläge, die Dichte der Holzwerkstoffe durch Zusätze zum Leim oder zu den Holzpartikeln zu verringern.Furthermore, there are proposals in the prior art to reduce the density of the wood materials by adding glue or to the wood particles.

In CH 370229 werden leichte und gleichzeitig druckfeste Formpressstoffe beschrieben, die aus Holzspänen oder -fasern, einem Bindemittel und einem als Füllstoff dienenden porösen Kunststoff bestehen. Zur Herstellung der Formpressstoffe werden die Holzspäne oder -fasern mit Bindemittel und verschäumbaren oder teilweise verschäumbaren Kunststoffen gemischt, und das erhaltene Gemisch bei erhöhter Temperatur verpresst. Als Bindemittel sind alle für die Verleimung von Holz geeigneten üblichen Bindemittel, wie beispielsweise Harnstoff-Formaldehyd-Harze, brauchbar. Als Füllstoffe kommen verschäumbare oder bereits verschäumte Kunststoffteilchen, bevorzugt expandierbare Thermoplaste wie Styrolpolymerisate, in Frage. Die in den Beispielen beschriebenen Platten weisen bei einer Dicke von 18 bis 21 mm, eine Dichte von 220 kg/m3 bis 430 kg/m3 und eine mittlere Biegefestigkeit von 3,6 N/mm2 bis 17,7 N/mm2 auf. Querzugsfestigkeiten werden nicht angegeben. Zu durch Zerkleinerung von Formkörpern gewonnene verschäumte Kunststoffteilchen äußert sich CH 370229 nicht.In CH 370229 Lightweight and pressure-resistant molding materials are described, which consist of wood chips or fibers, a binder and serving as a filler porous plastic. To produce the molding materials, the wood chips or fibers are mixed with binders and foamable or partially foamable plastics, and the resulting mixture is compressed at elevated temperature. Binders are all customary binders for gluing wood, such as urea-formaldehyde resins. Suitable fillers are foamable or already foamed plastic particles, preferably expandable thermoplastics such as styrene polymers. The plates described in the examples have a thickness of 18 to 21 mm, a density of 220 kg / m 3 to 430 kg / m 3 and an average bending strength of 3.6 N / mm 2 to 17.7 N / mm 2 on. Cross tensile strengths are not specified. Foamed plastic particles obtained by comminution of moldings are expressed CH 370229 Not.

WO 02/38676 beschreibt ein Verfahren zur Herstellung von leichten Produkten, in dem 5 bis 40 Gew.-% verschäumbares oder bereits verschäumtes Polystyrol mit einer Teilchengröße von kleiner 1 mm, 60 bis 95 Gew.-% lignocellulosehaltiges Material und Bindemittel vermischt und bei erhöhter Temperatur und erhöhtem Druck zu dem fertigen Produkt verpresst werden. Es werden die üblichen Bindemittel genannt. Zu durch Zerkleinerung von Formkörpern gewonnene verschäumte Kunststoffteilchen äußert sich WO 02/38676 nicht. WO 02/38676 describes a process for the preparation of light products, in which 5 to 40 wt .-% foamable or already foamed polystyrene having a particle size of less than 1 mm, 60 to 95 wt .-% lignocellulosic material and binder mixed and at elevated temperature and elevated pressure be pressed to the finished product. The usual binders are mentioned. Foamed plastic particles obtained by comminution of moldings are expressed WO 02/38676 Not.

JP 06031708 beschreibt leichte Holzwerkstoffe, wobei für die Mittelschicht einer Dreischichtspanplatte eine Mischung aus 100 Gewichtsteilen Holzpartikeln und 5 bis 30 Gewichtsteilen Partikeln aus synthetischem Harzschaum verwendet werden, wobei diese Harz-Partikel ein spezifisches Gewicht von nicht mehr als 0,3 g/cm3 und eine Druckfestigkeit von mindestens 30 kg/cm2 aufweisen. Ferner wird beschrieben, dass die spezifische Dichte der Holzpartikel einen Wert von 0,5 g/cm3 nicht überschreiten sollte. Die Bindemittel unterliegen laut JP 06031708 keinen Restriktionen. Zu durch Zerkleinerung von Formkörpern gewonnene verschäumte Kunststoffteilchen äußert sich JP 06031708 nicht. JP 06031708 describes light wood materials, wherein for the middle layer of a three-layer chipboard, a mixture of 100 parts by weight of wood particles and 5 to 30 parts by weight of synthetic resin foam particles are used, these resin particles having a specific gravity of not more than 0.3 g / cm 3 and compressive strength of at least 30 kg / cm 2 . Further, it is described that the specific gravity of the wood particles should not exceed 0.5 g / cm 3 . The binders are loud JP 06031708 no restrictions. Foamed plastic particles obtained by comminution of moldings are expressed JP 06031708 Not.

Der Nachteil des Standes der Technik besteht zusammengefasst darin, dass die beschriebenen leichten (Holz)Werkstoffe zum Beispiel für die Möbelherstellung eine zu geringe mechanische Festigkeit, wie beispielsweise einen zu geringen Schraubenauszugswiderstand, aufweisen.The disadvantage of the prior art is summarized in that the described light (wood) materials, for example, for the furniture manufacturing too low mechanical strength, such as a too low Schraubenauszugresistance have.

Eine zu geringe mechanische Festigkeit kann beispielsweise zum Brechen oder Reißen der Bauelemente führen. Ferner neigen diese Bauelemente beim Bohren oder Sägen zum zusätzlichen Abplatzen von weiterem Holzmaterial. Bei diesen Werkstoffen ist das Befestigen von Beschlägen erschwert.Too low mechanical strength, for example, lead to breaking or cracking of the components. Furthermore, these components tend during drilling or sawing to additional flaking of further wood material. Fastening hardware is difficult with these materials.

Auch im Hinblick auf die Kombination von guter Querzugfestigkeit mit guter Biegefestigkeit bleibt bei den Holzwerkstoffen des Standes der Technik Raum für Verbesserungen.Also with regard to the combination of good transverse tensile strength with good flexural strength remains in the wood materials of the prior art room for improvement.

Die Aufgabe der vorliegenden Erfindung bestand darin, leichte holzhaltige Stoffe und leichte Holzwerkstoffe aufzuzeigen, die eine im Vergleich zu den handelsüblichenThe object of the present invention was to show light wood-containing materials and light wood materials, which in comparison to the commercial

Holzwerkstoffen geringere Dichte aufweisen bei guten mechanischen Festigkeiten und guten Verarbeitungseigenschaften.Wood materials have lower density with good mechanical strength and good processing properties.

Die mechanische Festigkeit kann beispielsweise durch die Messung der Querzugsfestigkeit nach DIN EN 319 oder der Biegefestigkeit nach DIN EN 310 bestimmt werden.The mechanical strength can be determined, for example, by measuring the transverse tensile strength according to DIN EN 319 or the bending strength according to DIN EN 310.

Ferner sollten diese leichten Holzwerkstoffe vorzugsweise unter Verwendung von heimischen, europäischen Hölzern herstellbar sein.Furthermore, these lightweight wood-based materials should preferably be producible using domestic European woods.

Weiterhin sollte der Quellwert der leichten Holzwerkstoffe durch die verringerte Dichte nicht negativ beeinträchtigt werden.Furthermore, the swelling value of the light wood materials should not be adversely affected by the reduced density.

Die Aufgabe wurde gelöst durch einen leichten holzhaltigen Stoff mit einer mittleren Dichte im Bereich von 200 bis 600 kg/m3 gemäß dem Anspruch 1. tigen Stoff:The object has been achieved by a light wood-containing material having an average density in the range from 200 to 600 kg / m 3 according to claim 1.

Die Summe der Komponenten A) bis D) beträgt 100 Gew.-% und ist auf den Feststoff des holzhaltigen Stoffes bezogen.The sum of components A) to D) is 100% by weight and is based on the solids of the wood-containing substance.

Der holzhaltige Stoff kann die üblichen geringen Mengen Wasser (in einer üblichen geringen Schwankungsbreite) enthalten; dieses Wasser ist bei den Gewichtsangaben der vorliegenden Anmeldung nicht berücksichtigt.The wood-containing substance may contain the usual small amounts of water (in a usual small range of variation); This water is not included in the weight of the present application.

Die Gewichtsangabe der Holzpartikel bezieht sich auf, in üblicher, dem Fachmann bekannter Weise, getrocknete Holzpartikel.The weight of the wood particles refers to, in the usual manner known to those skilled, dried wood particles.

Die Gewichtsangabe des Bindemittels C) bezieht sich im Hinblick auf die Aminoplastkomponente im Bindemittel auf den Feststoffgehalt der entsprechenden Komponente (bestimmt durch Verdunsten des Wassers bei 120 °C, innerhalb von 2 h nach, zum Beispiel, Günter Zeppenfeld, Dirk Grunwald, Klebstoffe in der Holz- und Möbelindustrie, 2. Auflage, DRW-Verlag, Seite 268).With regard to the aminoplast component in the binder, the weight specification of the binder C) relates to the solids content of the corresponding component (determined by evaporation of the water at 120 ° C., within 2 h, for example, Günter Zeppenfeld, Dirk Grunwald, Klebstoffe in Wood and furniture industry, 2nd edition, DRW-Verlag, page 268).

Die Gewichtsangabe des Bindemittels C) bezieht sich im Hinblick auf organisches Isocyanat mit mindestens zwei Isocyanatgruppen auf diese Sustanz an sich, also ohne Berücksichtigung von beispielsweise Lösungsmittel.The weight of the binder C) refers to this Sustanz in terms of organic isocyanate having at least two isocyanate groups per se, ie without consideration of, for example, solvent.

Die erfindungsgemäßen leichten holzhaltigen Stoffe haben eine mittlere Dichte von 200 bis 600 kg/m3, bevorzugt 200 bis 575 kg/m3, besonders bevorzugt 250 bis 550 kg/m3, insbesondere 300 bis 500 kg/m3.The light wood-containing substances according to the invention have an average density of 200 to 600 kg / m 3 , preferably 200 to 575 kg / m 3 , particularly preferably 250 to 550 kg / m 3 , in particular 300 to 500 kg / m 3 .

Die Querzugsfestigkeit der erfindungsgemäßen leichten holzhaltigen Stoffe oder vorzugsweise der erfindungsgemäßen mehrschichtigen Holzwerkstoffe liegt im Bereich von 0,1 N/mm2, bis 1,0 N/mm2, bevorzugt 0,3 bis 0,8 N/mm2, besonders bevorzugt 0,30 bis 0,6 N/mm2.The transverse tensile strength of the light wood-containing materials according to the invention or preferably of the multilayer wood-base materials according to the invention is in the range from 0.1 N / mm 2 to 1.0 N / mm 2 , preferably 0.3 to 0.8 N / mm 2 , particularly preferably 0 , 30 to 0.6 N / mm 2 .

Die Bestimmung der Querzugsfestigkeit erfolgt nach DIN EN 319.The determination of the transverse tensile strength is in accordance with DIN EN 319.

Die Biegefestigkeit der erfindungsgemäßen leichten holzhaltigen Stoffe oder vorzugsweise der erfindungsgemäßen mehrschichtigen Holzwerkstoffe liegt im Bereich von 3 N/mm2, bis 30 N/mm2, bevorzugt 5 bis 25 N/mm2, besonders bevorzugt 9 bis 20 N/mm2.The flexural strength of the light wood-containing materials according to the invention or preferably of the multilayer wood-base materials according to the invention is in the range of 3 N / mm 2 to 30 N / mm 2 , preferably 5 to 25 N / mm 2 , particularly preferably 9 to 20 N / mm 2 .

Die Bestimmung der Biegefestigkeit erfolgt nach DIN EN 310.The determination of the bending strength is according to DIN EN 310.

Als mehrschichtige Holzwerkstoffe kommen alle Werkstoffe in Betracht, die aus Holzfurnieren, vorzugsweise mit einer mittleren Dichte der Holzfurniere von 0,4 bis 0,85 g/cm3, gefertigt sind, beispielsweise Furnierplatten oder Sperrholzplatten oder Laminated Veneer Lumber (LVL).As multilayer wood materials are all materials into consideration, which are made of wood veneer, preferably with an average density of the wood veneer from 0.4 to 0.85 g / cm 3 , for example, veneer or plywood boards or Laminated Veneer Lumber (LVL).

Als mehrschichtige Holzwerkstoffe kommen besonders alle Werkstoffe in Betracht, die aus Holzspänen, vorzugsweise mit einer mittleren Dichte der Holzspäne von 0,4 bis 0,85 g/cm3 gefertigt sind, beispielsweise Spanplatten oder OSB-Platten, sowie Holzfaserwerkstoffe wie LDF-, MDF- und HDF-Platten. Bevorzugt sind Spanplatten und Faserplatten, insbesondere Spanplatten.As multilayer wood materials are particularly all materials into consideration, which are made of wood chips, preferably with a mean density of wood chips from 0.4 to 0.85 g / cm 3 , for example chipboard or OSB boards, and wood fiber materials such as LDF, MDF and HDF plates. Particleboard and fiberboard, in particular chipboard, are preferred.

Die mittlere Dichte der Holzpartikel der Komponente A) liegt in der Regel bei 0,4 bis 0,85 g/cm3, bevorzugt bei 0,4 bis 0,75 g/cm3, insbesondere bei 0,4 bis 0,6 g/cm3.The average density of the wood particles of component A) is generally 0.4 to 0.85 g / cm 3 , preferably 0.4 to 0.75 g / cm 3 , in particular 0.4 to 0.6 g / cm 3 .

Für die Herstellung der Holzpartikel kommt jede beliebige Holzart in Frage; gut geeignet sind beispielsweise Fichten-, Buchen-, Kiefern-, Lärchen-, Linden-, Pappeln-, Eschen-, Kastanien- oder Tannenholz, bevorzugt sind Fichten- und/oder Buchenholz, insbesondere Fichtenholz.For the production of wood particles any wood species comes into question; For example, spruce, beech, pine, larch, linden, poplar, ash, chestnut or fir wood are very suitable; spruce and / or beech wood, in particular spruce wood, are preferred.

Die Dimensionen der Holzpartikel sind nach derzeitigem Kenntnisstand nicht kritisch und richten sich wie üblich nach dem herzustellenden Holzwerkstoff, zum Beispiel den oben genannten Holzwerkstoffen, wie Spanplatte oder OSB.The dimensions of the wood particles are not critical according to the current state of knowledge and, as usual, are based on the wood material to be produced, for example the wood-based materials mentioned above, such as chipboard or OSB.

Als Füllstoff B) kommen verschäumbare noch kompakte oder aber bereits verschäumte Kunststoffteilchen, vorzugsweise thermoplastische Kunststoffteilchen in Frage. Es können aber auch Kunststoffteilchen verwendet werden, die sich in einem beliebigen Zwischenstadium der Verschäumung befinden.As filler B) are foamable yet compact or already foamed plastic particles, preferably thermoplastic plastic particles in question. But it can also be used plastic particles that are in any intermediate stage of foaming.

Füllstoff B) enthält Kunststoff-Schaumstoff-Teilchen, die aus Formkörpern, zum Beispiel aus Polyurethanschaumformkörpern, Polyethylenschaumformkörpern, Polypropylenschaumformkörpern oder vorzugsweise Polystyrolschaumformkörpern, durch Zerkleinern, vorzugsweise Mahlen, gewonnen werden können in einer Menge im Bereich von 15 Gew.-% bis 85 Gew.-%, besonders bevorzugt im Bereich von 25 Gew.-% bis 75 Gew.-%, ganz besonders bevorzugt im Bereich von 40 Gew.-% bis 60 Gew.-%, jeweils bezogen auf die Komponente B).Filler B) contains plastic foam particles which can be obtained from moldings, for example from polyurethane foam moldings, polyethylene foam moldings, polypropylene foam moldings or preferably polystyrene foam moldings, by comminution, preferably grinding, in an amount in the range from 15% by weight to 85% by weight. -%, particularly preferably in the range of 25 wt .-% to 75 wt .-%, most preferably in the range of 40 wt .-% to 60 wt .-%, each based on the component B).

Wenn nicht ausdrücklich anders beschrieben, werden alle diese schäumbaren oder verschäumten oder vorgeschäumten oder durch Zerkleinern gewonnenen Kunststoffteilchen im folgenden erfindungsgemäße Kunststoffteilchen genannt.Unless expressly described otherwise, all of these foamable or foamed or prefoamed plastic particles obtained by comminution are referred to below as plastic particles according to the invention.

Der Begriff verschäumter Kunststoff oder speziell Schaumstoff ist zum Beispiel in DIN 7726: 1982 - 05 erläutert.The term foamed plastic or especially foam is explained, for example, in DIN 7726: 1982-05.

Geeignete Polymere, die den erfindungsgemäßen Kunststoffteilchen zugrunde liegen sind alle Polymere, vorzugsweise thermoplastische Polymere, die sich verschäumen lassen. Diese sind dem Fachmann bekannt.Suitable polymers on which the plastic particles according to the invention are based are all polymers, preferably thermoplastic polymers, which can be foamed. These are known to the person skilled in the art.

Gut geeignete derartige Polymere sind beispielsweise PVC (hart und weich), Polycarbonate, Polyisocyanurate, Polycarbodiimide, Polyacrylimide und Polymethacrylimide, Polyamide, Polyurethane, Aminoplastharze und Phenolharze, Styrolhomopolymere, Styrolcopolymere, C2-C10-Olefinhomopolymere, C2-C10-Olefincopolymere und Polyester. Bevorzugt verwendet man zur Herstellung der genannten Olefinpolymere die 1-Alkene, zum Beispiel Ethylen, Propylen, 1-Buten, 1-Hexen, 1-Octen.Highly suitable such polymers are, for example, PVC (hard and soft), polycarbonates, polyisocyanurates, polycarbodiimides, polyacrylimides and polymethacrylimides, polyamides, polyurethanes, aminoplast resins and phenolic resins, styrene homopolymers, styrene copolymers, C 2 -C 10 -olefin homopolymers, C 2 -C 10 -olefin copolymers and polyester. The 1-alkenes, for example ethylene, propylene, 1-butene, 1-hexene, 1-octene, are preferably used for the preparation of said olefin polymers.

Die erfindungsgemäßen Kunststoffteilchen der Komponente B) weisen eine Schüttdichte, von 10 bis 150 kg/m3 auf, bevorzugt 15 bis 80 kg/m3, besonders bevorzugt 20 bis 70 kg/m3, insbesondere 30 bis 60 kg/m3. Die Schüttdichte wird üblicherweise durch Wiegen eines mit dem Schüttgut gefüllten definierten Volumens ermittelt.The plastic particles of component B) according to the invention have a bulk density of from 10 to 150 kg / m 3 , preferably from 15 to 80 kg / m 3 , particularly preferably from 20 to 70 kg / m 3 , in particular from 30 to 60 kg / m 3 . The bulk density is usually determined by weighing a volume filled with the bulk material.

Vorgeschäumte erfindungsgemäße Kunststoffteilchen werden im allgemeinen in Form von Kugeln oder Perlen mit einem mittleren Durchmesser von vorteilhaft 0,25 bis 10 mm, bevorzugt 0,5 bis 5 mm, insbesondere 0,75 bis 3 mm, eingesetzt.Foamed plastic particles according to the invention are generally used in the form of spheres or beads having an average diameter of advantageously 0.25 to 10 mm, preferably 0.5 to 5 mm, in particular 0.75 to 3 mm.

Vorgeschäumte erfindungsgemäße Kunststoffteilchen-Kugeln weisen vorteilhaft eine kleine Oberfläche pro Volumen auf, beispielsweise in Form eines sphärischen oder elliptischen Partikels.Prefabricated plastic particle beads according to the invention advantageously have a small surface area per volume, for example in the form of a spherical or elliptical particle.

Die vorgeschäumten erfindungsgemäßen Kunststoffteilchen-Kugeln sind vorteilhaft geschlossenzellig. Die Offenzelligkeit nach DIN-ISO 4590 beträgt in der Regel weniger als 30 %.The prefoamed plastic particle beads according to the invention are advantageously closed-celled. The open cell density according to DIN-ISO 4590 is usually less than 30%.

Kunststoff-Schaumstoff-Teilchen, die aus Formkörpern, zum Beispiel aus Polyurethanschaumformkörpern, Polyethylenschaumformkörpern, Polypropylenschaumformkörpern oder vorzugsweise Polystyrolschaumformkörpern, durch Zerkleinern, vorzugsweise Mahlen, gewonnen werden können, sind im allgemeinen unregelmäßig geformt, können aber auch kugelförmig vorliegen.Plastic foam particles, which can be obtained from shaped articles, for example from polyurethane foam moldings, polyethylene foam moldings, polypropylene foam moldings or preferably polystyrene foam moldings, by comminution, preferably grinding, are generally irregular in shape but can also be spherical.

Besteht der Füllstoff B) aus unterschiedlichen Polymertypen, also Polymertypen denen unterschiedliche Monomere zugrunde liegen (beispielsweise Polystyrol und Polyethylen oder Polystyrol und Homo-Polypropylen oder Polyethylen und Homo-Polypropylen), so können diese in unterschiedlichen Gewichtsverhältnissen vorliegen, die allerdings, nach derzeitigem Stand des Wissens, nicht kritisch sind.If the filler B) from different types of polymers, so polymer types which are based on different monomers (for example, polystyrene and polyethylene or polystyrene and homo-polypropylene or polyethylene and homo-polypropylene), they may be present in different weight ratios, however, according to the current state of the Knowledge, not critical.

Des weiteren können den erfindungsgemäßen Thermoplasten Additive, Keimbildner, Weichmacher, Flammschutzmittel, lösliche und unlösliche anorganische und/oder organische Farbstoffe und Pigmente, z. B. IR-Absorber, wie Ruß, Graphit oder Aluminiumpulver, gemeinsam oder räumlich getrennt als Zusatzstoffe zugegeben werden.Furthermore, the thermoplastics of the invention, additives, nucleating agents, plasticizers, flame retardants, soluble and insoluble inorganic and / or organic dyes and pigments, for. As IR absorbers, such as carbon black, graphite or aluminum powder, are added together or spatially separated as additives.

Vorzugsweise verwendet man Polystyrol und/oder Styrolcopolymerisat, jeweils inklusive solches, das man durch Zerkleinern von Formkörpern gewinnt, als einzige erfindungsgemäße Kunststoffteilchen-Komponente in Füllstoff B).Polystyrene and / or styrene copolymer, in each case including those which are obtained by comminution of shaped bodies, are preferably used as the sole inventive plastic particle component in filler B).

Der Füllstoff Polystyrol und/oder Styrolcopolymerisat kann nach allen den Fachmann bekannten Polymerisierungsverfahren hergestellt werden [siehe z. B. Ullmann's Encyclopedia, Sixth Edition, 2000 Electronic Release]. Beispielsweise erfolgt die Herstellung in an sich bekannter Weise durch Suspensionspolymerisation oder mittels Extrusionsverfahren.The filler polystyrene and / or styrene copolymer can be prepared by all polymerization processes known to those skilled in the art [see, for example, US Pat. B. Ullmann's Encyclopedia, Sixth Edition, 2000 Electronic Release]. For example, the preparation is carried out in a conventional manner by suspension polymerization or by extrusion.

Bei der Suspensionspolymerisation wird Styrol, gegebenenfalls unter Zusatz weiterer Comonomere in wässriger Suspension in Gegenwart eines üblichen Suspensionsstabilisators mittels radikalbildender Katalysatoren polymerisiert. Das Treibmittel und gegebenenfalls weitere Zusatzstoffe können dabei bei der Polymerisation mit vorgelegt werden oder im Laufe der Polymerisation oder nach beendeter Polymerisation dem Ansatz zugefügt werden. Die erhaltenen perlförmigen expandierbaren Styrolpolymerisate werden nach beendeter Polymerisation von der wässrigen Phase abgetrennt, gewaschen, getrocknet und gesiebt.In the suspension polymerization, styrene, optionally with the addition of further comonomers in aqueous suspension, is polymerized in the presence of a customary suspension stabilizer by means of free-radical-forming catalysts. The propellant and optionally further additives may be included in the polymerization be added to the batch in the course of the polymerization or after completion of the polymerization. The resulting bead-shaped expandable styrene polymers are separated from the aqueous phase after the end of the polymerization, washed, dried and sieved.

Bei dem Extrusionsverfahren wird das Treibmittel beispielsweise über einen Extruder in das Polymer eingemischt, durch eine Düsenplatte gefördert und zu Partikeln oder Strängen granuliert.In the extrusion process, the blowing agent is mixed for example via an extruder in the polymer, conveyed through a nozzle plate and granulated into particles or strands.

Als Treibmittel können alle dem Fachmann bekannten Treibmittel verwendet werden, beispielsweise C3- bis C6-Kohlenwasserstoffe, wie Propan, n-Butan, Isobutan, n-Pentan, Isopentan, Neopentan und/oder Hexan, Alkohole, Ketone, Ether oder halogenierte Kohlenwasserstoffe. Vorzugsweise wird ein handelsübliches Pentanisomerengemisch verwendet.Suitable blowing agents are all blowing agents known to those skilled in the art, for example C 3 to C 6 hydrocarbons, such as propane, n-butane, isobutane, n-pentane, isopentane, neopentane and / or hexane, alcohols, ketones, ethers or halogenated hydrocarbons , Preferably, a commercially available pentane isomer mixture is used.

Des weiteren können den Styrolpolymerisaten Additive, Keimbildner, Weichmacher, Flammschutzmittel, lösliche und unlösliche anorganische und/oder organische Farbstoffe und Pigmente, z. B. IR-Absorber, wie Ruß, Graphit oder Aluminiumpulver, gemeinsam oder räumlich getrennt als Zusatzstoffe zugegeben werden.Furthermore, the styrene polymers additives, nucleating agents, plasticizers, flame retardants, soluble and insoluble inorganic and / or organic dyes and pigments, for. As IR absorbers, such as carbon black, graphite or aluminum powder, are added together or spatially separated as additives.

Gegebenenfalls können auch Styrolcopolymerisate eingesetzt werden, vorteilhaft weisen diese Styrolcopolymerisate mindestens 50 Gew.-%, vorzugsweise mindestens 80 Gew.-%, einpolymerisiertes Styrol auf. Als Comonomere kommen z. B. α-Methylstyrol, kernhalogenierte Styrole, Acrylnitril, Ester der Acryl- oder Methacrylsäure von Alkoholen mit 1 bis 8 C-Atomen, N-Vinylcarbazol, Maleinsäure(anhydrid), (Meth)acrylamide und/oder Vinylacetat in Betracht.Optionally, it is also possible to use styrene copolymers; these styrene copolymers advantageously have at least 50% by weight, preferably at least 80% by weight, of copolymerized styrene. As comonomers come z. As α-methyl styrene, ring halogenated styrenes, acrylonitrile, esters of acrylic or methacrylic acid of alcohols having 1 to 8 carbon atoms, N-vinylcarbazole, maleic acid (anhydride), (meth) acrylamides and / or vinyl acetate into consideration.

Vorteilhaft kann das Polystyrol und/oder Styrolcopolymerisat eine geringe Menge eines Kettenverzweigers einpolymerisiert enthalten, d. h. einer Verbindung mit mehr als einer, vorzugsweise zwei Doppelbindungen, wie Divinylbenzol, Butadien und/oder Butandioldiacrylat. Der Verzweiger wird im Allgemeinen in Mengen von 0,005 bis 0,05 Mol-%, bezogen auf Styrol, verwendet.Advantageously, the polystyrene and / or styrene copolymer in copolymerized form contain a small amount of a chain splitter, d. H. a compound having more than one, preferably two, double bonds, such as divinylbenzene, butadiene and / or butanediol diacrylate. The branching agent is generally used in amounts of from 0.005 to 0.05 mole percent, based on styrene.

Vorteilhaft verwendet man Styrol(co)polymerisate mit Molekulargewichten und Molgewichtsverteilungen, wie sie in EP-B 106 129 und in DE-A 39 21 148 beschrieben sind. Bevorzugt werden Styrol(co)polymerisate mit einem Molekulargewicht im Bereich von 190.000 bis 400.000 g/mol eingesetzt.It is advantageous to use styrene (co) polymers having molecular weights and molecular weight distributions as described in US Pat EP-B 106 129 and in DE-A 39 21 148 are described. Preference is given to using styrene (co) polymers having a molecular weight in the range from 190,000 to 400,000 g / mol.

Auch Mischungen verschiedener Styrol(co)polymerisate können verwendet werden.Mixtures of different styrene (co) polymers can also be used.

Bevorzugt werden als Styrolpolymere glasklares Polystyrol (GPPS), Schlagzähpolystyrol (HIPS), anionisch polymerisiertes Polystyrol oder Schlagzähpolystyrol (A-IPS), Styrol-α-Methylstyrol-copolymere, Acrylnitril-Butadien-Styrolpolymerisate (ABS), Styrol-Acrylnitril (SAN), Acrylnitril-Styrol-Acrylester (ASA), Methylacrylat-Butadien-Styrol (MBS), Methylmethacrylat-Acrylnitril-Butadien-Styrol (MABS)-Polymerisate oder Mischungen davon oder mit Polyphenylenether (PPE) eingesetzt.Preferred as styrene polymers are glassy polystyrene (GPPS), impact polystyrene (HIPS), anionically polymerized polystyrene or toughened polystyrene (A-IPS), styrene-α-methylstyrene copolymers, acrylonitrile-butadiene-styrene polymers (ABS), styrene-acrylonitrile (SAN), acrylonitrile-styrene-acrylic esters (ASA), methyl acrylate-butadiene-styrene (MBS), methyl methacrylate-acrylonitrile-butadiene-styrene (MABS) polymers or mixtures thereof or with polyphenylene ether (PPE).

Als Polystyrol wird besonders bevorzugt Styropor®, Neopor® und/oder Peripor® der Firma BASF Aktiengesellschaft eingesetzt.As polystyrene Neopor ® and / or Peripor ® from BASF Aktiengesellschaft is particularly preferred ® Styrofoam used.

Vorteilhaft wird bereits vorgeschäumtes Polystyrol und/oder Styrolcopolymerisate eingesetzt.Pre-expanded polystyrene and / or styrene copolymers are advantageously used.

Generell lässt sich das vorgeschäumte Polystyrol nach allen dem Fachmann bekannten Verfahren herstellen (beispielsweise DE 845 264 ). Für die Herstellung von vorgeschäumten Polystyrol und/oder vorgeschäumten Styrolcopolymerisaten werden die expandierbaren Styrolpolymerisate in bekannter Weise durch Erhitzen auf Temperaturen oberhalb ihres Erweichungspunkts, beispielsweise mit Heißluft oder vorzugsweise Dampf, expandiert.In general, the prefoamed polystyrene can be prepared by all methods known to the person skilled in the art (for example DE 845 264 ). For the production of prefoamed polystyrene and / or prefoamed styrene copolymers, the expandable styrene polymers are expanded in a known manner by heating to temperatures above their softening point, for example with hot air or preferably steam.

Das vorgeschäumte Polystyrol oder vorgeschäumte Styrolcopolymerisat der Komponente B) und die durch Zerkleinerung entsprechender Polystyrol- oder Styrolcopolymerisat-Formkörper gewonnenen erfindungsgemäßen Kunststoffteilchen der Komponente B), weisen vorteilhaft eine Schüttdichte von 10 bis 150 kg/m3 auf, bevorzugt 15 bis 80 kg/m3, besonders bevorzugt 20 bis 70 kg/m3, insbesondere 30 bis 60 kg/m3.The prefoamed polystyrene or prefoamed styrene copolymer of component B) and the plastic particles of component B according to the invention obtained by comminution of corresponding polystyrene or styrene copolymer molded articles advantageously have a bulk density of 10 to 150 kg / m 3 , preferably 15 to 80 kg / m 3 , more preferably 20 to 70 kg / m 3 , in particular 30 to 60 kg / m 3 .

Das vorgeschäumte Polystyrol oder vorgeschäumte Styrolcopolymerisat wird vorteilhaft in Form von Kugeln oder Perlen mit einem mittleren Durchmesser von vorteilhaft 0,25 bis 10 mm, bevorzugt 0,5 bis 5 mm, insbesondere 0,75 bis 3 mm, eingesetzt.The prefoamed polystyrene or prefoamed styrene copolymer is advantageously used in the form of spheres or beads having an average diameter of advantageously 0.25 to 10 mm, preferably 0.5 to 5 mm, in particular 0.75 to 3 mm.

Die vorgeschäumten Polystyrol- oder vorgeschäumten Styrolcopolymerisat-Kugeln weisen vorteilhaft eine kleine Oberfläche pro Volumen auf, beispielsweise in Form eines sphärischen oder elliptischen Partikels.The prefoamed polystyrene or prefoamed styrene copolymer spheres advantageously have a small surface area per volume, for example in the form of a spherical or elliptical particle.

Die vorgeschäumten Polystyrol- oder vorgeschäumten Styrolcopolymerisat-Kugeln sind vorteilhaft geschlossenzellig. Die Offenzelligkeit nach DIN-ISO 4590 beträgt in der Regel weniger als 30 %.The prefoamed polystyrene or prefoamed styrene copolymer spheres are advantageously closed-cell. The open cell density according to DIN-ISO 4590 is usually less than 30%.

Als Ausgangsmaterial für geschäumtes Polystyrol oder geschäumtes Styrolcopolymerisat können Formteile aus geschäumtem Styrolpolymerisat oder Styrolcopolymerisat dienen. Diese können mit den üblichen Zerkleinerungsmethoden bis zum Grad der einzelnen Styrolpolymerisat- oder Styrolcopolymerisat-Teilchen, vorzugsweise kugelförmig, zerkleinert werden. Eine gut geeignete und bevorzugte Zerkleinerungsmethode ist das Mahlen.As a starting material for foamed polystyrene or foamed styrene copolymer moldings of foamed styrene polymer or styrene copolymer can serve. These can be comminuted with the usual comminution methods to the degree of the individual styrene polymer or styrene copolymer particles, preferably spherical. A well suited and preferred shredding method is milling.

Formteile aus geschäumtem Styrolpolymerisat oder Styrolcopolymerisat können nach den bekannten Verfahren hergestellt werden und dienen zum Beispiel als Verpackungsmaterial oder Dämm-Material.Moldings of foamed styrene polymer or styrene copolymer can be prepared by the known methods and serve, for example, as packaging material or insulating material.

Als Ausgangsmaterial für geschäumtes Polystyrol- oder geschäumtes Styrolcopolymerisat können Formteile aus geschäumtem Styrolpolymerisat oder Styrolcopolymerisat dienen, die für die Entsorgung vorgesehen sind, zum Beispiel Styrolpolymerisat- oder Styrolcopolymerisatverpackungsmaterial-Abfall oder Styrolpolymerisat- oder Styrolcopolymerisatdämmmaterial-Abfall.As the starting material for the foamed polystyrene or foamed styrene copolymer, foamed styrene polymer or styrene copolymer molded articles intended for disposal, for example, styrene polymer or styrene copolymer packaging waste or styrene polymer or styrene copolymer insulating waste, may be used.

Besonders bevorzugt weist das Polystyrol oder Styrolcopolymerisat oder das vorgeschäumte Polystyrol oder vorgeschäumte Styrolcopolymerisat eine antistatische Beschichtung auf.Particularly preferably, the polystyrene or styrene copolymer or the prefoamed polystyrene or prefoamed styrene copolymer has an antistatic coating.

Als Antistatikum können die in der Technik üblichen und gebräuchlichen Substanzen verwendet werden. Beispiele sind N,N-Bis(2-hydroxyethyl)-C12-C18-alkylamine, Fettsäurediethanolamide, Cholinesterchloride von Fettsäuren, C12-C20-Alkylsulfonate, Ammoniumsalze.As antistatic agents, the usual and common in the art substances can be used. Examples are N, N-bis (2-hydroxyethyl) -C 12 -C 18 -alkylamines, fatty acid diethanolamides, choline ester chlorides of fatty acids, C 12 -C 20 -alkyl sulfonates, ammonium salts.

Geeignete Ammoniumsalze enthalten am Stickstoff neben Alkylgruppen 1 bis 3 hydroxylgruppenhaltige organische Reste.Suitable ammonium salts contain on nitrogen in addition to alkyl groups 1 to 3 hydroxyl-containing organic radicals.

Geeignete quaternäre Ammoniumsalze sind beispielsweise solche, die am Stickstoff-Kation 1 bis 3, vorzugsweise 2, gleiche oder verschiedene Alkylreste mit 1 bis 12, vorzugsweise 1 bis 10 C-Atomen, und 1 bis 3, vorzugsweise 2 gleiche oder verschiedene Hydroxyalkyl- oder Hydroxyalkylpolyoxyalkylen-Reste gebunden enthalten, mit einem beliebigen Anion, wie Chlorid, Bromid, Acetat, Methylsulfat oder p-Toluolsulfonat.Suitable quaternary ammonium salts are, for example, those having on the nitrogen cation 1 to 3, preferably 2, identical or different alkyl radicals having 1 to 12, preferably 1 to 10 carbon atoms, and 1 to 3, preferably 2 identical or different hydroxyalkyl or hydroxyalkylpolyoxyalkylene Radicals bound with any anion, such as chloride, bromide, acetate, methyl sulfate or p-toluenesulfonate.

Die Hydroxyalkyl- und Hydroxyalkyl-polyoxyalkylen-Reste sind solche, die durch Oxyalkylierung eines Stickstoff-gebundenen Wasserstoffatoms entstehen und leiten sich von 1 bis 10 Oxyalkylenresten, insbesondere Oxyethylen- und Oxypropylen-Resten ab.The hydroxyalkyl and hydroxyalkyl-polyoxyalkylene radicals are those which are formed by oxyalkylation of a nitrogen-bonded hydrogen atom and are derived from 1 to 10 oxyalkylene radicals, in particular oxyethylene and oxypropylene radicals.

Besonders bevorzugt wird als Antistatikum ein quartäres Ammoniumsalz oder ein Alkalisalz, insbesondere Natriumsalz eines C12-C20 Alkansulfonats, z. B Emulgator K30 von Bayer AG, oder Mischungen davon eingesetzt. Die Antistatika können in der Regel sowohl als Reinsubstanz als auch in Form einer wässrigen Lösung zugegeben werden.An antistatic agent which is particularly preferred is a quaternary ammonium salt or an alkali metal salt, in particular the sodium salt of a C 12 -C 20 alkanesulfonate, eg. B emulsifier K30 from Bayer AG, or mixtures thereof. The antistatic agents can generally be added both as a pure substance and in the form of an aqueous solution.

Das Antistatikum kann beim Verfahren zur Herstellung von Polystyrol oder Styrolcopolymerisat analog den üblichen Zusatzstoffen zugesetzt werden oder nach der Herstellung der Polystyrol partikel als Beschichtung aufgetragen werden.The antistatic agent can be added in the process for the preparation of polystyrene or styrene copolymer analogously to the customary additives or applied after the preparation of the polystyrene particles as a coating.

Das Antistatikum wird vorteilhaft in einer Menge von 0,05 bis 6 Gew.-%, bevorzugt 0,1 bis 4 Gew.-%, bezogen auf das Polystyrol oder Styrolcopolymerisat, eingesetzt.The antistatic agent is advantageously used in an amount of 0.05 to 6 wt .-%, preferably 0.1 to 4 wt .-%, based on the polystyrene or styrene copolymer.

Die Füllstoff-Teilchen B) liegen vorteilhaft auch nach dem Verpressen zum leichten Holzwerkstoff, vorzugsweise mehrschichtigen Holzwerkstoff, in einem Zustand vor, in welchem ihre ursprüngliche Form noch erkennbar ist. Gegebenenfalls kann es zu einem Schmelzen der Füllstoff-Teilchen, die sich auf der Oberfläche des leichten holzhaltigen Stoffs oder vorzugsweise des mehrschichtigen Holzwerkstoffs befinden, kommen.The filler particles B) are advantageous even after pressing to light wood material, preferably multi-layer wood material, in a state in which their original shape is still recognizable. Optionally, there may be melting of the filler particles that are on the surface of the light wood-containing material, or preferably the multilayer wood material.

Die Gesamtmenge des Füllstoffs B), bezogen auf den leichten holzhaltigen Stoff, liegt im Bereich von 1 bis 25 Gew.-%, vorzugsweise 2 bis 15 Gew.-%, besonders bevorzugt 3 bis 12 Gew.-%.The total amount of filler B), based on the light wood-containing material, is in the range of 1 to 25 wt .-%, preferably 2 to 15 wt .-%, particularly preferably 3 to 12 wt .-%.

Die Gesamtmenge des Füllstoffs B) mit Polystyrol und/oder Styrolcopolymerisat, jeweils inklusive solches, das man durch Zerkleinern von Formkörpern gewinnt, als einziger Kunststoffteilchen-Komponente, bezogen auf den leichten holzhaltigen Stoff, liegt im Bereich von 1 bis 25 Gew.-%, vorzugsweise 2 bis 15 Gew.-%, besonders bevorzugt 3 bis 12 Gew.-%.The total amount of filler B) with polystyrene and / or styrene copolymer, in each case including that which is obtained by comminuting shaped bodies, as the only plastic particle component, based on the light wood-containing substance, is in the range from 1 to 25% by weight, preferably 2 to 15 wt .-%, particularly preferably 3 to 12 wt .-%.

Als Bindemittel C) können alle dem Fachmann für die Herstellung von Holzwerkstoffen bekannten Bindemittel verwendet werden, zum Beispiel Aminoplastharze und/oder organische Isocyanate, wie PMDI.As binder C) it is possible to use all binders known to the person skilled in the art for the production of wood-based materials, for example aminoplast resins and / or organic isocyanates, such as PMDI.

Das Bindemittel C) enthält in der Regel die dem Fachmann bekannten für Aminoplastharze im allgemeinen eingesetzten und üblicherweise als Härter bezeichneten Substanzen, wie Ammoniumsulfat oder Ammoniumnitrat oder anorganische oder organische Säuren, zum Beispiel Schwefelsäure, Ameisensäure, oder säureregenerierende Substanzen, wie Aluminiumchlorid, Aluminiumsulfat, jeweils in den üblichen, geringen Mengen, beispielsweise im Bereich von 0,1 Gew.-% bis 3 Gew.-%, bezogen auf die Gesamtmenge an Aminoplastharz im Bindemittel C).As a rule, the binder C) contains the substances generally known to the person skilled in the art for aminoplast resins and commonly referred to as hardeners, such as ammonium sulfate or ammonium nitrate or inorganic or organic acids, for example sulfuric acid, formic acid or acid regenerating substances, such as aluminum chloride, aluminum sulfate in the usual, small amounts, for example in the range of 0.1 wt .-% to 3 wt .-%, based on the total amount of aminoplast resin in the binder C).

Als Aminoplastharz werden hier Polykondensationsprodukte aus Verbindungen mit mindestens einer, gegebenenfalls teilweise mit organischen Resten substituierten, Carbamidgruppe (die Carbamidgruppe wird auch Carboxamidgruppe genannt) und einem Aldehyd, vorzugsweise Formaldehyd, verstanden.As aminoplast resin are here polycondensation products of compounds having at least one, optionally partially substituted with organic radicals, carbamide group (the carbamide group is also called carboxamide) and an aldehyde, preferably formaldehyde understood.

Als gut geeignetes Aminoplastharz können alle dem Fachmann, vorzugsweise die für die Herstellung von Holzwerkstoffen bekannten, Aminoplastharze verwendet werden. Derartige Harze sowie ihre Herstellung sind beispielsweise in Ullmanns Enzyklopädie der technischen Chemie, 4., neubearbeitete und erweiterte Auflage, Verlag Chemie, 1973, Seiten 403 bis 424 "Aminoplaste " und Ullmann's Encyclopedia of Industrial Chemistry, Vol. A2, VCH Verlagsgesellschaft, 1985, Seiten 115 bis 141 "Amino Resins " sowie in M. Dunky, P. Niemz, Holzwerkstoffe und Leime, Springer 2002, Seiten 251 bis 259 (UF-Harze) und Seiten 303 bis 313 (MUF und UF mit geringer Menge Melamin) beschrieben.As a suitable aminoplast resin, all of the specialist, preferably known for the production of wood materials, aminoplast resins can be used. Such resins and their preparation are, for example, in Ullmann's Encyclopedia of Industrial Chemistry, 4th, revised and expanded edition, Verlag Chemie, 1973, pages 403 to 424 "aminoplasts " and Ullmann's Encyclopedia of Industrial Chemistry, Vol. A2, VCH Verlagsgesellschaft, 1985, pages 115 to 141 "Amino Resins " as in M. Dunky, P. Niemz, wood materials and glues, Springer 2002, pages 251 to 259 (UF resins) and pages 303 to 313 (MUF and UF with a small amount of melamine).

Bevorzugte Aminoplastharze sind Polykondensationsprodukte aus Verbindungen mit mindestes einer, auch teilweise mit organischen Resten substituierten, Carbamidgruppe und Formaldehyd.Preferred aminoplast resins are polycondensation products of compounds having at least one, also partially substituted by organic radicals, carbamide group and formaldehyde.

Besonders bevorzugte Aminoplastharze sind Harnstoff-Formaldehydharze (UF-Harze), Melamin-Formaldehydharze (MF-Harze) oder melaminhaltige Harnstoff-Formaldehydharze (MUF-Harze).Particularly preferred aminoplast resins are urea-formaldehyde resins (UF resins), melamine-formaldehyde resins (MF resins) or melamine-containing urea-formaldehyde resins (MUF resins).

Ganz besonders bevorzugte Aminoplastharze sind Harnstoff-Formaldehydharze, beispielsweise Kaurit® Leim-Typen der Firma BASF Aktiengesellschaft.Especially preferred amino resins are urea-formaldehyde resins, for example Kaurit ® glue types from BASF Aktiengesellschaft.

Weiterhin ganz bevorzugte Aminoplastharze sind Polykondensationsprodukte aus Verbindungen mit mindestens einer, auch teilweise mit organischen Resten substituierten, Aminogruppe und Aldehyd, worin das molare Verhältnis Aldehyd : gegebenenfalls teilweise mit organischen Resten substituierten Amino-Gruppe im Bereich von 0,3 bis 1,0, bevorzugt 0,3 bis 0,60, besonders bevorzugt 0,3 bis 0,45, ganz besonders bevorzugt 0,30 bis 0,40 liegt.Furthermore, very preferred aminoplast resins are polycondensation products of compounds having at least one, also partially substituted by organic radicals, amino group and aldehyde, wherein the molar ratio of aldehyde: optionally partially substituted with organic groups amino group in the range of 0.3 to 1.0, preferably 0.3 to 0.60, more preferably 0.3 to 0.45, most preferably 0.30 to 0.40.

Weiterhin ganz bevorzugte Aminoplastharze sind Polykondensationsprodukte aus Verbindungen mit mindestens einer Aminogruppe -NH2 und Formaldehyd, worin das molare Verhältnis Formaldehyd : -NH2-Gruppe im Bereich von 0,3 bis 1,0, bevorzugt 0,3 bis 0,60, besonders bevorzugt 0,3 bis 0,45, ganz besonders bevorzugt 0,30 bis 0,40 liegt.Furthermore, very preferred aminoplast resins are polycondensation products of compounds having at least one amino group -NH 2 and formaldehyde, wherein the molar ratio of formaldehyde: -NH 2 group in the range of 0.3 to 1.0, preferably 0.3 to 0.60, especially preferably 0.3 to 0.45, very particularly preferably 0.30 to 0.40.

Weiterhin ganz bevorzugte Aminoplastharze sind Harnstoff-Formaldehydharze (UF-Harze), Melamin-Formaldehydharze (MF-Harze) oder melaminhaltige Harnstoff-Formaldehydharze (MUF-Harze), worin das molare Verhältnis Formaldehyd : -NH2-Gruppe im Bereich von 0,3 bis 1,0, bevorzugt 0,3 bis 0,60, besonders bevorzugt 0,3 bis 0,45, ganz besonders bevorzugt 0,30 bis 0,40 liegt.Furthermore, very preferred amino resins are urea-formaldehyde resins (UF resins), melamine-formaldehyde resins (MF resins) or melamine-containing urea-formaldehyde resins (MUF resins), wherein the molar ratio of formaldehyde: -NH 2 group in the range of 0.3 to 1.0, preferably 0.3 to 0.60, more preferably 0.3 to 0.45, most preferably 0.30 to 0.40.

Weiterhin ganz bevorzugte Aminoplastharze sind Harnstoff-Formaldehydharze (UF-Harze), worin das molare Verhältnis Formaldehyd : -NH2-Gruppe im Bereich von 0,3 bis 1,0, bevorzugt 0,3 bis 0,60, besonders bevorzugt 0,3 bis 0,45, ganz besonders bevorzugt 0,30 bis 0,40 liegt.Furthermore, very preferred aminoplast resins are urea-formaldehyde resins (UF resins), wherein the molar ratio of formaldehyde: -NH 2 group in the range of 0.3 to 1.0, preferably 0.3 to 0.60, particularly preferably 0.3 to 0.45, most preferably 0.30 to 0.40.

Die genannten Aminoplastharze werden üblicherweise in flüssiger Form, meist in einem flüssigen Suspendiermittel suspendiert oder gelöst, vorzugsweise in wässriger Suspension oder Lösung, eingesetzt, können aber auch als Feststoff eingesetzt werden.The aminoplast resins mentioned are usually suspended in liquid form, usually in a liquid suspending agent or dissolved, preferably in aqueous suspension or solution, but can also be used as a solid.

Der Feststoffgehalt der Aminoplastharz-Suspensionen, vorzugsweise wässrigen Suspension, liegt üblicherweise bei 25 bis 90 Gew.-%, vorzugsweise bei 50 bis 70 Gew.-%.The solids content of the aminoplast resin suspensions, preferably aqueous suspension, is usually from 25 to 90% by weight, preferably from 50 to 70% by weight.

Der Feststoffgehalt des Aminoplast-Harzes in wässriger Suspension kann nach Günter Zeppenfeld, Dirk Grunwald, Klebstoffe in der Holz- und Möbelindustrie, 2. Auflage, DRW-Verlag, Seite 268 bestimmt werden. Zur Bestimmung des Feststoffgehalts von Aminoplast-Leimen wird 1 g Aminoplast-Leim in eine Wägeschale genau eingewogen, am Boden fein verteilt und 2 Stunden bei 120 °C in einem Trockenschrank getrocknet. Nach Temperierung auf Raumtemperatur in einem Exsikkator wird der Rückstand gewogen und als prozentualer Anteil der Einwaage berechnet.The solids content of the aminoplast resin in aqueous suspension can be determined according to Günter Zeppenfeld, Dirk Grunwald, adhesives in the wood and furniture industry, 2nd edition, DRW-Verlag, page 268. To determine the solids content of aminoplast glues, 1 g of aminoplast glue is weighed exactly into a weighing dish, finely distributed on the bottom and dried for 2 hours at 120 ° C. in a drying oven. After tempering to room temperature in a desiccator, the residue is weighed and calculated as a percentage of the initial weight.

Die Aminoplastharze werden nach bekannten Verfahren (siehe oben angegebene Ullmann-Literatur "Aminoplaste" und "Amino Resins", sowie oben angegebene Literatur Dunky et al.) durch Umsetzen der Carbamidgruppen-haltigen Verbindungen, vorzugsweise Harnstoff und/oder Melamin, mit den Aldehyden, vorzugsweise Formaldehyd, in den gewünschten Molverhältnissen Carbamidgruppe : Aldehyd, vorzugsweise in Wasser als Lösungsmittel, hergestellt.The aminoplast resins are prepared by known processes (see above Ullmann-Literatur "Aminoplasts" and "Amino Resins", as well as literature Dunky et al.) By reacting the carbamido-containing compounds, preferably urea and / or melamine, with the aldehydes, preferably formaldehyde, in the desired molar ratios carbamide group: aldehyde, preferably in water as a solvent.

Das Einstellen des gewünschten molaren Verhältnisses Aldehyd, vorzugsweise Formaldehyd : gegebenenfalls teilweise mit organischen Resten substituierten AminoGruppe kann auch durch Zusatz von -NH2-Gruppen-tragenden Monomeren zu formaldehydreicheren fertigen, vorzugsweise kommerziellen, Aminoplastharzen geschehen. NH2-Gruppen-tragende Monomere sind vorzugsweise Harnstoff, Melamin, besonders bevorzugt Harnstoff.The setting of the desired molar ratio of aldehyde, preferably formaldehyde: optionally partially substituted with organic radicals amino group can also be done by addition of -NH 2 group-carrying monomers to formaldehyde-rich finished, preferably commercial, Aminoplastharzen. NH 2 group-carrying monomers are preferably urea, melamine, more preferably urea.

Die Gesamtmenge des Bindemittels C), bezogen auf den leichten holzhaltigen Stoff, liegt im Bereich von 0,1 bis 50 Gew.-%, vorzugsweise 0,5 bis 15 Gew.-%, besonders bevorzugt 0,5 bis 10 Gew.-%.The total amount of the binder C), based on the light wood-containing substance, is in the range from 0.1 to 50% by weight, preferably 0.5 to 15% by weight, particularly preferably 0.5 to 10% by weight. ,

Hierbei liegt die Gesamtmenge des Aminoplastharzes (immer bezogen auf den Feststoff), vorzugsweise des Harnstoff-Formaldehydharzes und/oder Melamin-Harnstoff-Formaldehydharzes und/oder Melamin-Formaldehydharzes, besonders bevorzugt Harnstoff-Formaldehydharzes, im Bindemittel C), bezogen auf den leichten holzhaltigen Stoff im Bereich von 1 bis 45 Gew.-%, vorzugsweise 4 bis 14 Gew.-%, besonders bevorzugt 6 bis 9 Gew.-%.Here, the total amount of the aminoplast resin (always based on the solid), preferably the urea-formaldehyde resin and / or melamine-urea-formaldehyde resin and / or melamine-formaldehyde resin, particularly preferably urea-formaldehyde resin, in the binder C), based on the light wood-containing Substance in the range of 1 to 45 wt .-%, preferably 4 to 14 wt .-%, particularly preferably 6 to 9 wt .-%.

Falls ein organisches Isocyanat einziger oder weiterer Bestandteil des Bindemittels C) ist, liegt die Gesamtmenge des organischen Isocyanats, vorzugsweise des oligomeren Isocyanats mit 2 bis 10, vorzugsweise 2 bis 8 Monomereinheiten und im Mittel mindestens einer Isocyanatgruppe pro Monomereinheit, besonders bevorzugt PMDI, im Bindemittel C), bezogen auf den leichten holzhaltigen Stoff im Bereich von 0,1 bis 5 Gew.-%, vorzugsweise 0,25 bis 3,5 Gew.-%, besonders bevorzugt 0,5 bis 1,5 Gew.-%.If an organic isocyanate is a single or further constituent of the binder C), the total amount of the organic isocyanate, preferably of the oligomeric isocyanate having 2 to 10, preferably 2 to 8 monomer units and an average of at least one isocyanate group per monomer unit, more preferably PMDI, in the binder C), based on the light wood-containing material in the range of 0.1 to 5 wt .-%, preferably 0.25 to 3.5 wt .-%, particularly preferably 0.5 to 1.5 wt .-%.

Bevorzugte Ausführungsformen des leichten holzhaltigen Stoffs enthalten (i) 55 bis 92,5 Gew.-%, bevorzugt 60 bis 90 Gew.-%, insbesondere 70 bis 88 Gew.-%, bezogen auf den leichten holzhaltigen Stoff, Holzpartikel A), wobei die Holzpartikel A) eine mittlere Dichte von 0,4 bis 0,85 g/cm3, bevorzugt 0,4 bis 0,75 g/cm3, insbesondere 0,4 bis 0,6 g/cm3 aufweisen; (ii) 1 bis 25 Gew.-%, bevorzugt 2 bis 15 Gew.-%, insbesondere 3 bis 12 Gew.-% bezogen auf den leichten holzhaltigen Stoff, Polystyrol und/oder Styrolcopolymerisat Füllstoff B), wobei der Füllstoff B) eine Schüttdichte von 10 bis 150 kg/m3, bevorzugt 20 bis 80 kg/m3, insbesondere 30 bis 60 kg/m3 aufweist und wobei der Füllstoff B) durch Zerkleinerung von Formkörpern gewonnene Polystyrol und/oder Styrolcopolymerisat Kunststoffeilchen in einer Menge im Bereich von 1 Gew.-% bis 100 Gew.-%, bevorzugt im Bereich von 25 Gew.-% bis 75 Gew.-%, besonders bevorzugt im Bereich von 40 Gew.-% bis 60 Gew.-%, jeweils bezogen auf die Komponente B) enthält; (iii) und 0,1 bis 50 Gew.-%, bevorzugt 0,5 bis 15 Gew.-%, insbesondere 0,5 bis 10 Gew.-%, bezogen auf den leichten holzhaltigen Stoff, Bindemittel C), wobei die Gesamtmenge des Aminoplastharzes, vorzugsweise des Harnstoff-Formaldehydharzes und/oder Melamin-Harnstoff-Formaldehydharzes und/oder Melamin-Formaldehydharzes, besonders bevorzugt Harnstoff-Formaldehyd-harzes, im Bindemittel C), bezogen auf den leichten holzhaltigen Stoff im Bereich von 1 bis 45 Gew.-%, vorzugsweise 4 bis 14 Gew.-%, besonders bevorzugt 6 bis 9 Gew.-% und wobei die mittlere Dichte des leichten holzhaltigen Stoffs im Bereich von 200 bis 600 kg/m3, bevorzugt im Bereich von 300 bis 575 kg/m3, liegt.Preferred embodiments of the light wood-containing material contain (i) 55 to 92.5 wt .-%, preferably 60 to 90 wt .-%, in particular 70 to 88 wt .-%, based on the light wood-containing material, wood particles A), wherein the wood particles A) have an average density of 0.4 to 0.85 g / cm 3 , preferably 0.4 to 0.75 g / cm 3 , in particular 0.4 to 0.6 g / cm 3 ; (Ii) 1 to 25 wt .-%, preferably 2 to 15 wt .-%, in particular 3 to 12 wt .-% based on the light wood-containing material, polystyrene and / or styrene copolymer filler B), wherein the filler B) a Bulk density of 10 to 150 kg / m 3 , preferably 20 to 80 kg / m 3 , in particular 30 to 60 kg / m 3 and wherein the filler B) by comminution of moldings obtained polystyrene and / or styrene copolymer plastic in an amount in the range from 1 wt .-% to 100 wt .-%, preferably in the range of 25 wt .-% to 75 wt .-%, particularly preferably in the range of 40 wt .-% to 60 wt .-%, each based on the Component B) contains; (iii) and 0.1 to 50 wt .-%, preferably 0.5 to 15 wt .-%, in particular 0.5 to 10 wt .-%, based on the light wood-containing material, binder C), wherein the total amount of the aminoplast resin, preferably of the urea-formaldehyde resin and / or melamine-urea-formaldehyde resin and / or melamine-formaldehyde resin, more preferably urea-formaldehyde resin, in the binder C), based on the light wood-containing material in the range from 1 to 45 wt. %, preferably 4 to 14 wt .-%, particularly preferably 6 to 9 wt .-% and wherein the average density of the light wood-containing material in the range of 200 to 600 kg / m 3 , preferably in the range of 300 to 575 kg / m 3 , lies.

Gegebenenfalls können in dem erfindungsgemäßen leichten holzhaltigen Stoff oder dem erfindungsgemäßen mehrschichtigen Holzwerkstoff weitere handelsübliche und dem Fachmann bekannte Additive als Komponente D) vorliegen, zum Beispiel Hydrophobierungsmittel, wie Paraffin-Emulsionen, Pilzschutzmittel und Flammschutzmittel.If appropriate, further commercial additives known to the person skilled in the art may be present as component D) in the light wood-containing substance or multilayer wood material according to the invention, for example water repellents, such as paraffin emulsions, antifungal agents and flame retardants.

Die vorliegende Erfindung betrifft weiterhin einen mehrschichtigen Holzwerkstoff, der mindestens drei Holzwerkstoffschichten enthält, wobei mindestens die mittlere(n) Schicht(en) einen leichten holzhaltigen Stoff enthält oder enthalten mit folgenden Merkmalen des leichten holzhaltigen Stoffs: einer mittleren Dichte im Bereich von 200 bis 600 kg/m3 und enthaltend, jeweils bezogen auf den leichten holzhaltigen Stoff

  1. A) 30 bis 95 Gew.-% Holzpartikel;
  2. B) 1 bis 25 Gew.-% eines Füllstoffs mit der Schüttdichte im Bereich von 10 bis 150 kg/m3, ausgewählt aus der Gruppe bestehend aus verschäumbaren Kunststoffteilchen und bereits verschäumten Kunststoffteilchen;
  3. C) 0,1 bis 50 Gew.-% eines Bindemittels, und gegebenenfalls
  4. D) Additive,
wobei die Komponente B) durch Zerkleinerung von Formkörpern gewonnene verschäumte Kunststoffteilchen in einer Menge, bezogen auf die Komponente B), im Bereich von 1 Gew.-% bis 100 Gew.-% enthält.The present invention further relates to a multilayer wood material containing at least three layers of wood material, at least the middle layer (s) containing or containing a light wood-containing material having the following characteristics of the light wood-containing material: an average density in the range of 200 to 600 kg / m 3 and containing, in each case based on the light wood-containing substance
  1. A) 30 to 95 wt .-% wood particles;
  2. B) 1 to 25 wt .-% of a filler having a bulk density in the range of 10 to 150 kg / m 3 , selected from the group consisting of foamable plastic particles and already foamed plastic particles;
  3. C) 0.1 to 50 wt .-% of a binder, and optionally
  4. D) additives,
wherein component B) contains plasticized particles obtained by comminution of shaped bodies in an amount, based on component B), in the range from 1% by weight to 100% by weight.

Die mittlere Dichte des erfindungsgemäßen mehrschichtigen, vorzugsweise des erfindungsgemäßen dreischichtigen, Holzwerkstoffs liegt im Bereich von 300 kg/m3 bis 600 kg/m3, vorzugsweise im Bereich von 350 kg/m3 bis 600 kg/m3, besonders bevorzugt im Bereich von 400 kg/m3 bis 500 kg/m3.The average density of the multilayer, preferably of the three-layer, wood material according to the invention is in the range of 300 kg / m 3 to 600 kg / m 3 , preferably in the range of 350 kg / m 3 to 600 kg / m 3 , particularly preferably in the range of 400 kg / m 3 to 500 kg / m 3 .

Bevorzugte Parameterbereiche sowie bevorzugte Ausführungsformen im Hinblick auf die mittlere Dichte des leichten holzhaltigen Stoffs und im Hinblick auf die Komponenten A), B) ,C) und D) sowie die Kombination der Merkmale entsprechen den oben beschriebenen.Preferred parameter ranges and preferred embodiments with respect to the average density of the light wood-containing material and with regard to the components A), B), C) and D) and the combination of the features correspond to those described above.

Mittlere Schichten im Sinne der Erfindung sind alle Schichten, die nicht die äußeren Schichten sind.Middle layers in the sense of the invention are all layers that are not the outer layers.

Bevorzugt weisen die äußeren Schichten (üblicherweise "Deckschicht(en)" genannt) keine Füllstoffe auf.Preferably, the outer layers (usually called "cover layer (s)") have no fillers.

Bevorzugt enthält der erfindungsgemäße mehrschichtige Holzwerkstoff drei Holzstoff-Schichten, wobei die äußeren Deckschichten zusammen 1 bis 25 % der gesamten Dicke des erfindungsgemäßen mehrschichtigen Holzwerkstoffs ausmachen, bevorzugt 3 bis 20 %, insbesondere 5 bis 15 %.Preferably, the multilayer wood material according to the invention contains three layers of wood pulp, wherein the outer cover layers together make up 1 to 25% of the total thickness of the multilayer wood material according to the invention, preferably 3 to 20%, in particular 5 to 15%.

Das für die äußeren Schichten verwendete Bindemittel ist üblicherweise ein Aminoplastharz, beispielsweise Harnstoff-Formaldehydharz (UF), Melamin-Formaldehydharz (MF), Melamin-Harnstoff-Formaldehydharz (MUF) oder das erfindungsgemäße Bindemittel C). Vorzugsweise ist das für die äußeren Schichten verwendete Bindemittel ein Aminoplastharz, besonders bevorzugt ein Harnstoff-Formaldehydharz, ganz besonders bevorzugt ein Aminoplastharz worin das molare Formaldehyd : -NH2-Gruppen-Verhältnis im Bereich von 0,3 bis 1,0 liegt.The binder used for the outer layers is usually an aminoplast resin, for example urea-formaldehyde resin (UF), melamine-formaldehyde resin (MF), melamine-urea-formaldehyde resin (MUF) or the binder C according to the invention. Preferably, the binder used for the outer layers is an aminoplast resin, more preferably a urea-formaldehyde resin, most preferably an aminoplast resin wherein the molar formaldehyde: -NH 2 group ratio is in the range of 0.3 to 1.0.

Die Dicke des erfindungsgemäßen mehrschichtigen Holzwerkstoffs variiert mit dem Anwendungsgebiet und liegt in der Regel im Bereich von 0,5 bis 100 mm; vorzugsweise im Bereich von 10 bis 40 mm, insbesondere 15 bis 20 mm.The thickness of the multilayer wood material according to the invention varies with the field of application and is generally in the range of 0.5 to 100 mm; preferably in the range of 10 to 40 mm, in particular 15 to 20 mm.

Ferner betrifft die vorliegende Erfindung ein Verfahren zur Herstellung von erfindungsgemäßen mehrschichtigen Holzwerkstoffen wie oben definiert, wobei man die Komponeten für die einzelnen Schichten übereinanderschichtet und unter erhöhter Temperatur und erhöhtem Druck verpresst.Furthermore, the present invention relates to a method for producing multilayer wood products according to the invention as defined above, wherein the components for the individual layers are stacked and pressed under elevated temperature and elevated pressure.

Die Verfahren zur Herstellung von mehrschichtigen Holzwerkstoffen sind im Prinzip bekannt und zum Beispiel in M. Dunky, P. Niemz, Holzwerkstoffe und Leime, Springer 2002, Seiten 91 bis 150 beschrieben.The processes for the production of multilayer wood-based materials are known in principle and, for example, in M. Dunky, P. Niemz, Holzwerkstoffe und Leime, Springer 2002, pages 91 to 150 described.

Ein Beispiel für ein Verfahren zur Herstellung der erfindungsgemäßen mehrschichtigen Holzwerkstoffe wird im folgenden beschrieben.An example of a method for producing the multilayer wood-based materials according to the invention is described below.

Nach der Zerspanung des Holzes werden die Späne getrocknet. Danach werden gegebenenfalls Grob- und Feinanteile entfernt. Die verbleibenden Späne werden durch Sieben oder Sichten im Luftstrom sortiert. Das gröbere Material wird für die Mittelschicht, das feinere für die Deckschichten eingesetzt. Mittelschicht- und Deckschichtspäne werden getrennt voneinander jeweils mit den Komponenten B) (nur die Mittelschicht(en)), C) (Mittelschicht) und gegebenenfalls D) (Mittelschicht und/oder Deckschichten) sowie mit einem Aminoplastharz (Deckschicht) beleimt, beziehungsweise vermischt und anschließend gestreut. Zunächst wird das Deckschichtmaterial auf das Formband gestreut, anschließend das Mittelschichtmaterial - enthaltend die Komponenten B), C) und gegebenfalls D) - und schließlich noch ein mal Deckschichtmaterial. Der so erzeugte dreischichtige Spänekuchen wird kalt (in der Regel bei Raumtemperatur) vorverdichtet und anschließend heiß gepresst. Das Verpressen kann nach allen dem Fachmann bekannten Verfahren erfolgen. Üblicherweise wird der Holzpartikelkuchen bei einer Press-Temperatur von 150 °C bis 230 °C auf die gewünschte Dicke gepresst. Die Pressdauer beträgt normalerweise 3 bis 15 Sekunden pro mm Plattendicke. Man erhält eine dreischichtige Spanplatte.After cutting the wood, the chips are dried. Thereafter, if necessary, coarse and fines are removed. The remaining chips are sorted by sieving or sifting in the air stream. The coarser material is used for the middle layer, the coarser material for the cover layers. Middle layer and outer layer chips are glued separately from each other with the components B) (only the middle layer (s)), C) (middle layer) and optionally D) (middle layer and / or outer layers) and with an aminoplast resin (top layer), or mixed and then scattered. First, the cover layer material is scattered on the forming belt, then the middle layer material - containing the components B), C) and optionally D) - and finally once more cover layer material. The three-layer chip cake thus produced is precompressed cold (usually at room temperature) and then pressed hot. The pressing can be carried out by all methods known to the person skilled in the art. Usually, the wood particle cake is pressed at a press temperature of 150 ° C to 230 ° C to the desired thickness. The pressing time is normally 3 to 15 seconds per mm plate thickness. This gives a three-layer chipboard.

Bevorzugte Parameterbereiche sowie bevorzugte Ausführungsformen im Hinblick auf die mittlere Dichte des leichten holzhaltigen Stoffs, des mehrschichtigen Holzwerkstoffs und im Hinblick auf die Komponenten A), B) ,C) und gebenenfalls D) sowie die Kombination der Merkmale entsprechen den oben beschriebenen.Preferred parameter ranges and preferred embodiments with regard to the average density of the light wood-containing material, the multilayer wood-based material and with regard to the components A), B), C) and optionally D) and the combination of the features correspond to those described above.

In einer weiteren bevorzugten Ausführungsform wird das vorgeschäumte oder nichtvorgeschäumte Polystyrol und/oder Styrolcopolymerisat vor dem Mischen mit dem Bindemittel und/oder den Holzpartikeln mit einer antistatischen Beschichtung versehen. Im Hinblick auf das Antistatikum gilt das oben Gesagte.In a further preferred embodiment, the pre-foamed or non-pre-foamed polystyrene and / or styrene copolymer is provided with an antistatic coating prior to mixing with the binder and / or the wood particles. With regard to the antistatic agent, the above applies.

Ferner betrifft die vorliegende Erfindung die Verwendung des erfindungsgemäßen leichten holzhaltigen Stoffs und des erfindungsgemäßen mehrschichtigen Holzwerkstoffs zur Herstellung von Gegenständen aller Art, zum Beispiel Möbel, Möbelteile oder Verpackungsmaterialien, die Verwendung des erfindungsgemäßen leichten holzhaltigen Stoffs und des erfindungsgemäßen mehrschichtigen Holzwerkstoffs im Baubereich. Beispiele für Gegenstände aller Art sind neben Möbeln, Möbelteilen und Verpackungsmaterialien, Wand- und Deckenelemente, Türen und Fußböden.Furthermore, the present invention relates to the use of the light wood-containing material according to the invention and the multilayer wood material according to the invention for the production of objects of all kinds, for example furniture, furniture parts or packaging materials, the use of light wood-containing material according to the invention and the multilayer wood material according to the invention in the construction sector. Examples of items of all kinds include furniture, furniture parts and packaging materials, wall and ceiling panels, doors and floors.

Beispiele für Möbel oder Möbelteile sind Küchenmöbel, Schränke, Stühle, Tische, Arbeitsplatten, beispielsweise für Küchenmöbel, Schreibtischplatten.Examples of furniture or furniture parts are kitchen furniture, cabinets, chairs, tables, countertops, for example for kitchen furniture, desk tops.

Beispiele für Verpackungsmaterialien sind Kisten, Kästen. 'Examples of packaging materials are boxes, boxes. '

Beispiele für den Baubereich sind Hochbau, Tiefbau, Innenausbau, Tunnelbau, wo die erfindungsgemäßen holzhaltigen Stoffe oder erfindungsgemäßen mehrschichtigen Holzwerkstoffe als Verschalungsplatten oder als Träger eingesetzt werden können.Examples of the construction sector are structural engineering, civil engineering, interior construction, tunneling, where the wood-containing materials or multilayer wood-based materials according to the invention can be used as shuttering panels or as a carrier.

Die Vorteile der vorliegenden Erfindung liegen in der geringen Dichte des erfindungsgemäßen leichten holzhaltigen Stoffs oder erfindungsgemäßen mehrschichtigen Holzwerkstoffs , wobei eine gute mechanische Stabilität beibehalten wird. Insbesondere zeigt der erfindungsgemäße holzhaltige Stoff oder der erfindungsgemäße mehrschichtige Holzwerkstoff gute Querzugwerte in Verbindung mit guten Biegefestigkeitswerten. Ferner lassen sich der erfindungsgemäße leichte holzhaltige Stoff und erfindungsgemäße mehrschichtige Holzwerkstoff leicht herstellen; es besteht kein Bedarf, die bestehenden Anlagen zur Herstellung der erfindungsgemäßen mehrschichtigen Holzwerkstoffe umzurüsten.The advantages of the present invention lie in the low density of the light wood-containing material or multilayer wood material according to the invention, wherein a good mechanical stability is maintained. In particular, the wood-containing material according to the invention or the multilayer wood-based material according to the invention exhibits good transverse tensile values in conjunction with good flexural strength values. Furthermore, the light wood-containing material and multi-layer wood material according to the invention can be easily produced; there is no need to retrofit the existing plants for the production of the multilayer wood-based materials according to the invention.

Überraschend gut ist die Bekantbarkeit der erfindungsgemäßen leichten holzhaltigen Stoffe oder besonders der mehrschichtigen Holzwerkstoffe. Die Kante haftet besonders gut und ist nicht uneben oder gewellt, die Schmalfläche, insbesondere des mehrschichtigen Holzwerkstoffs, zeichnet sich nicht durch die Kante hindurch ab, die Kante ist druckstabil und die Bekantung kann mit den üblichen Maschinen der Plattenherstellung und Bekantung erfolgen.Surprisingly good is the Bekantbarkeit the light wood-containing materials according to the invention or especially of the multilayer wood materials. The edge adheres particularly well and is not uneven or wavy, the narrow surface, in particular of the multilayer wood material, is not characterized by the edge through, the edge is pressure-stable and edging can be done with the usual machines of plate making and edging.

Die Quellwerte der erfindungsgemäßen mehrschichtigen Holzwerkstoffe sind vorteilhaft 10 % kleiner, bevorzugt 20 % kleiner, insbesondere 30 % kleiner als die Quellwerte einer analogen Platte gleicher Dichte ohne Füllstoff.The swelling values of the multilayer wood-base materials according to the invention are advantageously 10% smaller, preferably 20% smaller, in particular 30% smaller than the swelling values of an analogous plate of the same density without filler.

BeispieleExamples Herstellung des vorgeschäumten PolystyrolsProduction of prefoamed polystyrene

  • A1) Durch Vorschäumen
    Neopor® N2200 (Neopor® ist ein Handelsprodukt und Marke der BASF Aktiengesellschaft) wurde mit Wasserdampf in einem kontinuierlichen Vorschäumer behandelt. Die Schüttdichte von 50 kg/m3 der vorgeschäumten Polystyrolkügelchen wurde durch Variation des Dampfdrucks und der Bedampfungszeit eingestellt. Der mittlere Teilchendurchmesser betrug nach dem Vorschäumen 1,9 bis 2,5 mm.     A1) By pre-foaming
    Neopor ® N2200 (neopor ® is a commercial product and trademark of BASF Aktiengesellschaft) was treated with steam in a continuous prefoamer. The bulk density of 50 kg / m 3 of the pre-expanded polystyrene beads was adjusted by varying the vapor pressure and the steaming time. The average particle diameter after pre-foaming was 1.9 to 2.5 mm.
  • A2) Durch Zerkleinern von Formkörpern
    • A2.1) Ein Polystyrolschaum-Block, der als Verpackungsmaterial benutzt wurde und eine Dichte von 20 kg/m3 hat, wurde in einer Pallmann-Prallmühle Typ PP auf einen mittleren Teilchendurchmesser von 1 bis 2 mm gemahlen.
    • A2.2) Ein Neopor®-Schaum-Block, der als Isoliermaterial benutzt wurde, und eine Dichte von 20 kg/m3 hat, wurde in einer Pallmann-Prallmühle Typ PP auf einen mittleren Teilchendurchmesser von 1 bis 2 mm gemahlen.
    A2) By crushing of shaped bodies
    • A2.1) A polystyrene foam block that has been used as a packaging material and a density of 20 kg / m 3, was ground in an impact mill Pallmann type PP to an average particle diameter of 1 to 2 mm.
    • A2.2) A Neopor ® foam block, which has been used as an insulating material, and a density of 20 kg / m 3, was ground in an impact mill Pallmann type PP to an average particle diameter of 1 to 2 mm.
B) Herstellung des leichten holzhaltigen Stoffs mit und ohne Füllstoffe unter Verwendung von Harnstoff-FormaldehydleimenB) Production of the light wood-containing substance with and without fillers using urea-formaldehyde glues B1) Mischen der EinsatzstoffeB1) mixing of the starting materials

Als Leime wurde Harnstoff-Formaldehydleim (Kaurit® Leim 340 der BASF Aktiengesellschaft) verwendet. Der Feststoffgehalt wurde jeweils mit Wasser auf 67 Gew.-% eingestellt. Näheres siehe auch in der Tabelle.As glues was urea-formaldehyde glue (glue Kaurit ® 340 from BASF Aktiengesellschaft) were used. The solids content was adjusted in each case with water to 67 wt .-%. For details see also in the table.

In einem Mischer wurden 450 g Späne (Komponente A)) gemäß Tabelle und gegebenenfalls Komponente B) gemäß Tabelle gemischt. Anschließend wurden 58,8 g einer Leimflotte aus 100 Teilen Kaurit®-Leim 340 und 4 Teilen einer 52 % wässrigen Ammoniumnitratlösung und 10 Teilen Wasser aufgebracht.In a mixer, 450 g of chips (component A)) were mixed according to the table and optionally component B) according to the table. Subsequently, 58.8 g of a glue liquor comprising 100 parts Kaurit ® -Leim 340 and 4 parts of a 52% aqueous ammonium nitrate solution and 10 parts of water were applied.

B 2) Verpressen der beleimten SpäneB 2) pressing the glued chips

Die beleimten Späne wurden in einer 30x30cm-Form kalt vorverdichtet. Anschließend wurde in einer Heißpresse gepresst (Presstemperatur 190 °C, Presszeit 210 s). Die Solldicke der Platte betrug jeweils 16mm.The glued chips were cold pre-compacted in a 30x30cm-form. It was then pressed in a hot press (pressing temperature 190 ° C, pressing time 210 s). The nominal thickness of the plate was 16mm in each case.

C) Untersuchung des leichten holzhaltigen StoffsC) Examination of the light wood-containing substance C 1) DichteC 1) density

Die Bestimmung der Dichte erfolgte 24 Stunden nach Herstellung nach DIN EN 1058.The density was determined 24 hours after preparation according to DIN EN 1058.

C 2) QuerzugsfestigkeitC 2) transverse tensile strength

Die Bestimmung der Querzugsfestigkeit erfolgte nach DIN EN 319.The determination of the transverse tensile strength was carried out according to DIN EN 319.

C 3) Quellwerte und WasseraufnahmeC 3) Swelling values and water absorption

Die Bestimmung der Quellwerte und der Wasseraufnahme erfolgte nach DIN EN 317.The determination of the swelling values and the water absorption was carried out according to DIN EN 317.

C 4) BiegefestigkeitC 4) bending strength

Die Bestimmung der Biegefestigkeit erfolgte nach DIN EN 310.The determination of the bending strength was carried out according to DIN EN 310.

Die Ergebnisse der Versuche sind in der Tabelle zusammengestellt.The results of the experiments are summarized in the table.

Die Mengenangaben beziehen sich immer auf die Trockensubstanz. Bei der Angabe der Gewichtsteile wird das trockene Holz bzw. die Summe des trockenen Holzes und des Füllstoffs auf 100 Teile gesetzt. Bei der Angabe der Gew.-% ist die Summe aller trockenen Bestandteile des leichten holzhaltigen Stoffs gleich 100 %.The quantities always refer to the dry matter. When specifying the parts by weight, the dry wood or the sum of the dry wood and the filler is set to 100 parts. When specifying the wt .-%, the sum of all dry constituents of the light wood-containing substance is equal to 100%.

Die Versuche in der Tabelle ohne Zusatz von Komponente B) dienen zum Vergleich. Tabelle: Versuch U F-Leim
(Feststoff), Gew.-Teile UF-Leim
(Feststoff), Gew.-% Holz, Gew.-Teile Holz, Gew.-% Perlen, Gew.-% Komp. B) ePS-Perlen, Gew.-Teile Komp B) ePS gemahlen
(Neopor Block), Gew.-Teile Komp. B) ePS gemahlen
(Neopor Block), Gew.-% Komp. B) ePS gemahlen
(Styropor Block, Verpackung, Gew.-Teile Komp. B) ePS gemahlen
(Styropor Block, Verpackung, Gew.-% 1 11 9,91 90 81,08 5 4,50 0 0 5 4,50 2 11 9,91 90 81,08 5 4,50 0 0 5 4,50 3 11 9,91 90 81,08 5 4,50 0 0 5 4,50 4 11 9,91 90 81,08 5 4,50 5 4,50 0 0 5 11 9,91 90 81,08 5 4,50 5 4,50 0 0 6 11 9,91 90 81,08 5 4,50 5 4,50 0 0 7 11 9,91 90 81,08 0 0 0 0 10 9,01 8 11 9,91 90 81,08 0 0 0 0 10 9,01 9 11 9,91 90 81,08 0 0 0 0 10 9,01 10 [1] 11 9,91 90 81,08 0 0 10 9,01 0 0 11 11 9,91 90 81,08 0 0 10 9,01 0 0 12 11 9,91 90 81,08 0 0 10 9,01 0 0 13 11 9,91 100 90,09 0 0 0 0 0 0 14 11 9,91 100 90,09 0 0 0 0 0 0 15 11 9,91 100 90,09 0 0 0 0 0 0 16 11 9,91 100 90,09 0 0 0 0 0 0 [1] Nicht erfindungsgemäß Tabelle: Fortsetzung Versuch Dichte Werkstoff, [kg/m3] Querzugsfestigkeit,
[N/mm2] Biege-festigkeit,
[N/mm2] Wasseraufnahme 24 St., [%] Quell-Wert 24 St., [%] 1 504 0, 57 9, 78 105 18,1 2 547 0,67 11,71 98 19,7 3 591 0,74 16,65 89 20,6 4 598 0,69 16,26 89, 7 21, 7 5 553 0,6 12,35 98,5 19,5 6 573 0,64 12,60 94,3 21,0 7 589 0,58 14,39 96,3 23,9 8 554 0,54 11,65 101,8 21,4 9 500 0,42 9,36 118,0 20,1 10 [1] 613 0,63 14,36 95,9 23,4 11 573 0,48 11,91 104,7 22,7 12 521 0,37 9,97 120,8 21,0 13 [1] 608 0,57 10,45 100,9 25,8 14 [1] 549 0,55 8,73 113,9 22,0 15 [1] 502 0,45 6,08 128,2 20,5 16 [1] 454 0,33 4,35 142,0 18,0 [1] Nicht erfindungsgemäß The experiments in the table without the addition of component B) are for comparison. Table: attempt U F glue
(Solid), parts by weight UF glue
(Solid), wt% Wood, parts by weight Wood, weight% Beads,% by weight Comp. B) ePS beads, parts by weight Comp B) ePS ground
(Neopor Block), parts by weight Comp. B) ePS ground
(Neopor Block), wt% Comp. B) ePS ground
(Styrofoam block, packaging, parts by weight Comp. B) ePS ground
(Styrofoam Block, Packaging,% by Weight 1 11 9.91 90 81.08 5 4.50 0 0 5 4.50 2 11 9.91 90 81.08 5 4.50 0 0 5 4.50 3 11 9.91 90 81.08 5 4.50 0 0 5 4.50 4 11 9.91 90 81.08 5 4.50 5 4.50 0 0 5 11 9.91 90 81.08 5 4.50 5 4.50 0 0 6 11 9.91 90 81.08 5 4.50 5 4.50 0 0 7 11 9.91 90 81.08 0 0 0 0 10 9.01 8th 11 9.91 90 81.08 0 0 0 0 10 9.01 9 11 9.91 90 81.08 0 0 0 0 10 9.01 10 [1] 11 9.91 90 81.08 0 0 10 9.01 0 0 11 11 9.91 90 81.08 0 0 10 9.01 0 0 12 11 9.91 90 81.08 0 0 10 9.01 0 0 13 11 9.91 100 90.09 0 0 0 0 0 0 14 11 9.91 100 90.09 0 0 0 0 0 0 15 11 9.91 100 90.09 0 0 0 0 0 0 16 11 9.91 100 90.09 0 0 0 0 0 0 [1] Not according to the invention attempt Dense material, [kg / m3] transverse tensile strength,
[N / mm2] Flexural strength,
[N / mm2] Water absorption 24 hours, [%] Source value 24 hours, [%] 1 504 0, 57 9, 78 105 18.1 2 547 0.67 11.71 98 19.7 3 591 0.74 16.65 89 20.6 4 598 0.69 16.26 89, 7 21, 7 5 553 0.6 12.35 98.5 19.5 6 573 0.64 12.60 94.3 21.0 7 589 0.58 14.39 96.3 23.9 8th 554 0.54 11.65 101.8 21.4 9 500 0.42 9.36 118.0 20.1 10 [1] 613 0.63 14.36 95.9 23.4 11 573 0.48 11.91 104.7 22.7 12 521 0.37 9.97 120.8 21.0 13 [1] 608 0.57 10.45 100.9 25.8 14 [1] 549 0.55 8.73 113.9 22.0 15 [1] 502 0.45 6.08 128.2 20.5 16 [1] 454 0.33 4.35 142.0 18.0 [1] Not according to the invention

Claims (13)

  1. A light wood-containing material having an average density in the range from 200 to 600 kg/m3, comprising, based in each case on the wood-containing material:
    A) from 30 to 95% by weight of wood particles;
    B) from 1 to 25% by weight of a filler having a bulk density in the range from 10 to 150 kg/m3, selected from the group consisting of foamable plastic particles and already foamed plastic particles;
    C) from 0.1 to 50% by weight of a binder and, if appropriate,
    D) additives,
    the component B) comprising foamed plastic particles obtained by comminution of molding, in an amount in the range from 15% by weight to 85% by weight, based on the component B).
  2. The light wood-containing material according to claim 1, the component B) being selected from the group consisting of styrene homopolymer, styrene copolymer, C2- to C10-olefin homopolymer, copolymers of C2- to C10-olefins, PVC (rigid and flexibly), polycarbonates, polyisocyanurates, polycarbodiimides, polyacrylimides, polymethacrylimides, polyamides, polyesters, polyurethanes, aminoplast resins and phenol resins.
  3. The light wood-containing material according to claim 1 or 2, the component B) being selected from the group consisting of styrene homopolymer and styrene copolymer.
  4. The light wood-containing material according to claims 1 to 3, component C) being an aminoplast resin selected from the group consisting of urrea-formaldehyde resin, melamine-formaldehyde resin, melamine-urea-formaldehyde resin.
  5. The light wood-containing material according to claims 1 to 4, component C) being an organic isocyanate having at least two isocyanate groups.
  6. The light wood-containing material according to claims 1 to 5, the content of the aminoplast resin in the component C), based on the light wood-containing material, being in the range from 1 to 45% by weight.
  7. A multilayer wood-base material which comprises at least three layers, only the middle layer or at least part of the middle layers comprising a light wood-containing material according to claims 1 to 6.
  8. A multilayer wood-base material which comprises at least three layers, only the middle layer or at least part of the middle layers comprising a light wood-containing material according to claims 1 to 6 and the outer covering layers comprising no filler.
  9. The multilayer wood-base material according to claims 7 and 8, having an average density in the range from 300 kg/m3 to 600 kg/m3.
  10. A process for the production of light wood-containing materials as defined in claims 1 to 6, in which
    A) from 30 to 95% by weight of wood particles;
    B) from 1 to 25% by weight of a filler having a bulk density in the range from 10 to 150 kg/m3, selected from the group consisting of foamable plastic particles and already foamed elastic particles;
    C) from 0.1 to 50% by weight of a binder and, if appropriate,
    D) additives,
    are mixed and are then pressed at elevated temperature and under superatmospheric pressure, the component B) comprising foamed plastic particles obtained by comminution of moldings, in an amount in the range from 15% by weight to 85% by weight, based on the component B).
  11. A process for the production of a multilayer wood-base material as defined in claims 7 to 9, the components for the individual layers being stacked one on top of another and being pressed at elevated temperature and under superatmospheric pressure.
  12. The use of the light wood-containing materials, defined in claims 1 to 6, or of the multilayer wood-base material, defined in claims 7 to 9, for the production of articles of all types and in the building sector.
  13. The use of the light wood-containing material, defined in claims 1 to 6, or of the multilayer wood-base material, defined in claims 7 to 9, for the production of pieces of furniture, furniture parts or packaging materials, in house construction or in interior finishing.
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