WO2002038676A1 - Method of making a finished product - Google Patents
Method of making a finished product Download PDFInfo
- Publication number
- WO2002038676A1 WO2002038676A1 PCT/IB2001/002108 IB0102108W WO0238676A1 WO 2002038676 A1 WO2002038676 A1 WO 2002038676A1 IB 0102108 W IB0102108 W IB 0102108W WO 0238676 A1 WO0238676 A1 WO 0238676A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- resin
- feedstock
- inclusive
- lignocellulosic material
- finished product
- Prior art date
Links
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
- B27N3/08—Moulding or pressing
-
- 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
- B27N3/002—Manufacture of substantially flat articles, e.g. boards, from particles or fibres characterised by the type of binder
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L97/00—Compositions of lignin-containing materials
- C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse
Definitions
- THIS invention relates to a method of making a finished product from a feedstock including polystyrene particles and finely divided lignocellulosic particles or fibres, and a thermosetting resin.
- MDF medium density fibre board
- a method of making a finished product including the steps of:
- thermosetting resin in solid finely divided dry particle form or in the form of a solution or a dispersion in a liquid
- step (c) removing any liquid present from the product of step (b);
- step (d) subjecting the product of step (c) to suitable conditions of temperature and pressure to cause the polystyrene to melt and to cause the thermosetting resin to set and then cooling to form the finished product.
- a finished product comprising:
- thermosetting resin from 2% to 15% by weight relative to the feedstock of a thermosetting resin; components (a) and (b) being mixed together, the polystyrene having impregnated the lignocellulosic material and formed a skin at or near the outer surfaces of the finished product, and the thermosetting resin having set to bind the feedstock into the finished product.
- the crux of the invention is a method of making a finished product from a feedstock and from a thermosetting resin.
- the feedstock comprises a mixture of unexpanded or foamed polystyrene particles and a lignocellulosic material in finely divided particle or fibre form.
- the polystyrene foam particles must have a particle size of less than 1.00 mm in diameter.
- unexpanded polystyrene particles they preferably have a particle size of less than 0,3 mm in diameter. More preferably for both unexpanded and foamed polystyrene particles, the particle size is less than 150 micron in diameter, i.e dust.
- the foamed polystyrene particles are preferably produced by feeding the polystyrene foam onto a moving abrasive belt, such as 36 grit sandpaper.
- the particles are abraded from the foam in a suitable particle size, which is dependent upon the grit of the sandpaper or abrasive projections on the belt.
- This method provides particles which are difficult or impossible to produce through techniques such as milling.
- the belt must be cooled or the feed oscillated to prevent heat build up to the softening point of the polystyrene foam.
- the bulk density of the polystyrene foam regrind is of the order of 40 g/l.
- Polystyrene foam regrind has the advantage of providing the finished product with good hardness, low water absorption, of the order of less than 0,04% to 0,06% after 24 hour immersion, and excellent impact resistance.
- the unexpanded polystyrene particles are preferably produced by milling polystyrene beads with a diameter of about 2 mm, to produce particles with a particle size of less than 0,3 mm in diameter.
- step (d) the polystyrene melts and firstly impregnates the particles or fibres of the lignocellulosic material and secondly tends to migrate towards the surface of the product to produce a hard water resistant skin.
- the second component of the feedstock is a lignocellulosic material in finely divided dry particle or fibre form.
- lignocellulosic material there is meant any plant material emanating from the photosynthetic phenomenon.
- the lignocellulosic material may be wood particles or fibres, paper waste or pulp, ground nutshells, cork particles, and agricultural fibres such as cotton waste.
- the preferred lignocellulosic material is a reed from the Typha species, for which the common name is cattail, which grows in wetland areas. These reeds may be harvested and then chopped into suitable short lengths or may be reduced to fibres in any suitable manner.
- the particular advantage of this fibre source is that a commercial benefit may be derived from wetlands designed for the natural purification of effluent or nutrient rich water.
- the fibre may be harvested all year.
- the fibre is soft and compliant to a shape on pressing, and is inexpensive.
- the lignocellulosic material when in finely divided particle form must have a particle size with a diameter of from 0,25 mm to 0,75 mm inclusive.
- the lignocellulosic material when in fibre form has fibres with a length not exceeding 16 mm, with an aspect ratio (being the ratio of length to cross- section) preferably of the order of 20:1 or greater.
- the feedstock contains from 5% to 40% inclusive by weight of the polystyrene particles and 60 to 95% inclusive by weight of the lignocellulosic material, preferably 10% to 20% inclusive by weight of the polystyrene particles and 80% to 90%o inclusive by weight of the lignocellulosic material.
- step (a) the polystyrene particles and the lignocellulosic material in finely divided particle or fibre form are simply mixed together. Separation does not occur as a result of electrostatic attraction and the small particle size of the polystyrene particles.
- step (b) the feedstock is mixed with a thermosetting resin in solid finely divided particulate form or in the form of a solution or a dispersion in a liquid.
- thermosetting resin is preferably selected from the group comprising:
- step (i) an MDI or urethane pre-polymer, typically dispersed in a mineral oil, vegetable oil or water, which is evaporated in step (c);
- step (ii) a phenol-formaldehyde resole resin dissolved in water or methyl alcohol, optionally including a further solvent such as, for example, acetone, to which is added an acid catalyst, the water, alcohol and other solvent if present being evaporated in step (c);
- a further solvent such as, for example, acetone
- a urea formaldehyde resin acid catalysed in water;
- a melamine formaldehyde resin acid catalysed in water;
- an unsaturated polyester resin optionally modified with a styrene monomer and with a latent catalyst therefor.
- thermosetting resin may be provided in finely divided dry particle form. By finely divided there is meant that the thermosetting resin must have a particle size of 98% passing a 200 mesh screen.
- thermosetting resin is preferably used in an amount of from 2% to 15% by weight relative to the feedstock, i.e to 100% by weight of the feedstock.
- any liquid present e.g a solvent for the thermosetting resin or a dispersing agent for the thermosetting resin, is removed by evaporation or in any other suitable manner.
- step (d) the product of step (c) is subjected to suitable conditions of temperature and pressure to cause the polystyrene to melt and to cause the thermosetting resin to set to form the finished product.
- the product of step (c) may be laid on the platens of a suitable press and subjected to a temperature of from 140°C to 220°C inclusive and a pressure of from 10 kg/cm 2 to 70 kg/cm 2 inclusive for a time sufficient to allow the polystyrene to melt and the thermosetting resin to set, whereafter the product is cooled to form the finished product.
- the melted polystyrene impregnates the lignocellulosic material, with some of the melted polystyrene migrating to the outer surfaces of the finished product to form a water resistant skin.
- the result is a strong lightweight general purpose board such as a roof sheet or pallet deck, that may easily be nailed, cut, worked, handled and painted.
- the mixture was spread on a carrier sheet (600 mm x 500 mm).
- the product was then pressed to a corrugated profile, the depths of the corrugations being 25 mm and the corrugations being spaced at 75 mm centre to centre.
- the thickness of the product was 4,5 mm and the density was 1 ,2 g/cm 3 . Thereafter the carrier sheet was removed to give the finished product.
- the foamed polystyrene particles may be replaced with an equivalent amount of unexpanded polystyrene particles, with a particle size of less than 250 mm in diameter.
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2002214183A AU2002214183A1 (en) | 2000-11-10 | 2001-11-09 | Method of making a finished product |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
ZA2000/6525 | 2000-11-10 | ||
ZA200006525 | 2000-11-10 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2002038676A1 true WO2002038676A1 (en) | 2002-05-16 |
Family
ID=25588975
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/IB2001/002108 WO2002038676A1 (en) | 2000-11-10 | 2001-11-09 | Method of making a finished product |
Country Status (2)
Country | Link |
---|---|
AU (1) | AU2002214183A1 (en) |
WO (1) | WO2002038676A1 (en) |
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1914052A1 (en) * | 2006-10-19 | 2008-04-23 | Basf Se | Lightweight wooden material |
WO2011018373A1 (en) | 2009-08-13 | 2011-02-17 | Basf Se | Light lignocellulosic materials having good mechanical properties |
WO2011018372A1 (en) | 2009-08-13 | 2011-02-17 | Basf Se | Light lignocellulosic materials having good mechanical properties |
WO2011054790A1 (en) | 2009-11-06 | 2011-05-12 | Basf Se | Lignocellulose materials with good mechanical properties |
US8187709B2 (en) | 2007-09-19 | 2012-05-29 | Basf Se | Light wood-based materials having good mechanical properties and low formaldehyde emission |
US8623501B2 (en) | 2010-03-04 | 2014-01-07 | Basf Se | Lignocellulose materials having good mechanical properties |
CN103568097A (en) * | 2013-10-21 | 2014-02-12 | 黄宣斐 | Low-density plate containing natural wood fibers |
US8920923B2 (en) | 2010-03-04 | 2014-12-30 | Basf Se | Lignocellulose materials having good mechanical properties |
CN104786342A (en) * | 2015-04-24 | 2015-07-22 | 东北林业大学 | Wood composite board with low-density sandwich-type structure and preparation method thereof |
Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR1242425A (en) * | 1959-10-30 | 1960-08-22 | Composition based on a powder mixture (wood powder, straw or other plants or artificial substances) and molding process | |
GB1267918A (en) * | 1968-07-23 | 1972-03-22 | Amos Roy Paske | Improvements in or relating to particle board |
SU844375A1 (en) * | 1979-12-04 | 1981-07-07 | Центральный Научно-Исследовательскийинститут Фанеры | Mouldable wood mass |
GB2193503A (en) * | 1986-08-04 | 1988-02-10 | Bohuslav Vaclav Kokta | Bonded composites of cellulose based fibers in polystyrene polymers characterized by a bonding agent |
JPH04272801A (en) * | 1991-02-28 | 1992-09-29 | Sanshin Seinetsu Kogyo Kk | Molded body using foaming styrol powder binder |
JPH06344361A (en) * | 1993-06-07 | 1994-12-20 | Ask:Kk | Manufacture of large-shaped resin-molding |
JPH079467A (en) * | 1993-06-22 | 1995-01-13 | Hitachi Chem Co Ltd | Production of composite body of wood meal and thermoplastic resin |
-
2001
- 2001-11-09 AU AU2002214183A patent/AU2002214183A1/en not_active Abandoned
- 2001-11-09 WO PCT/IB2001/002108 patent/WO2002038676A1/en not_active Application Discontinuation
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR1242425A (en) * | 1959-10-30 | 1960-08-22 | Composition based on a powder mixture (wood powder, straw or other plants or artificial substances) and molding process | |
GB1267918A (en) * | 1968-07-23 | 1972-03-22 | Amos Roy Paske | Improvements in or relating to particle board |
SU844375A1 (en) * | 1979-12-04 | 1981-07-07 | Центральный Научно-Исследовательскийинститут Фанеры | Mouldable wood mass |
GB2193503A (en) * | 1986-08-04 | 1988-02-10 | Bohuslav Vaclav Kokta | Bonded composites of cellulose based fibers in polystyrene polymers characterized by a bonding agent |
JPH04272801A (en) * | 1991-02-28 | 1992-09-29 | Sanshin Seinetsu Kogyo Kk | Molded body using foaming styrol powder binder |
JPH06344361A (en) * | 1993-06-07 | 1994-12-20 | Ask:Kk | Manufacture of large-shaped resin-molding |
JPH079467A (en) * | 1993-06-22 | 1995-01-13 | Hitachi Chem Co Ltd | Production of composite body of wood meal and thermoplastic resin |
Non-Patent Citations (8)
Title |
---|
AL. MADFAI SUHAM H. F. ET AL.: "Typha as raw material for particleboard manufacturing", J. PETROL. RES., vol. 6, no. 1, 1987, pages 157 - 167, XP008002182 * |
DATABASE CHEMABS [online] chemical abstracts service, columbus, ohio, us; "CHARACTERIZATION OF tYPHA DOMINGENSIS AND ITS USE IN THE MANUFACTURE OF PAPER AND PRESSED FIBERBOARDS", XP002195852, retrieved from STN Database accession no. 132:109602 * |
DATABASE WPI Week 198219, Derwent World Patents Index; AN 1982-38728e, XP002195853, "Wood based pressure moulding compsn. - contg ground wood filler, phenol-formaldehyde resin binder and pulverised waste polystyrene additive" * |
DATABASE WPI Week 199245, Derwent World Patents Index; AN 1992-370502, XP002195855, "Prodn. of polystyrene formed body - comprises pressing powdery resin composn. binder with reinforcing material and/or filler, and foamed polystyrene powder" * |
DATABASE WPI Week 199510, Derwent World Patents Index; AN 1995-069693, "Mfr. of large resin mouldings - includes pressure moulding resin contg. reinforcing material heating and tzhen auttoclaving to harden" * |
DATABASE WPI Week 199512, Derwent World Patents Index; AN 1995-084876, XP002195854, "Wood powder-thermoplastic resin composite material prepn. - by mixing fine wood powder and thermoplastic resin and hot pressing" * |
ESCOTO T. ET AL., INVEST. TEC. PAP., vol. 36, no. 140, 1999, pages 157 - 168 * |
PATENT ABSTRACTS OF JAPAN vol. 1995, no. 03 28 April 1995 (1995-04-28) * |
Cited By (22)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8304069B2 (en) | 2006-10-19 | 2012-11-06 | Basf Se | Light wood-based materials |
WO2008046892A2 (en) * | 2006-10-19 | 2008-04-24 | Basf Se | Light wood-based materials |
EP2319670A1 (en) | 2006-10-19 | 2011-05-11 | Basf Se | Lightweight wooden material |
WO2008046891A1 (en) * | 2006-10-19 | 2008-04-24 | Basf Se | Light wood materials with good mechanical characteristics |
WO2008046890A3 (en) * | 2006-10-19 | 2008-06-12 | Basf Se | Light wood-based materials |
WO2008046892A3 (en) * | 2006-10-19 | 2008-08-21 | Basf Se | Light wood-based materials |
DE202006020503U1 (en) | 2006-10-19 | 2008-10-09 | Basf Se | Light wood materials |
EA013666B1 (en) * | 2006-10-19 | 2010-06-30 | Басф Се | Light wood-based material |
CN101541488B (en) * | 2006-10-19 | 2014-01-15 | 巴斯夫欧洲公司 | Light wood-based materials |
EP1914052A1 (en) * | 2006-10-19 | 2008-04-23 | Basf Se | Lightweight wooden material |
US9089991B2 (en) | 2006-10-19 | 2015-07-28 | Basf Se | Light wood-based materials |
WO2008046890A2 (en) * | 2006-10-19 | 2008-04-24 | Basf Se | Light wood-based materials |
EA013665B1 (en) * | 2006-10-19 | 2010-06-30 | Басф Се | Light wood-based materials |
US8187709B2 (en) | 2007-09-19 | 2012-05-29 | Basf Se | Light wood-based materials having good mechanical properties and low formaldehyde emission |
CN101802104B (en) * | 2007-09-19 | 2012-05-30 | 巴斯夫欧洲公司 | Light wood-based materials having good mechanical properties and low formaldehyde emission |
WO2011018373A1 (en) | 2009-08-13 | 2011-02-17 | Basf Se | Light lignocellulosic materials having good mechanical properties |
WO2011018372A1 (en) | 2009-08-13 | 2011-02-17 | Basf Se | Light lignocellulosic materials having good mechanical properties |
WO2011054790A1 (en) | 2009-11-06 | 2011-05-12 | Basf Se | Lignocellulose materials with good mechanical properties |
US8623501B2 (en) | 2010-03-04 | 2014-01-07 | Basf Se | Lignocellulose materials having good mechanical properties |
US8920923B2 (en) | 2010-03-04 | 2014-12-30 | Basf Se | Lignocellulose materials having good mechanical properties |
CN103568097A (en) * | 2013-10-21 | 2014-02-12 | 黄宣斐 | Low-density plate containing natural wood fibers |
CN104786342A (en) * | 2015-04-24 | 2015-07-22 | 东北林业大学 | Wood composite board with low-density sandwich-type structure and preparation method thereof |
Also Published As
Publication number | Publication date |
---|---|
AU2002214183A1 (en) | 2002-05-21 |
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