CA1307089C - Process for the production of an optionally panel-like synthetic resin plastic pressure moulded body as well as an initial product for use in such a process - Google Patents
Process for the production of an optionally panel-like synthetic resin plastic pressure moulded body as well as an initial product for use in such a processInfo
- Publication number
- CA1307089C CA1307089C CA000581019A CA581019A CA1307089C CA 1307089 C CA1307089 C CA 1307089C CA 000581019 A CA000581019 A CA 000581019A CA 581019 A CA581019 A CA 581019A CA 1307089 C CA1307089 C CA 1307089C
- Authority
- CA
- Canada
- Prior art keywords
- wood
- bonding agent
- fibres
- resin
- production
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 238000000034 method Methods 0.000 title claims abstract description 43
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 12
- 229920003002 synthetic resin Polymers 0.000 title claims 6
- 239000000057 synthetic resin Substances 0.000 title claims 6
- 239000002023 wood Substances 0.000 claims abstract description 63
- 229920005989 resin Polymers 0.000 claims abstract description 33
- 239000011347 resin Substances 0.000 claims abstract description 33
- 238000009833 condensation Methods 0.000 claims abstract description 17
- 230000005494 condensation Effects 0.000 claims abstract description 17
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 16
- 239000007787 solid Substances 0.000 claims abstract description 5
- 238000007731 hot pressing Methods 0.000 claims abstract description 4
- 239000007767 bonding agent Substances 0.000 claims abstract 23
- 229920002522 Wood fibre Polymers 0.000 claims abstract 18
- 239000007788 liquid Substances 0.000 claims abstract 5
- 239000000654 additive Substances 0.000 claims abstract 3
- 239000000463 material Substances 0.000 claims description 3
- 238000001035 drying Methods 0.000 claims description 2
- 150000002989 phenols Chemical class 0.000 claims description 2
- 239000000203 mixture Substances 0.000 claims 5
- 239000012876 carrier material Substances 0.000 claims 4
- 125000002485 formyl group Chemical class [H]C(*)=O 0.000 claims 2
- 125000002924 primary amino group Chemical group [H]N([H])* 0.000 claims 1
- 239000000123 paper Substances 0.000 abstract description 15
- 239000000049 pigment Substances 0.000 abstract 1
- 239000007858 starting material Substances 0.000 abstract 1
- 239000003795 chemical substances by application Substances 0.000 description 24
- 239000010410 layer Substances 0.000 description 23
- 239000002655 kraft paper Substances 0.000 description 7
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 6
- 239000002344 surface layer Substances 0.000 description 4
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- 229920000877 Melamine resin Polymers 0.000 description 2
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 2
- 229920002678 cellulose Polymers 0.000 description 2
- 239000001913 cellulose Substances 0.000 description 2
- 239000012792 core layer Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 241001163743 Perlodes Species 0.000 description 1
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 1
- 239000004202 carbamide Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- SLGWESQGEUXWJQ-UHFFFAOYSA-N formaldehyde;phenol Chemical compound O=C.OC1=CC=CC=C1 SLGWESQGEUXWJQ-UHFFFAOYSA-N 0.000 description 1
- WSFSSNUMVMOOMR-NJFSPNSNSA-N methanone Chemical compound O=[14CH2] WSFSSNUMVMOOMR-NJFSPNSNSA-N 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000004580 weight loss Effects 0.000 description 1
Classifications
-
- 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
-
- 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.]
Abstract
ABSTRACT
During the production of pressure moulded bodies a bonding agent that is a condensation resin with a solid resin content of at least 80% and a water content of at most 7%-wt, preferably however, of at most 5%-wt is applied in liquid or brushable form to wood chips and/or wood fibres having a moisture content of at most 10%-wt, preferably however, at most 8%-wt as starting material (this condensation resin optionally containing additives such as pigments). The wood chips and/or fibres that have been so coated--optionally between cover layers of paper that has been impregnated with synthetic resin--are hot pressed together with the cover layers at, for example, 70 bar as the resin is hardening, so as to form a pressure moulded body. Panel-like rough-pressed blocks can be formed from the above mentioned coated wood chips and/or fibres or alternatively, one can coat wood fibres that are already in the form of insulating panels or mats with the bonding agent. These then form rough cast blocks or insulating panels that can be handled and transported, and which are then used as press goods for the hot-pressing process.
During the production of pressure moulded bodies a bonding agent that is a condensation resin with a solid resin content of at least 80% and a water content of at most 7%-wt, preferably however, of at most 5%-wt is applied in liquid or brushable form to wood chips and/or wood fibres having a moisture content of at most 10%-wt, preferably however, at most 8%-wt as starting material (this condensation resin optionally containing additives such as pigments). The wood chips and/or fibres that have been so coated--optionally between cover layers of paper that has been impregnated with synthetic resin--are hot pressed together with the cover layers at, for example, 70 bar as the resin is hardening, so as to form a pressure moulded body. Panel-like rough-pressed blocks can be formed from the above mentioned coated wood chips and/or fibres or alternatively, one can coat wood fibres that are already in the form of insulating panels or mats with the bonding agent. These then form rough cast blocks or insulating panels that can be handled and transported, and which are then used as press goods for the hot-pressing process.
Description
~3~7~89 Technlcal Domain The present lnventlon relates to a process for the productlon of a synthetlc resln pressure moulded body ln whlch a bondlng agent that ls a phenol-aldehyde or an amlno-aldehyde condensatlon resln, such as formaldehyde, ls applled to drled wood chlps and~or wood flbres for purposes of lmpregnatlon and ls hot pressed during the hardenlng of the resln. Other materlals, such as coverlng and/or lntermedlate layers, may also be present. The present lnventlon also relates to preformed products whlch can be used ln such a process.
Prlor Art EP 0081147 Bl relates to a process for the productlon of a decoratlve structural panel ln whlch one applles an aqueous alkallne solutlon or dlsperslon of a phenol-formaldehyde resln to wood flbres, and then drles the resln coated wood flbres to a resldual rnolsture content of 2 to 15%. A flbre mat ls then formed from the resln coated, drled wood flbres, and thls 1~ then mechanlcally consolldated and then is hot pressed ln one or a plurallty of layers arranged one above the other to form a core layer~ a decoratlve layer can be applled to the core layer slmultaneously or subsequent to the presslny process.
Thls known process ls lntended to produce a structural panel that has propertles slmllar to those found ln moulded laminated plastlc panels produced ln the usual way, whlch are made by hot presslng ao-called "prepregs," that are of paper lmpregnated when dry wlth hardenable synthetlc resins. However, as a result of the preferred orlentatlon of the cellulose flbres of the paper ln the dlrectlon preferred durlng the productlon of . :. .
~7~89 such paper, under varylng cllmatlc conditlons such moulded lamlnated plastic panels dlsplay shrlnkage and stretch behavlour that dlffers ln the longltudlnal or transverse dlrectlon of the paper that ls used, and thls can have a dlsadvantageous effect when they are used. In addltlon, the papers that are used ln such panels are a materlal that ls produced from wood as a raw materlal, uslng a process that ls costly and harmful to the ecology.
The anlsotropy ln the stretch and shrlnkage behavlour, whlch has been noted above, ls avolded ln panels produced accordlng to the process that ls known from EP 0081147 Bl and, ln addltlon, slnce to a very great extent wood flbres are used here ln place of paper, one can--vlewed overall--manage wlth a lower productlon cost than ls the case wlth the conventlonal productlon of moulded lamlnated plastlc panels. However, the drylng of the resin coated wood flbres remalns a costly stage ln the process and 18, in some lnstances, harmful to the envlronment.
EP 0035133 ~1 also descrlbes the productlon of decoratlve lamlnates~ ln thls process, a powdered phenol resln ls lntroduced lnto a current of molst alr wlthln whlch cellulose and cellulose-llke flbres are dlspersed, and the flbres and the phenol reslns then mlx. The mlxture of wood flbres and phenol resln ls then deposlted on a sleve-llke band ln the form of a layer, whlch after preconsolldatlon ls lntended for use ln the same way as a paper "prepreg" that ha~ been lmpregnated wlth resln, for the productlon of the lamlnate. However, the use of powdered resln ln such flbre "prepregs" entalls several fundamental dlsadvantages.
Flrst, there ls a danger that the flbres and the powdered resln ~3~7~89 wlll become segregated durlng storage and transportatlon wlthln the framework of the productlon process. In addltion, phenol reslns ln powder form have a smaller low-molecular component than llquid phenol resins. This can result ln the fact that, durlng subsequent hot pressing, the resln does not flow as well, whlch can cause lmperfect wettlng and penetratlon of the resin through the flbres.
DescrlPtlon of the Inventlon Thus, lt ls an ob~ect of the present lnventlon to provlde a process ln whlch the dlsadvantages of the known process can be reduced or avoided by uslng a resln bondlng agent that flows well when used.
Accordlngly, the present lnventlon provldes a process for the productlon of a synthetlc resln pressure moulded body ln whlch a bondlng agent that ls a phenol-aldehyde or an amlno-aldehyde conden~atlon resln ln llquld form or brushable form ls heated to lower lts vlscoslty and applled to dry wood chlps or flbres, the bondlng agent, lf a phenol-aldehyde condensatlon resin, belng applled ln an amount of 25 to 55~ of the amount of wood or the bondlng agent, lf an amlno-aldehyde condensatlon resln, belng applled ln an amount of 80 to 160% of the amount of wood, and 18 hot pressed whlle the resln ls hardenlng, whereln the molsture content of the wood ls at mo~t 10%, preferably at most 8 and the condensatlon resln has a solld resln content of at least 80% wt and a water content of at most 7%. The resln composltlon can contaln addltlves, for lnstance colourlng plgments.
When the above descrlbed process ls carrled out, lt ls posslble to achleve a "volatlle content" of the mass of the wood -~7~89 chips an~/or flbres that are lmpregnated wlth the bondlng agent of between 3 and 10%, at whlch thls mass can be further processed wlthout the need for a drylng process. The "volatlle content" of the mass of the wood chlps and/or wood flbres lmpregnated wlth the bondlng agent ls determlned by the weight loss that thls mas.s exhiblts when heated, e.g., in a drying cabinet, for 5 mlnutes at 165C. The "volatile content" can be ad~usted by ad~usting the molsture content of the drled wood chlps and/or fibres to the water content of the condensation resin, while taking lnto account the quantlty of the addltlves that are used. To a great extent, the volatlle content conslsts of water and, for example, of phenol and low-molecular resln factions. An approprlate volatlle content is important for good flowlng of the resln durlng the hot presslng process. If the volatlle content ls too low, the resln does not flow well, and lf it ls too high, thls wlll have an effect on the hardening of the resln during the presslng process.
The ~olld resin content ls determlned ln a drylng cablnet, ln a dlsh wlth a welghed sample of appro~lmately 0.5 grams, after drylng for 60 mlnutes at 130C. The water content of the resln 1B determlned by the known Karl Flscher method.
Accordlng to an advantageous embodlment of the lnventlon, the bondlng agent ls applled to the wood chlps and/or flbres at an elevated temperature at whlch there ls a reductlon of the bondlng-agent viscoslty.
In an advantageous ernbodlment of the process accordlng to the present lnventlon, the bondlng agent ln liquld form ls applled to the wood chips and/or fibres in several steps, wlth the vlscoslty of the bondlng agent that ls to be applled belng lower ~L3~7~39 ln the first step than ln the other steps. When this ls done, the low vlscoslty bondlng agent that ls applled durlng the flrst step penetrates lnto the wood chlps and/or flbres, whereas the hlgher vlscoslty bondlng agent that ls applled ln the second or ln the subsequent steps serves malnly to bond the wood chlps and/or flbres together durlng the productlon of the hlgh pressure moulded body.
Accordlng to another advantageous embodiment of the present lnventlon, durlng productlon of a hlgh pressure moulded body that 18 based on wocd chlps and a condensatlon resln that ls predomlnantly based on phenols, the quantity of resln that ls applled amounts to between 35 and 55%-wt of the quantlty of the wood chip~ or durlng the productlon of a hlgh pressure moulded body based on wood flbres, the quantlty of bondlng agent that ls applled amounts to between 25 and 50%-wt of thls quantlty, whereas durlng the productlon of a hlgh pressure moulded body wlth a condensation resln that ls based predomlnantly on amlno compounds, the quantity of resln that 18 applled ls between 80 and 160~-wt of the quantity of wood chlps and~or flbres.
In a further advantageous ernbodlment of the present inventlon the wood chlps and~or flbres that are lmpregnated wlth the bondlng agent are applled ln one layer on a base (such as kraft paper) and then pressed so as to form a rough-pressed block or mat, which can optlonally be handled or transported. The rough-pre~sed block or mat can then form at least part of the mass that iB to be pressed durlng the production of the high pressure moulded body. The rough-pressed block can be applied as a layer on an optlonally flat carrier rnaterial (such as decor paper) ., 7~9 whlch bonds wlth the rough-pressed block durlng the subsequent consolldatlon of thls and thus forms part of the rough-pressed block. A second layer of the carrler materlal can be lald onto the other slde of the rough-pressed block this carrler materlal then also bondlng wlth the block when lt ls subsequently consolldated, and thus formlng a part of the rough-pressed block.
In addltlon, the carrler materlals that are used can advantageously be coated or lrnpregnated wlth the hardenable bondlng agent.
Another advantageous process accordlng to the present lnventlon ls characterlzed ln that a wood flbre lnsulatlng panel or wood flbre mat ls coated on one or both sldes wlth layers of bondlng agent whlch penetrate at least ln part lnto thl~
lnsulatlng panel or mat. The lnsulatlng panel or mat that has been so coated wlth bondlng agent can then form at least part of the mass that 18 to be pressed durlng productlon of the hlgh pressure moulded body.
Accordlng to a further advantageous conflguratlon of the lnventlon, a plurallty of the clted rough-cast blocks and/or wood flbre lnsulatlng panels or wood flbre mats that have been coated wlth bondlng agent are arranged one above the other and sub~ected to hot presslng.
In addltlon, the present lnventlon relates to lnltlal products ln the form of rough-pressed blocks or wood flbre insulatlng panels lmpregnated wlth synthetlc resln such as are produced durlng the process accordlng to the present lnventlon and used durlng the productlon of the hlgh pressure moulded bodles.
~3~7;~39 DescrlPtlon of Preferred Embodlments The lnventlon wlll be further descrlbed, by way of example, showlng embodlments of the lnventlon ln whlch:
Flgure 1 shows a sectlon of a panel-llke hlgh pressure moulded body, the productlon of whlch ls descrlbed ln Example 1.
Flgures 2a and 2b relate to Example 2, flgure 2a showlng a rough-pressed block and flgure 2b showlng a flnlshed hlgh pressure moulded body.
Flgures 3a, 3b and 3c relate to Example 3, flgure 3a showlng an lnsulatlng panel coated on one slde wlth synthetlc resin, flgure 3b showing an lnsulatlng panel coated on both sldes wlth synthetlc resln, and flgure 3c showlng a hlgh pressure moulded body produced from a plurallty of lnsulatlng panels of thls klnd.
Flgures 4a and 4b shows the embodlment descrlbed i.n Example 4, accordlng to whlch a hlgh pressure moulded body ls produced from a plurallty of wood flbre mats that have been brushed [smeared] wlth bondlng agent.
Fxample 1l Wood chlps of the sort used for the surface layers durlng productlon of wood chlp panels, are drled ln a dryer to a molsture content of 3 0% and then mlxed wlth a hlghly concentrated phenollc resln (solld resln contentt 82%, water content: 1.8%), whlch had been heated to 40C ln order to reduce lts vlscoslty, wlth a resln appllcatlon quantlty of 40%, thls resultlng ln a water content of the chlps coated wlth the resln of 2.65%.
A press wlth a clrculatlon of the presser plates was used to form the hlgh pressure moulded body. The followlng were -~3~7~as applled one on top of the other in the sequence lndlcated: a separatlng foll, a decor paper 3 lmpregnated wlth a melamlne resln wlth a resln appllcatlon of 140% wlth a welght per unlt area of 100 g/m2 and a soda kraft paper 2 (200 g/m2) lmpregnated wlth phenollc resln wlth a resln appllcatlon of 40% and then a layer, approxlmately 90 mm thlck of chlps lmpregnated wlth resln 1, at a spread denslty of 0.15 kg/l was bullt up. Subsequently, another layer of lmpregnated kraft paper 2, decor paper 3 and separator foll as descrlbed above were applled to the layer of chlps but in the reverse order. Thls whole structure was then placed on the pressure plate ln the press and compressed for 20 mlnutes at a pressure of 70 bar at a temperature of 140C. When thls ls done, the synthetlc reslns contalned ln the layer of chlps and ln the lmpregnated papers flow and harden ln sequence. When the press had cooled down the finlshed panel-llke hlgh pressure moulded body was removed from the press. Its structure ls shown ln Figure l.
The compact plastlc core wlth the lncorporated wood chlp materlal ls numbered 1, and thls ls coated on both sldes wlth the lmpregnated soda kraft paper and decor paper layers 2 and 3, respectlvely, whlch have decoratlve surface~ of contlnuous, pore-free melamine resln.
r.t a thlckness of 10 mm, the panel-llke high pressure moulded body so formed has a denslty of approxlmately 1.4 g/cm3, a flexural strength of 90 N/mm2 (DIN 53799) a tenslle strength of 52 N/mm2 and a water absorptlon capacity of 0.9% (DIN 53799).
For reasons of productlon technology lt may be expedlent durlng the productlon of the hlgh pressure moulded body as a pressed substance, whlch contalns the wood chlps and/or flbres, to 1 "07~1~9 proceed from lnitlal products that can be handled and/or transported and whlch can be used ln the same manner as ls the case wlth the prepregs ln the conventlonal production of synthetlc resln moulded lamlnated plastlc panels. Varlatlons of the process accordlng to the present lnventlon, ln which such lnltlal products or preforrns are used, are descrlbed below on the basls of examples 2 to 4.
~xample 2:
In thls example, one proceeds from wood flbres produced ln the usual manner, which are flrst drled to a molsture content of 4% and then coated wlth a hlghly concentrated phenollc resln as a bondlng agent (solld resln content, 83.5%; water content: 2.2%).
In order to produce a panel-llke rough-pressed block, a heated multl~tage press 15 used, such as can produce a compresslon pressure of Z0-Z5 bar. Flrst, a separator foll and then a sodlum kraft paper 2 (200 g/m~) lmpregnated wlth a phenollc resln at 40%
resln appllcatlon, are applled as a lower surface layer and then the coated wood flbres 1' are applled at a layer thlckness of 210 mm (layer welght 0.0Z kg/l). Thls wood layer læ then covered wlth the same lmpregnated sodlum kraft paper as was used for the lower surface layer and then covered wlth a separator foil. The whole structure ls then placed on the pressure plate ln the press and compacted at a pressure of 20 bar, at a temperature of 80C, for 5 rnlnutes. One then obtains a panel-llke rough-pressed body that ls approxlmately 7 mm thlck, and thls ls then removed hot out of the press and can be used as a preproduct that can be handled and transported, durlng the product lon of the hlgh pressure moulded ~3~7~B9 ~ 26129-18 bodles.
The structure of thls rough-pressed block ls shown ln figure 2a, wherein the prepressed plastic core with the lncorporated wood flbres ls numbered 1' and the upper and lower surface layers of the lmpregnated sodlum kraft paper are numbered In order to produce the hlgh pressure moulded body shown ln cross sectlon ln flgure 2b, two rough-pressed blocks are placed, one on top of the other, between two layers of decor paper 3 (100 g/m2) lmpregnated wlth melamine resln at 110% resln applicatlon. The whole structure ls placed between two separator foll~ and two pressure plates and then compacted ln a hlgh pressure press at a pressure of 70 bar and at a temperature of 140C for 20 mlnutes, and hardened. Once the press has cooled down the panel that has been so produced, and whlch has a decoratlve and structured surface, ls removed from the press.
This panel is 6 mm thlck, and has a specific welght of 1.4 g/cm3, a flexural strength of 90 N/mm2, and a water absorptlon capaclty of 0.6%.
Accordlng to another varlatlon of this example, urea resln, whlch ls cheaper than phenolic resln, i8 added to the phenollc resln that ls used, at a quantlty of approximately 10%, thls then causing no signlflcant change ln the quallty of the panel that ls produced.
Example 3, In order to produce a panel-llke lnltlal product for the productlon of a hlgh pressure moulded body, a wood flbre 13~37~9 lnsulatlng panel such as ls commerclally avallable for constructlon purposes (e.g. a wood flbre insulatlng panel æuch as produced by Leitgeb, Kaernten) and which ls 10 mm thlck and of a specific weight of 0.25 g/cm3, is ad~usted, if necessary by drylng, to a molsture content of approxlmately 5~. Then, this lnsulatlng panel ls coated by a slngle or repeated brush or sprayed appllcation on one surface slde with a highly concentrated phenollc resln at a temperature of 50C (solid resin content: 83%, water content: 2.7%), wlth a resln appllcatlon of 40% relatlve to the welght of the panel (whlch is equal to 1 kg of resin per m2 of panel surface). An insulatlng panel 5 coated on one side is shown in Figure 3a. Thls application of resin is then immediately absorbed by the fibrous panel material and forms a layer approximately 3 mm thick on the surface of the panel shown as 4.
In order to produce the moulded body according to the present embodiment, one also requlres insulating panels coated on both sldes wlth resln for the later processlng stages, as shown ln Flgure 3b. In order to produce the panel shaped high pressure moulded body one re~ulres one lnsulatlng panel coated on both sldes (Flgure 3b) and three lnsulatlng panels coated on one slde (Flgure 3a)~ The ln~ulatlng panel coated on both sides forms one of the outer layers, for example the bottom layer, and the three lnsulating panels coated on one side are placed on top of the panel coated on both sldes such that thelr coated layer faces away from the panel coated on both sldes. The resultlng structure ls placed on a pressure plate between two separator folls, lnstalled in a hlgh pressure press and hot pressed. When thls ls done, thls lnltlal product structure ls flrst heated to 100C durlng a , ~, ., r -1$~7~9 -13- 2612g-18 heatlng phase, and then compressed to one-half of lts orlglnal thlckneæs and malntalned at thls temperature for 5 mlnutes.
Durlng thls heatlng phase and the walting perlod, the phenollc resln that ls now free-flowlng spreads through the pressed materlal and flnally forms an even lmpregnatlon ln the four wood flbre lnsulatlng panels 5' whlle the flbre structure ls still loose. Next, the temperature and the pressure are lncreased to 140C and 70 bar and malntained at thls for 20 mlnutes whlle the phenollc resln hardens. The resultlng structure ls shown ln Flgure 3c.
The panel-llke hlgh pressure moulded body that is removed from the press after coollng ls lO mm thlck, has a flexural strength of 95 N/mm2, a tenslle strength of 70 N/mm2, and a water absorptlon capablllty of approxlmately 0.8% once lt has cooled down.
Example 4.
In order to produce a panel-llke lnltlal product, one proceeds from a wood flbre mat 6 (see Flgure ga) of a bleached wood flbre materlal, 5 mm thlck and wlth a speclflc welght of 0.10 g/m3 (welght per unlt area 0.05 g/cm2), drled to a molsture content of 2.5~. A mlxture of 30%-wt of solld melamlne formaldehyde powder resln and 40%-wt of a partlally snethyl-etherlfled hexamethylol melamlne and 30% TlO2 as a plgment addltlve serves as the bondlng agent. Thls mlxture ls heated to 50C, at whlch lt ls hlghly vlscose but can be applled by brush, and ls applled to the wood flbre mat 6 ln the form of an even, thlck layer 7, when 0.075 g/cm2 ls applled. Immedlately after thls brush appllcatlon the bondlng agent layer 7 slnks sllghtly ~;
~3~7~39 -14- 2~129-18 lnto the mat 6.
In order to produce the hlgh pressure moulded body shown ln flgure 4b, five resln coated wood flbre mats 6' are placed one on top of the other, covered on the upper and lower slde in each lnstance wlth two whlte decor papers 3 lmpregnated wlth melamlne resln, and then compressed ln a hlgh pressure press at 100C for 5 mlnutes to one half the volume of the crude mat to allow the bondlng agent to lmpregnate the mats, and then pressed under hlgh pressure at 75 bar for 20 mlnutes at 140C to form a 5 mm thlck decoratlve panel that ls whlte throughout lts whole thlckness.
Whlle the above examples descrlbe the productlon of panels, lt ls to be appreclated that other formed moulded bodles can be produced uslng the process accordlng to the present invention.
Utl~ltv and APP llcatlon The pressure moulded bodies produced by the process accordlng to the present lnventlon can, to a very great extent, be used ln the same areas as conventlonal decoratlve plastlc resln hlgh pressure lamlnates that are of greater thickness (e.g., between 3 and 15 mm thlck), e.g., for the productlon of self-supportlng structural elements or as weatherproof panels for exterlor appllcatlons.
Prlor Art EP 0081147 Bl relates to a process for the productlon of a decoratlve structural panel ln whlch one applles an aqueous alkallne solutlon or dlsperslon of a phenol-formaldehyde resln to wood flbres, and then drles the resln coated wood flbres to a resldual rnolsture content of 2 to 15%. A flbre mat ls then formed from the resln coated, drled wood flbres, and thls 1~ then mechanlcally consolldated and then is hot pressed ln one or a plurallty of layers arranged one above the other to form a core layer~ a decoratlve layer can be applled to the core layer slmultaneously or subsequent to the presslny process.
Thls known process ls lntended to produce a structural panel that has propertles slmllar to those found ln moulded laminated plastlc panels produced ln the usual way, whlch are made by hot presslng ao-called "prepregs," that are of paper lmpregnated when dry wlth hardenable synthetlc resins. However, as a result of the preferred orlentatlon of the cellulose flbres of the paper ln the dlrectlon preferred durlng the productlon of . :. .
~7~89 such paper, under varylng cllmatlc conditlons such moulded lamlnated plastic panels dlsplay shrlnkage and stretch behavlour that dlffers ln the longltudlnal or transverse dlrectlon of the paper that ls used, and thls can have a dlsadvantageous effect when they are used. In addltlon, the papers that are used ln such panels are a materlal that ls produced from wood as a raw materlal, uslng a process that ls costly and harmful to the ecology.
The anlsotropy ln the stretch and shrlnkage behavlour, whlch has been noted above, ls avolded ln panels produced accordlng to the process that ls known from EP 0081147 Bl and, ln addltlon, slnce to a very great extent wood flbres are used here ln place of paper, one can--vlewed overall--manage wlth a lower productlon cost than ls the case wlth the conventlonal productlon of moulded lamlnated plastlc panels. However, the drylng of the resin coated wood flbres remalns a costly stage ln the process and 18, in some lnstances, harmful to the envlronment.
EP 0035133 ~1 also descrlbes the productlon of decoratlve lamlnates~ ln thls process, a powdered phenol resln ls lntroduced lnto a current of molst alr wlthln whlch cellulose and cellulose-llke flbres are dlspersed, and the flbres and the phenol reslns then mlx. The mlxture of wood flbres and phenol resln ls then deposlted on a sleve-llke band ln the form of a layer, whlch after preconsolldatlon ls lntended for use ln the same way as a paper "prepreg" that ha~ been lmpregnated wlth resln, for the productlon of the lamlnate. However, the use of powdered resln ln such flbre "prepregs" entalls several fundamental dlsadvantages.
Flrst, there ls a danger that the flbres and the powdered resln ~3~7~89 wlll become segregated durlng storage and transportatlon wlthln the framework of the productlon process. In addltion, phenol reslns ln powder form have a smaller low-molecular component than llquid phenol resins. This can result ln the fact that, durlng subsequent hot pressing, the resln does not flow as well, whlch can cause lmperfect wettlng and penetratlon of the resin through the flbres.
DescrlPtlon of the Inventlon Thus, lt ls an ob~ect of the present lnventlon to provlde a process ln whlch the dlsadvantages of the known process can be reduced or avoided by uslng a resln bondlng agent that flows well when used.
Accordlngly, the present lnventlon provldes a process for the productlon of a synthetlc resln pressure moulded body ln whlch a bondlng agent that ls a phenol-aldehyde or an amlno-aldehyde conden~atlon resln ln llquld form or brushable form ls heated to lower lts vlscoslty and applled to dry wood chlps or flbres, the bondlng agent, lf a phenol-aldehyde condensatlon resin, belng applled ln an amount of 25 to 55~ of the amount of wood or the bondlng agent, lf an amlno-aldehyde condensatlon resln, belng applled ln an amount of 80 to 160% of the amount of wood, and 18 hot pressed whlle the resln ls hardenlng, whereln the molsture content of the wood ls at mo~t 10%, preferably at most 8 and the condensatlon resln has a solld resln content of at least 80% wt and a water content of at most 7%. The resln composltlon can contaln addltlves, for lnstance colourlng plgments.
When the above descrlbed process ls carrled out, lt ls posslble to achleve a "volatlle content" of the mass of the wood -~7~89 chips an~/or flbres that are lmpregnated wlth the bondlng agent of between 3 and 10%, at whlch thls mass can be further processed wlthout the need for a drylng process. The "volatlle content" of the mass of the wood chlps and/or wood flbres lmpregnated wlth the bondlng agent ls determlned by the weight loss that thls mas.s exhiblts when heated, e.g., in a drying cabinet, for 5 mlnutes at 165C. The "volatile content" can be ad~usted by ad~usting the molsture content of the drled wood chlps and/or fibres to the water content of the condensation resin, while taking lnto account the quantlty of the addltlves that are used. To a great extent, the volatlle content conslsts of water and, for example, of phenol and low-molecular resln factions. An approprlate volatlle content is important for good flowlng of the resln durlng the hot presslng process. If the volatlle content ls too low, the resln does not flow well, and lf it ls too high, thls wlll have an effect on the hardening of the resln during the presslng process.
The ~olld resin content ls determlned ln a drylng cablnet, ln a dlsh wlth a welghed sample of appro~lmately 0.5 grams, after drylng for 60 mlnutes at 130C. The water content of the resln 1B determlned by the known Karl Flscher method.
Accordlng to an advantageous embodlment of the lnventlon, the bondlng agent ls applled to the wood chlps and/or flbres at an elevated temperature at whlch there ls a reductlon of the bondlng-agent viscoslty.
In an advantageous ernbodlment of the process accordlng to the present lnventlon, the bondlng agent ln liquld form ls applled to the wood chips and/or fibres in several steps, wlth the vlscoslty of the bondlng agent that ls to be applled belng lower ~L3~7~39 ln the first step than ln the other steps. When this ls done, the low vlscoslty bondlng agent that ls applled durlng the flrst step penetrates lnto the wood chlps and/or flbres, whereas the hlgher vlscoslty bondlng agent that ls applled ln the second or ln the subsequent steps serves malnly to bond the wood chlps and/or flbres together durlng the productlon of the hlgh pressure moulded body.
Accordlng to another advantageous embodiment of the present lnventlon, durlng productlon of a hlgh pressure moulded body that 18 based on wocd chlps and a condensatlon resln that ls predomlnantly based on phenols, the quantity of resln that ls applled amounts to between 35 and 55%-wt of the quantlty of the wood chip~ or durlng the productlon of a hlgh pressure moulded body based on wood flbres, the quantlty of bondlng agent that ls applled amounts to between 25 and 50%-wt of thls quantlty, whereas durlng the productlon of a hlgh pressure moulded body wlth a condensation resln that ls based predomlnantly on amlno compounds, the quantity of resln that 18 applled ls between 80 and 160~-wt of the quantity of wood chlps and~or flbres.
In a further advantageous ernbodlment of the present inventlon the wood chlps and~or flbres that are lmpregnated wlth the bondlng agent are applled ln one layer on a base (such as kraft paper) and then pressed so as to form a rough-pressed block or mat, which can optlonally be handled or transported. The rough-pre~sed block or mat can then form at least part of the mass that iB to be pressed durlng the production of the high pressure moulded body. The rough-pressed block can be applied as a layer on an optlonally flat carrier rnaterial (such as decor paper) ., 7~9 whlch bonds wlth the rough-pressed block durlng the subsequent consolldatlon of thls and thus forms part of the rough-pressed block. A second layer of the carrler materlal can be lald onto the other slde of the rough-pressed block this carrler materlal then also bondlng wlth the block when lt ls subsequently consolldated, and thus formlng a part of the rough-pressed block.
In addltlon, the carrler materlals that are used can advantageously be coated or lrnpregnated wlth the hardenable bondlng agent.
Another advantageous process accordlng to the present lnventlon ls characterlzed ln that a wood flbre lnsulatlng panel or wood flbre mat ls coated on one or both sldes wlth layers of bondlng agent whlch penetrate at least ln part lnto thl~
lnsulatlng panel or mat. The lnsulatlng panel or mat that has been so coated wlth bondlng agent can then form at least part of the mass that 18 to be pressed durlng productlon of the hlgh pressure moulded body.
Accordlng to a further advantageous conflguratlon of the lnventlon, a plurallty of the clted rough-cast blocks and/or wood flbre lnsulatlng panels or wood flbre mats that have been coated wlth bondlng agent are arranged one above the other and sub~ected to hot presslng.
In addltlon, the present lnventlon relates to lnltlal products ln the form of rough-pressed blocks or wood flbre insulatlng panels lmpregnated wlth synthetlc resln such as are produced durlng the process accordlng to the present lnventlon and used durlng the productlon of the hlgh pressure moulded bodles.
~3~7;~39 DescrlPtlon of Preferred Embodlments The lnventlon wlll be further descrlbed, by way of example, showlng embodlments of the lnventlon ln whlch:
Flgure 1 shows a sectlon of a panel-llke hlgh pressure moulded body, the productlon of whlch ls descrlbed ln Example 1.
Flgures 2a and 2b relate to Example 2, flgure 2a showlng a rough-pressed block and flgure 2b showlng a flnlshed hlgh pressure moulded body.
Flgures 3a, 3b and 3c relate to Example 3, flgure 3a showlng an lnsulatlng panel coated on one slde wlth synthetlc resin, flgure 3b showing an lnsulatlng panel coated on both sldes wlth synthetlc resln, and flgure 3c showlng a hlgh pressure moulded body produced from a plurallty of lnsulatlng panels of thls klnd.
Flgures 4a and 4b shows the embodlment descrlbed i.n Example 4, accordlng to whlch a hlgh pressure moulded body ls produced from a plurallty of wood flbre mats that have been brushed [smeared] wlth bondlng agent.
Fxample 1l Wood chlps of the sort used for the surface layers durlng productlon of wood chlp panels, are drled ln a dryer to a molsture content of 3 0% and then mlxed wlth a hlghly concentrated phenollc resln (solld resln contentt 82%, water content: 1.8%), whlch had been heated to 40C ln order to reduce lts vlscoslty, wlth a resln appllcatlon quantlty of 40%, thls resultlng ln a water content of the chlps coated wlth the resln of 2.65%.
A press wlth a clrculatlon of the presser plates was used to form the hlgh pressure moulded body. The followlng were -~3~7~as applled one on top of the other in the sequence lndlcated: a separatlng foll, a decor paper 3 lmpregnated wlth a melamlne resln wlth a resln appllcatlon of 140% wlth a welght per unlt area of 100 g/m2 and a soda kraft paper 2 (200 g/m2) lmpregnated wlth phenollc resln wlth a resln appllcatlon of 40% and then a layer, approxlmately 90 mm thlck of chlps lmpregnated wlth resln 1, at a spread denslty of 0.15 kg/l was bullt up. Subsequently, another layer of lmpregnated kraft paper 2, decor paper 3 and separator foll as descrlbed above were applled to the layer of chlps but in the reverse order. Thls whole structure was then placed on the pressure plate ln the press and compressed for 20 mlnutes at a pressure of 70 bar at a temperature of 140C. When thls ls done, the synthetlc reslns contalned ln the layer of chlps and ln the lmpregnated papers flow and harden ln sequence. When the press had cooled down the finlshed panel-llke hlgh pressure moulded body was removed from the press. Its structure ls shown ln Figure l.
The compact plastlc core wlth the lncorporated wood chlp materlal ls numbered 1, and thls ls coated on both sldes wlth the lmpregnated soda kraft paper and decor paper layers 2 and 3, respectlvely, whlch have decoratlve surface~ of contlnuous, pore-free melamine resln.
r.t a thlckness of 10 mm, the panel-llke high pressure moulded body so formed has a denslty of approxlmately 1.4 g/cm3, a flexural strength of 90 N/mm2 (DIN 53799) a tenslle strength of 52 N/mm2 and a water absorptlon capacity of 0.9% (DIN 53799).
For reasons of productlon technology lt may be expedlent durlng the productlon of the hlgh pressure moulded body as a pressed substance, whlch contalns the wood chlps and/or flbres, to 1 "07~1~9 proceed from lnitlal products that can be handled and/or transported and whlch can be used ln the same manner as ls the case wlth the prepregs ln the conventlonal production of synthetlc resln moulded lamlnated plastlc panels. Varlatlons of the process accordlng to the present lnventlon, ln which such lnltlal products or preforrns are used, are descrlbed below on the basls of examples 2 to 4.
~xample 2:
In thls example, one proceeds from wood flbres produced ln the usual manner, which are flrst drled to a molsture content of 4% and then coated wlth a hlghly concentrated phenollc resln as a bondlng agent (solld resln content, 83.5%; water content: 2.2%).
In order to produce a panel-llke rough-pressed block, a heated multl~tage press 15 used, such as can produce a compresslon pressure of Z0-Z5 bar. Flrst, a separator foll and then a sodlum kraft paper 2 (200 g/m~) lmpregnated wlth a phenollc resln at 40%
resln appllcatlon, are applled as a lower surface layer and then the coated wood flbres 1' are applled at a layer thlckness of 210 mm (layer welght 0.0Z kg/l). Thls wood layer læ then covered wlth the same lmpregnated sodlum kraft paper as was used for the lower surface layer and then covered wlth a separator foil. The whole structure ls then placed on the pressure plate ln the press and compacted at a pressure of 20 bar, at a temperature of 80C, for 5 rnlnutes. One then obtains a panel-llke rough-pressed body that ls approxlmately 7 mm thlck, and thls ls then removed hot out of the press and can be used as a preproduct that can be handled and transported, durlng the product lon of the hlgh pressure moulded ~3~7~B9 ~ 26129-18 bodles.
The structure of thls rough-pressed block ls shown ln figure 2a, wherein the prepressed plastic core with the lncorporated wood flbres ls numbered 1' and the upper and lower surface layers of the lmpregnated sodlum kraft paper are numbered In order to produce the hlgh pressure moulded body shown ln cross sectlon ln flgure 2b, two rough-pressed blocks are placed, one on top of the other, between two layers of decor paper 3 (100 g/m2) lmpregnated wlth melamine resln at 110% resln applicatlon. The whole structure ls placed between two separator foll~ and two pressure plates and then compacted ln a hlgh pressure press at a pressure of 70 bar and at a temperature of 140C for 20 mlnutes, and hardened. Once the press has cooled down the panel that has been so produced, and whlch has a decoratlve and structured surface, ls removed from the press.
This panel is 6 mm thlck, and has a specific welght of 1.4 g/cm3, a flexural strength of 90 N/mm2, and a water absorptlon capaclty of 0.6%.
Accordlng to another varlatlon of this example, urea resln, whlch ls cheaper than phenolic resln, i8 added to the phenollc resln that ls used, at a quantlty of approximately 10%, thls then causing no signlflcant change ln the quallty of the panel that ls produced.
Example 3, In order to produce a panel-llke lnltlal product for the productlon of a hlgh pressure moulded body, a wood flbre 13~37~9 lnsulatlng panel such as ls commerclally avallable for constructlon purposes (e.g. a wood flbre insulatlng panel æuch as produced by Leitgeb, Kaernten) and which ls 10 mm thlck and of a specific weight of 0.25 g/cm3, is ad~usted, if necessary by drylng, to a molsture content of approxlmately 5~. Then, this lnsulatlng panel ls coated by a slngle or repeated brush or sprayed appllcation on one surface slde with a highly concentrated phenollc resln at a temperature of 50C (solid resin content: 83%, water content: 2.7%), wlth a resln appllcatlon of 40% relatlve to the welght of the panel (whlch is equal to 1 kg of resin per m2 of panel surface). An insulatlng panel 5 coated on one side is shown in Figure 3a. Thls application of resin is then immediately absorbed by the fibrous panel material and forms a layer approximately 3 mm thick on the surface of the panel shown as 4.
In order to produce the moulded body according to the present embodiment, one also requlres insulating panels coated on both sldes wlth resln for the later processlng stages, as shown ln Flgure 3b. In order to produce the panel shaped high pressure moulded body one re~ulres one lnsulatlng panel coated on both sldes (Flgure 3b) and three lnsulatlng panels coated on one slde (Flgure 3a)~ The ln~ulatlng panel coated on both sides forms one of the outer layers, for example the bottom layer, and the three lnsulating panels coated on one side are placed on top of the panel coated on both sldes such that thelr coated layer faces away from the panel coated on both sldes. The resultlng structure ls placed on a pressure plate between two separator folls, lnstalled in a hlgh pressure press and hot pressed. When thls ls done, thls lnltlal product structure ls flrst heated to 100C durlng a , ~, ., r -1$~7~9 -13- 2612g-18 heatlng phase, and then compressed to one-half of lts orlglnal thlckneæs and malntalned at thls temperature for 5 mlnutes.
Durlng thls heatlng phase and the walting perlod, the phenollc resln that ls now free-flowlng spreads through the pressed materlal and flnally forms an even lmpregnatlon ln the four wood flbre lnsulatlng panels 5' whlle the flbre structure ls still loose. Next, the temperature and the pressure are lncreased to 140C and 70 bar and malntained at thls for 20 mlnutes whlle the phenollc resln hardens. The resultlng structure ls shown ln Flgure 3c.
The panel-llke hlgh pressure moulded body that is removed from the press after coollng ls lO mm thlck, has a flexural strength of 95 N/mm2, a tenslle strength of 70 N/mm2, and a water absorptlon capablllty of approxlmately 0.8% once lt has cooled down.
Example 4.
In order to produce a panel-llke lnltlal product, one proceeds from a wood flbre mat 6 (see Flgure ga) of a bleached wood flbre materlal, 5 mm thlck and wlth a speclflc welght of 0.10 g/m3 (welght per unlt area 0.05 g/cm2), drled to a molsture content of 2.5~. A mlxture of 30%-wt of solld melamlne formaldehyde powder resln and 40%-wt of a partlally snethyl-etherlfled hexamethylol melamlne and 30% TlO2 as a plgment addltlve serves as the bondlng agent. Thls mlxture ls heated to 50C, at whlch lt ls hlghly vlscose but can be applled by brush, and ls applled to the wood flbre mat 6 ln the form of an even, thlck layer 7, when 0.075 g/cm2 ls applled. Immedlately after thls brush appllcatlon the bondlng agent layer 7 slnks sllghtly ~;
~3~7~39 -14- 2~129-18 lnto the mat 6.
In order to produce the hlgh pressure moulded body shown ln flgure 4b, five resln coated wood flbre mats 6' are placed one on top of the other, covered on the upper and lower slde in each lnstance wlth two whlte decor papers 3 lmpregnated wlth melamlne resln, and then compressed ln a hlgh pressure press at 100C for 5 mlnutes to one half the volume of the crude mat to allow the bondlng agent to lmpregnate the mats, and then pressed under hlgh pressure at 75 bar for 20 mlnutes at 140C to form a 5 mm thlck decoratlve panel that ls whlte throughout lts whole thlckness.
Whlle the above examples descrlbe the productlon of panels, lt ls to be appreclated that other formed moulded bodles can be produced uslng the process accordlng to the present invention.
Utl~ltv and APP llcatlon The pressure moulded bodies produced by the process accordlng to the present lnventlon can, to a very great extent, be used ln the same areas as conventlonal decoratlve plastlc resln hlgh pressure lamlnates that are of greater thickness (e.g., between 3 and 15 mm thlck), e.g., for the productlon of self-supportlng structural elements or as weatherproof panels for exterlor appllcatlons.
Claims (17)
1. A process for the production of a synthetic resin pressure moulded body in which a bonding agent that is a phenol-aldehyde or an amino-aldehyde condensation resin in liquid form or brushable form is applied to dry wood chips or fibres, and is hot pressed while the resin is hardening wherein the bonding agent, if a phenol-aldehyde condensation resin, is applied in an amount of 25 to 55% of the amount of wood or the bonding agent, if an amino-aldehyde condensation resin, being applied in an amount of 80 to 160% of the amount of wood, and the moisture content of the wood is at most 10% and the condensation resin has a solid resin content of at least 80% wt and a water content of at most 7%.
2. The process according to claim 1 wherein the bonding agent is heated to lower its viscosity.
3. The process according to claim 1 wherein the moisture content of the dry wood is 8% or less.
4. The process according to claim 1 wherein the water content of the condensation mixture is 5% or less.
5. A process as defined in claim 1, whereby the mass of the wood chips and/or wood fibres can be further processed without a separate drying process after the application of the bonding agent.
6. A process as defined in claim 1 wherein the bonding agent in liquid form is applied to the wood chips and/or wood fibres in several steps, the viscosity of the bonding agent to be applied being lower in the first step than it is in each of the other steps.
7. A process as defined in any one of claims 1 to 6, wherein during the production of a high pressure moulded body based on wood chips using a bonding agent that is a phenol-aldehyde, the quantity of resin that is applied is between 35 and 55%-wt of the quantity of the wood chips.
8. A process as defined in any one of claims 1 to 6, wherein during the production of a high pressure moulded body based on wood fibres using a bonding agent that is a phenol-aldehyde the quantity of bonding agent that is applied is between 25 and 50%-wt of the quantity of wood fibres.
9. A process as defined in any one of claims 1 to 6, wherein the wood chips and/or fibres that have been impregnated with bonding agent are applied in one layer to a base and then compressed to form a rough-pressed block that can be handled or transported, said block forming at least one part of the mass that is to be compressed during the production of the high pressure moulded body.
10. A process as defined in claim 9, wherein the wood chips or fibres that have been impregnated with the bonding agent are applied in the form of a layer to a carrier material which, during the subsequent hot pressing of the wood chips or fibres, bonds with these and forms a part of the rough-pressed block.
11. A process as defined in claim 9 wherein a carrier material is applied to the wood chips or fibres that have been impregnated with bonding agent and layered onto a base, this carrier material bonding with the wood chips or fibres during the subsequent hot pressing and forming a part of the rough-pressed block.
12. A process as defined in claim 10 wherein the carrier materials that are used are coated or impregnated with a bonding agent that can be hardened.
13. A process as defined in any one of claims 1 to 6, wherein a wood fibre insulating panel or wood fibre mat is provided on one or both sides with layers of the bonding agent, which at least in part penetrates into this insulating panel or mat, the insulating panel or mat so coated with bonding agent and forming at least one part of the mass that is to be compressed during the production of the high pressure moulded body.
14. A process as defined in any one of claims 9 to 12, wherein a plurality of such rough-pressed blocks and/or wood fibre insulating panels or wood fibre mats that have been coated with bonding agent are arranged one above the other are hot-pressed with each other.
15. An initial product for use during the production of a synthetic resin high pressure moulded body, wherein this is a rough-pressed block or a wood fibre insulating panel or wood fibre mat that has been impregnated with synthetic resin, produced and used according to claim 8.
16. A process for the production of a synthetic resin pressure molded body in which a bonding agent containing a condensation resin or condensation resin mixture produced mainly on the basis of phenolic compounds and aldehydes in liquid form or brushable form is heated to an elevated temperature to lower its viscosity and applied to dried wood fibres in an amount of 25 to 50% of the amount of the wood fibres and optionally, together with other materials, such as surface and/or intermediate layers, is hot pressed while the resin is hardening, wherein the moisture content of the dried wood fibres is at most 10%, the condensation resin or condensation resin mixture has a solid resin content of at least 80% wt and a water content of at most 7% wt, and the bonding agent contains optional additives.
17. A process for the production of a synthetic resin pressure molded body in which a bonding agent containing a condensation resin or condensation resin mixture produced mainly on the basis of amino compounds and aldehydes in liquid or brushable form is heated to an elevated temperature to lower its viscosity and applied to dried wood fibres in an amount of 80 to 160% wt of the amount of the wood fibres and optionally, together with other materials such as surface and/or intermediate layers is hot pressed while the resin is hardening, wherein the moisture content of the dried wood fibres is at most 10%, the condensation resin or condensation resin mixture has a solid resin content of at least 80% wt and a water content of at most 7% wt, and the bonding agent contains optional additives.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| ATA2815/87 | 1987-10-23 | ||
| AT0281587A AT390396B (en) | 1987-10-23 | 1987-10-23 | METHOD FOR PRODUCING A PLANT-SHAPED PLASTIC RESIN HIGH-PRESSURE MOLDED PART, AND PRE-PRODUCT FOR USE IN SUCH A METHOD |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1307089C true CA1307089C (en) | 1992-09-08 |
Family
ID=3540731
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000581019A Expired - Lifetime CA1307089C (en) | 1987-10-23 | 1988-10-24 | Process for the production of an optionally panel-like synthetic resin plastic pressure moulded body as well as an initial product for use in such a process |
Country Status (10)
| Country | Link |
|---|---|
| US (1) | US5134026A (en) |
| EP (1) | EP0344231B1 (en) |
| JP (1) | JPH02501725A (en) |
| AT (2) | AT390396B (en) |
| AU (1) | AU615009B2 (en) |
| BR (1) | BR8807293A (en) |
| CA (1) | CA1307089C (en) |
| DE (1) | DE3885890D1 (en) |
| FI (1) | FI92027C (en) |
| WO (1) | WO1989003753A1 (en) |
Families Citing this family (32)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0378854A1 (en) * | 1989-01-19 | 1990-07-25 | General Electric Company | Expanded fiber composite structure and process for making said structure |
| US5855832A (en) * | 1996-06-27 | 1999-01-05 | Clausi; Robert N. | Method of molding powdered plant fiber into high density materials |
| US5759463A (en) * | 1997-03-10 | 1998-06-02 | Chang; Kou-I | Method for manufacturing a sandwiched sheet |
| US7763345B2 (en) | 1999-12-14 | 2010-07-27 | Mannington Mills, Inc. | Thermoplastic planks and methods for making the same |
| US8028486B2 (en) * | 2001-07-27 | 2011-10-04 | Valinge Innovation Ab | Floor panel with sealing means |
| SE525661C2 (en) | 2002-03-20 | 2005-03-29 | Vaelinge Innovation Ab | Floor boards decorative joint portion making system, has surface layer with underlying layer such that adjoining edge with surface has underlying layer parallel to horizontal plane |
| US20040206036A1 (en) * | 2003-02-24 | 2004-10-21 | Valinge Aluminium Ab | Floorboard and method for manufacturing thereof |
| US7886497B2 (en) | 2003-12-02 | 2011-02-15 | Valinge Innovation Ab | Floorboard, system and method for forming a flooring, and a flooring formed thereof |
| US7601282B2 (en) * | 2005-10-24 | 2009-10-13 | Johns Manville | Processes for forming a fiber-reinforced product |
| SE530653C2 (en) | 2006-01-12 | 2008-07-29 | Vaelinge Innovation Ab | Moisture-proof floor board and floor with an elastic surface layer including a decorative groove |
| US7875655B2 (en) | 2006-01-20 | 2011-01-25 | Material Innovations, Llc | Carpet waste composite |
| US8696958B1 (en) | 2006-08-21 | 2014-04-15 | Flowery Branch | Molded composite manufacturing process and products thereof |
| US20080042313A1 (en) * | 2006-08-21 | 2008-02-21 | David Wayne Moeller | Molded composite manufacturing process |
| US20080128933A1 (en) * | 2006-11-22 | 2008-06-05 | Przybylinski James P | Wood-Plastic Composites Using Recycled Carpet Waste and Systems and Methods of Manufacturing |
| US11235565B2 (en) | 2008-04-07 | 2022-02-01 | Valinge Innovation Ab | Wood fibre based panels with a thin surface layer |
| US20100021753A1 (en) * | 2008-07-25 | 2010-01-28 | E. I. Du Pont De Nemours And Company | Multizone wood polymer composite article |
| BRPI0922481A2 (en) | 2008-12-19 | 2018-06-05 | Fiber Composites Llc | wood-plastic composites using ionomer capstocks and manufacturing methods |
| US11725395B2 (en) | 2009-09-04 | 2023-08-15 | Välinge Innovation AB | Resilient floor |
| US8365499B2 (en) | 2009-09-04 | 2013-02-05 | Valinge Innovation Ab | Resilient floor |
| CN102770269B (en) | 2010-01-15 | 2016-01-20 | 瓦林格创新股份有限公司 | By the design that heat and pressure produce |
| AU2010341895B2 (en) | 2010-01-15 | 2015-03-05 | Valinge Innovation Ab | Bright colored surface layer |
| US8480841B2 (en) | 2010-04-13 | 2013-07-09 | Ceralog Innovation Belgium BVBA | Powder overlay |
| US10899166B2 (en) | 2010-04-13 | 2021-01-26 | Valinge Innovation Ab | Digitally injected designs in powder surfaces |
| EP3722104A1 (en) | 2011-04-12 | 2020-10-14 | Välinge Innovation AB | Method of manufacturing a layer |
| EP3960956A1 (en) | 2011-08-26 | 2022-03-02 | Ceraloc Innovation AB | Floor panel |
| PL3115161T3 (en) | 2011-08-29 | 2020-05-18 | Ceraloc Innovation Ab | Mechanical locking system for floor panels |
| US8920876B2 (en) * | 2012-03-19 | 2014-12-30 | Valinge Innovation Ab | Method for producing a building panel |
| MX363175B (en) | 2013-03-25 | 2019-03-12 | Vaelinge Innovation Ab | Floorboards provided with a mechanical locking system and a method to produce such a locking system. |
| UA118967C2 (en) | 2013-07-02 | 2019-04-10 | Велінге Інновейшн Аб | A method of manufacturing a building panel and a building panel |
| MX2017000379A (en) | 2014-07-16 | 2017-05-01 | Vaelinge Innovation Ab | Method to produce a thermoplastic wear resistant foil. |
| US10851579B2 (en) * | 2018-02-05 | 2020-12-01 | William-MacRae and Company | Composite molded shell with stiffening inner core for interior trim molding applications |
| US11572646B2 (en) | 2020-11-18 | 2023-02-07 | Material Innovations Llc | Composite building materials and methods of manufacture |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB791256A (en) * | 1955-10-20 | 1958-02-26 | Hakon Gisle | A method of manufacturing slabs, blocks or similar products of wooden particles or other fibrous material |
| US3220900A (en) * | 1960-03-14 | 1965-11-30 | Abitibi Power & Paper Co | Process for the manufacture of hard, or semi-hard, molded bodies of wood fiber material, preferentially wood fiber boards, having a resistant, covering surface |
| AT334068B (en) * | 1972-02-14 | 1976-12-27 | Oesterr Hiag Werke Ag | METHOD FOR MANUFACTURING LIGHT PANELED PANELS |
| US3843431A (en) * | 1972-06-23 | 1974-10-22 | Dostalik N | Process for making fibrous composition board |
| CA1135610A (en) * | 1978-07-20 | 1982-11-16 | Krishan K. Sudan | Waferboard process |
| ES8104065A1 (en) * | 1980-08-18 | 1981-04-01 | Patentes Novedades Sa | Process for producing hard fibreboards from lignocellulose |
-
1987
- 1987-10-23 AT AT0281587A patent/AT390396B/en not_active IP Right Cessation
-
1988
- 1988-10-24 BR BR888807293A patent/BR8807293A/en unknown
- 1988-10-24 WO PCT/AT1988/000083 patent/WO1989003753A1/en active IP Right Grant
- 1988-10-24 US US07/382,783 patent/US5134026A/en not_active Expired - Fee Related
- 1988-10-24 AT AT88908649T patent/ATE97605T1/en not_active IP Right Cessation
- 1988-10-24 DE DE88908649T patent/DE3885890D1/en not_active Expired - Fee Related
- 1988-10-24 JP JP63508375A patent/JPH02501725A/en active Pending
- 1988-10-24 CA CA000581019A patent/CA1307089C/en not_active Expired - Lifetime
- 1988-10-24 AU AU25570/88A patent/AU615009B2/en not_active Ceased
- 1988-10-24 EP EP88908649A patent/EP0344231B1/en not_active Expired - Lifetime
-
1989
- 1989-06-22 FI FI893085A patent/FI92027C/en not_active IP Right Cessation
Also Published As
| Publication number | Publication date |
|---|---|
| AT390396B (en) | 1990-04-25 |
| EP0344231A1 (en) | 1989-12-06 |
| AU615009B2 (en) | 1991-09-19 |
| BR8807293A (en) | 1990-04-17 |
| FI893085A0 (en) | 1989-06-22 |
| AU2557088A (en) | 1989-05-23 |
| US5134026A (en) | 1992-07-28 |
| FI893085A (en) | 1989-06-22 |
| DE3885890D1 (en) | 1994-01-05 |
| FI92027C (en) | 1994-09-26 |
| ATE97605T1 (en) | 1993-12-15 |
| JPH02501725A (en) | 1990-06-14 |
| EP0344231B1 (en) | 1993-11-24 |
| FI92027B (en) | 1994-06-15 |
| ATA281587A (en) | 1989-10-15 |
| WO1989003753A1 (en) | 1989-05-05 |
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| MKLA | Lapsed |