Special Aminoalkylsilane Compounds as Binders for Composite Materials

• US 20080233341A1
• Filed: 06/02/2006
• Published: 09/25/2008
• Est. Priority Date: 08/26/2005
• Status: Active Grant

• Current Assignee: Evonik Degussa GmbH (Rag-Stiftung)
• Original Assignee: Evonik Degussa GmbH (Rag-Stiftung)
• Inventors: Jenkner, Peter, Edelmann, Roland, Monkiewicz, Jaroslaw, Kharazipour, Alireza, Standke, Burkhard, Kloeser, Lars
• Granted Patent: US 8,039,110 B2
• Time in Patent Office: Days
• US Class Current: 428/113
• CPC Class Codes: C08K 5/544 containing nitrogen
• CPC Class Codes: C08K 5/548 containing sulfur C08K5/5477 takes precedence
• CPC Class Codes: C08L 2666/44 Silicon-containing compounds
• CPC Class Codes: C08L 83/04 Polysiloxanes
• CPC Class Codes: C08L 97/02 Lignocellulosic material, e.g. wood, straw or bagasse manufacture of articles made from lignocellulosic material by dry processes B27N
• CPC Class Codes: Y10T 428/24124 Fibers
• CPC Class Codes: Y10T 428/249965 Cellulosic
• CPC Class Codes: Y10T 428/249972 Resin or rubber element
• CPC Class Codes: Y10T 428/253 Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/254 Polymeric or resinous material
• CPC Class Codes: Y10T 428/31591 Next to cellulosic

Abstract

The present invention relates to composite materials based on (a) at least one cellulose- or lignocellulose-containing material and (b) at least one aminoalkylsilane of the formula (I) R¹R²N(CHR⁴)_aSi(R³)_r(OR)_3-r (I), in which groups R¹ and R² are identical or different and in each case are H or a linear, branched or cyclic C₁- to C₂₀-alkyl group or an aryl group or an aminocarbyl group, it being possible for groups R¹ and R² to be optionally substituted, groups R⁴ are identical or different and R is H or methyl, a is from 1 to 10, R³ is H or a linear or branched C₁- to C₈-alkyl group, groups R are identical or different and R is H or a linear or branched C₁- to C₈-alkyl group and r is 0 or 1 or 2, or at least one cocondensate of at least one aminoalkylsilane of the general formula (I) and at least one further functional silane of the general formula (II) R⁷(CHR⁶)_bSi(R⁵)_p(OR)_3-p (II), in which R⁷ is H or a vinyl group or an amino group or a glycidyloxy group or an acryloyloxy group or a methacryloyloxy group or a mercapto group or a sulfane group or a linear or branched C₁- to C₂0-alkyl group or an aryl group, it being possible for the group R⁷ to be optionally substituted, groups R⁶ are identical or different and R⁶ is H or methyl, b is from 0 to 18, R⁵ is H or a linear or branched C₁- to C₈-alkyl group, groups R are identical or different and R is H or a linear or branched C₁- to C₈-alkyl group and p is 0 or 1 or 2, it being possible for the amino functions in the cocondensate to be partly or completely neutralized with an inorganic or organic acid, or an aqueous solution which contains at least one aminoalkylsilane of the formula (I) or at least one cocondensate based on at least one aminoalkylsilane of the general formula (I) and at least one further functional silane of the general formula (II), as a binder, such composite materials being obtainable by—treating dried or moist cellulose- or lignocellulose-containing material with—a liquid which contains at least one aminosilane compound according to the formula (I) or at least one cocondensate based on at >least one aminoalkylsilane of the general formula (I) and at least one further functional silane of the general formula (II),—bringing the cellulose or lignocellulose material thus treated into a desired form and then hot-pressing it. The present invention furthermore relates to a corresponding process for the production of composite materials and the use of aminosilane compounds according to the formula (I) or at least one cocondensate based on at least one aminoalkylsilane of the general formula (I) and at least one further functional silane of the general formula (II) as a binder for producing wood-based materials.

Claims

1. A composite material comprising:

(a) at least one cellulose- or lignocellulose-containing material; and

(b) at least one aminoalkylsilane of the general formula (I);

R¹R²N(CHR⁴)_aSi(R³)_r(OR)_3-r 

 

(I),

wherein groups R¹ and R² are identical or different and in each case are H or a linear, branched or cyclic C₁- to C₂₀-alkyl group or an aryl group or an aminocarbyl group, it being possible for groups R¹ and R² to be optionally substituted, groups R⁴ are identical or different and R⁴ is H or methyl, a is from 1 to 10, R³ is H or a linear or branched C₁- to C₈-alkyl group, groups R are identical or different and R is H or a linear or branched C₁- to C₈-alkyl group and r is 0 or 1 or 2,

or

at least one cocondensate of at least one aminoalkylsilane of the general formula (I) and at least one further functional silane of the general formula (II);

R⁷(CHR⁶)_bSi(R⁵)_p(OR)_3-p 

 

(II),

wherein R⁷ is H or a vinyl group or an amino group or a glycidyloxy group or an acryloyloxy group or a methacryloyloxy group or a mercapto group or a sulfane group or a linear or branched C₁- to C₂₀-alkyl group or an aryl group, it being possible for the group R⁷ to be optionally substituted, groups R⁶ are identical or different and R⁶ is H or methyl, b is from 0 to 18, R⁵ is H or a linear or branched C₁- to C₈-alkyl group, groups R are identical or different and R is H or a linear or branched C₁- to C₈-alkyl group and p is 0 or 1 or 2, it being possible for the amino functions in the cocondensate to be partly or completely neutralized with an inorganic or organic acid,

or

an aqueous solution comprising at least one aminoalkylsilane of the general formula (I) or at least one cocondensate based on at least one aminoalkylsilane of the general formula (I) and at least one further functional silane of the general formula (II), as a binder.

2. The composite material according to claim 1, comprising

(a) at least one natural or near-natural cellulose- or lignocellulose-containing material selected from the group consisting of industrial wood, forestry industry wood, used or recycled wood, wood shavings, wood chips, wood fibers, wood wool, wood dust, particles, shuttering boards, veneer wastes, splinters and particle material from annual plants or a mixture with at least two of the abovementioned materials.

3. The composite material according to claim 1, the cellulose- or lignocellulose-containing fiber material originating from hardwood and softwood, palm plants and annual plants.

4. The composite material according to claim 1, comprising an aminoalkylsilane compound of the general formula (I) according to component (b) having at least one aminoalkyl group selected from the group consisting of 3-aminopropyl, 3-amino-2-methylpropyl, N-(2-aminoethyl)-3-aminopropyl, N-(2-aminoalkyl)-3-amino-2-methylpropyl, N—

[N′

-(2-aminoethyl)-2-aminoethyl]-3-aminopropyl, N—

[N′

-(2-aminoethyl)-2-aminoethyl]-3-amino-2-methylpropyl, N,N—

[di(2-aminoethyl)]-3-aminopropyl, N,N—

[di(2-aminoethyl)]-3-amino-2-methylpropyl, N-(n-butyl)-3-aminopropyl or N-(n-butyl)-3-amino-2-methylpropyl.

5. The composite material according to claim 1, wherein component (b) is an aqueous, alcohol-free hydrolysis product of at least one aminoalkylsilane compound according to the general formula (I) or at least one cocondensate based on at least one aminoalkylsilane of the general formula (I) and at least one further functional silane of the general formula (II).

6. The composite material according to claim 5, wherein the aqueous, alcohol-free hydrolysis product having a pH of from 3 to 12 and a viscosity of from 1 to 10 000 mPa·

s at an active substance content of from 0.1 to 80% by weight, based on the composition of the agent, it being possible to adjust the active substance content by diluting a concentrate with water.

7. The composite material according to claim 1, comprising

at least one further component (c) selected from the group consisting of the water repellents based on paraffin or wax, flameproofing agents, biocidal substances and the fragrances.

8. The composite material according to claim 1 produced by a process comprising:

treating dried or moist cellulose- or lignocellulose-containing material with—

a liquid comprising at least one aminosilane compound according to the general formula (I) or at least one cocondensate based on at least one aminoalkylsilane of the general formula (I) and at least one further functional silane of the general formula (II),—

bringing the cellulose or lignocellulose material thus treated into a desired form and then hot-pressing it.

9. A process for producing the composite material according to claim 1, wherein the process comprises:

treating dried or moist lignocellulose- or cellulose-containing material with—

a liquid comprising at least one aminosilane compound according to the general formula (I) or at least one cocondensate based on at least one aminoalkylsilane of the general formula (I) and at least one further functional silane of the general formula (II),—

bringing the cellulose or lignocellulose material thus treated into a desired form and then hot-pressing it.

10. The process according to claim 9, wherein the cellulose- or lignocellulose-containing material is sprayed in a rotating drum by a gluing apparatus operated with compressed air with an aqueous solution comprising at least one aminosilane compound according to the general formula (I) or at least one cocondensate based on at least one aminoalkylsilane of the general formula (I) and at least one further functional silane of the general formula (II).

11. The process according to claim 9, wherein up to 15% by weight of aminoalkylsilane compound according to the general formula (I) or cocondensate based on at least one aminoalkylsilane of the general formula (I) and at least one further functional silane of the general formula (II), calculated as SiO₂ and based on absolutely dry cellulose or lignocellulose material, are used as binder active substance according to component (b).

12. The process according to claim 9, wherein a wax in an amount of up to 8% by weight, based on absolutely dry cellulose or lignocellulose material, is used as further component (c) in addition to the components (a) and (b).

13. The process according to claim 9, wherein the cellulose or lignocellulose material thus treated at ambient temperature is scattered to form a cake, combed, and pressed at a temperature up to 250°

C. and a pressure up to 9 N/mm² and for a time up to 300 s/mm.

14. The process according to claim 9, wherein the cellulose-containing material is from annual plants.

15. The process according to claim 9, wherein the cellulose-containing material is from plants selected from the group consisting of hardwood, softwood, coconut, cotton, flax scrapings, hemp scrapings, bargasse, jute, sisal, reed, rice straw or cereal straw.

16. The process according to claim 9, wherein the cellulose or lignocellulose material thus treated or glued is thermally and/or mechanically pretreated before pressing.

17. The process according to claim 9, wherein the shaped articles obtained from shaping or pressing are postconditioned.

20. A wood-based material comprising a binder, wherein the binder comprises the composite material according to claim 1.

21. The wood-based material according to claim 20, which is selected from particleboards, fiberboards, ultralight fiberboards, light fiberboards, medium density fiberboards, high density fiberboards, OSB boards, veneer boards, plywood boards, moldings, moldings for automotive interior trim, industrial wood construction materials, insulating materials, wood pellets, wood briquettes and plant pots.

18. (canceled)

19. (canceled)