Method for production of lignocellulosic composite materials
First Claim
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1. A method for improving the bondability of annual plant materials to a formaldehyde-based resin selected from the group consisting of urea-formaldehyde resin (UF resin), melamine-urea formaldehyde resin (MUF resin), melamine-formaldehyde resin (MF resin), phenol-formaldehyde resin (PF resin), resorcinol-formaldehyde resin (RF resin) tannin-formaldehyde resin (TF resin) and mixtures thereof, said method comprising the steps of:
- (a) providing a straw plant material having a plurality of fibers with each of the fibers surrounded by a waxy and silica layer;
(b) extruding the straw plant material in a twin screw extruder while simultaneously subjecting the straw plant material to a thermal treatment with an aqueous solution containing a lignin modifying agent or steam, said thermal treatment being conducted at a temperature between about 40°
C. and 120°
C., said extruding subjecting the straw plant material to a sufficiently high shear force such that the extruding with simultaneous thermal treatment achieves a substantial defibration of the straw plant material with destruction of the waxy and silica layer and formation of individual fibers and such that the treated straw plant material has an enhanced affinity for the resin as compared with an affinity for the resin of the annual plant material provided in step (a), whereby to enable formation from the treated material of a fiberboard or particleboard that has greater internal bond strength, reduced thickness swelling and higher density than a fiberboard or particleboard formed from the straw plant material provided in step (a); and
(c) subjecting the treated material to heat and pressure in the presence of the formaldehyde-based resin to form a resin-bonded fiberboard or particleboard that has greater internal bond strength, reduced thickness swelling and higher density than a fiberboard or particleboard that is formable from the straw plant material provided in step (a) that is subjected to said heat and pressure.
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Abstract
A method for improving the bondability of annual plant materials to a formaldehyde-based resin including the steps of: (a) providing a straw plant material having a plurality of fibers with each of the fibers surrounded by a waxy and silica layer; (b) extruding the straw plant material in a twin screw extruder while simultaneously subjecting the straw plant material to a thermal treatment with an aqueous solution containing a lignin modifying agent or steam, the thermal treatment being conducted at a temperature between about 40° C. and 120° C., the extruding subjecting the straw plant material to a sufficiently high shear force such that the extruding with simultaneous thermal treatment achieves a substantial defibration of the straw plant material with destruction of the waxy and silica layer and formation of individual fibers and (c) subjecting the treated material to heat and pressure in the presence of the formaldehyde-based resin to form a resin-bonded fiberboard or particleboard.
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Citations
11 Claims
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1. A method for improving the bondability of annual plant materials to a formaldehyde-based resin selected from the group consisting of urea-formaldehyde resin (UF resin), melamine-urea formaldehyde resin (MUF resin), melamine-formaldehyde resin (MF resin), phenol-formaldehyde resin (PF resin), resorcinol-formaldehyde resin (RF resin) tannin-formaldehyde resin (TF resin) and mixtures thereof, said method comprising the steps of:
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(a) providing a straw plant material having a plurality of fibers with each of the fibers surrounded by a waxy and silica layer;
(b) extruding the straw plant material in a twin screw extruder while simultaneously subjecting the straw plant material to a thermal treatment with an aqueous solution containing a lignin modifying agent or steam, said thermal treatment being conducted at a temperature between about 40°
C. and 120°
C., said extruding subjecting the straw plant material to a sufficiently high shear force such that the extruding with simultaneous thermal treatment achieves a substantial defibration of the straw plant material with destruction of the waxy and silica layer and formation of individual fibers and such that the treated straw plant material has an enhanced affinity for the resin as compared with an affinity for the resin of the annual plant material provided in step (a), whereby to enable formation from the treated material of a fiberboard or particleboard that has greater internal bond strength, reduced thickness swelling and higher density than a fiberboard or particleboard formed from the straw plant material provided in step (a); and
(c) subjecting the treated material to heat and pressure in the presence of the formaldehyde-based resin to form a resin-bonded fiberboard or particleboard that has greater internal bond strength, reduced thickness swelling and higher density than a fiberboard or particleboard that is formable from the straw plant material provided in step (a) that is subjected to said heat and pressure. - View Dependent Claims (2, 3, 4, 5, 10)
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6. A method for improving the bondability of annual plant materials to a formaldehyde-based resin selected from the group consisting of, said method comprising the steps of:
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(a) providing a straw plant material having a plurality of fibers with each of the fibers surrounded by a waxy and silica layer;
(b) extruding the straw plant material in a twin screw extruder while simultaneously subjecting the straw plant material to a thermal treatment with an aqueous solution containing a lignin modifying agent selected from the group consisting of a metal hydroxide, an organic acid, an inorganic acid, a salt, an oxide and mixtures thereof, said thermal treatment being conducted at a temperature between about 40°
C. and 120°
C., said extruding subjecting the straw plant material to a sufficiently high shear force such that the extruding with simultaneous thermal treatment achieves a substantial defibration of the straw plant material with destruction of the waxy and silica layer and formation of individual fibers and such that the treated straw plant material has an enhanced affinity for the resin as compared with an affinity for the resin of the annual plant material provided in step (a), whereby to enable formation from the treated material of a fiberboard or particleboard that has greater internal bond strength, reduced thickness swelling and higher density than a fiberboard or particleboard formed from the straw plant material provided in step (a), and(c) subjecting the treated material to heat and pressure in the presence of the formaldehyde-based resin to form a resin-bonded fiberboard or particleboard that has greater internal bond strength, reduced thickness swelling and higher density than a fiberboard or particleboard that is formable from the straw plant material provided in step (a) that is subjected to said heat and pressure. - View Dependent Claims (7, 8, 9, 11)
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Specification
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Current AssigneeMarlit Ltd.
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Original AssigneeMarlit Ltd.
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InventorsRigal, Luc, Markessini, Efthalia Vergopoulou, Mouratidis, Pavlos, Roffael, Edmone
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Primary Examiner(s)YAO, SAMCHUAN CUA
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Application NumberUS09/171,087Time in Patent Office1,218 DaysField of Search156/62.2, 156/296, 264/109, 162/23, 162/26, 162/97, 162/99, 162/225US Class Current156/296CPC Class CodesB27N 1/00 Pretreatment of moulding ma...B27N 3/007 and at least partly compose...B27N 3/28 characterised by using extr...
