• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
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    • 专利摘要:
    Sheet material comprising at least a first layer (5) and a second layer (32) of particles (2-13) connected by polycondensation glue, characterized in that said first layer (5) is mainly composed of connected lignocellulose particles (2) , while said second layer (32) is mainly composed of connected cork granules.
    公开号:BE1018993A3
    申请号:E2009/0652
    申请日:2009-10-23
    公开日:2011-12-06
    发明作者:
    申请人:Unilin Bvba；
    IPC主号:
    专利说明:

    Plate material, methods for manufacturing plate material and panel containing such plate material.
    This invention relates to plate material, to methods for manufacturing plate material and to panels containing such plate material.
    More specifically, the invention relates to sheet material of the type that is mainly composed of connected flax logs, also called flax shives or flaps (flax shives). Such plate material is well known per se. Flax lemons are extracted from flax as a waste product in flax fiber production and concern pieces broken up from the stem of the flax plant in chips. However, the invention also relates to 'flat material' of the following types, for example to plate material of the type which is mainly composed of connected lignocellulose particles. Flax plates are known as bodies. good 'plàfèh' that can be used, for example, as filler material Vödr1 one paraeelparieffals £ basis for a furniture or wall panel or as an environmentally friendly insulation board. Flax chipboard also has good acoustic properties and a fire-retardant capacity than wood chipboard. .....
    It is already known from DÈ 20 2007 017 713 Ü1 to reduce the weight for wood chip boards by applying polypropylene balls in the middle layer of such wood chip board. Polystyrol or polystyrene is known per se as a fire-unsafe material. Däarorh is also proposed in the aforementioned document to use individual fire-retardant additives in such a plate.
    The present invention aims at further optimizing plates Vlh! T>. It is hereby inherited that it is possible to offer thick plates that nevertheless have a limited weight; so that these 'plates- are more ergonomic' in use and more ecologically in transport. To this end, according to its first independent aspect, the invention relates to a plate-shaped material of the type mainly composed of joined flaxenes, with the feature that the aforementioned plate material contains particulate filling material, preferably foamed particles, which is at least between the aforementioned flaxeners is located. Because the flax elements per se have a fire-retardant capacity, particulate filler materials can be used which have a less fire-retardant capacity, with only a limited decrease in the overall fire-retardant capacity of such a plate. Preferably a synthetic filler material is used. It is possible to work without the addition of individual fire-retardant additives or with fewer such additives, and possibly still achieve a similar result in terms of fire safety as is the case with the wood chip boards from the above-mentioned prior art.
    According to a preferred embodiment, a particulate filler material is used which has a lower density than the flax lemens. Preferably, this density is at least 10%, and better still 20% lower than the density of flaxen. Such a density difference can be achieved in the case of filling material in the form of foamed particles. A lighter vlässpäah plate can thus be obtained, which furthermore exhibits all the positive properties of the vlässpaähpläteri of the prior art. For example, it is possible to work as a particle-shaped filling material with a material that comprises at least polystyrene, such as with foamed particles which contain polystyrene or polystyrene or which exist in the same way: It is also possible to use polyurethane particles as particle-shaped filling material.
    Another possibility is to work with natural particulate material, for example with particulate filler material comprising cork granulate: According to an important possibility, the low-density cork, which is regarded as waste during the manufacture of cork products, can be used. The cork granulate preferably has a density of 10 to 80 kg / m3, or more preferably of 20 to 40 kg / m3. Thus another example is obtained of the above-mentioned preferred embodiment. In addition, cork itself has a fire-retardant capacity, so that it is ideally suited to be combined with flax spears. Moreover, in this way a very ecologically responsible sheet material is obtained. The cork granulate that is used preferably has an average particle size between 0.3 and 5 millimeters, and more preferably between 0.5 and 3 millimeters. Namely, such granulate is excellent for use as filler material in flax stems, or even, according to a different variant, between wood chips. It is possible to select the cork granulate so that the aforementioned average particle size is met. In this way, pre-processing of the particles becomes unnecessary or virtually unnecessary.
    Another possibility is to work with cork powder. This then involves mechanically broken cork granules, for example crushed cork granules. The use of such small cork particles can also relate to the use of cork particles that are incorporated into a surface layer of a sheet material. In this way, for example, sound-damping effects can be achieved without compromising the properties of the surface layers possibly made up of fine chips. The dimensions of cork powder are extremely suitable for use as filler material in fiber boards such as MDF or HDF.
    As stated, the use of cork granulate and / or cork powder is also interesting in other plate types. Therefore, according to a deviating aspect, the invention also relates to a sheet material with the characteristics of the first aspect, or the preferred embodiments thereof, wherein wood chips or wood fibers are used in the place of flaxen and wherein the particulate filling material or at least a fraction of cork granulate and / or cork powder contains or consists essentially or entirely of it. A modified chipboard, OSB board, wood fiber board, MDF or HDF board is thus obtained. It is also possible to use cork granulate and / or cork powder as filler material in a plate material which is mainly composed of a connected mixture of wood and flax particles, such as from a connected mixture of wood chips and flax litters. This embodiment is interesting as the availability of flaxen can fluctuate greatly depending on the season. With a low availability of such flax logs, they can then be supplemented with wood chips. The share of the woodchips in the woodchips / flax blend can hereby be between 10 and 50% by weight. This proportion is preferably between 25 and 40%.
    It is noted that the geometry of compressed flax fibers is well suited to accommodate filling materials, and in particular ball or particle-shaped filling materials. Because flax logs are typically coarser than wood chips, they build gaps for such filling material, moreover, filling material can more easily be distributed through the flax logs in a relatively homogeneous manner.
    Preferably the flax fibers mentioned in the first aspect are connected on the basis of a polycondensation glue. Preferably, the aforementioned polycondensation glue contains at least urea formaldehyde. Whether or not in combination with urea formaldehyde, such polycondensation glue may also contain at least lignosulfonate and / or substances selected from the list of melamine glue, melamine formaldehyde glue, methane diphenyl diisocyanate glue, phenol formaldehyde glue, resorcinol formaldehyde glue and resorcinol glue formaldehyde glue. Preferably, said polycondensation glue consists essentially of a thermosetting polycondensation glue. It is preferable to use a weight ratio of binder, for example polycondensation glue, to flaxen between 2:98 and 12:88. Preferably, in the manufacture of the sheet material of the invention and in the case of the use of urea formaldehyde as a binder for flaxen, a supplement of urea is used so that any free formaldehyde can still be bound. It is clear that the ratios mentioned here also preferably apply when flax, woodchips or wood fibers or mixtures of wood particles and flax particles are used, the weight ratio of binder to lignocellulose particles being considered.
    The above-mentioned lignosulphonate can, for example, be obtained as a waste product from paper production and a sheet material containing at least a fraction of lignosulphonate as a binder can therefore be regarded as a very ecological one. An ideal combination arises when such ligosulphohate is used with particulate filler material consisting essentially or entirely of cork granulate.
    According to a preferred embodiment of the first aspect, the joined flax fibers forms a layer that is centrally located in the thickness of the sheet material, while one or both surfaces of the sheet material are formed by a layer containing bonded wood chips or wood fibers. Various effects are achieved on the basis of this preferred embodiment. Because one or both of the surfaces exhibits the composition of wood chipboard, a layer of relatively high density is obtained at these surfaces which can contribute significantly to the strength of the board material, and in particular to the flexural strength and / or the resistance to impact loads and / or the hardness of the plate or plate material. Moreover, on the basis of such a layer a surface that can be easily finished can be obtained which, optionally after being sanded, is excellent for being finished with a laminate layer, a veneer layer, a lacquer layer or another preferably decorative layer which may or may not does not show a pattern. Preferably, the thickness of the layer formed by the flaps forms at least 70% of the thickness of the sheet material. Because the majority of the sheet material consists of flax logs, the positive properties of flax logs, such as their low density, are largely retained. Preferably, the average dimensions of the wood chips or wood fibers that are located on one or both surfaces are smaller than the average dimensions of the flaxeners that are centrally located. This achieves that the texture of the surfaces, possibly after sanding them, can be smooth. The normative dimension is preferably used with the longest dimension of the relevant chips or loams.
    It is clear that, in the case of the above-mentioned deviating aspect, the sheet material can also have different layers, wherein the filling material is then preferably located at least in a central layer of wood chips or wood fibers, while on one or both surfaces a layer is formed with wood chips or wood fibers of smaller average dimensions, wherein these layers are preferably free of the aforementioned filler material.
    The plate material of the invention preferably has a total thickness between 18 and 60 millimeters, and more preferably between 25 and 50 millimeters. A significant weight reduction can be achieved in this range.
    Preferably, the aforementioned particulate material, for example, the aforementioned foamed particles or the aforementioned cork granulate, as mentioned above, is homogeneously or substantially homogeneously dispersed in the entire layer formed by flaxen. In this way the invention comes into its own very well. A homogeneous or almost homogeneous spread of the filler material minimizes the risk of defects, such as porous areas, in a laminate top layer applied to the plate material. Namely, inhomogeneities can lead to pressure differences in the pressing device, which in turn give rise to defects in the curing of melamine or other resin present in the laminate top layer.
    /
    Preferably, the aforementioned particulate material, for example the aforementioned foamed particles or the aforementioned cork granulate, is essentially only in the layer formed by the flaxeners. Better still, such particles are absent in any other layers that are free or at least practically free from flax spears.
    Preferably, the layer formed by flax fibers is free or substantially free of wood chips and / or other chip-like material.
    Preferably, the sheet material of the invention has a density of less than 500 kilograms per cubic meter, and more preferably less than 300 kilograms per cubic meter. Interesting plates, for example, exhibit a density laid between 350 and 450 kilograms per cubic meter. In this range, the plates of the invention can exhibit the combination of both a limited weight and acceptable mechanical properties. It is of course not excluded that good mechanical properties can also be achieved at lower densities, depending on the intended application.
    According to a second independent aspect, the invention also relates to a sheet material of the above-mentioned type, characterized in that the aforementioned flaxeners are connected at least in part by means of a foamed binder. It is obvious that similar effects can be achieved on the basis of such plate material as with the plate materials above with regard to weight reduction. Moreover, it is possible to achieve a more pronounced weight reduction. The aforementioned foamed binder may contain, for example, melamine foam, urea foam and / or polyurethane foam. It may also be a foamed binder based on polyethylene, polysytrene, polyurethane, polyvinyl chloride or the like. Preferably, this is also a plate which on one or both surfaces thereof has a layer formed by joined wood chips or wood fibers.
    The foaming of the binder preferably takes place at least partially in a pressing device. For example, for manufacturing the sheet material of the second aspect, use can be made of a method starting from a material mass comprising flaxen and binder, wherein this material mass is introduced into a press device, or passed therethrough, and wherein foaming or expanding of the binder occurs at least partially in the press device. The pressing device can then be used per se as a calendar for adjusting the final thickness of the relevant sheet material.
    A method in which a component of a sheet material is foamed or expanded in the pressing device is per se interesting, irrespective of whether this component in question is now used as a binder, filler material or self-contained layer. Such a method therefore forms a third independent aspect of the present invention. For example, the particulate filler material of the first aspect can be foamed or expanded in this way or, by means of such a method, a sheet material can be obtained which internally has a layer of foamed or expanded plastic. It is clear that for the material of such a component, the foamable or expandable materials mentioned in connection with the first aspect can be used. Preferably, polyurethane or polystyrene-containing plastics are used. The plate material obtained according to the third aspect preferably has one or more layers, for example surface layers; containing associated flax and / or wood chips and / or wood fibers. In this way a light, ecological plate is obtained, which nevertheless has a sufficient strength and / or allows a good finish of the flat sides thereof.
    It is clear that the invention according to the aforementioned third independent aspect can be defined as a method for manufacturing sheet material, characterized in that a material mass is used which comprises at least flaxen, or other lignocellulose particles, and an expandable or foamable component, wherein this mass of material is introduced into, or passed through, a pressing device, and wherein the foaming or expansion of the aforementioned expandable or foaming component takes place at least partially in the pressing device. The pressing device is herein preferably used per se for adjusting the final thickness of the plate material. A pressing device of the continuous type is preferably used herein. However, it is not excluded that so-called stroke presses are used. Preferably, the aforementioned material mass undergoes at least two consecutive or non-consecutive pressing cycles, wherein a lower pressure and / or temperature is applied in the second pressing cycle than in the first pressing cycle, and wherein the expansion of the aforementioned component mainly takes place during this second press cycle. In the first pressing cycle, the higher pressure and / or temperature present there can be used at least for connecting the material mass which will be present in the surface layers of the plate material.
    According to a deviating variant of the above aspects of the invention, instead of flaxen, it is possible to use chips obtained from dried grass species, such as from straw, hay, hemp, elephant grass, bamboo and the like. . *
    According to a fourth independent aspect, the invention contemplates an alternative plate material which, according to various preferred embodiments, can have special decorative and / or technical properties and / or allows a decorative and / or technically superior plate to be manufactured in a relatively simple manner. To this end the invention relates to a plate material which is mainly composed of connected lignocellulose particles, for example in the form of flakes, chips, powder and / or fibers, characterized in that at least one flat side of the plate material is mainly formed by connected cork granulate. Preferably, both the connection between the individual cork granules and the connection between the granulate and the underlying lignocellulose particles are established by means of polycondensation glue, preferably on the basis of the same polycondensation glue. The polycondensation adhesives mentioned in connection with other aspects can be used for this purpose. As the cork granulate, the above-mentioned low-density cork can be used and / or cork with the particle size stated therein. The plate material of the fourth aspect preferably has an internal transition zone between the connected lignocellulose particles and the connected cork granulate, said transition zone comprising a connected mixture of cork granules and lignocellulose particles.
    The aforementioned lignocellulose particles are preferably selected from the range of wood particles, grass particles and flax particles. For example, it can be wood chips, wood fibers or flax spears. For the connection between the lignocellulose particles, the above-mentioned polycondensation adhesives can also be used, whether or not in the aforementioned ratios.
    The total thickness of the sheet material from the fourth aspect is preferably between 5 and 25 millimeters, and more preferably between 10 and 20 millimeters. Such a thickness is suitable, for example, when the sheet material of the second aspect serves as a starting material for the manufacture of floor panels or other decorative interior panels. For example, the relevant flat side can be finished with one or more lacquer, varnish or melamine layers, wherein the appearance of the decorative side of the relevant panels is then preferably determined by the aforementioned cork granulate. According to another example, a different decorating material can be applied to the relevant flat side, such as a printed decor or a veneer, wherein the cork granulate then, for example, at least partially fulfills the function of damping noises that arise when the panels are used.
    According to a special embodiment of the aforementioned fourth aspect, printing is carried out on the cork granulate, either directly or indirectly. To this end, one or more primer layers are preferably applied to the cork granulate, such as primer layers comprising spatulae material and / or which impart a substantially uniform or uniform basic color to the sheet material or panel. The printing can then be carried out directly on these base layers on the basis of a technique such as rotation or set printing or rotary intaglio printing or on the basis of a digital technique such as ink-jet printing. Such printing can then be further finished on the basis of one or more transparent lacquer, varnish or melamine layer, wherein such layers can comprise hard particles such as aluminum oxide, in order to increase the wear-resistant properties of such sheet material or panel. According to this special embodiment, a decorative panel is obtained which has very good sound-insulating or sound-damping properties.
    The plate material of the fourth aspect is preferably manufactured by means of a method in which the connection between the cork granules, as well as the connection between the cork granulate and the lignocellulose particles, whether or not already connected, is obtained simultaneously or at least substantially simultaneously, e.g. in the same press device. Thus, for example, a material mass, whether or not pre-compacted and / or already or not already consolidated, comprising at least one layer of glued lignocellulose particles can be assumed, whereby on this material mass preferably unconnected or not yet fully connected cork granules are applied, the whole of material mass and cork granules are arranged in, or passed through, a heated pressing device, whereby both the connections between the cork granules themselves and the connection between the crank granulate and the underlying mass of material are obtained in said pressing device. Preferably, the final connection between the lignocellulose particles is also obtained on the basis of the same pressing operation. For this purpose, for example, the continuous pressing devices can be used which are customary in the production of flax chipboard or wood chipboard. One or more spreading operations can be used to assemble the aforementioned material mass. One or more spreading operations can also be applied for applying the loose cork granules. Optionally, the whole of material mass and cork granules, or only a part thereof, can be pre-compacted or vented before it is introduced into the actual pier device. It is even possible that the material mass of lignocellulose particles is already fully connected and compacted before the loose cork granules are applied to it.
    It is clear that the method described above constitutes per se a particularly independent aspect of the present invention, which can be defined as a method for manufacturing plate material, starting from a material mass comprising at least one layer of glued lignocellulose particles, characterized in that cork granules or other particulate filling material are applied to this material mass, wherein the whole of material mass and cork granules, or other filling material, is applied in a heated pressing device, wherein both the connections between the cork granules or the filling material mutually, and the connection between the cork granulate, whether the filling material and the underlying material mass are obtained in the aforementioned pressing device. For the other particulate filler material, the filler materials mentioned elsewhere can be used, such as, for example, the said expanded or expanding filler materials.
    It is clear that sheet material obtained or obtainable by means of a method with the characteristics of the above-mentioned special aspect also forms an object of the present invention. Such a sheet material can be defined independently as a sheet material comprising at least a first layer and a second layer of particles connected by polycondensation glue, characterized in that said first layer is mainly made up of connected lignocellulose particles, while said second layer is mainly built up from connected cork granules or filling particles. The connection between the first and the second layer is preferably also obtained by means of polycondensation glue, more preferably by means of the same polycondensation glue which is used in the first and / or the second layer. The cork granules or the filling particles preferably have a lower density than the lignocellulose particles used. This density is preferably 10% and more preferably 20% lower than the density of the lignocellulose particles. It is clear that filler or cork granules can be used which have been mentioned in connection with other aspects and that similar advantages can be achieved with this, for example with regard to the ecological and / or economic properties of the plate material. Furthermore, it is clear that as lignocellulose particles, for example, wood chips, wood fibers, flax stains or mixtures thereof can be used. It is noted that said second layer may, according to a first possibility, be located on the surface of the sheet material, wherein in fact an embodiment of the aforementioned fourth aspect can be obtained. According to a second possibility, said second layer can be designed as an internal layer, said first layer then preferably being located on the surface of the plate material. In the latter case, the total thickness of the plate material is preferably between 18 and 60 millimeters, and more preferably between 25 and 50 millimeters. The sheet material of the aforementioned second option is preferably used as a filling material, for example of a door or other comparable wall or furniture panel. It is not excluded that both of the aforementioned possibilities are combined and that, for example, a plate material is realized which has both an internal layer and a surface layer which is mainly composed of particulate filling material, for example cork granules.
    The sheet material of the second option mentioned in the special aspect preferably has a density of less than 500 kilograms per cubic meter, and more preferably less than 300 kilograms per cubic meter. Interesting plates, for example, have a density between 350 and 450 kilograms per cubic meter. In this range, the plates of the invention can exhibit the combination of both a limited weight and acceptable mechanical properties. Of course, it is not excluded that good mechanical properties can also be achieved at lower densities, depending on the intended application. For the use of the sheet material as filler material in a door or other panel, a density between 200 and 300 kilograms per cubic meter will suffice.
    According to the invention in general, an internal layer, whether formed by filling material or cellulose particles or both, preferably covers at least 50% of the total thickness of the plate material, and more preferably at least 70% of this thickness.
    It is noted that, according to the fourth aspect or the particular aspect mentioned above, other components may be provided in the connected cork granule. For example, metal particles or color pigments can be mixed in, whereby a very attractive decorative effect can then be achieved.
    It is further noted that according to a different variant of the aforementioned fourth aspect or the aforementioned special aspect and the preferred embodiments thereof, a preferably compressible other granulate can be used instead of cork granulate, such as for instance a plastic granulate such as a granulate based on of polystyrene. By "compressible" is meant here more compressible than the lignocellulose particles that are used in the same sheet material. It is also possible that the granulate comprises a mixture of different granules, whether or not based on cork. The difference between the granules can for example manifest itself in a difference in grain size, color and / or material or the like. According to this deviating variant, particularly interesting effects can be achieved. Possibly even motifs can be realized, which may or may not be repeatable and / or may be preset.
    The invention also relates to panels made on the basis of the sheet materials of the invention. To this end the invention relates to a panel for furniture, doors or walls, characterized in that this panel mainly consists of the above-mentioned plate material, wherein one or both surfaces of this panel are provided with a finishing layer based on paper and / or plastic and / or a low wood, such as veneer. It may, for example, be a lacquer layer, a melamine layer, a laminate layer or a layer of wood thicker than veneer. The plate material of the invention is preferably used as filler material.
    With the insight to better demonstrate the features of the invention, a preferred embodiment is described below as an example without any limiting character, with reference to the accompanying single drawing, in which: Figure 1 shows a cross-section through the thickness of the composition of a sheet material with the characteristics of inter alia the first aspect of the invention; figure 2 represents the composition of a plate material with the features of inter alia the fourth aspect of the invention in the same view; Figure 3 shows some steps in a possible method for manufacturing a sheet material with the characteristics of the fourth aspect; figure 4 shows, in a view similar to that of figures 1 and 2, the composition of a sheet material obtained by means of a method with the characteristics of the third aspect; and figure 5 represents another plate material in a view similar to that of figure 4.
    As shown in Figure 1, according to its first aspect, the present invention relates to a sheet material 1 of the type mainly composed of connected flax logs 2. The connected flax logs 2 form a layer 3 which is at least centrally located in the thickness T of the sheet material 1. The thickness T1 of the relevant layer 3 is hereby at least 70%, and in this case even more than 90% of the total thickness T of the sheet material 1.
    The special feature of the first aspect of the present invention is that the sheet material 1 contains filler material, in this case foamed polystyrene particles 4, which are at least between said flax elements 2. In this case, the foamed particles 4 are exclusively in the aforementioned layer 3, which is formed by connected flax elements 2.
    While the total thickness T of the sheet material 1 of the example is approximately 30 millimeters, the central layer 3 containing flax fibers 2 thereof has a thickness T1 of approximately 28 millimeters, and the outer layers 5 of the sheet material 1 are each formed by an approximately 1 millimeter thick separate layer 5. Figure 1 clearly shows this. Both surfaces 6 of the sheet material 1 are, in this case, formed by a separate layer 5 containing finer material, for example connected wood chips or wood fibers. For example, the sheet material 1 may exhibit on the surface the typical composition of a wood chip board or a wood fiber board, wherein the aforementioned wood particles are preferably connected to a similar or the same binder as the flax lords 2 of the central layer 3, using a polycondensation glue selected from the aforementioned options for this.
    Figure 1 also shows that the extreme zones 7 of the central layer 3 are more compacted than the internal zone 8 of this central layer 3. The filling material 4 located in the extreme zones 7 is then also substantially less expanded or foamed than the filling material 4 that is in the internal zone 8, or that is more compressed than the filling material 4 that is in the internal zone 8. The more compacted zones 7 together cover approximately one third of the thickness T1 of the central layer 3 containing flax fibers 2.
    Figure 1 also illustrates that the foamed particles 2 are dispersed substantially homogeneously in the entire layer 3 formed by the flax fibers.
    Dotted line 9 also shows that on the basis of such plate material 1 a panel can be manufactured which is provided on at least one of the aforementioned surfaces 6, but preferably on both surfaces 6, with one or more finishing layers (10-11-12) . Because a finish is provided on both surfaces 6 in the example, the risk of the panel curving is minimized. Optionally, one of these surfaces 6 can be worked with a so-called balancing layer 10, whose main purpose is to counteract such a curvature as well as possible. On the other surface 6, a laminate layer can then be used, as in the example, which comprises, for example, a decorative layer 11 and a transparent or transparent protective layer 12 or overlay, both preferably based on paper and plastic. Said decorative layer can for instance be provided with a print of a motif, but this is not shown here.
    It is clear that on the basis of the example of Fig. 1 an example of the deviating aspect mentioned in the introduction can also be formed when the aforementioned flax stalks are replaced by wood chips and when particle-like filling material is used in the layer concerned which comprises cork granulate.
    Figure 2 shows a plate material 1 that is mainly composed of connected lignocellulose particles, in this case wood chips and / or flax logs 2. In the example, one flat side or surface 6 of the plate material 1 is formed by connected granulate 13, in this case connected cork granulate. Both the connection between the individual cork granules 14 and between the cork granulate and the underlying wood chips and / or flax logs 2 has been achieved by means of polycondensation glue. The underlying wood chips and / or flax logs 2 themselves are also connected by polycondensation glue. The plate material 1 shown in this case also has a transition zone 15 between the granulate 13 and the connected lignocellulose particles, wherein this transition zone 15 comprises a connected mixture of cork granules 14 and lignocellulose, namely wood particles and / or flax glands 2. In this zone 15, the granules 14 are rather present as particulate filler material 4. This mixture is also connected by polycondensation glue. It is clear that, according to a variant of the embodiment shown in Figure 2, instead of wood chips and / or flax logs 2, for example, wood fibers can also be used.
    Figure 3 shows how such a variant can be formed by consolidating a material mass composed exclusively or mainly of particles 16.
    To this end, Figure 3 schematically shows some steps S0-S1-S2 in a method with the features of the particular independent aspect of the invention mentioned in the introduction. In the example, it concerns a method that is carried out on the basis of a production line 17 that essentially corresponds to a typical MDF or HDF production line. This is based on a material mass 18 which is composed in a preceding step SO at least on the basis of two components. In this case, both components are supplied simultaneously to a scattering machine 19 in the form of wood particles 20, which are previously provided with binder, namely polycondensation glue, more particularly polycondensation glue provided with wood fibers 20.
    The spreading machine 19 of such a production line 17 can be constructed in any way. In the example, a spreading machine 19 is used as is known per se from WO 03/053642. The spreading machine 19 of the example is provided with a plurality of agitating elements 21 which move the glued wood fibers 20 into the spreading chamber 22. On the basis of the wood fibers 20 leaving the spreading chamber 22 on the underside, the material mass 18 is assembled on the Conveyor or conveyor belt 23 located beneath it For further description of such a spreading machine 19, reference is made to the aforementioned international patent application. Other types of spreading machines are of course also suitable, such as, for example, the spreading machines described in international patent applications WO 99/36623 and WO 2005/044529. It is clear that when instead of using wood fibers 20, with wood chips and / or flax logs 2, preferably at least the scattering machine 19 is adapted to this.
    Seen in transit, a so-called scalpel roller 24 is located after the scattering machine 19, which removes any excess wood fibers 20 from the material mass 18, after which a material mass 18 with a flat or almost flat top surface is obtained. It is noted that it is not necessary to work with such a scalpel roller 24.
    Seen in transit, a device 25 is provided after the scattering machine 19 for applying unconnected cork granules 14 to the material mass 18, but provided with polycondensation glue 14. In this case, the device 25 performs a scattering operation. To this end, for example, a spreading device can be used as is known per se from GB 1,003,597 or GB 1,035,256. As shown in Figure 3, such a spreading device may comprise a container 26 which is in communication with a dosing roller 27 which carries the granules 14 away from the container 26. Such a dosing roller 27 is preferably structured, wherein the granules 14 are then entrained mainly via the lower structural parts of the dosing roller 27. Furthermore, such a spreading device preferably comprises a device 28 which detaches the granules 14 from the above-mentioned metering roller 27. In this case, a brushing device is used for this purpose. A sufficiently homogeneous spread pattern can be obtained on the basis of such a spreading device.
    The composite material mass 16 thus obtained can have a thickness D that is up to 50 times or more than the thickness T of the plate material 9 to be finally obtained, since it is compressed in one or more compaction steps S1-S2 to this required thickness T of the plate 1 or the panel has been reached. During these compaction steps S1-S2, the composite material mass 16 preferably experiences at least a doubling of its density. These further compaction steps S1-S2 are also shown schematically here.
    Passing after the aforementioned scalpel roller 24 is a compacting device or pre-press 29 in which the composite material mass 16 is gradually compacted prior to the actual hot pressing in step S2 to a state in which it can be transported in a more simple manner in comparison with the non-compacted composite material mass 16. For this purpose, the composite material mass 16 is preferably conveyed between press belts 30 during step S1, wherein these press belts 30 have a progressively decreasing intermediate distance. With this pre-compression in the pre-press 29, preferably no heat is supplied and / or, preferably, the binder present is not yet or only partially activated. Rather, the pre-compaction preferably involves at least partial removal of the gases present in the composite material mass 16, such as air.
    According to a variant of the method shown in Figure 3, the granules 14 or a part thereof are only applied to the material mass 18 after said pre-compaction has been carried out in step S1.
    After the compacting device or pre-press 29, viewed in the flow direction, the actual pressing device 31 is located in which the material mass 16, which may or may not already be pre-compacted, is compressed under the influence of heat. The applied temperature may, for example, be between 100 ° C and 150 ° C and the applied pressure may, for example, be between 4 and 10 bar on average, but brief peak pressures of up to 40 bar are not excluded. The activation of at least the binder present on the granules 14 preferably takes place mainly in this pressing device 31. Preferably, the binder present on the wood fibers also takes place here. In the case of a polycondensation glue, water or steam may be formed in this pressing device 31.
    The pressing device 31 shown here is of the continuous type, namely of the type in which the composite material mass 16 is transported between pressing belts 30 and / or is gradually compressed. A pressure and / or temperature profile can be set in the flow of such a pressing device 31. On the basis of this pressing device 31, the density of the already partially compacted composite material mass 16 can be at least doubled. It is clear that the method of the invention can also be carried out with other pressing devices, such as, for example, with a vapor pressure press, with a multi-level press or with a so-called cork-stroke press. With these other pressing devices 31, the applied pressure and / or temperature can be adjusted as a function of the time that the material mass 16 in question remains in the pressing device 31.
    On the basis of the production line 17 shown here, a method with the characteristics of the third aspect can also be carried out. For this purpose, an expandable or foamable agent must be included in the material mass 18, which agent then expands or foams in the pressing device 31. For this purpose, the temperature and / or pressure variation in the pressing device 31 can be adjusted such that the material mass 18 undergoes at least two consecutive pressing cycles, wherein a lower pressure and / or temperature is applied in the second pressing cycle than in the first pressing cycle. With this it can be achieved that the expansion or foaming of the respective agent takes place mainly in the aforementioned second pressing cycle. The pressing device 31 can then be used as a calendar for adjusting the thickness T of the final plate material 1. The first pressing cycle can essentially lead to the joining of the material mass 16 in the layers 5 on the surface 6 of the final plate material 1. Such a method is not illustrated here.
    Figure 4, however, illustrates a sheet material 1 that may have been obtained by such a method. This is a plate material 1 in which the expanded or foamed agent forms an independent internal layer 32. This means that this layer 32 is substantially free of lignocellulose particles. The plate material 1 has a layer 5 on both surfaces 6 which contains, or even consists essentially of, wood chips and / or flax logs 2.
    Figure 5 shows another sheet material 1 that can be obtained on the basis of a method with the features of the special aspect of the invention mentioned in the introduction. The plate material 1 in question has an internal layer 32 which is mainly built up of connected cork granules 13. In this case the plate material is provided on both surfaces 6 with a layer 5 which mainly consists of connected lignocellulose particles, in this case flax lords 2. Both the cork granules 13 and the lignocellulose particles 2 are connected on the basis of a polycondensation glue. The connection between the internal layer 32 and the surface layers 5 has also been obtained on the basis of such polycondensation glue. It is clear that the plate material 1 shown here is an example of the second possibility for the second layer mentioned in connection with the special aspect.
    ; "- /
    It is clear that the internal layer 32 of the plate material of Fig. 5 can also be mainly composed of a filling material other than the connected cork granules 13 or the cork granulate 14. Thus, for example, such internal layer 32 can also be essentially composed of polycondensation glue expanded plastic particles, such as polystyrene particles.
    The plate material 1 of figure 5 can for instance be used as a substitute for a honeycomb plate. In such a plate 1, an internal layer is formed by a cardboard honeycomb structure. The plate material 1 of Figure 5 can provide a greater fire retardancy than a plate with honeycomb core, since the cork granulate 14 per se has a fire-retardant capacity.
    It is generally noted that the thickness of the different layers of the sheet material shown in the figures should be interpreted as non-limiting.
    The present invention is by no means limited to the embodiments described above, but such sheet material, panels and methods can be realized according to different variants without departing from the scope of the present invention.
    权利要求:
    Claims (25)
    [1]
    Sheet material comprising at least a first layer (5) and a second layer (32) of particles (2-13) connected by polycondensation glue, characterized in that said first layer (5) is mainly composed of connected lignocellulose particles ( 2), while said second layer (32) is mainly composed of connected cork granules.
    [2]
    Sheet material according to claim 1, characterized in that in addition to the connection between the individual particles (2-14) of the respective first layer (5) and second layer (32), also the connection between this first layer (5) and second layer (32) is achieved at least partially by polycondensation glue.
    [3]
    Sheet material according to claim 1 or 2, characterized in that said second layer forms an internal layer (32) of said sheet material (1).
    [4]
    Plate material according to one of the preceding claims, characterized in that the total thickness of the plate material is between 18 and 60 millimeters.
    [5]
    Plate material according to one of the preceding claims, characterized in that this plate material has a density of less than 500 kilograms per cubic meter.
    [6]
    A sheet material, which is mainly composed of connected lignocellulose particles (2), characterized in that at least one flat side (6) of the sheet material (1) is mainly formed by connected cork granulate (13) and that the aforementioned sheet material (1) further still has one or more of the following properties: - the property that both the connection between the individual granules (14) and the connection between the granulate (13) and the underlying lignocellulose particles (2) are at least partially achieved by polycondensation glue brought; - the property that the plate material (1) has an internal transition zone (15) between the connected cork granulate (13) and the connected lignocellulose particles (2), said transition zone (15) having a connected mixture of cork granules (14) and lignocellulose particles (2).
    [7]
    Sheet material according to one of the preceding claims, characterized in that the aforementioned lignocellulose particles (2) are selected from the series of wood particles, grass particles and flax particles (2).
    [8]
    Sheet material according to one of the preceding claims, characterized in that another compressible granulate is used instead of cork granulate (13).
    [9]
    Method for manufacturing sheet material, starting from a material mass (18) comprising at least one layer of glued-on lignocellulose particles (2), characterized in that cork material (14) is applied to this material mass (2), the whole of material mass (2) and cork granules (14) are provided in a heated pressing device (31), wherein both the connections between the cork granules (14) and the connection between the crank granulate (13) and the underlying material mass (2) in said pressing device ( 31).
    [10]
    A method for manufacturing sheet material, characterized in that a material mass (18) is used which comprises at least flax elements (2) and an expandable or foamable component, said material mass (18) being introduced into a pressing device (31), or passed therethrough, and wherein foaming or expanding occurs at least partially in the pressing device (31).
    [11]
    A sheet material of the type mainly composed of connected flax logs (2), characterized in that the aforementioned flax logs (2) are connected at least in part by means of a foamed binder.
    [12]
    A sheet material of the type mainly composed of connected flax logs (2), characterized in that the aforementioned sheet material (1) contains particle-shaped filling material (4) which is at least between the aforementioned flax logs (2).
    [13]
    Sheet material according to claim 12, characterized in that the flax logs (2) are connected on the basis of a polycondensation glue.
    [14]
    Plate material according to claim 12 or 13, characterized in that said particle-shaped filling material comprises foamed particles.
    [15]
    The sheet material according to claim 14, characterized in that the aforementioned foamed particles (4) comprise at least polystyrene.
    [16]
    The sheet material according to any of claims 12 to 15, characterized in that said particulate filler material comprises cork granutate.
    [17]
    The sheet material according to claim 16, characterized in that said cork granulate has a density of 10 to 80 kg / m3, and preferably of 20 to 40 kg / m3.
    [18]
    Plate material according to claim 16 or 17, characterized in that said cork granulate has an average particle size between 0.3 and 5 millimeters, and preferably between 0.5 and 3 millimeters.
    [19]
    Sheet material according to one of Claims 16 to 18, characterized in that wood chips or wood fibers are used instead of flax spears.
    [20]
    Sheet material according to one of claims 12 to 19, characterized in that the joined flax elements (2) form a layer (3) centrally located in the thickness (T) of the sheet material (1), while one or both surfaces ( 6) of the sheet material (1) is formed by a layer (5) containing bonded wood chips or wood fibers.
    [21]
    Sheet material according to claim 20, characterized in that the average dimensions of the wood chips or wood fibers that are located on one or both surfaces (6) are smaller than the average dimensions of the flax blades (2) which are centrally located.
    [22]
    The sheet material according to any of claims 12 to 21, characterized in that said particle-shaped filler material (4) is distributed homogeneously or substantially homogeneously in the entire layer (3) formed by the flax elements (2).
    [23]
    The sheet material according to any of claims 12 to 22, characterized in that it has a density of less than 500 kilograms per cubic meter.
    [24]
    Panel for furniture, doors or walls, characterized in that this panel consists essentially of the sheet material (1) of one of the preceding claims, respectively obtained according to a method with the features of one of the preceding claims, wherein one or both surfaces (6) of this panel are provided with a finishing layer (10-11-12) based on paper and / or plastic and / or a layer of wood, such as veneer.
    [25]
    Panel according to claim 24, characterized in that the aforementioned plate material (1) is used as filler material.
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    同族专利:
    公开号 | 公开日
    WO2010119431A2|2010-10-21|
    EP2419250A2|2012-02-22|
    BE1019618A3|2012-09-04|
    WO2010119431A3|2011-01-20|
    BE1018721A3|2011-07-05|
    BE1018765A3|2011-08-02|
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    法律状态:
    2017-12-13| MM| Lapsed because of non-payment of the annual fee|Effective date: 20161031 |
    优先权:
    申请号 | 申请日 | 专利标题
    BE200900239|2009-04-16|
    BE2009/0239A|BE1018721A3|2009-04-16|2009-04-16|PLATE MATERIAL AND PANEL THAT CONTAINS SUCH PLATE MATERIAL.|
    BE2009/0329A|BE1018765A3|2009-04-16|2009-05-28|PLATE MATERIAL AND PANEL THAT CONTAINS SUCH PLATE MATERIAL.|
    BE200900329|2009-05-28|
    BE2009/0538A|BE1019618A3|2009-04-16|2009-09-03|PLATE MATERIAL, METHODS FOR MANUFACTURING PLATE MATERIAL AND PANEL CONTAINING SUCH PLATE MATERIAL.|
    BE200900538|2009-09-03|PCT/IB2010/051667| WO2010119431A2|2009-04-16|2010-04-16|Board material, methods for manufacturing board material and panel which contains such board material.|
    EP10723322A| EP2419250A2|2009-04-16|2010-04-16|Board material, methods for manufacturing board material and panel which contains such board material.|
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