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    • 专利摘要:
    The present invention relates to a solid composition suitable for fire-resistant wood-based plate material, the composition comprising: - 5 to 95% by weight ammonium phosphate; - 2 to 95% by weight ammonium sulfate; wherein ammonium phosphate and ammonium sulfate present in the form of both optically detectable solid particles and non-optically detectable solid particles.
    公开号:BE1022919B1
    申请号:E2015/5856
    申请日:2015-12-31
    公开日:2016-10-19
    发明作者:Pieter Daeseleire；Herman Meynaerts
    申请人:Ecochem International, Naamloze Vennootschap；
    IPC主号:
    专利说明:

    AMMONIUM PHOSPHATE COMPOSITIONS AS FIRE-DELAYING ADDITIVES FOR PLATE MATERIAL
    TECHNICAL DOMAIN
    The present invention relates to ammonium phosphate composition systems and their production. More specifically, the invention relates to ammonium phosphate compositions with fire retardant properties that are suitable as additives for combustible material such as sheet material.
    BACKGROUND ART
    The fire retardant properties of ammonium phosphate are known in the art. For example, ammonium phosphate is part of the dry powders in fire extinguishers. Because of their fire-retardant properties, ammonium phosphate compositions are also used as fire-retardant additives in sheet material or composite material based on natural fibers (not limited to) such as wood, cellulose, flax, straw, cotton, wool. US4514327 describes an aqueous composition based on mono-ammonium phosphate and ammonium sulfate for addition to a wood-based material. The wood-based material is placed in a pressure vessel or autoclave and immersed in the composition, after which the container is placed under pressure. As a result, the material is impregnated with the fire-retardant additive. EP2505326 describes a fire-resistant OSB material provided with a fire-retardant additive.
    Although widely used, the known compositions do not always provide sufficient stability when added to wood-based material. There is also the risk that the addition of the additive negatively influences certain mechanical properties of the wood-based material. There is therefore a need for a preferably ammonium phosphate-based composition that ensures adequate fire-retardant action when added to wood-based material, which also has as little impact as possible on the properties of the material.
    In addition, there is also a need for a suitable method to make wood-based material fire-resistant by adding the additive during the production of sheet material.
    It is an object of the present invention to find a solution to at least some of the aforementioned problems.
    SUMMARY OF THE INVENTION
    The invention relates to a composition as in claim 1. The composition is suitable as an additive in the production of fire or flame-retardant wood-based plate material. The obtained sheet material has good mechanical characteristics and meets all quality standards with regard to fire resistance. The composition can easily be added to the existing production processes of wood-based panels.
    In a second aspect, the present invention describes the use of this composition as a flame-retardant additive in wood-based sheet material according to claim 6.
    In a disadvantageous aspect, the present invention describes a method for the production of HDF, MDF, chipboard or insulation material based on natural fibers such as wood, cellulose, flax, straw, cotton, wool. The production process makes it possible to make wood-based panels that meet all quality requirements.
    DETAILED DESCRIPTION
    The invention relates to a solid composition suitable for fire-resistant wood-based board material, such as OSB, MDF, HDF, chipboard or wood-fiber material. The term "solid" denotes a composition that is not liquid, and that is preferably in powder form.
    The term "well-based" refers to a material based on natural fibers such as wood, cellulose, or other derivatives of the aforementioned materials.
    In particular, the present invention relates to a solid composition suitable for fire-resistant wood-based plate material, the composition comprising: - 5 to 95% by weight ammonium phosphate; and - 2 to 95% by weight ammonium sulfate.
    In particular, both the ammonium phosphate and ammonium sulfate will be present in the form of both optically detectable solid particles and non-optically detectable solid particles in the composition.
    The term non-optically detectable particles refers to particles that have an average particle size that is smaller than 0.1 micron.
    The distinction between optically detectable and non-optically detectable particles can be determined by a person skilled in the art using methods known in the art. The standard reference in this regard is laser diffraction analysis. With the current known technology one can currently detect particles up to 0.1 micron, this is the lower limit. The quantification of the amount of non-optical is then done via indirect method, also known in the art. It should be understood that the laser diffraction particle size analysis method as quoted herein is not limiting of the present invention.
    This specific composition with well-defined particle size has the advantage that the composition will be extremely suitable for adding to the production process of wood-based plate material to make it fire or flame retardant, without thereby affecting the characteristics of the plate material. The material is easy to mix with the wood chips or fibers due to the specifically selected particle size and will simply distribute uniformly, without causing local accumulations. Depending on the end material to be produced, the average particle size can be determined.
    Preferably, the ammonium phosphate present will be selected from the group of mono-ammonium phosphate (MAP), di-ammonium phosphate, oligo-ammonium phosphate and phosphates of alkaline earth metals. More preferably, mono-ammonium phosphate (MAP) is used.
    In addition to ammonium phosphate and ammonium sulfate as active ingredients, the composition may also include excipients. These auxiliaries are preferably selected from the group of smoke suppressing chemicals such as, for example, boron compounds. In a preferred form, the boron compound will be zinc borate.
    Preferably all ingredients will be mixed in a blender.
    Optionally, in addition to ammonium phosphate and ammonium sulfate, the composition may also comprise a third or further fire-retardant component. Preferably, this third agent will be selected from the group of guanidine sulfamate, guanidine sulfate and (di) guanidine phosphate, boric acid, borax, sodium octaborate, polyborate, zinc borate compounds or mixtures thereof.
    The composition is extremely suitable for use as a flame or flame retardant additive and can be used in the dry state or mixed with liquid water. The pH of the composition is specifically adjusted to the glue or binder used in the process.
    In particular, the composition will be suitable as an additive for OSB (oriented strand board), MDF (medium density fiber board), HDF (high density fiber board), plywood, chipboard or (wood fiber) insulation material. This material is used in particular as construction and / or insulation material and should preferably have fire-retardant properties. In this way, safe use is guaranteed.
    The aforementioned sheet materials are generally produced with wood particles as the basis. By the term wood particles as used in this description and in the appended claims is meant, inter alia, wood particles, chips, shavings, flakes, and the like of the type suitable for use in the production of said sheet material.
    Preferably, the fire or flame retardant composition as described above will be added in-line to the wood particles during the production process of the sheet material. This has the advantage that existing production processes can be easily adjusted. Another advantage is the fact that an addition during the production process prevents the characteristics of the end product from being affected by the addition of the composition.
    Preferably, the composition of the present invention will be added in a concentration between 3 and 30 parts by weight per 100 parts by weight of wood particles.
    It has been found that these are concentrations at which the obtained fire-resistant properties and the amount of composition to be used, and therefore the cost price, show a good optimum.
    In one embodiment, the wood particles will be dry wood particles. In another embodiment, these are wet wood particles. The choice between dry or wet wood particles will depend on the end material to be produced. For example, the production of MDF and HDF board material will be made from dry fibers. For the production of hardboard (hard fiberboard), use is then again made of wood fibers that have been moistened.
    The present invention also relates to a method for the production of wood-based plate material.
    For the production of HDF, MDF board material or wood-fiber insulation material with flame and fire-retardant properties, the composition as described above will be added in line with existing production.
    For the production of HDF and / or MDF, the composition will preferably be provided with an average particle size between 1 and 500 microns. For (wood fiber) insulation material with flame-retardant properties, the composition will have a particle size between 200 and 3000 microns. It was found by the inventors of the present invention that such an average particle size has a good dispersion through the plate material
    The production of fire-retardant MDF, HDF boards or (wood fiber) insulation material according to the present invention preferably takes place in five major steps: a refining step, a gluing step, a drying step, a pressing step and a cooling step.
    Round timber, sawn timber and waste wood from the wood processing industry are suitable for producing MDF or HDF. Round timber is stripped of the bark and, together with any sawn timber, reduced to chips in a machining machine. Then chips can be added from sawmills. The mixture is then sieved to remove large and small chips, after which it is washed.
    The fibers then undergo a refining step, during which the fibers are stripped of any contaminants, compacted and processed into a wood pulp. This step takes place in a specially designed refiner, in which use is made of higher temperature and / or specific pressure.
    In an embodiment of the present invention, the fire retardant composition is added before or after the refining step.
    In a next step, the fibers are mixed with binder or glue, usually based on urea-formaldehyde (UF) or melamine, urea-formaldehyde (MUF) or a polycondensation glue (MDI). These fibers are preferably glued in a 'blowline'. A blowline can be considered as a tube through which glue and fibers are blown through at high speed.
    In a possible embodiment of the present invention, the fire-retardant composition is added to the blowline before, after or during the addition of the glue.
    The wet fibers are dried after mixing with glue. The dried fibers are then transported to a forming station and scattered there on a belt. Air is extracted at the bottom of the tire, causing the fibers to form a mat. The resulting mats are then pressed into plates.
    In an embodiment according to the present invention, pressing takes place in two steps. In a first step, the fiber mat is passed through a belt press, through which it is flattened and becomes denser. The edges are then cut straight. The mat then goes to a second press (preferably a continuous or uploader working on steel tires) that will press the mat under high pressure and temperature.
    In a final step, the plates are cooled in a conditioned room. The glue hardens during this cooling. After the resulting plates have cooled down sufficiently, they can be sanded to remove any unevenness and they can be cut to size.
    In another aspect, the present invention provides a method for the production of flame-retardant chipboard. Such chipboards are produced from wood chips and sawdust that are compressed and glued together. In particular, the production process consists of the following steps: preparation of the wood particles and drying, mixing with a binder or glue, pressing and finishing the plate.
    The wood material for chipboard often comes from wood waste and residues such as sawdust, shavings, etc. Given the diversity in origin, the material must be selected and / or separated in advance. A further reduction in size may have to be done. The wood particles are then dried until they contain a water content between 1 and 10%. Such a water content allows good bonding with water-based adhesives.
    The wood particles are then glued. Adhesives based on urea formaldehyde (UF), melamine urea formaldehyde (MUF) or a polycondensation glue (MDI) are preferred here. The mixing with the glue preferably takes place in a blender. More preferably, 1 to 10 weight percent of glue is used.
    In particular, the fire-retardant or flame-retardant composition as described above will be added before the glue is added or together with the glue in the blender. More specifically, the average particle size of the composition in the chipboard will be between 100 and 1500 microns.
    Subsequently a mat is made from the resulting mixture which is brought in a subsequent step to a pre-press and a drying press, whereby the mat is pressed to the final plate under high temperature and pressure. After pressing, the plate is cooled and further finished. This also means that it is cut to size.
    The present invention provides important advantages over the known fire-retardant systems in the prior art, and this in particular because of the specific particle size and composition. The invention offers: - simple incorporation into the production process of wood-based plate materials; - reduction of the flammability of the end products and high satisfaction with regard to the quality requirements of the end product; and - good distribution of the additive in the end product.
    In the following, the invention is described a.d.h.v. non-limiting examples illustrating the invention, and which are not intended or may be interpreted to limit the scope of the invention.
    EXAMPLE
    A mixture of cedar chipwood, splints and sawdust is processed in a shredder, sent through a refiner and then dried. The resulting mixture consists of wood particle fractions of different sizes. Petroleum wax (45% aqueous emulsion) is then sprayed in a quantity of 1.25% (dry basis) per dry weight of the wood particles in a drum mixer. In a subsequent step, urea formaldehyde resin is added in an amount of 6% per dry weight of the wood particles.
    Then 10% per dry weight of wood of a fire-resistant additive based on MAP and ammonium sulphate is added. The fire-resistant salt is mixed with the other ingredients, after which a mat is formed from the resulting mixture. This mat is hot pressed into a finished sheet material.
    权利要求:
    Claims (15)
    [1]
    CONCLUSIONS
    A solid composition suitable for fire-resistant wood-based plate material, wherein the composition comprises: - 5 to 95% by weight ammonium phosphate; - 2 to 95% by weight ammonium sulfate; wherein ammonium phosphate and ammonium sulfate are present in the form of both optically detectable solid particles and non-optically detectable solid particles.
    [2]
    A composition according to claim 1, characterized in that ammonium phosphate is selected from the group of mono-ammonium phosphate (MAP), di-ammonium phosphate, oligo-ammonium phosphate and phosphates of alkaline earth metals.
    [3]
    Composition according to claim 2, characterized in that the ammonium phosphate is mono-ammonium phosphate.
    [4]
    A composition according to any one of the preceding claims, wherein the pH of the composition is specifically adjusted to the type of glue or binder
    [5]
    A composition according to any one of the preceding claims, further comprising smoke suppressing chemicals.
    [6]
    Use of the composition according to any of claims 1 to 5, as a flame-retardant additive in wood-based plate material.
    [7]
    Use according to claim 6, characterized in that the wood-based board material is OSB, MDF, HDF, plywood, chipboard, or insulating material.
    [8]
    Use according to any one of the preceding claims, characterized in that the composition can be added in solid or in solution.
    [9]
    Method for the production of an HDF or MDF plate with flame-retardant properties, characterized in that a composition according to any one of claims 1 to 5 is provided, wherein the composition has a particle size between 1 and 500 microns.
    [10]
    Method according to claim 9, comprising a refining step of the wood fibers, followed by a drying step, wherein a binder is added to the wood particles, characterized in that the composition is added before or after the refining step and / or before or after adding the binder.
    [11]
    Method for making insulating material with flame-retardant properties, characterized in that a composition according to any one of claims 1 to 5 is provided, wherein the composition has an average particle size between 200 and 3000 microns.
    [12]
    A method according to claim 11, characterized in that the composition is added before or during a mixing step of wood particles with a resin agent.
    [13]
    Chipboard provided with a composition according to any of claims 1 to 5, characterized in that the average particle size of the composition in the chipboard is between 100 and 1500 microns.
    [14]
    An HDF or MDF board provided with a composition according to any one of claims 1 to 5, characterized in that the average particle size of the composition in the chipboard is between 1 and 500 microns.
    [15]
    Insulation material provided with a composition according to any one of claims 1 to 5, characterized in that the average particle size of the composition of the material is between 200 and 3000 microns.
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