The invention relates to a method for producing multi-layered lignocellulose materials having a core and an upper and a lower cover layer, said method comprising the following steps a) mixing the components, b) spreading the mixtures in layers, c) pre-compressing, d) applying a high-frequency electric field e) hot pressing. According to the invention, a mixture of C) 1-15 wt.-% of a binding agent selected from the group consisting of aminoplastic resin and organic isocyanate having at least two isocyanate groups [components C)], F) 0.1-3% alkali-/akaline earth salts, for the cover layers of the lignocellulose particles G) with H) 1-15% of a binding agent selected from the group consisting of aminoplastic resin and an organic isocyanate is mixed. After step a) the mixture for the core contains, with respect to the total dry weight of the mixture of the components A)-F) 3-15% water, the mixture for the cover layers of the components G)-K) contains 5-20% water, and the following conditions are met: F)1,1components K) and [components F)+components D)]1,1[components K)+components I)].

Methods of forming a lightweight reinforced thermoplastic core layer and articles including the core layer are described. In some examples, the methods use a combination of thermoplastic material, reinforcing fibers and bicomponent fibers to enhance retention of lofting agents in the core layer. The processes permit the use of less material while still providing sufficient lofting capacity in the final formed core layer.

A method of producing a veneered element, including providing a substrate, applying a sub-layer on a surface of the substrate, applying a veneer layer on the sub-layer, and applying pressure to the veneer layer and/or the substrate, such that at least a portion of the sub-layer permeates through the veneer layer. Also, such a veneered element.

The present invention relates to a process for the batchwise or continuous, preferably continuous production of single-layer lignocellulose-based boards or of multilayer lignocellulose-based boards with a core and with at least one upper and one lower outer layer, comprising the following steps: a) mixing of the components of the individual layer(s), b) layer-by-layer scattering of the mixtures to give a mat, c) compaction after the scattering of the individual layer(s), d) application of a high-frequency electrical field, during and/or after the compaction and thermal hardening of the binder(s), e) then optionally hot pressing, and f) cooling the lignocellulose material,
where, in step a),
for the core or the single layer, the lignocellulose particles A) [component A)] are mixed with B) from 0 to 25% by weight of expanded plastics particles with bulk density in the range from 10 to 150 kg/m.sup.3 [component B)], C) from 1 to 15% by weight of one or more binders selected from the group consisting of aminoplastic resin and organic isocyanate having at least two isocyanate groups [component C)], D) from 0 to 3% by weight of ammonium salts [component D)], E) from 0 to 5% by weight of additives [component E)] and F) from 0.1 to 3% by weight of alkali metal salts or alkaline earth metal salts from the group of the sulfates, nitrates, halides and mixtures of these [component F)],
and optionally for the outer layers, the lignocellulose particles G) [component G)] are mixed with H) from 1 to 15% by weight of one or more binders selected from the group consisting of aminoplastic resin and organic isocyanate having at least two isocyanate groups [component H)], I) from 0 to 2% by weight of ammonium salts [component I)], J) from 0 to 5% by weight of additives [component J)] and K) from 0.1 to 3% by weight of alkali metal salts or alkaline earth metal salts from the group of the sulfates, nitrates, halides and mixtures of these [component K)],
wherein at the juncture Z the temperature of the layer of the core or of the single layer is more than 90 C., and this temperature is reached in less than 40 s/mm.Math.d after the application of the high-frequency electrical field, where d is the thickness of the sheet of lignocellulose material at the juncture Z.

The present invention relates to a batchwise or continuous process for producing single-layer one multilayer lignocellulosic materials, comprising the process steps of (I) mixing the components of the individual layers, (II) scattering the mixture(s) produced in process step (I) to give a mat, (III) optionally precompacting the scattered mat and (IV) hot-pressing the optionally precompacted mat,
by using, in process step (I), for the core of multilayer lignocellulosic materials or for single-layer lignocellulosic materials, a mixture (component A) comprising a.sub.1) 50% to 99% by weight, preferably 70% to 97% by weight, more preferably 80% to 95% by weight and especially 85% to 92% by weight of organic isocyanate having at least two isocyanate groups or mixtures thereof and a.sub.2) 1% to 50% by weight, preferably 3% to 30% by weight, more preferably 5% to 20% by weight and especially 8% to 15% by weight of organic carboxylic acid, carboxylic anhydride, carbonyl chloride or mixtures thereof and a.sub.3) 0% to 49% by weight, preferably 0% to 10% by weight and more preferably 0% to 5% by weight of auxiliaries or mixtures thereof.

The present invention relates to a process for the production of lignocellulose materials via mixing A) of lignocellulose-containing particles or fibers, B) with organic isocyanate having at least two isocyanate groups or a mixture of these, and optionally with C) binders selected from the group of the phenol-formaldehyde resins, the aminoplastic resins, the protein-based binders, and other polymer-based binders, and mixtures of these, D) additives or a mixture of these, and E) plastics particles or a mixture of these,
with the steps of: i.) scattering of the resultant mixture to give a mat, ii.) precompaction and heating of the mat during or after the precompaction process, and iii.) then hot pressing,
wherein, in the step ii.), operations are carried out at elevated temperature during and/or after the precompaction process, and a value of at least 4 cm is achieved for the resultant mat in the push-off test.

An insulation composition including a biomass-derived polymer, a cellulose component, and a fire retardant applied to at least a portion of either or both of the biomass-derived polymer and the cellulose component. The biomass-derived polymer may be used to bind the cellulose component. The cellulose component may be fibers, cellulose dust, nanocrystalline structure, or a combination. The insulation composition may be formed into batts, assemblies, or boards. The insulation composition may be processed in the field by shredding to form loose fill insulation. The composition may be treated with one or more additives, including an expansion component selected to reduce the density of the composition.

A method of producing a veneered element, including providing a substrate, applying a sub-layer on a surface of the substrate, applying a veneer layer on the sub-layer, and applying pressure to the veneer layer and/or the substrate, such that at least a portion of the sub-layer permeates through the veneer layer. Also, such a veneered element.

Thermoplastic composite articles are described that comprise biomaterials in one or more of a core layer and a skin layer. In certain arrangements, the thermoplastic composite article can include a porous core layer comprising a web of open celled structures comprising random crossing over of a plurality of reinforcing fibers held together by a thermoplastic material. The thermoplastic material can include virgin and recycled thermoplastic materials if desired. The web may also comprise biomaterials that can be bioparticles, biofibers or both. Exterior and interior components including the thermoplastic composite articles are also described.

A building panel with a surface layer including a wood veneer, a wood fibre based core and a sub-layer between the surface layer and the core. The sub-layer includes wood fibres and a binder. The surface layer has surface portions including material from the sub-layer. The surface portions including material from the sub-layer extend into the wood veneer.