The present invention provides a moldable mixture containing large portion of agricultural fibers and small portion of a binding agent and a flow-promoting filler material. The moldable mixture is substantially free of formaldehyde, with low moisture content and high draw ratio. The present invention also provides methods of manufacturing molded products and related parts, based on the claimed moldable mixture. Molded products (830) and related parts such as runner (810) and plank (820) with light weight, high density and more complex profile are manufactured by the claimed methods including steps of providing required materials for a moldable mixture, mixing the provided materials to form a moldable mixture, shaking the moldable mixture in preparing for compression molding and compression molding the moldable mixture to form molded products and related parts.

The system comprises a grinder for crushing and pulverizing waste phenolic polymer material, wood fiber and porous material to form a powder; a homogenizer for mixing waste phenolic polymer material powder uniformly with resin for bonding the powder of the waste phenolic polymer material, wherein resin is added for bonding the powder of the waste phenolic polymer material, the powder of wood fiber and powder of porous material; a mixing chamber for mixing powder of waste phenolic polymer material, wood fiber and porous material uniformly; a pressing device for applying one of the methods of hot pressing, cold pressing, injection by an injection machine, extrusion by an extruder, or foaming of the obtained mixture to form desired solid material; and an analysis unit for determining a physical and mechanical properties of these boards using a series of tests such as compressive, tensile, flexural, thickness swelling, water absorption, and moisture content.

Provided is a novel cured article that enables to expand the use of debris and the like as well as the use of plant biomass. The cured article contains an inorganic material and at least one selected from lignin and cellulose.

A method for producing a shaped article comprising: a) providing a binder, which has been produced by a process of: (i) mixing (A) fungi or glucan and (B) starch with an alkaline agent to form an alkaline composition; and mixing the alkaline composition with an acidic agent to form the binder; or (ii) mixing (A) fungi or glucan and (B) starch with an acidic agent to form an acidic composition; and mixing the acidic composition with an alkaline agent to form the binder; (b) forming a binder composition by mixing the binder with filler material; (c) shaping the binder composition into a three-dimensional shape; and (d) curing the binder composition to form a shaped article having said three-dimensional shape, wherein steps c) and d) can be carried out simultaneously or separately, and wherein during one or both of steps c) and d) pressure is applied to the binder composition.

The invention relates to a process for producing a thermoformable and/or embossable particle/polymer composite using a substrate S based on shredded polymer-coated paper and a thermoplastic polymer P, therewith providing a new method of recycling/upcycling paper waste. Furthermore, a process for the manufacturing of a molded article obtained from the paper-based particle/polymer composite and its use as an element in buildings or in furniture are disclosed.

A method for producing a shaped article comprising: a) providing a binder, which has been produced by a process of: (i) mixing (A) fungi or glucan and (B) starch with an alkaline agent to form an alkaline composition; and mixing the alkaline composition with an acidic agent to form the binder; or (ii) mixing (A) fungi or glucan and (B) starch with an acidic agent to form an acidic composition; and mixing the acidic composition with an alkaline agent to form the binder; (b) forming a binder composition by mixing the binder with filler material; (c) shaping the binder composition into a three-dimensional shape; and (d) curing the binder composition to form a shaped article having said three-dimensional shape, wherein steps c) and d) can be carried out simultaneously or separately, and wherein during one or both of steps c) and d) pressure is applied to the binder composition.

A wood chip material, especially a fireproof water resistant wood chip material, especially a fireproof water resistant wood chip material to make oriented strand boards which consists of a mixture containing 30 to 43 weight percent of wood chips, 53 to 61.9 weight percent of an aqueous solution of silicate, 2 to 5 weight percent of aluminium hydroxide, 1 to 3 weight percent of water, 0.1 to 1 weight percent of a stabilizer of the aqueous solution of silicate, and a hardener of the aqueous solution of sodium silicate in the concentration of 0.5 to 5 weight percent to the pure aqueous solution of sodium silicate providing always that the density of the aqueous solution of sodium silicate ranges from 1370 to 1400 kg/m.sup.3 and the SiO.sub.2 to NA.sub.2O molar ratio in the aqueous solution of sodium silicate ranges from 3.2 to 3.4. A method of production of a wood chip material, especially method of production of a fireproof water resistant wood chip material, especially method of production of a fireproof water resistant wood chip material to make oriented strand boards according to which, as the first step, the aluminium hydroxide is mixed with water, then wood chips are added into the mixture and everything is stirred thoroughly in such a manner that a wood chip mixture is formed, then the stabilizer of the aqueous solution of sodium silicate is added in the aqueous solution of silicate and after that the hardener of the aqueous solution of sodium silicate is admixed in this solution. Then the solution is stirred for 1 to 10 minutes until a binding solution is formed. Then the wood chip mixture is poured, at continuous stirring, in the binding solution and everything is stirred thoroughly again. Then the resulting mixture is poured in the place of application.

The invention relates to a process for forming a wood-base product comprising the steps of a) providing particles of wood, b) resinating the particles of wood with a binder, c) compressing the resinated particles of wood to form a wood-base product, wherein before, during or after step b) the particles of wood and/or the binder are brought into contact with a broken dispersion. The invention also relates to the use of a polyfunctional compound as demulsifier for breaking a wax-containing dispersion containing an aqueous phase as continuous phase, a disperse phase containing wax and at least one emulsifier. The invention further relates to a broken dispersion for hydrophobicizing lignocellulose-containing material, wherein the broken dispersion is obtainable by mixing at least mixed a wax-containing dispersion A) containing the following components: i) at least one aqueous phase as continuous phase, ii) at least one disperse phase containing wax, and iii) at least one emulsifier, with a demulsifier B) having at least one functional group. The invention additionally relates to a two-component system (kit-of-parts) containing at least two components A and B: a wax-containing dispersion A) containing at least one aqueous phase as continuous phase, at least one disperse phase containing wax, and at least one emulsifier, and a demulsifier B) having at least one functional group for breaking the wax-containing dispersion.

The present invention relates to a process for lignin dissolution in which partial methylolation of lignin is carried out during the step of preparing a solution of lignin in an aqueous medium comprising alkali. The lignin prepared according to the process of the present invention can be used to manufacture lignin-based phenolic resins, which are particularly useful in the manufacture of laminates.

The present invention relates to a process for lignin dissolution in which partial methylolation of lignin is carried out during the step of preparing a solution of lignin in an aqueous medium comprising alkali and phenol. The lignin prepared according to the process of the present invention can be used to manufacture lignin-based phenolic resins, which are particularly useful in the manufacture of laminates.