BINDER COMPOSITION COMPRISING POLY(AMINO ACID)S FOR FIBER COMPOSITE ARTICLES

Abstract

The present invention relates to a binder composition comprising component A comprising polymer(s) A1 and optionally component B comprising component B1 which is selected from the group consisting of a mono-saccharides, disaccharides, droxyacetone, glycolaldehyde and mixtures thereof, wherein polymer(s) A1 comprises at least 70 wt.-% poly(amino acid)s based on the total weight of the polymers) A1 and has (have) a total weight average molecular weight M.sub.w, total of 800 g/mol to 10.000 g/mol, wherein the binder composition comprises 60 to 100 wt.-% polymer(s) A1, and 0 to 40 wt.-% component B1, based on the total weight of the sum of polymer(s) Al and component B1, wherein the weight amounts of the polymer(s) Al and component B1 are selected such that the total weight of the sum of polymer(s) A1 and component B1 is 100 wt.-%.

Claims

1.-28. (canceled)

29. Use of a binder composition comprising component A comprising polymer(s) A1 and optionally component B comprising component B1 which is selected from the group consisting of monosaccharides, 5 disaccharides, hydroxyacetone, glycolaldehyde and mixtures thereof, wherein polymer(s) A1 consist(s) of polylysine(s) and has(have) a total weight average molecular weight M.sub.w, total of 800 g/mol to 10,000 g/mol, wherein the binder composition comprises 80 to 100 wt.-% polymer(s) A1, and 0 to 20 wt.-% component B1, based on the total weight of the sum of polymer(s) A1 and component B1, wherein the weight amounts of the polymer(s) A1 and component B1 are selected such that the total weight of the sum of polymer(s) A1 and component B1 is 100 wt.-%, for the preparation of a lignocellulosic fiber board, wherein 3 to 15 wt-% polymer(s) A1 and component B1 in total based on the total oven-dry weight of the lignocellulosic fibers are used for the preparation of the lignocellulosic composite article.

30. Use according to claim 29, wherein component B1 is selected from the group consisting of hydroxyacetone, 1,3-dihydroxyacetone, xylose, fructose, glucose, mannose, saccharose and mixtures thereof.

31. Use according to claim 29 , wherein no compound B is included.

32. Use of a reacted Binder composition obtainable or obtained by reacting the binder components A and B and lignocellulosic fibers or reacting component A and lignocellulosic fibers as defined in claim 29, for the preparation of a lignocellulosic fiber board.

33. Use of a composition kit comprising the binder composition as defined in claim 29, wherein component A and component B are stored separately, for the preparation of a lignocellulosic fiber board.

34. A lignocellulosic fiber board comprising a plurality of lignocellulosic fibers, and a binder composition as defined claim 29, wherein 3 to 15 wt-% polymer(s) A1 and component B1 in total based on the total oven-dry weight of the lignocellulosic fibers are used for the preparation of the lignocellulosic composite article.

35. The lignocellulosic fiber board according to claim 34, having a thickness of 1.5 to 5 mm.

36. The lignocellulosic fiber board according to claim 34, having an internal bond strength of more than 0.8 N/mm.sup.2.

37. A process for the batchwise or continuous production of lignocellulosic fiber boards which are multi-layered lignocellulose-based fiber boards with a core and with at least one upper and one lower surface layer, comprising the following steps: a) mixing of the lignocellulosic fibers with a binder composition for each layer, wherein the mixture for at least one layer comprises the binder composition as defined in claim 29, b) layer-by-layer scattering of the mixtures of the individual layers to form a mat, c) pressing the mat to a board at a temperature of 80 to 300 C. and at a pressure of 1 to 100 bar wherein 3 to 15 wt.-% polymer(s) A1 and component B1 in total based on the total 20 oven-dry weight of the lignocellulosic fibers, are used for the preparation of the lignocellulose-based fiber boards.

38. A process for the batchwise or continuous production of single layered lignocellulosic fiber boards comprising the following steps: a) mixing of the lignocellulosic fibers with a binder composition, wherein the mixture comprises the binder composition as defined in claim 29, b) scattering of the mixtures to form a mat, c) pressing the mat to a board at a temperature of 80 to 300 C. and at a pressure of 1 to 100 bar or c) pressing the mat to a board at a temperature of 80 to 200 C. and at a pressure of 0.1 to 100 bar, wherein a high-frequency electrical field is applied during pressing until 80 to 200 C. is reached in the center of the mat wherein 3 to 15 wt.-% polymer(s) A1 and component B1 in total based on the total oven-dry weight of the lignocellulosic fibers, are 5 used for the preparation of the lignocellulose-based fiber boards.

39. A process for the batchwise or continuous production of lignocellulosic fiber boards which are multi-layered lignocellulose-based fiber boards with a core and with at least one upper and one lower surface layer, comprising the following steps: a) mixing of the lignocellulosic fibers with a binder composition for each layer, wherein the mixture for at least one layer comprises the binder composition as defined in claim 29, b) layer-by-layer scattering of the mixtures of the individual layers to form a mat, c) pressing the mat to a board at a temperature of 80 to 300 C. and at a pressure of 1 to 100 bar wherein 3 to 15 wt.-% polymer(s) A1 and component B1 in total based on the total 20 oven-dry weight of the lignocellulosic fibers, are used for the preparation of the lignocellulose-based fiber boards. wherein both components A and B of the binder composition as defined in claim 29 are added to the lignocellulosic pieces in step a) either a1) separately from one another or a2) as a mixture.

40. The process according to claim 37, wherein the lignocellulosic fibers are prepared from wood.

41. The process according to claim 38, wherein the boards obtained in step c) or step c) have an internal bond strength of more than 0.8 N/mm.sup.2.

Description

EXAMPLES

Example 1

Synthesis of Polylysines 1-8

[0371] 2200 g of L-lysine solution (50 wt.-% in water, ADM) was heated under stirring in an oil bath (external temperature 140 C.). Water was distilled off and the oil bath temperature was increased by 10 C. per hour until a temperature of 180 C. is reached. The reaction mixture was stirred for an additional hour at 180 C. (oil bath temperature) and then pressure was slowly reduced to 200 mbar. After reaching the target pressure, distillation was continued for another period of time t (as specified in the following Table 1). The product was hotly poured out of the reaction vessel, crushed after cooling and dissolved in water to give a 50 wt.-% solution.

[0372] Residual lysine monomer content, NC.sub.ps and M.sub.w values were determined from this solution without any further purification. The residual lysine monomer is included in the calculation of M.sub.w.

TABLE-US-00002 TABLE 1 synthesis and analytic data of the different Polylysine L-Lysine Mw NCps monomer content ratio Polylysine t [min] [g/mol] [wt.- %] [wt.- %]* / Polylysine-1 120 1880 10.6 5.8 2.0 Polylysine-2 150 2600 10.0 2.6 2.2 Polylysine-3 180 3050 9.66 2.1 2.3 Polylysine-4 210 3590 9.26 1.3 2.3 Polylysine-5 255 5360 7.81 0.7 2.2 Polylysine-6 285 6690 6.76 0.4 2.3 Polylysine-7 300 9430 4.59 0.3 2.3 Polylysine-8 330 11080 3.27 0.3 2.3 *The residual lysine monomer content is given as wt.- % based on the total weight of polylysine including lysine monomer.

Example 2

[0373] HDF boards (4 mm) with different polylysines (Polylysine-1 to Polylysine-8) and lysine

Preparation of the Resinated Fibers (Examples 2-1 to 2-8)

[0374] In a mixer, 120 g of Polylysine-X solution (50 wt.-% in water) was sprayed onto 1.04 kg (1.0 kg dry weight) of spruce fibers (moisture content 4.1%) while mixing. After addition mixing was continued for 3 min.

Preparation of the Resinated Fibers (Examples 2-0)

[0375] In a mixer, 120 g of lysine solution (50 wt.-% in water) was sprayed onto 1.04 kg (1.0 kg dry weight) of spruce fibers (moisture content 4.1%) while mixing. After addition mixing was continued for 3 min.

Pressing the Resinated Fibers to Fiberboards

[0376] Immediately after resination 336 g of the resinated fibers were scattered into a 3030 cm mold and pre-pressed under ambient conditions (0.4 N/mm2). Subsequently, the pre-pressed fiber mat thus obtained was removed from the mold, transferred into a hot press and pressed to a thickness of 4 mm to give a HDF (temperature of the press plates 210 C., max pressure 4 N/mm.sup.2). The pressing time was 40 s.

TABLE-US-00003 TABLE 2 HDF boards, 4 mm, binder amount 6 wt.- % (solid/dry wood), press time factor = 10 sec/mm. polymer(s) Mw internal bond swelling 24 h density Example A1 [g/mol] [N/mm.sup.2] [%] [kg/m.sup.3] 2-0 Lysine* 146 no boards 2-1 PL-1 1880 0.77 0.38 801 2-2 PL-2 2600 0.86 0.33 786 2-3 PL-3 3050 0.93 0.34 800 2-4 PL-4 3590 1.21 0.32 806 2-5 PL-5 5360 1.20 0.32 801 2-6 PL-6 6690 1.15 0.31 799 2-7 PL-7 9430 0.94 0.34 803 2-8 PL-8 11080 no boards *Lysine was used instead of polymer(s) A1, PL = Polylysine

Example 3

[0377] HDF boards (2 mm) with Polylysine-4

Preparation of the Resinated Fibers

[0378] In a mixer, 120 g of Polylysine-4 solution (50 wt.-% in water) was sprayed onto 1.04 kg (1.0 kg dry weight) of spruce fibers (moisture content 4.1%) while mixing. After addition mixing was continued for 3 min.

Pressing the Resinated Fibers to Fiberbaords:

[0379] Immediately after resination 168 g of the resinated fibers were scattered into a 3030 cm mold and pre-pressed under ambient conditions (0.4 N/mm2). Subsequently, the pre-pressed fiber mat thus obtained was removed from the mold, transferred into a hot press and pressed to a thickness of 2 mm to give a HDF (temperature of the press plates 210 C., max pressure 4 N/mm.sup.2). The pressing time was 20 s.

TABLE-US-00004 TABLE 3 HDF board, 2 mm binder amount 6 wt.- % (solid/dry wood), press time factor = 10 sec/mm. Polymer(s) Mw internal bond swelling 24 h density Example A1 [g/mol] [N/mm.sup.2] [%] [kg/m.sup.3] 3-1 Polylysine-4 3590 1.28 0.40 809

Example 4

[0380] HDF boards (4 mm) with different ratios of Polylysin-4 and glucose / hydroxyacetone

Preparation of the Resinated Fibers

[0381] In a mixer, Y g of Polylysine-4 (PL-4) solution (50-wt.-% in water) was sprayed onto 1.04 kg (1.00 kg dry weight) of spruce fibers (moisture content 4.1%) while mixing. Subsequently, Z g of a glucose solution (50 wt.-% in water) or X g of a hydroxyaceton solution (50 wt.-% in water) was sprayed onto the mixture while mixing (Y, Z and X are given in table 4). After addition, mixing was continued for 3 min.

TABLE-US-00005 TABLE 4 Amounts of binder for Example 4-1 to Example 4-8 Polymer A1 Component B1 amount PL-4 ratio of PL in amount Glu amount HA solution (Y) binder** solution (Z) solution (X) Example [g] [%] [g] [g] 4-1 120 100 0 0 4-2 110 91.6 10 0 4-3 100 83.3 20 0 4-4 80 66.7 40 0 4-5 60 50.0 60 0 4-6 40 33.0 80 0 4-7 20 16.7 100 0 4-8 0 0 120 0 4-9 92 76.6 0 28 4-10 92 100 0 0 **weight ratio of A1 to (A1 + B1) based on solids

Pressing the Resinated Fibers:

[0382] Immediately after resination 336 g of the resinated fibers were scattered into a 3030 cm mold and pre-pressed under ambient conditions (0.4 N/mm2). Subsequently, the pre-pressed fiber mat thus obtained was removed from the mold, transferred into a hot press and pressed to a thickness of 4 mm to give a HDF (calculated density of 800 kg/m3) (temperature of the press plates 210 C., max pressure 4 N/mm.sup.2). The pressing time was 40 s.

TABLE-US-00006 TABLE 5 HDF boards, 4 mm binder amount mainly 6 wt.-% (solid/dry wood), press time factor = 10 sec/mm amount amount amount ratio of PL in internal swelling Polymer(s) PL-4 Glu HA binder*** bond 24 h density Example A1 [wt.-%]** [wt.-%]** [wt.-%]** [%] [N/mm.sup.2] [%] [kg/m] 4-1 PL-4 6.0 0.0 100 1.21 0.32 806 4-2 PL-4 5.5 0.5 91.7 1.20 0.32 796 4-3 PL-4 5.0 1.0 83.3 1.18 0.34 800 4-4 PL-4 4.0 2.0 66.7 1.05 0.34 808 4-5 PL-4 3.0 3.0 50.0 0.71 0.37 778 4-6 PL-4 2.0 4.0 33.3 0.68 0.48 820 4-7 PL-4 1.0 5.0 16.7 no boards 4-8 PL-4 0.0 6.0 0 no boards 4-9 PL-4 4.6 1.4 76.7 1.07 0.33 799 4-10 PL-4 4.6 100 1.09 0.34 809 **based on solid per dry wood ***weight ratio of A1 to (A1 + B1) based on solids

Example 5

[0383] HDF boards (4 mm) with different amounts of Polylysine-6 and glucose as comparative example (EP 3611225A2, Example 9 and 11, table 4)

[0384] Preparation of the resinated fibers

Example 5-0

[0385] In a mixer, 100 g of Polylysine-6 solution (50 wt.-% in water) was sprayed onto 1.04 kg (1.0 kg dry weight) of spruce fibers (moisture content 4.1%) while mixing. Subsequently, 20 g of a glucose solution (50 wt.-% in water) was sprayed onto the mixture while mixing. After addition mixing was continued for 3 min.

Comparative Example 5-1

[0386] In a mixer, 60 g of Polylysine-6 solution (50 wt.-% in water) was sprayed onto 1.04 kg (1.0 kg dry weight) of spruce fibers (moisture content 4.1%) while mixing. Subsequently, 60 g of a glucose solution (50 wt.-% in water) was sprayed onto the mixture while mixing. After addition mixing was continued for 3 min.

Comparative Example 5-2

[0387] In a mixer, 20 g of Polylysine-6 (PL-6) solution (50 wt.-% in water) was sprayed onto 1.04 kg (1.0 kg dry weight) of spruce fibers (moisture content 4.1%) while mixing. Subsequently, 100 g of a glucose solution (50 wt.-% in water) was sprayed onto the mixture while mixing. After addition mixing was continued for 3 min.

Pressing the Resinated Fibers:

[0388] Immediately after resination 336 g of the resinated fibers were scattered into a 3030 cm mold and pre-pressed under ambient conditions (0.4 N/mm2). Subsequently, the pre-pressed fiber mat thus obtained was removed from the mold, transferred into a hot press and pressed to a thickness of 4 mm to give a HDF (temperature of the press plates 210 C., max pressure 4 N/mm.sup.2). The pressing time was 40 s.

TABLE-US-00007 TABLE 6 HDF boards, 4 mm, binder amount 6 wt.-% (solid/dry wood), press time factor = 10 sec/mm. ratio of amount amount PL in internal swelling Polymer(s) PL-6 Glucose binder*** bond 24 h density Example A1 [wt.-%]** [wt.-%]** [%] [N/mm.sup.2] [%] [kg/m] 5-0 PL-6 5.0 1.0 83.3 1.07 0.35 804 5-1 PL-6 3.0 3.0 50.0 0.64 0.41 781 5-2 PL-6 1.0 5.0 16.7 no boards **based on solid per dry wood ***weight ratio of A1 to (A1 + B1) based on solids

Example 6

[0389] Single-Layered Chipboards with Different Polymer(s) A1

Preparation of the Resinated Chips

[0390] In a mixer 648 g of Polylysine-X solution (50 wt.-% in water) was sprayed onto 5.56 kg (5.40 kg dry weight) of spruce wood chips (moisture content 3.0%) while mixing. Subsequently, 48.6 g of water was sprayed onto the mixture while mixing to adjust the final moisture of the resinated chips. After addition of the water mixing was continued for 3 min.

Pressing the Resinated Chips to Chipboards

[0391] Immediately after resination, 1.10 kg of the chips/binder mixture were scattered into a 3030 cm mold and pre-pressed under ambient conditions (0.4 N/mm.sup.2). Subsequently, the pre-pressed chip mat thus obtained was removed from the mold, transferred into a hot press and pressed to a thickness of 16 mm to give a chipboard (temperature of the press plates 210 C., max pressure 4 N/mm.sup.2). The pressing time was 160 sec.

TABLE-US-00008 TABLE 7 chipboards 16 mm binder amount 6 wt.- % (solid/dry wood), press time factor = 10 sec/mm pressed with different Polylysine polymer(s) Mw internal bond swelling density Example A1 [g/mol] [N/mm{circumflex over ()}2] 24 h [%] [kg/m{circumflex over ()}3] 6-1 Polylysine-1 1880 no boards** 6-2 Polylysine-2 2600 no boards** 6-3 Polylysine-3 3050 no boards** 6-4 Polylysine-4 3590 no boards** 6-5 Polylysine-5 5360 no boards** 6-6 Polylysine-6 6690 no boards** 6-7 Polylysine-7 9430 no boards** 6-8 Polylysine-8 11080 no boards** **no board means that the resulting material after pressing was not a sound chipboard andshowed fractures, blows and/or bursts

[0392] Even the prolongation of the pressing time to 240 s did not lead to sound chipboards.

[0393] Surprisingly, it was found that fiber boards with good mechanical properties can be formed with polylysine, whereas chipboards cannot be formed with the same type and amount of polylysine binder.