阅读说明：本技术 定向刨花板、制造定向刨花板的方法和制造定向刨花板的设备 (Oriented strand board, method for manufacturing oriented strand board, and apparatus for manufacturing oriented strand board ) 是由 彼得·斯塔德勒 于 2017-07-20 设计创作，主要内容包括：本发明涉及一种新的定向刨花板(OSB)，所述定向刨花板至少在芯层中包括通过对回收木材进行刨片而获得的回收木薄片。同样地，本发明涉及一种用于制造相应的定向刨花板的方法并且涉及一种设备，通过所述设备可以制造本发明的定向刨花板或可以利用所述设备执行本发明的方法。(The present invention relates to a new Oriented Strand Board (OSB) comprising, at least in the core layer, recycled wood flakes obtained by flaking recycled wood. The invention also relates to a method for producing a corresponding oriented strand board and to a device with which the oriented strand board according to the invention can be produced or with which the method according to the invention can be carried out.)

1. An oriented strand board comprising at least the following three layers:

a) an upper surface layer (11), said upper surface layer (11) comprising or consisting of oriented strands adhered to each other by means of an adhesive,

b) at least one core layer (20, 21, 22, 23) comprising lamellae obtained by shaving Recycled Wood (RW) and bonded to each other by means of an adhesive,

c) a lower surface layer (12), said lower surface layer (12) comprising or consisting of oriented strands bonded to each other by means of an adhesive,

wherein the at least one core layer (20, 21, 22, 23) is arranged between the two surface layers (11, 12).

2. Oriented strand board according to claim 1, characterized in that the at least one core layer (20, 21, 22, 23) comprises or is formed by a mixture of strands bonded to each other by means of an adhesive and flakes obtained from recycled wood.

3. Oriented strand board according to any of the preceding claims, characterized in that the strands present in the at least one core layer (20, 21, 22, 23) have a smaller average length than the strands present in the upper surface layer (11) and the lower surface layer (12), the average length being a number average length.

4. Oriented strand board according to any of the preceding claims, characterized in that the oriented strand board has:

exactly one core layer (20), or

The three core layers, the inner core layer (22), are surrounded by two outer core layers (21, 23).

5. Oriented strand board according to any of the preceding claims, characterized in that the weight proportion of flakes obtained from recycled wood in the at least one core layer (20, 21, 22, 23), in particular in the exactly one core layer (20), is at least 5 wt. -%, preferably at least 50 wt. -%, more preferably at least 60 wt. -%, more preferably at least 70 wt. -%, particularly preferably at least 80 wt. -%, based on the sum of all strands and flakes in the at least one core layer (20, 21, 22, 23).

6. An oriented strand board according to any of the preceding claims, characterized in that if the oriented strand board has three core layers, i.e. an inner core layer (22) is surrounded by two outer core layers (21, 23),

the weight ratio of the flakes obtained from the recycled wood in the inner core layer (22) is higher than the weight ratio of the flakes obtained from the recycled wood in the outer core layers (21, 23), and

the weight proportion of strands having a smaller average length as a number average length than the strands in the upper surface layer (11) and the lower surface layer (12) in the inner core layer (22) is lower than the weight proportion thereof in the outer core layers (11, 12).

7. Oriented strand board according to the preceding claim,

the weight proportion of flakes in the inner core layer (22) obtained from recycled wood is at least 5 wt. -%, preferably 5 to 100 wt. -%, more preferably at least 50 to 90 wt. -%, particularly preferably 60 to 85 wt. -%, and/or based on the sum of all strands and flakes in the inner core layer (22)

The weight proportion of flakes in the outer core layer (21, 23) obtained from recycled wood is at least 5 wt. -%, preferably 5 to 100 wt. -%, more preferably 20 to 80 wt. -%, particularly preferably 30 to 70 wt. -%, based on all flakes in the outer core layer (21, 23),

wherein the weight proportion of flakes obtained from recycled wood in the inner core layer (22) and the outer core layer (21, 23) is different, the weight proportion of flakes obtained from recycled wood in the inner core layer (22) preferably being greater than the weight proportion of flakes obtained from recycled wood in the outer core layer (21, 23).

8. An oriented strand board according to any of the preceding claims, characterized in that if the oriented strand board has three core layers, an inner core layer (22) being surrounded by two outer core layers (21, 23), and at least the outer core layers (21, 23) comprise strands, the strands in the outer core layers (21, 23) are arranged perpendicular to the orientation of the oriented strands in the surface layers (11, 12).

9. Oriented strand board according to any of the preceding claims, characterized in that the strands present in the upper surface layer (11) and/or the lower surface layer (12) have:

an average length as a number average length of 40mm to 250mm, preferably 70mm to 150mm,

an average width as a number average width of 2mm to 40mm, preferably 5mm to 25mm, and/or

An average thickness as a number average thickness of 0.3mm to 1.5mm, preferably 0.5mm to 1.2 mm.

10. Oriented strand board according to any of the preceding claims, characterized in that the flakes obtained from recycled wood have:

an average length as a number average length of 5mm to 50mm, preferably 10mm to 30mm,

an average width as a number average width of 0.2mm to 10mm, preferably 0.5mm to 5mm, and/or

An average thickness as a number average thickness of 0.3mm to 2mm, preferably 0.3mm to 1.2 mm.

11. Oriented strand board according to any of the preceding claims, characterized in that the strands present in the at least one core layer (20, 21, 22, 23) have:

an average length as a number average length of 10mm to 150mm, preferably 30mm to 100mm,

an average width as a number average width of 0.5mm to 30mm, preferably 2mm to 15mm, and/or

An average thickness as a number average thickness of 0.3mm to 1.5mm, preferably 0.5mm to 1.2mm,

wherein the average length as a number average length of the strands in the at least one core layer (20, 21, 22, 23) is smaller than the average length as a number average length of the strands present in the upper surface layer (11) and/or the lower surface layer (12).

12. Oriented strand board according to any of the preceding claims, characterized in that the flakes obtained from the recycled wood are obtained by flaking chips of Recycled Wood (RW), in particular by means of knife ring flaker.

13. Oriented strand board according to any of the preceding claims, characterized in that the strands present in the upper surface layer (11) and the lower surface layer (12) are oriented with respect to the longitudinal axis of the oriented strand board such that at least 60%, preferably at least 70%, particularly preferably at least 80% of the longitudinal alignment of the strands deviates by no more than 20 ° from the longitudinal direction of the oriented strand board.

14. Oriented strand board according to any of the preceding claims, characterized in that the oriented strands in the upper surface layer (11) and the lower surface layer (12) are oriented in the same way.

15. An oriented strand board according to any preceding claim, characterized in that the total thickness of the oriented strand board is 4 to 100mm, preferably 6 to 40 mm.

16. Oriented strand board according to any of the preceding claims,

the thickness of the upper surface layer (11) and the lower surface layer (12) accounts for 20% to 60%, preferably 25% to 50%, more preferably 30% to 40%, and/or the total thickness of the oriented strand board

The thickness of the at least one core layer (20, 21, 22, 23) accounts for 80% to 40%, preferably 75% to 50%, more preferably 70% to 60% of the total thickness of the oriented strand board.

17. Oriented strand board according to any of the preceding claims, characterized in that the apparent density of the oriented strand board is 450kg/m³To 750kg/m³Preferably 520kg/m³To 670kg/m³。

18. Oriented strand board according to any of the preceding claims, characterized in that the binder used for bonding the individual flakes is selected from the group consisting of: a polymeric diphenylmethane diisocyanate (PMDI) -based binder; melamine-formaldehyde-urea based adhesives (MUF); melamine-urea-phenol-formaldehyde binder (MUPF); a phenol-formaldehyde based binder; natural binders, such as starch-based binders, protein-based binders, binders based on tannins, lignin or carbohydrates that have been degraded to monomers; a thermoplastic binder or a crosslinked thermoplastic binder; and mixtures and compositions thereof.

19. Oriented strand board according to any of the preceding claims, characterized in that the strands present in the upper surface layer (11) and/or the lower surface layer (12) and the strands that may be present in the at least one core layer are obtained by flaking Virgin Fiber Wood (VFW).

20. A method for manufacturing an oriented strand board according to any of the preceding claims, wherein a mat of dispersed particles is manufactured by the steps of:

a) producing (112) a surface layer mat (12 ') by directionally dispersing strands already provided with a binder or directionally dispersing a flake mixture comprising strands already provided with a binder, the surface layer mat (12') comprising or consisting of strands provided with a binder,

b) -dispersing (120, 121, 122, 123) at least one core layer blank (20 ', 21 ', 22 ', 23 ') to the surface layer blank (12 ') manufactured in step a), the at least one core layer blank (20 ', 21 ', 22 ', 23 ') comprising flakes obtained by flaking Recycled Wood (RW) and having been provided with a binder,

c) producing (111), on the at least one core layer slab (20 ', 21', 22 ', 23') produced in step b), a further surface layer slab (11 ') by directionally dispersing shavings already provided with a binder or directionally dispersing a flake mixture comprising shavings already provided with a binder, the further surface layer slab (11') comprising or consisting of shavings already provided with a binder,

then, in order to harden and cure the binder, the dispersed particle mat is pressed (200) at an elevated temperature relative to standard conditions to obtain the oriented strand board.

21. Method according to the preceding claim, characterized in that the flakes obtained from the recycled wood are obtained by flaking chips (800) of Recycled Wood (RW), in particular by means of knife ring flaker flaking.

22. Method according to the preceding claim, characterized in that the chips of Recycled Wood (RW) are manufactured by shredding (1000) the Recycled Wood (RW), in particular shredding (1000) the Recycled Wood (RW) by means of a shredder, such as a drum shredder or a screw shredder, a hammer shredder or an impact chipper; or the chips of the Recycled Wood (RW) originate from the outside.

23. Method according to the preceding claim, characterized in that the Recycled Wood (RW) is coarsely pre-shredded (1100) to form chips (1000) before shredding, for example by means of a shredder.

24. Method according to any one of claims 21 to 23, characterized in that the chips are sorted (950) by means of a sorter (size sorting), in particular by means of a disk sorter and/or a roller sorter, before flaking, wherein

The fraction (952) having an average maximum size as a number average maximum size of 20mm to 150mm, preferably 30mm to 120mm is sent to a flaking operation (800), and

preferably, the fraction (953) of chips having an average maximum size as a number average maximum size of more than 150mm, preferably more than 120mm, is fed back to the chopping operation (1000) for producing chips, and/or

Preferably, the chip parts (951) having an average maximum dimension as a number average maximum dimension of less than 20mm, preferably less than 30mm are thermally utilized or used for particle board manufacturing.

25. The method according to any one of claims 21 to 24, wherein at least one, preferably all, of the following steps are performed in any order before the flaking operation (800) and/or before the chopping (1000):

removing substances having a density lower than that of wood, such as plastic films, paper, cardboard,

removal of ferromagnetic metal (910) for example by means of a magnetic separator,

removal of non-ferromagnetic metals (920), in particular aluminium,

removing material (stones, glass, sand, minerals) having a density higher than that of wood by gravimetric sorting (930), such as a winnowing sorter, a gravity sorter or a flotation sorter, and/or

Removal of non-woody material, for example by an X-ray sorter and/or video sorter (940).

26. Method according to any of claims 20 to 25, characterized in that prior to manufacturing the dispersed particle mat, recycled wood flakes are sorted by size (850) and a medium fraction (852) is used for manufacturing the dispersed particle mat, and in particular the fine fraction (851) is removed and e.g. thermally utilized and/or the coarse fraction (853) is removed, which coarse fraction (853) is sent back to the flaker.

27. The method according to any one of claims 20 to 26, wherein after producing recycled wood flakes by flaking (800), said recycled wood flakes are mixed (600) with wood shavings, in particular obtained by flaking (700) raw fiber wood (VFW).

28. The method according to any one of claims 20 to 27,

drying (500) the strands and/or flakes obtained from the recycled wood, in particular a mixture of strands and flakes obtained from the recycled wood, in particular in a tumble dryer,

alternatively, the sheet for the surface layer blank (11 ', 12') and the sheet for the respective core layer blank (20 ', 21', 22 ', 23') are dried separately before the adhesive is applied.

29. The method according to any of the two preceding claims, characterized in that the weight ratio of flakes to wood shavings obtained from recycled wood in the mixture is selected from 5:95 to 95:5, preferably 20:80 to 90:10, more preferably 40:60 to 75:25, particularly preferably 45:55 to 60: 40.

30. Method according to either of claims 27 to 29, characterized in that, before the production of the dispersed-particle mat, the mixture is classified (400) according to the average size of the strands and flakes obtained from recycled wood, in particular by means of a disc classifier, a sieve classifier, a roller classifier, a vibratory classifier, or a combination of two or more of these same or different measures as described above:

a surface layer portion (410) comprising shavings, said surface layer portion (410) being intended to manufacture said surface layer blank (11 ', 12'), and

a core layer portion (420), the core layer portion (420) being used for manufacturing the at least one core slab (20 ', 21 ', 22 ', 23 '), in particular exactly one core slab (20 ') or outer core slab (21 ', 23 '), wherein the core layer portion (420) can comprise shavings having a smaller average length as a number average length compared to the shavings present in the surface layer portion, and

optionally, a fine particle fraction (421) formed partly or entirely of recycled wood flakes, the fine particle fraction (421) being used for manufacturing the inner core mat (22').

31. Method according to either of the two preceding claims, characterized in that in step b) it is produced:

exactly one core slab (20'), or

Three core slabs, i.e. an inner core slab (22 '), one on each side, are surrounded by one outer core slab (21 ', 23 '), one on each side.

32. The method according to any one of claims 20 to 31, characterized in that the weight proportion of recycled wood flakes in the at least one core slab (20 ', 21 ', 22 ', 23 '), in particular in the exactly one core slab (20 '), is at least 5 wt. -%, preferably at least 50 wt. -%, more preferably at least 60 wt. -%, more preferably at least 70 wt. -%, particularly preferably at least 80 wt. -%, based on all flakes in the at least one core slab (20 ', 21 ', 22 ', 23 '), and

the weight proportion of strands having a smaller average length as a number average length than the strands in the upper surface layer slab (11 ') and the lower surface layer slab (12') in the at least one core layer slab (20 ', 21', 22 ', 23') is not more than 95 wt. -%, preferably not more than 50 wt. -%, more preferably not more than 40 wt. -%, more preferably not more than 30 wt. -%, particularly preferably not more than 20 wt. -%, based on all flakes in the at least one core layer slab (20 ', 21', 22 ', 23').

33. Method according to any of claims 20-32, characterized in that if three core slabs are manufactured, i.e. the inner core slab (22 ') is surrounded on each side by one outer core slab (21 ', 23 '),

the proportion by weight of flakes obtained from recycled wood in the inner core mat (22 ') is set higher than the proportion by weight of flakes obtained from recycled wood in the outer core mat (21 ', 23 '), and

the weight proportion of strands in the inner core slab (22 ') having a smaller average length as a number average length than strands in the two surface layer slabs (11', 12 ") is set lower than in the outer core slab (21 ', 23').

34. The method of any one of claims 20 to 33,

the weight proportion of flakes in the inner core mat (22 ') obtained from recycled wood is set to be at least 5 wt. -%, preferably to 5 wt. -% to 100 wt. -%, more preferably to at least 50 wt. -% to 90 wt. -%, particularly preferably to 60 wt. -% to 85 wt. -%, and/or based on all flakes in the inner core mat (22')/or

The weight proportion of flakes in the outer core slabs (21 ', 23') obtained from recycled wood is set to be at least 5 wt. -%, preferably to 5 wt. -% to 100 wt. -%, more preferably to 20 wt. -% to 80 wt. -%, particularly preferably to 30 wt. -% to 70 wt. -%, based on all flakes in the outer core slabs (21 ', 23'),

wherein the weight proportion of flakes obtained from recycled wood in the inner core mat (22 ') and the outer core mat (21', 23 ') is different in each case, preferably the weight proportion of flakes obtained from recycled wood in the inner core mat (22') is greater than the weight proportion of flakes obtained from recycled wood in the outer core mat (21 ', 23').

35. The method according to any of the claims 20 to 34, characterized in that if an inner core slab (22 ') is manufactured surrounded by two outer core slabs (21 ', 23 ') and shavings are included at least in the outer core slabs (21 ', 23 '), the outer intermediate sheets in the outer core slabs (21 ', 23 ') are arranged perpendicular to the orientation of the oriented shavings in the surface layer slabs (11 ', 12 ').

36. Method according to any one of claims 20-35, characterized in that the shavings present in the surface layer slabs (11 ', 12') have:

an average length as a number average length of 40mm to 250mm, preferably 70mm to 150mm,

an average width as a number average width of 2mm to 40mm, preferably 5mm to 25mm, and/or

An average thickness as a number average thickness of 0.3mm to 1.5mm, preferably 0.5mm to 1.2 mm.

37. The method according to any one of claims 20 to 35, wherein the flakes obtained from recycled wood have:

an average length as a number average length of 5mm to 50mm, preferably 10mm to 30mm,

an average width as a number average width of 0.2mm to 10mm, preferably 0.5mm to 5mm, and/or

Average thickness as number average thickness of 0.3mm to 2mm, preferably 0.3mm to 1.2 mm.

38. The method according to any one of claims 20 to 37, wherein the shavings present in the at least one core slab (20 ', 21', 22 ', 23') have:

an average length as a number average length of 10mm to 150mm, preferably 30mm to 100mm,

an average width as a number average width of 0.5mm to 30mm, preferably 2mm to 15mm, and/or

An average thickness as a number average thickness of 0.3mm to 1.5mm, preferably 0.5mm to 1.2mm,

wherein the average length as a number average length is smaller than the average length as a number average length of the shavings present in the surface layer slabs (11 ', 12').

39. The method according to any of the claims 20 to 38, wherein in step a) and step c) the strands are oriented with respect to the longitudinal axis of the oriented strand board such that at least 60%, preferably at least 70%, particularly preferably at least 80% of the longitudinal alignment of the strands deviates by no more than 20 ° from the longitudinal direction of the oriented strand board.

40. Method according to the preceding claim, characterized in that the strands in step a) and step c) have the same orientation.

41. A method according to any of claims 20 to 40, wherein the total thickness of the oriented strand board is set to 4mm to 100mm, preferably 6mm to 40 mm.

42. The method of any one of claims 20 to 41, wherein the binder is selected from the group consisting of: a polymeric diphenylmethane diisocyanate (PMDI) -based binder; melamine-formaldehyde-urea based adhesives (MUF); melamine-urea-phenol-formaldehyde binder (MUPF); a phenol-formaldehyde based binder; natural binders, such as starch-based binders, protein-based binders, binders based on tannins, lignin or carbohydrates that have been degraded to monomers; thermoplastic adhesives or crosslinked thermoplastic adhesives, and mixtures and compositions thereof.

43. An apparatus for manufacturing an oriented strand board according to any of claims 1 to 19 and/or for performing a method according to any of claims 20 to 42, comprising:

at least one dispersion device (112) for producing a first surface layer blank (12 '), the first surface layer blank (12') comprising or consisting of oriented strands which have been provided with a binder,

at least one dispersing device (120, 121, 122, 123) for producing at least one core slab (20 ', 21 ', 22 ', 23 ') on the first surface layer slab (12 '), in particular one dispersing device (120, 121, 122, 123) or two dispersing devices for producing exactly one core slab (20 '), or at least three dispersing devices for producing three core slabs, the three core slabs, i.e. the inner core slab (22 '), being surrounded on each side by one outer core slab (21 ', 23 '), wherein at least one adhesive device (320, 322) for applying adhesive to the strands of the at least one core slab (20 ', 21 ', 22 ', 23 ') is arranged upstream of the at least one dispersing device (120, 121, 122, 123),

at least one dispersion device (111) for producing a second surface layer slab (11 ') on the at least one core layer slab (20', 21 ', 22', 23 '), the second surface layer slab (11') comprising or consisting of oriented strands that have been provided with a binder,

wherein a common binder device (310) for applying binder to the sheets of surface layer blanks (11 ', 12') or each individual binder device for each sheet of surface layer blanks is arranged upstream of the at least one dispersion device (111) for producing the first surface layer blank (12 ') and the second surface layer blank (11'),

a press (200), said press (200) being arranged downstream of said dispersing device (112, 120, 121, 122, 123, 111), said press (200) being adapted to press said dispersed particle mat at an elevated temperature relative to standard conditions,

it is characterized in that the preparation method is characterized in that,

a) the apparatus comprising at least one sorting device (400), which at least one sorting device (400) is connected upstream of the dispersion devices (112, 120, 121, 122, 123, 111), which at least one sorting device (400) is used for producing a surface layer section (410), a core layer section (420) and optionally a fine-grained fraction (421, 422), wherein the produced surface layer section (410) is in each case fed to the at least one dispersion device (111) for producing a first surface layer slab (11 ') and to the at least one dispersion device (112) for producing the second surface layer slab (12'), and a medium section (420) and optionally the fine-grained fraction (421, 422) are fed to the at least one dispersion device (120) for producing at least one core layer slab (20 ', 21', 22 ', 23'), 121, 122, 123), and

at least one mixing silo (600) for mixing shavings and recovered wood flakes is arranged upstream of the at least one sorting device (400) and/or

b) A chipper device (700) for manufacturing wood wool from logs (VW) is arranged upstream of each of the at least one dispersion device (111) for manufacturing the first surface layer mat (11 ') and the at least one dispersion device (112) for manufacturing the second surface layer mat (12'), and

at least one device (800) for flaking Recycled Wood (RW) to obtain recycled wood flakes is arranged upstream of the at least one scattering device (120, 121, 122, 123) for producing at least one core slab (20 ', 21', 22 ', 23').

44. The device according to the preceding claim,

a) at least one drying device (500) is present, the at least one drying device (500) being arranged between the at least one sorting device (400) and the at least one mixing silo (600), and/or

b) Separate drying means (501, 502) are arranged upstream of each of the adhesive means (310, 320, 322) connected upstream of the dispersion means.

45. The apparatus according to any of the two preceding claims, comprising:

at least one flaking device (700) (OSB flaker) for producing flakes, in particular connected upstream of the mixing silo (600), and/or

At least one flaking device (800) for producing recycled wood flakes, in particular at least one knife ring flaker for flaking chips of Recycled Wood (RW), in particular said at least one flaking device for producing recycled wood flakes is connected upstream of said mixing silo (600).

46. The apparatus according to any one of claims 43 to 45, characterised in that at least one device for producing chips from Recycled Wood (RW) is arranged upstream of the flaking device (800) for producing flakes obtained from recycled wood.

47. The apparatus according to any one of claims 43 to 46,

there is at least one device (850) for sorting flakes obtained from recycled wood, the at least one device (850) for sorting flakes obtained from recycled wood being arranged between the at least one flaking device for manufacturing flakes obtained from recycled wood and the mixing silo (600), and/or

There is at least one device (950) for sorting chips of used wood, said at least one device (950) for sorting chips of used wood being arranged between said at least one flaking device for producing flakes obtained from recycled wood and said at least one device for producing chips from used wood.

48. An apparatus according to any one of claims 43 to 47, characterized in that the apparatus comprises at least one device, preferably all of the following:

means for removing substances having a density lower than that of wood, for example by pneumatic sorting (905), such as plastic films, paper, cardboard, hardboard,

means for removing ferromagnetic metal (910), for example by means of a magnetic separator,

means (920) for removing non-ferromagnetic metals, for example by means of an eddy current separator, in particular aluminium,

means for removing substances (stones, glass, sand, minerals) having a density higher than that of wood by weight sorting (930), such as air, gravity or flotation classifiers, and/or

Means for removing non-woody material, such as by an X-ray sorter and/or video sorter (940).

Technical Field

The present invention relates to a new Oriented Strand Board (OSB) comprising recycled wood flakes obtained by flaking recycled wood in at least a core layer. The invention also relates to a method for producing an oriented strand board according to the invention, and to a device with which the oriented strand board according to the invention can be produced or with which the method according to the invention can be carried out.

Background

Oriented strand board has hitherto been made from raw wood. For this purpose, the trunk is used, which, after debarking (exocortion), is sliced into "shavings". This is done using a so-called OSB flaker. The produced strands are classified by size, the strands are usually divided into two parts, the part with the largest strands is used for making the surface layer of the oriented strand board, and the part with smaller flakes is usually used for the inner core layer of the oriented strand board or discharged from the OSB process. The resulting strands are typically dried prior to sorting. The dried portions of the strands are then glued and the dried portions are placed on top of each other to obtain an oriented sheet mat. After pressing and simultaneously hardening the binder, the oriented strand board is completed.

Disclosure of Invention

The object of the present invention is therefore to produce oriented strand board which can be used with alternative raw material sources from raw wood only, wherein the corresponding oriented strand board is produced in a manner according to DIN EN 300: the mechanical requirements of 2006 are by no means inferior.

This object is achieved by an oriented strand board according to claim 1, by a method for producing a corresponding oriented strand board having the features of claim 20, and by an apparatus for producing a corresponding oriented strand board or for carrying out a corresponding process having the features of claim 43. The dependent claims of each of the above claims constitute advantageous developments.

Accordingly, in a first aspect, the present invention relates to an oriented strand board comprising at least the following three layers:

a) an upper surface layer comprising or consisting of oriented strands bonded to each other,

b) at least one core layer comprising flakes obtained by flaking recycled wood (recycled wood flakes) and bonded to each other,

c) a lower surface layer comprising or consisting of oriented strands bonded to each other,

wherein the at least one core layer is arranged between the two surface layers.

Here, the respective flakes, strands and layers are bonded together with respect to one another by means of an adhesive to obtain an oriented strand board.

Surprisingly, no prejudice has been demonstrated which prevails in the prior art, i.e. the mechanical properties of oriented strand board have yet to be improved if other raw materials than raw wood are processed. The oriented strand board according to the invention is in no way inferior to oriented strand board already 100% made from raw wood and meets DIN EN 300: 2006 all mechanical properties specified for OSB: given a specific configuration, the oriented strand board of the invention may meet the requirements set out in DIN EN 300: all requirements described in 2006 for OSB/1, OSB/2, OSB/3 or even OSB/4 types.

In addition, the oriented strand boards of the invention are particularly advantageous in that they can be produced in a resource-saving manner, so that fewer raw wood are required for the production of the oriented strand boards of the invention. Furthermore, another source of raw material, i.e. recycled wood (or used wood) can be switched on, which hitherto only appeared to be suitable for the manufacture of particle board or has been thermally utilized.

Here, the oriented strand board of the present invention is characterized in that at least the one core layer (if the oriented strand board has only one core layer) or the plurality of core layers (if the oriented strand board has a plurality of core layers) comprise recycled wood flakes, which are obtained by flaking recycled wood, or at least one or more core layers have been completely formed of recycled wood flakes.

The expression "recovered wood" is used herein in the sense of "Altholz" in German Federal republic of Federal regulations concerning the requirements for the utilization and elimination of recovered wood (Altholzverordnung "Verordnung ü ber for averderung an dieVerwertung und beseitignung von Altholz" published in BGBI [ German Federal Law Gazette I, No. 59, p. 3302-3317 ].

For the purposes of the present invention, the invention can be carried out with all recycled wood, particularly preferably with A I-type and/or AII-type recycled wood.

Here, the arrangement of the recycled wood used is not critical; thus, recycled wood flakes can be made from recycled wood using any desired wood product (e.g., used furniture, window frames, cladding, wood panels, pallets, etc.).

In contrast, the term "logs" is understood to mean wood that has not been recovered but is obtained directly from raw wood stock. A particular form of raw wood is "raw fiber wood", i.e. raw round wood, which comprises, inter alia, the trunk of a tree immediately after felling and delimbing, but not necessarily after debarking.

According to the present invention, it is preferred when said at least one core layer comprises or is formed by a mixture of recycled wood flakes and shavings bonded to each other.

It is also possible that both surface layers likewise comprise a mixture of recycled wood flakes and shavings bonded to each other, or that both surface layers are formed of a mixture of recycled wood flakes and shavings bonded to each other; however, in the case of this embodiment, it is also advantageous when the proportion of the recycled wood flakes in the surface layer is smaller than the proportion of the recycled wood flakes in the core layer.

In another preferred embodiment, it is preferred when the strands present in the at least one core layer have a smaller average length (number average) than the strands present in the upper and lower surface layers.

In the context of the present invention, the length of a particle (e.g. a flake) is understood to mean the maximum extent of the particle (e.g. flake). Average length is understood to mean a numerically weighted average. The average length may be determined, for example, by optical analysis.

In the context of the present invention, the width of a particle (e.g. a flake) is understood to mean the second largest extent of the particle (e.g. flake). The average width is understood to mean a numerically weighted average. The average width may be determined, for example, by optical analysis.

In the context of the present invention, the thickness of a particle (e.g. a flake) is to be understood as referring to the smallest range of the particle (e.g. flake). Average thickness is understood to mean a numerically weighted average. The average thickness may be determined, for example, by optical analysis.

The oriented strand board according to the invention may have exactly one core layer, or alternatively, in particular, three core layers, i.e. an inner core layer surrounded by two outer core layers. Thus, in each of the preferred cases described above, oriented strand board has a symmetrical structure and therefore well-balanced mechanical properties.

In addition to recycled wood flakes, wood flakes of logs may be included, in which case the wood flakes of logs may replace a portion of the recycled wood flakes. Logs are herein understood to mean wood that has not been recycled but obtained directly from wood. If not only recycled wood flakes but also raw wood flakes are included, the preferred weight data of the recycled wood flakes described in detail below is adapted to the total weight ratio of the recycled wood flakes to the raw wood flakes.

Preferably, the geometry of any log flakes present is the same as the geometry of the recycled wood flakes; more particularly, the (average) dimensions listed further below for the recycled wood flakes are also suitable for the raw wood flakes. This may be due to the fact that: preferably, the log flakes are manufactured in a similar manner to recycled wood flakes, in particular by flaking log pieces in a knife and ring flaker.

If a proportion of raw wood flakes is present to partially replace recycled wood flakes, it is preferred that the proportion of recycled wood flakes is 0.1 to 80% by weight, preferably 1 to 70% by weight, more preferably 5 to 50% by weight, replaced with raw wood flakes. This applies to all embodiments of oriented strand board described hereinafter.

In a further preferred embodiment, the weight proportion of recycled wood flakes and any raw wood flakes in said at least one core layer, in particular in said exactly one core layer, is at least 5 wt. -%, preferably at least 50 wt. -%, more preferably at least 60 wt. -%, more preferably at least 70 wt. -%, particularly preferably at least 80 wt. -%, based on all flakes in said at least one core layer.

Here, the process is described. It should also be mentioned that the core layer may equally be 100% formed from recycled wood flakes or from a mixture of recycled wood flakes and raw wood flakes.

If the core layer is formed from a flake mixture comprising recycled wood flakes and any log flakes, it is advantageous when the strands are also a component of the core layer, as are recycled wood flakes and any log flakes. Here, preferably, the weight ratio of the strands in the core layer is complementary to the weight ratio of the recycled wood flakes and any raw wood flakes; in other words, preferably the weight proportion of wood strands in a core layer (in particular in said exactly one core layer) is not more than 95 wt. -%, preferably not more than 50 wt. -%, more preferably not more than 40 wt. -%, more preferably not more than 30 wt. -%, particularly preferably not more than 20 wt. -%, based on the sum of all wood particles (i.e. all flakes and strands) in said at least one core layer.

In an alternative and equally preferred embodiment, the oriented strand board may have three core layers and thus (including the upper and lower surface layers) a total of five layers. Here, the three core layers constitute an inner core layer surrounded by two outer core layers. In this embodiment it is preferred that the weight ratio of the recycled wood flakes and any raw wood flakes in the inner core layer is higher than in the outer core layer, and that the weight ratio of the strands in the inner core layer having a smaller average length (number average) than the strands in the upper and lower surface layers is smaller than in the outer core layer.

In the above-described embodiment of an oriented strand board having three core layers, it is advantageous that the weight proportion of recycled wood flakes and any raw wood flakes in the inner core layer is at least 5 wt. -%, preferably 5 to 100 wt. -%, more preferably at least 50 to 90 wt. -%, particularly preferably 60 to 85 wt. -%, based on all wood particles in the inner core layer (i.e. the sum of all flakes and strands),

and/or the weight proportion of recycled wood flakes in the outer core layer is at least 5 wt.%, preferably from 5 wt.% to 100 wt.%, more preferably from 20 wt.% to 80 wt.%, particularly preferably from 30 wt.% to 70 wt.%, based on all flakes in the outer core layer,

when the weight ratio of the recycled wood flakes in the inner core layer and the outer core layer is different, it is preferable that the weight ratio of the recycled wood flakes in the inner core layer is greater than that in the outer core layer.

In the construction of the inner and outer core layers, it is also possible, for example, that the inner core layer is formed only from recycled wood flakes and any log flakes, and that the outer core layer is formed from a mixture of wood shavings and recycled wood flakes and any log flakes.

In this case, it is particularly preferred when the strands in the outer core layer are oriented perpendicular to the orientation of the strands present in the surface layer.

This also includes the following possibilities: both the inner and outer core layers are 100% formed from recycled wood flakes and any raw wood flakes, in which case it is preferred to use recycled wood flakes having a smaller average size (e.g., a smaller average mean length) for making the inner core layer than the recycled wood flakes used to make the outer core layer.

Preferably, the strands used for the surface layer have an average length (number average) of 40mm to 250mm, preferably 50mm to 250, more preferably 70mm to 150mm, an average width (number average) of 2mm to 40mm, preferably 5mm to 25mm, and/or an average thickness (number average) of 0.3mm to 1.5mm, preferably 0.5mm to 1.2 mm.

In preferred embodiments, the recycled wood flakes and any log flakes have an average length (number average) of from 5mm to 50mm, preferably from 10mm to 30mm, an average width (number average) of from 0.2mm to 10mm, preferably from 0.5mm to 5mm, and/or an average thickness (number average) of from 0.3mm to 2mm, preferably from 0.3mm to 1.2 mm.

If the core layer likewise comprises wood strands, it is preferred that these wood strands have an average length (number average) of 10mm to 150mm, preferably 30mm to 100mm, an average width (number average) of 0.5mm to 30mm, preferably 2mm to 15mm, and/or an average thickness (number average) of 0.3mm to 1.5mm, preferably 0.5mm to 1.2mm, wherein the average length (number average) is smaller than the average length of the wood strands present in the upper and/or lower surface layer.

Preferably, the recycled wood flakes present in the oriented strand board of the present invention are obtained by flaking pieces of recycled wood, in particular by means of knife ring flaker. Any log flakes present can be obtained by slicing the log pieces accordingly.

Preferably, the shavings present in both surface layers are arranged in an oriented manner. The orientation of the strands gives the oriented strand board high mechanical strength, in particular in a preferred longitudinal direction. Preferably, the strands are oriented in this case with respect to the longitudinal axis of the oriented strand board such that at least 60%, preferably at least 70%, particularly preferably at least 80%, of the longitudinal alignments of the strands deviate by not more than 20 ° from the longitudinal direction of the oriented strand board.

The orientation of the strands can be determined in a conventional manner, for example by sample analysis of the finished oriented strand board in the dispersion during manufacture as described below, or by optical testing methods.

Here, it is particularly preferred that the oriented strands in the upper and lower surface layers have the same orientation, i.e. are oriented in the same way.

The total thickness of the oriented strand board may be 4mm to 100mm, preferably 6mm to 40 mm.

Here, it is also preferred that the total thickness of the upper and lower surface layers accounts for 20% to 60%, preferably 25% to 50%, more preferably 30% to 40% of the total thickness of the oriented strand board, and/or that the thickness of the at least one core layer accounts for 80% to 40%, preferably 75% to 50%, more preferably 70% to 60% of the total thickness of the oriented strand board.

In particular, the oriented strand board according to the invention has an apparent density of 450kg/m³To 750kg/m³Preferably 520kg/m³To 670kg/m³。

In another preferred embodiment, the adhesive used to bond the individual sheets is selected from the group consisting of: a polymeric diphenylmethane diisocyanate (PMDI) -based binder; melamine-formaldehyde-urea based adhesives (MUF); melamine-urea-phenol-formaldehyde binder (MUPF); a phenol-formaldehyde based binder; natural binders, such as starch-based binders, protein-based binders, binders based on tannins, lignin or carbohydrates that have been degraded to monomers; a thermoplastic binder or a crosslinked thermoplastic binder; and mixtures and compositions thereof.

In particular, the strands present in the surface layer and any strands present in the at least one core layer may be obtained by flaking the raw wood.

In a second aspect, the invention relates to a method for manufacturing oriented strand board as described in detail above, wherein a mat of dispersed particles consisting of a plurality of mats is first dispersed and then pressed to obtain oriented strand board. In order to produce a discrete particle mat, the following steps are carried out:

a) the surface layer blank is manufactured by directionally dispersing the strands already provided with the binder or directionally dispersing the flake mixture containing strands already provided with the binder, said surface layer blank comprising or consisting of the strands provided with the binder.

b) Dispersing at least one core mat onto the surface layer mat manufactured in step a), the at least one core mat comprising recycled wood flakes, which have been obtained by flaking recycled wood and which have been provided with a binder.

c) Producing or laying a further surface layer slab on or on the at least one core slab produced in step b) by directionally dispersing shavings already provided with a binder or directionally dispersing a flake mixture comprising shavings already provided with a binder, the further surface layer slab comprising or consisting of shavings already provided with a binder.

Subsequently, the mat of dispersed particles is pressed at an elevated temperature relative to standard conditions in order to harden and cure the binder, to obtain an oriented strand board.

The essential feature of the method according to the invention is therefore that the slabs representing the individual layers, i.e. the surface layer or the at least one core layer of the oriented strand board to be manufactured, are separately and successively spread one on top of the other, and finally the spread particle slabs consisting of the individual slabs are pressed to obtain the final oriented strand board. In this case, the recycled wood flakes are used at least for the manufacture of the core slab.

In particular, recycled wood flakes can be obtained in a previous step by flaking chips of recycled wood, in particular by means of a knife ring flaker. Any log flakes used may similarly be obtained by flaking log pieces.

If the recycled wood flakes are produced by flaking chips of recycled wood, it is also preferred that the chips of recycled wood are produced by shredding the recycled wood, in particular by means of a shredder, such as a drum shredder, a hammer shredder or an impact chipper, or that the chips of recycled wood originate from outside.

Alternatively, it is also possible here that the chips of the recycled wood can originate from an external source.

If it happens that the recycled wood is shredded to obtain chips and the source of the recycled wood is too large for the respective shredding device (e.g. in the case of large pieces of furniture or the like), one option is to pre-shred the recycled wood material in the form of pieces roughly, for example by means of a shredder, before shredding into chips, wherein large pieces of recycled wood are shredded into smaller pieces.

In order to achieve maximum flaking efficiency, it is also advantageous to sort the flakes (either manufactured separately or originating from an external source) by means of, for example, a sorter (i.e. size sorting), in particular by means of a disk sorter and/or a roller sorter, and to distribute the flakes having an average maximum size (number average) of 20mm to 150mm, preferably 30mm to 120mm, to the flaker before flaking.

It may be the case that further larger and/or smaller fractions are obtained.

Preferably, the fraction of chips having an average maximum size (number average) of more than 150mm, preferably more than 120mm, is fed back to the shredding operation for the manufacture of chips.

Alternatively or additionally, it is also possible that the fraction having an average maximum size (number average) of less than 20mm, preferably less than 30mm, obtained in the sorting operation is thermally utilized or used for particle board manufacturing.

Since recycled wood is a relatively heterogeneous material, one option is to perform at least one purification step before being used for the purposes of the present invention. In particular, at least one, preferably all, of the following steps are performed in any order before flaking and/or before chopping and/or before rough pre-chopping:

removal of substances having a density lower than that of wood (e.g. plastic film, paper, cardboard) for example by pneumatic sorting,

removal of ferromagnetic metals for example by means of a magnetic separator,

removal of non-ferromagnetic metals, in particular aluminium, for example by means of an eddy current separator,

removal of substances (stones, glass, sand, minerals) having a density higher than that of wood by gravimetric sorting (e.g. winnowing, gravity or flotation sorting), and/or

Removal of non-woody material, for example by X-ray sorting and/or video sorting.

Preferably, one or more of the above purification steps are repeatedly performed in the method of the invention.

For example, it may be the case that the removal of metal (ferromagnetic or non-ferromagnetic metal) is repeatedly performed. Repeated removal of non-metallic material is also possible.

In particular immediately before the flaking of the fragments, a new and separate removal of the metal and/or ceramic material is advantageous in order to avoid damage to the flaking device.

It is also possible that the recycled wood flakes (e.g. having been produced by flaking from recycled wood chips or originating from the outside) and any raw wood flakes are sorted by size prior to making the discrete mat of particles. More particularly, recycled wood flakes having an average length (number average) of 5mm to 50mm, preferably 10mm to 30mm, an average width (number average) of 0.2mm to 10mm, preferably 0.5mm to 5mm, and/or an average thickness (number average) of 0.3mm to 2mm, preferably 0.3mm to 1.2mm are used for the purpose of the process of the present invention.

The fine particle fraction produced in the sorting step and separated from the recycled wood flakes and any raw wood flakes, i.e. recycled wood flakes having an average length (number average) of less than 5mm, can be, for example, thermally utilized or used in particle board manufacturing. It is also possible to sort the fine fraction again and to separate the flake fraction in the above-mentioned size range. The foil portion may equally be used for the purpose of the present invention.

Any coarse fraction removed, i.e. recycled wood flakes and any raw wood flakes having an average length (number average) of more than 50mm, can be returned to the chipper and further chipped, thereby obtaining a flake fraction useful for the purposes of the present invention.

In particular, the medium fraction in which the recycled wood flakes have, for example, the above-mentioned average size, is used for manufacturing the oriented strand board of the present invention.

For the purpose of the invention it is possible that the surface layer mat is made entirely of wood shavings with a binder, said wood shavings being obtained, for example, by flaking logs, while said one or more core layer mats may be formed entirely of recycled wood flakes and optionally log flakes.

However, for the purpose of manufacturing the individual slabs, it is particularly preferred that the manufactured shavings and the recycled wood flakes and any original wood flakes are first mixed with each other, the obtained mixture is subsequently sorted according to size, and the individual parts are used for manufacturing the individual slabs.

This particularly preferred variant is described in detail below.

As mentioned above, if a mixture of shavings and recycled wood flakes and any virgin wood flakes is manufactured, this may be achieved, for example, by actively mixing the individual types of flakes, but preferably the mixture is automatically manufactured by conveying or processing the mixture of flakes in a subsequent operation step, for example, by storing the different flake types together in a storage bin or by conveying together in a conveying device.

More particularly, the mixture of recycled wood flakes and any raw wood flakes and shavings may be dried, for example, particularly in a drum dryer.

In the case of co-drying the shavings and recovered wood flakes, as well as any raw wood flakes, only a single device is therefore required to dry the flake mixture, so that the complexity of the apparatus can be minimized.

If the different layers can be made of a single type of shavings or recycled wood flakes, it is of course equally possible to dry them separately, for example in a separate drum dryer.

In the case of the above-described recycled wood flake mixture, here, it is preferable to select a mixing ratio of the recycled wood flakes to the wood shavings of 5:95 to 95: 5. preferably 20:80 to 90:10, more preferably 40:60 to 75:25, particularly preferably 45:55 to 60: 40.

Thus, preferably, the pre-manufactured flake mixture is sorted according to the average size of the recycled wood flakes and shavings. Depending on its size, the resulting fraction is used for the surface layer slab or the core layer slab(s), wherein the coarser fraction of the flake mixture is used for the surface layer slab and the smaller-sized fraction of the flake mixture is used for the core layer slab(s).

The classification can be effected here, for example, by a disk classifier, a sieve classifier, a roller classifier, a vibrating classifier or a combination of two or more of these classifiers described above, which may be identical or different.

Here, the implementation is classified into two or three parts, i.e. a surface layer part, a core layer part and optionally a fine-grained part.

The surface layer portion is used for manufacturing the surface layer blank and has the largest average sheet size (largest average length (number average)). Generally, the classification is made such that the surface layer portion is mainly formed of shavings.

In addition, a core portion is formed, which is used for manufacturing the core slab(s). If the oriented strand board to be manufactured has exactly one core layer, the core layer part will be used completely for manufacturing the core layer slab. If the oriented strand board has a plurality of core layers, for example three core layers (two outer core layers and one inner core layer), this core layer portion is used to produce an outer core layer slab, which then produces the outer core layer. The core layer portion is characterized by the presence of strands having a smaller average length (number average) than strands present in the surface layer portion.

If the oriented strand board also has an inner core layer, the inner core layer is produced using an inner core layer blank which is embedded between two outer core layer blanks. For this purpose, a fine particle fraction is used, which consists essentially of recycled wood flakes and optionally raw wood flakes, the flakes of the fine particle fraction having overall the smallest average size (average length (number average)).

A classification corresponding to the above details is not necessary if a single type of wood wool is used for manufacturing the surface layer slab and a single type of recycled wood flakes is used for manufacturing the core layer slab or a mixture of separately manufactured recycled wood flakes and wood wool is used for manufacturing the core layer slab.

In step b) described at the beginning, it is therefore preferred to produce exactly one core slab or three core slabs on top of one another (i.e. the inner core slab is surrounded on each side by one outer core slab).

It is also preferred that the weight proportion of recycled wood flakes and any raw wood flakes in the at least one core slab, in particular in the exactly one core slab, is at least 5 wt. -%, preferably at least 50 wt. -%, more preferably at least 60 wt. -%, more preferably at least 70 wt. -%, especially preferably at least 80 wt. -%, based on all flakes in the at least one core slab, and the weight proportion of shavings having a smaller average length (number average) than the shavings in the upper and lower surface layer slabs is not more than 95 wt. -%, preferably not more than 50 wt. -%, more preferably not more than 40 wt. -%, more preferably not more than 30 wt. -%, especially preferably not more than 20 wt. -%.

It is advantageous if three core slabs are manufactured, i.e. the inner core slab is surrounded on each side by one outer core slab, when: (i) the weight ratio of recycled wood flakes and any raw wood flakes in the inner core mat is set higher than the weight ratio in the outer core mat, and (ii) the weight ratio of strands in the inner core mat having a smaller average length (number average) than the strands in the two surface layer mats is set to a lower level than the weight ratio in the outer core mat.

If strands are present in the outer core slab, they are preferably dispersed perpendicular to the orientation of the strands in the surface layer slab.

The aforementioned options also include forming the inner core mat entirely from recycled wood flakes and any log flakes. It is also possible that no shavings are present in the outer core slab. If three core slabs are used and none of the core slabs comprises wood shavings, it is preferred here that recycled wood flakes and optionally log flakes having a larger average size, i.e. a larger average length (number average), are used for the outer core slabs.

In a preferred embodiment, it is the case here that the weight proportion of recycled wood flakes and any original wood flakes in the inner core slab is set to at least 5 wt.%, preferably to 5 wt.% to 100 wt.%, more preferably to at least 50 wt.% to 90 wt.%, particularly preferably to 60 wt.% to 85 wt.%, based on all flakes in the inner core slab.

Alternatively or additionally, it is also possible that the weight proportion of the recycled wood flakes and any raw wood flakes in the outer core mat is set to at least 5 wt. -%, preferably to 5 to 100 wt. -%, more preferably to 20 to 80 wt. -%, particularly preferably to 30 to 70 wt. -%, based on all flakes in the outer core mat,

when the weight proportions of the recycled wood flakes and any raw wood flakes in the inner and outer core slabs are different in each case, it is preferred that the weight proportion of the recycled wood flakes in the inner core slab is greater than the weight proportion of the recycled wood flakes in the outer core slab.

For the production of the surface layer blank, in particular, the following shavings are used: the strands have an average length (number average) of 40mm to 250mm, preferably 50mm to 250mm, more preferably 70mm to 150mm, an average width (number average) of 2mm to 40mm, preferably 5mm to 25mm, and/or an average thickness (number average) of 0.3mm to 1.5mm, preferably 0.5mm to 1.2 mm. It is immaterial here whether the shavings are used in the form of a single type or, if appropriate, are obtained by classification of a mixture of shavings and recycled wood flakes.

Also preferably, the strands present in the at least one core slab have an average length (number average) of 10mm to 150mm, preferably 30mm to 100mm, an average width (number average) of 0.5mm to 30mm, preferably 2mm to 15mm, and/or an average thickness (number average) of 0.3mm to 1.5mm, preferably 0.5mm to 1.2mm, wherein the average length (number average) is smaller than the average length of the strands present in the surface slab.

Here, it is immaterial whether the shavings for the at least one core slab are used in the form of a single type or are obtained by classifying a mixture of shavings and recycled wood flakes.

In a preferred embodiment, in step a) and step c), the strands are oriented with respect to the longitudinal axis of the oriented strand board such that at least 60%, preferably at least 70%, particularly preferably at least 80% of the longitudinal alignment of the strands deviates by no more than 20 ° from the longitudinal direction of the oriented strand board.

It is particularly preferred that the strands in step a) and step c) have the same orientation.

In particular, the total thickness of the oriented strand board is set to 4mm to 100mm, preferably 6mm to 40 mm. For this purpose, the size and the compaction factor of the dispersed particle mat in the pressing operation are suitably matched to each other.

Preferably, the binder is selected from the group consisting of: a polymeric diphenylmethane diisocyanate (PMDI) -based binder; melamine-formaldehyde-urea based adhesives (MUF); melamine-urea-phenol-formaldehyde binder (MUPF); a phenol-formaldehyde based binder; natural binders, such as starch-based binders, protein-based binders, binders based on tannins, lignin or carbohydrates that have been degraded to monomers; a thermoplastic binder or a crosslinked thermoplastic binder; and mixtures and compositions thereof.

In a third aspect, the invention relates to an apparatus for manufacturing oriented strand board as described above, with which the above-described method of the invention can also be carried out.

The apparatus of the present invention comprises:

at least one dispersion device for producing a first surface layer blank, which first surface layer blank comprises or is formed by oriented strands which have been provided with a binder,

at least one dispersing device for producing at least one core slab on the first surface layer slab, in particular one dispersing device or two dispersing devices for producing exactly one core slab, or at least three dispersing devices for producing three core slabs, the three core slabs, i.e. the inner core slab, being surrounded on each side by one outer core slab, wherein a binder device is arranged upstream of the at least one dispersing device,

at least one dispersing device for manufacturing a second surface layer slab on the at least one core layer slab, the second surface layer slab comprising or consisting of oriented strands that have been provided with a binder,

wherein a common binder device or each individual binder device for each surface layer blank is arranged upstream of the at least one dispersion device for producing the first and second surface layer blanks, and

a press disposed downstream of the dispersion device for pressing the dispersed particulate mat at an elevated temperature relative to standard conditions.

The device of the invention can be configured in two alternative variants, which can also be combined with one another.

Here, the respective adhesive means are used for applying at least one adhesive to the sheet. These adhesive means are thus gluing means.

In a first variant, the apparatus of the invention comprises (i) at least one sorting device connected upstream of the dispersion device, the at least one classifying device is used to produce a coarse fraction, a medium fraction and optionally a fine fraction, wherein the produced coarse fraction is in each case passed to the at least one dispersion device for producing the first surface layer slab and the second surface layer slab, and the medium fraction and optionally the fine fraction are sent to the at least one apparatus for manufacturing at least one core slab, and (ii) at least one mixing area (e.g., a mixing silo) for mixing the shavings and the recycled wood flakes, the at least one mixing zone (e.g., a mixing silo) is upstream of the at least one sorting device.

The above-described first variant of the device of the invention provides the following options: a mixture of wood shavings and recycled wood flakes and any virgin wood flakes is first produced and then sorted and used for the purpose of individual slabs to produce the individual layers of oriented strand board.

In particular, the second variant of the configuration of the apparatus of the invention enables the production of homogeneous layers in oriented strand board, for example a homogeneous surface layer formed only by wood shavings and a core layer formed only by recycled wood flakes and any raw wood flakes.

If a mat is manufactured according to the first variant, the second variant can also be used to control the content of the individual flake types (i.e. shavings and recycled wood flakes and any raw wood flakes) in the individual mat. This variant therefore combines the measures of the first and second variants.

In the first variant described above, it is particularly advantageous if at least one drying device is arranged between the at least one sorting device and the at least one mixing zone (for example a mixing silo).

In a second variant of the apparatus of the invention, it may be preferred that each individual drying device is arranged upstream of each adhesive device connected upstream of the dispersion device.

Preferably, the apparatus of the invention also comprises at least one flaking device (OSB flaker) for producing shavings, which flaking device is in particular connected upstream of the mixing silo.

Alternatively or additionally, the inventive apparatus preferably comprises at least one flaking device for producing recycled wood flakes, in particular at least one knife ring flaker for flaking chips of recycled wood, in particular the at least one flaking device being connected upstream of the mixing silo.

More particularly, at least one device for producing chips from recycled wood may be arranged upstream of the chipper device for producing recycled wood chips.

In another preferred embodiment, there is at least one device for sorting the recycled wood flakes, which is arranged between the at least one flaking device for producing recycled wood flakes and the mixing silo.

In another preferred embodiment, there is at least one device for sorting chips of recycled wood, which is arranged between the at least one chipper device for producing recycled wood chips and the at least one device for producing chips from recycled wood.

Preferably, the apparatus of the invention comprises at least one, preferably more than one, and particularly preferably all of the following means:

means for removing substances having a density lower than that of wood (e.g. plastic film, paper, cardboard, hardboard), for example by pneumatic sorting,

means for removing ferromagnetic metals, for example by means of a magnetic separator,

means for removing non-ferromagnetic metals, in particular aluminium, for example by means of an eddy current separator,

devices for removing substances with a density higher than that of wood (stones, glass, sand, minerals) by gravimetric sorting, such as air, gravity or flotation classifiers, and/or

Means for removing non-woody material, for example by means of an X-ray sorter and/or video sorter.

Drawings

The invention is described in detail with reference to the following drawings, but the invention is not limited to the specific parameters detailed.

The figures show:

figure 1 is a first embodiment of an oriented strand board of the present invention,

figure 2 is another embodiment of an oriented strand board of the present invention,

figure 3 is a variant of the apparatus for manufacturing oriented strand board according to the invention,

FIG. 4 is a production line connected upstream of the apparatus according to FIG. 3 for processing recycled wood, an

Figure 5 is another variation of an apparatus for manufacturing oriented strand board of the present invention.

Detailed Description

Fig. 1 shows a first construction form of an oriented strand board according to the invention. The panel has a three-layer structure and comprises two surface layers, an upper surface layer 11 and a lower surface layer 12. Here, the surface layers 11, 12 consist either 100% of wood shavings (OSB shavings) or of a mixture of wood shavings and smaller recycled wood flakes, but the proportion by weight of the wood shavings in the surface layers 11, 12 preferably prevails over the recycled wood flakes. Likewise, the oriented strand board according to fig. 1 comprises a core layer 20, the core layer 20 being either 100% formed by recycled wood flakes or, as in the present case, by a mixture of wood shavings and recycled wood flakes, the proportion by weight of the recycled wood flakes in the core layer 20 being superior to that of the wood shavings. Here, all the sheets in the layers have been bonded to one another by means of a suitable adhesive and pressed. Oriented strand board is produced by pressing discrete particle mats consisting of different sheet mats, which have been provided with a binder between them. Likewise, a corresponding slab of dispersed particles can be deduced from fig. 1. In this case, first, a lower surface layer slab 12' is deposited. Since the surface layer mat has been formed either 100% of shavings or a mixture of recycled wood flakes and primary shavings, as already mentioned above, the shavings are deposited in a manner known in the art such that a preferential direction is imparted to the flakes and thus the shavings in the lower surface layer mat 12' are directionally aligned. A core mat 20 ', for example 100% consisting of recycled wood flakes or a mixture of recycled wood flakes and shavings, is deposited on the lower surface layer mat 12 ', wherein the weight proportion of recycled wood flakes in the core mat 20 ' preferably prevails over the shavings. Another upper surface layer slab 11 ' is deposited on the core layer slab 20 ', preferably with the same sheet used for the upper surface layer slab as also used for the lower surface layer slab 12 '. As is any flake mixture for each of the upper surface layer blank 11 'and the lower surface layer blank 12'. The sheets or sheet mixtures used are already provided with a binder when the individual blanks are produced. Finally, the manufactured mat of discrete particles is pressed in a manner known in the art to obtain the final oriented strand board.

Figure 2 shows another embodiment of the oriented strand board of the invention, which is in the form of five layers compared to the oriented strand board shown in figure 1.

Here, an oriented strand board (similar to the oriented strand board according to fig. 1) has an upper surface layer 11 and a lower surface layer 12, which are either 100% formed by wood shavings or a flake mixture formed by a major proportion of wood shavings and a further minor proportion of recycled wood flakes.

The oriented strand board according to fig. 2 comprises three core layers, i.e. an inner core layer 22 surrounded by two outer core layers 21, 23. The inner core layer 22 is either formed of recycled wood flakes at 100% by weight or includes recycled wood flakes and a small proportion of wood shavings. The proportion of strands in the outer core layers 21, 23 may be greater than the proportion of strands in the inner core layers, but less than the proportion of strands in the surface layers 11, 12.

Likewise, the slab sequence used in the manufacture of the oriented strand board shown in fig. 2 can be inferred from fig. 2.

First, a lower surface layer slab 12 ' is manufactured, and a first outer core layer slab 23 ' is deposited on the lower surface layer slab 12 '. The inner core slab 22 'is spread over the first outer core slab 23', followed by the other surface layer slab 21 ', and finally the upper surface layer slab 11'. The resulting mat of dispersed particles is subsequently pressed to obtain the final oriented strand board.

Fig. 3 shows the overall construction of a plant for manufacturing oriented strand board according to the invention. With the apparatus according to fig. 3, a three-layer particle board as shown in fig. 1 can be manufactured.

For the production of the individual slabs, three separate dispersing devices are present for the production of the individual slabs. Using the dispersion apparatus 112, a lower surface layer mat 12' comprising oriented strands may be produced. The dispersion apparatus 120 is used to produce a core layer slab 20 'deposited on the lower surface layer slab 12'. By means of the dispersion device 111, the upper surface layer blank 11 'on the core layer blank 20' can be manufactured. More specifically, the slabs can be manufactured continuously by applying the individual slabs 11 ', 20 ', 12 ', for example on a conveyor belt (not shown). Likewise, the slabs are subsequently supplied to a pressing apparatus 200, in which pressing apparatus 200 the individual slab layers consisting of the flakes already provided with the binder are pressed to obtain the final oriented strand board.

If further slabs are to be formed in sequence, for example to realize an oriented strand board as shown in fig. 2, further dispersing means are included to disperse the individual slabs.

Here, a common binder device 310 is connected upstream of the dispersion devices 111 and 112, in which binder device 310 the shavings for the individual surface layer slabs 11 'and 12' are glued. For example, the apparatus may comprise a conventional large glue cylinder (roll coater). In the dispersing device 120, there is also an upstream adhesive device 320 for gluing the sheets for the core mat 20'. Due to the fact that the core slab 20' consists mainly of recycled wood flakes, which are small relative to the wood shavings, it is preferred to use a standard flake gluing mixer for the purpose of the adhesive means 320.

The adhesive means may be supplied with the sheets in two different ways, which will be described in detail below separately.

A first option is to supply a flake mixture consisting of wood shavings (which preferably have been obtained by slicing logs, for example in an OSB flaker) and recycled wood flakes (which for example have been obtained by slicing fragments of used wood in a knife and ring flaker), which mixture has been previously classified.

This option is shown in the portion shown at the top in fig. 3. In this case, first, the pieces of the recovered wood are used to manufacture the wood pieces of the used wood (referred to as recovered wood pieces) in the chipping device 800 (e.g., a knife ring chipper). Preferably, the manufactured recycled wood flakes are then sorted in a sorting device 850. For this purpose, for example, a disk classifier or a roller classifier can be used, but also a screening device can be used. Combinations of the mentioned sorting measures are likewise possible. In the illustrative case of fig. 3, the manufacture of three recycled flake fractions, namely a fine fraction 851 comprising, for example, powder and very small particles, is achieved with a sorting device 850. The fine particle fraction 851 may be thermally utilized, for example. Preferably, the resulting coarse fraction 853 can be recycled to the flaking device 800 for further raw material utilization. The resulting medium size fraction 852, which meets the desired requirements for the size of the recycled wood flakes, may be used to make oriented strand board of the present invention.

The medium size fraction 852 of the recycled wood flakes is fed into the blending bin 600. Likewise, the mixing silo 600 is supplied with shavings, which are produced, for example, in a flaking device 700 (e.g., OSB flaker) for the raw fiber wood VFW. The mixing silo 600 may be an active mixing device or a passive mixing device. In the case of an active mixing silo, the flakes are actively moved to make a flake mixture. In contrast, in a passive mixing silo, no active mixing takes place; instead, the flakes mix themselves if appropriate during shipping. Here, an illustrative embodiment of the passive mixing area is a silo with a moving conveyor belt, into which the respective shavings or recycled wood flakes are introduced for storage for further processing.

In particular, it is likewise possible to introduce flakes which have been produced by flaking of log chips into the mixing silo 600 (introduction option 601), so that the flake mixture in this case comprises 3 different flake types.

The sheet mixture stored in the mixing silo 600 is then fed to the drying device 500, where the sheet mixture is dried together in the drying device 500. Suitable apparatuses for this purpose are, in particular, drum dryers or belt dryers.

In some cases, it is also possible that the drying device 500 also assumes the function of a mixing silo 600, so that the individual chip types (i.e. shavings and intermediate portions 852 of recycled wood chips) are fed separately to the drying device 500 and mixed in the drying device 500 at the time of drying. In this case, the mixing silo and the drying device are identical.

The dried sheet mixture is then fed to a sorting device 400, in which sorting device 400, in the exemplary case of the apparatus according to fig. 3, the sheet mixture is divided into two parts, namely a surface layer part 410 and a core layer part 420. In particular, the sorting device may be a roller sorter or a disk sorter; screening devices or combinations of the above may also be used.

In this case, the core portion 420 is manufactured to include a greater weight proportion of recycled wood chips than the surface layer portion 410. Preferably, the strands present in the core portion 420 are of smaller size (i.e., have a smaller number-average length) than the strands present in the surface layer portion 410.

If oriented strand board as shown in fig. 2 is to be manufactured, the dried flake mixture is divided into three parts, in which case also a fine-grained fraction is produced, which after gluing can be used in particular for manufacturing inner core slabs. This option is not shown in fig. 3 for clarity.

The individual portions (i.e., the surface layer portion 410 and the core layer portion 420) are fed to respective adhesive means 310 and 320 and then dispersed in the manner described above to produce individual surface layer slabs 11 ' and 12 ' or core layer slabs 20 '.

Alternatively or additionally, individual recycled wood flakes produced with the flaking device 800 or shavings produced with the flaking device 700 may likewise be fed to the separate drying devices 501 and 502. This option is illustrated in fig. 3 by the dashed arrow.

For example, the resulting medium sized portion 852 may be fed to a separate drying device 502 without being pre-mixed with the strands. Likewise, the same options are possible for shavings produced using the shaving apparatus 700. The flakes may also be fed to, for example, a separate drying device 501. The respective homogenized wood shavings or recycled wood flakes may then be fed into the adhesive means 310 and 320, respectively, and dispersed. It is thus possible to manufacture homogeneous surface layer slabs 11 ', 12 ' or core layer slabs 20 '. Likewise, homogenous flakes may be mixed with portions 410 and 420 to increase or decrease the proportion of the respective flake types. These options are significant in particular when the thickness of the oriented strand board to be produced is to be modified during operation and therefore, as the case may be, the overall proportion of recycled wood flakes in the oriented strand board also varies.

Likewise, the raw wood flakes 601 may be introduced into a recycled wood flake production line.

The part of the apparatus shown by the dashed line with reference sign a, which is used for producing chips of recovered wood which are chipped in the chipping device 800, and which is also part of the apparatus shown in fig. 3 in a preferred embodiment, is shown separately in fig. 4.

Fig. 4 shows a flow chart showing how the supplied recycled wood RW is used to manufacture chips of recycled wood that can be chipped in the chipping device 800 shown in fig. 3.

The supplied recycled wood is first coarsely pre-shredded by a shredding device 1100 (e.g., a shredder), if desired. This is necessary especially when the recycled wood is supplied in the form of e.g. complete furniture pieces or large wooden beams, boards (e.g. oriented strand board). The recycled wood herein is especially A I type wood and A II type wood according to the Altholzverordnung regulation in the Federal republic of Germany. In the crusher 1100, smaller pieces are produced which can then be processed into pieces.

A corresponding device 1000 for producing chips is therefore connected downstream of the crusher 1100. In particular, the device may comprise a shredder (e.g. a disc shredder or a drum shredder) or a hammer mill.

There may also be one or more intermediate connection means between the shredder 1100 and the shredder 1000 for removing extraneous matter, such as ferromagnetic metals (especially iron), non-ferromagnetic particles (especially aluminum), non-wood materials (especially stone, glass, ceramic or plastic). In the illustrative case of the apparatus according to fig. 4, the removal of ferromagnetic material is effected here, for example, by means of a permanent magnet or electromagnet 910, and, if appropriate, the removal of aluminum components, for example, with an eddy current separator 920.

Preferably, the chips produced by the shredder 1000 are divided into three sections 951, 952, 953 in the sorting device 950. The chip part 951 with the smallest average size can be sent, for example, to chipboard manufacture or thermally utilized.

The large chip fraction 953 having the largest average size may be fed back into the shredder 1000.

The chip fraction 952 having a suitable average maximum size may be used for further processing and final flaking to obtain recycled wood flakes.

If chips of recycled wood are manufactured elsewhere, they may be introduced into the sorting apparatus 950. This possibility is indicated by C in fig. 4.

The chips are preferably subjected to a plurality of purification steps prior to flaking in flaking apparatus 800.

To this end, for example, substances having a lower specific density than wood, such as polymer films or various paper or cardboard materials, can be removed by means of pneumatic sorting 905. Similarly, ferromagnetic metal is removed using magnets 910, and non-ferromagnetic metal (e.g., aluminum) is removed by eddy current sorter 920. In addition, density separation 930 is likewise possible, in which, for example, substances having a greater specific density than wood (in particular stone, ceramics and glass) are removed. For example, remaining impurities, particularly from plastic materials, may be removed by X-ray sorting and/or by video sorting 940. The various purification stages may also be performed more than once or more than once. The resulting chips, as also shown by reference character a in fig. 4, are sent to a chipper 800 in fig. 3. Additionally, in the case of the introduction option 954, pieces of log may also be introduced together with pieces of recycled wood and chipped together in the chipper 800.

Fig. 5 shows another embodiment of an apparatus according to the invention for manufacturing an oriented strand board according to the invention. The apparatus has the same configuration as that shown in fig. 3 except for the sorting device 400 for a flake mixture. For clarity only, the upstream components are not shown again. However, interfaces with components (drying devices 500, 501, 502) not explicitly shown are shown. In contrast to the apparatus according to fig. 3, the apparatus according to fig. 5 has a total of 5 dispersing devices 111, 121, 122, 123, 112 and thus enables the manufacture of five-layer oriented strand board, for example, as described in fig. 2. A particular advantage of the apparatus according to fig. 5 that should be mentioned is that it can be operated in a flexible manner and also enables, for example, the manufacture of three-layer oriented strand board as shown in fig. 3. The apparatus shown in fig. 5 comprises a sorting device 400 for the dried flake mixture obtained from the drying device 500. In contrast to the apparatus according to fig. 3, the sorting device 400 is able to divide the flake mixture into three fractions, namely a surface layer fraction 410, a medium fraction 420 and a fine particle fraction 421. These portions 410, 420 and 421 differ in the average sheet size (number average) reduction, and in particular in the average sheet length (number average) reduction. The surface layer portion 410 mainly contains shavings and is used for manufacturing the surface layer blanks 11 ', 12'. Depending on the arrangement, the intermediate portion 420 contains a proportion of shavings and recycled wood flakes (and optionally a proportion of raw wood flakes, which may be applied in the case of a feeding device 601 arranged for this purpose), and the intermediate portion 420 is used for manufacturing the outer core slabs 21 ', 23'. The fine particle fraction 421 is substantially free of wood shavings and consists essentially of recycled wood flakes (and any raw wood flakes). Alternatively, the core portion 420 may also be adjusted to be substantially free of shavings. In this case, the core portion 420 consists essentially of recycled wood flakes (and any raw wood flakes). In this case, the average flake size (number average) (particularly, the average flake length (number average)) of the reclaimed wood flakes (and any raw wood flakes) present in the core layer portion 420 is larger than the average flake size (number average) (particularly, the average flake length (number average)) of the reclaimed wood flakes (and any raw wood flakes) present in the fine particle portion 421. To remove the powder or ultra-fine fraction 460, the fine fraction layer portion may optionally be sent to a suitable sorting device 450 (e.g., a screening device) in order to obtain a fine fraction 422 substantially free of powder, preferably the fine fraction 422 may be used for the purposes of the present invention. The powder may be thermally utilized or used in particle board manufacturing, for example.

The surface layer portion 410 is fed into the adhesive means 310 and an adhesive is provided in the adhesive means 310. The chips can also be metered into the adhesive device 310 separately, for example from a drying device 501 not shown in fig. 5. The surface layer portion 410, which has been provided with the binder, is introduced into and dispersed in two dispersion devices 111, 112 to obtain the respective surface layer blanks 11 ', 12'.

The apparatus according to fig. 5 comprises two further adhesive means 320, 322, wherein, in the case of the manufacture of three-layer oriented strand board, only the adhesive means 320 is operated; in the case of manufacturing five-layer oriented strand board, both adhesive means 320, 322 are operated.

If three-layer oriented strand board is manufactured, the flow chart shown by the solid lines starting from the adhesive devices 310, 320, 322 is used, and in the case of manufacturing five-layer oriented strand board, the flow chart shown by the dashed lines is used. First, the manufacture of three-layered oriented strand board by the apparatus shown in fig. 5 will be explained in detail. Core portion 420 is fed to adhesive device 320. At the same time, the fine fraction 422 (or, if the fine fraction 421 is not further classified (450)), the fine fraction 421 is introduced into the binder means 320. The combined parts 420 and 422 (or 421) are glued in the adhesive means 320 and then introduced into the dispersion means 122 for the manufacture of the core slab 20' (in this case the only core slab). The two dispersing means 121 and 123 and the same adhesive means 322 are not supplied with the sheet mixture.

To manufacture a five-layer oriented strand board, only the core part 420 is introduced into the binder device 320, and this core part, which has been provided with binder, is then introduced into each of the dispersion devices 121, 123 in equal parts for dispersing the individual outer core slabs 21 ', 23'. The fine particle fraction 422 (or, if the fine particle fraction 421 is not further classified (450), the fine particle fraction 421) is introduced into the binder device 322, and then the fine particle fraction 422 or 421, which has been provided with the binder, is introduced into the dispersion device 122 and the inner core slab 22' is manufactured.

In each case, the resulting mat of dispersed particles is sent to a press 200 for the manufacture of oriented strand board, as shown in fig. 3.

List of reference numerals:

11 upper surface layer

12 lower surface layer

20 core layer

21, 23 outer core layer

22 inner core layer

11' upper surface laminate blank

12' lower surface layer plate blank

20' core slab

21 ', 23' outer core layer plate blank

22' inner core layer slab

111, 112, 120, 121, 122 dispersing device

200 pressing machine

310, 320, 322 adhesive means

400 sorting device for flake mixtures

410 surface layer portion

420 core layer part, outer core layer part

421 fine fraction for other classification

422 fine particle fraction, inner core fraction

450 sorting device for fine particle fraction 421

460 Wood powder/ultrafine particle fraction

500. 501, 502 drying device

600 mixing bunker

601 feeding options for log flakes

700 OSB flaker

800 chipper device for recovering wood/log chips

850 sorting device for recycling wood flakes

851 recovering the fine fraction of the wood flakes

852 recovering the medium size fraction of wood flakes

853 recovering the coarse fraction of wood flakes

905 pneumatic separation

910 magnet

920 vortex separator

930 weight sorting

940 x-ray sorting/video sorting

950 Wood powder

951 Fine fraction of debris

952 middle part of the fragment

953 coarse fraction of chips

954 introduction options for log pieces

1000 chopper

1100 crusher