COMPOSITE PRODUCTS FROM LIGNOCELLULOSIC MATERIALS

Abstract: A low cost process for converting lignocellulosic materials into reconstituted composite products, such as building boards, furniture boards, reconstituted lumber and moulded articles, with no addition of resin binders. The hemicellulose portion of lignocel­ lulosic materials is decomposed and hydrolyzed by high pressure steam to generate free sugars, furfural and other decomposition products, which are chemically transformed by the application of heat and pressure into a polymeric substance, which acts as a thermoset adhesive binder, providing both a bonding and bulking effect. The reconstituted composite products thus produced possess good strength property and superb dimensional stability.

Description: COMPOSITE PRODUCTS FROM LIGNOCELLULOSIC MATERIALS FIELD OF THE INVENTION This invention relates to a process of converting lignocellulosic materials into composite products. This invention particularly relates to a process of converting lignocellulosic materials into composite products such as panel products, reconstituted lumber and moulded articles, without the use of any adhesive binders which are an essential part of the conventional dry process of manufacturing composite products, such as wood-based particle-board, waferboard and medium density fibreboard, etc. BACKGROUND OF THE INVENTION In my United States patent application serial no. 480,570 there is disclosed a process for making composite products from sugarcontaining lignocellulosic materials, specifically of annual plants of non-woody nature, such as sugarcane bagasse, stalks of corn, sorghum, sunflower, and flax, etc., without the addition of adhesive binders. The free sugars within the lignocellulosic materials, which are water soluble, are chemically transformed, in situ, by the application of heat and pressure into an insoluble and infusible polymeric substance, acting as both a bonding and bulking agent, to strengthen the reconstituted composite products with strong mechanical strength and superb dimensional stability. It is believed that the free sugars, carbohydrates or saccharides, and water soluble materials are chemically transformed into furfural and other derivatives, and further thermoset under heat and pressure to form a bond during the hot moulding operation. Thus produced, the bond binds, bulks and strengthens the lignocellulosic materials into reconstituted composite products with good mechanical strength and superb dimensional stability. However, this patented process is limited to lignocellulosic materials containing free sugars only and is not applicable to lignocellulosic materials containing no free sugars, such as wood, cereal straws, rice husks, reeds, etc. The conventional process for making composite panel products from these lignocellulosic materials relies exclusively on synthetic resin binders for bonding. Since synthetic resins, such as phenol-. and urea-formaldehyde, are expensive, they normally constitute a large portion of production cost for the conventional panel products, such as particleboard, waferboard and medium density fibreboard. This is especially true in the case of agricultural residues. Because of their physical nature, a relatively high content of resin binders is required for manufacturing, thus resulting in an expensive panel product. This is one of the major reasons why agricultural residues are not widely utilized today in the manufacturing of panel products, in spite of the abundance and availability of the raw materials. Th recent years a number of lanufacturing processes have been developed to utilize agricultural residues as raw material for the production of panel products, for example rice husks, one of the most abundant yet the least utilized agricultural residues around the world. However,none of those processes so far developed has found commercial acceptance. Thus E. C. Lathrop et al. in "Hardboard frii agricultural residues", Modern Plastics, 126 (April 1951) reported the use of a combination of powdered thermosetting phenolic resin, pine gum and ground rice husks to make composite panel products. He found that boards by using as much as 15 percent phenolic resin were too brittle to be nailed. Moreover, the boards had a density of 1.12 (69.9 Ibis. per cubic foot). This combination of 15 percent powdered resin and high density makes the product too expensive to compete with currently available products, and the brittleness of the board places a severe limitation to its use. The use of a specially fointlated phenolic resin for bonding rice husks has been reported by R. C. v3sisshth in the U. S. Patent No. 3,850,677 dated Now. 26, 1974. Rice husks boards can be made with 8 to 10 percent of a water irrmisciable, caustic free, thermosetting phenol-formaldehyde resin and pretreated rice husks. In his process, the pretreatment is essential because it breaks up rice husk pods into individual leaves, removes loosely bonded surface materials, and screens out fine particles. It is claimed that the inclusion of fine materials generated from the pretreatment would not only increase the resin consumption, but also introduce some undesirable effects on board property. More recently, there was a publication "New opportunities in manufacturing conventional particleboard using isocyanate binders" reported by G. W. Ball (Proceedings - Washington State University Particleboard Symposium. No. 15, P 266 - 285, 1981). Rice husks board was made with pretreated rice husks, using 9 percent of very expensive polymeric isocyanate resins as a bonding agent. Since isocyanate resins are more expensive than the conventional phenolic resin, the production cost of rice husks boards must be very high. This makes rice husks board too expensive to compete with the conventional wood-besed panel products. Presently, the conventional manufacturing of panel products from lignocellulosic materials relies exclusively upon synthetic resin for bonding. Synthetic resin binders are expensive because they are derived from petrochemicals. In general resin cost constitutes a major portion of production cost for panel products. Resin cost has been reported as high as 60 percent of production cost for panel products from agricultural residues . Therefore, in view of resin cost and raw material selection,a process that eliminates synthetic resin for manufacturing of composite products and uses any lignocellulosic materials would be very attractive. SUMMARY OF THE INVENTION In accordance with one aspect of this invention, there is provided a novel process Wh39ty reconstituted composite products, such as panel boards, composite lumber, moulded articles and the like, can be produced from lignocellulosic materials without the use of synthetic resin binders. This new process is applinshle to all lignocellulosic materials, regardless of origin, species, source, form, and shape. Such lignocellulosic materials can be any vegetations, particularly the residues from forestry and agricultural crops, in the forra of trunk, bark, stalk, root, foliage, shell, pod, straw, husk, nut, etc. they nay be used singularly or in combination with other lignocellulosic materials to form reconsitituted composite products without using the synthetic resin binders, such as urea- and phenol-formaldehyde resin commonly being employed in the conventional manufacturing of wood-based panel products. I have dis"ered that free sugars can be generated from hemicellulose in any lignocellulosic materials and utilized as a bonding agent for reconstituted composite products, thus eliminating the use of synthetic resin binders It is well kmown that lignocellulosic materials comprise three main components; cellulose, hemicellulose and lignin. Chemically, cellulose,which is the main structural component of all plant cell walls and which constitutes about 40 to 60 percent of lignocellulosic materials, is a linear polysaccharide built up from anhydro glucose units having the general formula (C6 H10 O5)n. Cellulose is crystalline in nature. Hemicellulose is the narrre given to non- cellulosic low molecular weight polysaccarides, associated in plant tissues with cellulose in the lignocel lulosic materials. 11-ticellulose ,which constitutes about 20 to 35 percent of the lignocellulosic materials,may be repeated by the general formula (C5 H8 O4)nl (C6 H10 O5)n2, representing 5 and 6 carbon sugars, such as pentosan and hexosan. The third main component is lignin which occurs in 20 to 30 percent of the lignocellulosic materials. The precursors of lignin and its formation in lignocellulosic materials are still not completely elucidated, although re cently ,considerable progress has been trade. Today lignin is generally accepted to be a polymeric material made up of phenylpropane units. Since hemicellulose is in situ largely amorphous in character, it has great accessibility to water. Thus, hemicellulose is decomposed about 100 tines faster than cellulose, and hence hemicellulose can be hydrolyzed selec tively without the degradation of cellulose. The general hydrolysis reaction is: (C5 H8 nl (C6 10 O5)n2 + (n1 + n2) H20 -+ n1 C5 H10 05 + n C6 H12 O yielding 5 and 6 carbon sugars. These free sugars are reactive and can be decomposed under heat into furfural and other decomposition products, w-hich can be further transformed into a polymeric substance to provide a bonding and bulking effect on lignocellulosic materials by the application of heat and pressure in a moulding operation, resulting in reconstituted composite products with good mechanical strength and excellent dimensional stability. PREFERRED EMBODIMENT OF THE INVENTION This invention process comprises two major parts of operation. The first part is to decompose and hydrolyze the hemicellulose portion of the lignocellulosic materials and convert it into free sugars, carbohydrates, or monosaccharide ,such as xylose, arabinose, mannose, galactose, etc. The second part of the process is to chemically transform and thermoset the free sugars, in situ, into a polymerized substance, compounding the lignocellulosic materials into a reconstituted composite products. It has been found that since hemicellulose can be selectively decomposed and hydrolyzed at a much faster rate than cellulose, it is possible to convert only the hemicellulose into free sugars for bonding without destroying the cellulose. To achieve this, a high pressure steam treating method or so-called auto-hydrolysis has been discovered to be very satisfactory for the invention. During high pressure steaming of lignocellulosic materials, hemicellulose would first undergo decomposition reaction. First, acetic acid is formed by cleavage of acetyl side chains, and the weak acidic environment thus created is sufficient to promote hydrolysis of hemicellulose. The depolymerization reaction is believed to be a sequential reaction. During the initial phase of the reaction process, random attack by acid in hemicellulose chains produces oligomers of varying degrees of polymerization. The oligomers are further hydrolyzed to monomers which are further degraded to furfural and other decomposition products Simultaneously, the lignin portion of lignocellulosic materials is also decomposed and hydrolyzed to low weight lignin and lignin products. Only the cellulose remains relatively unchanged. The steam treated lignocellulosic materials normally have about 10 to 30 percent of water solubles which contain sugars, sugar polymers, dehydrated carbohydrates, furfural products, lignin and lignin products. The free sugars, furfural, and other decomposition products are essential parts of the present invention. When chemically transformed under heat and pressure, they thenmset and crosslink into a polyieric substance acting as both a bonding and bulking agent for the reconstituted composite products from the steam treated lignocellulosic materials. 'The conventional process for making panel products from lignocellulosic materials requires an amount of 8 to 12 percent by weight of synthetic resin binder. Since hemicellulose normally constitutes about 20 to 35 percent of lignocellulosic materials, there is enough basic matter to generate free sugars for bonding. The amount of free sugars which can be generated from the lignocellulosic materials is mainly dependant upon the nature of the raw materials and the degree of steaming treatment. Normally, agricultural residues and hardwood contain more hemicellulose than coniferous softwood. In order to optimize the conversion of hemicellulose into free sugars, a proper control of the high pressure steaming treatment is an important part of the present invention. Oversteaming 'would not only cause carbonization of the treated material but also lose some of the free sugars and the furfural products in particular. Experimental work on rice husks which contain about 20.4 percent hemicellulose as determined by pentosan analysis indicated that by the nation of steam temperature, or steam pressure, and steaming time, 70 to 80 percent of the hemicellulose can be converted into pentose sugars and furfural products. The accompaning drawing demonstrates the time steam temperature required to obtain the maximum of free sugars and furfural products. The inverse relation ship between tirre and steam temperature is clearly shown: The higher the temperature used, the shorter the time required, and vice versa. To a lesser extent, moisture content, shape and size of the lignocellulosic materials also have some effect on maximization of the free sugars. At the end of the steaming treatment, the lignocellulosic material can be collected either by a sudden release or by a gradual release of steam pressure from the pressure vessel. The sudden release of high pressure steam would explode and shred the treated material into a fibrous lump with high moisture content. The slow and gradual release of steam pressure enables the treated material to retain, more or less, its original shape and size. In contrast to the batch system of treating the lignocellulosic material, it is also practical to use a continuous process to steam treat the raw material. This process can be easily adopted to a continuous digester or vessel in which the lignocellulosic material is constantly under the steam pressure, and is fed and extruded continuously from the digester. The material thus treated by the high temperature steam is light to dark brown in colour and has a moisture content from about 40 to more than 100 percent, depending on the initial moisture content of the lignocellulosic material and the severity of hydrolysis. The water in the treated material is also light to dark brown in colour and contains mostly sugars, lignin and a small amount of furfural products. The treated lignocellulosic materials should be dried inmediately to a low moisture content of less than 18 percent. Otherwise, the sugars in the treated lignocellulosic material would start fermention particularly in a humid and warm environment. If fermentation takes place, all free sugars would be transformed to alco'lol and acetic acid. Once this happens, the treated lignocellulosic material would not be acceptable for making composite products because there are no free sugars remaining to provide the bonding effect. Here the first part of the present invention ends: A dried lignocellulosic material containing a high proportion of free sugars is ready for the manu facturing of reconstituted composite products. me second part of the present invention begins. In the for of individual fibres, particles, strands, flakes1 or in a fori of lumps, chunks, bundles and aggregates, the dried lignocellulosic materials are formed singularly or in combination with other lignocellulosic materials into a desired mat, and then moulded under heat and pressure for a sufficient time to consolidate the mat into a rigid article. The moulding temperature can be in the range of 160 to 250 C, preferably in the range of 200 to 220-C. The e press time is dependent on press temperature and oat dinension, while the pressure is mainly the function of density of the moulded article desired. During the hot moulding operation, the sugars, furfural products and other decomposition products will polymerize and bond in situ the lignocellulosic material to produce a rigid article. In addition, the sugars, which penrx3ate within the cell wall tissue of the lignocellulosic material, will also be transformed and therooset to a polymeric substance, acting as a bulking agent throughout the entire moulded article. Thus, the moulded articles possess excellent mechanical strength and superb dimensional stability with a thermoset adhesive bond which is resistant to boiling water and acid hydrolysis. Furthermore, the composite products thus manufactured are free from the toxic formaldehyde emission because conventional synthetic resin binders are not used. Another important feature of this invention is the discovery of destruction of epidjeeris in agricultural residues such as rice husks, sugar cane bagasse, cereal straws, etc. by the steaming treatment, particularly when corn- bined with a sudden release of steam pressure at the end of the steaming treatment. Because of the waxy material of the epidermis which is impervious to water and hence the adhesive bond, the elimination of epidermis would enhance the interface bonding between individual elements. Yet another unique feature of my invention is the discovery of the extra benefits from the destruction and conversion of hemicellulose. As stated, in natural condition, hemicellulose is largely amorphous in character and has great accessibility to water, making lignocellulosic materials highly hygroscopic, and resulting in dimensional changes. Since the treated lignocellulosic materials are almost completely free from hemicellulose, in accordance with my invention the reconstituted composite products would be far less hygroscopic, and hence have better dimensional stability. Embodiment of the invention will be described and illustrated in detail in the following examples: Example 1. Rice Husk Boards This example shows the effect of steaming time and steam temperature on rice husk board. Seven batches of rice husks were treated to various steaming conditions. Dry rice husks with 8% moisture content were first packed in the pressure vessel and the vessel was rapidly filled with high pressure steam to heat up the rice husks to a desired temperature for a predetermined time. At the end of steaming, the steam pressure was suddenly released and the rice husks were extracted from the vessel in a hot, moist and fibrous condition. The moisture content of the steamed rice husks varied from about 40 to 60%. A total of 7 batches was treated with different temperatures (from 190 to 260 C) and times (from 15 seconds to 10 minutes). Samples were taken from each batch of the treated rice husks for pentosan determination (Tappi method - T 223 OS - 78). To be pressed into boards the steamed rice husks were immediately dried to a moisture content of about 3 to 4%. Seven boards, each 18 x 18 x 7/16 inches, were made with a specific gravity of 1.0 (62.4 pcf). The same press condition was used for all 7 boards (press temperature 220"C, press pressure 600 psi and press time 10 minutes). Test results are summarized in the following Table 1. Table 1. Pentosan analysis and physical property of 7 rice husks boards. Treatment Pentosan* Modulus of Modulus of Internal Swell after t.eKerature time obtained elasticity rupture(psi) bond 2 hrs boil ( C ) ( sec ) ( psi ) dry boiled ( psi ) ( % ) 280 15 18.2 624,000 2740 1360 156 9.6 260 20 17.6 631,000 2720 1280 164 10.2 250 30 18.2 644,000 2660 1380 152 10.7 240 60 17.3 606,000 2540 1400 142 11.2 230 120 16.7 597,000 2520 1360 156 11.8 210 360 16.2 556,000 2490 1280 148 12.0 190 600 15.5 524,000 2380 1170 108 15.2 * Chemical analysis indicated that the original rice husks contained 20.4 % pentosans. The mechanical strength end physical property of all 7 rice husk boards surpassed the CAN 3-0188-2M 78 requirements for exterior grade waferboard. Example 2. Wheat Straw Medium Density Fibreboard Wheat straws were cut into 3 to 4 inch lengths and air dried to a moisture content of 8 to 10%. The wheat straws were given a steam treatment at 240 C for 35 seconds. The pressure was instantly released. The treated mass had a moisture content of about 60% and was dried to a moisture content of 4 to 5%. The dried straws were shredded to a loose fibrous state and then formed into a isat. The sat was hot pressed at 210'C and at a pressure of 400 psi for 10 minutes. The board 18 x 18 x 7/16 inches having a specific gravity of 0.75 (47 pct). Tests Of the board indicated as follows: MOR: 2400 psi, wet MOR: 1100 psi IB: 78 psi MOE: 547,000 psi Swelling after 2 hrs boiling: 8.6% Example 3. Peanut Shell Board Dried peanut shells with a moisture content of 7% were treated with high pressure steam at 240"C for 30 seconds. The pressure was instantly released. The treated mass contained 63% moisture content and had a water soluble material of 16.2% by weight. The treated material was dried to 5% moisture content and shredded into a fluffy fibrous bundle. A mat was formed and hot pressed at 220"C with a pressure of 400 psi for 10 minutes to produce a panel of 18 x 18 x 7 h6 inches with a specific gravity of 0.82 (51 pcf). Test results show the following properties: MOR: 1900 psi, wet MOR 1080 psi IB: 86 psi MOE: 460,000 psi Swelling after 2 hrs boiling: 8.6% Example 4. Aspen Particleboard This example shows the combination of steam treated lignocellulosic material with other lignocellulosic material for making board. Aspen chips were treated with high pressure steam at 250"C fo 70 seconds and the pressure was then instantly released. The pulpy mass contained a high proportion of sugars and water soluble materials. After drying, this material was ground into fine powdery particles and passed through a 100 mesh screen. The powdery particles were mixed with an equal amount by weight of aspen wood splinters (passed through a 1/4 mesh screen). A mat was formed with 40% by weight of the ground material for face layers. The core of the mat was comprised of 60% by weight of the mixture of steam treated and ground powdery particles and aspen splinters. The mat was hot pressed at 210"C with a pressure of 400 psi for 8 minutes to yield a panel of 18 x 18 x 7/16 irdEs with a specific gravity of 0.78 (49 pcf). Test results indicate the following properties: HOR: 2540 psi, wet MOR: 1420 psi IB: 78 psi MCE: 590,000 psi Swelling after 2 hrs boiling: 7.5% This panel had a very smooth and tight suface, being of equal or superior quality to that of wet process hard board made conventionally. All the properties surpassed the CAN. 3-0188.2-M78 requirements for exterior grade waferboard. Example 5. Hixed Species Board This example shows the steam treatment to a mixture of different ligno cellosic materials for board making. Equal parts, by bone dry weight, of peanut shell, rice straw and planet shavings of spruce wood were mixed and treated at a steal tetperature 240'C for about 35 seconds. The pressure was instantly relsed. The wet lumpy mass having 50% moisture content was dried to 5% H.C. and shredded to fibrous mass. A board of 18 x 18 x 7/16 inches was pressed at a temperature of 220 C for 10 minutes with a pressure of 450 psi. The specific gravity of the board was 0.80 (50 pef). Test results indicate the following properties: MOR: 2200 psi, wet MOR: 1090 psi IB: 86 psi HOE: 497,000 psi Swelling after 2 hrs boiling: 8.6% Example 6. Poplar waferboard This example demonstrates the high pressure steam treatment but without the explosion release of pressure at the end. This particular treatment enables the treated lignocellulosic material to retain its shape and size. Poplar wafers of 1.5 x 2 x 0.03 inches were treated to steam temperature of 240 C for about 30 seconds. Next, the steam pressure was gradually released to atmos pheric pressure (about 1.5 minutes). me treated wafers contained about 526 moisture content and were dried to 4% for board making. A panel of 18 x 18 x 7/16 inches was made to a specific gravity of 0.70 (44 pcf). The platen temperature was 220"C;press time 8 minutes;pressure 450 psi. Test results are summarized as follows: MOR: 2480 psi, wet MOR: 1350 psi IB: 68 psi MOE: 648,000 psi swelling after 2 hrs boiling: 16.5% This board would pass the CAN 3-0188.2-M78 requirements for exterior grade waferboard. Example 7. Logging Residue Board This example shows the possibility of converting logging residues into panel products with no addition of adhesive binders. A white spruce tree top which consisted of about 40% wood, 40% foliage and 20% bark was chipped to pass a 1/2 inch screen. The chips contained about 53% moisture content and showed sign of fungus attack. The chips were packed in a pressure vessel to receive a steam treatment at 235"C for 60 seconds. The pressure was instantly released at the end of the treatment. The fibrous material had a moisture content of 116% and a sugar content of 15.5%. This material was dried to a low moisture content of 3% for making board. One board of 18 x 18 x 7/16 inches was made to a specific gravity of 0.92 (57.4 pcf) with a press temperature of 230"C, a pressure of 450 psi and a press time of 12 minutes. Test results are listed below: MOR: 1870 psi, wet MOR: 1160 psi IB: 86 psi MOE: 448,000 psi Swelling after 2 hrs boiling: 14.5% Example 8. The Effect of Acidic Catalyst This example demonstrates the usefulness of acidic catalysts in preparing lignocellulosic materials for board making. Fresh sugarcane bagasse containing 49% moisture content was added to 0.4% by weight of sulfuric acid insolution. The bagasse was treated at a steam temperature of 220 C for 2 minutes. For comparison purposes, another batch of the same bagasse was treated with same steaming temperature and time, but without the addition of sulfuric acid. After the steam treatment, the bagasse was dried to a moisture content of 5%. One board of 18 x 18 x 7/16 inches with a specific gravity of 0.72 (45 pcf) was made from each batch of bagasse, using one press condition, press temperaturse 220 C, pressure 400 psi and press time 10 minutes. Test results are listed as follows: Acid Treated MOR: 2630 psi, wet MOR: 1820 psi IB: 75 psi MOVE: 574,000 psi Swelling after 2 hrs boiling: 8.7% Not Treated MOR: 1540 psi, wet MOR: 260 psi IB: 36 psi MOE: 368, 000 psi Swelling after 2 hrs boiling: 52% The higher mechanical strength and lower thickness swelling of the board made from the acid treated bagasse was mainly due to the higher proportion of the free sugars, furfurals and other decomposition products generated from the hemicellulose. Chemical analysis indicated that the acid treated bagasse conatained 16.5 percent pentosans and the control contained only 7.3 percent. Example 9. Densified fuel log This example demonstrates the making of waterproof densified solid fuel logs from saw mill residues which contain about 60% wood and 40 % bark by weight. These residues were made up from softwood species of pine , spruce and fir with a moisture content of about 40%. They were first chipped to pass 1/4 inch sreen, dried to a moisture content of less than 10%, and then given a steaming treatment at 2200c for 1 minute. The treated material was extruded continuously from the treating vessel at the end of of steaming, and was immediately fed to a heated extrusion machine in such a way that a minimum of heat was lost from the treated material. After extrusion, a waterproof solid fire log of 12 inch length and 4 inch diameter was obtained. This fuel log had a specific gravity of 1.22 and did not disintegrate in boiling water. After a long period of outdoor storage, the weathered fuel log retained its good handling properties and combustion characterisitics.

Claims: CLAIMS 1. A process of converting a lignocellulosic material into a reconstituted composite product, comprising; treating the lignocellulosic material in divided form with steam to heat the lignooellulosic material to a temperature high enough to release hemicellulose but not exceeding the temperature of carbonization, for a tine sufficient to dbeox5ose and hydrolyze hemicellulose into free sugars, sugar polymers, dehydrated carbohydrates, furfural products and other decomposition products, forming the treated lignocellulosic material into a mat and pressing the mat at a temperature not exceding the temperatuPe at which the mat would char, at a pressure and for a time sufficient to transform and thermoset the free sugars, sugar polymers, dehydrated carbohydrates, furfural products and other decomposition products in the lignocellulose material into a polymeric substance, which adhesive bonds together the lignocellulosic material to yield the reconstituted composite product 2. A process of converting ligroceflulosic materials into reconstituted composite products, comprising: a. preparing the lignocellulosic material in either dry or wet condition , from either a single species or a mixed species in a divided form, b. packing the divided lignocellulosic material in a pressure vessel having a closed outlet for extraction, c. filling the pressure vessel rapidly with a high pressure steam to heat all the lignocellulosic material to a temperature high enough to release the hemicellulose but not exceeding the temperature of carbonization, for a time sufficient to decompose and hydrolyze hemicellulose into free sugars, sugar polymers, dehydrated carbohydrates, furfural products and other decomposition products, to provide both a bonding and bulking effect, d. as soon as the optimization of decomposition and hyrolysis of hemicellulose is attained, shutting off the steam and then opening the pressure vessel outlet thus releasing the internal steam pressure to atmospheric pressure to extract the lignocell ulosic material, e. preparing the lignocellulosic material for formation into a mat, by, in either order, drying the lignocellulosic material as soon as possible to a low moisture content to prevent fermentation, or loosening, separating and reducing the lignocellulosic material into fibres, particulates, strands, flakes and other forms, f. forming the dried lignocellulosic material wholly or in combinaton with otherlignocellulosic materials into a desired mat and g. pressing the mat at an elevated temperature but not exceeding the temperature of charring the mat, at a pressure and for a time sufficient to transform the free sugars, sugar polymers, dehydrated carbohydrates, furfural products and other decomposition products in the lignocellulosic material into a polymeric substance, to thermoset the adhesive bond, in situ, and to yield a reconstituted composite product. 3. A process according to claim 1 or 2, wherein the hemicellulose portion of the lignocellulosic material is decomposed and hydrolyzed, using proportionally high pressure steam at a temperature in the range of 1200C to 2600C for a time less than 60 minutes, into free sugars, sugar polymers, dehydrated carbohydrates, furfural products and other decomposition products to provide both a bonding and bulking effect. 4. A process according to any preceding claim, wherein the cellulose portion of lignocellulosic material is not degraded by the steaming treatment. 5. A process according to any preceding claim, wherein the lignin portion of lignocellulosic material is decomposed and hydrolyzed to low molecular weight lignin and lignin compounds. 6. A process according to any preceding claim, wherein the hydrolysed lignocellulosic material contains less than 30 percent by weight, of water solubles which contain sugars, dehydrated carbohydrates, furfural products, sugar polymers, lignin, lignin products and other decoipsition products. 7. A process according to any of claims 1 to 6, wherein the steam pressure is instantly released with an explosive discharge to the the lignocellulosic material in fibrous and particulate form. 8. A process according to any of claims 1 to 6, wherein the steam pressure is gradually released to atmospheric pressure to retain the lignocellulosic material in original form. 9. A process according to any of claims 1 to 6, wherein the steam pressure is constantly maintained within the pressurized vessel while the steam treated material is continuously extruded. 10. A process according to any preceding claim, wherein the lignocellulosic material, after high pressure steam treatment, is dried to a moisture content of less than 18 percent to prevent fermentation and to accelerate the thermoset during hot-pressing. 11. A process according to any preceg claim, wherein the formed mat is hot-pressed at a temperature in the range of 1602500C, at a pressure, and for a time, sufficient to chemically transform the sugars, sugar polymers, furfural products, dehydrated oarbohydrates and other decomposition products derived from hemicellulose and to develop and thermoset the bend, in situ, providing both a bonding and bulking effect on the reconstituted wmposite product. 12. A process according to any preceding claim, wherein the divided lignocellulosic material is mixed with an acidic catalyst in an amount of no more than 5 percent by weight before steaming. 13, A process according to any preceding claim, wherein the reconstituted composite product is waterproof. 14. A process of preparing a waterproof reconstituted composite product, wherein lignocellulosic material is treated to a high temperature by high pressure steam for a time sufficient to decompose and hydrolyze the hemicellulose into free sugars, sugar polymers, dehydrated carbohydrates, furfural products, and other decomposition products, dried to a low moisture content, separated into fibres, particles, strands, or flakes formed into a mat, and hot pressed at a high temperature, and at a pressure and for a time sufficient to consolidate, develop and thermoset the adhesive, in situ, to provide both a bonding and bulking effect. 15. A process according to any preceding claim, wherein the resulting thermoset adhesive bond is both insoluble in boiling water and resistant to acid hydrolysis. 16. A process according to any preceding claim, wherein the lignocellulosic material is derived from forest vegetation and agricultural plants of woody or non-woody nature in the form of stem, stalk, shrub, foliage, bark, root; shell, pod, nut, husk, fibre, straw, vine, grass, bamboo and reed, singularly or in a mixture. 17. A process according to any preceding claim, wherein the divided lignocellulosic material is in the form of particles, fibres, strands, wafers or flakes. 18. A process according to any preceding claim, wherein the reconstituted composition product is waterproof and is in the form of building board, furniture board, composite lumber, densified fuel log, or other moulded articles.

Inventors: SHEN, KUO CHENG
Applicants: SHEN, KUO CHENG
Application year: 1985
Main classification: B27N3
IPC codes: B27N3, C08L97, B27N1, B27K9