Hot-Air/Hot-Steam Process for the Production of Laccase-Mediator-System Bound Wood Fiber Insulation Boards

In this study, a new technical process for hardening wood fiber insulation boards is introduced. During the dry-process, the fibers are usually glued with polymeric-diphenylmethane-diisocyanate (pMDI) and hardened to wood fiber insulation boards using a steam-air mixture. However, the maximum temperature reached in the steam-air process was 100 degrees C, and it was impossible to use an alternative binding agent for the gluing of the wood fiber insulation boards other than pMDI. When incubated with laccase-mediator-system (LMS) as a naturally based bonding system, temperatures of over 120 degrees C are required because of the chemical wood composition, especially the lignin. In this case, the hot-air/hot-steam process offers new technical opportunities for realizing temperatures above 100 degrees C. In this study, wood fiber insulation boards were glued with LMS, vs. reference boards with inactivated LMS, laccase alone, and 4% pMDI. Then, the boards were hardened using one of three processes: with steam-air mixture, with hot-air, and with hot-air/hot-steam. Through the hot-air/hot-steam process, temperatures of well over 120 degrees C were attainable. All the insulation boards hardened using the hot-air/hot-steam process showed better physical and technical properties than those hardened with steam-air mixture or hot-air alone. The reason for this is a sudden increase of temperature after the adding of steam because high temperatures insure that the LMS activated wood fiber surface lignins are completely plasticized. As a result the physical-technological properties such as internal bond strength, compression strength, and short term water absorption of insulation boards treated with LMS were comparable to those boards treated with 4% pMDI.