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Engineered wood product

A wood product and engineering technology, applied in the field of engineered wood products, can solve problems such as cracking and warping

Inactive Publication Date: 2009-12-02
MALLARD CREEK POLYMERS +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

The main limitation of these products, such as oriented strand board and especially particle board, is that they are very likely to warp and / or crack when exposed to excessive moisture

Method used

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Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1-5

[0179] Examples 1-5: Preparation of Representative Engineered Wood Products

[0180] A series of five formulations of the engineered wood products described herein were prepared and tested using the following general procedure.

[0181] Measure out water in an appropriately sized beaker to process the remainder of the recipe ingredients with agitation. Add all fibers and fillers (fibers and fillers can be premixed) to the water under agitation with a good vortex.

[0182] The desired amount of wet strength resin, such as Kymene 736 (Hercules), is measured out and added to the fiber stock. After 1 minute, latex, antioxidant and hydrophobic agent such as wax are added (these components can optionally be premixed). After 1 minute, a polyamine such as Alcofix 159 (Ciba) is added. After 1 minute, polyacrylamide (Nalco 61067) was added. After 1 minute, if necessary, improve the mixture with variable amounts of silica gel such as Eka NP 780 (Eka Chemicals) until clear water is ob...

Embodiment 6

[0194] Example 6: Additional Formulation Examples

[0195] Two additional formulations (Examples 7 and 8) were prepared following the order of addition shown in Table 4. Example 8 used recycled denim and recycled carpet fibers instead of wood fibers. The use of formulations of such materials can lead to improvements in different properties such as sound insulation or cushioning or strength properties.

[0196]Samples were prepared by layering different combinations of these materials. It is desirable to make samples 1 / 2 inch thick to 1 inch thick. In order to improve the bonding of the layers in the middle of the laminate, it was decided to compress in stages. For example, a 3 / 4" thick sample was made by combining a total of 12 sheets of the formulation of Example 7. The process was started with 4 stacks of 3 sheets / stack and heated in a hot press at 500 gauge pressure. All 4 individual stacks were compressed simultaneously on the board. After 1 minute, the 4 laminated sam...

Embodiment 7

[0206] Example 7: Additional formulation examples

[0207] The following examples show the effect of latex level on the hydrophobicity of engineered wood products. Formulations 1-4 were made following the order of addition shown.

[0208] Unlike the previous examples, it should be noted that in this example no additional hydrophobic agents were added to any of the formulations shown. The amount of latex added to each formulation was reduced by 5%, with formulation 1 containing 15% latex and formulation 4 containing no latex. The removal of latex was offset by a corresponding increase in recycled carpet fiber, as this fiber was felt to have minimal impact on the water management performance of the resulting wood samples.

[0209] Local adjustments were made to the flocculant packs in formulations 3 and 4 to obtain proper flocculant formation. The data (shown in Table 5) show that the addition of latex helped reduce the level of water intrusion into the samples and retarded d...

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Abstract

Engineered wood products, methods of making the products, laminates including the products, and articles of manufacture which include the engineered products or composites, are disclosed. The products include wood and / or other cellulosic fibers, and can include non-cellulosic fibers, all or part of which can be derived from post-industrial and / or post-consumer materials. The products also include a binding agent, such as a latex dispersion, as well as hydrophobic materials, processing aids, colorants, and the like. The product can be in the form of a sheet, a three dimensional article or a plurality of laminated sheets, and can include one or more additional layers, such as top coat layers, reinforcing layers, cushioning layers, wood veneer layers, and / or additional product layers. The products can be used as flooring, and in construction, cabinetry, and the like.

Description

[0001] This application claims the benefit of US Provisional Application No. 60 / 856221, filed November 1, 2006. field of invention [0002] The following inventions are generally in the field of composite materials, and more specifically relate to composite materials comprising wood or other cellulosic fibers and a binder, which composite materials are referred to for the purposes of this application as engineered wood products. Background of the invention [0003] Many consumer products are manufactured from wood, including plywood, oriented strand board (OSB), glue-lams, I-beam, particle board, chipboard, flooring, panels, and the like. During the manufacture of wood products, a certain amount of post-industrial waste is generated when wood is cut into shapes. There is also a certain amount of post-user waste that is generated when wood is discarded (for example, in the form of used pallets). [0004] Conventional methods exist for recycling post-industrial wood chips, wh...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B32B5/02
CPCB32B21/02Y10T428/31982Y10T428/31957B27N3/04B27N3/08B32B5/02
Inventor D·B·迪拜施雷J·K·纳恩B·R·T·纳恩S·哈格赫斯
Owner MALLARD CREEK POLYMERS
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