Processes for manufacturing engineered composite objects

Abstract

Methods for forming composite objects, wherein the methods comprise providing a plurality of material particles, applying a liquid adhesive to at least a portion of the plurality of material particles, wherein the adhesive is comprised of droplets, at least about 80% of the droplets having an average droplet diameter of about 50 to about 200 microns, to form a material / adhesive mixture, and forming the material / adhesive mixture into a composite object.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is based upon, and claims priority under 35 U.S.C. § 119(e) of, provisional U.S. Patent Application No. 60 / 628,628, filed on Nov. 17, 2004, the entire contents of which are incorporated herein by reference.BACKGROUND OF THE INVENTION

[0002] Various types of engineered composites, including wood-based composites such as flakeboard, waferboard, particle board, and strand board, are known and used in many high-strength and stiffness requirement industries, such as, e.g., construction applications. Strand board, particularly oriented strand board, has enjoyed success as a building material since its introduction to market in approximately 1982.

[0003] Engineered composites are materials in which two or more different materials are combined to form a single structure with an identifiable interface between the two or more materials. In general, the properties of the composite depend on the constituent materials and the interfa...

Examples

example 1

Resin Spraying:

[0049] Droplet size distribution of three separate materials was evaluated using a Sono-Tek ultrasonic spray nozzle, Model No. S / N 25048, fed by a Cole-Parmer digital pump. Droplet size analysis was carried out using a Malvern Spraytec laser diffraction drop size analyzer. The ultrasonic spray nozzle had an operating frequency of 25 kHz and an atomizing surface diameter of 0.46 inches. The power generator had a maximum input power of 15 watts. The laser wavelength of the drop size analyzer was 760 nm, with a 100 mm lens. The pump was connected with L / S 13 tubing and a pulse dampener. The four materials analyzed were: Material A, a pMDI adhesive resin (“polymeric methylene diphenyl diisocyanate”), obtained from Huntsman; Material B, a Borden “E-wax”; Material C, a lignosulfonate-stabilized wax emulsion; and Material D, a phenol-formaldehyde (PF) resin, Prefere™ 13B024 obtained from Dynea Company.

[0050] Both wax materials and the pMDI resin were successfully atomized...

example 2

Oriented Strand Board Production:

[0053] Oriented strand board is a type of layered particle panel product composed of strand-type flakes that are purposefully aligned in directions (usually perpendicular relative to one another) that make a panel that is stronger, stiffer, and exhibits improved dimensional properties in the alignment directions. Oriented strand board is manufactured from flakes which are cut, dried, and screen classified. After drying, a phenol-formaldehyde resin-adhesive is spray applied to the flakes using an atomizer as described above in Example 1 in conjunction with a tumbling blender. The flakes are conveyed to aligners which orient the board layers. The flake mats are then conveyed on screens to the stacker prior to insertion into a hot press. After pressing, the boards are hot stacked. Final preparation includes trimming, sanding, edge coating, and grade stamping.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is based upon, and claims priority under 35 U.S.C. § 119(e) of, provisional U.S. Patent Application No. 60 / 628,628, filed on Nov. 17, 2004, the entire contents of which are incorporated herein by reference.BACKGROUND OF THE INVENTION

[0002] Various types of engineered composites, including wood-based composites such as flakeboard, waferboard, particle board, and strand board, are known and used in many high-strength and stiffness requirement industries, such as, e.g., construction applications. Strand board, particularly oriented strand board, has enjoyed success as a building material since its introduction to market in approximately 1982.

[0003] Engineered composites are materials in which two or more different materials are combined to form a single structure with an identifiable interface between the two or more materials. In general, the properties of the composite depend on the constituent materials and the interfa...

Examples

example 1

Resin Spraying:

[0049] Droplet size distribution of three separate materials was evaluated using a Sono-Tek ultrasonic spray nozzle, Model No. S / N 25048, fed by a Cole-Parmer digital pump. Droplet size analysis was carried out using a Malvern Spraytec laser diffraction drop size analyzer. The ultrasonic spray nozzle had an operating frequency of 25 kHz and an atomizing surface diameter of 0.46 inches. The power generator had a maximum input power of 15 watts. The laser wavelength of the drop size analyzer was 760 nm, with a 100 mm lens. The pump was connected with L / S 13 tubing and a pulse dampener. The four materials analyzed were: Material A, a pMDI adhesive resin (“polymeric methylene diphenyl diisocyanate”), obtained from Huntsman; Material B, a Borden “E-wax”; Material C, a lignosulfonate-stabilized wax emulsion; and Material D, a phenol-formaldehyde (PF) resin, Prefere™ 13B024 obtained from Dynea Company.

[0050] Both wax materials and the pMDI resin were successfully atomized...

example 2

Oriented Strand Board Production:

[0053] Oriented strand board is a type of layered particle panel product composed of strand-type flakes that are purposefully aligned in directions (usually perpendicular relative to one another) that make a panel that is stronger, stiffer, and exhibits improved dimensional properties in the alignment directions. Oriented strand board is manufactured from flakes which are cut, dried, and screen classified. After drying, a phenol-formaldehyde resin-adhesive is spray applied to the flakes using an atomizer as described above in Example 1 in conjunction with a tumbling blender. The flakes are conveyed to aligners which orient the board layers. The flake mats are then conveyed on screens to the stacker prior to insertion into a hot press. After pressing, the boards are hot stacked. Final preparation includes trimming, sanding, edge coating, and grade stamping.